AM855 Elevator

AM855 Elevator
Maintenance
and Parts Manual
Altec Industries, Inc. reserves the right to improve models and change specifications without notice.
749-20158
2010
Copyright © 2010 by Altec Industries, Inc.
All rights reserved. No part of this publication may be used or reproduced by any means, or stored in a
database or retrieval system, without prior written permission of the publisher. Making copies of any part
of this publication for any purpose other than personal use is a violation of United States copyright laws.
Preface
This unit is the result of Altec’s advanced technology and quality awareness in design,
engineering, and manufacturing. At the time of delivery from the factory, this unit met or
exceeded all applicable requirements of the American National Standards Institute. All
information, illustrations, and specifications contained within this manual are based on the
latest product information available at the time of publication. It is essential that all personnel
involved in the use and/or care of this unit read and understand the Operator’s Manual.
Given reasonable care and operation, according to the guidelines set forth in the manuals
provided, this unit will provide many years of excellent service before requiring major
maintenance.
The scope of this manual is limited to periodic maintenance. It does not cover methods that
may be required to inspect and repair major damage to the unit. Impacts to and excessive
forces on the hydraulic utility equipment, through vehicular accidents, rollovers, excessive
loading, and the like, may result in structural damage not obvious during a visual inspection.
If the hydraulic utility equipment is subjected to such impacts or forces, a qualified person may
need to perform additional testing such as acoustic emissions, magnuflux or ultrasonic testing
as applicable. If structural damage is suspected or found, contact Altec for additional
instructions.
Warning
Death or serious injury can result from component failure. Continued use of a mobile
unit with hidden damage could lead to component failure.
Never alter or modify this unit in any way that might affect the structural integrity or operational
characteristics without the specific written approval of Altec Industries, Inc. Unauthorized
alterations or modifications will void the warranty. Of greater concern, is the possibility that
unauthorized modification could adversely affect the safe operation of this unit, resulting in
personal injury and/or property damage.
Danger
Death or serious injury will result from unprotected contact with energized conductors.
Non-insulating units have no dielectric rating. Maintain safe clearances, as defined by
federal, state, and local authorities, and your employer, from energized conductors.
No unit can provide absolute safety when in proximity to energized conductors. No unit is
designed or intended to replace or supersede any protective device or safe work practice
relating to work in proximity to energized conductors. When in proximity to energized
conductors, this unit shall only be used by trained personnel using their company’s accepted
work methods, safety procedures, and protective equipment. Training manuals are available
from a variety of sources.
Set-up requirements, work procedures, and safety precautions for each particular situation
are the responsibility of the personnel involved in the use and/or care of this unit.
Table of Contents
Section 1 — Introduction
About This Manual… ..................................................................................................... 1
Section 2 — Unit Specifications

General Specifications ................................................................................................... 3
Component Identification ............................................................................................... 4
Section 3 — Safety
Safety Instructions ......................................................................................................... 5
Disclaimer of Liability ..................................................................................................... 5
Section 4 — Preventive Maintenance and Inspection

Equipment Storage ........................................................................................................ 7
Protective Measures ............................................................................................... 7
Hydraulic System .......................................................................................................... 7
Cleanliness Precautions .......................................................................................... 8
Filtration .................................................................................................................. 8
Oil Specifications .................................................................................................. 10
Oil Condition .......................................................................................................... 10
Changing Oil and Flushing the System ................................................................. 12
Lubrication ................................................................................................................... 13
Lubrication Chart and Diagram .............................................................................. 14
Structures .................................................................................................................... 17
Cleaning ................................................................................................................ 17
Welds .................................................................................................................... 17
Fasteners ..................................................................................................................... 19
Methods of Lockwiring ................................................................................................. 20
Rotation Bearing Cap Screws ................................................................................ 22
Elbow Bearing Cap Screws ................................................................................... 22
Rotation Gearbox Mounting Cap Screws ............................................................... 24
Pins and Pin Retainers ................................................................................................ 25
Pin Installation Into Self-Lubricating Bearings ....................................................... 26
Bearings ....................................................................................................................... 26
Spherical Bearings ................................................................................................ 26
Pressure Cast Cylindrical Bearings ....................................................................... 26
Self-Lubricating Bearings ...................................................................................... 26
Tapered Roller Bearings ........................................................................................ 27
Rotation Bearing .................................................................................................... 28
Elbow Bearing ....................................................................................................... 30
Cylinders ...................................................................................................................... 31
Hydraulic Lines ............................................................................................................ 31
Single Handle Control and Control Handle Covers ....................................................... 32
Atmospheric Vents ...................................................................................................... 32
Fiberglass and Plastic Components ............................................................................ 32
Cleaning ................................................................................................................ 33
Plastic ................................................................................................................... 33
Determining the Degree of Boom Damage ............................................................ 33
Repair .................................................................................................................... 34
Platform Leveling ......................................................................................................... 36
Winch Line ................................................................................................................... 37
Accident Prevention Signs ........................................................................................... 38
Accident Prevention Signs Diagram ...................................................................... 39
Section 5 — Hydraulic System
Load Sense .................................................................................................................. 45
Oil Reservoir ................................................................................................................ 45
Pump ........................................................................................................................... 45
Emergency Operating DC Pump .................................................................................. 45
Rotary Joint ................................................................................................................. 46
Valves .......................................................................................................................... 46
Outrigger Control Valve ......................................................................................... 47
Outrigger/Tool Control Valve ................................................................................. 47
Pump Control Valve .............................................................................................. 47
Machine/Outrigger Selector Valve ......................................................................... 47
Control Selector Valve ........................................................................................... 48
Elevator Selector Valve ......................................................................................... 48
Lower Winch Control Valve ................................................................................... 48
Lower Platform Rotate Control Valve .................................................................... 48
Lower Control Valve .............................................................................................. 49
Lower Controls Solenoid Pilot Control Valve ......................................................... 49
Upper Control Valve .............................................................................................. 49
Interlock Valve ...................................................................................................... 50
Jib/Winch/Tool Valve (Manual Extend Jib) ............................................................ 50
Jib/Winch Valve (Hydraulic Extend Jib) ................................................................ 50
Platform Rotator Valve (One-Man Platform) .......................................................... 50
Platform Rotate/Tool/Tilt Control Valve (Two-Man Platform) ................................. 51
Tool Control Valve ................................................................................................. 51
Relief Valves ......................................................................................................... 51
Lower Boom Stow Valve ....................................................................................... 51
Upper Elevator Control Valve ................................................................................ 52
Upper Elevator Selector Valve .............................................................................. 52
Holding Valves ...................................................................................................... 52
Cavitation and Aeration ................................................................................................ 52
Air Bleeding ................................................................................................................. 53
Pilot System .......................................................................................................... 53
Leakage ....................................................................................................................... 54
Heat Generation ........................................................................................................... 54
Hydraulic Lines ............................................................................................................ 54
Hose Bundle .......................................................................................................... 55
Fittings and Valve Cartridges ....................................................................................... 55
Torque and Tightening Procedures ........................................................................ 56
Cylinders ...................................................................................................................... 57
Radial Outrigger Cylinder ....................................................................................... 58
Elevator Lower Arm Cylinder ................................................................................. 59
Double Elevator Upper Arm or Single Elevator Arm Cylinder ................................ 60
Lower Boom Cylinder ............................................................................................ 60
Upper Boom Cylinders ........................................................................................... 61
Jib Tilt Cylinder ..................................................................................................... 62
Jib Extension Cylinder ........................................................................................... 62
Platform Rotator Cylinder ...................................................................................... 63
Section 6 — Mechanical Systems

Rotary Joint ................................................................................................................. 65
Rotation System .......................................................................................................... 66
Rotation Bearing .................................................................................................... 67
Rotation Bearing Cap Screws ................................................................................ 69
Rotation Gearbox .................................................................................................. 69
Elbow Bearing .............................................................................................................. 70
Leveling System .......................................................................................................... 73
Winch ........................................................................................................................... 77
Line ....................................................................................................................... 77
Section 7 — Electrical System
On/Off Circuit ............................................................................................................... 79
Proportional Circuits ..................................................................................................... 79
Cable Assemblies ........................................................................................................ 80
Diodes .......................................................................................................................... 81
Solenoids ..................................................................................................................... 82
Truck/Machine Selector Switch ................................................................................... 82
Power Distribution Module (PDM) ................................................................................ 82
Outrigger Interlock System .......................................................................................... 82
Slip Ring ...................................................................................................................... 83
Section 8 — Troubleshooting, Testing, and Adjustments

Troubleshooting Procedure .......................................................................................... 85
Hydraulic System ........................................................................................................ 85
Cycle Times .......................................................................................................... 85
System/Compensator Pressure ............................................................................ 85
Relief Valves ......................................................................................................... 86
Pump Flow ............................................................................................................ 87
Standby Pressure .................................................................................................. 88
Sense Signal Pressure Increasing Circuit ............................................................. 88
Pilot System Pressure .......................................................................................... 89
Outriggers .............................................................................................................. 89
Rotary Joint ........................................................................................................... 91
Lower Control Valve .............................................................................................. 91
Upper Control Valve .............................................................................................. 92
Elevator Control Valve ........................................................................................... 94
Lower Boom Cylinder ............................................................................................ 95
Bottom Upper Boom Cylinder ................................................................................ 95
Top Upper Boom Cylinder ..................................................................................... 96
Lower Boom Stow Valve ....................................................................................... 96
Pressure Relief ...................................................................................................... 96
Lower Tool Circuit .................................................................................................. 97
Jib/Winch, Platform Rotate, and Upper Tool Circuit .............................................. 98
Holding Valves ...................................................................................................... 99
Mechanical System ....................................................................................................101
Engine Throttle Control .........................................................................................101
Rotation Gearbox .................................................................................................102
Leveling System ...................................................................................................103
Overcenter Cam ...................................................................................................104
Upper Controls Interlock Trigger ...........................................................................106
Winch Brake ......................................................................................................... 106
Electrical System ....................................................................................................... 108
Failure Identification ............................................................................................. 108
Circuit Protection ..................................................................................................108
Engine Throttle Control .........................................................................................109
Power Distribution Module (PDM) .........................................................................109
Outrigger Interlock System ..................................................................................109
Hand Controls ....................................................................................................... 110
Section 9 — Dielectric, Structural, and Stability Testing

Dielectric ..................................................................................................................... 113
Single Handle Control ........................................................................................... 113
Structural .................................................................................................................... 113
Stability .......................................................................................................................114
Appendix
Glossary
Service Tools and Supplies
Preventive Maintenance and Inspection Checklist
Accessory Checklist
Torque Values
Basic JIC Symbols
Hydraulic System Schematics
Basic Electrical Symbols
Wiring Line Diagrams
Troubleshooting Chart
Dielectric Test Forms
Stability Test Forms
Section 1 — Introduction
Throughout the manual, the term unit is used to describe

About This Manual… the Altec device, subbase, outriggers, and the associated
This manual provides instruction to safely inspect, repair, interface with the vehicle.
troubleshoot, and test the unit. Charts and figures are
provided to support the text. Because options vary from Additional copies of this manual may be ordered through
one model to another, some figures may only be a your Altec representative. Supply the model and serial
representation of what is actually on the unit. number found on the serial number placard and the manual
part number from the front cover to assure that the correct
Knowledge of the information in this manual combined with manual will be supplied.
proper skills and training in hydraulic, electrical, and
mechanical systems, provide a basis for safely maintain- This symbol is used throughout this manual to
ing the unit. Read and understand the applicable procedure indicate danger, warning, and caution instruc-
before beginning. Carefully follow each procedure. tions. These instructions must be followed to
reduce the likelihood of personal injury and/or property
Contact the following organizations for additional informa- damage.
tion.
The terms danger, warning, caution, and notice represent
• American National Standards Institute (ANSI) varying degrees of personal injury and/or property damage
A92.2 for aerial devices; A10.31 for digger derricks that could result if the preventive instructions are not
• American Public Power Association followed. The following paragraphs from ANSI publica-
(Safety Manual for an Electric Utility) tions explain each term.
• American Society for Testing and Materials (ASTM)
• American Welding Society (AWS) Danger
• Canadian Standards Association (CSA) Indicates a hazardous situation which, if not
• European Committee for Standardization (CEN) avoided, will result in death or serious injury. This
• Fluid Power Society (FPS) signal word is to be limited to the most extreme
• Hydraulic Tool Manufacturer’s Association (HTMA) situations.
• International Electrotechnical Commission (IEC)
• International Organization for Standardization (ISO) Warning
• Occupational Safety and Health Administration Indicates a hazardous situation which, if not
(OSHA) avoided, could result in death or serious injury.
Dealers, installers, owners, users, operators, renters, Caution

lessors, and lessees must comply with the appropriate Indicates a hazardous situation which, if not
sections of the applicable ANSI standard. avoided, may result in minor or moderate injury. It
may also be used to alert against unsafe prac-
The Appendix contains reference items to help maintain tices.
the unit. A glossary of industry terms is provided for your
convenience. This glossary provides an understanding of Notice
the industry terms and phrases used in Altec manuals. The preferred signal word to address practices not
related to personal injury.
Section 1 — Introduction • 1
2 • Section 1 — Introduction
Section 2 — Unit Specifications
is impregnated with a wax compound, providing a smooth

General Specifications surface for moisture to bead. The outer surface has a
This unit uses a side-by-side boom design. Unit height smooth gelcoat finish to protect the fiberglass.
specifications are based on 40″ (101.6 cm) frame height,
but common frame heights vary from 29″ to 40″ (73.7 to The nonconductive components, when properly main-
101.6 cm). Figure 2.1 provides general unit specifications. tained, clean, dry, free from tracking, and in good condition
as established by dielectric testing, will meet the dielectric
The basic structural components are the outriggers, sub- requirements of ANSI in effect at the time of unit manufac-
base, elevator lift, pedestal, turntable, lower boom, and ture. The ratings of the unit must be known and understood
upper boom. The steel structures are made in the form of by its users.
a closed box. This structural style resists torsional load-
ing, as well as tension, compression, and bending loads This unit shall be used near energized conductors only by
that may be applied to the unit. Careful consideration has qualified operators who are fully trained and proficient as
been given to the design and manufacturing process to electrical linemen. Personnel using this equipment must
minimize the possibility of fatigue cracks. be familiar with the hazards of contact with energized
conductors, for the protection of themselves, their cowork-
The insulating boom structural components are made of ers, and the public. The nature of electrical hazards is
centrifugally cast fiberglass. The inner fiberglass surface described in the Operator’s Manual.
Item AM855-E68 AM855-E81

Maximum ground to bottom of platform height 67.8′ (20.7 m) 80.5′ (24.5 m)
Working height 72.8′ (22.2 m) 85.5′ (26.1 m)
Maximum side reach — upper boom overcenter, lower boom at 0° 46.8′ (14.3 m) 46.8′ (14.3 m)
Maximum side reach — upper boom overcenter, lower boom at 100° 34.7′ (10.6 m) 34.7′ (10.6 m)
Travel height 11.3′ (3.4 m) 13.5′ (4.1 m)
Maximum hydraulic pressure setting 3,000 psi (207 bar) 3,000 psi (207 bar)
Rotation Continuous Continuous
Lower boom articulation 0° to 100° 0° to 100°
Lower boom isolation 24″ (610 mm) 24″ (610 mm)
Upper boom articulation 0° to 230° 0° to 230°
Upper boom isolation 150″ (3810 mm) 150″ (3810 mm)
Winch capacity (full drum) 2,000 lb (907.2 kg) 2,000 lb (907.2 kg)
Jib articulation Varies by option Varies by option
1
Maximum jib capacity (extended) Varies by option Varies by option
1
Maximum jib capacity (retracted) 2,000 lb (907.2 kg) 2,000 lb (907.2 kg)
1
Maximum material handling capacity 2,000 lb (907.2 kg) 2,000 lb (907.2 kg)
1
Maximum lower boom lifting eye capacity 2,000 lb (907.2 kg) 2,000 lb (907.2 kg)
Synthetic winch line 80′ 105′
Maximum tool pressure 2,000 psi (138 bar) 2,000 psi (138 bar)
Maximum tool flow 8 gpm (30.3 l/min) 8 gpm (30.3 l/min)
Platform capacity — one man 350 lb (158.8 kg) 350 lb (158.8 kg)
Platform capacity — two man 700 lb (317.5 kg) 700 lb (317.5 kg)
Total platform capacity — dual one man 600 lb (272.1 kg) 600 lb (272.1 kg)
Platform rotation Varies by option Varies by option
1
Refer to capacity placards
Figure 2.1 — Unit Specifications
Section 2 — Unit Specifications • 3

Component Identification
Jib Upper
Controls
Upper Boom Tip
Upper Boom
Platform
Lower
Lower Boom Boom Insulator Upper Boom Elbow
Cylinders
Boom Pin
Turntable Lower
Boom Cylinder
Upper Boom
Lower Controls
Drive Mechanism
Upper Pedestal
Parallel Upper Arm Cylinder

Link
Arm Below Rotation
Controls
Riser
Lower
Lower Arm Cylinder
Pedestal
Outrigger
Controls
Outriggers
4 • Section 2 — Unit Specifications

Section 3 — Safety
General Maintenance Information

Safety Instructions • Read and understand the complete procedure
It is essential that all personnel involved in the care of this before beginning.
unit read and understand the Operator’s and Maintenance • Remove the pressure in a hydraulic circuit before
Manuals. Safety alerts throughout the manuals highlight disconnecting its components.
situations in which accidents can occur. Give special • Use lifting devices of suitable capacity to support
attention to all safety alerts. and handle components.
• Use a test block to adjust the relief setting on
The safety information in this manual applies only to the counterbalance holding valves.
maintenance of this unit. Although procedures have been • Be aware of your surroundings.
written to protect the mechanic and other personnel, there • Fully open all shutoff valves after servicing the unit.
is no safety system to account for human error or negli- • Complete the required procedures before returning the
gence. unit to operation.
• After completing a procedure, check the oil level in
the hydraulic reservoir and add oil if necessary.
Danger
Death or serious injury will result from unprotected Disclaimer of Liability
contact with an energized conductor. This unit does
not provide protection from contact with or proximity Altec Industries, Inc. will not be liable for unauthorized
to an electrically charged conductor when you are in alterations or modifications of the unit. Altec Industries,
contact with or in proximity to another conductor or Inc. will not be liable for improper or abusive operation of
any grounded device, material, or equipment. Main- the unit.
tain safe clearances from energized conductors.
Do not alter or modify this unit in any way that might affect
its structural integrity, dielectric integrity, or operational
Warning characteristics without specific written approval from
Death or serious injury can result from careless or Altec Industries, Inc.
improper use of the unit. The mechanic bears ultimate
responsibility for following all regulations and safety Unauthorized alterations or modifications will void the
rules of their employer and/or any state or federal law. warranty. However, of a greater concern is the possibility
that unauthorized changes could adversely affect the
Notice unit’s operation that could endanger personnel and/or
Maintenance personnel must be trained in safe service damage property. Altec will not be responsible for unautho-
procedures. rized alterations or modifications that cause death, seri-
ous injury, and/or property damage.
Work practices may expose maintenance personnel to
hazardous materials. Before using any chemical, read and Altec Industries, Inc. assumes no liability for any personal
understand the manufacturer’s label and the material injury and/or property damage related to the use of this
safety data sheet (MSDS). These sheets explain emer- manual when performing testing, operating, maintenance
gency and first aid procedures and waste disposal meth- and/or repair procedures on this Altec unit.
ods. Properly dispose of oil and hazardous materials.
Section 3 — Safety • 5
6 • Section 3 — Safety
Section 4 — Preventive Maintenance and Inspection
Proper maintenance will reduce downtime, lower operating equipment generally has a number of heavy, cylindrical
and repair costs, and extend equipment life. Safety alone actuators. As these components are allowed to rest in one
justifies a preventive maintenance program. position for a period of time, the seals on the piston will
tend to flatten along the loaded side. Since the seal
This section contains information on properly inspecting material is synthetic, its elasticity is limited and it may not
the hydraulic system, structures, individual unit compo- resume its original shape completely. At best, there will be
nents, and lubrication. Use the Lubrication Chart and some failure to seal well for a short period of time after
Diagram in this section when lubricating the unit. putting the equipment back into use. At worst, the seal will
never resume its original shape and will have to be
A Preventive Maintenance and Inspection Checklist is replaced.
provided in the Appendix. Use this checklist when per-
forming routine maintenance and inspections to insure no Protective Measures
areas are overlooked. Components may be installed on If it is known that equipment will be stored for a month or
your unit that require additional maintenance at different more, some steps should be taken to preserve the
intervals outside the scope of the Preventive Maintenance equipment.
and Inspection and Accessory Checklists. Refer to these
component manuals for more information. Keep perma- 1. The best preservative is to fully cycle (operate) the
nent, written, and dated records of all service performed on equipment once weekly if even for a short time.
the unit.
2. Coat exposed ferrous (iron or steel) bare metal sur-
Routine maintenance is performed on different compo- faces with a light grease or heavy oil compatible with
nents of the unit at different times (refer to the Preventive system hydraulic oil. This includes cylinder rods,
Maintenance and Inspection Checklist in the Appendix). shafts, gears, linkages, and unpainted parts.
More frequent maintenance may be necessary if the unit
is operated under severe conditions. In addition to the 3. Top off fluid reservoirs to allow as little air space as
Preventive Maintenance and Inspection Checklist recom- possible, to limit the effects of condensation. Remove
mendations, follow these recommendations on new units. excess oil before operating to limit the chance of
overflow when cylinders are cycled.
• Measure the turntable tilt before using a new unit.
• Change the return line filter after the first 15 to 25 PTO 4. Cover or wrap exposed rubber or neoprene parts with
hours. an ultraviolet resistant covering to shield the parts
• Gearbox manufacturers recommend an initial oil from sun exposure.
change after the first 15 to 25 PTO hours.
• Check the oil and collect an oil sample for analysis. 5. Unplug electrical connectors and apply a dielectric
grease or an aerosol product designed for protecting
electrical connectors. Plug the connector back to-
Equipment Storage
gether.
Mobile hydraulic equipment needs maintenance when
stored, or not used, for extensive periods of time. Depend- 6. Cover switch panels and control panels to prevent
ing upon the climate, lack of use may begin to have a direct intrusion of rain or moisture, while allowing air to
negative effect in as little as two weeks. Storage for a circulate over the panel.
period of several months will almost certainly produce
some deterioration of the equipment. 7. Cover personnel platforms to prevent the accumula-
tion of water in the platform.
Rust will form on unprotected ferrous metal surfaces very
quickly and water will collect inside unit structures. In dry 8. Shield fiberglass components from the sun and other
climates, gaskets will begin to shrink during long periods elements, if stored outside.
of non-use, and lubricants will lose their ability to provide
lubrication. In cold climates, condensation may occur in
fluid reservoirs and other components.
Hydraulic System
Maintaining the hydraulic system is critical to the proper
Even when protective measures have been taken prior to operation of the unit. Using the proper type of oil helps to
storage, some degradation of performance must be ex- prevent many hydraulic system problems. Maintaining the
pected when the equipment is put back into use. oil is also important. If the oil is dirty or contaminated,
components may be damaged.
One of the most noticeable effects of prolonged periods of
non-use is seal deformation. By its nature, hydraulic
Section 4 — Preventive Maintenance and Inspection • 7

Warning Filler Return Line
Cover Breather Cap Filter Head
Death or serious injury can result if the recommended
hydraulic oil is not used. Use of other fluids in the
hydraulic system can affect the insulating capability of
the unit.
Suction
Notice Filter Return Line
Only use hydraulic oil as recommended. Other fluids Filter Cartridge
added to the hydraulic system can increase compo-
3″ Hex Bottom
nent wear and affect the lubricating characteristics of
the oil.
Shutoff Angled
Check the oil level in the reservoir with the vehicle level Valve Opening
Drain Pipe
and the booms and outriggers stowed. Under these condi-
tions, the proper oil level is between the Add and Full
marks on the dipstick. Figure 4.1 — Reservoir
Cleanliness Precautions The cap allows air to flow in and out of the reservoir as the
Contamination will ruin any hydraulic system. It is very oil level changes. It contains a filter that cleans the air as
important that no contamination enter the system. Dirt, it enters the hydraulic system. The cap strainer basket
water and air are types of contaminants. They can enter filters large particles when oil is poured into the reservoir.
the hydraulic system in many ways. Contaminants can
enter the system when filling the reservoir or changing Replacement filler breather caps include a new cap,
filters. They can also enter when changing components or strainer basket, gaskets, mounting flange, and mounting
performing other service procedures. screws. Use the new gaskets, flange, and strainer basket
but do not use the new mounting screws. Use the original
The following precautions will help protect the cleanliness mounting screws with the O-ring seals. Apply Dow Corning
of the hydraulic system. #730 sealant under the screw heads to provide a watertight
seal. Replace the filler breather cap annually. If the unit is
• Filter new oil with a 10 micron filter as it is added to the operated in an extremely dusty environment, it may be
reservoir. necessary to replace the filler breather cap more often.
• Clean hydraulic connections before opening them.
• Cap or plug ports and lines opened for service. Remove and flush out (or replace) the strainer basket any
• Keep replacement hoses, tubes, and other compo- time it has collected dirt or other contaminants. Flush the
nents plugged while stored. strainer basket when the hydraulic oil is changed. Reseal
• Make sure components are clean before installation. the screws as described in the previous paragraph after
• Clean the reservoir and return line filter covers servicing the strainer basket.
before opening them.
• Clean the filler breather cap before opening it. Magnetic Suction Strainer
• After servicing the reservoir, immediately replace Hydraulic oil leaving the reservoir through the suction line,
the cover. on its way to the pump, passes through a magnetic suction
• Make sure quick disconnect couplers are clean strainer, located in the bottom of the reservoir at the outlet
before connecting them. (refer to Figure 4.1).
• Do not spray water on the reservoir filler breather
cap. This could force contaminants into the reser- This filter has a pleated wire mesh screen to prevent large
voir. particles from entering the pump. Several large doughnut-
shaped magnets are located within the strainer in the path
Filtration of oil flow to attract and accumulate iron and steel particles
The unit is equipped with a complete filtration system. which have entered the system.
When properly maintained, this system will reduce con-
tamination of the hydraulic system. The filtration system The magnetic suction strainer should be removed from the
must be serviced regularly to be effective. reservoir and cleaned whenever the hydraulic oil is changed.
Filler Breather Cap and Strainer Basket Use the following procedure to remove and clean the
The filler breather cap is located on top of the fill hole of the magnetic suction strainer.
reservoir (refer to Figure 4.1).
8 • Section 4 — Preventive Maintenance and Inspection

1. Drain the reservoir and wipe off the top of the reservoir Change or clean in-line filter cartridges each time the return
cover. Remove the cover. line filter cartridge is replaced. These filters do not have a
replaceable element, so the entire filter must be replaced.
2. Reach down into the reservoir with a crow’s foot
wrench or chain wrench. Unscrew the filter by turning Return Line Filter
the 3″ hex bottom counterclockwise (refer to Figure The return line filter is a 10 micron filter that cleans the oil
4.1). Do not grip the wire mesh screen with the wrench. as it enters the reservoir. It is mounted in the reservoir
This will crush the screen. (refer to Figure 4.1).
3. Remove the nut at the top end of the filter. Pull the Particles trapped by the return line filter are collected in the
magnet assembly out of the suction filter. filter cartridge. This cartridge is disposable and is available
from your Altec representative (refer to Service Tools and
Supplies in the Appendix).
Warning
Death or serious injury can result from improper use The return line filter is equipped with a bypass valve in the
of solvents. Follow the manufacturer’s label for proper filter head. The bypass valve opens when there is a
use and disposal. pressure drop of 25 psi (1.72 bar) across the filter cartridge.
When the valve is open, oil flows directly into the reservoir.
This prevents the cartridge from collapsing during cold oil
Caution start-ups or if it is clogged.
Injury can result from airborne particles entering the
eyes. Wear appropriate safety equipment. If the filter becomes clogged, oil will flow directly into the
reservoir through the bypass valve. The lack of oil filtration
4. Clean the filter by flushing it with solvent. Use an air will eventually damage hydraulic components.
hose to dry the filter, blowing the air from the inside of
the screen to the outside. Check for holes or other During the break-in period of a new unit, the hydraulic
damage. Replace the filter screen if it is damaged. components will deposit break-in wear particles in the
return line filter cartridge. Change the return line cartridge
5. Clean the magnet assembly by flushing it with sol- after the first 15 to 25 PTO hours of operation. Then,
vent. Blow it dry with an air hose and wipe it with a lint- change the cartridge at the interval recommended by the
free rag. Preventive Maintenance and Inspection Checklist. If the
unit is operated in very dusty conditions, replace the return
6. Slide the magnet assembly into the suction filter. line filter more often. Also, replace the cartridge after new
Install the nut at the top end of the filter. oil has circulated through the system for the first time.
7. Inspect the inside of the reservoir. If necessary, clean Always replace the return line filter cartridge with a genuine
it as described in this section under Changing Oil and Altec replacement part. Other filters may fit into the filter
Flushing the System. housing, but they may not have the same micron rating.
Also, other filters may allow oil to bypass at a different rate.
8. Install the filter in the reservoir by turning the 3″ hex
bottom clockwise (refer to Figure 4.1). Clean the filter Use the following procedure to change the return line filter
no more than four times before replacing it. cartridge.
In-Line Filters 1. Wipe off the cover and remove it from the filter head
In-line filters (refer to Figure 4.2) are used in the sense line (refer to Figure 4.1).
of the pump, in the purge line of the lower control valve on
the turntable, and in the purge line of the elevator control 2. Lift the cartridge, bypass valve, and spring out of the
valve at the below rotation controls. This type of filter is filter housing.
screwed into a break in the hydraulic line. These filters
have an arrow on them to indicate the direction of oil flow. 3. Inspect the inside of the filter housing for dirt buildup.
Wipe out the housing if necessary. Take care not to
drop any dirt through the outlet hole at the bottom of
the filter housing.
4. Insert a new cartridge in the housing. Do not clean and

Figure 4.2 — In-Line Filter reuse the old cartridge. If the filter housing was
removed, reinstall it with the outlet pipe positioned so

the angled opening is toward the end of the reservoir Notice
(Figure 4.1). Only use hydraulic oil as recommended. Other fluids
added to the hydraulic system can increase compo-
5. At the bottom end of the cartridge there is a sealing nent wear and affect the lubricating characteristics of
grommet. Fit the raised portion of the outlet tube the oil.
through the grommet. Push the cartridge down until it
sits against the bottom of the housing. Using a hydraulic fluid outside the temperature range
it was prescribed for may cause system damage.
6. Remove the bypass valve from the old cartridge.
Press it into the sealing grommet at the top end of the Only use oils meeting the viscosity rating for military
new cartridge. specification MIL-5606 in extremely cold climates.
These oils have fewer antiwear characteristics and are
7. Install the spring on top of the bypass valve. Make not recommended for full time use.
sure the large O-ring that seals the cover on the filter
head is in position. Figure 4.3 shows hydraulic oil recommendations for differ-
ent temperatures. The requirements are for mineral based
8. Replace the filter cover. Tighten the cover cap screws. and biodegradable hydraulic fluids. Most companies can
As the cap screws are tightened, the cover will supply equivalent oils. The oil selected for the hydraulic
compress the spring against the bypass valve. Do not system depends on the temperature during unit operation.
overtighten the cap screws. Excessive torque will
strip the threads in the aluminum filter housing. When refilling or changing hydraulic fluids it is recom-
mended the replacement fluid meet oil cleanliness require-
Oil Specifications ment 21/17/14 as specified by ISO 4406.
Use high quality oil in the hydraulic system. The oil should
contain rust, oxidation, and corrosion inhibitors. It should Oil Condition
also contain antifoam and antiwear additives. An important part of hydraulic system preventive mainte-
nance includes checking the condition of the hydraulic oil.
Hydraulic oils used in insulating equipment must possess
high demulsibility to allow the oil to separate from the water Periodic laboratory analysis is the most accurate method
in the reservoir. These oils must pass the ASTM D877 test of determining the condition of hydraulic oil and determin-
for dielectric breakdown voltage of insulating oils at 25 ing when it should be changed. A visual inspection may
kilovolts or higher for new oil. also be useful to check oil condition.
Hydraulic oil is commonly classified by viscosity. The A hydraulic oil supplier should be able to do testing or
viscosity of hydraulic oil changes with temperature. The recommend a test laboratory. The laboratory should pro-
higher the viscosity index of an oil, the less the viscosity vide the following information.
will change as the temperature changes. A multiviscosity
oil contains additives which increase the viscosity index. • Particle count
Multiviscosity oils should have high shear stability to • Trace element analysis (component wear, outside
maintain oil performance by avoiding excessive change in contaminants, and oil additive concentrations)
viscosity. • Viscosity test
• Water content test
The ability of hydraulic oil to provide adequate fluid at low • Dielectric strength test (when requested)
temperatures is measured by its pour point. If the pour
point is not low enough, oil will not flow into the pump at a Before taking a sample of oil, operate the unit to circulate
fast enough rate when the pump is operated at low the oil. Warm it to operating temperature. Take the sample
temperatures. This will cause cavitation, which can quickly from the middle level of the reservoir using a clean hand
destroy the pump. pump, such as a disposable syringe and a piece of plastic
tubing. If this is not available, the sample can be drained
from the bottom of the reservoir. Allow several quarts of oil
Warning to flow out before collecting the sample. This will remove
Death or serious injury can result if the recommended any dirt and water that has collected in the reservoir.
hydraulic oil is not used. Use of other fluids in the
hydraulic system can affect the insulating capability of If a sample container has not been provided by the
the unit. laboratory, use a wide mouth, screw top, clear glass
container. Clean it with hot water and detergent. Rinse it
thoroughly and let it air dry before putting oil into it.

Specification All Weather Oil Cold Weather Oil Warm Weather Oil
ISO grade 22 15 32
Ambient temperature range -10° to 95° F (-23° to 35° C) -50° to 60° F (-46° to 16° C) 40° F (4° C) and above
Viscosity @ 104° F (40° C) 24 cSt 15 cSt 32 cSt
Viscosity @ 212° F (100° C) 4.6 cSt 4.4 cSt 6.0 cSt
Pour point, biodegradable -31° F (-35° C) -58° F (-50° C) -31° F (-35° C)
Pour point, mineral based -48° F (-55° C) -76° F (-60° C) -49° F (-45° C)
Flash point (min) 356° F (180° C) 340° F (171° C) 356° F (180° C)
Dielectric strength (min) 35 kV 35 kV 35 kV
Four-ball wear, scar (max) 0.028 (0.70 mm) 0.028 (0.70 mm) 0.028 (0.70 mm)
Oxidation stability, TOST (min) 2,000 hours — 2,000 hours
Oxidation stability, RPVOT (min) 250 minutes 177 minutes 250 minutes
Water content (max) 63 ppm 38 ppm 63 ppm
Demulsibility, minutes to pass 15 10 15
Copper corrosion 1A 1A 1A
Rust test, pass/fail Pass Pass Pass
Foam test, pass/fail Pass Pass Pass
Figure 4.3 — Hydraulic Oil Viscosity Recommendations
Once the report is received, compare it to previous oil system’s condition. Contact your Altec representative for
analysis reports for the same unit. This information will further information.
provide trends toward oil deterioration. It may give early
warnings of a problem developing within hydraulic system Oxidation produces varnishes that bake onto hot surfaces.
components. Oxidation products are acidic and tend to attack metal
surfaces. This can damage pumps, motors, and valves.
Notice
Change the oil if the sample has any of the character- High operating temperatures will increase the rate of
istics listed in Figure 4.4. oxidation of the oil. The presence of water or air in hydraulic
oil also causes oxidation.
If making a visual inspection, compare the sample of oil to
a sample of new oil of the same type. Also, compare it to The presence of water may cause rust and corrosion. It
previous samples taken from the same unit. Look for the also reduces the dielectric capability of the oil.
signs of oil deterioration listed in Figure 4.4.
If laboratory analysis or visual inspection indicate that the
There are fluid contamination detector kits available which oil is deteriorating prematurely, determine the cause of the
allow for rapid, on-the-spot analysis of the hydraulic problem and correct it.
Condition Possible Cause

Dark color Oxidation; contamination
Cloudiness or milky appearance Presence of water or wax
Rancid or burned odor Oxidation
Increase in viscosity Oxidation; addition of improper fluids; presence of water
Decrease in viscosity Addition of improper fluids; additive deterioration
Separation of water or other fluids from the oil Presence of water; addition of improper fluids
Foreign particles or other visible contamination Contamination; emulsion of water with oil additives
Figure 4.4 — Hydraulic Oil Conditions

Changing Oil and Flushing the System 1. If the oil is being changed because of contamination
A properly maintained filtration system greatly extends the due to hydraulic component failure, proceed to step 2.
useful life of the hydraulic oil. However, the oil will Otherwise, operate the unit to circulate the oil and
eventually need to be replaced due to contaminants that warm it to operating temperature. This will allow many
form during normal operation of the unit. of the impurities to drain off in suspension.
It is impossible to recommend an exact time interval for oil 2. Drain the oil reservoir completely.
changes due to varying conditions of unit use. Use the
following guidelines to determine when the hydraulic oil 3. Wipe off the top of the reservoir, reservoir cover, filler
should be changed. breather cap, and return line filter.
• Change the oil as recommended by the Preventive 4. Remove oil filler hole strainer basket.
Maintenance and Inspection Checklist.
5. Remove the reservoir cover and the magnetic suction
• If a hydraulic component fails and contaminates the separator filter. Disassemble and clean it as de-
system with metallic particles, change the component scribed in this section under Suction Filter.
and the oil immediately.
• In climates with a wide variation in operating tempera- Warning

tures between summer and winter months, change to Death or serious injury can result from improper use
the appropriate weight oil each spring and fall. of solvents. Follow the manufacturer’s label for proper
use and disposal.
Replace the return line filter cartridge and filler breather cap
every time the hydraulic oil is changed. Also, clean or 6. Inspect the inside of the reservoir. If sludge or other
replace the suction filter. contamination is found, clean it using solvent and lint-
free rags. Remove the return line filter to provide an
A significant quantity of oil remains in the cylinders and additional access hole for cleaning. Disconnect the
lines of the hydraulic system when the reservoir is drained. pump suction line from the bottom of the reservoir
Flush the system when the oil is changed. This is while cleaning. This will keep dirt and solvent out of the
especially important if the system is heavily contaminated suction line.
with metal particles.
7. Reconnect the suction line immediately after clean-
If the oil is contaminated with water, it may not be ing. Use new seals on the cap screws that clamp the
necessary to change the oil and flush the system. Follow filter head to the reservoir. Position the outlet pipe of
the instructions under Water Removal in this section. the return line filter so the angled opening is toward the
side of the reservoir (refer to Figure 4.1).
The following equipment and supplies are necessary to
properly flush the hydraulic system. 8. Install the clean suction filter and new oil fill hole
strainer basket. The replacement filler breather cap
• Approximately 75 gallons (284 l) of proper hydraulic comes with a new cap, strainer basket, gaskets,
oil mounting flange, and screws. However, do not use
• Three return line filter cartridges these screws. Use the original mounting screws with
• Return filter assembly sealing washers the O-ring seals. Apply Dow Corning #730 sealant
• Clean, lint-free rags under the screw heads to provide a water-tight seal.
• Filler breather cap and strainer basket (if compo-
nent has not been replaced within one year) 9. Check the reservoir cover gasket. If it is not in good
• Reservoir cover gasket (if component is not in condition, use a new one. Install the reservoir cover
reusable condition) using new seals for the cap screws.
• Reservoir cover sealing washers
10. If hydraulic component failure has contaminated the
system, change the return line filter cartridge and
Caution clean the in-line filters.
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
work areas clean. Warning
Death or serious injury can result if the recommended
Use the following procedure to flush the hydraulic system. hydraulic oil is not used. Use of other fluids in the

hydraulic system can affect the insulating capability of supplier or a qualified laboratory can determine if water has
the unit. caused excessive oil oxidation or additive deterioration.
Notice If analysis shows oil deterioration beyond an acceptable

Only use hydraulic oil as recommended. Other fluids level, drain the reservoir and flush the system as de-
added to the hydraulic system can increase compo- scribed earlier in this section. Use a water removal filter
nent wear and affect the lubricating characteristics of cart to remove any residual water from the system.
the oil.
If the oil condition is acceptable except for the water
11. Add approximately 25 gallons (100 l) of new hydraulic content, allow time for it to separate from the oil. Then drain
oil of the proper grade to the reservoir. Filter the oil the water off the bottom of the reservoir. Circulate the oil
through a 10 micron filter as it is put into the reservoir. in the reservoir through a water removal filter cart. When
doing this, occasionally start the unit and cycle all the
12. If the new oil was not filtered as it was put into the functions to flush contaminated oil back to the reservoir.
reservoir, connect a service hose to the tool outlets
and allow the new oil to circulate through the tool Continue this process until the water content in the oil is
circuit for about 15 minutes. reduced to an acceptable level. The preferred method of
determining the water content in the oil is laboratory
13. Use a slow engine speed, cycle all the cylinders and testing. Another method is a dielectric test.
motors to flush the contaminated oil from the lines and
components of the hydraulic system. Fully open the Do not attempt to use a water removal cartridge in the
signal drain line needle valve. return line to remove water from the system. The flow rate
of the pump, even at engine idle, exceeds the flow at which
14. Change the return line filter cartridge and clean the in- efficient water absorption occurs.
line filter cartridges.
15. Adjust the signal drain line needle valve 1½ turns open.
Lubrication
Proper lubrication will extend the life of the equipment and
16. Drain the reservoir completely. reduce maintenance problems. The frequency of lubrica-
tion will depend on the amount of use and the conditions
17. Fill the reservoir with new hydraulic oil of the proper the unit is operated in. Lubricate the unit as recommended
grade to the Full mark on the dipstick. Filter the oil by the Preventive Maintenance and Inspection Checklist.
through a 10 micron filter as it is put into the reservoir. Operation in extremely dusty, sandy, or rainy environ-
ments will require more frequent lubrication. After washing
18. If the new oil was not filtered as it was put into the and cleaning the unit, relubricate as necessary.
reservoir, circulate the oil through the tool circuit as
described in steps 12 and 13. The Lubrication Chart and Diagram identifies each compo-
nent, type of lubricant, and method of application. Any
19. Change the return line filter cartridge after approxi- brand of lubricant that meets or exceeds the specifications
mately 25 PTO hours. of the products listed is acceptable. Select the appropriate
interval and lubricate the components identified by the
20. Purge the air from the pilot system by placing the symbol(s).
emergency stop/upper/lower control selector on the
below rotation control in the Emergency Stop position. Components may be installed on your unit that require
Purging the system in warm weather should not additional lubrication. Refer to these component manuals
require more than three to five minutes. for more information.
21. Return control selector to the Lower Controls position. Always wipe grease fittings clean before and after greas-
ing to keep contaminants from entering the points of
22. Operate the unit from the lower controls. Purge the lubrication. To avoid bearing damage, use manually oper-
system again if necessary. ated grease guns. Air-driven grease guns may have
enough force to cause bearing damage.
23. Return control selector to the Upper Controls position.
If the unit is not used, or is stored for any length of time,
Water Removal apply fresh lubricant at all points shown on the Lubrication
If the hydraulic system was contaminated with water, Chart and Diagram. This will help prevent corrosion.
special water removal filtration may be necessary. An oil

Lubrication Chart and Diagram
Service items identified by the symbol(s) at the appropriate level.
85 hours/1 month 500 hours/6 months 1,000 hours/1 year 2,000 hours/2 year If disassembled
Letter Lubricant Application Method
A Anti-Seize Compound — Extreme pressure lubricant that prevents seizure, Brush

corrosion, rust, and galvanic pitting.
C Chassis Grease — Multipurpose lithium base grease with good water Grease gun
resistance, rust inhibition, oxidation stability, and extreme pressure properties.
G Open Face Gear Lubricant — Spray lubricant that penetrates and adheres with Spray
good water resistance, is unaffected by temperature extremes, and has extreme
pressure properties.
R Wire Rope Lubricant — Penetrating, cleaning, nongumming protective spray; Spray

must minimize friction and eliminate rust.
S General Purpose Spray Lubricant Spray
W SAE 140 Worm Gear Oil — AGMA Grade 7 compounded or 7EP, must be Pour
noncorrosive to bronze.
Lift Cylinder Link Pivot

Pivot Pins C Pins C
Cylinder and
Shoe Pins
A
Radial Outriggers Elevator
C Output Shaft
Upper Bearing
Drain Plug Input Shaft

on Bottom Splines
W Oil Level A
W Change Oil
Change Oil W W Oil Level Drain Plug
Rotation Gearbox Winch Gearbox Hydraulic Pump

Platform
Tilt Pin R A Platform Shaft
Winch Drum A
• Shaft
Control Handle Linkage • Keys
• Single handle control • Set screws
• All control handle linkages at platform • Line anchor
• Lower control valve
• Outrigger control valve
Platforms
Valve Spools
• Outrigger
• Tool
• Jib/winch
• Platform rotate
R Upper Boom
Leveling Cables
R Lower Boom Leveling Cables
Leveling System
Elbow Bearing
C Ball Race Rotation Bearing
C Ball Race
Lower Boom Cylinder

Spherical Bearings C A
Rotation Gearbox
Eccentric Ring Rotation Pinion and
G Bearing Gear Teeth
Turntable/Booms

Outriggers
Pin connections on the outriggers are made with zinc Caution
plated pins coated with anti-seize compound to prevent Injury can result from contact with pinion and rotation
corrosion. These connections do not require additional bearing gear teeth. Keep hands clear.
lubrication unless they are disassembled.
Injury can result from being pinched or trapped be-
Bearings tween moving components. Keep hands clear.
Spherical bearings are used in several places on the unit.
They require periodic lubrication with a chassis lubricant. Use caution when access covers have been removed to
It is very important to grease this type of bearing regularly. service the unit. Pinch points and shear points may exist
If they are not greased properly, the usable life of the between moving parts. Replace the access covers imme-
bearing will be greatly reduced. These bearings can diately after servicing.
produce enough twisting force on the mounting pins to
break the pin retainers and make removal difficult if they Remove the pinion cover from the turntable to lubricate the
are not properly lubricated. rotation gear teeth. Replace the cover after the lubrication
has been completed.
Self-lubricating bearings do not require lubrication.
Rotation Bearing Warning

The rotation bearing ball path is lubricated by a grease Death or serious injury can result from being trapped
fitting on the front of the turntable. between moving components. Maintain a safe dis-
tance while components are in motion.
Warning Do not lubricate the gear teeth while operating the unit.
Death or serious injury can result from being trapped Stop turntable movement before lubricating. Rotate the
between moving components. Maintain a safe dis- turntable slowly through a complete 360 degree revolution.
tance while components are in motion.
Gearboxes
Do not lubricate the bearing while operating the unit. Stop The need to add oil regularly to the rotation or winch
turntable movement before lubricating. Rotate the turn- gearbox is a sign of a leak. Determine the cause of the leak
table slowly through at least 2 complete 360 degree and correct it. A low oil level can damage the internal
revolutions, stopping periodically to lubricate. Operate the components of a gearbox.
manual grease gun three to five times at each stop.
The overall life expectancy of a gearbox may be extended
Elbow Bearing by regularly draining and refilling the oil. The best time to
The elbow bearing ball path is lubricated by two grease drain a gearbox is right after it has been operating. At this
fittings on the outside of the outer race. time, the oil is warm and the wear particles are suspended
in the oil. If a gearbox is overheated and the oil smells
burned, change the oil immediately.
Warning
Death or serious injury can result from being trapped If the oil level of a gearbox appears to increase, there may
between moving components. Maintain a safe dis- be an internal hydraulic leak from a defective motor shaft
tance while components are in motion. seal. Change the oil if it becomes diluted with hydraulic oil
from a leaking seal.
Do not lubricate the elbow bearing while rotating the upper
boom. The top bearing on the rotation gearbox requires periodic
lubrication. Three to five pumps with a manually operated
Lubricate the bearing in several positions of the upper grease gun will adequately grease the gearbox bearing.
boom through at least one complete cycle. Operate the The oil should be level with the bottom of the fill hole.
manual grease gun three to five times on each grease
fitting. Rotate the boom 10 to 15 degrees and lubricate The rotation and winch gearboxes have vent plugs that
each fitting again. After lubricating, fold and unfold the must be kept free of paint and dirt. The vents prevent
upper boom through two full cycles. excessive pressure buildup inside the gearboxes as the oil
expands during operation.
Rotation Gear Teeth
Apply an open face gear lubricant to the rotation gear and
pinion teeth.

Leveling Cables Keep the platform clean of debris. The weight of the
The cables for the leveling system require lubrication with operator and the debris may overload the platform.
a wire rope lubricant. Do not allow the cables to run dry.
If a pressure washer or steam cleaner is used to clean the
Control Handles unit, be careful where the spray is directed. Do not direct
The connecting link pivot points of the single handle the spray where the cleaning liquid might get into electrical
control, outrigger, tools, jib tilt, winch, and platform level- components, such as electrical connections, switches, or
ing, rotate, and tilt controls require periodic lubrication. lights. Even though electrical components on the unit are
Use a general purpose spray lubricant on the linkage. designed for all weather use, water pressure from the
nozzle can push a seal out of position. Do not direct spray
Single Handle Control at the filler breather cap of the reservoir. The high pressure
Use a small amount of general purpose spray lubricant on can force water and cleaning liquid into the reservoir and
the control linkage pivot points. Wipe off the isolating links contaminate the hydraulic oil. Do not clean the rotary joint
and any excess lubricant. Isolating links must be clean or spool ends of any hydraulic valve with direct pressure
and dry. from a pressure washer. Limit the water pressure to 500 psi
(34 bar) and keep the spray tip at least 18″ (46 cm) away
Valve Spools from these components while washing. After washing and
Use a small amount of general purpose spray lubricant on cleaning the unit, relubricate as necessary.
the exposed surfaces of valve spools to keep the spools
operating smoothly. Operate the valve handle to spread Refer to Fiberglass and Plastic Components in this section
the lubricant on the spool. Wipe off any excess lubricant. for information on cleaning the fiberglass components.
Welds
Structures All welds on the unit are originally applied in conformance
The structural components of the unit are identified in the to AWS standards. Every weld on the unit is important and
Component Identification in Section 2. The unit has been should be periodically inspected.
designed to meet or exceed the ANSI specifications for
vehicle-mounted rotating and elevating aerial devices.
Warning
Regular inspection of the welds and structures is required Death or serious injury can result from improper use
to insure that components maintain their strength. Peri- of solvents. Follow the manufacturer’s label for proper
odic cleaning of the structures is also recommended to use and disposal.
prevent damage that can occur from dirt accumulation.
If paint has lifted off a weld, or rust is found, a closer
inspection is required. Remove loose paint or rust with a
Caution wire brush. Clean the area with a solvent such as acetone.
Injury can result from slipping and falling. Use care Closely inspect for cracks in the welds. Dye penetration
and all handles and steps provided. and magnetic particle testing are simple processes that
may be used to verify or disprove a suspected problem.
Periodic inspection of the structures is recommended to
be certain there is no deformation, abnormal wear or Visual inspections can be very effective if conducted
abrasion, interference between moving parts, or cracking properly. Clean the area to be inspected. Look for visible
of the welds on structural members. cracks in the weld and at the weld-to-parent material joint.
Use a bright light to aid visibility of the inspection area.
Inspect the structures and welds as recommended by the
Preventive Maintenance and Inspection Checklist. Pay close attention to welds that are located where
changes in cross section take place and near the attach-
Cleaning ment points of highly loaded components. To assist in the
Accumulated dirt can damage the unit and cause it to inspection of the welds on the unit, Figure 4.5 illustrates
malfunction. It also accelerates wear on the components. these areas. If any cracks or unacceptable conditions are
discovered, report them to your Altec representative.
Caution Any welds added in the field should be done by qualified
Spilled hydraulic oil creates slick surfaces and can personnel and also conform to AWS standards.
work areas clean. After doing repair work on the unit, such as weld repair,
some testing of the unit may be required.

Boom Tip
Upper Boom
Weldment
Upper and Lower

Boom Elbow
Weldments Upper Boom
Cylinder Attachment
Lower Boom
Cylinder Attachment
Pin Bosses
Cylinder
Attachment Brackets
Lower Boom
Weldment Pin Bosses Pedestal and
Turntable Bearing
Mounting Plates
Pin Bosses Cylinder

Attachment Brackets
Pin Bosses
Front and Rear

Pedestal to
Subbase Area
Figure 4.5 — Weld Inspection Areas

Refer to Section 6 for information on repairing mechanical screws, or special high strength cap screws, are used in
components. highly loaded areas. A variety of other fasteners such as
socket head, flat countersunk head, and button head cap
screws are also used on the unit.
Fasteners
A variety of fasteners are used on the unit. Fasteners have Check all fasteners for tightness as recommended by the
different inspection and installation requirements depend- Preventive Maintenance and Inspection Checklist.
ing on their use and design. This section explains different
fasteners on the unit, torque specifications, and the use of Figure 4.6 represents general locations of fasteners to
thread locking and anti-seize compounds. inspect. When inspecting fasteners, pay particular atten-
tion to the following fasteners.
The standard grade of fastener used on the unit is a zinc
plated, SAE Grade 5, steel cap screw. SAE Grade 8 cap
Winch
Platform
Upper Boom
Elbow Bearing
All Pin
Insulator Retainers
Rotation Gearbox Rotation Bearing
All Pin Retainers

All Pin
Retainers
Figure 4.6 — Fasteners

• Subbase fasteners Methods of Lockwiring
• Outrigger attachment fasteners Drilled head cap screws retained by lockwires are used at
• Elevator arm attachment cap screws certain locations on the unit. For example, cap screws
• Rotation bearing mounting cap screws used with forged pin retainers are lockwired. Fasteners
• Rotation gearbox mounting cap screws that must be lockwired are noted in the Parts Manual.
• Lower boom insulator attachment cap screws
• Elbow bearing mounting cap screws The turnbuckles used in the leveling system are also
• Upper boom base end attachment cap screws lockwired. The technique used to lockwire the turnbuckles
• Boom tip attachment cap screws is covered in Section 6 under Leveling System.
• Winch mounting cap screws
• Platform mounting cap screws If any lockwires are found broken or damaged during
• Lanyard attachment cap screws inspection, the wires must be replaced. If a lockwire is cut
• All pin retainer cap screws off to remove a fastener, it must be replaced.
A properly installed cap screw applies a clamping force A relatively soft, aircraft-type safety wire must be used for
equal to or greater than the load applied to it. A cap screw lockwiring. The following types are acceptable.
installed at less than the recommended torque value does
not provide enough clamping force. The cap screw may • Stainless steel safety wire
fatigue, causing it to loosen or fail. If the cap screw is Alloy 304, 0.043″ diameter
torqued beyond the recommended torque value, the elas-
tic range of the cap screw may be exceeded. This may • Zinc coated carbon steel wire
result in premature failure of the cap screw. MS20995F41, 0.041″ diameter
When checking fastener torque value, check at 90 percent Notice

of the original value. For example, if the torque value for a Use only new wire for lockwiring.
cap screw is 100 foot-pounds (136 N•m), check the cap
screw for tightness at 90 foot-pounds (122 N•m). Before lockwiring, make sure the fasteners are properly
tightened to the proper torque value. Do not loosen
Some fasteners require torque values that differ from fasteners or torque them beyond specified values to try to
common torque charts. Refer to Figure 4.7 for the proper improve the location of the holes in the cap screw heads.
tightening torque for these fasteners on this unit.
Handle the wire carefully during installation. Make sure it
Foot-Pounds (N•m) does not become kinked, nicked, or flattened. Avoid
pulling the wire around sharp corners. Also avoid twisting
Rotation bearing cap screws 325 (441)
it excessively or gripping it tightly with the pliers.
Rotation gearbox mounting cap screws 225 (305)
Lower boom insulator cap screws 142 (193) Use pliers that have smooth, flat jaw surfaces to minimize
nicking the wire. Special wire twister pliers are available
Elbow bearing cap screws to lower boom 225 (305)
from tool manufacturers. These pliers make it much easier
Elbow bearing cap screw nuts to upper boom 175 (237) to produce neat and effective lockwires.
Upper boom base end attachment cap screws 70 (95)
Boom tip attachment cap screws 70 (95) Snug Twists With no Slack
Platform mounting cap screws 55 (75) Snug Loop Around Head
Figure 4.7 — Torque Values
Many general application fasteners would not normally

require an installation torque or lubrication but instead
would be installed using sound mechanical practices. If it
is desired to more closely control the fastener clamp load
Pigtail
it is recommended that a copper-based anti-seize com-
pound be applied. Refer to Torque Values in the Appendix Retaining Plate Forged Pin Retainer
as a guide to determine the proper cap screw torque value.
Figure 4.8 — Lockwiring

Lockwiring Procedure 4. Clean the area where the inspection stripe is to be
1. Install the lockwire so that it keeps the fastener from applied with a soft clean cloth and acetone.
turning counterclockwise.
5. Start at the center of the cap screw and apply a 1/32″
2. Twist the wires between the anchor point and the to 1/16″ (0.8 to 1.6 mm) thick stripe of inspection
fastener so that there is no slack. Twist the wire tightly lacquer to the head of the cap screw, across the
enough to secure the part. Do not over twist or the wire washer, and onto the surface of the parent material.
will become brittle or stressed. The stripe should extend 1/8″ to 1/4″ (3.2 to 6.4 mm) onto
the parent material.
3. Install and twist the lockwires so that the loop around
the cap screw head is snug and does not come off and 6. The stripe must be continuous across the surfaces. If
leave a slack loop. it is not, remove the stripe with cleaner and reapply the
inspection lacquer properly.
4. Cut the wire off straight with wire cutters.
Thread Locking Adhesives
5. Make a pigtail of three to six twists at the end of the and Anti-Seize Compounds
wiring. Bend the end of the pigtail back or under. This Anaerobic thread locking adhesives work in the absence
will prevent the sharp wire ends from being a potential of air. When a fastener is removed, it must be cleaned
cause of injury or a snag point. thoroughly and the adhesive must be applied before
reinserting. Properly torque the fastener before the adhe-
Inspection Marks sive cures, which occurs within 15 minutes of application.
Nuts or cap screws with locking patch element used in
combination with inspection marks are used at specific Apply medium strength anaerobic thread locking adhesive
locations on the unit. Many are visible to the operator on the threads of the fasteners listed below to provide
during daily inspections. additional security against loosening.
If any inspection marks are found to be cracked or broken • Pin retaining fasteners
during inspection, the original mark must be totally re- • Rotation gearbox mounting cap screws
moved. The fastener torque must be checked (if no
damage is evident) or the fastener replaced and torqued (if
damage is evident), and the inspection mark reapplied. Warning
Death or serious injury can result from improper use
The inspection lacquer (refer to Service Tools and Sup- of solvents. Follow the manufacturer’s label for proper
plies in the Appendix) should not be used after the use and disposal.
expiration date printed on the container.
Use the following procedure to apply a new inspection mark. Caution

1. Remove the majority of the original inspection mark by eyes. Wear appropriate safety equipment.
chipping it off with a chisel or other cutting method. Do
not damage the surface on the nut, fastener, washer, If the threads of the fasteners are not clean and free of
and part or structure being attached to. grease and oil, the effectiveness of the thread locking
adhesive will be reduced. Clean the threads of the fasten-
ers with solvent and blow dry with compressed air before
Warning applying the thread locking adhesive.
of solvents. Follow the manufacturer’s label for proper For optimum thread locking, follow the manufacturer’s
use and disposal. label for proper use and disposal.
2. Be sure the cleaning operation is performed in a well- Anti-seize compound may be used to prevent rust and
ventilated area. Remove the remaining residue using corrosion from forming on the metal-to-metal contact
inspection lacquer cleaner (refer to Service Tools and areas between a connecting pin and its boss. It is also
Supplies in the Appendix). Apply the cleaner to a rag recommended for certain fasteners to reduce friction
and completely remove the inspection stripe. during torquing to increase clamping load. Apply anti-seize
compound to the following components.
3. Properly torque the fastener.

• Pump output shaft splines Bearing Cap Screws). If a cap screw will not remain
• Outrigger cylinder and shoe pins properly torqued between normal inspections, further in-
• Radial outrigger pivot pins spection may be required.
• Rotation gearbox eccentric ring
• Boom pin Impacts to and excessive forces on the unit due to
• Lower boom cylinder pins vehicular accidents, rollovers, and excessive loading may
• Upper boom cylinder pins result in structural damage not obvious during a visual
• Upper boom drive link pins inspection. A more detailed inspection by a qualified
• Leveling sheaves — inside bore/keys/keyways individual may be required to determine if replacement of
• Winch drum shaft/keys/set screws/line anchor the rotation bearing and fasteners is required.
• Platform pin
Visual Inspection Procedure
The area on which the anti-seize is applied must be clean Perform this visual inspection procedure as recommended
and dry for the anti-seize to be effective. by the Preventive Maintenance and Inspection Checklist.
Visually inspect all rotation bearing cap screws, looking for
Chrome pins used with self-lubricating bearings require any evidence that a cap screw is loose. Check for loose
special attention. Apply anti-seize compound to the sur- washers under the heads of the cap screws by trying to
face of the pin only where the pin and steel pin bosses turn each washer by hand. If movement is indicated, all the
make contact. This pin installation procedure is described cap screws must be retorqued using the Retorquing
under Pins and Pin Retainers in this section. Procedure.
Rotation Bearing Cap Screws Annual Torque Inspection Procedure

Special high strength 3/4″ cap screws are used to secure Check the cap screws to be sure they are torqued to 90
the rotation bearing to the pedestal and the turntable. The percent of the normal installation torque. Use a regularly
cap screws are coated with a dry film lubricant and have calibrated, accurate torque wrench. If one or more of these
a patch lock material permanently bonded to the threads. cap screws turns before the wrench clicks, check the
The torque value for the cap screws is 325 foot-pounds torque on all the cap screws as described under Retorquing
(441 N•m). The cap screws require special inspection Procedure in this section. If the rotation bearing is replaced
procedures. Insufficient or uneven cap screw tightness or removed, the same inspection intervals must be fol-
can contribute to reduced life of the bearing. lowed.
Notice Retorquing Procedure

Only use Altec supplied cap screws and washers to Perform this procedure on the entire bearing race if any cap
install the rotation bearing. screws were found loose at the visual or annual inspec-
tions.
When rotation bearing cap screws or washers are re-
moved, they must be replaced with new ones. Contact 1. Retorque according to the appropriate pattern shown
your Altec representative for replacement fasteners. in Figure 4.9.
2. Begin with cap screw number 1 on the outer race and

Caution torque it to 325 foot-pounds (441 N•m).
tween moving components. Keep hands clear. 3. Continue around the pattern, torquing each cap screw
to 325 foot-pounds (441 N•m).
Use caution when access covers have been removed to
service the unit. Pinch points and shear points may exist 4. Retorque all cap screws to 325 foot-pounds (441 N•m)
between moving parts. Replace the access covers imme- again, beginning at number 1. Go around in a circular
diately after servicing. pattern instead of in the numbered order.
Notice 5. Repeat steps 1 through 4 on the inner race cap

Use an accurate 3/4″ drive click-type manual torque screws, torquing each cap screw to 325 foot-pounds
wrench for the inspection of these cap screws. Torque (441 N•m).
the cap screws by a smooth pull on the torque wrench
without jerking. Do not overtighten the cap screws. Elbow Bearing Cap Screws
Special high strength cap screws are used to secure the
If any cap screws are broken or missing, replace all the elbow bearing to the lower and upper booms. The cap
fasteners in that race (refer to Section 6 under Rotation screws require special inspection procedures.

Grease Tube
23 Connector
1 20 21
13 14 17
16
8 6 12 13
8 9
12 9 4 5
3 4 2 1
11 10 6 3
Loading Plug
10 7
5 7 11
14
16 15 18 15
2 22 19
Outer Race Inner Race
Figure 4.9 — Cap Screw Torque Patterns
The cap screws securing the outer race to the lower boom tion Checklist. Perform this inspection at the same interval
are coated with a dry film lubricant and have a patch lock on units that have had a new elbow bearing installed.
material permanently bonded to the threads. The torque
value for the cap screws is 225 foot-pounds (315 N•m). Some seating in of the cap screw threads and mounting
surfaces may occur in any fastened joint during the initial
The cap screws securing the inner race to the upper boom break-in period. This causes a partial loss of cap screw
are installed with self-locking nuts and flat washers. The tension without any cap screw rotation. A spot check of the
torque value for the cap screws is checked on the nut at cap screw torque is required as recommended in the
175 foot-pounds (245 N•m). Preventive Maintenance and Inspection Checklist.
Insufficient or uneven cap screw tightness can contribute Outer Race

to reduced life of the bearing. 1. Remove the covers from the elbow area. If this is the
inspection after the unit’s first six months of operation,
remove and discard the protective plastic caps from
Caution the cap screw heads.
tween moving components. Keep hands clear. 2. Only one cap screw per quadrant requires a torque
test. At this inspection, the cap screws are to be
Use caution when access covers have been removed to checked at 90 percent of the recommended torque or
service the unit. Pinch points and shear points may exist 200 foot-pounds (271 N•m). If all four quadrant fasten-
between moving parts. Replace the access covers imme- ers are tight, the inspection is complete for the outer
diately after servicing. race.
Notice 3. If any of the four cap screws that are checked move,
Only use Altec supplied cap screws and washers to mark them and check the remaining cap screws in a
install the elbow bearing. circular pattern. If six or more of the entire cap screw
pattern are found loose, use the torque pattern in
Use an accurate 1/2″ drive click-type manual torque Figure 4.10 for the retorquing sequence. If less than
wrench for the inspection of these cap screws. Torque six are found loose, use a circular pattern. If any of the
the cap screws by a smooth pull on the torque wrench elbow bearing cap screws moved when torquing, you
without jerking. Do not overtighten the cap screws. must retorque each cap screw again. This torquing
should be done at 225 foot-pounds (305 N•m).
Initial Torque Inspection Procedure
Perform the initial inspection on a new unit at the interval
recommended in the Preventive Maintenance and Inspec-

Visually inspect all elbow bearing cap screws, looking for
15 1
10 8 any evidence that a cap screw is loose. Check for loose
washers under the nuts or the heads of the cap screws.
3 13 Also check for evidence of movement between the bearing
and boom weldment. Movement can be checked by
17 6 raising the upper boom a few feet out of the boom rest and
rocking the upper boom side to side. If there is any
12 11 indication of movement or a loose washer, follow the
complete torque inspection procedure as described under
5 18 Initial Torque Inspection Procedure.
14 4 Annual Torque Inspection Procedure

Perform the following procedures yearly.
7 9
2 16
• Initial Torque Inspection Procedure
Figure 4.10 — Cap Screw Torque Pattern • Bearing Clearance Test
(refer to Elbow Bearing in this section)
Inner Race
1. Use a circular pattern to check the torque of the nuts. Rotation Gearbox Mounting Cap Screws
The inner race is attached to the upper boom side Special 5/8″ cap screws are used to secure the rotation
using cap screws with self-locking nuts. An antirotation gearbox to the turntable. The torque value for the cap
ring holds the cap screw heads stationary. It may be screws is 225 foot-pounds (305 N•m). The cap screws
necessary to loosen the leveling cables and remove require special inspection procedures.
the leveling cable sheave to access all of the nuts.
Insufficient or uneven cap screw tightness can contribute
2. Check the torque value on the nut at 90 percent of the to reduced life of the gearbox.
recommended torque or 158 foot-pounds (214 N•m).
Caution
3. If a nut is loose, mark it and continue around the
pattern until all have been checked at 158 foot-pounds Injury can result from being pinched or trapped be-
(214 N•m). If less than nine nuts moved when check- tween moving components. Keep hands clear.
ing the torque, use a circular pattern to retorque the
nuts to 175 foot-pounds (237 N•m). If all fasteners Use caution when access covers have been removed to
were properly torqued, the inspection for the inner race service the unit. Pinch points and shear points may exist
is complete. If nine or more of the nuts moved when between moving parts. Replace the access covers imme-
checking the torque, use the pattern shown in Figure diately after servicing.
4.10 to retorque the nuts to 175 foot-pounds (237
N•m). Notice
Only use Altec supplied cap screws and washers to
4. If nine or more of the nuts are loose on either side of install the rotation gearbox.
the bearing, examine the bearing for excessive wear
as described under Bearing Clearance Test. Use an accurate 3/4″ drive click-type manual torque
wrench for the inspection of these cap screws. Torque
5. If it was necessary to loosen the leveling cables and the cap screws by a smooth pull on the torque wrench
remove the leveling cable sheave, install the sheave without jerking. Do not overtighten the cap screws.
and properly tighten the leveling cables as described
in Section 8 under Leveling System. Visual Inspection Procedure
Perform this visual inspection procedure as recommended
6. Replace the covers. by the Preventive Maintenance and Inspection Checklist.
Visual Torque Inspection Procedure Visually inspect all rotation gearbox cap screws, looking
Perform the visual inspection procedure at the interval for any evidence that a cap screw is loose. Check for loose
recommended in the Preventive Maintenance and Inspec- washers under the heads of the cap screws by trying to
tion Checklist. turn each washer by hand. If movement is indicated,
retorque all the cap screws.

Annual Torque Inspection Procedure If a forged pin retainer is damaged, determine the cause of
Check the cap screws to be sure they are torqued to 203 damage. Lubricate or take the connection apart and
foot-pounds (275 N•m) or 90 percent of the normal instal- replace the necessary parts.
lation torque of 225 foot-pounds (305 N•m). Use a regularly
calibrated, accurate torque wrench. If one or more of these Retaining Rings
cap screws turns before the wrench clicks, retorque all the Retaining rings are used as a back-up retaining system for
cap screws to 225 foot-pounds (305 N•m). If the rotation some pins and as the only retaining system for others.
gearbox is replaced or removed, follow the same inspec- When inspecting retaining rings, check that they are
tion intervals. properly installed and undamaged.
Figure 4.11 shows how retaining rings are used as a back-

Pins and Pin Retainers up retainer on the lower boom cylinder pivot pins. If the
A variety of pins and pin retainers are used on the unit. The forged pin retainer should fail or fall out, the retaining rings
type of pin or pin retainer used depends on the particular will hold the pin in place. However, they will not prevent the
application. pin from rotating. Immediately determine the cause of the
problem and replace and/or repair the necessary parts.
Chrome plated pins are used in many areas, such as the
lower boom pivot pin. The chrome plating reduces the Install retaining rings with the sharp edge out (refer to
likelihood of rust and provides long wear for pins used with Figure 4.12). This makes it more difficult for the retaining
self-lubricating bearings. ring to come off the pin if the pin is being forced out the
other side.
Use a dead blow hammer to remove or install pins. Striking
the pin with a steel hammer may distort the pin or close the
retaining ring groove. This may make pin installation Sharp
difficult or cause the retaining ring to come out of its Edge
groove.
Inspect all pivot and mounting pins as recommended by

the Preventive Maintenance and Inspection Checklist.
Forged Pin Retainers Section A-A

Forged pin retainers are used to retain some pins on the
unit. A forged pin retaining system is illustrated in Figure Figure 4.12 — Retaining Ring
4.11.
Flange and Lug Retainer
Lockwire Lock A flange and lug retainer system is used on the upper boom
Cylinder Eye
Washers drive link connections (refer to Figure 4.13).
Weld Rollpin Bearing Retaining

Stem
Plate
Pin
Forged Pin
Retaining
Retainer
Ring
Retaining
Ring End Plate Lockwire
Pivot Tube
Figure 4.11 — Forged Pin Retaining System
Figure 4.13 — Flange and Lug Retention System
During inspection, look for bent or broken stems. A bent or
broken stem may indicate the bearing within the joint is The pivot pin has an end plate welded to one end, and a
worn out. Also, if the pin binds within the joint and tries to retaining plate held to the other end by two cap screws that
turn, the stem could bend or break. This may indicate a are lockwired. A rollpin has been installed through the pivot
lack of lubrication. Make sure the cap screw through the pin end plate to prevent the pin from turning.
eye of the pin retainer is secure.

When inspecting the link pivot pins, check for cracking of First Boss Second Boss
the end plate weld, distortion of the holes in the end plate, Bearing
Pin
and shearing of the rollpins. Any of these conditions
indicate that the bearings are binding, requiring the con-
nection be taken apart and the necessary parts replaced.
Lower Boom Pin Retainer

A retention method similar to the flange and lug system
holds the lower boom pin in place. This system uses an end
plate held in position by four cap screws that are lockwired
(refer to Figure 4.14). The other end of the pin is threaded
and uses a self-locking nut with a flat washer. The torque
value for the self-locking nut is 225 foot-pounds (305 N•m).
Anti-Seize Compound
Flat Washer Lockwire Figure 4.15 —

Pin Installation Into Self-Lubricating Bearings
Pin Bearings
The unit is equipped with a variety of bearings. The type
of bearing used depends on the particular application.
Self-Locking End Plate Spherical Bearings

Nut Bearing Spherical bearings are used at both ends of the lower boom
cylinder. Self-aligning bearings such as these are used in
Figure 4.14 — Lower Boom Retention System
areas where perfect alignment is difficult to maintain. This
type of bearing allows the component to follow the move-
When inspecting the lower boom pin, check for cracking of
ments of the structure without applying a side load to the
the flange welds and cap screw distortion. Inspect the nut
internal components of the cylinder.
for signs of looseness. Any of these conditions indicate
that the bearings are binding and that the pin is trying to
Periodic lubrication of these bearings is required. Lubrica-
turn. Take apart the connection and replace the necessary
tion prevents the inner rim that maintains the alignment
parts. The self-locking nut is not reusable. If the nut is
from seizing to the outer rim of the bearing. Lubrication in
removed from the pin, it must be replaced with a new nut.
this section describes how to lubricate these bearings.
Pin Installation Into
Pressure Cast Cylindrical Bearings
Self-Lubricating Bearings
A pressure cast cylindrical bearing is used to connect the
When installing a pin into a self-lubricating bearing, only
outrigger pad to the rod end of the cylinder on some radial
lubricate the area where the pin and the boss make contact
outriggers. This bearing is designed for high strength, high
(refer to Figure 4.15).
load situations. Excellent impact, wear, and corrosion
resistance are characteristics of this bearing. Particles of
Use the following procedure to properly install the pin.
molybdenum disulfide solid lubricant have been dispersed
throughout the bearing material. This type of bearing
1. Slide the pin through the first boss and through the
requires no additional lubrication.
bearing until it reaches the second boss.
Self-Lubricating Bearings
2. Apply an anti-seize compound to the second pin boss
Self-lubricating bearings are designed for long life. Under
and pin surface that is still exposed.
normal use, this type of bearing will provide many years of
service with virtually no maintenance. These bearings
3. Slide the pin completely into the second pin boss and
resist impact and shock loads and abrasive contaminants.
install the appropriate retaining system.
Self-lubricating bearings are made with a braided cord liner
containing Teflon fibers. The liner is bonded to the outer
shell of the bearing with epoxy resin. The epoxy resin has
a self-lubricating filler added to it. A chrome plated pin is
used with this bearing.

The inside diameter of a self-lubricating bearing contains 4. Place the new bearing on a bearing driver. Line it up
Teflon fibers. Once a pin is installed in the bearing, some with the bearing boss and drive the bearing into place
of the Teflon transfers to the pin surface and provides using a dead blow hammer. An old pin may be used as
lubrication. Applying anti-seize compound to the entire a driver (refer to Figure 4.16).
surface of the pin will prevent the Teflon from transferring.
This may shorten bearing life. 5. Inspect the pin before installing it into the bearing. If
the chrome is flaked, cracked, or galled, use a new
Replace these bearings if the components are disas- pin.
sembled for other purposes. Replacement of this type of
bearing due to wear is not a normal consideration. 6. Slide the pin through the first pin boss and through the
bearing until it reaches the second pin boss.
If it is desirable to measure the bearing to determine when
it is worn, consider several factors. The only accurate way 7. Apply anti-seize compound to the second pin boss
to measure bearing wear is to keep a record of the and pin surface still exposed (refer to Figure 4.15).
clearance between the chrome pin and bearing. Place the
magnetic base of a dial indicator in a position that allows 8. Slide the pin completely into the second pin boss and
the clearance between the pin and bearing to be measured install the appropriate pin retaining system.
under load. Take an initial measurement when the unit is
new to provide a reference point. Monitor the change in 9. Pins equipped with flange and lug fasteners require
bearing clearance with subsequent measurements. from 0.010″ to 0.080″ (0.254 mm to 2.032 mm) pin play
(end clearance between the bushing and the boss).
For self-lubricating bearings, clearance wear on the bear- This is accomplished by adding or subtracting ma-
ing of 0.005″ (0.13 mm) may suggest that the bearing chine bushings to obtain the desired dimensions.
needs to be replaced. This figure takes into account only
the wear of the bearing. Over time, there may also be pin Measure Clearance Here
and pin boss wear. An overall change in the clearance
between the pin and the bearing of 0.020″ (0.5 mm) or more Lug
indicates the pin and bearing both need to be replaced.
Replacement
The following steps describe how to remove and install Pin
self-lubricating bearings.
1. Drive out the old bearing. If this is not possible,

remove it with a die grinder, cut point chisel, or Lockwire
hacksaw blade (refer to Figure 4.16). Be careful not to Machine Bushing Bearing
damage the inside diameter of the bearing boss.
Figure 4.17 — Machine Bushings Clearance
Removal
Tool
Tapered Roller Bearings
Tapered roller bearings are often used in gearboxes. This
bearing type can be used at high speeds and will support
radial and axial loading. Depending on the application, this
Bearing bearing may be installed with several thousandths inch
end clearance, no clearance, or with a preload.
Driver
Removal Installation
A preload is 0.000″ clearance minus a few thousandths.
Figure 4.16 — Removal and Preload is sometimes checked with a torque wrench (stall
Installation of Self-Lubricating Bearings torque) or with a line and scale (rolling torque). Shaft load
and speed of the particular application will determine the
2. Use a screwdriver and needle nose pliers to collapse method of installation. Light loads and high speeds will call
the bearing and pull it out of the bearing boss. for a specific amount of end clearance. Heavy loads and
low speeds will call for a specific amount of preload on the
3. Clean the bearing boss. Do not remove any metal from bearing. Proper installation and lubrication of the tapered
the boss surface. If metal is removed, the new bearing roller bearing are very important in determining the useful
may not fit properly in the boss. life of the bearing.

Rotation Bearing measurement, and periodic measurements show a
The turntable rotates on a shear ball bearing called the trend of accelerated wear, replace the bearing.
rotation bearing. The inner race is mounted to the turn-
table. The outer race is mounted to the pedestal. The outer 500 Hour/6 Month
race has gear teeth that mesh with the rotation pinion. The Inspections Example 1 Example 2
bearing provides for very low torque rotation. 1 0.112″ (2.84 mm) 0.110″ (2.79 mm)
2 0.114″ (2.89 mm) 0.114″ (2.89 mm)
Monitoring Bearing Wear
The internal bearing clearance will increase slightly during 3 0.116″ (2.95 mm) 0.122″ (3.10 mm)
the break-in period. It should then remain essentially
Figure 4.18 — Turntable Tilt Measurements
constant for many years if the bearing is properly lubri-
cated and not overloaded. As the bearing raceway begins
Because the major portion of the measured turntable
to wear, clearance will increase. It should increase steadily
tilt results from structural deflection, the total tilt
at first and accelerate toward the end of bearing life.
measurement varies from model to model. For ex-
ample, overall turntable tilt measurements approach-
An increase in bearing clearance is one sign of bearing
ing 0.200″ (5.08 mm) are not uncommon on some
wear. Periodic bearing tilt measurements will help deter-
models, even on bearings which have not reached the
mine when bearing replacement is necessary. Perform
end of their usable life. Severely worn bearings could
bearing inspection and turntable tilt measurements as
have a measured turntable tilt as much as 0.500″ (12.7
recommended by the Preventive Maintenance and In-
mm) or more in addition to other prominent symptoms
spection Checklist. More frequent inspections are re-
of wear such as unusual noise and roughness. There-
quired when the total increase in turntable tilt measurement
fore, the total turntable tilt measurement itself should
reaches 0.050″ (1.27 mm).
not be used to gauge a bearing’s remaining usable life.
The change in turntable tilt and the trend toward
Take an initial turntable tilt measurement when the unit is
accelerated wear is more important than the total tilt
delivered. This will provide a baseline for future bearing tilt
measurement itself.
measurements. Future bearing tilt measurements will be
compared to this baseline to determine how much the
• Evaluating the “feel” of the unit
bearing tilt has increased since the initial (new bearing)
If there is no trend toward accelerated wear, consider
measurement. The greatest portion of the measured
the “feel” of the unit during load reversals. Operators
turntable tilt results from structural deflection rather than
may notice an increase in turntable tilting or rocking.
bearing internal clearance. It is important that the deflec-
tion be held constant by using the same measurement
• Checking for rotation bearing noise and roughness
procedure each time. Keep a maintenance log to monitor
Determine whether there is any presence of rough-
the bearing inspections and turntable tilt measurements
ness or noise in the rotation bearing during rotation.
during the life of the unit.
Severely worn bearings commonly exhibit grinding,
snapping, and popping noises during rotation. These
Bearing Replacement Criteria
noises may indicate the bearing has broken ball
The rotation bearing must be inspected and evaluated.
spacers, split ball bearings, or excessive galling, the
The recommended bearing inspection procedures include
presence of which would require immediate bearing
the following items.
replacement. Popping or clicking noises might also be
caused by broken or improperly torqued bearing fas-
• Monitoring the trend of turntable tilt measurements
teners, a warped mounting surface, or worn teeth. A
Use bearing inspections and turntable tilt measure-
check of the fastener torque and the rotation bearing
ments to determine when to replace a bearing. Gener-
grease purged during lubrication will usually determine
ally, an increase in turntable tilt of 0.065″ (1.65 mm)
if bearing noise is due to internal or external problems.
above the initial tilt measurement indicates the bear-
ing may be reaching the end of its useful life. Other
• Inspecting the condition of the purged bearing grease
factors related to the condition of the bearing must
Grease from a well worn, poorly maintained, or dam-
also be considered. Determine if the increase in
aged bearing will typically contain fairly large rust or
turntable tilt measurements has been steady or if it
metal particles, instead of metal dust specks which
shows a trend of accelerated wear (refer to Figure
might be found in any bearing. Large rust or metal
4.18). Example 1 shows a steady increase in wear,
particles indicate the bearing has reached an acceler-
which is normal. Example 2 shows an accelerated
ated wear condition and immediate bearing replace-
increase in wear, indicating bearing replacement may
ment is required. The presence of rust indicates
be necessary. If the tilt measurement has reached
inadequate lubrication. Rust is commonly indicated
0.065″ (1.65 mm) above the initial (new bearing) tilt

by extremely dirty grease. Correct this situation to 5. Attach the magnetic base of the dial indicator to the
optimize the performance of the new bearing. Always pedestal, positioning the pointer at either the front or
check the purged bearing grease at each inspection rear of the turntable. The pointer of the dial indicator
and turntable tilt measurement procedure even if there should be positioned against the underside of the
is no presence of roughness, noise in the bearing, or turntable base plate, as close as possible to the
significant change in the turntable tilt measurement. bearing gear cover. Figure 4.20 shows three possible
positions for the dial indicator pointer. Any one of
One or more of these evaluation criteria should detect the these positions may be used. It may be difficult to
need for rotation bearing replacement long before any position the dial indicator and pointer in some zones
threat of failure. By maintaining proper rotation bearing of rotation without interference with the turntable or
lubrication and avoiding overload conditions, the replace- pedestal. In this case, position the dial indicator and
ment bearing should provide many years of service. pointer to the area as close as possible to the
recommended position. Once a correct indicator pointer
Bearing Inspection and Turntable Tilt Measurement position is chosen, it is very important that the same
1. Position the unit on a level surface where the booms pointer position is used for each subsequent tilt
can be elevated and rotated. Apply the parking brake measurement. Therefore, record the pointer position
and chock the wheels. Engage the hydraulic system in the maintenance or service log where the tilt
and properly set the outriggers. measurements are recorded. Some inspectors prefer
to permanently mark the location where the dial
2. Position the booms in a position of near maximum indicator pointer contacts the bearing base plate to
side reach. Exact boom position is not critical. Slowly ensure that subsequent measurements are made in
rotate the turntable 360 degrees using the lower exactly the same spot.
controls while checking for roughness or noise in the
rotation bearing. Repeat using the upper controls
Pinion Gear Cover
since roughness may be felt more accurately from the
platform. Note in the maintenance log whether un-
A • •B
usual noise or roughness was encountered.
3. Rotate the turntable to the position to be used for the

turntable tilt measurement. If the aerial device is Rotation Bearing
normally operated within a particular zone of rotation, •
C Gear Cover
the tilt should be measured with the turntable rotated
to this position. For consistent measurement, always Figure 4.20 — Pointer Positions
use the same rotational position with no load in the
platform each time the tilt measurement is done. 6. Set the dial indicator at zero with the booms in Position
Record the rotational position in the maintenance log. A (refer to Figure 4.19).
4. Position the boom as in Figure 4.19. For reference, 7. Position the booms to Position B as shown in Figure
this position is called Position A. 4.21. Do not rotate the turntable. Record the indicator
reading.
Upper Boom Horizontal

Upper Boom Vertical
Lower Boom Vertical

Lower Boom Horizontal
Figure 4.19 — Position A

Figure 4.21 — Position B

8. Repeat steps 6 and 7 two more times to obtain an 2. Raise the upper boom 4′ to 6′ from the rest position,
accurate reading. disengage the PTO and turn off the engine.
9. Remove the dial indicator to prevent accidental dam- 3. Remove the retract hydraulic hose from the top upper
age. boom cylinder. Plug or cap the openings.
Notice 4. Engage the PTO and use the below rotation controls
Metal particles may be in the grease. Use a putty knife to lower the upper boom into the rest. Disengage the
to collect and wipe the grease. PTO. Do not allow the upper links to contact the lower
cylinder rod.
10. Stow the booms. Lubricate the bearing to purge some
grease for inspection. Wipe some of the purged 5. Attach a magnetic base dial indicator to the end of the
bearing grease, which should be visible around the lower boom. Position the stem of the indicator so that
inside ring of the bearing, on a piece of clean white or its tip will touch on the elbow star weldment as close
light-colored paper. Smear the grease on the paper to the elbow bearing raceway as possible.
into a very thin layer using a straight edge such as a
putty knife. Using a bright light, look for metal particles 6. Wrap a sling around the upper boom tip near the
which are larger than normal specks of metal dust. platform. Connect the sling to an overhead hoist or
Normally, particles large enough to be concerned other lifting device to support the upper boom tip. Use
about will be felt as a rough spot when smearing the the lifting device to raise the upper boom tip 6″ to 8″
grease. The smaller, insignificant particles will not out of the rest.
normally be felt under the straight edge. Also, look for
signs of rust which would indicate poor lubrication. 7. Set the dial indicator at zero. Have someone at the
Record information about the condition of the purged platform end of the upper boom steadily push the
grease in the maintenance log. upper boom away from the turntable. Record the
reading on the dial indicator.
a. If there are metal particles found in the grease that
exceed 1/32″ (0.79 mm), the bearing should be 8. Pull the upper boom toward the turntable and record
replaced at the next maintenance interval. that reading.
b. If there are any signs of rust in the grease, lubricate 9. Repeat the measurement process a couple of times to
the bearing more frequently to purge the old grease verify that accurate readings have been taken. Sub-
out. tract the indicator readings to determine the total axial
clearance. This will typically be 0.012″ to 0.025″ (0.30
11. Refer to Bearing Replacement Criteria to determine if mm to 0.64 mm). The maximum allowable total
bearing replacement is required. clearance is 0.050″ (1.3 mm). If the clearance ex-
ceeds 0.050″ (1.3 mm), the elbow bearing should be
Elbow Bearing replaced.
The elbow bearing will provide many years of service if
properly maintained. As the bearing raceway wears, the 10. Use the lifting device to lower the upper boom to its
internal clearance will increase steadily at first, flatten out rest and remove the sling. Remove the dial indicator
during most of the bearing’s life, and then accelerate and reconnect the upper boom cylinder hydraulic
toward the end of the bearing’s usable life. Periodic hose.
measurement of the elbow bearing, under load reversal
using a magnetic base dial indicator, is the correct means
of monitoring the condition of the bearing. Warning
Death or serious injury can result from uncontrolled
The clearance test should be done annually after insuring movement. Purge the air from the actuator before
the mounting fasteners of the bearing are tight. An inspec- operating the unit.
tion of the lubrication and grease seal should be done at
this time. Keep a permanent record of this measurement 11. Cycle the upper boom several times to the overcenter
so the life of the bearing can be mapped out. position to purge air from the cylinder before putting
the unit back into service. Do not raise the boom more
Bearing Clearance Test than halfway up the first two or three times.
1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the PTO and
properly set the outriggers.

Inspection a. If there is any blistered paint on the bearing itself,
1. Position the unit on a level surface, apply the parking the paint in that area must be removed and the steel
brake, and chock the wheels. Engage the PTO and surface examined for fractures. Dye penetrate can
properly set the outriggers. be used to verify a fine fatigue fracture.
2. Remove the elbow covers. b. If there are any signs of bearing movement or loose
fasteners, check the fasteners with an accurate
3. Wipe off the grease seal. torque wrench using the Initial Torque Inspection
Procedure in this section.
4. Use a screwdriver or other tool to pry the grease seal
out of the groove. 10. Fold and unfold the upper boom while listening for any
noise associated with bearing movement. If any noise
5. Gently pull the seal 4″ to 6″ out of the groove without is heard, report the noise to your Altec representative
damaging the seal. and follow their recommendations.
Notice
Cylinders
Metal particles may be in the grease. Use a putty knife
to collect and wipe the grease. Inspect all cylinders as recommended by the Preventive
Maintenance and Inspection Checklist.
6. Take a sample of grease from between the rings.
7. Wipe the sample on a piece of clean white or light Warning

colored paper. Smear the grease on the paper into a Death or serious injury can result from cylinder fail-
very thin layer using a straight edge such as a putty ure. Do not operate a cylinder that has a dented barrel
knife. Using a bright light, look for metal particles or a damaged rod.
which are larger than normal specks of metal dust.
Normally, particles large enough to be concerned Visually inspect the cylinders for leaks, loose or missing
about will be felt as a rough spot when smearing the pin retainers, broken bearings, bent rods, and dents in the
grease. The smaller, insignificant particles will not rod or barrel.
normally be felt under the straight edge. Also, look for
signs of rust which would indicate poor lubrication. Check for proper operation of the cylinder holding valves
Record information about the condition of the purged by positioning the boom, arm, or outrigger so a load is
grease in the maintenance log. applied to the cylinder to put pressure against the holding
valves. Disengage the PTO. Fully shift the manual lever
a. If there are metal particles found in the grease that for the function being tested. Hold the lever momentarily
exceed 1/32″ (0.79 mm), the bearing should be to allow oil flow from the holding valve to tank. If the
replaced at the next maintenance interval. cylinder does not move, the extend holding valve is
operating properly. If the cylinder retracts slowly, the
b. If there are any signs of rust in the grease, lubricate holding valve may be leaking. Determine the cause of the
the bearing more frequently to purge the old grease problem and correct it before operating the unit.
out.
8. Use a small, sharp tool with a point to check for

Hydraulic Lines
fractures along the inside diameter of the outer ring. Hydraulic hoses and tubes transmit hydraulic oil through-
Move the tool underneath the portion of the grease out the hydraulic system.
seal that has not been removed. If there are any signs
of fractures detected in the ring, take the unit out of Inspect all hoses and tubes as recommended by the
service and replace the bearing immediately. Preventive Maintenance and Inspection Checklist for
wear and/or physical damage. Make sure the hoses are
9. Inspect the outside diameter of the outer ring for any properly routed to avoid sharp edges, kinking, and scuff-
paint blisters and evidence of the outer ring moving on ing. Inspect the tubes for dents or other damage that may
the upper boom mounting surface such as rubbing, restrict oil flow. Make sure all hoses and tubes are held
splinters, or paint cracks. firmly in their support brackets.

lower boom insulator and the base end of the upper boom.
Single Handle Control
If the fasteners are properly tightened and the chemical
and Control Handle Covers
bonds are good, it is unlikely damage will be found. If a
Inspect and perform a confirmation test of the single chemical bond has failed and the unit is operated using the
handle control, if so equipped, as recommended by the mechanical backup fasteners, cracks or elongation of the
Preventive Maintenance and Inspection Checklist. holes may develop around the fasteners. The fasteners
will then begin to show frictional wear. Other fiberglass and
Keep the green single handle control clean, dry, in good plastic components have a variety of mechanical fasten-
condition, and periodically tested to maintain its limited ers that require inspection.
dielectric properties. Wipe any contaminants or moisture
from the surface of the control handle assembly and the Leveling Rods
insulating linkages with a clean dry cloth. Isopropyl alcohol The general condition of the leveling rods should be noted.
may be used to clean these components. Replace any Check rods for scratches, signs of rubbing, cleanliness, or
damaged components with replacement parts from your any other possible damage or wear such as nicks (no nicks
Altec representative and perform a confirmation test on are acceptable). Replace the rods that show signs of
the control. cracks or nicks. There are no repair procedures for leveling
rods. The allowable wear for leveling rods is explained in
Inspect the rubber control valve handle covers as recom- the following paragraphs.
mended by the Preventive Maintenance and Inspection
Checklist. Keep the rubber control valve handle covers in Inspect the entire length of each leveling rod for wear
place and in good condition. Replace damaged covers with marks. Wear marks will have a dull appearance. This dull
replacement parts from your Altec representative. area may show a flat worn into the round surface of the rod
Atmospheric Vents
Wear Mark
Atmospheric vents are located at the boom tip/platform
area. Inspect these vents as recommended by the Pre-
ventive Maintenance and Inspection Checklist. On Cat-
egory A units these vents must also be tested for proper Rod
operation. An atmospheric vent testing kit may be ob-
tained from your local Altec representative (refer to Ser-
vice Tools and Supplies in the Appendix).
Dial Caliper
Fiberglass and Plastic Components
The fiberglass components are covered with gelcoat to Figure 4.22 — Leveling Rod Wear Mark
protect the fiberglass and resin composite. The gelcoat
contains ultraviolet inhibitors to retard the effect of ultra- The cause(s) of the wear must be determined and cor-
violet light on the fiberglass. With minimal care, the sealing rected. Generally, wear marks are caused by the rod
and ultraviolet properties of the fiberglass can be main- contacting a steel edge. Wear marks are not usually
tained for many years. The following sections include caused by the inside diameter of the fiberglass boom. Be
information on the cleaning and repair of fiberglass and certain all metal edges have the burrs removed.
plastic components.
The recommended method for determining an accurate
Inspect the components for cleanliness and any visible measurement of the wear is to use a dial caliper. Should
damage such as scratched, cracked, or chipped gelcoat. a significant wear flat area or several wear flat areas be
Surface irregularities may trap dirt and contaminants, discovered along the length of a leveling rod, contact your
which over time may reduce the dielectric properties of the Altec representative.
fiberglass. Of particular concern are irregularities running
lengthwise on the boom. Trapped contaminants, such as Use the following procedure to determine an accurate
dust particles and water, can cause tracking, providing a measurement of leveling rod wear.
path to ground or possible dielectric failure.
1. Measure an unworn section of the leveling rod to
Search for signs of looseness or movement at the bond establish its true diameter.
areas (fiberglass-to-steel connections) at the ends of the

2. Measure the wear groove. Use the deepest portion of Notice
the wear groove in the wear mark for this measure- Do not coat a fiberglass surface with any product that
ment. Subtract the measurement found in step 1 from will reduce its dielectric characteristics or cause sur-
this measurement. This difference is the depth of the face flashover.
wear groove.
Do not use petroleum-based products to clean the fiber-
Normal operation and maintenance should minimize the glass components. Petroleum-based products will leave
possibility of wear or scratches on the leveling rods. Small an oily residue that attracts dust.
wear marks need to be documented, their possible cause(s)
corrected, and rechecked at another inspection to make Do not use steel wool to clean fiberglass components.
sure they have not increased in size. Retained metallic particles can provide a conductive path.
Replacement of the leveling rods is explained in Section Surface flashover occurs when a substance causes an
6 of this manual. Adjustment of the leveling system is arcing of electricity between two points on the boom. If this
explained in Section 8 of this manual. occurs, the dielectric integrity of the boom can be perma-
nently damaged.
Cleaning
Keep fiberglass and plastic components clean and in good Notice
condition to preserve the dielectric properties and appear- When using a power buffer to polish fiberglass, do not
ance. Clean all components passing through the boom damage or overheat the gelcoat surface.
fiberglass sections.
After the exterior surfaces are clean and dry, polish with
Notice Formula Five Clean ‘N Glaze. For best results, polish
Do not spray water from a high pressure washer fiberglass surfaces by hand.
directly at hydraulic components.
Plastic
The boom interior may be cleaned (as necessary) using a Plastic covers on the unit are covered with an acrylic
pressure washer and directing the stream of soapy water surface to protect the plastic from damage from ultraviolet
inside the boom. Rinsing with clean water will then remove damage. Use a pressure washer and mild detergent to
any detergent residue. Elevate the booms to a vertical clean plastic covers. Rinse with clean water to remove any
position for draining and drying. Allow the booms to dry detergent residue.
thoroughly before operating the unit.
Notice
Using solvents (such as acetone, MEK, or lacquer
Warning thinner) can damage plastic covers. Use only isopro-
Death or serious injury can result from improper use pyl alcohol (rubbing alcohol) to clean plastic covers.
of solvents. Follow the manufacturer’s label for proper
use and disposal. In some situations, pressure washing may not remove all
of the contaminants from plastic covers. Use isopropyl
In some situations, pressure washing may not remove all (rubbing) alcohol to clean this type of contamination.
of the contaminants from the boom interior. A solvent may
be used to clean this type of contamination with some type After the covers are clean and dry, hand polish using an
of swab device. Suitable solvents, such as acetone or automotive type wax.
Methyl Ethyl Ketone (MEK), may be used to clean these
stubborn areas. Please refer to the precautions and Determining the
instructions on the solvent selected for this cleaning Degree of Boom Damage
procedure. This may require removal of some interior Minor damage (scratches on the boom, the boom tip, and
boom components, such as leveling rods and cables, and fiberglass control covers) is repairable. If no fiberglass
hoses. After the contaminated area is swabbed, use the cloth fibers are cut or damaged, determine if the scratch
pressure washer and follow up with a thorough rinsing with or nick affects only the gelcoat or if it is through to the resin.
clean water. To do this, look at the color at the bottom of the scratch.
If the color is white, the damage is on the surface. This
The exterior of the upper boom, lower boom insulator, and damage is minor and can be sanded out as described
the balance of the fiberglass components, may be washed under Surface Damage in this section.
with a mild detergent. When washing these components,
take care not to create any surface scratches.

Notice such damage is discovered, contact your Altec represen-
If the fiberglass is damaged past the gelcoat and tative. They can evaluate the affect of the damage on the
shows up black, and/or the fiberglass cloth fibers are structural integrity of the boom and determine if the
damaged, contact Altec before any repairs are started. damage is repairable or if the boom must be replaced.
If the color at the bottom of the scratch or nick is dark, and If it is determined that the extent and location of the
there is no visible damage to the layers of fiberglass cloth, damage will not reduce the safety factor of the boom, it
the damage is through the gelcoat and just into the resin. may be acceptable to repair the damaged area with gelcoat
This requires a more thorough repair of the gelcoat and is to seal it and place the unit back into service.
described under Gelcoat in this section.
Repair
Any time there is doubt regarding damage to the boom or Repair procedures for all of the fiberglass components on
lower boom insulator, use the following procedure to the unit are described in the following text.
accurately describe the damage before calling Altec.
Surface Damage
1. Identify the quadrant in which the damage has oc- Minor scratches in the surface of the gelcoat may be easily
curred (refer to Figure 4.23). If the damaged area is on repaired. If the bottom of the scratch is the same color as
a line between quadrants, switch to the clock method the gelcoat pigment, repair according to the following
(example—the damage is at the three o’clock posi- procedure.
tion).
Caution
eyes and lungs. Wear appropriate safety equipment.
Quadrant 1
1. Use a dual acting sander with 320 grit sandpaper to
sand the scratched area. Move the sander to sand
Quadrant 4 around the circumference of the boom. Do not sand
Quadrant 2
lengthwise on the boom.
2. When the scratch has almost disappeared, sand by

Quadrant 3 hand with a 600 grit wet or dry sandpaper until the
scratch is no longer visible.
Figure 4.23 — Boom Damage Location 3. Use Formula Five Clean ‘N Glaze to polish the area.
2. Identify the exact area along the boom’s length (or the Gelcoat
lower boom insulator) where the damage is. To do this, Use an Altec gelcoat repair kit (refer to Service Tools and
measure from the base end of the boom to the damage Supplies in the Appendix) with the following procedure.
site (example — 46″ (1168 mm) from the base end of Any scratch that is dark at the bottom is through the
the upper boom). gelcoat and into the resin below.
3. Define the type, size, and the cause of the damage In order for gelcoat repairs to cure properly, the following
[example — 2″ long x 1″ wide x 1/8″ deep (51 mm long special temperature considerations must be understood.
x 25 mm wide x 3.2 mm deep); gouge caused by a The highest quality gelcoat repairs are accomplished
chain saw]. indoors in a heated and well ventilated area.
4. When calling Altec to describe the damage in ques- Notice

tion, be sure to explain where you are in relation to the The gelcoat can be burned during the warming pro-
unit (example — curb side of the unit, facing the base cess. Continually move the heat gun or paint stripper
end of the boom in the rest position). during warming.
If the upper boom or the lower boom insulator has several • If the unit has been outside and the temperature is less
damaged or cut inner fiberglass cloth layers, it may not be than 70 degrees Fahrenheit (21 degrees Celsius), or if
repairable. At this point, the boom’s strength may be this is a field repair, the boom area must be warmed
reduced and repairs will not restore the boom strength. If before proceeding. Warm the fiberglass using a heat

gun until it is warm to the touch. It will take approxi- Platform and Fiberglass Covers
mately 40 minutes to do this. A paint stripper gun will The first step in successful platform repair is to analyze
provide a faster method. Do not concentrate the heat the damage and determine the cause. Cracks in the
of the gun in one specific area for any length of time. gelcoat or outer surface of the platform are easily repaired.
Damage to the fiberglass structure can be more serious
• If the outside temperature is below 60 degrees Fahr- and should be carefully evaluated before attempting to
enheit (16 degrees Celsius), a field gelcoat repair is repair the platform.
not suggested. Makeshift tents over the repair area
will not hold sufficient heat, preventing proper curing. Structural components of the platform include the rim,
mounting ribs, platform sides, and the bottom (refer to
Figure 4.24). The platform is constructed similar to a
Caution basketball hoop and net. The rim supports the sides in the
Injury can result from airborne particles entering the same way a basketball hoop supports a net. The structural
eyes and lungs. Wear appropriate safety equipment. integrity of the platform rim is critical in determining
whether or not the platform can be successfully repaired.
Use the following procedure to repair the gelcoat.
Rim
1. Use a die grinder to widen the scratch to 1/8″ (3.18 mm).
Do not grind into the fiberglass cloth. Mounting
Ribs
2. Inspect the scratch. If the fiberglass cloth is cut,
contact your Altec representative. If no fiberglass
cloth is damaged, bevel the edges of the 1/8″ (3.18 mm)
cut to about 45 degrees.
3. Lightly sand the damaged area by hand to roughen it

up. This will help the resin bond to the surface. Sides
Figure 4.24 — Platform

Warning
Death or serious injury can result from improper use The platform bottom and the side with the mounting ribs
of solvents. Follow the manufacturer’s label for proper are substantially thicker than the other three sides. The
use and disposal. mounting ribs are the areas where the platform mounting
bracket fastens to the platform. Consider these factors
4. Use a solvent such as acetone to clean the area and when determining whether a successful repair can be
remove any dust. made on the platform bottom or mounting rib side.
5. The Altec gelcoat repair kit contains a can of resin, a Altec cannot determine if the platform is repairable in the
can of fumed silica powder, and a bottle of hardener. field. Evaluate the platform and determine whether or not
Refer to the material safety data sheet included with it can be repaired and safely used for future service. Altec
the kit for the special precautions and recommenda- does not recommend that repairs be made to platforms
tions for use with this product. Mix the resin, powder, which have the following damage.
and hardener according to the kit instructions.
• Cracks through the fiberglass of the mounting ribs
6. Apply the mixture to the damaged area with a plastic • Cracks through the fiberglass of the rim
spatula. Work the spatula back and forth to remove • A hole through the floor or mounting rib side of the
any air bubbles. Build up the area so it is slightly above platform
the boom surface. The mixture will shrink slightly as
it cures. Altec only assumes responsibility for platform repair
performed by Altec personnel.
7. When the area has cured, sand the area by hand with
600 grit wet or dry sandpaper. Sand until the patch is
no longer visible. Warning
Death or serious injury can result from contact with
8. Use Formula Five Clean ‘N Glaze to polish the area. energized conductors. Do not operate the unit with a
hole in the platform or liner.

The following items are required to perform field repair of Notice
the platform or fiberglass boom tip covers. Do not coat a fiberglass surface with any product that
will reduce its dielectric characteristics or cause sur-
• Circular grinder with 24 grit sandpaper face flashover.
• Dual acting sander with 320 grit sandpaper
• Cleaning solvent (acetone) 10. Paint the area to match the platform. Do not apply
• Fiberglass cloth or mat metallic paint to the platform.
• Gelcoat repair kit
• Good quality rubber gloves Damage to the gelcoat layer may be repaired using the
• Dust mask instructions that accompany the gelcoat repair kit. This kit
• Safety glasses may be ordered from your Altec representative. The
• Nonmetallic spray paint (white to match the platform) gelcoat provides a protective layer of ultraviolet inhibitors.
The gelcoat layer has no inherent strength.
Use the following procedure as a guide in making a quality
field repair. Before making any repair, the structural integrity of the
platform and the safety of the operator must be kept in
1. Outline the damage with a box that is 1″ (25.4 mm) mind. More specific repair information for a particular
wider on all sides of the damaged area. Example — If situation should be requested from your Altec representa-
the damage is 1″ x 3″ (25.4 x 76.2 mm), the box would tive.
be 3″ x 5″ (76.2 x 127 mm).
Platform Leveling
Caution A cable is a mechanism within itself, consisting of moving
Injury can result from airborne particles entering the parts which are called strands and wires. The wires move
eyes and lungs. Wear appropriate safety equipment. in relationship to each other under operating conditions.
Two general operating conditions that the cable inspector
2. While wearing safety glasses and a dust mask for must be concerned with are as follows.
breathing protection, grind the area within the box to a
depth of approximately 1/8″ (3.18 mm). • The movement of wires against each other as the
cable is loaded and unloaded
3. Cut strips of fiberglass cloth to fit the box area.
• The flexibility and bending of the cable as it passes
over sheaves
Warning
Death or serious injury can result from improper use Inspection is an important part of satisfactory cable life, as
of solvents. Follow the manufacturer’s label for proper well as the safety and reliability of the cable. Likewise,
use and disposal. lubrication plays a very important part in extending cable
life by reducing internal wear as the wires move in
4. Clean the area thoroughly with solvent. relationship to each other. While the platform leveling
system is designed with a safety factor several times
5. While wearing rubber gloves, mix the approximate greater than the rated loads applied to the platform,
amount of polyester resin and catalyst according to periodic inspection and lubrication must be performed, as
the directions in the gelcoat repair kit. with any other part of the unit.
6. While wearing rubber gloves, saturate the fiberglass Specific inspection of leveling cables must be performed
cloth with the mixed resin and apply it to the damaged as recommended by the Preventive Maintenance and
area. Work the area to squeeze out any air. Inspection Checklist.
7. After the resin has set up completely, grind off any

rough areas or high spots.
Caution
Injury can result from handling wire rope. Wear appro-
8. Mix an additional cup of resin and catalyst according priate safety equipment.
to the directions in the gelcoat repair kit and apply
smoothly to completely cover the affected area. Injury can result from being pinched or trapped be-
tween moving components. Keep hands clear.
9. Sand the area with a dual acting sander and 320 grit
sandpaper.

Use caution when access covers have been removed to cables are riding on each other. If they do, they can be
service the unit. Pinch points and shear points may exist carefully guided into place on the cast sheaves with a
between moving parts. Replace the access covers imme- screwdriver. Investigate the cause if this condition contin-
diately after servicing. ues to exist.
In order to perform a thorough inspection, all covers must Position 3

be removed from the booms. Carefully slide a soft cloth Place the lower boom in a horizontal position and unfold
along the surface of the cable. Snags and broken wires will the upper boom in an overcenter position to the ground.
catch in the soft cloth. If four or more broken wires are Reach inside the upper boom and inspect the cable as in
found, the cable should be replaced. If it is determined that Position 2.
there are broken wires, but not enough to cause replace-
ment, it will be necessary to perform more frequent Notice
inspections. Any time there is doubt in the mind of the Lubricate the leveling cables after using a high pres-
inspector concerning the safety of a cable, it should be sure washer or chemical degreasers.
changed.
Winch Line
Wear will be greatest at those places where the cables are
contacting the sheaves. While operating the unit, observe Inspect the winch line as recommended by the Preventive
the sheaves for freedom of movement. It is extremely Maintenance and Inspection Checklist.
important that all idler sheaves turn as the cable moves.
Evidence of a frozen or slipping sheave is a very shiny
groove. As the cable slips, it wipes the lubrication off. Warning
During the inspection, lubricate the cables with a good Death or serious injury can result when the synthetic
quality chain and cable fluid. winch line contacts an energized conductor and the
ground. Do not allow the winch line to contact an
The general condition of the leveling system components, energized conductor.
including leveling rods, boom interiors, hydraulic hoses,
etc., should be noted. Check the rods for scratches, signs The synthetic winch line is not to be considered an
of rubbing, cleanliness, or any other possible damage. insulator. Contact between an energized conductor and
Replace the rods that show signs of cracks, damage or the ground can result when the winch line is extended to
wear. Check the boom interiors for hydraulic leaks and the the ground.
accumulation of debris or other foreign material, particu-
larly units used in tree trimming activity. Check the cables Normal use will gradually reduce the strength of synthetic
for rust, even if they are galvanized. Tree sap, etc., may winch line. The entire length of the line must be inspected
act as an acid which may produce rust. as recommended by the Preventive Maintenance and
Inspection Checklist.
The aerial device booms must be placed in three different
positions to perform a thorough inspection of the leveling Keep a permanent, written, and dated report of the line’s
system. condition and any corrective action taken during the
inspection on file.
Position 1
With the booms in the rest, inspect the cables at the Follow the instructions of the line manufacturer when
turntable. Inspect the sheave grooves for evidence of splicing a synthetic winch line. A properly made splice is
scuffing. Inspect the cables and sheaves at the elbow. a strong and efficient means of attachment.
Make sure the cable keepers are in place. Reach inside the
upper boom at the platform through the side access holes When inspecting the winch line, use the following guide-
at the boom tip for inspection. Pay particular attention to lines to determine the condition of the line.
the cables where they come off the top of a sheave. Reach
into the boom past the nylon sheaves for inspection. • A few damaged strands spaced out along the length
of the line are acceptable. List the location of the
Position 2 damaged strands in the report. Check these strands
From the stowed position, raise the lower boom to a carefully in future inspections.
vertical position. This will expose a new length of cable.
Inspect the cables at the turntable and boom tip. With • To determine wear, compare an individual strand in an
another aerial platform, inspect the cables at the elbow. area where it is exposed and subjected to wear with an
Have someone raise the upper boom and make sure no area of the same strand where it has been protected

from wear. If individual cover strands have worn to Rinse the line thoroughly after washing it. Squeeze out the
within 50 percent of their original bulk over an ex- water by placing the line under tension. Then allow the line
tended area of the line, replace the line. to air dry.
• If half of the cover strands are cut at a given point, Rotate the winch line end-for-end on a periodic basis. This
replace the line or cut out the damaged section and will vary the high stress and wear points, extending the
splice the line back together. useful life of the line. This is not possible if a closed thimble
is spliced into the lifting eye.
• Replace a spliced line if it does not meet the length
requirements in Section 6 under Line.
Accident Prevention Signs
• If a damaged section is removed near the eye of the This unit was equipped with accident prevention signs at
line, put in a new eye splice. Use a standard end-for- the time of manufacture. If any of these are lost or become
end splice to rejoin the line in other areas. illegible, obtain replacements from your Altec representa-
tive.
Knots can reduce line strength. A winch line should never
have a knot tied in it. The location, part numbers, and descriptions of all plac-
ards are listed in the Parts Manual. Refer to the Accident
Wash the line with a mild detergent and warm water. Strong Prevention Signs Diagram for examples of the placards
cleaning agents or bleaches may be harmful to the line and and their locations.
must not be used.

Accident Prevention Signs Diagram
7 3
15 15
4
21
2* 6
With Hydraulic
21 Extend Jib Only Item Information
2*, 6, 15 Located on both sides
8 and 9 Located in the platform area
18
2
2
12 3 7
12 4
18
18 10 11
14

3 1 20
9 6 70-40 453 C
Top and Bottom

of Boom
19
A
8 16 7 5 13
A
All Placards on Top
and Bottom of Boom
on Overcenter Units
17
View A - A
DANGER
16 7 3 1
5 13
21
All Placards on Top
and Bottom of Boom
8 on Overcenter Units

2
3 5

6 7
•
•
•
•
•
10

11
12
13
14 15

17
16
19
18
21
20

Section 5 — Hydraulic System
Load Sense Pump

The unit uses a closed center, load sensing hydraulic The hydraulic pump may be driven by the vehicle engine
system. A variable displacement, pressure compensated, or an auxiliary engine. It is a variable displacement,
piston pump is used to supply the flow and pressure, as pressure compensated, piston pump. The pump delivers
required, to operate the aerial device functions. The pump 141/2 gpm (55 l/m) at 3,000 psi (207 bar).
reacts to a signal from the outrigger valves, tool control
valve, lower control valve, elevator control valve, or the In case of catastrophic pump failure, the hydraulic system
pump control valve. The upper controls and the below must be flushed. This procedure is described in Section 4
rotation controls remotely operate the control valve spools, under Changing Oil and Flushing the System. Flushing the
which in turn sends the signal to the pump. The signal is hydraulic system will remove most of the metallic con-
the result of pressure required at the work port to move the tamination from the system.
load. Separate internal porting sends this requirement
(signal) to the pump compensator valve. Before servicing the pump, close the shutoff valve in the
suction line between the reservoir and the pump. Closing
Hydraulic schematic drawings are an important tool in the shutoff valve allows the pump to be serviced or
understanding the operation of a hydraulic system. The removed without draining the reservoir.
symbols identify the flow paths and operation of the
components in the system. A thorough understanding of Notice
these symbols can reduce downtime and increase the Damage to the pump or return line filter can result if the
accuracy of diagnosing malfunctions. Basic hydraulic unit is operated with either or both of the shutoff valves
schematic symbols are identified in the Appendix. closed. Fully open the shutoff valves before engaging
the PTO.
This section describes the hydraulic components and
provides an illustration of the components. Hydraulic When service is completed, open the shutoff valve before
schematics of the components can be found in the operating the unit.
Appendix.
Compensator
Oil Reservoir Drive
The 50 gallon (189 l) reservoir is vented. An internal 10 Shaft
micron filter with a replaceable cartridge is located at the
inlet of the reservoir. A 300 micron magnetic suction
separator filter is located at the outlet. A filler breather cap
is located on top of the fill hole. The cap contains a 40
micron filter and has a strainer basket. Refer to Filtration
in Section 4 for information on the filters.
Figure 5.2 — Pump
Filler Return Line
Cover Breather Cap Filter Head Emergency Operating DC Pump
The emergency operating DC pump and motor assembly
has two hydraulic connections: inlet and outlet. This as-
sembly has an internal check valve and an internal 2,500
Suction psi pressure relief valve. The pump is a fixed displacement
Filter Return Line pump with an output of less than 21/2 gpm (9.5 l/m). The
Filter Cartridge motor receives its power from the vehicle battery.
3″ Hex Bottom
Motor
Pump
Shutoff Angled
Valve Opening
Drain Pipe
Figure 5.1 — Hydraulic Oil Reservoir
Figure 5.3 — Emergency Operating DC Pump
Section 5 — Hydraulic System • 45

The inner core of the rotary joint is fastened to the
Rotary Joint
pedestal. The outer housing rotates with the turntable
The rotary joint (refer to Figure 5.4) permits continuous driven by a drive pin on the side of the housing. Hydraulic
rotation of the turntable without twisting the hydraulic fittings on the rotary joint are the SAE straight thread type.
hoses in the pedestal and turntable. The rotary joint
assembly consists of a housing, core, seals, and wear
rings.
Valves
When describing hydraulic valves, “position” identifies the
number of operating positions of the valve spool. A two-
position blocking valve has two operating positions, open
and closed.
The word “way” identifies the number of ports in a valve

section. A four-way control valve has four ports. One port
is for a pressure connection, one is for a return line
connection, and the other two ports are the working ports.
Refer to Figure 5.5 for the general location of the hydraulic

system valves.
Figure 5.4 — Rotary Joint
Jib/Winch
Upper Control
Upper Tool
Upper Control Interlock
Platform Rotate
Upper Elevator Control
Upper Elevator Selector

(Double Elevator)
Lower Lower Control Solenoid

Boom Stow Pilot Control (Opposite Side)
Tool Control
Lower Control Lower/Winch/

Platform Rotate
Elevator
Selector
Pump Control
Outrigger
Control
Outrigger/Machine Control
Selector Selector
Figure 5.5 — Valve Locations
46 • Section 5 — Hydraulic System

Outrigger Control Valve Pump Control Valve
The outrigger control valves are three-position, four-way The pump control valve (refer to Figure 5.8), located
valves. The three positions of the valve spools are extend, behind a panel underneath the below rotation controls, is
neutral, and retract. The four connections are pressure, made up of five valves in one housing.
return, and work ports A and B. The valve spools are spring
centered, operated by a manual control handle, and have
bleed-off notches and motion switches.
Figure 5.8 — Pump Control Valve
Figure 5.6 — Outrigger Control Valve The adjustable pressure reducing valve adds a 100 psi (6.9
bar) signal to the sense signal going to the pump.
Outrigger/Tool Control Valve
The outrigger/tool control valves are located at the tailshelf The normally open, two-position, two-way, solenoid oper-
and operate the outriggers and lower tool circuit. The ated valve is used to block the sense signal to the primary
outrigger/tool control valve consists of three spool valves pump when the DC pump is being operated.
and a relief valve.
The tool pressure reducing valve reduces the pressure to
The valve spools are three-position, four-way, and have the lower tool circuit. This valve is used to reduce system
bleed-off notches and motion switches. The tool valve pressure to 2,000 psi (137.9 bar). This is accomplished by
spool is a three-position, four-way, open port spool. These reducing signal pressure to 1,650 psi (113.8 bar) and
manually operated spools direct hydraulic oil flow to the adding that to the pump compensator pressure of 350 psi
outrigger cylinders and the tools pressure outlet. (24.1 bar). This produces a system pressure of 2,000 psi
(137.9 bar) for the lower tools.
The valve spool for the tools has a detent position in one
direction to provide hydraulic oil flow to the lower tool The shuttle valve receives a signal from the outrigger
circuit. circuit or the aerial device and sends the strongest signal
to the pump.
The outrigger interlock valve is a normally closed, two-

position, two-way, solenoid operated valve. The valve
prevents above rotation sense line signals from reaching
the pump until the outriggers have been properly set.
Machine/Outrigger Selector Valve

The machine/outrigger selector valve (refer to Figure 5.9)
is located on the tailshelf. The valve is a two-position, four-
way, manually operated valve.
Figure 5.7 — Outrigger/Tool Control Valve

Figure 5.9 — Machine/Outrigger Selector Valve
The machine/outrigger selector valve has two detent

positions. The positions are Machine and Ground Level
Functions. Figure 5.11 — Elevator Selector Valve
When the machine/outrigger selector handle is in the Lower Winch Control Valve
Ground Level Functions position, hydraulic oil flow is The lower winch valve located on the turntable consists of
directed to the outrigger control valves and/or the lower two valve spools. The spools are three-position, four-way,
tool circuit. solenoid operated valves. They are used to operate the
boom tip winch from the turntable.
When the machine/outrigger selector handle is in the
Machine position, hydraulic oil flow is directed through the
rotary joint to the inlet manifold in the turntable.
Control Selector Valve

The control selector valve (refer to Figure 5.10) is located
near the below rotation controls. The valve is a three-
position, four-way, solenoid operated valve. It is used to
select lower controls, upper controls, and emergency
stop. The upper controls cannot be operated when the
selector is placed in the Emergency Stop or Lower
Controls position.
Figure 5.12 — Lower Winch Control Valve
Lower Platform Rotate Control Valve

The lower platform rotate valve located on the turntable
consists of two valve spools. The spools are three-
position, four-way, solenoid operated valves. They are
used to operate the boom tip platform rotator from the
turntable.
Figure 5.10 — Control Selector Valve
Elevator Selector Valve

The elevator selector valve (refer to Figure 5.11) is located
near the below rotation controls. The valve has four two-
position, three-way pilot operated valves and one two-
position, two-way solenoid operated valve. The pilot
operated valves receive pilot oil from the upper elevator
control valve and direct the flow to the elevator valve to
operate the elevator. The solenoid operated valve is
controlled by the control selector valve and allows for
purging of the upper elevator selector pilot line. Figure 5.13 — Lower Platform Rotate Control Valve

Lower Control Valve
The lower control valve assembly (refer to Figure 5.14)
located on the turntable is made up of several compo-
nents. These include a relief valve, a pilot pressure
reducing valve, a blocking valve, and the spool valves for
each function.
Figure 5.15 —
Lower Controls Solenoid Pilot Control Valve
This valve bank consists of six single solenoid valves. As

the upper controls are used to operate a function, the pilot
flow for that function is routed through the solenoid pilot
control valve block. The solenoid for that function is
bypassed by the use of a shuttle valve and the pilot flow
is then directed to the lower control valve to operate the
desired function.
Figure 5.14 — Lower Control Valve When the below rotation controls are used to operate a
function, an electrical signal is sent to the corresponding
The system pressure relief valve is set to open at 3,250 psi solenoid valve. The electrical signal varies with the dis-
(224 bar). It prevents the hydraulic system from building up tance of hand controller movement and is used to control
excessive pressure if the pressure compensator in the the length of time that the solenoid valve is in the open
pump malfunctions and fails to limit maximum system position. The amount of hydraulic oil flow through the
pressure to 3,000 psi (207 bar). solenoid valve is in proportion to the electrical signal and
the distance of below rotation hand controller movement.
The pilot pressure reducing valve reduces system pres- This proportional hydraulic signal created by the solenoid
sure to 350 psi (24.1 bar) for use as pilot pressure. pilot control valve is then used to shift the valve spool in
the lower control valve for the chosen function.
Three spool valves are used for the boom functions. These
valves are three-position, four-way valves. The spool Most solenoid-operated valves are two-position valves
valves direct hydraulic flow to the actuators that operate that are spring shifted to one position and electrically
the boom functions. These spools also send hydraulic shifted to the other position by the solenoid’s magnetic
pressure and flow requirements through the load sense field.
line to the pump. Maximum travel of the spools may be
adjusted to control the speeds of the boom functions (refer Upper Control Valve
to Section 8 under Hydraulic System). The upper control valve assembly includes the mechani-
cal linkage, the remote control valve, which houses six
Shuttle valves are located between each spool in the load variable pressure reducing valves, and the interlock valve.
sense circuit. When more than one boom function is When the interlock trigger is engaged, the interlock valve
operated at the same time, shuttle valves send the highest is opened by a mechanical connection to the trigger. The
pressure requirement to the pump. blocking valve in the lower control valve is then opened by
pilot pressure.
The lower control valve has a pressure compensator for
each boom spool valve. When more than one boom The remote control valve (refer to Figure 5.16) is mounted
function is operated at the same time, the highest pressure directly under the single handle control. As the single
requirement is delivered to the valve spools. If the function handle control is moved, it varies the mechanical force
requires less than the pressure delivered, the pressure applied to the internal spring pack of the variable pressure
compensator delivers an accurate oil flow to the work port. reducing valve. As the mechanical force applied to the
spring changes, the pilot pressure output from the upper
Lower Controls Solenoid control valve is varied as the spool shifts. The output
Pilot Control Valve pressure from the upper control valve can be varied from
The lower controls solenoid pilot control valve bank (refer 0 psi to 350 psi (0 to 24.1 bar). The hydraulic oil output from
to Figure 5.15) is located behind an access cover on the the upper control valve is directed to the lower control
lower boom, on the side opposite the lower control valve, valve spools.
just above the lower boom cylinder.

Interlock Trigger
Figure 5.18 —
Jib/Winch/Tool Valve (Manual Extend Jib)
Jib/Winch Valve (Hydraulic Extend Jib)

The jib/winch control valve is a manual three spool valve.
Interlock The spools are full pressure, three-position, four-way,
Remote Control Valve manually operated, and spring centered. They control the
Valve (Upper Control Valve)
jib tilt, winch up/down, and jib extend/retract functions.
Figure 5.16 — Upper Control Valve The winch function is connected to the lower controls so
the winch can be operated from the below rotation, upper,
Interlock Valve or lower controls.
The upper control interlock valve is a two-position, three-
way, manually operated valve. The valve is spring shifted
to block the flow of hydraulic oil to the upper control valve.
It is manually shifted by engaging the interlock trigger on
the bottom of the single handle control. In this position,
pilot oil opens the blocking valve in the lower control valve
and flows to the upper control valve to operate the aerial
device functions. Oil also flows to the blocking valve in the
tool control valve to prevent operation of the upper tool
circuit while the aerial device functions are being operated.
Figure 5.19 —
Jib/Winch Valve (Hydraulic Extend Jib)
Platform Rotator Valve

(One-Man Platform)
The platform rotator valve contains a three-position, four-
way valve spool, a counterbalance valve and a pilot
operated check valve. The valve spool is spring centered
and manually operated.
Figure 5.17 — Interlock Valve
Jib/Winch/Tool Valve
(Manual Extend Jib)
The jib/winch/tool valve is a manual three spool valve. The
spools are full pressure, three-position, four-way, manu-
ally operated, and spring centered. They control the jib tilt,
winch up/down, and upper tool circuit. The tool spool is
detented in two positions. The winch function is connected
to the lower controls so the winch can be operated from the
below rotation, upper, or lower controls.
Figure 5.20 — Platform Rotator Valve

Platform Rotate/Tool/Tilt Control Valve Relief Valves
(Two-Man Platform) System relief valves are located in the outrigger/tool,
The platform rotate/tool/tilt control valve is a manual three elevator control, and the lower control valves.
spool valve. The spools are three-position, four-way and
manually operated. The tool valve has one detent position. They prevent the hydraulic system from building up
The rotate and tilt valves are spring-centered. excessive pressure in case the pressure compensator
valve in the pump fails to limit maximum system pressure
to 3,000 psi (207 bar).
Figure 5.23 — Relief Valve
Figure 5.21 — Platform Rotate/Tool/Tilt Valve Lower Boom Stow Valve

The lower boom stow valve assembly is a two-position,
Tool Control Valve two-way valve, with a low pressure relief valve. This valve
The tool control valve on the turntable is made up of four is used to prevent excessive hydraulic pressure from
valves in one housing. A two-position, two-way, hydrauli- being applied to the lower boom during stowing. The boom
cally shifted on/off valve is used to control the upper tool stow valve is located inside the turntable.
circuit pressure and flow. The flow control valve for the
tools is adjustable with a range from 0.1 to 8 gpm (0.4 to The boom stow valve is mechanically activated when a
30.3 l/m). The flow rate has been factory adjusted at 8 gpm metal tab welded to the lower boom contacts a cam roller
(30.3 l/m). on the valve. When the tab contacts the roller, the port to
the relief valve is opened. This internal low pressure relief
The pressure reducing valve limits the tool signal going valve between the lower control valve and the rod end of
back to the pump, which in turn limits the tool pressure. A the lower boom cylinder limits any pressure applied to the
two-position, two-way blocking valve is used to disable the lower boom as it is lowered into the boom rest.
tools circuit if the upper controls are operated. When the
interlock trigger on the upper controls single handle control
Valve Position
is engaged, a pilot signal is sent to close this valve, Adjustment Slots
preventing tool operation while positioning the booms.
There are also quick disconnects on the valve for testing

system and tool pressure.
System Pressure Tool Pressure

Test Port Reducing Valve
Tool Pressure Pressure Relief

Test Port Tool Flow Valve Adjustment
Control
Figure 5.24 — Lower Boom Stow Valve
Figure 5.22 — Tool Control Valve

Upper Elevator Control Valve Testing of pilot operated check valves and counterbalance
The elevator control valve at the platform is a variable valves is described in Section 8 under Hydraulic System.
pressure reducing valve. As the control is moved, a
hydraulic signal is sent to the lower elevator control valve Pilot Operated Check Valves
to shift the spool and proportionally control the function. Pilot operated check valves are used to block flow out of
the following actuators.
• Outrigger cylinders
• Jib tilt cylinder
• Jib extension cylinder
• Platform rotator (two-man platform)
• Platform tilt cylinder (two-man platform)
A pilot operated check valve allows free flow into the

actuator and blocks return flow. The valve has an internal
pilot piston that allows it to be hydraulically opened,
allowing flow out of the actuator.
The pilot operated check valves are installed in pairs and

are cross-ported. Oil sent to one work port of the actuator
is used to pilot open the check valve for the other work port
of the actuator.
Counterbalance Valves
Figure 5.25 — Upper Elevator Control Valve Counterbalance valves are used to block flow out of the
following actuators.
Upper Elevator Selector Valve
The upper elevator selector valve at the platform is a two- • Elevator lift cylinders
position, four-way selector valve. It is used to choose • Lower boom cylinder
between the upper or lower elevator arm. Pilot oil is • Upper boom cylinders
directed by this valve to the pilot operated blocking valves • Platform rotate cylinder(s) (one-man platform)
in the elevator selector valve below rotation. • Rotation gearbox motor
A counterbalance valve is a combination of a check valve

and a relief valve. The check valve allows free flow into the
actuator and blocks the flow from coming back out.
The relief valve function can be pilot operated to allow flow

out of the function. It also allows the valve to relieve
excess pressure and prevents damage from thermal
expansion of the oil.
Counterbalance valves are usually installed in pairs and

are cross-ported. Oil sent to one side of the actuator is
used to pilot open the counterbalance valve on the other
Figure 5.26 — Upper Elevator Selector Valve side of the actuator.
Holding Valves
Cavitation and Aeration
The unit uses holding valves to insure that various
actuators maintain their position under load or if there is Cavitation and aeration are two problems that can cause
hydraulic line failure. These holding valves block the pump damage. Pump cavitation occurs when inlet oil does
hydraulic oil in the actuators to prevent movement. Pilot not entirely fill the cavities that open during the intake part
operated check valves and counterbalance valves are of the pumping cycle and the pump tries to draw a vacuum.
types of holding valves.

The characteristic sound of cavitation is a high pitched
scream. This sound increases with the degree of cavita-
Air Bleeding
tion and increased flow. The following items are possible The presence of air in the hydraulic system will cause
causes of cavitation. abnormal operation, noise, and damage to the pump. The
presence of air in the hydraulic system can usually be
• Excessive pump operating speed traced to one of the following.
• Clogged suction filter
• Excessive oil viscosity (thickness) • If the oil level in the reservoir gets too low, the pump
• Restrictions or sharp bends in hose suction can cause a whirlpool to form in the reservoir
• Excessive inlet hose length which will allow air to be sucked into the system.
• Pump inlet too high above reservoir level
• Shutoff valve in suction line not fully open • A leak in the plumbing between the reservoir and the
pump can suck air in and not leak out when the system
Notice is shut down.
Cavitation can quickly destroy the pump. If signs of
pump cavitation are noticed, determine the cause and • Loose connections in the pressure system will nor-
promptly repair the problem. mally leak externally during unit operation, but can
suck air into the system after the unit is shut down as
If pump cavitation is due to excessive oil viscosity caused the oil tries to find its way to the low points of the
by cold temperatures, allow the oil to warm up before system.
operating the unit.
• Hydraulic lines taken loose during maintenance op-
Aeration occurs when air bubbles are introduced into the erations.
hydraulic oil and carried along as the oil flows through the
pump. Aeration can be caused by the following conditions. Notice
Air circulating through the pump can cause unit
• Low oil level in the reservoir. This can cause a malfunctions or pump damage. Determine the cause
whirlpool at the suction line opening, which sucks air and repair the problem.
into the system along with the oil.
Air entering the system, due to low oil levels or leaks in the
• Leaking connections in the suction line between the suction line, will cause the most problems and should be
reservoir and the pump. corrected immediately.
• Return line outlet is located above the oil level in the Pilot System
reservoir. This causes turbulence as the return oil Air trapped in the control system would have the same
stream discharges above the surface of the oil. effect as air in an automotive braking system. Air bubbles
compress as pressure is applied to the oil, causing a
Notice spongy feeling in the control system. This condition may
Air circulating through the pump can cause unit lead to hesitancy in the control system or poor metering of
malfunctions or pump damage. Determine the cause the control functions as the control handle is moved.
and repair the problem.
Placing the lower/upper/emergency stop control selector
An air leak in the suction line can occur even if there is no at the below rotation controls in the Emergency Stop
oil leak when the system is shut down. A leak in the suction position will force oil flow into the chambers of the lower
line can often be located by slowly squirting clean hydrau- control valve. By means of check valves, oil flow is
lic oil around each connection in the suction line. Do this established in a reverse manner, from the lower controls
with the pump running at normal operating speed. A to the upper controls, bleeding any air to the system high
suction leak will suck oil in. The pump may temporarily run point, then back to the reservoir. This action purges the
quietly as the air leak is sealed by the oil. The leak can then control system of any air and restores a solid column of
be repaired. fluid for precise control. Purging the system in warm
weather should only take a minute. It can be repeated if
When aeration occurs, the oil in the reservoir is likely to necessary after test operating the control. After any
become foamy. The pump may also become noisy. purging operation, place the control selector in the Upper
position.

The purging system can be used to warm up the control A leaking holding valve in a cylinder can cause drifting or
system in cold weather, if the fluid in the reservoir is warm. malfunction of the cylinder. It may be stopped by replacing
The procedure is the same except that it may take several the holding valves in the component. However, some
minutes in extremely cold weather to warm the oil. types of damage, such as scoring of the inside of a
cylinder barrel, require more extensive repair.
Leakage
Heat Generation
If components and connections are properly installed,
leakage can be kept to a minimum. Small external leaks Heat is the result of pressurized fluid escaping to the
are usually easy to find because dust will collect on the reservoir. Most hydraulic components have a small inter-
hydraulic oil film. nal leak due to machining tolerances. This type of leak
generates a very small amount of heat that is taken into
External leakage is the escape of hydraulic oil outside the account when the component is designed.
hydraulic system. Improperly tightened fittings are a
primary cause of external leakage. Follow the torque and Internal leaks in the system may be caused by internal
tightening specifications explained under Fittings and housing cracks, bad relief valves, or leaking seals. This
Valve Cartridges in this section to properly tighten hydrau- type of leak allows a large volume of pressurized oil to
lic fittings. return to the reservoir, creating excessive heat in the
hydraulic system. Continuous operation with excessive
heat will damage the hydraulic oil, seals, and O-rings
Warning throughout the system.
Death or serious injury can result from hydraulic oil
being injected into the flesh. Do not use hands or other The following conditions cause heat generation.
body parts to check hydraulic lines and fittings for
leaks. • Excessive pump speed
• Worn or defective pump
Seek medical attention if injured by escaping hydrau- • Defective or improperly adjusted relief valve
lic oil. Serious infection or reaction can result if cartridges
medical treatment is not given immediately. • Contaminated spool in a control valve
• Low hydraulic oil level
Spilled hydraulic oil creates slick surfaces and can • Improper hydraulic oil
cause personnel to slip and/or fall. Keep the unit and • Internal component leakage
work areas clean.
Refer to Section 8 under Hydraulic System for information
If a connection is properly tightened but continues to leak, about troubleshooting specific components for internal
disassemble the connection. Seal the necessary parts leaks.
and/or replace the defective part.
Hydraulic Lines
Worn or damaged parts such as scratched cylinder rods
and output shafts on a hydraulic motor can cause leaks. Hydraulic lines provide a passageway for fluid flow be-
Such conditions must be repaired or replaced. A new seal tween components in the hydraulic system. Fluid is
should also be installed. transmitted through the lines from the pump to the actuator
to operate the unit. A variety of lines may be used on the
Internal leaks allow pressurized hydraulic oil to escape to unit depending on the specific application. The lines may
tank or another hydraulic circuit. Most hydraulic compo- be conductive or nonconductive rubber hoses, flexible
nents have a small internal leak due to machining toler- plastic, or rigid steel tube.
ances.
Most hoses have a lay line on them. The lay line contains
An internal leak can cause a variety of problems in a the following information.
hydraulic system. An internal leak in a cylinder can cause
drifting or malfunction of a cylinder. Internal leakage in a • Manufacturer’s name
rotary joint will cause functions to slow down and/or fail to • Manufacturer’s part number
build pressure. Replacing the seals in the leaking compo- • SAE rating
nent will usually stop an internal leak. • Burst pressure (sometimes)
• Nonconductive (on nonconductive hoses)

Use caution when access covers have been removed to
Danger service the unit. Pinch points and shear points may exist
Death or serious injury can result from unprotected between moving parts. Replace the access covers imme-
contact with energized conductors. Never replace a diately after servicing.
nonconductive hose with a conductive hose.
Mark all hydraulic line fittings before disconnecting them
The hoses in the boom, at the turntable, and platform are to ease installation later. Place a container under the
non-pin perforated, nonconductive, thermoplastic hoses. hoses to catch the hydraulic oil. Cap or plug all open ports,
Replace the hoses with hoses of the same type. hoses, and fittings to prevent contamination.
When replacing a hose, use one that is the same size, Warranty will be denied on components returned to Altec
length, and pressure rating. If hose size is doubled, four if ports are not plugged and cylinder rods are not retracted.
times the amount of oil will flow at the same pressure. If
hose size is decreased, the flow in the circuit will decrease Properly torque all connections. Refer to the Torque and
and back pressure will increase. The increase in back Tightening Procedures in this section.
pressure will cause heat to build up in the system.
After completing a procedure, check the oil level in the
hydraulic oil reservoir and add oil if necessary.
Warning
Death or serious injury can result from uncontrolled Hose Bundle
movement. Purge the air from the actuator before The hose bundle transports hydraulic oil between the
operating the unit. turntable and the boom tip. All hoses in the bundle are
nonconductive.
being injected into the flesh when loosening or dis- The hoses in the upper boom are positioned and supported
connecting hydraulic components. Remove the pres- by hose separators. Four clamps are used to secure the
sure before loosening or disconnecting hydraulic hose bundle in the lower boom. These components allow
components. the hoses to be securely positioned and keep them from
rubbing against one another. They also make the hoses
Seek medical attention if injured by escaping hydrau- easier to service.
lic oil. Serious infection or reaction can result if
medical treatment is not given immediately. The hoses in the bundle have connectors at the elbow.
They are not full length lines. When service requires
Spilled hydraulic oil creates slick surfaces and can removal, there is an option of removing the complete
cause personnel to slip and/or fall. Keep the unit and system or separating the hose lines at the elbow end of the
work areas clean. lower boom.
After removing a hydraulic line from a cylinder, do not

Fittings and Valve Cartridges
operate the unit from the upper controls until all air is
purged from the cylinder after the hydraulic lines are Most hydraulic ports and fittings are SAE straight thread
reinstalled. The presence of air in the cylinder can cause O-ring or 37 degree flared JIC straight thread. These types
inadvertent retraction or extension of the cylinder, result- of fittings provide a good seal and resist vibration.
ing in death or serious injury.
Use the proper torque and tightening specifications when
Remove all fluid pressure from a hydraulic circuit before installing a hydraulic fitting to reduce the likelihood of leaks
disconnecting lines or fittings. in the system. Use caps and plugs during the handling and
storage of hydraulic components to prevent damage to
sealing surfaces and fitting threads.
Caution
Injury can result from airborne particles entering the When installing a valve cartridge into a valve body,
eyes and lungs. Wear appropriate safety equipment. properly torque the cartridge. Tightening the cartridge less
than the specified torque value may cause a leak.
Injury can result from being pinched or trapped be- Overtorquing a cartridge can damage the valve, valve
tween moving components. Keep hands clear. body, or bind internal parts. A damaged valve may not
function properly.

Torque and Tightening Procedures 4. Tighten the locknut with a wrench and torque to the
Overtorquing a component can distort the part and cause proper value for the size and material (stainless steel
a leak. When a leaking fitting is found, check to see if it is or steel) so the backup washer contacts the boss
tight. If it is not tight, torque it to the proper value. Replace face.
the fitting if it will not stay tight.
SAE O-Ring Fittings Without Locknuts
If the fitting is tight, stop the unit, determine the cause of 1. Lubricate the O-ring and threads with hydraulic oil or
the leak and take corrective action. When making a light grease, such as petroleum jelly.
connection that uses a swivel nut, use one wrench to hold
the hose, tube, or fitting and another wrench to turn the nut. 2. Turn the fitting in full length until finger tight.
This is necessary to prevent damage to the sealing
surface of the JIC connections. 3. Use a wrench to tighten the fitting to the proper value.
The following procedure describes proper torque and Tube and JIC Fittings
tightening procedures for various types of hydraulic fit- 1. Clean the male threads of the fitting with a cleaning
tings. Refer to Torque Values in the Appendix for the solvent.
appropriate torque chart.
2. Tighten the nut until first wrench resistance [approxi-
mately 30 inch-pounds (3.4 N•m)].
Warning
Death or serious injury can result from improper use 3. Using a felt tip pen or marker, mark a line lengthwise
of solvents. Follow the manufacturer’s label for proper on the nut and extend it onto the adapter body (refer
use and disposal. to Torque Values in the Appendix).
Tapered Pipe Thread Fittings 4. Determine the proper number of hex flats the nut must
1. Clean the male threads of the fitting with a cleaning be turned with a wrench. Using a wrench to hold the
solvent. adapter body, rotate the nut with another wrench the
proper number of hex flats from wrench resistance
2. Apply pipe sealant to the male threads of the fitting, (F.F.W.R.).
being careful not to get sealant on the first two male
threads. Apply enough sealant to form a ring of sealant 5. Use the marks to count the proper number of hex flats
on the outside of the connection when the threads are to turn the nut. The marks also serve as a visual
tightened into the mating body. indicator that the fitting has been properly tightened.
3. Screw the fitting into the mating part and finger tighten. Compression Fittings
1. Cut the tubing to length, allowing for bend, equipment
4. Turn the fitting with a wrench the appropriate turns movement, etc.
from finger tight (T.F.F.T.), taking the final position of
the tube end into consideration. 2. Fit the brass insert into the nylon pilot tubing with the
flanged end out. The insert should fit snug in the pilot
5. Follow the sealant manufacturer’s directions for cure tubing. The color coded 5/16″ outer diameter tubing
time. The ring of sealant described in step 2 will not requires the use of an insert.
completely harden due to its exposure to air.
3. With the threaded end of the compression nut facing
SAE O-Ring Fittings With Locknuts the fitting body, slide the nut onto the nylon tubing,
1. Lubricate the O-ring and threads with hydraulic oil or followed by the compression sleeve.
light grease, such as petroleum jelly.
Notice
2. Screw the fitting into the SAE straight thread boss To prevent damaging nut and threads, do not over-
until the backup washer bottoms out on the boss face tighten compression fittings.
with the O-ring squeezed into the boss cavity.
4. Insert the tubing into the fitting body. Making sure the
3. Unscrew the fitting (maximum of one full turn) to align tubing rests firmly on the shoulder of the fitting, hand
the fitting with the mating part. tighten the compression nut. Tighten the compression
nut the proper number of turns.

Four-Bolt Split Flange Assembly —
SAE Code 61 (3,000 psi)
Cylinders
1. Clean the sealing surface of any burrs, scratches, or Hydraulic cylinders operate the outriggers, elevator arms,
foreign particles. upper and lower booms, platform rotation, and jib extend/
retract/tilt on hydraulic jib equipped units. All cylinders
2. Lubricate the O-ring with hydraulic oil. used on the unit are double-acting cylinders.
3. Position the flange and clamp halves. Put the bolts Holding valves are often used to maintain cylinder position
with the lock washers in place (refer to Figure 5.27) if there is hydraulic line failure. The elevator arms, lower
and hand tighten the bolts. and upper boom, and platform (one-man platform) rotate
cylinders use counterbalance holding valves. The outrig-
Flange Clamping Bolt ger, jib/tilt, and platform tilt/rotate (two-man platform)
Lock cylinders use pilot-operated check valves.
Washer
The holding valves may be installed in cavities machined
directly into the cylinders. They may also be installed in a
Split
valve block in the hydraulic lines connected to the cylinder
Clamp
Half or directly mounted on the cylinder.
All cylinder rods are chrome plated to prevent rust and

corrosion. The chrome plating also provides a smooth
O-Ring surface for the end gland bearing and seal.
Figure 5.27 — Four-Bolt Flange Assembly

Warning
4. Follow the pattern in Figure 5.28 to torque the bolts in Death or serious injury can result from uncontrolled
place. movement. Use a sling and hoist of adequate capacity.
Death or serious injury can result from cylinder fail-

ure. Do not operate a cylinder that has a dented barrel
or a damaged rod.

ure. Never reuse a self-locking piston nut or retention
device.

ure. Properly install and torque a piston nut or gland
Figure 5.28 — Four-Bolt Flange Torque Pattern retention device.
5. Use small increments to torque the bolts. Death or serious injury can result from uncontrolled
movement. Purge the air from the actuator before
Valve Cartridges operating the unit.
1. Clean the male threads of the cartridge with a cleaning
solvent. Death or serious injury can result from hydraulic oil
being injected into the flesh. Properly cap or connect
2. Lubricate the threads and O-ring with hydraulic oil. hydraulic lines before operating the unit.
3. Turn the cartridge in until it is finger tight. Death or serious injury can result from hydraulic oil
being injected into the flesh when loosening or dis-
4. Use a wrench to tighten the cartridge to the proper connecting hydraulic components. Remove the pres-
value. sure before loosening or disconnecting hydraulic
components.

Seek medical attention if injured by escaping hydrau- Mark all hydraulic line fittings before disconnecting them
lic oil. Serious infection or reaction can result if to ease installation later. Place a container under the
medical treatment is not given immediately. hoses to catch the hydraulic oil. Cap or plug all open ports,
hoses, and fittings to prevent contamination.
cause personnel to slip and/or fall. Keep the unit and Warranty will be denied on components returned to Altec
work areas clean. if ports are not plugged and cylinder rods are not retracted.
Do not move the boom overcenter until all the air is purged Properly torque all connections and cap screws. Refer to
from the rod end of the cylinder. The presence of air in the Torque and Tightening Procedures in this section.
cylinder can cause inadvertent extension of the cylinder
when the boom is overcenter, resulting in death or serious After completing a procedure, check the oil level in the
injury. hydraulic oil reservoir and add oil if necessary.
After replacing a major component, such as a lift cylinder,

Caution perform a structural test as described in Section 9.
eyes and lungs. Wear appropriate safety equipment. Radial Outrigger Cylinder
A sling and a hoist are needed to perform the following
Injury can result from being pinched or trapped be- procedures.
Removal
Pinch points exist at both ends of the cylinder. Be 1. Position the unit on a level surface, apply the parking
extremely careful when removing or installing cylinders. brake, and chock the wheels.
Use caution when access covers have been removed to 2. Engage the PTO and lower the outrigger until it just
service the unit. Pinch points and shear points may exist makes contact with the ground.
between moving parts. Replace the access covers imme-
diately after servicing. 3. Remove the forged pin retainer from the pin connect-
ing the rod end of the cylinder to the outrigger leg and
Never install a cylinder with side pressure on the rod. Do the folding shoe (refer to Figure 5.29).
not operate a cylinder if the cylinder barrel is dented or if
the rod is damaged. 4. Secure the cylinder with a sling and hoist. Carefully
retract the cylinder to avoid scratching the rod. With
Altec does not recommend repairing cylinders in the field. the cylinder fully retracted, disengage the PTO and
Most repairs require disassembly of the cylinder which turn off the engine.
should be done in a clean, properly equipped shop. The
Parts Manual contains a drawing of each hydraulic cylin- 5. Release any pressure in the hoses connected to the
der. The drawing lists the Altec part numbers for the seal cylinder by shifting the outrigger control handle for the
kits and provides torque specifications for piston nuts and cylinder in both directions several times.
end glands.
6. Remove the hoses from the cylinder.
Hydraulic cylinder piston nuts and end glands must be
torqued to the proper values at assembly. Many piston 7. Remove the two cap screws or forged pin retainer that
nuts and end glands have retention devices, such as secure the pin at the base end of the cylinder (refer to
cotter pins and set screws. These retention devices must Figure 5.29).
be installed properly.
8. On some units, it may be necessary to use a puller
If the internal size tolerance of the cylinder barrel is threaded into a 1/2″-13 UNC tapped hole in the end of
exceeded, the piston seal could be pushed out when the the pin to remove the pin.
cylinder is put under a load. This will cause cylinder failure.
9. With the hoist, carefully lift the cylinder out of the
After reconnecting a hydraulic line from any cylinder, outrigger weldment. Remove the hydraulic tube from
extend and retract the cylinder five to six times to purge the the cylinder.
air out of the cylinder and to check for hydraulic leaks.

Base End
Forged Pin Retainer

Cap
Screws Forged Pin Retainer
Rod End or Cap Screws
Forged
Section B-B Pin Retainer
Figure 5.29 — Radial Outrigger Cylinder Fasteners
Installation 3. Position the unit so the booms are not directly above
1. Install the hydraulic tube on the new cylinder. the elevator lower arm cylinder to provide room for
removing the cylinder. Make sure the lower arm is in
2. Secure the cylinder to the hoist. Lift the cylinder above the rest.
the outrigger leg weldment. Carefully guide the cylin-
der as it slides into the outrigger leg weldment. 4. Disengage the PTO and turn off the engine. Release
any pressure in the hoses connected to the lower arm
3. Install the pin that secures the base end of the cylinder cylinder by shifting the lower arm control handle on the
in the weldment. Install the cap screws or forged pin below rotation controls in both directions several
retainer that secures the pin. times.
4. Reconnect the hoses to the cylinder. 5. Remove the hoses from the cylinder.
5. Start the engine and engage the PTO. With the 6. Use a sling and hoist to support the cylinder.
cylinder properly secured, extend the cylinder. Be
careful not to scratch the rod. Line up the pin hole in 7. Remove the pin retainers and the pins. Using the sling
the rod end with the bosses in the outrigger leg and and hoist, lift the cylinder from the elevator weldment
folding shoe. Make sure the bearings for the outrigger and lower it to the ground.
leg and folding shoe are in place.
Installation
6. Install the pin connecting the cylinder, leg, and shoe. 1. Remove the fittings from the old cylinder and install
Install the forged pin retainer that secures the pin. them in the new cylinder. Plug the openings in the old
cylinder.
7. Extend and retract the outrigger leg five to six times
to purge any air in the cylinder while checking for 2. Using the sling and hoist, position the new cylinder in
hydraulic leaks and proper operation. place and install the pins and pin retainers.
8. Perform a structural test as described in Section 9. 3. Connect the hoses to the cylinder.
Elevator Lower Arm Cylinder 4. Remove the sling and hoist.

Removal
1. Position the unit on a level surface, apply the parking 5. Use the below rotation controls to raise and lower the
brake, and chock the wheels. Start the engine, engage arm five to six times while checking for leaks and
the PTO, and properly set the outriggers. proper operation.
2. Raise the upper arm until the elevator upper arm 6. Perform a structural test as described in Section 9.
cylinder is fully extended.

Double Elevator Upper Arm 3. Remove the pin retainers and the pin from the rod end
or Single Elevator Arm Cylinder of the cylinder.
Removal
1. Position the unit on a level surface, apply the parking 4. Using the hydraulic system, completely retract the
brake, and chock the wheels. Start the engine, engage cylinder rod.
the PTO, and properly set the outriggers.
5. Disengage the PTO and turn off the engine. Release
2. Position the unit so the booms are not directly above any pressure in the hoses connected to the lower
the elevator upper arm cylinder to provide room for boom cylinder by shifting the lower boom control
removing the cylinder. Make sure the upper arm is in handle on the lower control valve in both directions
the rest position. several times.
3. Disengage the PTO and turn off the engine. Release 6. Remove the hoses connected to the lower boom
any pressure in the hoses connected to the upper arm cylinder.
cylinder by shifting the upper arm control handle on the
below rotation controls in both directions several 7. Use another sling and hoist to support the base end of
times. the cylinder.
4. Remove the hydraulic hoses from the cylinder ports 8. Remove the pin retainers and the pin from the base
and cap or plug all openings to prevent contamination. end of the cylinder.
5. Use a sling and hoist to support the cylinder. 9. Immediately lower the cylinder to the ground.
6. Remove the pin retainers and the pins. Using the sling Installation
and hoist, lift the cylinder from the elevator weldment 1. With the new cylinder on the ground, secure the slings
and lower it to the ground. around the cylinder housing.
Installation 2. Lift the cylinder with the hoist and align the base end
1. Remove the fittings from the old cylinder and install of the cylinder with the cylinder attachment bracket on
them in the new cylinder. Plug the openings in the old the turntable. Install the cylinder pin through the pin
cylinder. boss of the attachment bracket, the base end of the
cylinder, and the second pin boss in the cylinder
2. Using the sling and hoist, position the new cylinder in attachment bracket.
place and install the pins and pin retainers.
3. Install the pin retainers to secure the cylinder pin.
3. Connect the hoses to the cylinder. Torque the cap screw to the proper value.
4. Remove the sling and hoist. 4. Connect the hydraulic hoses to the cylinder.
5. Use the below rotation controls to raise and lower the 5. Remove the sling from the base end of the cylinder.
arm five to six times while checking for leaks and Start the engine and engage the PTO. From the lower
proper operation. controls, extend the rod end of the cylinder to align
with the mounting holes in the boom. Connect the rod
6. Perform a structural test as described in Section 9. end of the cylinder to the boom.
Lower Boom Cylinder 6. Install the pin retainers to secure the rod end cylinder
Removal pin. Torque the cap screw to the proper value.
brake, and chock the wheels. Engage the PTO and 7. Use the lower controls to raise and lower the boom five
properly set the outriggers. Position the lower boom in to six times to purge any air in the cylinder while
the rest. checking the lift cylinder for leaks and proper opera-
tion. Do not raise the boom more than halfway the first
2. Use a sling and hoist to support the cylinder. two to three times.
8. Perform a structural test as described in Section 9.

Upper Boom Cylinders 8. Remove the pin retainers and pin from the base end.
Removal Lower the cylinder from the unit and place it on a stable
Two slings and hoists are necessary for this procedure. work surface.
It will be necessary to be able to lift the upper boom at least Top Cylinder
5′ (1.5 m) above the lower boom at a point above the boom 1. Position the unit on a level surface so the top upper
rest saddle. Carefully handle the upper boom to avoid the boom cylinder is under a hoist. Apply the parking
possibility of damaging the fiberglass surface. brake and chock the wheels. Engage the PTO and
Warning 2. From the stored position, using the unit’s hydraulic
Death or serious injury can result from uncontrolled system, raise the upper boom about 5′ (1.5 m) out of
movement. Properly support the component before the upper boom rest.
loosening fasteners and removing components.
3. Disengage the PTO and turn off the engine. Move the
When removing and installing the upper boom cylinder(s) upper boom control handle on the lower control valve
or linkage, take measures to prevent accidental lowering several times in each direction to release any pres-
of the upper boom. It may be necessary for personnel to sure. Disconnect the hose to the R port on the top
be under the suspended upper boom during at least part of upper boom cylinder.
the work.
4. Lower the upper boom to about 2′ (0.61 m) out of the
Bottom Cylinder boom rest, just high enough to allow access to the top
1. Position the unit on a level surface, apply the parking upper boom cylinder base end pin. Support the upper
brake, and chock the wheels. Engage the PTO and boom with a sling and hoist.
properly set the outriggers. Rotate the aerial device so
the booms are over the side of the vehicle. 5. Support the cylinder with a sling and hoist. Disconnect
the other two hoses on the top upper boom cylinder.
2. Raise the upper boom 4′ to 6′ from the rest position. Remove the pin retainers and pin at the base end of the
Disengage the PTO and turn off the vehicle engine. cylinder.
3. Move the upper boom control handle on the lower 6. Lift the cylinder with the hoist to allow access to the
control valve several times in each direction to release rod end pin and remove the pin retainers and pin.
any pressure. Remove the retract hydraulic hose from Remove the cylinder with the hoist.
the top upper boom cylinder.
If the cylinders are going to be left off the unit for an
4. Engage the PTO and use the lower controls to lower extended period of time, use the hoist to lower the upper
the upper boom into the rest. Disengage the PTO and boom into the boom rest and store the unit.
turn off the engine.
Installation
5. Connect a hoist to the fiberglass boom near the outer 1. Use an auxiliary hydraulic power source to extend the
end. Lift the fiberglass with a nylon strap connected as new cylinders.
a choker. Restrict the choker from sliding up the boom
as the boom is lifted. Protect the fiberglass from 2. Attach the power source to the base end ports of the
damage while lifting. Use the hoist to raise the upper cylinder being actuated. Attach one hydraulic line to
boom tip 6″ to 8″ (15 to 20 cm) out of the rest. the R port on the cylinder. Attach the second line to the
E port on the cylinder base end. Connect the E and P
6. Move the upper boom control handle on the lower ports on the base end of the cylinder in order to open
control valve several times in each direction to release the counterbalance valve to allow the cylinder to
any pressure. Disconnect and cap all hydraulic hoses extend. Completely extend the bottom upper boom
on the cylinder to prevent oil loss and contamination. cylinder. Extend the top upper boom cylinder approxi-
mately 3″ (7.6 cm) from fully retracted.
7. Support the bottom upper boom cylinder. Remove the
pin retainers and pin from the rod end of the bottom 3. With the cylinder on the ground, secure the slings
upper boom cylinder. around the cylinder housing.

4. Lift the cylinder with the hoist and align the base end Installation
of the cylinder with the cylinder attachment bracket on 1. Install the hydraulic tube, fittings, and the pilot oper-
the lower boom. Install the cylinder pin through the pin ated check valve on the new cylinder.
boss of the attachment bracket, the base end of the
cylinder and the second pin boss in the cylinder 2. Install the pins and pin retainers in each end of the
attachment bracket. cylinder and the attachment points on the boom and
the jib/winch package.
5. Install the pin retainers to secure the cylinder pin.
3. Connect the hoses to the cylinder.
6. Connect the hydraulic hoses to the cylinder.
4. Start the engine and engage the PTO. Raise and lower
7. Align the rod end of the cylinder with the mounting the jib several times to purge air from the cylinder while
holes in the links. Install the pin through the link and checking for leaks and proper operation.
the rod end of the cylinder.
5. Replace the cover.
8. Install the pin retainers to secure the rod end cylinder
pin. 6. Perform a structural test as described in Section 9.
Jib Extension Cylinder

Warning Removal
Death or serious injury can result from uncontrolled 1. Position the unit on a level surface, apply the parking
movement. Purge the air from the actuator before brake, and chock the wheels. Disengage the PTO and
operating the unit. turn off the engine.
Do not position the upper boom overcenter until you know 2. Release any pressure in the hoses connected to the
there is oil in the rod end of both upper boom cylinders. cylinder by shifting the jib/extension control handle in
both directions several times.
9. Use the lower controls to purge any air from the upper
boom cylinders while checking the cylinders for leaks 3. Remove the jib/winch and jib extension cylinder cov-
and proper operation. With the lower boom in a vertical ers.
position, move the upper boom up and down about 60
degrees, for 5 or 6 cycles. 4. Disconnect the hoses from the cylinder.
10. Perform a structural test as described in Section 9. 5. Remove the pin and pin retainers that secure the rod
end of the cylinder.
Jib Tilt Cylinder
Removal 6. Remove the cap screws that secure the barrel of the
1. Position the unit on a level surface, apply the parking cylinder.
brake, and chock the wheels. Disengage the PTO and
turn off the engine. 7. Carefully remove the hydraulic tube, fittings, and the
pilot operated check valve from the cylinder.
2. Remove the jib/winch cover.
Installation
3. Support the jib with a sling. 1. Install the hydraulic tube, fittings, and the pilot oper-
ated check valve on the new cylinder.
4. Release any pressure in the hoses connected to the
cylinder by shifting the jib tilt control handle in both 2. Install the cap screws that secure the barrel of the
directions several times. cylinder to the attachment points on the jib/winch
package.
5. Disconnect the hoses from the cylinder.
3. Install the pin and pin retainers through the rod end of
6. Remove the pin and pin retainers that secure the ends the cylinder and the attachment points on the jib/winch
of the cylinder. package.
7. Carefully remove the hydraulic tube, fittings, and the 4. Connect the hoses to the cylinder.
pilot operated check valve from the cylinder.

5. Start the engine and engage the PTO. Extend and 6. Carefully remove the hydraulic tube, fittings, and the
retract the jib several times to purge air from the pilot operated check valve from the cylinder.
cylinder while checking for leaks and proper operation.
Installation
6. Replace the covers. 1. Install the hydraulic tube, fittings, and the pilot oper-
ated check valve on the new cylinder.
2. Install the pin and pin retainers in the base end of the
Platform Rotator Cylinder cylinder and the attachment point on the mounting
Removal bracket.
brake, and chock the wheels. Engage the PTO and 3. Connect the hoses to the cylinder.
rotate the platform to access the rotation cylinder.
4. Start the engine and engage the PTO. Extend the
2. Disengage the PTO and turn off the engine. cylinder to align the rod end of the cylinder and the
attachment point on the pivot arm.
3. Release any pressure in the hoses connected to the
cylinder by shifting the platform rotate control handle 5. Install the pin and pin retainers in the rod end of the
in both directions several times. cylinder and the attachment point on the pivot arm.
4. Disconnect the hoses from the cylinder. 6. Rotate the platform several times to purge air from the
cylinder while checking for leaks and proper operation.
5. Remove the pin and pin retainers that secure the ends
of the cylinder.

Section 6 — Mechanical Systems
A mechanical system consists of unit components ar- the hoses to catch the hydraulic oil. Cap or plug all
ranged so the motion of one mechanically moves the open ports immediately.
other. Examples of mechanical components are the rota-
tion bearing, rotation gearbox, and the booms. Mechanical 6. After reconnecting a hydraulic line, operate the con-
components may be moved by each other or by hydraulic trols in the system five to six times to purge the air out
or electrical actuators. of the system and to check for hydraulic leaks.
When welding on the unit, a welding ground clamp must be 7. Properly torque all connections and cap screws. Refer
attached to the same structure on which the welding is to Section 5 under Torque and Tightening Procedures.
being performed. This is necessary to prevent electrical
current from being sent through components. 8. Perform a structural test as described in Section 9
after replacing a major component. Hydraulic cylin-
Components such as the rotation bearing, rotary joint, wire ders, pivot pins, rotation bearing, and leveling system
braid hoses, and hydraulic cylinders can be damaged by components are examples of items that require test-
electrical current. Electrical current flowing through a ing after installation.
component can be very intense, causing serious internal
damage to the component. 9. Perform a dielectric test as described in Section 9
after any component is installed that could affect the
Follow this list of safety procedures when servicing the dielectric integrity of the unit.
unit.
1. Select a work site large enough to operate the required Caution

functions. Injury can result from being pinched or trapped be-
brake, and chock the wheels. Check the hydraulic oil Use caution when access covers have been removed to
level. Engage the PTO and properly set the outriggers. service the unit. Pinch points and shear points may exist
diately after servicing.
Warning
movement. Use a sling and hoist of adequate capacity.
Rotary Joint
The rotary joint permits continuous rotation of the turntable
3. Use a hoist to safely support heavy components without twisting the hydraulic hoses in the pedestal and
before loosening the fasteners on that component. turntable. The inner core of the rotary joint is fastened to
the pedestal. The outer housing rotates with the turntable
driven by a drive pin on the side of the housing.
Warning
Death or serious injury can result from hydraulic oil Removal
being injected into the flesh when loosening or dis- 1. Position the unit on a level surface, apply the parking
connecting hydraulic components. Remove the pres- brake, and chock the wheels. Engage the PTO and
sure before loosening or disconnecting hydraulic properly set the outriggers.
components.
2. Position the boom to allow for access to the rotary joint
Seek medical attention if injured by escaping hydrau- from the inside of the turntable. Use a sling and hoist
lic oil. Serious infection or reaction can result if to support the boom.
medical treatment is not given immediately.
3. Disengage the PTO and turn off the engine.
cause personnel to slip and/or fall. Keep the unit and 4. Move the control selector to Lower Controls. Relieve
work areas clean. the pressure in the hoses by moving all the control
handles at the turntable controls in both directions
4. Never loosen or remove a pressurized hose or fitting. several times.
5. Mark all hydraulic hose fittings before disconnecting 5. Remove the access hole covers from the pedestal.
them to ease installation later. Place a container under
Section 6 — Mechanical Systems • 65

6. Remove the slip ring from the rotary joint (refer to 6. Start the engine and engage the PTO. Operate the unit
Section 7 under Slip Ring). from the turntable controls to purge air from the
system while checking for leaks and proper operation.
7. Disconnect the hydraulic hoses in the turntable and
pedestal that are connected to the rotary joint. 7. Replace the covers.
8. Support the rotary joint (refer to Figure 6.1) from inside

the pedestal. Remove the cap screws that secure the
Rotation System
rotary joint mounting plate to the pedestal. The turntable rotates on a shear ball bearing, referred to as
the rotation bearing. The inner race of the bearing is
fastened to the turntable. The outer race of the bearing is
fastened to the pedestal. It has gear teeth cut on the
outside surface of the outer race.
Rotation is accomplished by a worm gearbox mounted on

the turntable (refer to Figure 6.2). The gearbox is driven by
a hydraulic motor. The rotation pinion meshes with the
teeth on the rotation bearing.
24-Pin Rotation
Connector Gearbox
Rotary Joint
Motor
Steel Pipe
Slip Ring
Rotation Pinion
Meshing With
Rotation Bearing
Figure 6.1 — Rotary Joint/Slip Ring Assembly
9. Remove the rotary joint from the pedestal.

Figure 6.2 — Rotation System
Installation
1. Remove the hydraulic fittings, mounting plate, and When the rotation function is operated, hydraulic oil flows
drive pin from the old rotary joint and install them on to the rotation motor for the direction of operation (clock-
the new rotary joint. wise or counterclockwise). The motor powers the worm,
which in turn drives the worm gear. The worm gear is
2. Position the rotary joint inside the pedestal and secure attached to the rotation pinion. As the rotation pinion
it to the pedestal with the cap screws. travels around the rotation bearing, the turntable rotates.
3. Install the slip ring on the rotary joint (refer to Section A valve block is mounted directly to the rotation motor that
7 under Slip Ring). contains two cross-ported counterbalance holding valve
cartridges. The valves prevent accidental rotation if one or
4. Connect the hydraulic hoses to the rotary joint. both of the hydraulic lines connected to the rotation motor
fail.
5. Remove the sling and hoist supporting the boom.
66 • Section 6 — Mechanical Systems

Rotation Bearing 9. Remove the cap screws and washers from the outer
The rotation bearing provides for very low torque rotation. race of the rotation bearing. These cap screws are
The bearing should provide many years of service if accessible from the pedestal side of the rotation
properly maintained. bearing.
A grease tube is connected to the inner race of the rotation 10. Using a sling and hoist, lift the bearing off the pedestal.
bearing and to a grease fitting on the front of the turntable.
Lubricate the bearing race, the gear teeth on the outer race, Installation
and the rotation pinion as recommended by the Preventive New rotation bearing kits shipped from Altec include cap
Maintenance and Inspection Checklist. Refer to Section 4 screws, hardened washers, anaerobic adhesive com-
under Lubrication for information. pound, cleaning solvent, and installation instructions.
Procedures for measuring turntable tilt and inspecting the

rotation bearing cap screws are found in Section 4 under Warning
Rotation Bearing. Death or serious injury can result from improper use
of solvents. Follow the manufacturer’s label for proper
Removal use and disposal.
Components may need to be removed to access the
rotation bearing cap screws. 1. Clean the rotation bearing mounting surfaces on the
pedestal, turntable, and the bearing with a cloth and
1. Position the unit on a level surface, apply the parking solvent to remove any dirt or grease. Allow the
brake, and chock the wheels. Engage the PTO and surfaces to completely dry.
properly set the outriggers. Disengage the PTO and
turn off the engine. 2. Remove the grease tube from the old rotation bearing
and install it on the new bearing.
2. Relieve the pressure in the system by moving all the
handles at the turntable controls in each direction 3. Shake the bottle of adhesive compound. Apply the
several times. adhesive to the pedestal side of the bearing surface
according to the pattern shown in Figure 6.3. The
3. Remove the gearbox. Refer to Rotation Gearbox in bearing must be completely installed within 30 min-
this section. utes of applying the adhesive. Do not get adhesive in
the cap screw holes.
4. Remove the rotary joint and slip ring. Refer to Rotary
Joint in this section.
3
/16″ to 1/4″
Wide Bead
Warning
movement. Properly support the component before
loosening fasteners and removing hydraulic compo-
nents.
5. Support the turntable and booms to prevent them from

coming off of the pedestal after the cap screws are
removed. More than one lifting device may be required
to adequately support the turntable and booms.
6. Disconnect the grease tube from the turntable.

Figure 6.3 —
7. Remove the inner race cap screws and washers. The Anaerobic Adhesive Application Pattern
cap screws are accessible from the turntable side of
the rotation bearing. 4. Position the new rotation bearing on the pedestal with
the high tooth, marked by yellow or blue paint, in the
8. Use a sling and hoist to lift the turntable and booms proper position (refer to Figure 6.4). Align the mounting
from the rotation bearing. holes with the cap screw holes in the bearing.

1
13 14
8 6
12 9
3 4
High
Tooth 11 10
Location
Rotation
Gearbox X 5 7
Location
X 16 15
2
Figure 6.4 — Figure 6.5 —

Rotation Bearing High Tooth Location Outer Race Cap Screw Torque Pattern
Notice 8. Use a sling and hoist to position the turntable on top

Only use Altec supplied cap screws and washers to of the rotation bearing. Align the turntable mounting
install the rotation bearing. holes with the mating cap screw holes in the bearing.
5. Install the cap screws with washers in the outer race 9. Install the cap screws and washers in the inner race
of the bearing. Notice that the washer has a more of the bearing in the same manner as the outer race
rounded edge on one side. Install the washer with the cap screws.
rounded edge toward the cap screw head. Do not
torque the cap screws until all of them have been 10. Torque the cap screws in three phases with the same
installed on the outer race. procedure used on the outer race in step 6. Follow the
alternating star pattern shown in Figure 6.6.
Notice
Use an accurate 3/4″ drive click-type manual torque 23
wrench for the installation of the rotation bearing cap 20 21
16 17
screws. Torque the cap screws by a smooth pull on the 12 13
torque wrench without jerking. Do not overtighten the
cap screws. 8 Grease Tube 9
4 Connector
5
Insufficient or uneven cap screw tightness can contribute
to reduced life of the rotation bearing. 2 1
6. Torque the cap screws in three phases. 6 3
10 Loading Plug 7
a. Torque the cap screws to 165 foot-pounds (224
N•m) using the alternating star pattern shown in 14 11
Figure 6.5. 18 15
22 19
b. Set the torque wrench to 325 foot-pounds (441 Figure 6.6 — Inner Race Cap Screw Torque Pattern
N•m). Follow the same alternating star pattern.
11. Install the rotation gearbox. Apply thread locking
c. Keep the torque wrench set for 325 foot-pounds adhesive to the threads of the cap screws. Install the
(441 N•m). Torque each cap screw using a circular four cap screws, and washers. Do not torque the cap
pattern starting with cap screw number one. screws yet.
7. Rotate the inner race to position the grease tube as it 12. Adjust the backlash between the rotation pinion and
was in the original bearing. rotation bearing gear teeth as described in Section 8
under Rotation Gearbox.

13. Install the rotary joint and slip ring. Reconnect all 4. Torque the cap screw to 100 percent of the normal
hydraulic lines and electrical wires. Connect the installation torque value.
grease tube to the turntable.
5. Repeat steps 2 through 4 for each cap screw in the
14. From the turntable controls, operate each function five race, going around in a circular pattern.
or six times to purge any air in the system.
6. Conduct a rotation system seating procedure. Posi-
15. Lubricate the rotation bearing raceway and gear teeth tion the booms and apply the appropriate test weight
as described in Section 4. for a level surface stability test. Provide a suitable
restraint, securely anchored to the ground, to prevent
16. Conduct a rotation system seating procedure. Posi- overturning. Rotate the turntable through three com-
tion the booms and apply the appropriate test weight plete revolutions to properly seat the bearing and
for a level surface stability test. Provide a suitable fasteners.
restraint, securely anchored to the ground, to prevent
overturning. Rotate the turntable through three com- 7. Torque the rotation bearing cap screws to 100 percent
plete revolutions to properly seat the bearing and of the normal installation torque value using a circular
fasteners. pattern.
17. Torque the rotation bearing fasteners (both inner and Resume regular inspection of the rotation bearing cap
outer race) again to 100 percent of the normal instal- screws as recommended by the Preventive Maintenance
lation torque, using a circular pattern. Torque the and Inspection Checklist. Use the inspection procedures
rotation gearbox fasteners again to 100 percent of the in Section 4 under Rotation Bearing Cap Screws.
normal installation torque.
Rotation Gearbox
18. Inspect the rotation bearing cap screws as recom- Removal
mended by the Preventive Maintenance and Inspec- 1. Position the unit on a level surface, apply the parking
tion Checklist. Use the inspection procedures in brake, and chock the wheels. Engage the PTO and
Section 4 under Rotation Bearing Cap Screws. properly set the outriggers. Disengage the PTO and
Rotation Bearing Cap Screws
Use this procedure when only the rotation bearing cap
screws are being replaced. Warning
Notice movement. Secure the booms before removing the
Only use Altec supplied cap screws and washers. rotation gearbox.
When rotation bearing cap screws or washers are re- 2. Secure the boom with a strap so the turntable cannot
moved, they must be replaced with new ones. Contact rotate when the gearbox is removed.
your Altec representative for replacement fasteners.
1. Position the unit on a level surface, apply the parking Caution

brakes, and chock the wheels. Engage the PTO and Injury can result from contact with pinion and rotation
properly set the outriggers. Disengage the PTO and bearing gear teeth. Keep hands clear.
eyes. Wear appropriate safety equipment.
Warning
Death or serious injury can result from uncontrolled Wear eye protection while adjusting the eccentric ring to
movement. Replace only one cap screw at a time. prevent particles of metal or dirt from entering the eyes.
2. Loosen and replace only one cap screw at a time. 3. Remove any wiring, control lines, hoses, or tubes that
are in the way of the gearbox removal. Cap or plug all
3. Install the new cap screw and washer. Notice the open connections to prevent contamination from en-
washer has a more rounded edge on one side. Install tering the system.
the washer with the rounded edge toward the cap
screw head. 4. Remove the pinion cover. Loosen the eccentric ring
lock and the four cap screws securing the gearbox.

5. Engage a suitable bar or drift pin, preferably of a soft 9. Operate the unit through all boom angles and rotation
material such as brass, in a drive slot of the eccentric from the upper controls while checking for smooth-
ring. Rotate the eccentric ring using light blows from ness of rotation.
a hammer against a bar or drift pin. Rotate the
eccentric ring to position the gearbox the maximum 10. Inspect the rotation gearbox mounting cap screws as
distance from the rotation bearing gear teeth. recommended by the Preventive Maintenance and
Inspection Checklist.
6. Manually operate the rotation control at the turntable
controls to relieve the pressure from the rotation
Elbow Bearing
function lines.
Removal
7. Remove the rotation motor hydraulic hoses. Plug and
cap the openings. Warning
8. Place a nylon sling around the gearbox. The sling may movement. Properly support the component before
be tied together to make a basket under the gearbox. loosening fasteners and removing components.
9. Connect the sling to a hoist. Remove the eccentric 1. Position the unit on a level surface, apply the parking
ring lock and the four gearbox mounting cap screws. brake, and chock the wheels. Start the engine, engage
Lift the gearbox out of the turntable and lower it to the the PTO, and properly set the outriggers.
ground.
2. Raise the upper boom 4′ to 6′ above the boom rest,
Installation disengage the PTO, and shut off the engine.
1. Position the boom and hoist as instructed during the
removal procedure.
Warning
2. Clean the mounting surface and eccentric ring. Apply Death or serious injury can result from hydraulic oil
anti-seize compound to the inside and outside surface being injected into the flesh when loosening or dis-
of the eccentric ring and boss. Install the eccentric connecting hydraulic components. Remove the pres-
ring in a position so that adjusting 1/4 turn one way will sure before loosening or disconnecting hydraulic
produce full adjustment and 1/4 turn the other way will components.
completely loosen the gearbox.
Seek medical attention if injured by escaping hydrau-
3. Position the nylon sling on the gearbox as before and lic oil. Serious infection or reaction can result if
connect it to the hoist. Position the gearbox on the medical treatment is not given immediately.
turntable.
4. Install the gearbox mounting cap screws loosely. cause personnel to slip and/or fall. Keep the unit and
work areas clean.
5. Adjust the rotation pinion to the rotation bearing
following the procedure in Section 8 under Rotation 3. Bleed the hydraulic pressure from the hydraulic sys-
Gearbox. tem by moving each of the control levers at the
turntable controls in both directions several times.
6. Connect the rotation motor hoses. Connect any other
wiring, hoses, tubes, and control lines that may have 4. Remove the retract hose from the top cylinder. Plug or
been removed for this procedure. Remove the strap(s) cap the openings.
used to secure the boom.
5. Start the engine and engage the PTO. Use the
7. Position the unit on a level surface with sufficient turntable controls to lower the upper boom into the
clearance for full boom movement. Apply the parking boom rest. Disengage the PTO and turn off the engine.
brake and chock the wheels. Engage the PTO and
properly set the outriggers. 6. Wrap a sling around the upper boom tip near the
platform and connect it to an overhead hoist.
8. Operate the unit through all boom angles and rotation
from the turntable controls while checking for leaks 7. Raise the upper boom until there is enough slack in the
and proper operation. links to remove the top elbow link pin.

8. Use a sling and hoist or wood block to support the top 26. Remove the cap screws, washers, and nuts from the
cylinder and prevent it from dropping on the lower inner race of the bearing and discard them.
cylinder.
27. Separate the lower boom and the bearing from the
9. Remove the elbow link pin connecting the top cylinder upper boom.
link to the elbow weldment.
28. Support the elbow bearing with a sling and hoist.
10. Use a sling and hoist to support the bottom cylinder.
29. Remove the cap screws and washers from the outer
11. Remove the elbow link pin connecting the lower race of the bearing and discard them.
cylinder link to the elbow weldment.
30. Carefully remove the elbow bearing and place it on a
12. Lower the upper boom back into the rest. stable work surface.
13. Remove the elbow and lower boom access covers. Installation
1. Use a scraper, or the end of a flat file, to remove any
14. Loosen the leveling system. paint from the area around the cap screw holes on the
upper and lower boom elbow weldments where the
15. At the upper boom side of the elbow, rotate the leveling washers and nuts will be positioned. These areas
cable sheave counterclockwise until the upper level- must be cleaned of any paint film, oil, anti-seize
ing cable turnbuckle can be removed at the upper compound, excess weld, or other material. Bare metal
boom elbow access opening. must be exposed.
16. At the lower boom access opening, remove both

turnbuckles. Warning
17. Mark all the hose connections at the elbow to ease of solvents. Follow the manufacturer’s label for proper
installation later. use and disposal.
18. At the elbow, disconnect the upper boom, tool, and 2. Clean mounting surfaces on the upper and lower boom
pump sense hydraulic hoses from the lower boom. elbow weldments and both bearing mounting surfaces
Cap or plug all open ports. on the elbow bearing with a cleaning solvent. Use
emery paper to clean areas on the weldments that
19. Remove the lockwires, cap screws, and lugs from the appear to be stained. These stains are areas of
elbow pin ends. corrosion that may leave a rough surface on the
weldments. Apply the cleaning solvent and wipe off
20. If the unit has a two-man rotating platform, remove the the residue several times until there is no residue on
non-overcenter cam from the elbow pin upper boom the cleaning rags. Allow the cleaned surfaces to dry
end. completely. This may take up to 15 minutes, depend-
ing on temperature and humidity.
21. Remove the elbow pin and lower boom leveling sheave
from the lower boom elbow weldment. 3. Use a 6″ (15 cm) metal straight edge or ruler and a
0.002″ feeler gauge to check the mounting surface
22. Loosen the upper boom elbow leveling sheave. around each cap screw hole of the upper and lower
boom weldments for flatness.
23. Remove the lower boom elbow sheave and cable.
Drive the elbow pin through the lower boom end until 4. Place the straight edge across two cap screw holes
it is out of the lower boom side. and try to slide the 0.002″ feeler gauge under the
straight edge. There must be no more than 0.002″
24. Support the elbow end of the upper boom. Position the clearance between the weldment surfaces and the
support so it will also prevent the upper boom from straight edge.
rotating.
5. Areas with more than 0.002″ clearance must be filed
25. Tie the ends of the links together with a suitable flat before further assembly. Remove any high spots
material. around the cap screw holes on the weldments using a
hand file to obtain a flat surface. Do not use a grinder

or sander to true the surface as excessive material 9. Position the elbow bearing on the upper boom and
may be removed using these tools. align the grease fitting as shown in Figure 6.8. The
bearing should sit flush with the machined surfaces,
6. Clean the boom mounting surfaces and the bearing without requiring cap screws to pull it into position.
surfaces on the elbow bearing using a cleaning sol-
vent. Apply the cleaning solvent and wipe off the 10. Install the longer cap screws in the inner race. Position
residue several times until there is no residue on the the heads of the cap screws in the antirotation ring.
cleaning rags. Allow the cleaned surfaces to dry Make sure the thin washers under the ring are in place.
completely. This may take up to 15 minutes, depend- Install the thin washers and nuts on the cap screws.
ing on temperature and humidity. Notice that the washer has a more rounded edge on
one side. Install the washer with the rounded edge
Be ready to install the cap screws immediately after toward the nut. Do not torque the nuts until all of them
positioning the elbow bearing on the mounting sur- have been installed on the inner race.
face. After the elbow bearing and the weldment
surfaces meet, the elbow bearing must be aligned and 11. Torque the nuts on the upper boom side in three
secured with cap screws within 15 minutes. phases. The antirotation ring will hold the head of the
cap screw.
7. Remove the grease fittings from the old bearing and
install them on the new bearing. a. The initial torque value on the nut is 90 foot-pounds
(122 N•m), using the alternating star pattern shown
8. Shake the bottle of adhesive. Apply a bead of anaero- in Figure 6.9.
bic adhesive to the upper boom weldment bearing
surface in a pattern similar to the one shown in Figure 15 1
6.7. Do not get adhesive compound near or into the 10 8
cap screw holes.
3 13
17 6
/16″ to 1/4″
3
Wide Bead
12 11
5 18
14 4
7 9
2 16
Figure 6.9 —
Elbow Bearing Cap Screw Torque Pattern
Figure 6.7 — Adhesive Application Pattern
“G” (Soft Spot on Inner Race) Bearing to Seat Firmly

Located in this Area Against Shoulder
Grease Fitting
Loading Plug
Upper Boom Lower Boom
Figure 6.8 — Elbow Bearing Orientation

b. Set the torque to 175 foot-pounds (237 N•m) and 18. Install the lugs with cap screws on the elbow pin ends.
continue to use the alternating star pattern. Lockwire the cap screws.
c. Follow a circular pattern, with the torque wrench set 19. If the unit has a two-man rotating platform, install the
at 175 foot-pounds (237 N•m). cam on the elbow upper boom pin end.
12. Apply a bead of anaerobic adhesive to the lower boom 20. Adjust the cam. Refer to Overcenter Cam Adjustment
weldment bearing surface in a pattern similar to the in Section 8.
one shown in Figure 6.7. Do not get adhesive com-
pound near or into the cap screw holes. 21. Using a sling and hoist at the boom tip, raise the upper
boom until the top link pin clears the lower boom.
Make sure you are ready to install the cap screws
immediately after positioning the elbow bearing on the 22. Position the top link, align the holes, and install the link
mounting surface. After the elbow bearing and the pin. Secure the pin with a lug and cap screws.
weldment surfaces meet, the elbow bearing must be Lockwire the cap screws.
aligned and secured with cap screws within 15 min-
utes. 23. Fold the bottom link into position, align the holes, and
install the bottom link pin. Secure the pin with a lug and
13. Use the overhead sling and hoist to raise the upper cap screws. Lockwire the cap screws.
boom into position so it is parallel to the lower boom
and ready to be joined at the elbow. Rotate the outer 24. Lower the upper boom into the rest with the hydraulic
race as shown in Figure 6.8. The elbow bearing should system.
be flush with the machined surfaces of the lower
boom, without requiring cap screws to pull it into 25. Install the upper and lower boom leveling cable turn-
position. buckles. Readjust the leveling cable system tension
in the booms as instructed in Section 8 under Leveling
14. Install the cap screws and thick washers in the outer System.
race of the bearing. Notice that the washer has a more
rounded edge on one side. Install the washer with the 26. Reconnect all the hydraulic hoses in the lower and
rounded edge toward the cap screw head. Do not upper booms. Reconnect the top upper boom cylinder
torque the cap screws until all of them have been hydraulic hose.
installed on the outer race.
27. Install the fastener torque placards at the elbow.
15. Torque the cap screws on the lower boom side in three
phases. 28. Start the engine, engage the PTO, and operate the
aerial device from the lower controls. Check for leaks,
a. The initial torque value on the cap screw is 110 foot- proper leveling system operation, etc.
pounds (149 N•m) using the alternating star pattern
shown in Figure 6.9. 29. Perform a structural test as described in Section 9.
b. Set the torque to 225 foot-pounds (305 N•m) and 30. Retorque the cap screws to 225 foot-pounds (305
continue to use the alternating star pattern. N•m) and the nuts to 175 foot-pounds (237 N•m).
c. Follow a circular pattern, with the torque wrench set 31. Replace the elbow covers and all access covers.
at 225 foot-pounds (305 N•m).
Leveling System
16. Install the plastic caps onto the head of each cap
screw on the outer race and each nut on the inner race. One type of leveling cable must be replaced at least every
The plastic caps serve as a reminder that the cap 5 years or 5,000 hours, whichever comes first. The other,
screws require inspection six months after installa- newer type, of leveling cable must be replaced at least
tion. every 8 years or 8,000 hours, whichever comes first. The
newer type is recognized by yellow paint on the end
17. Install the elbow pin and the elbow sheaves. Place the coupling of the cable. This requirement is based on normal
leveling cables on the sheaves as instructed in this use, proper care, regular inspection, and lubrication. If the
section under Leveling System. unit is operated under severe conditions, or not properly
serviced, replace cables, leveling rods, or sheaves more

frequently. This emphasizes the need to perform regular platform through sheaves at the elbow and through the
inspections as instructed in this manual. keyed platform shaft.
Before removing or replacing leveling cables or rods, study Removal

Figure 6.10 thoroughly. These procedures must be fol- 1. Position the unit on a level surface with room to unfold
lowed to assure proper routing of cables for safe operation. the upper boom. Installation of the new cables will be
Several inspections will be required during cable replace- easier in this position. Apply the parking brake and
ment. It is strongly recommended that all replacement chock the wheels. Engage the PTO, properly set the
parts be genuine Altec parts. Substitution of inferior parts outriggers and position the upper boom. Disengage
can lead to dangerous conditions. the PTO and turn off the engine.
The leveling system functions to maintain the floor of the

platform parallel to the turntable base plate. This is a Caution
positive, mechanical system operated by cables, insulat- Injury can result from being pinched or trapped be-
ing rods, sheaves, etc. The two principal parts of the tween moving components. Keep hands clear.
leveling system are the leveling cables and leveling rods.
Each of the cables is anchored at the lower boom pivot pin Use caution when access covers have been removed to
and at the platform sheave. Because of the geometric service the unit. Pinch points and shear points may exist
arrangement, movement of the booms results in move- between moving parts. Replace the access covers imme-
ment of the platform. diately after servicing.
The leveling cables are 1/2″ (1.27 cm) in diameter. In the 2. Remove all access covers from the booms. This will
insulating section of the upper and lower booms, the permit access to the leveling system, which is mostly
leveling cable is connected to a 3/4″ (1.9 cm) fiberglass housed within the booms.
insulator rod to preserve the dielectric integrity of the
insulating components. Threaded ends on the leveling 3. It is necessary to remove the platform(s) for access
cables are mechanically swaged onto the wire rope. to the boom tip. This can be done by detaching the
Turnbuckles are provided in the lower boom for proper platform(s) from the mounting shaft. If the platform(s)
adjustment for the entire leveling system. Leveling cables can be supported while it is removed, it may not be
and insulator rods are thoroughly tested before they are necessary to remove the control head. The jib/winch
installed in the unit. package will also have to be removed.
Movement of the booms and the subsequent movement of 4. Disconnect the leakage monitoring wires from the
the leveling cable and rod system is transmitted to the leveling rods inside the upper boom at the elbow.
Leveling Rod to
Cable Connection
Boom Tip
R.H. L.H. R.H.
Approx.
30°
Approx.
R.H. L.H. R.H. 30°
Upper Boom
Torque to 75 foot-pounds
and lockwire Approx. 25°
Leveling Rod Turnbuckle Torque to
Approx. R.H. R.H. 50 foot-
30° L.H. pounds
and
R.H. R.H. lockwire
Leveling Cable L.H. Turntable
Lower Boom
Figure 6.10 — Leveling System Assembly

the rods for secure attachment and condition. Replace
Caution the rods if there are any signs of cracks, damage, or
Injury can result from handling wire rope. Wear appro- wear. Clean the rods before reusing them to avoid
priate safety equipment. degrading their dielectric strength.
5. Remove the cable keepers from all sheaves. 17. Inspect all idler sheaves. Sheaves must not be reused
if they show signs of scuffing on the surface which
Notice contacts the cable. All sheaves must turn freely
Use wrenches to support and position the rod and without excessive looseness in the bearing.
cable ends while turning the turnbuckle to prevent
damage. 18. Inspect the large sheaves at the elbow. If there are any
broken flanges or excessive wear, replace the sheaves.
6. Unscrew the turnbuckles in the lower boom to release If excessive wear is noted in the shaft bearings, they
the lower boom leveling rods from the cables. Push must be replaced.
the lower boom leveling rods through the lower boom
to extend outside at the elbow. 19. Inspect all cable keepers for wear, damage, or defor-
mation. Never use a cable keeper not in good condition.
7. Remove the idler sheave at the elbow end of the lower
boom. The upper boom leveling system will now Installation
freewheel on the sheaves and may easily be posi- Before installing the leveling system, carefully study the
tioned to access the turnbuckles. leveling system assembly (refer to Figure 6.10).
8. Release the upper boom leveling rods from the cables

by unscrewing the turnbuckles at the lower end of the Caution
upper boom. Injury can result from being pinched or trapped be-
9. Make note of the leveling rods to become familiar with
the right hand and left hand threads at the ends of the Use caution when access covers have been removed to
rods as identified in Figure 6.10. service the unit. Pinch points and shear points may exist
10. Unscrew the turnbuckles in the upper boom to release diately after servicing.
the upper boom leveling rods from the elbow cables.
1. Spray the new leveling cables with wire rope lubricant
11. Remove the platform mounting shaft from the upper before installation. Wipe them with a clean cloth to
boom tip. Note the orientation of the 12″ (30.5 cm) remove excess lubricant. Lubricant must not be
sheaves at the tip and at the elbow. allowed to dry on fiberglass surfaces because dirt can
collect and reduce the dielectric strength of the
12. Remove the pins from the 8″ (20.3 cm) idler sheaves fiberglass. Avoid getting dirt or grit on the cable.
at the boom tip and the lower 8″ (20.3 cm) idler
sheaves at the elbow end of the upper boom. 2. Install the long end of the elbow upper leveling cable
to the top upper boom rod end using jam nuts and a
13. Slide the 8″ (20.3 cm) idler sheaves at the boom tip, 11/2″ (3.8 cm) outside hex turnbuckle. Screw the
12″ (30.5 cm) boom tip sheave, boom tip cable, and turnbuckle onto the leveling rod and the cable end
the leveling rods out of the boom tip. fitting at least 11/4″ (3.2 cm). Slide the top upper rod
toward the tip until the upper end of the rod protrudes
14. At the boom tip, remove the cables from the leveling out of the boom tip. Slide the bottom rod so that its
rods. upper end protrudes from the boom tip.
15. After removing the sheave from the lower boom pivot 3. Attach the boom tip leveling cable assembly to the top
pin and detaching the cables from the sheave, remove upper boom leveling rod. Engage the cable end fitting
the lower end cables. threads at least 11/4″ (3.2 cm), tighten the jam nuts
securely against the leveling rod end fittings, and
16. Thoroughly inspect all leveling rods to determine if lockwire the assemblies. Likewise, attach the long
they can be used again. Check the rods for severe end of the boom tip leveling cable to the bottom upper
scratches, signs of rubbing, cleanliness, or any other boom leveling rod. Be sure to lockwire the assemblies
damage or wear. Inspect the terminals at the ends of according to Figure 6.11.

L.H. Thread R.H. Thread
Section C-C Section D-D
Figure 6.11 — Leveling Rod/Cable Connection
4. Position the boom tip leveling sheaves according to 9. Install the lower cables to the split sheave anchor
Figure 6.10. Wrap the cable as shown and engage the point and wrap them around the lower boom pivot pin
drive lug on the cable assembly into the recess on the sheave as shown in Figure 6.10. Install the 8″ (20.3
leveling sheave. cm) Nylatron sheaves, pins, bushings, thrust wash-
ers, pin retainers, and retaining cap screws at the
5. Install the 8″ (20.3 cm) Nylatron idler sheaves at the lower boom.
boom tip. Use the appropriate thrust washers, pin,
retainers, and drilled head fasteners. Lockwire the 10. Install the lower boom elbow leveling cable with the
fasteners as shown in the lockwiring section. long end on the upper side of the lower boom elbow
sheave. Engage the drive lug into the recess on the
6. Install the platform mounting shaft and drive key leveling sheave securely. Attach the end fittings of the
through the boom tip assembly and platform leveling lower boom elbow assembly to the lower boom level-
sheave. Use anti-seize compound on the keyways, ing rods, engaging the end fittings at least 11/4″ (3.2
keys, and the inside bore of the platform leveling cm). Tighten the jam nuts and lockwire as shown in
sheaves. Install the idler sheave cable keepers. Figure 6.11. Install the 6″ idler sheave, thrust wash-
ers, pivot pin, pin retainer, and retaining bolts at the
7. Position the elbow upper boom leveling sheave as elbow end of the lower boom. Lockwire the pin retainer
shown in Figure 6.10. Install the 8″ (20.3 cm) Nylatron bolt according to the lockwiring section.
idler sheaves, spacer, thrust washers, pin retainers,
and retaining cap screws. The pivot pins for the idler 11. Slide the lower boom leveling rods toward the lower
sheaves will retain the cables in their sheave grooves end of the lower boom, being sure to keep them
and eliminate the need for additional cable keepers. separate as to which is the top and which is the
bottom.
Notice
Use wrenches to support and position the rod and 12. Connect the lower end of the leveling rod to the cable
cable ends while turning the turnbuckle to prevent at the lower boom main pivot with the turnbuckle in the
damage. lower boom (refer to Figure 6.12). Tighten the turn-
buckle sufficiently to permit operation of the leveling
8. Attach the bottom upper boom leveling rod to the short system, but do not adjust the platform at this time. It
end of the elbow upper boom leveling cable using the is very important that all cables and rods be held with
11/2″ (3.8 cm) hex turnbuckle and jam nuts. The drive wrenches while the turnbuckles are tightened. Severe
lug on the elbow upper boom leveling cable must be twisting can damage the cable and leveling rods.
secured into the recess on the elbow leveling sheave.
This drive lug should be positioned as shown in Figure 13. Inspect the entire leveling system to make certain
6.10. Tighten the lower turnbuckle hand tight and then cables are not crossed and that they will operate freely
an additional five turns. This will provide the proper without rubbing. The cable wrap at the lower boom
pretension on the leveling system for the initial run-in pivot sheave, the elbow sheave, and the boom tip
of the new cables. Tighten the jam nuts securely. Do sheave can be pushed into alignment for good track-
not lockwire at this time. ing without rubbing.

Turn
R.H. L.H.
R.H. L.H.
Hold Hold
Figure 6.12 — Turnbuckle Assembly
14. Install the platform(s) onto the platform mounting extended and elevated and the load hook is on the ground.
shaft. Keep this length requirement in mind when installing a new
winch line. If it is necessary to cut out a damaged section
15. Position the unit on a level surface, apply the parking and splice in a new piece of line, the new length of line must
brake, and chock the wheels. Engage the PTO and also meet this requirement.
properly set the outriggers. Place the rated load in the
platform. Use the lower controls to operate the boom The first layer of line around the winch drum should be put
through all positions. on closely, under a tension of at least 50 pounds (23 kg).
This will prevent subsequent wraps from slipping down
between the wraps in the first layer when a load is applied
Warning to the winch.
movement. Do not permit anyone to occupy the plat- The fibers of synthetic line can be cut and damaged by
form until the unit has passed applicable tests. sharp edges and burrs on winch drums, sheaves, shack-
les, wire slings, etc. Remove any sharp edges the syn-
Do not permit anyone to occupy the platform until after the thetic line may come in contact with. To prevent damage
operations have been tested. The unit must also pass both to the synthetic winch line, repair or replace hardware that
a structural test and a dielectric test after replacement of has been scored or damaged.
critical components.
Removal
16. Inspect cables, rods, pins, etc. at the turntable, elbow, 1. Pay out all of the winch line.
and boom tip to determine that there is no rubbing
between the moving parts. This inspection can be 2. Remove the button head cap screw on the winch line
made from another aerial device. keeper (refer to Figure 6.13).
17. Connect all leakage monitoring wires at the elbow end

of the upper boom. Install all covers.
18. Adjust the leveling cables (refer to Leveling System in Drum

Section 8).
20. The unit must be given a dielectric test any time work Keeper
has been performed which might affect the insulating
properties of the fiberglass. Maintain records in a Button Head
permanent file, as instructed in Section 9. Cap Screw
Figure 6.13 — Winch

Winch
Line 3. Remove the keeper and winch line from the drum.
A properly installed winch line must have at least four full
wraps on the drum when the arms, booms, and jib are fully

Installation 2. Place the keeper over the anchor.
Warning 3. Install and properly torque the button head cap screw
Death or serious injury can result from loss of load through the keeper into the top of the anchor.
control. Install the winch line in the proper direction of
the drum rotation. 4. Operate the winch to place the line on the drum.
1. Place the loop at the end of the winch line over the 5. Operate the winch, checking for leaks and proper
anchor. operation.

Section 7 — Electrical System
Electrical power is supplied from the vehicle battery. On/off circuits are used to operate the following functions.
Figure 7.1 shows a comparison between electrical and
hydraulic components. • Engine start/stop
• DC pump
• Upper/lower/emergency stop selector
Caution • Jib up/down
Injury can result from electric shock. Severe arcing • Winch out/in
can occur even when working with low voltage vehicle • Platform rotation (units with two-man, side-mount
electrical systems. Use caution when working with platform)
any electrical device. • Outrigger interlock system
• Outrigger motion alarm
Voltage levels of this system are based on a constant
vehicle power source. Voltage may vary from 11 to 14
Proportional Circuits
volts and still be considered normal in a 12 VDC system.
A proportional circuit supplies a varying electrical signal
The electrical system uses two basic types of circuits — that corresponds with the distance the control is moved.
an on/off circuit and a proportional circuit. The major Maximum control movement produces the maximum
electrical components and their operation are described in signal strength and operating speed of the function se-
this section. Wiring Line Diagrams in the Appendix illus- lected. If the control is moved half the maximum travel
trate the component wiring. Refer to Section 8 for trouble- available, the signal strength and speed of the function is
shooting information. reduced to half that available. The function will continue to
move until the control is returned to neutral or the function
reaches its maximum travel.
On/Off Circuit
The on/off circuit supplies low voltage constant power to Proportional circuits are used to energize solenoid oper-
a solenoid or other component when a switch or relay is ated pilot control valves to operate of the following func-
closed. When the circuit is opened, the power is removed. tions from the below rotation controls station.
All of the circuits on this unit are on/off electrical circuits.
Electrical Component Hydraulic Component Function Performed

Battery Pump Source of energy or power
Voltage Pressure Creates a potential energy difference between two points in a
system
Current Oil flow Allows potential energy to become kinetic and do useful work
Wire Hose or tube Transmits power from place to place
Fuse or circuit breaker Relief valve Protects system from overload
Diode Check valve Allows power to flow in one direction but not the other
Switch Shutoff valve Blocks power or allows it to flow
Controller Control valve Varies the amount of power which passes through it depend-
ing upon the distance the control handle is moved
Resistor Orifice Restricts the flow of power
Relay Pilot operated Allows power to flow through upon receiving a signal from
check valve another source
Solenoid Cylinder Causes axial movement of its central element when power
is applied to it
Slip ring assembly Rotary joint Transmits power through a continuously rotating connection
Figure 7.1 — Electrical/Hydraulic Comparison
Section 7 — Electrical System • 79

• Lower boom down/up lic oil flow to shift the valve spool in the aerial control valve
• Upper boom fold/unfold to operate the function selected.
• Turntable rotation clockwise/counterclockwise
Cable Assemblies
A proportional control system is used for these functions
because they require variable operating speeds and slow Console Cable
starts and stops. A 24-wire console cable assembly is used to electrically
connect the below rotation control station to the slip ring
The below rotation controls station is equipped with three cable below rotation. Both ends of the cable have perma-
hand control levers to operate the lower boom, upper nently attached 24-pin connectors. This cable assembly
boom, and turntable rotation functions. The circuit board establishes a common ground between components.
on each control assembly converts the varying analog
voltage signal into a digital pulse width modulated signal. Slip Ring Cable
When the control lever for a particular function is moved, The 24-wire slip ring cable assembly is used to pass
the amount of on time is adjusted to be in proportion with analog and digital electrical signals through the slip ring.
the amount of movement requested. Each proportional
function has different letter codes for its circuits within the The cable is actually divided into two sections, which are
control console cable. These codes are shown in Section terminated inside the slip ring. One end of the cable
8 under Pin and Circuit Identification. protrudes from the slip ring below rotation while the other
end is routed through a steel pipe, which passes through
As the control lever is moved to operate a function, a the rotary joint to emerge above rotation. Both ends of the
potentiometer in the control assembly varies an analog cable have permanently attached 24-pin connectors. The
voltage signal in proportion to the amount of movement. portion of the cable that extends above rotation is long
The circuit board in the control assembly converts the enough so that the connector can be replaced two times
varying voltage signal into an on/off digital signal. The before the cable must be replaced. The slip ring cannot be
grouping and length of time between pulses in the digital removed from the rotary joint without replacing the connec-
signal indicates which function is selected and the amount tor.
of movement requested.
Y-Cable
The digital signal is sent through the control console cable, The Y-cable consists of one 24-wire cable and two wire
slip ring, and Y-cable to the appropriate solenoid operated harnesses that are joined together in the center (refer to
valve on the lower control solenoid pilot control valve. The Figure 7.2). The Y-cable is used to electrically connect the
solenoid operated pilot control valve regulates the hydrau- solenoid operated valves and the lower control solenoid
Figure 7.2 — Y-Cable Assembly
80 • Section 7 — Electrical System

pilot control valve to one 24-pin connector. The Y-cable is from moisture, but makes it difficult to see the pin
connected to the slip ring cable above rotation. identification letters on the plugs and receptacles.
Multi-Pin Connectors When connecting a multi-pin connector, make sure the

Multi-pin connectors are used to connect the electrical plug contains silicone grease. Push the plug fully into the
cable assemblies to each other and the below rotation receptacle. Tighten the clamping ring to make a proper
control station. The pin identification letters shown in connection and engage the O-ring seal. When multi-pin
Figure 7.3 are molded into the corresponding multi-pin connectors are disconnected, cap the plugs or wrap them
plugs and receptacles. in plastic bags to prevent contamination.
An O-ring in the multi-pin connector plug seals the connec-

tion from moisture when it is properly tightened. The
Diodes
connector plugs are packed with potting compound at Diodes are used on the below rotation controls station
assembly. The grease provides extra sealing protection circuit board to prevent electrical current from flowing
24 - Socket Wiring
Viewed From Cable Entry End
Figure 7.3 — Y-Cable Pin Identification

backwards through the electrical system. They allow
Outrigger Interlock System
electrical current to flow through them to a relay, but block
any current that might attempt to flow through the wiring The outrigger interlock system is a combination of electri-
from the relay. cal and hydraulic components designed to prevent boom
operation until all outriggers are properly set.
Solenoids There is one outrigger interlock electrical switch for each
A solenoid consists of a coil that surrounds a movable iron outrigger leg. They are mounted on the outrigger outer legs
core. When the coil is energized by current flowing through (refer to Figure 7.4). When the outriggers are extended or
it, a magnetic field is produced within the coil that moves lowered, the switches close, allowing current flow to the
the iron core or valve spool to a different position. solenoid of the interlock valve. The solenoid energizes and
shifts the valve open. This directs all above rotation sense
Solenoids control the hydraulic spool valves in the follow- line signals to the pump.
ing valves.
• Control selector valve

• Pump control valve
• Platform rotation control valve (units with two-man,
side-mount platform)
• Winch control valve
• Lower control solenoid pilot control valve
The spool valves are spring centered and remain so until

the solenoid is electrically energized. As electrical current Figure 7.4 —
is applied to the solenoid, the spool valve shifts to operate Outrigger Interlock Electrical Switch Locations
the function.
When the outriggers are retracted or raised, the outrigger
interlock switches are open. Therefore, the solenoid for the
Truck/Machine Selector Switch outrigger interlock valve is not energized and does not
The truck/machine selector switch, if so equipped, is allow the sense signal to go to the pump.
located in the cab of the vehicle. On some units, selection
of the machine is accomplished by engaging the PTO. Removal
Caution
Power Distribution Module (PDM)
Injury can result from electric shock. Severe arcing
The PDM is the central connection point between the can occur even when working with low voltage vehicle
remote start/stop system and the vehicle electrical sys- electrical systems. Use caution when working with
tem. The engine can be started and stopped from the any electrical device.
ignition switch in the cab, a toggle switch on the below
rotation controls, and the captive air system at the upper Place the truck/machine switch, if so equipped, in the
controls station. If the engine stops, the DC pump can be Truck position or disengage the PTO if the unit does not
started and stopped with a toggle switch mounted on the have the truck/machine switch. This will remove the
below rotation controls or the captive air system at the electrical current from the vehicle to the unit while working
upper controls. When any of the controls for the DC pump on the electrical switch.
is moved to the On position, electrical power is sent to a
terminal inside the PDM to energize the pump relay. Refer Remove the two fasteners that secure the switch to the
to the Wiring Diagrams in the Appendix for remote start outrigger frame. At the end of the switch wiring, disconnect
system wiring information. the connector. Remove the switch and wiring.
The PDM is installed in place of the remote start/stop Installation

control box when electronic circuits are required to operate Connect the electrical connector of the new switch. Attach
additional accessories or when electronic engine controls the new switch to the outrigger frame with one fastener.
are used. The PDM performs the same functions as the The wired end of the switch must be located toward the
control box, but includes some additional features and outrigger shoe. Use the other fastener to lock the switch
terminals. Refer to the PDM Information Manual for in place after it has been adjusted.
introduction, familiarization, and onboard diagnostic sys-
tem information.

4. Guide the wire bundle through the rotary joint and pipe
Slip Ring while removing the slip ring.
The slip ring is mounted below the rotary joint by a steel
pipe through the center of the rotary joint. The wiring Installation
bundle on top of the slip ring is routed through the pipe with 1. Position the slip ring on the bottom of the rotary joint.
a 24 pin connector above the rotary joint connected to the Route the wires through the rotary joint and pipe.
wiring bundle above rotation. The rotary joint uses SAE
straight thread type fittings. Pipe fittings do not fit in these 2. Install the slip ring to the rotary joint with the cap
ports. Do not install pipe fittings in the rotary joint ports. screws.
The brushes inside the slip ring may be removed and 3. Install a new MS connector on the end of the wire
cleaned if necessary. No other maintenance is required. bundle. Apply potting compound to seal the newly
soldered wire to pin connections. It is recommended
Removal that a person who is experienced in the proper tech-
1. Remove the covers from the turntable and pedestal to niques of soldering install the new connector. Using
access the slip ring. improper tools and techniques will result in poor
connections caused by solder bridging and cold-
2. Inside the turntable disconnect the 24-pin connector solder joints.
above the rotary joint. Cut the connector from the wire
bundle. The connector is larger than the pipe and must Use the pin identification chart in Figure 7.6 as a
be removed to pull the wire bundle out of the pipe. reference guide to ensure that the proper wire connec-
tions are made.
3. Remove the cap screws that attach the slip ring (refer
to Figure 7.5) to the rotary joint. Pin Color Pin Color
A Red N White/black
B White P Brown
C Green Q Tan
D Grey R Blank
E Orange S Yellow
F Pink T Violet
G Red/green U Black
H Red/yellow V Blank
24-Pin J White/red W Blank
Connector
K White/green X Blank
Rotary Joint L Red/black Y Blank
M Blue Z Blank
Figure 7.6 — Pin Identification
Steel Pipe
Slip Ring
Figure 7.5 — Slip Ring

Section 8 — Troubleshooting, Testing, and Adjustments
mines whether or not the actuator will move. Movement

Troubleshooting Procedure occurs when sufficient pressure is applied to the movable
Establish a troubleshooting procedure to be followed any component of an actuator. If an actuator does not move,
time there is a malfunction. This procedure will provide a the cause may be insufficient pressure.
starting point for determining the root cause of the mal-
function and increase troubleshooting accuracy. Consider Flow is a measure of the amount of fluid displaced during
using the following procedure. a specified amount of time. The flow rate determines the
speed of actuator movement. The more fluid that is
1. Position the unit on a level surface. Apply the parking displaced, the faster the actuator will move. If an actuator
brake and chock the wheels. Check the oil level in the moves slowly, the cause may be low flow.
reservoir.
Cycle Times
2. Engage the PTO, warm the hydraulic oil to operating Figure 8.1 shows average cycle times in seconds.
temperature, and properly set the outriggers.
Function Seconds
3. Before testing each function through its full travel
Lower boom raise 48 to 54
capabilities, try small movements to be certain the
function is operating properly. Test each function for Lower boom lower 44 to 50
full travel capabilities. Upper boom unfold — 180 degrees 40 to 46
Upper boom fold — 180 degrees 34 to 40
Warning Rotate — 360 degrees 61 to 67
Death or serious injury can result from falling from the Single Elevator
platform. All platform occupants must properly use an
Arm raise 51 to 61
appropriate OSHA approved personal fall protection
system. Arm lower 68 to 77
Double Elevator
4. Operate the unit from the lower controls and then the
Lower arm raise 51 to 61
upper controls to identify the malfunction.
Lower arm lower 68 to 77
5. Use the Hydraulic System Schematic and Wiring Line Upper arm raise 62 to 70
Diagrams in the Appendix to determine the flow path
Upper arm lower 60 to 68
required to operate the failed function. Make a list of
the components used to operate the failed function. Figure 8.1 — Average Cycle Times
Cross off components used to operate other functions
that are operating properly. This should minimize the The Hydraulic System Schematic (refer to the Appendix)
number of items to check. identifies the paths of oil flow in the system. It also
identifies the operation of every hydraulic component. A
6. Check the easiest component first. Verify the proper thorough understanding of JIC symbols and their mean-
operation of each component remaining on the list ings is helpful in troubleshooting (refer to Basic JIC
until the bad component is found. Symbols in the Appendix).
7. Use accurate test equipment to verify flow, pressure, Use an accurately calibrated gauge to test the pressure of
voltage, and current. a particular circuit. A calibrated gauge will provide an
accurate reading, which is essential for proper hydraulic
Once the symptom has been positively identified, use the adjustments.
Troubleshooting Chart in the Appendix for suggested
causes and corrective actions. Before testing or adjusting unit functions, position the unit
on a level surface, apply the parking brake, and chock the
wheels.
Hydraulic System
Hydraulic fluid pressure and flow are required to operate System/Compensator Pressure
the hydraulic system functions. System pressure is controlled by the compensator spring
in the pressure compensator valve housing on the hydrau-
Pressure is a measure of the pounds of force applied on lic pump. System pressure is 3,000 psi (207 bar).
a one square inch area. The amount of pressure deter-
Section 8 — Troubleshooting, Testing, and Adjustments • 85

When the output pressure of the pump reaches 3,000 psi 8. While holding the control handle in the Unfold position,
(207 bar), it overcomes the spring tension of the compen- the pressure gauge should indicate 3,000 psi (207
sator spool. Pressure is then directed to the stroking bar). If the pressure is above or below this value,
piston to stop pump flow or control flow at the level adjust the system pressure.
necessary to maintain a pressure of 3,000 psi (207 bar).
Adjustment
A system pressure test port (marked PD) quick discon- 1. Disengage the PTO and turn off the engine.
nect coupler is located on the tool control valve (refer to
Figure 8.2). 2. Adjust the system pressure at the pump compensator
(refer to Figure 8.3). If present, cut the wire seal and
remove it.
Main System Pressure

Adjustment
Tool Pressure
Standby
Pressure
Adjustment
System (under plug)
Pressure
Figure 8.3 — Pump Compensator
3. Turn the adjusting screw clockwise to increase sys-

tem pressure. Turn the adjusting screw counterclock-
wise to decrease system pressure. Use small
adjustment increments.
4. Test the system pressure. If system pressure cannot

be raised by adjusting the compensator, the system
Figure 8.2 — pressure relief valve may be set too low.
System Pressure Test Port Quick Disconnect
5. When the proper pressure has been reached, install a
Testing wire seal (if possible). If the screwdriver slot and seal
1. Position the unit on a level surface that will allow the hole do not line up, use a small center punch and stake
upper boom to be fully unfolded. the threads lightly at the screwdriver slot to prevent
movement of the adjustment.
2. Apply the parking brake and chock the wheels. En-
gage the PTO and properly set the outriggers. 6. Disconnect the pressure gauge.
3. Disengage the PTO and turn off the engine. Relief Valves
The system relief valve cartridges are located in the
4. Check the standby pressure as described under elevator control and lower control valve on the turntable.
Standby Pressure in this section.
Notice
5. Install a pressure gauge [4,000 psi (276 bar) minimum] To prevent excessive heat generation, the system
on the quick disconnect coupler on the tool control relief pressure must be higher than the compensator
valve. pressure.
6. Start the engine and engage the PTO. The relief valve cartridge in the elevator control valve is set
to open at 3,250 psi (224 bar). It prevents the hydraulic
7. Using the lower controls, fully unfold the upper boom. system from building up excessive pressure if the pres-
86 • Section 8 — Troubleshooting, Testing, and Adjustments

sure compensator in the piston pump malfunctions and the Spilled hydraulic oil creates slick surfaces and may
relief valve cartridge in the lower control valve fail to limit cause personnel to slip and/or fall. Keep the unit and
pressure to 3,000 psi (207 bar) or 3,250 psi (224 bar). work areas clean.
The relief valve cartridge in the lower control valve inlet is Testing
set to open at 3,250 psi (224 bar). It prevents the hydraulic 1. Position the unit on a level surface, apply the parking
system from building up excessive pressure if the pres- brake, and chock the wheels.
sure compensator in the piston pump and the relief
cartridge in the elevator control valve malfunction and fail 2. Disengage the hydraulic system and turn off the
to limit pressure to 3,000 psi (207 bar) or 3,250 psi (224 engine.
bar).
3. Disconnect the pump pressure line from the pump.
Pump Flow
A slow down in unit movement may indicate a worn or
defective pump. If a worn or defective pump is suspected, Danger
perform the following procedure to determine if full flow can Death or serious injury will result from contact with
be generated. rotating components in the pump driveline. Keep
hands and clothing clear of the pump driveline.
Warning 4. Connect the inlet of the flowmeter (refer to Figure 8.4)
Death or serious injury can result from hydraulic oil to the pump using a long section of hydraulic hose.
being injected into the flesh when loosening or dis- The hose diameter must be the same size or larger
connecting hydraulic components. Remove the hy- than the hose used on the unit and long enough to
draulic pressure before loosening or disconnecting allow reading the flowmeter without possible contact
hydraulic components. with the pump driveline.
Seek immediate medical attention if injured by escap- 5. If the pump is equipped with a compensator, connect
ing hydraulic oil. Serious infection or reaction can the pump sense line to the pump pressure line entering
result if medical treatment is not given immediately.
Fixed Displacement Pump Variable Displacement Pump
Figure 8.4 — Pump Flow Test Connections

the flowmeter (refer to variable displacement pump in 1. Disengage the PTO and turn off the engine.
Figure 8.4).
2. Remove and cap the sense line from the pump. Do not
6. Connect the outlet of the flowmeter to a reservoir plug the port on the pump standby compensator.
return line. Fully open any shutoff valves on the
flowmeter. 3. Install a pressure gauge [1,000 psi (69 bar) minimum]
on the system pressure test port (PD) on the pump
control valve.
Warning
Death or serious injury can result from pump or 4. Start the engine and engage the PTO. Move the
hydraulic system failure. Do not perform this proce- machine/outriggers selector to the Machine position.
dure without a pressure relief installed.
5. The pressure gauge should indicate 350 psi (24 bar)
7. Install a pressure relief to bypass the pump flow with no functions being operated.
around the flowmeter and shutoff valve. Refer to
Figure 8.4 for relief placement. The relief should be set 6. If the pressure does not need adjustment, connect the
no more than 200 psi (13.8 bar) above the required unit sense line to the pump.
system pressure. System pressure is stamped on the
unit serial number placard. Cap and plug any open Adjustment
connections. 1. Disengage the PTO and turn off the vehicle engine.
8. Start the vehicle engine and engage the hydraulic 2. Remove the plug from the compensator housing on
system. the pump (refer to Figure 8.3).
Notice 3. Adjust the screw with an Allen wrench. Clockwise

If the pump is equipped with a compensator, test full rotation of the screw will increase standby pressure
flow at 500 psi (34.5 bar) below the pressure listed in and counterclockwise rotation will decrease standby
the following step. pressure.
9. The flowmeter will indicate the flow from the pump. 4. Replace the adjustment plug.
Increase the load on the pump by slowly closing the
load inducing shutoff valve. Do not exceed the unit 5. Repeat the test procedure and readjust if necessary.
system pressure as indicated on the unit serial num-
ber placard. The flowmeter should indicate approxi- 6. Connect the sense line to the pump and disconnect
mately 14.5 gpm (55 lpm) at 2,750 psi (190 bar). If the the pressure gauge.
pump flow is less than required for unit operation, the
pump may be defective or worn. Sense Signal Pressure Increasing Circuit
A sense signal pressure increasing circuit adds 100 psi (7
10. If the pump flow is correct, disengage the hydraulic bar) to the sense signal coming from the lower control
system and turn off the engine. valve in the turntable.
11. Open the load inducing shutoff valve. Remove the The sense signal pressure increasing circuit is located
flowmeter, temporary lines, and fittings. Reconnect below the below rotation controls in the pump control valve
the unit lines to their original positions. (refer to Figure 8.5).
Standby Pressure The sense signal pressure increasing circuit uses a

Standby pressure is 350 psi (24 bar). The load sensing pressure reducing valve cartridge. The pressure reducing
valve in the compensator housing of the pump controls the valve reduces the system pressure in the pump control
standby pressure (refer to Figure 8.3). Operation of the valve to 100 psi (7 bar). The 100 psi (7 bar) signal is then
load sensing valve for this standby pressure function is added to the sense signal coming from the work functions.
similar to a direct-acting relief valve. When the pump This causes the signal being sent to the pump to be 100
output exceeds the spring tension of the valve, a spool is psi (7 bar) higher than the signal being sent by the work
shifted to direct this pressure to stop pump flow. functions. This helps maintain the required flow by com-
pensating for the natural pressure drop in the pressure
Testing lines and components between the pump and the valve.
To test standby pressure, make sure all functions are
turned off so that no signals are being sent to the pump.

Testing
Jam Nut Adjusting Screw 1. Check the standby pressure as described under
Standby Pressure in this section.
Tool Pressure Sense Signal
Reducing Valve Reducing Valve
Cartridge 2. Disengage the PTO and turn off the engine.
3. Install a pressure gauge [1,000 psi (69 bar) minimum]

on the pilot system pressure test port on the inlet
section of the lower control valve.
4. Start the engine and engage the PTO.
5. Move the station selector to the Upper Controls

position. Using the upper controls, engage the single
handle control interlock and operate upper boom fold
with the booms stowed.
Figure 8.5 — Pump Control Valve
6. The gauge should indicate 350 psi.
Testing
1. Position the unit on a level surface, apply the parking Adjustment
brake, and chock the wheels. The pressure reducing valve is not adjustable and must be
replaced. Contact your Altec representative for replace-
2. Verify that the standby pressure is 350 psi (24 bar). ment parts.
Disengage the PTO and turn off the engine.
Outriggers
3. Remove the cover below the below rotation controls. Outrigger cylinders and holding valves must operate
properly to assure unit stability. Any leaks must be
4. Install a pressure gauge [1,000 psi (69 bar) minimum] corrected before placing the unit in service.
on the quick disconnect coupler on the system pres-
sure test port (PD) on the pump control valve.
Warning
5. Start the engine and engage the PTO. Move the Death or serious injury can result from hydraulic oil
machine/outriggers selector to the Machine position. being injected into the flesh when loosening or dis-
connecting hydraulic components. Remove the pres-
6. The pressure gauge should indicate 450 psi (31 bar). sure before loosening or disconnecting hydraulic
components.
Adjustment
1. Loosen the jam nut on the sense signal pressure Seek medical attention if injured by escaping hydrau-
increasing circuit cartridge (refer to Figure 8.5). lic oil. Serious infection or reaction can result if
2. Turn the adjusting screw clockwise to increase the
pump pressure reading. Turn the adjusting screw Spilled hydraulic oil creates slick surfaces and can
counterclockwise to decrease the pressure reading. cause personnel to slip and/or fall. Keep the unit and
Make the necessary adjustment. work areas clean.
3. Tighten the jam nut and check the pressure again. Use the appropriate test to determine the cause of outrig-
Repeat steps 1 through 3 until the pump pressure ger drift.
reading is between 450 psi (31 bar).
Drift Up
4. Disengage the PTO and turn off the engine. If an outrigger drifts up several inches when it is loaded, the
pilot operated check valve in the extend circuit may be
5. Disconnect the pressure gauge and replace the cover. leaking. If the outrigger drifts up a little and stops, there
may be an internal leak in the piston seal.
Pilot System Pressure
The pilot system pressure is 350 psi (24 bar). Pilot Testing — Internal Cylinder Leakage
pressure is controlled by a pressure reducing valve in the A liquid container is required to perform this test.
input housing of the lower control valve.

1. Start the engine and engage the PTO. 6. Let the jack down so the outrigger carries its own
weight. Let the unit sit overnight.
2. Retract the cylinder completely. Disengage the PTO
and turn off the engine. a. If the retract hose container has oil in it, the pilot
operated check valve is defective.
3. Shift the outrigger control handle in both directions
several times to relieve any pressure in the hoses. b. If the cylinder moved a few inches and stopped, the
cylinder piston seal is leaking.
4. Disconnect the outrigger cylinder hose from the ex-
tend port of the outrigger control valve. Allow the oil c. If the cylinder retracts all the way in and there is oil
remaining in the hose to drain into a container. Cap the in the extend hose container, the cylinder piston
fitting at the valve. seal is leaking and the pilot operated check valve
is defective.
5. Hold the open end of the hose over a container and
engage the PTO. Shift the outrigger control handle to 7. The pilot operated check valve port marked V1 con-
the Raise position. trols cylinder extension and the port marked V2
controls cylinder retraction. Both ports are located in
6. If a heavy stream of oil drains from the hose with the the base end of the outrigger cylinder (refer to Figure
control handle in the Raise position, the cylinder is 8.6). Replace the appropriate valve cartridge as de-
leaking internally. Reconnect the hose to the outrigger scribed under Holding Valves in this section and
control valve. Repair or replace the cylinder. repeat the test.
Testing — Piston Seal and Check Valve Drift Down

A vehicle jack, a liquid container, and the ability to let the If the outrigger drifts down from the raised position over-
unit sit overnight are required to perform this test. night or over the weekend, the cylinder may be leaking
internally or the pilot operated check valve in the retract
1. Start the engine and engage the PTO. circuit may be leaking.
2. Extend the outrigger cylinder completely. Disengage Testing — Internal Cylinder Leakage and Check Valve
the PTO and turn off the engine. A vehicle jack, a liquid container, and the ability to let the
unit sit overnight are required to perform this test.
3. Raise the vehicle with a jack so the outrigger does not
carry its own weight. 1. Place a jack under the outrigger shoe to support the
outrigger. Disengage the PTO and turn off the engine.
4. Shift the outrigger control handle in both directions
several times to relieve any pressure in the hoses. 2. Shift the outrigger control handle in both directions
several times to relieve any pressure in the hoses.
5. Disconnect the retract hose from the control valve and
place the hose in a liquid container. Disconnect the 3. Disconnect the retract hose from the control valve and
extend hose from the valve and place the hose in place the hose in a liquid container. Remove the jack
another liquid container. and let the unit sit overnight.
Base End
Screw
Rod End
Pilot Operated
Check Valve
Pilot Operated
Check Valve
Figure 8.6 — Outriggers

a. If the outrigger extended and there is liquid in the 7. Start the engine and engage the PTO. The compensa-
container, the retract pilot operated check valve is tor on the pump will limit pump pressure to 3,000 psi
leaking. Place a jack under the outrigger shoe to (207 bar). The pressure line and the rotary joint will be
support the outrigger. Replace the pilot operated pressurized to 3,000 psi (207 bar).
check valve in the V2 port at the base end of the
cylinder (refer to Holding Valves in this section). 8. If the flowmeter does not indicate flow, remove the
flowmeter and return the hydraulic connections back
b. If the outrigger extended but there is no liquid in the to normal.
container, the cylinder is leaking internally. Re-
place or repair the cylinder. 9. If the flowmeter indicates flow, reseal or replace the
rotary joint.
Rotary Joint
A leaking seal in the rotary joint can cause oil flowing to any
hydraulic circuit above rotation to be diverted directly to
the return line. This will cause functions to slow down and/ Cap
or fail to build pressure.
Testing
To properly test the rotary joint, a few simple hydraulic
connections must be made.

Flowmeter
2. Turn off the engine and disengage the PTO.
Temporary
Connection
3. Move the machine/outrigger selector to Machine.
Shift the lower control handles in both directions Figure 8.7 — Rotary Joint Testing
several times to relieve any pressure in the hoses.
Lower Control Valve
There are two adjusting screws on each control valve
Warning
section (refer to Figure 8.8). The screws limit valve spool
Death or serious injury can result from hydraulic oil travel which controls hydraulic fluid flow to a function.
being injected into the flesh when loosening or dis-
connecting hydraulic components. Remove the pres- Testing
sure before loosening or disconnecting hydraulic Before testing the speed of a function, use a flowmeter to
components. verify that the pump is delivering the proper hydraulic oil
flow of 141/2 gpm (55 l/m).
Seek medical attention if injured by escaping hydrau-
lic oil. Serious infection or reaction can result if
medical treatment is not given immediately. Caution
Injury and property damage can result from contact of
Spilled hydraulic oil creates slick surfaces and can the booms or platforms with fixed objects. Make sure
cause personnel to slip and/or fall. Keep the unit and there is sufficient clearance before operating the unit.
work areas clean.
Testing of the lower control valve functions requires an
4. Remove the pressure line (P) from the top of the rotary open area with sufficient clearance for full unit extension.
joint. Cap the open (P) port on the rotary joint and the
open hose end. 1. Position the unit on a level surface, apply the parking
5. As illustrated in Figure 8.7, connect a flowmeter in the properly set the outriggers.
pressure line just below the rotary joint.
2. Operate each aerial device function from the lower
6. Make a temporary connection between the sense controls, making sure the lower control valve handle
signal line and the pressure line below the flowmeter. is held in the full stroke position for the entire timing

Function Port
Rotation
Rotation Counterclockwise A
Clockwise B
Upper Boom Upper Boom
B Port
Adjusting Unfold A
Lower Boom
Screws Fold B
Lower Boom
A Port
Raise B
End View Lower A
Front View
Figure 8.8 — Lower Control Valve
process. Compare the measured times with the times

in Figure 8.1.
Adjustment
If adjustment is required, refer to Figure 8.8 to determine
which screw to adjust.
1. Loosen the jam nut and turn the adjusting screw.

Clockwise rotation will decrease the speed and coun- Interlock Trigger
terclockwise rotation will increase the speed.
2. After making the adjustment, tighten the jam nut and

test the function again. Use care when making the
adjustment. The adjusting screw and threads are
easily damaged.
Upper Control Valve

The upper control valve assembly (refer to Figure 8.9)
includes the mechanical linkage, an interlock valve, and Interlock Remote Control Valve
Valve (Upper Control Valve)
the remote control valve which houses six variable pres-
sure reducing valves.
Figure 8.9 — Upper Control Valve Assembly
When the interlock trigger is engaged, the interlock valve
is opened by a mechanical connection with the trigger. The Although it is unlikely that the variable pressure reducing
blocking valve in the lower control valve is then opened by valves will require adjustment under normal use, a new
pilot pressure. The mechanical linkage to operate the remote control valve may require adjustment. Start pres-
interlock valve is adjustable. This adjustment is explained sure and forced opening are shim adjustable at the variable
later in this section. pressure reducing valve.
The remote control valve is mounted directly under the Testing

single handle control. As the control handle is moved, it The pilot system pressure must be 350 psi (24 bar) before
varies the mechanical force applied to the internal spring testing the upper control system.
pack of the variable pressure reducing valve (refer to
Figure 8.10). As the mechanical force applied to the spring It is recommended that the start pressure, move pressure,
changes, the pilot pressure output from the upper control and forced opening for all six boom functions be tested
valve is varied as the spool shifts. The output pressure before disassembling the upper control valve assembly for
from the upper control valve can be varied from 0 to 350 adjustment. Start and move pressure and forced opening
psi (0 to 24 bar). The hydraulic oil output from the upper will be checked in the following procedure. These terms
control valve is directed to the lower control valve spools are explained in the following upper control valve test
so that boom movement can occur. procedure.

Lower Lower Rotation
Boom Boom CW
Raise Lower
To Lower
Interlock Control
Valve Valve
Work
Upper Upper Port
Boom Boom Rotation Variable Pressure Tank Pressure
Unfold Fold CCW Reducing Valve Port Port
Figure 8.10 — Remote Control Valve Assembly
far enough to start boom movement. The difference

Caution between start and move pressure is called differential
Injury and property damage can result from contact of pressure.
the booms or platforms with fixed objects. Make sure
there is sufficient clearance before operating the unit. 6. During the last 10 percent of handle movement, forced
opening will be reached. Forced opening insures that
1. Position the unit in a level area with sufficient room to there will be full function speed from the upper con-
operate the boom functions. Apply the parking brake, trols. While holding the upper control in this position,
chock the wheels, engage the PTO, and properly set have someone move the same function at full stroke
the outriggers. It is not required that the booms be in from the lower control valve. If there is little or no
any specific position for the start and move pressure change in the speed of the function, the forced
tests. opening does not need adjustment. If there is a
substantial increase in the speed of the function,
2. Operate the unit from the lower control valve to insure adjust the forced opening.
the valve and actuator are operating properly.
7. Repeat this test for all boom functions.
3. Remove the upper controls cover.
Adjustment
4. Install a low pressure gauge [400 to 1,000 psi (28 to 69 Move pressure is not adjustable in this control system.
bar) maximum] on the tee for the function being Start pressure must be adjusted to obtain the desired
tested. differential pressure of 30 psi (2.07 bar ) +/-5 (.34 bar). Start
pressure for each boom function is controlled by an
internal spring pack in the control valve. The tension of the
Warning spring pack is shim adjusted. Adding shims will increase
Death or serious injury can result from falling from the start pressure and removing shims will decrease start
platform. All platform occupants must properly use an pressure.
appropriate OSHA approved fall protection system.
Determine the start and move pressures and subtract the
5. Operate the function from the upper controls. Move start pressure from the move pressure to determine the
the control handle very slowly while watching the differential pressure. Use the following example to help
pressure gauge for this function. determine the proper adjustment to be made.
A rapid rise in pressure should be noticed to a point Example

and a slow rise in pressure after that. This point is the Move pressure 130 psi (9 bar)
initial pressure required to move the lower control Start pressure -80 psi (5.5 bar)
valve spool and is referred to as start pressure. Differential pressure 50 psi (3.5 bar)
Continue slow movement of the control handle while
watching the pressure gauge rise slowly until boom The recommended differential pressure is 30 psi (2.07
movement is seen or felt. This is referred to as move bar). Subtract the recommended differential pressure from
pressure, when the lower control valve spool is moved the actual differential pressure.

Example the recessed unpolished area of the valve spool and
Differential pressure 50 psi (3.5 bar) grip it with narrow jawed pliers or vise grips. Use an
Recommended differential pressure -30 psi (2.1 bar) Allen wrench and remove the socket head cap screw
Start pressure must be adjusted 20 psi (1.4 bar) that fastens the spring cap to the valve spool.
If the value of start pressure adjustment is a positive Notice

number, increase the start pressure by adding shims to the Do not stick anything through the hole in the valve
internal shim pack (refer to Figure 8.11). In the example, spool. This will damage the spool and make the entire
to obtain the recommended differential pressure of 30 psi valve unusable.
(2.07 bar), increase the start pressure by 20 psi (1.4 bar).
6. If forced opening occurred a significant distance
before full handle travel, it may be necessary to
Pressure Start Forced
Pin Pressure Shims Opening Shims remove one or two of the small shims from the center
Assembly of the spring pack. These shims are located between
the valve spool and the socket head cap screw that
secures the internal spring pack to the valve. If forced
opening did not occur at full handle travel, it may be
necessary to add one or two forced opening shims.
7. Start pressure may be increased by adding shims

Allen Screw between the spring and the spring cap. Removing
shims will lower the start pressure. A 0.007″ (0.18 mm)
Figure 8.11 — Variable Pressure Reducing Valve shim will change the start pressure approximately 5
psi (0.35 bar).
If the actual differential pressure was smaller than the
recommended differential pressure, a negative number 8. Assemble the spring and valve spool assembly and
would result, indicating that the start pressure would need install it in the valve housing. Place the return spring
to be decreased by removing shims. in the valve housing.
Each 0.007″ (0.18 mm) shim thickness added to the start 9. Place the pressure pin assembly in the valve housing
pressure shim set will increase the start pressure by and reassemble the upper control assembly. Test the
approximately 5 psi (0.35 bar). If start pressure must be operation of the remote control valve, while watching
increased by 20 psi (1.4 bar), as in the above example, the start and move pressures on the pressure gauge.
0.028″ (071 mm) shim thickness must be added to the Determine the differential pressure to see if it is within
start pressure shim set. the recommended specification of 30 psi (2.07 bar ) +/
-5 (0.34 bar).
Use the following procedure if testing of the start, move,
and differential pressure indicates a need for adjustment. 10. Remove the gauge and install the covers.
1. Remove the protective cover from the single handle Notice
control. Do not adjust the pressure pin assembly or move it to
another function.
2. Remove the hex head cap screws that fasten the base
weldment to the front and rear mounting brackets to If the function operates faster or slower than desired at full
allow access to the remote control valve assembly. stroke of the handle, adjust the speed of the function at the
lower control valve.
3. Lift the pressure pin assembly out of the valve housing.
Elevator Control Valve
Notice There are two adjusting screws on each control valve
Do not adjust the pressure pin assembly or move it to section (refer to Figure 8.8). These screws limit the valve
another function. spool travel which controls the flow of hydraulic fluid to a
function.
4. Lift the return spring out of the valve housing. Remove
the spring pack and valve assembly. Testing
Before testing the speed of a function, use a flowmeter to
5. A socket head cap screw fastens the spring pack to verify that the pump is delivering the proper hydraulic oil
the valve. Wrap a narrow strip of emery cloth around flow of 141/2 gpm (55 l/m).

1. Loosen the jam nut and turn the adjusting screw.
Caution Clockwise rotation will decrease the speed and coun-
Injury and property damage can result from contact of terclockwise rotation will increase the speed.
the booms or platforms with fixed objects. Make sure
there is sufficient clearance before operating the unit. 2. After making the adjustment, tighten the jam nut and
test the function again. Use care when making the
Testing of the lower control valve functions requires an adjustment. The adjusting screw and threads are
open area with sufficient clearance for full unit extension. easily damaged.
1. Position the unit on a level surface, apply the parking Lower Boom Cylinder
brake, and chock the wheels. Start the engine, engage Testing
the PTO, and properly set the outriggers. Move the If the boom drifts down under load or its own weight, first rule
machine/outriggers selector to the Machine position out external causes such as a control valve malfunction.
and select lower controls.
1. Start the engine, engage the PTO, and properly set the
2. Operate each elevator arm from the below rotation outriggers.
controls, making sure the elevator control valve lever
is held in the full stroke position for the entire timing 2. Place rated load in the platform.
process. Compare the measured times with the times
in Figure 8.1. A range of plus or minus four seconds 3. Raise the lower boom 6′ to 8′ (1.8 to 2.4 m) out of the
to the times listed is acceptable. rest.
Adjustment 4. Rotate the unit to a position that allows the boom to be

If adjustment is required, refer to the Figure 8.12 and the lowered as far as possible.
JIC to determine which screw to adjust. For example, the
upper elevator arm cylinder lowering function is controlled 5. Disengage the PTO and turn off the engine.
by the C1 port.
a. If the boom drifts down, move the lower control
handle to the Lower position. If movement in-
creases, the extend counterbalance holding valve
is leaking.
b. If the boom drifts down slightly and stops, there is

an internal cylinder leak.
C2 Port Bottom Upper Boom Cylinder

Adjusting Testing
Screws If the boom drifts down under load or its own weight, first
C1 Port rule out external causes such as a control valve malfunc-
tion.
outriggers.
2. Place rated load in the platform.
3. Raise the upper boom to a 30 degree angle with the

lower boom in the rest.
a. If the boom drifts down, move the lower control

handle to the Fold position. If movement increases,
the unfold counterbalance holding valve is leaking.
Figure 8.12 — Elevator Control Valve b. If the boom drifts down slightly and stops, there is
an internal cylinder leak.

Top Upper Boom Cylinder The boom stow valve contains a low pressure relief valve.
Testing The relief valve limits the hydraulic pressure that may be
If the boom drifts down under load or its own weight, first applied to the lower boom as it is stowed.
rule out external causes such as a control valve malfunc-
tion. The boom stow valve is mechanically activated when the
lower boom weldment contacts a plunger on the valve.
outriggers. The hydraulic pressure relief setting should be 500 to 600
psi (34 to 41 bar). A certain amount of hydraulic pressure
2. Place rated load in the platform. is needed to open the counterbalance valve in the lower
boom cylinder to lower the boom into the rest. The 500 to
3. Raise the upper boom to an overcenter position at a 600 psi (34 to 41 bar) pressure relief setting will provide
150 degree angle with the lower boom in the rest. enough hydraulic pressure to lower the boom into the rest
without excessive pressure being applied to the boom.
Plunger Adjustment
a. If the boom drifts down, move the lower control 1. Position the unit on a level surface, apply the parking
handle to the Unfold position. If movement in- brake, and chock the wheels. Engage the PTO and
creases, the fold counterbalance holding valve is properly set the outriggers.
leaking.
2. Position the lower boom in the rest.
b. If the boom drifts down slightly and stops, there is
an internal cylinder leak. 3. Loosen the nuts on the two cap screws securing the
boom stow valve to the turntable.
Lower Boom Stow Valve
An improperly adjusted boom stow valve can allow exces- 4. Place a 0.050″ (1.27 mm) or 3/64″ (1.2 mm) shim
sive hydraulic pressure to be applied to the lower boom between the plunger on the boom stow valve and the
while placing it in the rest. weldment on the boom. The cap screw holes in the
valve housing are slotted so that the housing may be
The boom stow valve is located inside the turntable (refer moved up or down on the side of the turntable (refer to
to Figure 8.13). Figure 8.14). Slide the valve up until the plunger
bottoms out in the valve housing. Tighten the nuts.
Valve Position
Adjustment Slots
Boom
Stow Valve
Pressure Relief Valve

Adjusting Screw
Jam Nut
Figure 8.14 — Boom Stow Valve
Pressure Relief
Testing
brake, and chock the wheels.
Figure 8.13 — Turntable

2. Connect a pressure gauge [2,000 psi (138 bar) mini-
Jam Nut Adjusting Screw
mum] to the quick disconnect coupler on the boom
stow valve.
Tool Pressure Sense Signal
Reducing Valve Reducing Valve
3. Engage the PTO and properly set the outriggers. Cartridge
4. Raise the lower boom above the position where it

contacts the boom stow valve.
5. Lower the lower boom.
6. The boom should slow down and lower into the rest.
With the boom in the rest and the control handle in the
Lower position, the pressure gauge should indicate
500 to 600 psi (34 to 41 bar).
Adjustment Figure 8.15 — Pump Control Valve

1. The pressure relief valve has an adjusting screw and
jam nut (refer to Figure 8.14). Loosen the jam nut and Warning
turn the adjusting screw counterclockwise to de-
crease the pressure or clockwise to increase the Death or serious injury can result from hydraulic oil
pressure. After the adjustment has been made, tighten being injected into the flesh if the tool hoses burst or
the jam nut. the tool ruptures. Do not adjust the pressure of the tool
circuit above the hydraulic power tools manufacturer’s
2. With the gauge still attached, raise and lower the lower rating for the tool.
boom several times. At the same time, check for the
correct boom stow pressure relief setting on the Seek medical attention if injured by escaping hydrau-
gauge. Stow the boom firmly each time the boom is lic oil. Serious infection or reaction can result if
lowered, so an accurate reading is taken. medical treatment is not given immediately.
3. With the booms in the rest, retract the outriggers and Spilled hydraulic oil creates slick surfaces and can
disengage the PTO. cause personnel to slip and/or fall. Keep the unit and
work areas clean.
4. Remove the pressure gauge.
1. The pressure relief valve has an adjusting screw and
Lower Tool Circuit jam nut. Loosen the jam nut and turn the adjusting
Pressure screw counterclockwise to decrease the pressure or
Testing clockwise to increase the pressure. After the adjust-
1. Connect a pressure gauge [3,000 psi (207 bar) mini- ment has been made, tighten the jam nut.
mum] to the tools quick disconnect coupler at the
tailshelf. 2. Repeat the test procedure and readjust if necessary.
2. Start the engine and engage the PTO. Flow

The lower tool circuit flow control is installed between the
3. Move the tool control to the On position. outrigger valve and the tool quick disconnects.
4. The pressure gauge should indicate 2,000 psi (138 Testing

bar). 1. Disengage the PTO and turn the engine off.
Adjustment 2. Connect a flowmeter to the lower tool circuit.

The lower tool circuit pressure is controlled by a pressure
reducing valve on the pump control valve (refer to Figure 3. Start the engine, engage the PTO, and move the tool
8.15). control to the On position.
4. The flowmeter should indicate 8 gpm (30 l/m). If the

proper reading cannot be reached it may be necessary
to clean or replace the flow control.

Adjustment Adjustment
1. The flow control has an adjusting screw and jam nut.
Loosen the jam nut and turn the adjusting screw Warning
counterclockwise to decrease the flow or clockwise to Death or serious injury can result from hydraulic oil
increase the flow. After the adjustment has been being injected into the flesh if the tool hoses burst or
made, tighten the jam nut. the tool ruptures. Do not adjust the pressure of the tool
circuit above the hydraulic power tools manufacturer’s
2. Repeat the test procedure and readjust if necessary. rating for the tool.
Jib/Winch, Platform Rotate, Seek medical attention if injured by escaping hydrau-

and Upper Tool Circuit lic oil. Serious infection or reaction can result if
The tool control valve regulates the pressure and flow for medical treatment is not given immediately.
the jib/winch, platform rotate, and the main supply for the
upper tool circuit. Spilled hydraulic oil creates slick surfaces and can
Pressure work areas clean.
The pressure is controlled by a pressure reducing valve in
the tool control valve housing. The tool control valve is 1. Disengage the PTO and turn off the engine.
located on the turntable.
2. Remove the cap from the tool pressure reducing valve
Testing cartridge on the tool control valve (refer to Figure
1. Disengage the PTO and turn off the engine. 8.16).
2. Install a pressure gauge [4,000 psi (276 bar) minimum] 3. Turn the adjusting nut clockwise to increase pressure
to the tool pressure test port on the tool control valve and counterclockwise to decrease pressure.
4. Replace the cap, start the engine, engage the PTO,
and check the tool pressure again. If necessary,
System Pressure Tool Pressure repeat the adjustment procedure until the pressure
Test Port Reducing gauge indicates 2,000 psi (138 bar).
Valve
5. If necessary, adjust the upper tool circuit pressure to
operate tools that require a pressure setting below
2,000 psi (138 bar).
Flow
Tool Pressure Tool
Test Port The flow rate for the jib/winch, platform rotate, and the
Flow upper tool outlets is controlled by an adjustable tool flow
Control
control in the valve housing, as illustrated in Figure 8.16.
The standard flow rate is 8 gpm (30 l/m).
Figure 8.16 — Tool Control Valve
Testing
3. Start the engine, engage the PTO, and properly set the 1. Disengage the PTO and turn off the engine.
outriggers.
2. Connect a flowmeter to the upper tool disconnects at
4. Turn on the upper tools. the platform.
5. The pressure gauge should indicate 2,000 psi (138 3. Start the engine, engage the PTO, and turn the upper
bar). tool valve on.
6. If necessary, adjust the upper tool circuit pressure to 4. The flowmeter should indicate 8 gpm (30 l/m).
operate tools that require a pressure setting below
2,000 psi (138 bar). 5. If necessary, adjust the upper tool circuit flow to
operate tools that require flow below 8 gpm (30 l/m).

Adjustment Pilot Operated Check Valves
The adjustable range is from 0.1 to 8 gpm (0.4 to 30 l/m). A pilot operated check valve provides a positive lock
against hydraulic flow or leakage until it is opened by
1. Loosen the jam nut. pressure from a control valve. The following actuators use
pilot operated check valves.
2. Turn the adjusting screw counterclockwise to in-
crease flow and clockwise to decrease flow. When the • Outrigger cylinders
desired flow rate of 8 gpm (30 l/m) is reached on the • Jib tilt cylinder
flowmeter, tighten the jam nut. • Jib extension cylinder
• Platform rotator (two-man platform)
3. If necessary, adjust the upper tool circuit flow to • Platform tilt cylinder (two-man platform)
operate tools that require flow below 8 gpm (30 l/m).
Pilot operated check valves assure the actuator will
Holding Valves maintain its position if there is hydraulic line failure.
The unit uses holding valves to insure that various
actuators maintain their position under load or if there is Notice
hydraulic line failure. Holding valves block the hydraulic oil Pilot operated check valves are not adjustable and
in the actuators to prevent movement. The types of must be replaced if defective.
holding valves used are pilot operated check valves and
counterbalance valves. Testing
There are two methods for testing pilot operated check
If the valve stops holding the load, or malfunctions in some valves.
other way, it is most likely contaminated. Do not disas-
semble a holding valve in the field. Holding valves should Switching Valve Cartridges
only be disassembled by the manufacturer. 1. Securely stow the booms.
When removing a holding valve cartridge, do not allow dirt, 2. When testing the outriggers, extend the outriggers 1″
water, or other contaminants to enter the holding valve from the ground, turn off the engine, and disengage the
cavity when the cartridge is removed. PTO.
3. Relieve the fluid pressure from the pilot operated

Warning check valve by shifting the control handle for that
Death or serious injury can result from uncontrolled function in both directions several times. If the check
movement. Fully unload the actuator or position it so valve is used with a cylinder, shift the control handle
it cannot move, before removing a holding valve. until the cylinder can be rocked by hand.
Death or serious injury can result from hydraulic oil 4. Support the structure (such as the outrigger leg) the
being injected into the flesh when loosening or dis- pilot operated check valve supports. Switch the posi-
connecting hydraulic components. Remove the pres- tion of the two valve cartridges.
sure before loosening or disconnecting hydraulic
components. 5. If the problem moves to the other location, replace the
valve cartridge. If the problem does not move, the pilot
Seek medical attention if injured by escaping hydrau- operated check valve is not the cause of the malfunc-
lic oil. Serious infection or reaction can result if tion.
Loading the Function
Spilled hydraulic oil creates slick surfaces and can 1. Load the function protected by the pilot operated
cause personnel to slip and/or fall. Keep the unit and check valve.
work areas clean.
2. Turn off the engine and disengage the PTO.
Caution 3. Move the control selector handle to the Lower Controls

Injury can result from airborne particles entering the position.
eyes. Wear appropriate safety equipment.
4. Move the lower control handle for the function to
Wear eye protection at all times to prevent particles of dirt, connect the function to tank. If the function moves,
metal, or hydraulic oil from entering the eyes.

the pilot operated check valve is leaking and must be Relief Pressure
replaced. Counterbalance valves are set to relieve pressure at
different settings. The counterbalance valves used in the
Counterbalance Valves elevator arms, lower boom, upper boom, and leveling
A counterbalance valve provides a positive lock against system cylinders are set to relieve pressure at 3,250 psi
hydraulic flow or leakage until it is opened by pressure from (224 bar). The counterbalance valves used with the
a control valve. rotation motor are set to relieve pressure at 3,000 psi (207
bar). The counterbalance valves used with the platform
Counterbalance valves are used to block flow out of the rotate cylinders are set to relieve pressure at 1,050 psi (72
following cylinders. bar). Do not adjust counterbalance valves in the field. The
only exception is adjusting the counterbalance valves for
• Elevator arm cylinders manually stowing as described in the Operator’s Manual.
• Lower boom cylinder If the setting on a counterbalance valve has been changed,
• Upper boom cylinders the cartridge must be removed and adjusted with a test
• Rotation gearbox motor block or replaced.
• Platform rotate cylinders (one-man platform)
Counterbalance valves assure the actuator will maintain Warning

its position if there is hydraulic line failure. Death or serious injury can result from unexpected
movement. Counterbalance valves that have had the
Testing relief setting changed must be replaced or reset to the
There are two methods for testing counterbalance valves. proper setting using an Altec test block before the unit
is operated.
Switching Valve Cartridges
1. Stow the unit. Turn off the engine and disengage the Do not adjust a counterbalance valve without a test block.
PTO. Using a test block and pressure gauge is the only accurate
way to determine that the proper setting has been ob-
2. Move the control selector to the Lower Control posi- tained.
tion. Remove the hydraulic load from the valves by
shifting the control handle in both directions until the A test block and instruction sheet for 11/8″ and 7/8″ hex
cylinder can be rocked by hand. cartridges are available from your Altec representative
(refer to Service Tools and Supplies in the Appendix).
3. Locate the plugs in the extend and retract test ports at
the base end of the cylinder. Use an Allen wrench to Removal
slowly unscrew the test plugs. Allow the pressure to Before removing a counterbalance valve, the cylinder
bleed off before completely removing the plugs. If the must be unloaded. The following steps describe how to
cylinder is under pressure and the plugs are un- remove a counterbalance valve.
screwed quickly, hydraulic oil may spray out of the
test ports. 1. Stow the unit.
4. Switch the position of the two valve cartridges. 2. Disengage the PTO and turn off the engine.
5. If the problem moves to the other location, replace the 3. Shift the control handle for the function until the
valve. If the problem does not move, the counterbal- cylinder can be rocked by hand.
ance valve is not the cause of the malfunction.
4. Locate the plugs in the extend and retract test ports at
Loading the Function the base end of the cylinder or counterbalance valve
1. Load the function protected by the counterbalance block. Use an Allen wrench to slowly unscrew the test
valve. plugs. If the cylinder is under pressure and the plugs
are unscrewed quickly, hydraulic oil may spray out of
2. Turn off the engine and disengage the PTO. the test ports. If the test ports are not available, slowly
screw the counterbalance valve cartridge from its
3. Move the control selector to the Lower Control position. housing.
4. Move the control handle for the function to connect the 5. Carefully unscrew the cartridge from its housing to
function to tank. If the function moves, the counterbal- allow the pressure to bleed off before the cartridge is
ance valve is leaking and must be replaced. fully unscrewed from the cavity.

Testing 4. Repeat the test procedure at least three more times to
1. Lubricate the O-rings on the counterbalance valve confirm the correct setting.
cartridge and install the cartridge in the test block.
5. Relieve the pressure of the pressure source by turning
2. Connect a hydraulic pressure source and an accurate off the pressure source and moving the control several
pressure gauge to port 1 (refer to Figure 8.17). The times in both directions.
pressure source and gauge must be adequate for a
pressure greater than the desired counterbalance 6. Disconnect the pressure source from port 1 and
valve relief setting. remove the counterbalance valve cartridge.
Adjusting Screw Jam Nut Mechanical System

Counterbalance Engine Throttle Control
Valve Cartridge As the pump flow is directed into the hydraulic system,
Port 2 pressure rises in the pump outlet. A 200 to 300 psi (13.8
to 20.7 bar) rise will cause the throttle cylinder to be
extended. The rod end of the cylinder is connected to the
throttle linkage, causing the engine to speed up to the
adjusted rpm.
When the signal being sent to the pump bleeds off, the
Port 1 pump outlet pressure will decrease, allowing the throttle
cylinder to be retracted by its internal spring. The engine
Figure 8.17 — Counterbalance Valve Test Block speed will then return to idle.
3. Install a straight adapter in port 2 to aid in observing Some functions may not require enough pressure to
the oil flow from this port during the procedure. increase the engine rpm because the pump can supply
enough oil with the engine at idle speed.
4. Gradually increase the pressure at port 1 with the
pressure source. The counterbalance valve relief Adjustment
setting is the pressure at which a fine stream of oil The throttle control must be properly adjusted to avoid over
begins to flow from port 2. Note this pressure reading speeding the pump. The shaft of the throttle cylinder
and then remove the pressure from port 1. pushes against a sliding stop bolt. This sliding stop bolt
has a locknut that limits the stroke of the throttle cylinder.
5. If the relief setting is correct, relieve the pressure of By adjusting the nut, the engine speed may be fine tuned.
the pressure source by turning off the pressure source Figure 8.18 shows the throttle actuator box.
and moving the control several times in both direc-
tions.
Sliding Stop Bolt
6. Disconnect the pressure source from port 1 and Locknut
remove the counterbalance valve cartridge.
7. If the relief setting is incorrect, adjust the relief setting

as described in the following procedure.
Throttle
Cylinder
Adjustment
1. Loosen the jam nut and turn the adjusting screw
clockwise to decrease the setting or counterclock-
wise to increase the setting. Figure 8.18 — Throttle Actuator Box
2. Hold the adjusting screw from turning and tighten the Turning the nut counterclockwise will increase the engine
jam nut. speed. Turning the nut clockwise will decrease the engine
speed. The nut is self-locking to prevent movement due to
3. Repeat the test procedure until the correct relief vibration.
setting is obtained.

Rotation Gearbox Use caution when access covers have been removed to
Adjustment service the unit. Pinch points and shear points may exist
The rotation pinion can be adjusted to mesh properly with between moving parts. Replace the access covers imme-
the rotation bearing. Proper adjustment minimizes back- diately after servicing.
lash. Adjustment is accomplished with the eccentric ring
and lock. 3. Remove the pinion cover.
Excessive backlash will appear as excessive side-to-side 4. With another person rocking the lower boom tip back
boom movement when the rotation function is stopped. and forth, observe the movement of the pinion. If side-
Adjustment of the backlash may be necessary to compen- to-side movement between the pinion and rotation
sate for wear after extended operation. It is also necessary gear teeth occurs at the point of gear mesh, the mesh
if a new rotation gearbox and/or rotation bearing is in- between the pinion and rotation bearing is not properly
stalled. adjusted. Do not confuse backlash with slight lost
motion within the rotation gearbox. Internal gearbox
Use the following procedure to check and adjust the mesh backlash will cause the pinion to rotate back and forth
between the rotation pinion and the rotation bearing. slightly. This cannot be reduced externally. If adjust-
ment is necessary to bring the pinion into closer mesh
1. Position the unit on a level surface, apply the parking with the rotation bearing, continue with the following
brake, and chock the wheels. Engage the PTO and steps.
2. Rotate the booms to the position that has the least Caution
amount of movement between the rotation pinion and Injury can result from airborne particles entering the
the rotation bearing. This position is normally the high eyes. Wear appropriate safety equipment.
tooth location (refer to Figure 8.19). On a new rotation
bearing, it is painted blue or yellow. Turn off the engine Wear eye protection at all times to prevent particles of dirt,
and disengage the PTO. metal, or hydraulic oil from entering the eyes.
5. Remove the eccentric ring lock (refer to Figure 8.20).
Eccentric
Ring
High
Tooth
Location
Rotation
Gearbox Lock
Location X
X Figure 8.20 — Eccentric Ring
6. Loosen, but do not remove, the four cap screws that

Figure 8.19 — mount the rotation gearbox to the turntable base plate.
Rotation Bearing High Tooth Location If installing a new gearbox, install the washer with the
rounded edge of the washer hole toward the cap screw
head. Start the cap screws and washers in the
Caution gearbox mounting holes.
Injury can result from contact with pinion and rotation
bearing gear teeth. Keep hands clear. 7. The eccentric ring is located on top of the turntable
base plate, under the gearbox. Since the bore of the
Injury can result from being pinched or trapped be- eccentric ring is 1/16″ (1.6 mm) off center from the
tween moving components. Keep hands clear. outside diameter of the ring, rotating the ring will move
the gearbox and pinion toward or away from the
rotation bearing. The gearbox mounting holes are 1/8″

(3.2 mm) oversize to accommodate for this move- Leveling System
ment. One type of leveling cable must be replaced at least every
5 years or 5,000 hours, whichever comes first. The other,
Engage a suitable bar or drift pin (preferably of a soft newer type, of leveling cable must be replaced at least
material such as brass) in a drive slot of the eccentric every 8 years or 8,000 hours, whichever comes first. The
ring. Rotate the eccentric ring using light blows from newer type is recognized by yellow paint on the end
a hammer against a bar or drift pin. Should the gear coupling of the cable. This requirement is based on normal
mesh become looser, turn the ring in the opposite use, proper care, regular inspection, and lubrication. If the
direction. Rotate the eccentric ring until the pinion unit is operated under severe conditions, or not properly
bottoms out in the rotation gear teeth. At this point, the serviced, replace cables, leveling rods, or sheaves more
ring will stop rotating. Do not use excessive force to frequently.
drive the eccentric ring past this point.
Study Figure 8.21 before adjusting leveling cables or rods.
8. Align the lock to the eccentric ring so a hole lines up
with the hole in the turntable plate. It may be neces-
sary to rotate the eccentric ring to install the lock. Caution
Install the cap screw through the lock and turntable Injury can result from handling wire rope. Wear appro-
plate. Install the nut and torque it to the proper value. priate safety equipment.
9. Firmly tighten the gearbox mounting cap screws. Testing

Rotate the turntable slowly through at least two 1. Remove the access covers to access the turnbuckles
revolutions. If it rotates smoothly, go to step 10. If in the lower and upper booms.
rotation binds or hesitates in any position, the back-
lash may be set too tight. Loosen the gearbox mount- 2. Pull the cables together with one hand. There should
ing cap screws. Rotate the eccentric ring to loosen it be approximately 1/2″ (12.7 mm) of deflection in one
one locking increment (refer to step 8). Repeat step 9. cable from the starting position to the pulled together
position (refer to Figure 8.22).
10. Torque each gearbox mounting cap screw to 225 foot-
pounds (305 N•m). Starting Position
11. If a new gearbox was installed, or if the rotation teeth

are dry, apply an open face gear lubricant as recom- 1
/2″
mended in Section 4 under Lubrication.
Pulled Together
12. Install the pinion cover.
Figure 8.22 — Deflection
Leveling Rod to
Cable Connection
Boom Tip
R.H. L.H. R.H.
Approx.
30°
Approx.
R.H. L.H. R.H. 30°
Upper Boom
Torque to 75 foot-pounds
and lockwire Approx. 25°
Leveling Rod Turnbuckle Torque to
Approx. R.H. R.H. 50 foot-
30° L.H. pounds
and
R.H. R.H. lockwire
Leveling Cable L.H. Turntable
Lower Boom
Figure 8.21 — Leveling System Assembly

Adjustment 6. Loosen the jam nuts on both turnbuckles in the lower
When the leveling cable tension is properly adjusted, the boom.
platform will be carried parallel to the turntable base,
eliminating unnecessary platform movement. Too much As in any turnbuckle, one thread is a right hand pitch
tension on the leveling cable system will shorten the life of and one thread is a left hand pitch. Whenever the
the cables, sheaves, and bearings. turnbuckle is being turned, hold the end of the leveling
rods and the end of the cable with wrenches to avoid
Cable adjustment generally will not be required until after twisting the rod or cable (refer to Figure 8.23).
the initial seating in period or after extended periods of
operation. Without proper tension, platform movement 7. Tighten the top (back) turnbuckle to tilt the top of the
may be noticed as weight is shifted from front to back of platform toward the elbow or tighten the bottom (front)
the platform. Loose cables will allow the leveling rods, turnbuckle to tilt the bottom of the platform toward the
cables, and platforms to bounce during road travel. elbow. It may be necessary to loosen one turnbuckle
to tighten the other or to loosen the front turnbuckle to
1. Position the unit on a level surface, apply the parking access the back turnbuckle.
properly set the outriggers. 8. Level the platform using the vehicle body or turntable
as a baseline.
2. Raise both the upper and lower booms until they clear
the boom rests. The platforms must be stowed at the 9. Tighten the turnbuckles.
side of the boom.
10. Test the tension and adjust the turnbuckles again, if
3. Disengage the PTO and turn off the engine. necessary, until the proper deflection is obtained.
11. Tighten the jam nuts and lockwire both leveling cables
Caution as shown in Figure 8.24.
tween moving components. Keep hands clear. 12. Loosen the turnbuckle jam nuts on the upper boom
leveling rod at the access hole.
Use caution when access covers have been removed
to service the unit. Pinch points and shear points may 13. Tighten the turnbuckle.
exist between moving parts. Replace the access cov-
ers immediately after servicing. 14. Test the tension and tighten the turnbuckles again, if
necessary, until the proper deflection is obtained.
4. Remove the access covers from the side of the lower
and upper booms to access the turnbuckles. 15. Tighten the jam nuts on the turnbuckle and secure the
turnbuckle with lockwire as shown in Figure 8.25.
5. Lubricate both the upper and lower boom turnbuckle
threads, cable adapter threads, and rod end threads 16. Install the covers and stow the booms.
with a light lubricant, such as chain and cable fluid.
Overcenter Cam
Notice Adjustment
Use wrenches to support and position the rod and Units with a two-man, rotating platform use two cam
cable end while turning the turnbuckle to prevent valves. These valves prevent the boom from contacting
damage. the platform when it is rotated into the path of the upper
Turn
R.H. L.H.
R.H. L.H.
Hold Hold
Figure 8.23 — Turnbuckle Assembly

R.H. Thread L.H. Thread
Section A-A Section B-B

Figure 8.24 — Turnbuckle Lockwire
L.H. Thread R.H. Thread
Section C-C Section D-D
Figure 8.25 — Leveling Rod/Cable Connection
boom as it is moved overcenter. One cam valve is located

below the platform rotator to sense when the platform is Cam Lobe Cam Roller Cam Valve
rotated into this position. The other cam valve is located Mounting Bracket
at the elbow. Use the following procedure to adjust the cam
valve at the elbow.

brake, and chock the wheels.
2. Remove the cover from the upper boom side of the

elbow.
3. Loosen the cap screws securing the cam valve Cam Valve
mounting bracket (refer to Figure 8.26).
Figure 8.26 — Overcenter Cam
4. Slide the cam valve mounting bracket to position the
cam valve roller so that it only touches the cam and 6. Place a magnetic based angle indicator on the lower
is not pushed in. side of the upper boom near the elbow.
5. Tighten the cap screws securing the cam valve 7. Engage the PTO and properly set the outriggers. Use
mounting bracket. the lower controls to unfold the upper boom to approxi-
mately 85 degrees from its rest position.

8. Loosen the two cap screws that secure the cam. Adjust the interlock connecting linkage to insure that the
interlock spool fully shifts when the trigger is actuated. If
9. Rotate the cam so that the lobe pushes in on the cam the spool is not being fully shifted, adjust the interlock
valve roller and shifts the cam valve. linkage using the following procedure.
10. Tighten the cap screws securing the cam. Adjustment

1. Remove the cover over the upper control assembly.
11. Start the engine, engage the PTO, and lower the upper Locate the jam nut on top of the interlock cable (refer
boom into the rest. to Figure 8.27).
12. Release the platform rotation stop and rotate the

platform to the boom tip.
Caution
Injury and property damage can result from the plat-
form contacting the boom. Rotate the platform to the
side of the boom before moving the boom to an Jam Nut
overcenter position. Do not rotate the platform past the Interlock Trigger
stop when the boom is overcenter.
13. Use the lower controls to unfold the upper boom until
the cam valve shifts and boom movement is stopped.
The boom should not go overcenter. Do not unfold the
boom to a position where it will contact the platform.
14. The angle indicator should indicate approximately 85

degrees. If necessary, readjust the cam.
Interlock
Valve Remote Control Valve
15. Lower the boom, rotate the platform to the stowed (Upper Control Valve)
position, and place the lower boom into the rest.
Disengage the PTO, turn off the engine and replace Figure 8.27 — Upper Control Assembly
the cover.
2. The position of the adjusting nut on the cable assem-
Upper Controls Interlock Trigger bly will effect the amount of cable travel. Adjust the nut
The single handle control uses an interlock linkage to so that 0.03″ to 0.09″ (0.76 to 2.29 mm) of upward
prevent unintentional boom movement resulting from movement at the midpoint of the trigger will open the
accidental contact with the control. interlock valve. The adjustment should also allow the
interlock valve to be fully closed when the trigger is
When the interlock trigger on the bottom of the control released.
handle is engaged, the single handle control can be
operated. Squeezing the trigger causes a linkage inside 3. After adjusting the nut, replace the cover and operate
the single handle control assembly to manually shift the the unit to be sure the adjustment is correct.
blocking section of the upper control valve. When the
blocking section is shifted, it allows hydraulic oil flow to the 4. Repeat the steps until the proper adjustment is ac-
boom function spools of the upper control valve. complished.
When the control is not operated, the blocking section of Winch Brake
the upper control valve is spring offset to the closed The winch is a worm gear driven by the hydraulic motor.
position. The winch valve directs hydraulic oil to the winch motor.
The winch motor powers the worm gear set. The worm gear
The trigger on the single handle control should show set drives an output shaft keyed to the winch drum.
slightly when it is fully engaged into the handle. The trigger
should not bottom out or completely disappear into the The winch is equipped with a brake, located at the end of
handle, rather the spool should bottom out, stopping the worm shaft opposite from the winch motor (refer to
trigger movement. Figure 8.28). The brake is an overrunning clutch that runs
freely in the winch Raise position, but applies continuous

braking action in the winch Lower position. The brake connections and disconnect the hoses from the winch
assists the self-locking worm gear set in stopping a load motor. Cap the ports in the motor and plug the hoses.
that is being lowered when the control handle is returned
to neutral. 6. Remove the two cap screws that attach the hydraulic
motor to the winch gearbox. Remove the hydraulic
Motor Brake motor from the input of the winch.
7. If the shaft adapter remains on the winch input shaft,

remove the shaft adapter to expose the input shaft.
8. Place the brake torque adapter (refer to Service Tools

and Supplies in the Appendix) on the input shaft of the
winch gearbox, lining up the slot in the socket with the
key on the input shaft. Connect a torque wrench on the
Adjusting adapter socket.
Screw
9. Loosen the jam nut on the brake adjusting screw.
Figure 8.28 — Winch
10. Turn the torque wrench so that the drum turns in the
Adjustment pay out direction one full turn before taking a torque
If the winch brake is not holding or stopping the load measurement. Refer to the parts page for the torque
properly, adjust the brake using the following procedure. setting for the winch used on the unit. If the torque is
below the setting indicated on the parts page, turn the
1. Position the unit on a level surface, apply the parking adjusting screw clockwise 1/4 turn and check the
brake, and chock the wheels. Engage the PTO and torque again. Repeat until the torque is correct. If the
properly set the outriggers. torque is above the setting indicated on the parts
page, turn the adjusting screw counterclockwise 1/4
2. Position the booms to allow access to the winch. turn and check the torque again. Repeat until the
Disengage the PTO and turn off the engine. torque is correct.
11. Tighten the jam nut.

Warning
Death or serious injury can result from hydraulic oil 12. Install the hydraulic winch motor and shaft adapter on
being injected into the flesh when loosening or dis- the input shaft of the winch gearbox.
connecting hydraulic components. Remove the pres-
sure before loosening or disconnecting hydraulic 13. Install the hydraulic connections and winch covers.
components.
14. Start the vehicle engine, engage the PTO, and raise
Seek medical attention if injured by escaping hydrau- the upper boom enough to clear any obstacles as the
lic oil. Serious infection or reaction can result if lower boom is raised. Position the booms and jib using
medical treatment is not given immediately. the material handling capacity chart to a position that
will allow the unit to lift maximum capacity as shown
Spilled hydraulic oil creates slick surfaces and can on the chart.
work areas clean.
Warning
3. Release any pressure in the hoses connected to the Death or serious injury can result from overloading
winch motor by moving the winch control on the upper the unit. Do not exceed the rated capacity values.
controls to the Pay In and Pay Out positions several
times. 15. Attach the maximum load as determined by the
capacity chart to the winch line.
4. Remove the winch covers to allow access to the winch
and hydraulic winch motor. 16. From the lower controls, lift the load 3′ to 4′ (0.91 to
1.22 m) off the ground with the winch.
5. Place a container under the hoses connected to the
winch to catch the hydraulic oil. Mark the hose

17. Start lowering the load with the lower winch control It may be necessary to progressively isolate the location
handle shifted fully to the winch pay out position. At of a short by disconnecting circuits until the short disap-
the same time, move the upper control/lower control pears.
selector to the upper controls position. The load
should stop. A short can also be detected by turning off power to the unit
and using an ohmmeter to check the resistance to ground
18. Repeat this test three times. at connections and terminals that would have a voltage
applied to them during normal operation. Zero resistance
19. If the load stops every time, return the unit to service. between ground and one of these locations indicates a
If the load does not stop, follow the steps below. short circuit. This checking procedure should begin clos-
est to the power source.
20. Remove the winch covers and hydraulic connections
to allow access to the winch brake. Open Circuit
An open circuit prevents normal current flow through
21. Remove the brake cover and inspect for any worn or components of the electrical system. An open circuit can
damaged components. be caused by the following items.
22. If any broken or worn parts are found, replace with new • Broken wire
parts and reassemble. Test as previously described. • Corrosion
• Wire pulled from a connection
23. If the brake components are not damaged and do not • Poor contact where an electrical component is
look worn, but will not hold the load in the test grounded
described above, replace the gearbox.
Begin the search for an open circuit at the point closest to
the component that is not operating. Trace the wiring from
Electrical System
the component and look for a broken connection, corro-
A basic understanding of electrical components and sion, or other visible damage to the cable or wires. Make
system failures will aid in troubleshooting the unit’s elec- sure ground connections are good. If the wiring looks good
trical system. and the ground contact is good, disconnect the leads to the
component and check the resistance reading through the
Failure Identification component with an ohmmeter. A very high or infinite
A short circuit, an open circuit, or component failure can resistance indicates an open circuit.
cause the electrical system to operate improperly.
Component Failure
A component malfunction is sometimes the most difficult
Caution problem to locate. It may appear as an open or a short
Injury can result from electric shock. Severe arcing circuit, or the component may not perform to its design
can occur even when working with low voltage vehicle capacity. Determine what functions are affected and what
electrical systems. Use caution when working with components in the system could be the cause of the
any electrical device. problem. If no open or short circuits can be located, and the
proper voltage is being applied to the component’s electri-
Short Circuit cal connections, the problem may be hydraulic or me-
High current flow through a short circuit will usually chanical.
interrupt one or more circuit breakers or fuses.
Make every effort to locate the problem component before
A short circuit can be caused by the following items. installing new parts. Trial and error component replace-
ment to isolate the problem can be very costly.
• Pinched wires
• Worn insulation Circuit Protection
• Defective component Self-resetting thermal circuit breakers are used in the
• Loose connection touching a ground electrical system to protect wiring and components from
excessive current flow. These circuit breakers reset within
To find the location of a short circuit, analyze the location a few minutes after the electrical overload is removed.
of the circuit breaker or fuse that is opening and what is
operating when it opens. Notice
Damage to the electrical system can result if a circuit
breaker trips repeatedly.

A 50 amp circuit breaker is used in the circuit from the setting of the throttle pressure switch should be reduced.
vehicle battery to the units electrical system. A 20 amp, With the unit level, turn the adjusting screw counterclock-
thermal circuit breaker is used to protect the ignition splice wise until the engine speed increases to the preset rpm
in the remote start/stop circuit. The wire from the ignition when the rotation function is operated at full speed.
switch to the truck/machine selector has a 10 amp circuit
breaker in it. A 6 amp circuit breaker in the 12 volt in line, The engine speed should return to idle when all functions
inside the below rotation control console, is used to protect are returned to neutral. If it does not, the throttle pressure
the electrically controlled functions at that work station. switch setting should be increased. Turn the adjusting
screw clockwise until the engine speed is at idle when no
Engine Throttle Control functions are operating.
The throttle control system senses the pressure in the
pump sense line. When Upper or Lower Controls is The unit is designed to operate at a maximum pump flow
selected and all functions are in neutral, the pressure is at as specified. If flow testing determines that the pump
a low level, and the engine operates at idle speed. When output is too low or too high, the preset engine rpm may
a function is operated, the pressure increases to the level need to be adjusted.
required to operate the function. If this pressure exceeds
a certain value, the engine speed is increased to provide On an electronically controlled engine, the preset rpm is
maximum pump flow. programmed into the engine control module using equip-
ment and procedures specific to the particular engine and
On a unit with an electronically controlled engine, a throttle chassis. Contact your Altec representative or the chassis
pressure switch is connected to the pump sense line by a manufacturer for further information on changing the rpm
hydraulic line. The normally open lead of the switch is setting.
connected to the throttle input terminal on the PDM. The
throttle output terminal of the PDM is connected to the Power Distribution Module (PDM)
vehicle’s engine control module. When the pressure in the The PDM uses low voltage components and is equipped
sense line increases to a level above the setting of the with self-testing features and LEDs to make problems
throttle pressure switch, the switch closes. This causes easy to troubleshoot. Refer to the PDM Information
the PDM to send a signal to the engine control module to Manual for troubleshooting information.
increase the engine speed to the preset rpm. When the
pressure drops below the setting of the throttle pressure Outrigger Interlock System
switch, the switch opens and the engine speed returns to If the outrigger interlock electrical switches are out of
idle. alignment, the outrigger interlock valve will not open when
the outriggers are lowered. This will cause the functions
Adjustment above rotation to be inoperable. If adjusting the switches
The throttle pressure switch is usually installed on the does not correct the problem, perform the following proce-
firewall in the engine compartment (refer to Figure 8.29). dure to determine if the defective component is in the
electrical system or if it is the outrigger interlock valve.
Testing
Firewall 1. Locate the outrigger interlock valve (refer to Figure
8.30) in the pump control valve below the below
rotation controls. There are two wires connected to the
Adjusting outrigger interlock valve solenoid. One is the ground
Screw wire and the other provides electrical power. Locate
the electrical wire providing the power to the solenoid.
Use a jumper wire to connect this wire to the vehicle
electrical system.
2. Start the engine and engage the PTO. Try to operate

Figure 8.29 — Throttle Pressure Switch the outriggers and a boom function.
Operation of some functions may not require enough 3. Turn off the engine and disengage the PTO. Remove
pressure to increase the engine rpm because the pump the jumper wire. If the outriggers did not operate, skip
can supply sufficient oil flow with the engine speed at idle. to step 4. If the outriggers were operational in step 2,
However, the engine rpm should increase when control the defective component is in the electrical system.
functions are operated at full speed. If it does not, the

Troubleshoot the electrical wire connected to the Electrical Switch Adjustment
solenoid, the wires connected to the PDM, the outrig- The outrigger interlock electrical switches are connected
ger interlock electrical switches, and their wiring. to the outrigger interlock control module. If one switch is
defective or out of alignment, the outrigger interlock will not
operate.
Caution
Injury can result from electric shock. Severe arcing
can occur even when working with low voltage vehicle
electrical systems. Use caution when working with
any electrical device.
Disengage the PTO or place the truck/machine switch, if

so equipped, in the Truck position. This will remove the
Outrigger Interlock
Cartridge and Solenoid electrical current from the vehicle to the unit while working
on the electrical switch.
Figure 8.30 — Pump Control Valve 1. Loosen the switch fasteners.
2. Adjust the switch so it closes when the outrigger shoe

Warning is within 10″ to 14″ (25.4 to 35.6 cm) from the ground.
being injected into the flesh when loosening or dis- 3. Lock the switch in place by properly tightening the
connecting hydraulic components. Remove the pres- fasteners. If adjustment does not correct the problem,
sure before loosening or disconnecting hydraulic replace the switch.
components.
Hand Controls
Seek medical attention if injured by escaping hydrau- Each below rotation hand control has two trim potentiom-
lic oil. Serious infection or reaction can result if eters. The trim potentiometers have adjusting screws
medical treatment is not given immediately. located on the side of the hand control. The adjusting
screws are labeled Max and Thresh (refer to Figure 8.31).
work areas clean.
4. Move the outrigger control handles in both directions

several times to relieve any fluid pressure in the
hoses.
5. Remove the outrigger interlock valve and install an

SAE O-ring plug.
6. Start the engine and engage the PTO. Try to operate

a boom function. If the function operates, the outrig-
ger interlock valve cartridge, ground wire, or solenoid
coil is the source of the problem. If the function does
not operate, the outrigger interlock valve is not the
problem. Maximum
Adjustment
7. Move the outrigger control handles in both directions
Threshold Adjustment
several times to relieve any fluid pressure in the
hoses. Remove the SAE O-ring plug and install the Figure 8.31 — Hand Controls
interlock valve. Troubleshoot the hydraulic compo-
nents located below rotation.

The adjusting screw labeled Thresh controls the threshold, 5. If the function starts to move before reaching the
or start movement, of the function. The threshold screw handle position in step 4, turn the threshold screw
adjusts the current when the control is first moved out of counterclockwise until the function stops moving.
neutral. It controls the dead band, or null, near the center
rest position. Turn the screw clockwise to increase the 6. Turn the Thresh screw clockwise until the function
threshold current. Turn the screw counterclockwise to starts to respond. Then turn the screw counterclock-
decrease the threshold current. wise one turn. This provides a smooth start for the
function’s movement. If more dead band is desired,
The adjusting screw labeled Max controls the maximum continue to turn the Thresh screw counterclockwise
speed of the function. The Max adjustment is used to limit until the desired dead band is obtained.
the maximum output current of the proportional valve when
the hand control is in its full travel position. Turn the screw 7. To adjust the maximum output, move the hand control
clockwise to increase the maximum output current. Turn lever to full travel. Hold it in this position while
the screw counterclockwise to decrease the maximum adjusting the maximum output in steps 8 through 10.
output current.
8. Check whether the manual override lever on the aerial
Adjustment control valve section for the function is fully shifted
Use the following procedure to adjust the hand control with the lever at full travel. If it is not, turn the Max
maximum output and threshold. screw clockwise until the valve reaches the fully
shifted position.
1. Position the unit on a level surface that will allow for
full boom extension and rotation. Apply the parking 9. Turn the Max screw counterclockwise until the func-
brake and chock the wheels. Engage the PTO and tion starts to slow down. If this is difficult to detect,
properly set the outriggers. Position the lower boom watch for the manual override lever to begin to back off
slightly above the boom rest and remove the cover from the fully shifted position as the Max screw is
over the lower control valve. turned counterclockwise. Then turn the screw clock-
wise one to two turns.
2. Remove the screws retaining the top cover of the
below rotation control panel. Carefully lift off the top 10. If slower maximum function speed is desired, turn the
cover of the control panel housing. Turn it over. Make Max screw counterclockwise until the desired maxi-
sure to support the control panel cover. Do not let it mum function speed is obtained.
hang from the wires.
11. Check the threshold adjustment again. If necessary,
3. Locate the adjusting screws for the function that readjust by following steps 4 through 10.
needs to be adjusted.
The adjusting screws are 15 turns from one end of
4. To adjust the threshold, move the hand control to the adjustment to the other. It may be necessary to turn the
point that the function starts to respond (approxi- screw a number of turns (five or more) to observe a change
mately 1″ out of neutral). Hold it in this position while in function response. There is not a positive stop at the
adjusting the threshold in steps 5 and 6. ends of the adjustment screws. When a screw reaches
either end of the adjustment, it will begin to make a slight
clicking sound as it is turned.

Section 9 — Dielectric, Structural, and Stability Testing
This unit has been factory tested and, at the time of In addition to regular tests, conduct tests any time the
delivery, all applicable ANSI requirements were met or dielectric strength of the insulating components is in
exceeded. Any time an alteration is made that may affect doubt.
the unit’s stability or dielectric insulation, testing must be
performed to confirm that the unit operates safely and in If it is necessary to change or replace any component
compliance with all governing organizations. which is part of the unit’s insulation, including booms, tool
lines, control lines, etc., a dielectric test must be per-
formed. If there is any doubt about the dielectric strength
Dielectric
of the hydraulic oil, perform a dielectric test.
ANSI requires that manufacturers conduct an AC dielec-
tric qualification test on each device before it is sold to a The leakage monitor system is a tool used to measure the
customer. Once the unit is in the hands of the owner, ANSI leakage of electrical current through the components it is
permits the use of a less stringent periodic dielectric test. attached to and for dielectric tests of all voltages. This
This test is to be done at least annually, but typically in 1 system consists of wires connected to components inter-
to 12 month intervals. Since the AC periodic test as nal to the upper boom and to a test electrode that extends
defined by ANSI uses the very same procedure but with through the bottom of the fiberglass upper boom. A test
less voltage, Altec suggests using the qualification test to electrode may also be located on the turntable.
avoid confusion. However, some owners prefer to use DC
to do periodic dielectric testing. Dielectric test forms can be found in the Appendix. Choose
the appropriate form, thoroughly document all tests, and
This unit is tested to a rating listed on the serial number maintain records in a permanent file.
placard at the time of delivery. The platform liner, if
furnished, will carry the certification test of the liner Single Handle Control
manufacturer. This unit may be equipped with a single handle control(s).
This control, which is green in color, may offer limited
secondary dielectric protection. To maintain this limited
Danger secondary protection it must be kept clean, dry, and in
Death or serious injury will result from contact with or good condition with periodic tests of its dielectric proper-
proximity to an energized conductor. Maintain the ties. Never rely on the insulating feature of the single
dielectric characteristics of the fiberglass boom(s). handle control as a substitute for your primary protection
from electrical contact.
Surface irregularities such as scratched, cracked, or
chipped gelcoat can trap dirt and contaminants, which In addition to regular tests, conduct a test any time any
over time may reduce the dielectric properties of the component which is part of the controls insulation has
fiberglass. Of particular concern are irregularities running been replaced. A confirmation test form can be found in the
lengthwise on the boom. Trapped contaminants, such as Appendix. Complete the test, document the results, and
dust particles and water, can cause tracking, providing a maintain the test in a permanent file.
path to ground. Surface flashover occurs when a sub-
stance causes an arcing of electricity between two points
Structural
on the boom. If this occurs, the dielectric integrity of the
boom may be permanently damaged. After replacing any major component, perform a 1.5 to 1
structural test to verify structural soundness before put-
Dielectric tests that can be performed only after installa- ting the unit back into service.
tion are the responsibility of the installer, whether the
installer is a dealer, owner, or user. After the completed
unit is in the possession of the owner or user, subsequent Warning
testing becomes the responsibility of the owner or user. Death or serious injury can result if the unit becomes
unstable. Maintain stability of the unit while perform-
The importance of dielectric testing cannot be overempha- ing a structural test by following proper procedures.
sized. Understand the dielectric test procedures in ANSI
publications. Provide for periodic inspection and dielectric Use the following procedure to perform a structural test.
testing of insulating components at intervals of 1 to 12
months. This recommendation is not intended to alter 1. The area where the test is performed should be level
more frequent inspection or testing of other components and free from any overhead obstructions. Position the
as defined in ANSI publications. unit in the test area so the platform may be accessed
by a forklift (or other lifting device) to place the test
weight.
Section 9 — Dielectric, Structural, and Stability Testing • 113

2. Apply the parking brake and chock the wheels. En- specific written approval from Altec Industries, Inc. Com-
gage the PTO and properly set the outriggers. ponent replacement with original equipment parts will not
affect the stability of this unit.
3. The position of the booms for the test depends
somewhat upon the component(s) that have been ANSI A92.2 requires a level surface test and a five degree
replaced. If a component of the leveling system has slope test when the unit mounting is complete on the
been replaced, raise the booms approximately 1′ out vehicle. These stability tests are not required to be
of each rest. If other components have been replaced, performed again unless significant changes are made in
perform two tests. Perform one structural test with the the original vehicle and body mounting or the unit is
upper boom horizontal and the lower boom fully raised. remounted on another vehicle.
Perform an additional structural test with both booms
horizontal (rotate the unit so the lower boom is
horizontal and not in the rest, position the upper boom Warning
overcenter and horizontal). Death or serious injury can result from uncontrolled
movement. Do not permit anyone to occupy the plat-
4. Position the platform(s) in the end-mounted position. form until the unit has passed applicable tests.
Allow enough space to permit jib/winch operation.
Death or serious injury can result if the mobile unit
5. Calculate the test weight for the platform by multiply- becomes unstable. Provide a suitable restraint while
ing 1.5 times the platform capacity shown on the serial the stability tests are performed.
number placard.
Notice
If the unit is equipped with a platform liner, deduct the Carefully load the test weight to prevent damage to the
weight of the liner from the test weight figure. platform or liner.
Notice Test Forms

Carefully load the test weight to prevent damage to the Stability test forms are provided in the Appendix. The
platform or liner. forms designate the proper boom and jib positions and the
proper test loads to be used. They show the unit loading
6. Place a sling around the platform to suspend the configuration(s) that would most likely cause overturning.
weight directly under its centerline. Use a forklift (or Completed forms should be dated and signed by the test
other lifting device) to slowly apply the weight. If the technician after conducting the stability tests and should
test is being performed with the lower boom below be retained as part of the original unit documentation.
horizontal, the test weight can be placed in the
platform without the use of a lifting device. Additional test forms may be needed to show appropriate
stability tests for units equipped with special lifting fea-
7. Pay out the winch line so a weight of 1.5 times the tures, such as a lower boom lifting eye or a gin pole socket.
rated load may be applied to the winch line at less than If Altec Engineering determines that these special lifting
2′ from the ground. features will always produce less tendency toward over-
turning than would normal platform and jib stability test
8. Apply the test weight for five minutes. During that loads, stability tests using these special lifting features
time, do not operate any function of the unit. This is a are not required.
static test only.
General Test Conditions
9. Remove the weight from the platform and the winch • Remove all tools and material including removable
line. Inspect the unit for structural soundness if any boom supports, extra platforms (not attached to the
cracking or popping was heard during the test. unit), and all removable cargo.
10. Operate the unit through its full range of movement • Restrict the amount of total fuel in all tanks to 20
before returning it to service. gallons (75 l) or less.
• Inflate tires to tire manufacturer’s recommended pres-

Stability
sure settings (unless customer specified).
Due to the possible affect on stability, this unit and/or
vehicle should never be altered or modified without the • Use wheel chocks during all testing.
114 • Section 9 — Dielectric, Structural, and Stability Testing

• Only the test technician can be on the unit during the load line from the center of the platform(s). The
test. platform test load may be suspended on the jib line, in
addition to the jib test load, if the unit is equipped with
• Do not use outrigger pads unless a special case such a material handling jib structurally capable of carrying
as customer request exists. In such cases, the test the added load.
technician must note on the test form that pads were
used, the reason pads were used, and the thickness 5. Apply a load to the material handling jib, if equipped,
of the pads. When pads are used during the five equal to 1.5 times its rated load.
degree slope test, the test technician must prevent
the pads from sliding down the slope or the outrigger 6. Rotate the turntable in a full rotation cycle, watching
shoe from sliding off the pad. for any evidence of instability. Outriggers and tires
may lift off the surface during the test without indicat-
• Perform the test only while operating from the lower ing a condition of instability as long as the mobile unit
controls. does not tend to overturn.
• Provide a suitable restraint during all stability tests to 7. Add permanent counterweight if it is determined that
prevent the mobile unit from overturning in the event the mobile unit will not pass the test as originally built.
a condition of instability is reached. A typical restraint Use temporary counterweight to determine how much
method is a loose loop of chain around each side of the permanent counterweight is needed and where the
rear axle [allows the axle to raise off the test surface counterweight should be added. Rotate the unit in a full
at least 8″ to 10″ (20 to 25 cm) before tightening the rotation cycle, watching for any evidence of instability
chain], near the wheel, which is securely anchored to after adding the temporary counterweight. If the unit
the ground. Increase the length of the chain to allow passes the test with the temporary counterweight,
further movement if there is any doubt about whether remove the temporary weight and add the permanent
the mobile unit has reached a condition of instability. counterweight. Perform the test again. The unit must
Raising of outriggers or tires does not necessarily pass this test before moving on to the five degree
indicate a condition of instability. slope test.
• Choose Test A or Test B depending on the location of Five Degree Slope Test
the weight for the test. Test B can only be used if the 1. Position the unit on a constant five degree hard
jib can structurally carry both the jib load and the surface with the centerline of the vehicle positioned
platform load. approximately perpendicular to the direction of the
slope. If the level surface test showed the mobile unit
• The unit must pass the level surface test before has a greater tendency to overturn about one side than
conducting the five degree slope test. another, position the least stable side on the low side
of the slope. Apply the parking brake and chock the
Level Surface Test wheels. Engage the hydraulic system.
During the level surface test, the test technician must
determine which side of the vehicle, curb side or street 2. Properly set the outriggers as directed in the Operator’s
side, is the least stable. This information will be used in the Manual under Properly Setting on a Sloping Surface.
five degree slope test. If this is a recertification of the stability test, with
proper outrigger setup, the side-to-side slope indicator
1. Position the unit on a level, hard surface, apply the should read the value stamped on the slope indicator
parking brake, and chock the wheels. Engage the placard. If the reading cannot be attained or if another
hydraulic system. customer-specified angle is desired, contact Altec
Engineering on how to proceed.
2. Properly set the outriggers as directed in the Operator’s
Manual under Properly Setting on a Level Surface. 3. Move the booms and jib into a position to most likely
cause overturning (refer to the test form).
3. Move the booms and jib into a position to most likely
cause overturning (refer to the test form). 4. Apply a load at the center of the platform(s) equal to
1.33 times the rated platform load. The load can be
4. Apply a load at the center of the platform(s) equal to applied either into the platform(s) or suspended by a
1.5 times the rated platforms load. The load can be load line from the center of the platform(s). The
applied either into the platform(s) or suspended by a platform test load may be suspended on the jib line, in
Section 9 — Dielectric, Structural, and Stability Testing • 115

addition to the jib test load, if the unit is equipped with 8. After the test has been completed, the side-to-side
a material handling jib structurally capable of carrying slope indicator placard should be stamped with the
the added load. slope indicator reading (only required following initial
stability test at the time of initial installation of unit on
5. Apply a load to the material handling jib, if equipped, chassis). The reading shall be taken while the outrig-
equal to 1.33 times its rated load. gers are still set from the five degree test with the
loads removed and the booms stowed into the travel
6. Rotate the turntable in a full rotation cycle, watching position. The front-to-back slope indicator placard
for any evidence of instability. Outriggers and tires shall be stamped with a 5 unless the unit has a
may lift off the surface during the stability test without requirement for a specific angle, in which case the
indicating a condition of instability, as long as the placard shall be stamped with its appropriate angle.
mobile unit does not tend to overturn.
9. After the test has been completed, torque all acces-
7. Add permanent counterweight if it is determined that sible rotation bearing cap screws to 100 percent of the
the mobile unit will not pass the test as originally built. normal installation torque value using a circular pat-
Use temporary counterweight to determine how much tern (only required following initial stability test at the
permanent counterweight is needed and where the time of initial installation of unit on chassis).
counterweight should be added. Rotate the unit in a full
rotation cycle, watching for any evidence of instability 10. After the test has been completed, torque the rotation
after adding the temporary counterweight. If the unit gearbox mounting cap screws to 100 percent of the
passes the test with the temporary counterweight, normal installation torque value (only required follow-
remove the temporary weight and add the permanent ing initial stability test at the time of initial installation
counterweight. Perform the test again. The mobile unit of unit on chassis).
must pass this test.
116 • Section 9 — Dielectric, Structural, and Stability Testing

Appendix
Glossary
2nd stage boom — see intermediate boom. articulating-boom aerial device — an aerial device with two or more
3rd stage boom — see upper boom. boom sections that are connected at joint(s) which allow one boom to
pivot with respect to the adjacent boom.
A-frame outrigger — an extendible outrigger having two diagonal
members which are connected at the top and joined near the midsec- ASTM — American Society for Testing and Materials.
tion by a horizontal cross piece. Resembles a broad based “A.” atmosphere (one) — a pressure measure equal to 14.7 psi.
above rotation — in reference to a position on or about a unit that is atmospheric pressure — pressure on all objects in the atmosphere
vertically above the rotation bearing. because of the weight of the surrounding air. At sea level, about 14.7
absolute — a measure having as its zero point or base the complete psi absolute.
absence of the item being measured. atmospheric vents — a vacuum prevention device designed to allow
absolute pressure — a pressure scale with the zero point at a perfect air to enter a hydraulic line that has encountered an internal pressure
vacuum. below that of the atmosphere (vacuum).
accumulator — a container used to store fluid under pressure as a attention — information that must be followed to reduce the likelihood
source of hydraulic power or as a means of dampening pressure of property damage. Property damage could include structural damage
surges. to the unit, component failure, or damage to nearby property.
actuator — a device for converting hydraulic energy into mechanical auger — the hole boring tool of the digger, consisting of a hollow tube
energy, such as a motor or cylinder. with hardened teeth attached at one end to dig into and break up soil
and/or rock as the auger is rotated. Several turns of flighting are welded
adapter — a device used to connect two parts of different type or to the tube to carry the loose material away from the teeth.
diameter.
auger extension shaft — a shaft which fits into the auger tube to
adjusting stud — a component of a cable drive system that is threaded connect the digger output shaft to the auger.
on both ends and has a hex adjusting flat in the center. It secures the
drive cable to the cylinder rod and can be used to adjust the tension of auger rotation hydraulic system — the hydrostatic system on a
the drive cable. pressure digger which operates the auger transmission gearbox.
aeration — the entrapment of air in hydraulic fluid. Excessive aeration auger stow bracket — the bracket on a digger derrick lower boom
may cause the fluid to appear milky and components to operate which stores the digger and auger assembly when it is not in use.
erratically because of the compressibility of the air trapped in the fluid. auger stow switch — a limit switch which is actuated by the auger to
aerial control valve — the control valve on the turntable of an elevator shut off digger operation in the stowing direction when the auger
unit which operates the movement functions of the aerial device. reaches its fully stowed position in the auger stow bracket.
aerial device — a vehicle-mounted device with a boom assembly auger transmission gearbox — the gearbox mounted on the mast
which is extendible, articulating, or both, which is designed and used to weldment of a pressure digger that is used to rotate the kelly bar.
position personnel. The device may also be used to handle material, if auger tube — the hollow tube at the centerline of an auger to which the
designed and equipped for that purpose. auger flighting is welded.
Allen wrench — a six-sided wrench that fits into the hex socket of a cap auger windup sling — the cable or strap attached to the auger stow
screw or set screw. bracket which is used to store the digger and auger.
American National Standards Institute (ANSI) — a self-governing auxiliary engine — a separately mounted engine that is used to
body of professionals whose primary objective is to prevent accidents provide power for the unit’s hydraulic system.
by establishing requirements for design, manufacture, maintenance, auxiliary hydraulic system — the secondary hydraulic system of a
performance, use and training for manufactured goods including aerial pressure digger that operates all the hydraulic functions except auger
devices and digger derricks. rotation.
anaerobic adhesive — a bonding agent or adhesive that cures in the AWS — American Welding Society.
absence of air.
back pressure — pressure existing in the discharge flow from an
analog signal — an electrical signal that communicates information by actuator or hydraulic system. It adds to the pressure required to operate
the continuous variation of voltage or current level within a defined an actuator under a given load.
range, in proportion to an input parameter such as pressure or control
lever position. backlash — the clearance at the tooth contact point between the
adjacent gear teeth of two or more meshing gears.
annular area — a ring shaped area. Usually refers to the piston area
minus the cross-sectional area of the rod of a hydraulic cylinder. baffle — a device, usually a plate, installed in a reservoir to separate
the return line inlet from the suction line outlet.
ANSI — see American National Standards Institute.
band of arrows — decals used on extendible and articulating upper
antirotation fork — a two-pronged retainer which is fastened to the booms to define the boom tip area and the insulating portions of the
inside of the turntable and used to prevent movement of the rotary joint upper boom and lower boom insert.
outer housing.
bare-hand work — a technique of performing live line maintenance on
antifoam additive — an agent added to hydraulic fluid to inhibit air energized conductors and equipment whereby one or more authorized
bubbles from forming and collecting together on the surface of the fluid. persons work directly on an energized part after having been raised and
antiwear additive — an agent added to hydraulic fluid to improve the bonded to the energized conductors or equipment.
ability of the fluid to prevent wear on internal moving parts in the barrel — the hollow body of a hydraulic cylinder into which the piston
hydraulic system. and rod are assembled.
arbor bar — the shaft or spindle that is used to support a cable reel. base boom — see lower boom.
arbor bar collar — a cylindrical device that is used to secure a cable base end — 1: the closed end of a hydraulic cylinder, opposite from the
reel on an arbor bar. end that the rod extends from. 2: the end of an extendible boom that is
arm — 1: the primary load-carrying structure of an articulating arm. 2: closest to the turntable. 3: the end of an articulating boom that remains
the primary load-carrying structure of a single elevator. 3: the articulat- positioned closest to the turntable when the boom is fully unfolded.
ing structure which supports the arbor bar for reel lifting. basket — see platform.
arm cylinder — the hydraulic cylinder that moves the arm of a single battery charger — a device used to restore the electrical charge in a
elevator up and down. battery.
articulating arm — a system located between the turntable and lower bearing — a machine part that is installed between two adjacent
boom of an aerial device which is used for lifting the boom assembly to machine parts to allow those parts to rotate or slide with respect to each
increase the platform working height. This system includes the arm, other. Commonly used to decrease friction or wear on components.
link(s), riser and articulating arm cylinder.
behind cab mount — a pedestal mounting position located immedi-
articulating arm cylinder — the hydraulic cylinder that moves an ately behind the vehicle cab on the longitudinal centerline of the
articulating arm up and down. chassis.
1 Appendix — Glossary
below rotation — in reference to a position on or about a unit that is brake — a device used to slow or stop the rotation or movement of a
vertically below the rotation bearing. component such as a rotation gearbox, winch, gravity leveled platform,
below rotation controls — controls that are located on the chassis, or arbor bar.
used for operating some or all of the functions of the unit. breather — a device that permits air to move in and out of a container
bleed-off — to reduce the trapped pressure in a hydraulic system, line, or component to maintain atmospheric pressure.
or component, to a zero state by allowing fluid to escape under bridge mount — a unit mounting configuration in which the turntable
controlled conditions through a valve or outlet. is mounted on a pedestal structure which forms a bridge over the cargo
blocking valve — a two-position, two-way valve that blocks pump flow area.
to a hydraulic circuit or system when it is not actuated, and opens to broadband — a high speed telecommunication system utilizing fiber
allow fluid when actuated. optic and/or coaxial cable.
body — a structure containing compartments for storage of tools, bucket — see platform.
materials, and/or other payload which is installed on a vehicle frame or buckeye — see forged pin retainer.
subbase.
bullwheel assembly — an assembly of steel rollers used as a portion
body belt — a component in a personal fall protection system consist- of a cable stringing system.
ing of a strap which is secured about the waist of a person, with a means
for attaching it to a lanyard. (As of January 1, 1998, the use of a body burst pressure — the minimum internal pressure that will cause a
belt for personal fall protection is prohibited by OSHA.) hose, tube, cylinder, or other hydraulic or pneumatic component to
rupture or split open.
body harness — a component in a personal fall protection system
consisting of an assembly of straps which are secured about the waist, button head — a type of cap screw with a rounded head containing a
chest, shoulders, and legs of a person, with a means for attaching the socket into which a tool can be inserted to turn the cap screw.
assembly to a lanyard. bypass — a secondary passage for fluid flow.
bolt — a cylindrical fastener with external screw threads at one end and bypass valve — a hydraulic valve that allows for an alternate passage
a head configuration such hexagonal, square, or round at the other end, for fluid flow.
which conforms to the dimensional and material specifications pub-
lished for bolts. (These specifications are different from those for cap cable — 1: a wire or wire rope by which force is exerted to control or
screws.) operate a mechanism. 2: an assembly of two or more electrical
conductors or optical fibers laid up together, usually by being twisted
boom — a movable, mechanical structure that is used to support a around a central axis and/or by being enclosed within an outer covering.
platform, material handling components and/or other attachments on a
unit. cable chute — a device used to guide cable into strand for lashing the
cable to the strand when placing cable. A trolley allows the device to ride
boom angle indicator — a device which indicates the angle between on the strand as cable is fed through the chute.
the boom centerline and a horizontal plane.
cable drive system — an upper boom drive mechanism which utilizes
boom flares — steel structures mounted on the boom tip of a digger cables to produce upper boom movement.
derrick which are used to protect the boom tip from loads and support
poles carried on the winch line. cable guide — a bracket which is mounted on a boom to guide the
winch line.
boom functions valve — the control valve on a digger derrick that
directs hydraulic pressure and flow to the boom functions (boom, cable keeper — 1: a mechanical device attached to a cable that is used
rotation, intermediate boom, upper boom) hydraulic circuits. to maintain the position of the cable on a sheave. 2: a component used
to prevent a cable or winch line from coming off a sheave.
boom limiting system — the system of hydraulic cylinders or a
combination of switches that prevent the platform from moving into a cable lasher — a mechanical device which wraps lashing wire in a
non-working position. spiral configuration around a length of suspension strand and adjacent
communication cable.
boom pin — the horizontal pin that connects the lower boom to the
turntable or riser. cable lug — a mechanical device attached to a cable that is used to
maintain the position of the cable on a sheave.
boom rest — the structural member attached to the chassis or body to
support the lower boom in the travel or rest position. cable placer — a type of aerial device which contains a cable stringing
system and associated components for use in erecting overhead
boom stow switch — a limit switch which is actuated to shut off the communication cable.
boom lower function when the boom reaches its stowed position in the
boom rest. cable slug — the steel end fitting at each end of the drive cable in an
upper boom drive system. One end is attached to the cylinder rod and
boom stow valve — a mechanically actuated hydraulic valve that limits the other is secured in a pocket on the elbow sheave.
the downward pressure of a boom as it is placed in its rest.
cable stringing system — the group of steel rollers, bullwheel assem-
boom tip — the area at the end of an extendible or articulating upper blies, strand sheave assemblies and fairlead which directs communi-
boom that is farthest from the turntable when the boom assembly is cation cable or suspension strand from the reel it is stored on to the
extended or unfolded. This area includes all components at the end of working position of the operator.
the boom above the band of arrows.
calibrate — to check, adjust, or determine by measurement in compari-
boom tip idler sheave — the upper sheave in a digger derrick upper son with a standard, the proper value of each scale reading or setting
boom tip containing two sheaves, which carries the winch line as it on a meter or other device.
travels from the winch to the lower sheave (boom tip sheave).
caliper — a measuring instrument with two legs or jaws that can be
boom tip pin — a horizontal pin at the upper boom tip. Platform adjusted to determine the distance between two surfaces.
mounting bracket(s) and material handling devices are fastened to this
pin. cam — a rotating or sliding piece that imparts motion to a roller moving
against its edge or to a pin free to move in a groove on its face or that
boom tip sheave — 1: the sheave in a digger derrick upper boom tip receives motion from such a roller or pin.
containing only one sheave, which carries the winch line as it travels
from the winch to the load. 2: the lower sheave in a digger derrick upper candling — a method of inspecting filament wound fiberglass booms
boom tip containing two sheaves, which carries the winch line as it by slowly passing a light through the inside of the boom in a darkened
travels from the upper sheave (boom tip idler sheave) to the load. area. Cracks, crazing, and other damage show up as dark spots or
shadows.
boom tip tools — see upper tool circuit.
cap — a device located on the hand of a reel lifter that is used to retain
boom tip winch — a winch located at the tip of a boom. the arbor bar.
bore — the inside diameter of a pipe, tube, cylinder barrel, or cylindrical cap end — see base end.
hole in any of various other components.
cap screw — a cylindrical fastener with external screw threads at one
boss — protruding material on a part which adds strength, facilitates end and a head configuration such as hexagonal, hex socket, flat
assembly, provides for fastenings, etc. countersunk, round, or slotted at the other end, which conforms to the
dimensional and material specifications published for cap screws.
Appendix — Glossary 2
capacitive coupling — the transfer of electrical energy from one and stability requirements apply to the use of the derrick for lifting of
circuit to another through a dielectric gap. loads with the winch line at the upper boom tip or material handling jib
capacity chart — a table or graph showing the load capacity, rated tip, with the platform occupied.
capacity, or rated load capacity figures for a unit or accessory. come-along — a device for gripping and putting tension into a length
captive air system — a closed circuit, low pressure pneumatic of cable, wire, rope, or chain by means of two jaws or attaching devices
system used to actuate a pressure switch by means of a manually which move closer together when the operator pulls on a lever.
operated air plunger. communication cable — a copper wire, coaxial, or fiber optic cable
cartridge — 1: the replaceable element of a fluid filter. 2: the used for conducting telecommunication signals.
replaceable pumping unit of a vane pump, composed of the rotor, ring, compensating link — a mechanical linkage that serves as a connector
vanes and side plates. 3: A removeable hydraulic valve that is screwed between the turntable and the upper boom drive mechanism. As the
into place in a cavity in a hydraulic manifold or cylinder. lower boom is raised or lowered, this linkage causes the upper boom to
catrac — see hose carrier. maintain its relative angle in relationship to the ground.
caution — information that indicates a potentially hazardous situation compensator — a valve spool that is used to maintain a constant
which, if not avoided, may result in minor or moderate injury. It may also pressure drop regardless of supply or load pressure.
be used to alert against unsafe practices. compensator control — a control for a variable displacement pump
cavitation — the formation of gaseous voids in hydraulic fluid caused that alters displacement in response to pressure changes in the system
by a low pressure condition which typically occurs when inlet starvation as related to its adjusted pressure setting.
prevents the pump from filling completely with fluid. The characteristic component — a single part or self-contained assembly.
sound of cavitation is a high pitched scream. compressibility — the change in volume of a unit volume of a fluid
center mount — see behind cab mount. when it is subjected to a unit change in pressure.
center of gravity — the point in a component or assembly around conductive — having the ability to act as a transmitter of electricity.
which its weight is evenly balanced. Electricity will flow through metal, therefore metal is conductive.
centerline of rotation — the vertical axis about which the turntable of conductive shield — a device used to shield the lower test electrode
a unit rotates. system from capacitive coupling.
centrifugal pump — a pump in which motion and force are applied to conductor — a wire, cable, or other body or medium that is suitable for
fluid by a rotating impeller within a housing. carrying electric current.
chain — a series of identical rigid segments connected to each other constant resistivity monitor — device used to continuously measure
at joints which allow each segment to pivot with respect to adjacent the electrical resistance of the wash water in the tank of an insulator
segments, used to transmit mechanical force. washer.
chain extension system — a mechanical system consisting of a contaminate — to render unfit or to soil by introduction of foreign or
motor, gearbox, chains, and sprockets that is used to extend and retract unwanted material.
an extendible upper boom. continuous rotation — a rotation system in which the turntable is able
chain sling — an inverted Y-shaped length of chain used for lifting a to rotate an unlimited number of revolutions about the centerline of
strand reel with an aerial device and placing it in a strand carrier. rotation without restriction.
chamber — a compartment within a hydraulic component that may control — a device, such as a lever or handle, which is actuated by the
contain elements to aid in operation or control, such as a spring operator to regulate the direction and speed of one or more functions
chamber or drain chamber. of a unit.
channel — a fluid passage that has a large length dimension compared control station — a position where controls for unit operation are
to the dimension of the cross-section. located. These positions may include the platform, upper boom tip,
charge — to fill an accumulator with fluid under pressure. turntable, pedestal or vehicle tailshelf.
charge pressure — the pressure, above atmospheric pressure, at control valve — a directional valve controlled by an operator, used to
which replenishing fluid is forced into the hydraulic system. control the motion or function of an actuator or system.
charge pump — the hydrostatic hydraulic system pump that provides cooler — a heat exchanger used to remove heat from the hydraulic
fluid at low pressure to make up for internal leakage, provides cooling fluid.
fluid flow, and tilts the hydrostatic pump swash plate. corner mount — a pedestal mounting position located behind the rear
chassis — a vehicle on which a unit is mounted, such as a truck, trailer, axle(s) with the centerline of rotation located to one side of the chassis.
or all-terrain vehicle. corona ring — see gradient control device.
check valve — a valve that permits flow of fluid in one direction, but not counterbalance valve — a load holding valve that can be opened to
in the reverse direction. allow flow in the normally blocked direction by applying hydraulic
circuit — the complete path of flow in a hydraulic or electrical system. pressure to a pilot port, and which contains a relief capability to allow
flow from the blocked direction if the blocked pressure exceeds a
circuit breaker — a form of electrical switch which opens (trips) to certain value.
interrupt a circuit when it senses excessive current flow that may be
caused by a short circuit, to protect wiring and components from cracking pressure — the pressure at which a pressure actuated valve,
damage. Some types of circuit breakers reset automatically when the such as a relief valve, begins to pass fluid.
excessive current discontinues and others must be reset manually. crazing — a network of fine cracks on or below the fiberglass surface.
clevis — a U-shaped fastening device secured by a pin or bolt through Crazing often occurs when the fiberglass is struck with a blunt object,
holes in the ends of two arms. sometimes causing deformation and breakdown of the fiberglass resin.
closed center — a directional valve design in which pump output is crosstalk — a form of interference in which one circuit or channel
blocked by the valve spool(s) when the valve spool(s) is in the center receives some unintentional signal from another.
or neutral operating condition. cross-ported — a hydraulic path connected between the two opposite
clutch — the device on a reel lifter which allows the connection and flow paths of a hydraulic circuit that allows a route for flow between the
disconnection of the arbor bar and the driver. two paths in lieu of flow thru an actuator. To allow sensing of the
pressure in one path by a component installed in the other path.
coaxial cable — a type of shielded cable used for conducting telecom-
munication signals, in which the signal carrier is a single wire at the core, cSt (centistoke) — a metric unit of kinematic viscosity. In customary
surrounded by a layer of insulating material, which is in turn surrounded use, equal to the kinematic viscosity of a fluid having dynamic viscosity
by a metallic, conductive layer which serves as a shield, with an overall of one centipose and a density of one gram per cubic centimeter.
outer layer of insulation. curb side — the side of a vehicle which is opposite from oncoming
combined digger derrick and platform use — the stability criteria for traffic when the vehicle is traveling forward in the normal direction in a
a digger derrick mobile unit which indicates that the load capacity chart lane of traffic.
cushion — a device built into a hydraulic cylinder that restricts the flow diode — an electrical component that allows current flow in one
of fluid at the outlet port to slow the motion of the rod as it reaches the direction but not in the reverse direction.
end of its stroke. directional valve — a valve that selectively directs or prevents fluid
custom option — an option which is not shown on a standard order flow through desired passages.
form and which requires additional engineering work to supply. displacement — the quantity of fluid that can pass through a pump,
cylinder — a device that converts fluid power into linear mechanical motor or cylinder in a single revolution or stroke.
force and motion. It usually consists of a moveable piston and rod, or docking station — a device used to mount a remote control transmitter
plunger, operating within a cylindrical bore. on a platform.
danger — information that indicates an imminently hazardous situation dog clutch — see drum clutch.
which, if not avoided, will result in death or serious injury. This signal
word is to be used in the most extreme situations. double-acting cylinder — a cylinder in which fluid pressure can be
applied to either side of the piston to move the rod in either direction.
DC pump — a pump which is powered by a direct current electric motor.
double elevator — an elevator lift with two load carrying arms. The
dead band — the area or range near the center rest position of a hand double elevator system includes a lower pedestal, lower arm, lower arm
control where the function does not respond to movement of the lever cylinder(s), riser, upper arm, upper arm cylinder(s), and upper pedestal,
or handle. plus parallel links in both the lower and upper sections.
decal — a thin sheet of flexible material which is attached to another double-pole, double-throw (DPDT) switch — a six-terminal electrical
surface by adhesive, and is used to convey instructions, information switch or relay that connects, at the same time, one pair of terminals to
and warnings. either of two other pairs of terminals.
deenergize — to remove electrical power from a device, as from the coil double-pole, single-throw (DPST) switch — a four-terminal electrical
of a solenoid valve. switch or relay that, at the same time, opens or closes two separate
delivery — the volume of fluid discharged by a pump in a given time, circuits or both sides of the same circuit.
usually expressed in gallons per minute (gpm). down load — the downward force created when an external force is
demulsibility — the ability of a liquid to expel another type of liquid. exerted on the boom, such as a winch pulling cable on a cable placer.
Commonly used to describe a fluid’s ability to cause water to separate drain — a passage or a line from a hydraulic component that returns
out rather than being held in suspension. leakage fluid to the reservoir.
design voltage — the maximum rated line voltage for which an aerial drift — 1: a gradual, uncontrolled change from a set position of an
device has been designed, and for which it can be qualified. actuator or component. 2: a tool for ramming or driving something.
detent — a device for positioning and holding one mechanical part in driver — the gearbox and motor assembly on a reel lifter which is
relation to another so that the device can be released by force applied connected to and disconnected from the arbor bar through the clutch
to one of the parts. assembly.
diagnostic — relating to the practice of investigation or analysis of the drop pocket — an open top tool storage area on the chassis of a unit.
cause or nature of a condition, situation, or problem.
drum clutch — a clutch consisting of two or more drive lugs that engage
diagonal brace — the structural member attached near the top of a similar driven lugs to transmit torque. Commonly used between the
corner mount pedestal and extending downward and forward to a point gearbox and cable drum on front or bed mounted winches.
of attachment on the subbase or vehicle frame between the pedestal
and the vehicle cab. dump valve — a normally open, two-position, two-way valve that sends
pump flow through a path going directly to the reservoir or bypassing
dial indicator — a meter or gauge with a calibrated circular face and hydraulic circuit when it is not actuated, preventing operation of the
a spring-loaded plunger, used as a measuring device. hydraulic system or circuit. When it is actuated, it closes off this path,
diegrinder — a small, hand held, rotary grinding tool. redirecting flow to the hydraulic system or circuit to allow operation.
dielectric — nonconductive to electrical current. dynamometer — an instrument for measuring mechanical force or
differential cylinder — any cylinder that has two opposed piston areas power.
that are not equal. earth anchor — see screw anchor.
digger — the mechanism which drives the auger. eccentric ring — a ring with the center hole located in a position off the
digger bail — a tubular housing attached to the gearbox portion of a geometric center, commonly used to adjust the position of the rotation
digger, which surrounds the motor and provides an attachment point to pinion with respect to the rotation bearing gear teeth.
the digger link. eccentric ring lock — a device which engages a hole or notch in an
digger derrick — a multipurpose, vehicle-mounted device with an eccentric ring to prevent the ring from rotating.
extendible boom which may accommodate components that dig cylin- efficiency — the ratio of output to input. Volumetric efficiency of a pump
drical holes, set utility poles, and position materials, apparatus, and/or is the actual output in gpm divided by the theoretical or design output.
personnel. The overall efficiency of a hydraulic system is the output power divided
digger derrick use — the stability criteria for a digger derrick mobile by the input power. Efficiency is usually expressed as a percent.
unit which indicates that the load capacity chart and stability require- elbow — the structure on an articulating-boom aerial device that
ments apply to the use of the derrick for lifting of loads with the winch connects the upper boom to the lower boom. The elbow allows the
line at the upper boom tip or material handling jib tip, with the platform upper boom to pivot relative to the lower boom.
stowed or removed, if so equipped. elbow bearing — the rotating member that allows the upper boom to
digger hanger bracket — the structural member on a digger derrick rotate around the end of the lower boom. Used on aerial devices with
which supports the digger link on the extendible boom. the upper and lower booms mounted side by side.
digger latch mechanism — a mechanism which secures the digger to elbow pin — the horizontal pin that attaches the upper boom to the
the lower boom when it is stowed and to the extendible boom when it lower boom on an articulating-boom aerial device. Used on aerial
is unstowed. devices with the upper boom mounted over the lower boom.
digger link — the structural member which attaches the digger to the electrical harness — an assembly of electrical wires that is used to
digger hanger bracket. deliver electrical current between components.
digger/winch valve — the control valve on a digger derrick that directs electrocution — receiving an electrical shock resulting in death.
hydraulic pressure and flow to the digger and winch hydraulic circuits. electrohydraulic — a combination of electric and hydraulic control
digital signal — an electrical signal that communicates information by mechanisms in which an electrically controlled actuator is used to shift
the use of two distinct levels of voltage or current, a high “on” level and the spool in a hydraulic control valve.
a low “off” level, which are sent in a series of pulses. The timing of the electrohydraulic control system — a control system in which the
pulses is used to indicate the level of an input parameter such as control function control handles are connected to electric controls. The
lever position, or information such as the address setting of a radio electric controls actuate electrohydraulic valves to operate the func-
control transmitter linking it to its receiver. tions of the unit.
electrohydraulic valve — a directional valve that receives a variable flange — on a flange and lug pin retaining system, an end plate that
or controlled electrical signal which is used to control or meter hydraulic is welded to one end of the pin. The purpose of the flange is to position
flow. the pin in the connection.
elevator lift — a system located between the turntable and subbase flange and lug pin retaining system — a connecting pin retention
of an aerial device which is used for lifting the aerial device to increase system in which an end plate is welded to one end of the pin and a
the platform working height. This system may be configured as a single retaining plate is attached with cap screws to the other end to hold the
elevator or a double elevator. pin in position.
elevator unit — the overall device including the subbase, elevator lift flashover — a disruptive electrical discharge at the surface of electrical
and the aerial device. insulation or in the surrounding medium, which may or may not cause
emergency operating DC pump — see secondary stowage DC pump. permanent damage to the insulation.
emergency operating system — see secondary stowage system. flats from finger tight (F.F.F.T.) — a method of counting the number
of wrench flats when tightening a hydraulic adapter to establish a torque
end gland — a hollow, cylindrical part that screws into or is retained in value.
the open end of a hydraulic cylinder barrel, through which the rod
protrudes. flat-shoe outrigger — an outrigger which has a shoe that is fixed in a
horizontal position.
end-mounted platform — a platform which is attached to a mounting
bracket that extends beyond the boom tip, positioning the platform (and flighting — a curved plate or series of curved plates welded together,
platform rotation pivot, if so equipped) beyond the end of the upper spiraling along the axis of an auger tube or screw anchor rod.
boom. flow — the movement of fluid generated by pressure differences.
energize — to send electrical power to a device, as to the coil of a flow control valve — a valve that regulates the rate of fluid flow.
solenoid valve. flow rate — the volume, mass or weight of a fluid passing through any
energized conductor — an apparatus that is transmitting electric conductor per unit of time.
current. flow straightener — a component part of a nozzle used to straighten
energy — the ability or capacity to do work, measured in units of work. or remove any swirling motion of fluid going through the nozzle.
engine protection system — a system which detects when the flowmeter — an instrument used to measure the flow rate of fluid in a
auxiliary engine oil pressure or temperature is out of the proper range hydraulic tube or hose.
and shuts the engine off. fluid — a liquid that is specially compounded for use as a power
extendible — capable of linear movement of one or more portions of transmitting medium in a hydraulic system.
an assembly to increase the overall length or reach of the assembly. fold — to move a pivoting structure such an articulating upper boom
extendible-boom aerial device — an aerial device with a telescopic toward its stowed position.
or extendible boom assembly. fold-up shoe outrigger — an outrigger which has a shoe that pivots
extension cylinder — a hydraulic cylinder which extends and retracts into a vertical position when the outrigger is fully retracted.
an extendible boom(s). force — any push or pull measured in units of weight.
fairlead — the group of steel rollers at the platform of a cable placer forged pin retainer — a pin retainer made from forged steel, consisting
which guide the cable or suspension strand during the placing process. of a slender, cylindrical body with a flattened, circular head at one end,
fall protection system — a system consisting of a body harness or with a mounting hole through the head perpendicular to the body. The
body belt, a decelerating lanyard, connectors, and an anchor point at body is inserted through a hole in the pin to be retained, and the head
the boom tip, used to catch and hold a person who falls from a platform. is fastened to the adjacent structure with a cap screw.
(As of January 1, 1998, the use of a body belt for personal fall protection four-way valve — a valve having four ports for direction of fluid flow.
is prohibited by OSHA.)
FPS — Fluid Power Society.
feedback (feedback signal) — the return of part of an output signal to
the input for the purpose of modification and control of the output. frequency — the number of times an action occurs in a unit of time.
feeder tube — a telescopic hydraulic tube assembly mounted on an gasket — a packing made of a deformable material, usually in the form
extendible boom which carries pump flow to a device mounted on the of a sheet or ring, used to make a pressure tight fit between stationary
extendible portion of the boom such as a digger or boom tip winch. parts.
fiber optic cable — a type of cable used for conducting control or gate valve — see shutoff valve.
telecommunication signals, in which the signal carrier(s) is one or more gauge pressure — a pressure scale that ignores atmospheric pres-
optical fibers, enclosed within an outer covering. sure by establishing atmospheric pressure as its zero point. Its zero
fiber optics — the use of transparent fibers of glass or plastic which point is 14.7 psi absolute.
transmit light signals throughout the length of the fiber. Commonly used gauge snubber — see snubber valve.
to transmit signals from a remote control.
gearbox — an assembly with internal speed changing gears; a trans-
fiberglass — glass in fibrous form added as a reinforcement to a plastic mission. Gearboxes are commonly used to transmit power from a
for use in making various products. hydraulic motor to operate a function through an output shaft.
filler breather cap — the component on the top of a reservoir that gelcoat — a protective coating used on fiberglass components to
allows air to enter and exit the reservoir as the fluid level changes, and prevent the wicking of moisture into the fiberglass strands and to retard
which can be removed to access a fill hole when adding hydraulic fluid the degrading effect of ultraviolet light on the fiberglass.
to the reservoir.
GFI — ground fault interrupter.
filter — a device through which fluid is passed to remove and retain
insoluble contaminants from a fluid. gin pole — a vertical phase-holding apparatus which is attached to a
platform or upper boom tip.
filter cart — a portable device which can be connected to a unit’s
hydraulic system to filter water and/or other contaminants out of the gpm — gallons per minute.
hydraulic system fluid. gradient control device — a device at the upper end of an insulating
filter cartridge — a component containing filtration material which is boom that reduces electrical stress level(s) below that considered to be
installed within a filter housing or attached to a filter receptacle for use, disruptive.
and can be removed and replaced as a self-contained unit. gravity leveling system — a system which uses the force of gravity to
firm footing — outrigger placement and extension in accordance with keep the bottom of a platform parallel to level ground as the boom is
the instructions in a unit’s operator’s manual to ensure proper leveling raised or lowered. One means of accomplishing this is by allowing the
of the vehicle and adequate stability when operating the unit. platform to pivot freely about a horizontal shaft attached above the
platform’s center of gravity.
fixed displacement pump— a pump in which displacement is con-
stant, so that the output flow can be changed only by varying the drive grease fitting — a small fitting that acts as the connection between
speed. a grease gun and the component to be lubricated.
gripper tool — a component used for grasping an object or electrical hydraulically extendible jib — a jib boom that may be extended or
lines through the use of an articulated mechanism. retracted by hydraulic power.
ground — 1: a large conducting body with a potential of zero volts used hydraulics — an engineering science pertaining to liquid pressure and
as a common current return for an electric circuit. 2: an object that flow.
makes an electrical connection with a ground or with the earth. hydrostatic hydraulic system — any hydraulic drive in which a
ground fault interrupter (GFI) — a fast acting form of circuit breaker positive displacement pump and motor transfer rotary power by means
that opens to interrupt an electrical circuit if it senses a very small of fluid under pressure.
current leakage to ground, to protect personnel against a potential individual address setting — the code that identifies a specific
shock hazard from defective electrical tools or wiring. It does this by transmitter as the one emitting the signal corresponding to a specific
monitoring for any difference in current flow between the hot and neutral receiver’s reception address.
wires in the circuit. An imbalance exceeding a very small preset value
indicates that current is finding an improper path to ground, and causes in-line — the installation of a component in series between two portions
the breaker to trip. of a hydraulic line or electrical conductor so that flow in the line or
conductor toward the component passes through the component and
guard ring — see conductive shield. continues on in the line or conductor on the other side.
hand — an extension of the reel lifter arm that allows for loading the instability — a condition of a mobile unit where the sum of the moments
arbor bar. tending to overturn the mobile unit is equal to or exceeds the sum of the
hand control — a hand operated control lever or handle located at a moments tending to resist overturning.
control station used to regulate a function of a unit, where the speed of insulating aerial device — an aerial device with dielectric compo-
the function is proportional to the distance the control is moved. nents designed and tested to meet the specific electrical insulating
heat — the form of energy that has the capacity to create warmth or to rating consistent with the manufacturer’s name plate.
increase the temperature of a substance. Any energy that is wasted or insulating digger derrick — a digger derrick designed for and
used to overcome friction is converted to heat. Heat is measured in manufactured with a fiberglass boom(s) for use around energized
calories or British thermal units (Btu). One Btu is the amount of heat conductors at a maximum of 46 kV phase to phase.
required to raise the temperature of one pound of water one degree
Fahrenheit. insulating liner — see platform liner.
heat exchanger — a device that transfers heat through a conducting insulating portions — those sections which are designed, main-
wall from one fluid to another or into the atmosphere. tained, and tested in accordance with the electrical requirements of
ANSI A92.2.
hertz (Hz) — a unit of frequency equal to one cycle per second.
insulator — a device that isolates the energized conductor of a power
high tooth — the individual tooth out of all the gear teeth on a rotation line from the support structure.
bearing at which the minimum backlash occurs with the rotation pinion.
This is because of a slight difference between the actual and theoretical intercom system — a transmitter and receiver system that allows two-
tooth pitch lines due to manufacturing tolerances. way verbal communication between a platform operator and a person
at ground level.
HLIW — hot line insulator washer.
interference — any energy that inhibits the transmission or reception
holding valve — see load holding valve. of electrical or radio signals.
HOP — see hydraulic overload protection system. intermediate boom (INT BOOM) — an extendible boom section which
horsepower (HP) — the power required to lift 550 pounds one foot in is located between the upper boom and the lower boom in an extendible
one second or 33,000 pounds 1 foot in one minute. One horsepower is boom assembly.
equal to 746 watts or to 42.4 British thermal units per minute. ISO — International Standards Organization.
hose carrier — a flexible component which contains hydraulic, electri- jam nut — a nut that is screwed down firmly against another nut to
cal, and/or air lines, usually mounted inside or along the side of an prevent loosening.
extendible boom. As the boom is extended, the hose carrier unfolds in
a rolling motion to allow the lines to extend with the boom. jaw clutch — see drum clutch.
hose carrier tube — a rigid, enclosed tube which contains hydraulic, jib — an auxiliary boom which attaches to the upper boom tip to extend
electrical, and/or air lines, and may contain components for upper the reach of the boom.
controls. It is usually attached to a hose carrier on the side of an JIC — Joint Industry Conference.
extendible boom.
joystick — a two or three axis control lever which allows the operator
hot line insulator washer (HLIW) — a vehicle-mounted device which to simultaneously control multiple functions.
is designed and used for cleaning pole and structure mounted transmis-
sion and distribution insulators. junction box — an enclosed central connecting point for electrical
wiring.
HTMA — Hydraulic Tool Manufacturer’s Association.
kelly bar — 1: for derricks see auger extension shaft. 2: the auger drive
Huck bolt — a bolt-like fastener that is placed in position and then shaft of a pressure digger which is extendible from the ram cylinder.
stretched while an end fitting is swaged on. Commonly used to attach
a pedestal, subbase, and/or outriggers to a vehicle frame. key — a parallel-sided piece that fits into grooves in two adjacent parts
to prevent movement between the parts. Often used as the driving
hydrant — a discharge pipe with a valve and spout at which water may member between a shaft and a sheave or winch drum.
be drawn from a water main.
keyway — a groove that is cut in a shaft or bore for a key to fit into.
hydraulic control — a control that is actuated by hydraulically induced
forces. kilovolts (kV) — a unit of potential difference equal to 1,000 volts.
hydraulic leveling system — an automatic hydraulic control system knuckle — see elbow.
which keeps the bottom of a platform parallel to or at a fixed angle to the L-bracket — an L-shaped weldment that is used to connect a splicer
turntable base plate as the boom is raised or lowered. One means of platform to the upper boom tip.
accomplishing this is by transferring hydraulic fluid between a master lanyard — a component in a personal fall protection system consisting
cylinder actuated by movement of the lower boom and a slave cylinder of a flexible, nonmetallic strap or rope with a connector at each end for
mounted between the platform and the upper boom. connecting a body harness or body belt to a specified anchor point
hydraulic overload protection (HOP) system — the system on a provided at the boom tip, used to catch and decelerate a person in a fall
digger derrick that shuts off certain functions to help prevent damage from the platform. (As of January 1, 1998, the use of a body belt for
to the digger derrick structure when an overload is applied to the boom personal fall protection is prohibited by OSHA.)
in the downward direction. lashing wire — a thin, solid wire which is wrapped in a helix configu-
hydraulic schematic — a drawing that uses common hydraulic ration around a length of suspension strand and adjacent communica-
symbols to represent the hydraulic system of the unit. tion cable so that the suspension strand carries the weight of the cable.
hydraulic swivel — a fluid conducting fitting having two joined parts lay — the length of wire rope in which one strand makes one complete
that are capable of pivoting freely about each other to accommodate spiral around the rope.
motion of an attached hydraulic line.
layer — all wraps of winch line on a winch drum which are on the same equivalent) to interrupt the conductive path for electricity through the
level between drum flanges. lower boom.
leakage monitor system — a means by which current leakage is lower boom winch — a winch that is located on the lower boom.
measured through the insulating section(s) of a boom to confirm of lower control valve — the hydraulic valve on the vehicle, turntable,
dielectric integrity. or pedestal of an aerial device used for operating some or all of the
leveling cable — the wire rope portion of a mechanical leveling system functions of the aerial device.
that passes over the sheaves. lower controls — the controls on the vehicle, turntable, or pedestal,
leveling chain — the chain portion of a mechanical leveling system that used for operating some or all of the functions of the unit.
passes over the sprockets. lower pedestal — the structure within an elevator lift that connects the
leveling cylinder — 1: a cylinder that is used in a master/slave elevator lift to the subbase.
arrangement in a hydraulic leveling system to hydraulically level the lower test electrode system — a system on an insulating aerial
platform. 2: the hydraulic cylinder that is used to tilt the pivot and mast device utilizing conductive bands installed permanently on the inside
weldments of a pressure digger to either side of the vertical position. and outside surfaces of the insulating portion of the upper boom and
leveling rod — a slender, round, fiberglass rod used in a mechanical conductive connections to components inside that portion of the boom
leveling system that passes through a unit’s boom to connect the such as leveling rods and hydraulic lines. All the bands and component
leveling chains or cables at each end of the boom. connections are connected to a common pickup point for use in
leveling system — see platform leveling system. measuring current leakage to confirm of dielectric integrity.
leverage — a gain in output force over input force; mechanical lower tool circuit — a hydraulic tool circuit with quick disconnect
advantage or force multiplication. couplings located on the pedestal or on the vehicle.
lift cylinder — the hydraulic cylinder that moves the lower boom up and lug — a metal part which serves as a cap, handle, support, or fitting
down on a digger derrick or extendible-boom aerial device. connection.
lifter cylinder — the hydraulic cylinder that moves the reel lifter arms. magnetic suction separator filter — see magnetic suction strainer.
lifting eye — a shackle or weldment used for attaching chain, cable, magnetic suction strainer — a suction filter consisting of a strainer
rope, etc. to a boom for material handling. which contains one or more magnets to trap ferrous metallic contami-
nants that are small enough to pass through the strainer.
light emitting diode (LED) — a semiconductor diode that emits light
when subjected to an applied voltage. LEDs are used for electronic mainframe — see pedestal.
display. man-and-a-half platform — an oversized one-man platform.
line — a tube, pipe or hose used as a passageway to move hydraulic manifold — a fluid conductor that provides multiple connection ports.
fluid. manual lowering valve — a manually operated hydraulic valve used
linear — in a straight line. to lower the boom in the event of power failure.
linear actuator — a device for converting hydraulic energy into linear manual override — a means of manually actuating an automatically or
motion such as a cylinder or ram. remotely controlled device.
linear position transducer — an extendible length measuring device manually extendible jib — a jib that is capable of being extended and
which produces a variable electrical signal that is proportional to the retracted by human force.
length to which the device is extended. mast — the structure on a pressure digger which supports the auger
liner — see platform liner. transmission gearbox, ram cylinder, kelly bar, and pole setter.
link — the secondary load-carrying structure of an articulating arm. master control panel — the primary derrick lower control panel which
load capacity — (as defined by ANSI for digger derricks) the maximum contains the electrical connections between the derrick control system
load, specified by the manufacturer, that can be lifted by the mobile unit and components such as the power module and the dump or blocking
at regular intervals of load radius or boom angle, through the specified valve. The master control panel is used in conjunction with a slave panel
ranges of boom elevation, extension and rotation, with options installed to provide dual station lower controls.
and inclusive of stability requirements. master cylinder — a cylinder in which motion of the piston under an
load holding valve — a hydraulic valve which blocks fluid flow from a external force transfers hydraulic fluid to a slave cylinder to produce
hydraulic actuator, such as a cylinder or motor, to prevent motion when corresponding motion.
the control valve is not being operated or in case of a hydraulic line material handling — having the ability to use the boom or attachments
failure. on the boom to lift and position materials.
load radius — the horizontal distance from the centerline of rotation to material handling system — the system on an aerial device that
the winch line load attachment point. consists of a jib and winch used to lift material to the upper boom tip.
load sensing — (see sense line) the signal when a function is operated mechanical leveling system — a mechanical system which keeps the
that tells the hydraulic pump to stroke up from a non-stroked (neutral) bottom of a platform parallel to or at a fixed angle to the turntable base
position to supply oil to that function. plate as the boom is raised or lowered. One means of accomplishing
lock washer — a solid or split washer that is placed underneath a nut this is by utilizing a parallelogram arrangement of leveling rods attached
or cap screw to help prevent loosening by exerting pressure against the to cables or chains operating around sheaves or sprockets at boom
fastener. pivot points.
locknut — see self-locking nut. mercury switch — a switch that is closed or opened when an internal
globule of mercury moves to or away from the contacts when the switch
lockwire — a wire that is installed to prevent loosening of fasteners or is tilted.
components.
meter — to regulate the amount of fluid flow.
lower arm — the primary load-carrying structure of a double elevator
which is located between the lower pedestal and the riser. meter-in — to regulate the amount of fluid flow into an actuator or
system.
lower arm cylinder — the hydraulic cylinder that moves the lower arm
of a double elevator up and down. meter-out — to regulate the flow of the discharge fluid from an actuator
or system.
lower boom (LWR BOOM) — the boom section in a boom assembly
which is attached to the turntable or riser, and which supports the upper micron (micrometer) — one-millionth of a meter or about 0.00004″.
boom or intermediate boom. micron rating — the minimum size of the particles that a filter is
lower boom cylinder — the hydraulic cylinder that moves the lower designed to remove.
boom about its pivot point on an articulating-boom aerial device. microswitch — a small electrical device that is used to turn an electrical
lower boom insulator — the part of the lower boom made of high current on or off, or to change the connections in a circuit.
dielectric strength material (usually fiberglass reinforced plastic or minimum approach distance — the three dimensional area sur-
rounding a conductor into which a person may not enter nor bring any
conductive object unless they are: qualified electrical workers, wear- nozzle — a tube-like device for accelerating and directing the
ing insulating gloves (and sleeves when required), protected against discharge flow of fluid.
contact with any other objects at a different electrical potential. NPT — National Pipe Thread.
mobile operation — the use of the aerial device or digger derrick while NPTF — National Pipe Thread Fluid, a pipe thread form which is
the mobile unit is traveling. modified from the NPT form to improve the resistance to fluid leakage
mobile unit — the combination of a unit, its chassis and related through the threads in a connection.
permanently attached equipment. O-ring — a ring of material with a circular cross section that is used as
modified A-frame outrigger — an extendible outrigger that is config- a gasket, usually made of synthetic rubber.
ured like a large broad based “A” with an open top. ohmmeter — an instrument used to measure the resistance in ohms
modulation ratio — the “on” time vs. the “off” time of a pulse width between two points in an electrical component or circuit.
modulated digital signal. This ratio is determined by dividing the on time on/off circuit — circuit that supplies constant electrical power to a
during one cycle by the total cycle time. solenoid or other component when a relay or switch is closed and
moly — see molybdenum disulfide. removes the power when the relay or switch is opened.
molybdenum disulfide — a black inorganic chemical that is used as one-man platform — a platform designed to carry one person. It is
a dry lubricant and as an additive for grease and oils. Molybdenum usually 24″ wide x 30″ wide or 24″ wide x 24″ wide.
disulfide has a very high melting point and is insoluble in water. open center — a directional valve design in which pump output returns
molydisulfide — see molybdenum disulfide. freely to the reservoir when the valve spool(s) is in the center or neutral
moment — a force multiplied by the perpendicular distance from the position.
line of action of the force to an axis or point. The force may be the weight open circuit — an electric circuit that has infinitely high resistance,
of an item, with the vertical line of action located at the item’s center of resulting in no current flow. An open circuit may be caused by a loose
gravity. Moment is measured in units of force times distance; for connection, broken wire, corrosion or poor contact where an electrical
example, pound-feet or foot-pounds. component is grounded to the unit structure.
monitor head — remotely controlled articulated assembly with a operator — a person trained, authorized and engaged in the operation
nozzle, mounted at the upper end of an HLIW. of the unit.
motor — a device that converts hydraulic or electrical energy into optical fiber — a thin strand of transparent glass or plastic used to
continuous rotary motion and torque. transmit signals using light throughout the length of the strand.
multiple-part line — the arrangement of the winch line on a digger orifice — a restriction in a hydraulic or pneumatic circuit, the length of
derrick in which the winch line is routed between the boom tip and the which is small in respect to its diameter.
load two or more times. A snatch block is used at the load and a snatch OSHA — Occupational Safety and Health Administration.
block or additional boom tip sheave(s) is used on the boom to reverse
the direction of the winch line. The end of the winch line is connected out and down outrigger — an outrigger that has independently-
to a stationary attachment point on the boom or lower snatch block. A controlled horizontal and vertical extendible outrigger legs.
multiple-part line is used to reduce the tension in the winch line to a outboard bearing — a bearing which supports the end of a gearbox
value below the winch line rated working load when a lifting load that output shaft farthest from the gearbox.
exceeds the winch line rated working load.
output signal — a radio wave intended to pass communication from a
multiplexing — a process by which signals from multiple inputs are source to a destination.
combined and transmitted simultaneously over a single channel.
outrigger — a structural member, which when properly extended or
multiviscosity — the viscosity characteristic of a fluid which contains deployed on firm ground or outrigger pads, assists in stabilizing the
additives that increase the viscosity index. The fluid does not become mobile unit.
as thin at high temperatures or as thick at low temperatures as a fluid
without these additives. This allows the fluid to be used over a wider outrigger controls — the controls for operating the outriggers.
temperature range. outrigger cylinder — the hydraulic cylinder which extends and retracts
nonconductive — the characteristic of a substance that allows it to or unfolds and folds an outrigger leg.
transmit electricity only in a very small degree when it is clean, dry and outrigger interlock system — a system which requires all outriggers
properly maintained. to be extended to a specified position before other unit functions are
noncontinuous rotation — a rotation system in which the turntable is allowed to operate.
prevented from rotating more than approximately one revolution about outrigger interlock valve — a valve which prevents above rotation
the centerline of rotation. sense line signals from reaching the pump until the outriggers have
non-insulating aerial device or digger derrick — an aerial device been lowered.
or digger derrick which is not designed, manufactured, or tested to outrigger leg — 1: the moveable structural component of an outrigger
meet any dielectric rating. which extends or unfolds to position the outrigger shoe on the ground,
nonmetallic — formed of materials which are not any type of metal. and which retracts or folds to return the outrigger shoe to the stored
position. 2: the stationary structural component of an extendible outrig-
non-overcenter aerial device — a type of articulating-boom aerial ger from which the moveable outrigger leg extends.
device on which the upper boom will not unfold from the stored position
to beyond a vertical position regardless of the position of the lower outrigger motion alarm — an audible warning system to alert person-
boom. nel that outriggers are being lowered or moved.
nontransferable boom flares — boom flares that are permanently outrigger pad — a portable piece of rigid material which is placed
attached to the boom tip of a digger derrick. under an outrigger shoe to increase the contact area with the ground
surface when the ground surface is not firm enough to support direct
nontransferable upper controls — an upper control panel on a digger contact from the outrigger shoe.
derrick that is permanently attached to the upper boom tip.
outrigger shoe — the component of an outrigger that is attached to the
normally closed switch — a switch which is closed to allow current to moveable leg and that contacts the ground or outrigger pad to stabilize
flow through it when it is not actuated, and opens to interrupt current flow the mobile unit.
when actuated.
outrigger signal valve — a valve used to provide a signal to the pump
normally closed valve — a two-way valve which is closed to block fluid when the outriggers are being operated and to allow a separate signal
from flowing through it when it is not actuated, and opens to allow flow system to control the aerial device operation.
when actuated.
outrigger spread — the distance between the outer edges on fixed
normally open switch — a switch which is open to prevent current from shoes, or between pin centerlines on pivoting shoes, of opposite
flowing through it when it is not actuated, and closes to allow current outriggers which have been extended or deployed to a given position.
flow when actuated.
over travel — movement of a mechanism beyond its normal stopping
normally open valve — a two-way valve which is open to allow fluid to point.
flow through it when it is not actuated, and closes to block flow when
actuated.
overcenter aerial device — a type of articulating-boom aerial device platform heater — an electrically powered device mounted in a splicer
on which the upper boom can unfold from the stored position to beyond platform which is used to warm the occupant.
a vertical position. platform leveling system — a system which keeps the bottom of a
overframe — an outrigger weldment mounting position located above platform parallel to or at a fixed angle to the base plate of the turntable,
the vehicle chassis frame. or parallel to level ground, as the boom is raised or lowered. The system
overload — the condition existing when a load greater than the rated may be mechanically, hydraulically, or gravity operated.
capacity or design lead is applied to a unit or component. platform liner — a component made of material having a high
override — the takeover of boom movement control functions from the dielectric strength which is designed to be inserted into a platform to
platform controls by the activation of the lower control station controls. cover the walls and bottom of the platform.
overtighten — to torque a threaded fastener beyond the recom- platform pin — the horizontal pin that is used to fasten a platform
mended torque value. mounting bracket to the upper boom tip. The mounting bracket pivots
about this pin for platform leveling or positioning.
oxidation — the reaction of a substance with oxygen.
platform rest — the structural member attached to the chassis or body
parallel link — the secondary load-carrying structure of an elevator lift. to support and cushion the platform in the travel or rest position.
particle count — a visual count of the numbers of particulate contami- platform ring — a metal band around the lip of a splicer platform which
nants in a quantity of a hydraulic fluid. supports and guides the platform as it is rotated about its vertical
passage — a machined or cored fluid conducting path that lies within centerline.
or passes through a component. platform rotation override system — a system which allows the zone
payload — any tools, materials, fuel and occupants carried by the of platform rotation to extend beyond a predetermined limit when
mobile unit that are not permanently attached. actuated by the operator.
pedestal — the stationary base of a unit that supports the turntable and platform rotator — a system which allows the operator to rotate the
is attached to the subbase or vehicle frame. platform about a vertical axis. This permits the position of the platform
to be changed with respect to the boom tip.
pedestal mount — a mounting configuration for an aerial device in
which the turntable is mounted on a pedestal consisting of a box-like platform tilt system — a system which allows the operator to adjust the
structure. orientation of the platform about a horizontal axis. Some systems allow
the operator to adjust the working position of the platform floor and tilt
penetration — the distance the vehicle frame is lifted after the outrig- the platform for cleaning. Other systems allow tilting of the platform for
gers contact the ground surface. cleaning but do not provide for operator adjustment of the working
phase — a conductive wire or cable used for transmitting high voltage position.
electrical current. The phrase “phase to phase” can be referenced as platform use — the stability criteria for a digger derrick mobile unit
any two conductors of a three-phase electrical power line system. which indicates that the load capacity chart and stability requirements
pilot operated — condition in which a valve is actuated by hydraulic apply to the use of the derrick with the platform occupied, with no lifting
fluid pressure. of loads with the winch line.
pilot operated check valve — a check valve that can be opened to plunger — a cylindrically shaped part that is used to transmit thrust; a
allow flow in the normally blocked direction by applying hydraulic ram.
pressure to a pilot port. pole — a long cylindrical piece of material such as wood, metal, or
pilot pressure — auxiliary pressure used to actuate or control hydrau- concrete which is installed in a vertical position for use as a support
lic components. structure for power and communication lines.
pilot valve — an auxiliary valve used to control the operation of another pole guide — a mechanism at the tip of a boom used for guiding and
valve. stabilizing a utility pole while using the winch line to raise or lower the
pin — a cylindrical structural device used to allow a pivoting joint or to pole.
connect mating parts. pole guide tilt cylinder — the hydraulic cylinder which is used to tilt
pin retainer — a device which is used to hold a pin in place in an (raise or lower) the pole guide.
assembly. pole guide tong cylinder — the hydraulic cylinder which opens and
pinch point — a particular location in which a human body or a part of closes the pole guide tongs.
the body may become pinched or pinned between moving mechanical pole guide tongs — moveable arms on a pole guide used to stabilize
parts. and guide a utility pole as it is being raised or lowered with the winch line.
pinion — a gear with a small number of teeth that has been designed pole puller — an apparatus consisting of a hydraulic cylinder, chain
to mesh with a larger gear. and other components used to loosen a utility pole from the ground.
piston — a cylindrically shaped part that fits within a cylinder or pole setter — an assembly attached to the mast of a pressure digger
cylindrical bore and transmits or receives linear motion by means of a that is used to pick up, position, and set a pole.
connecting rod or other component. polyethylene — a moisture proof plastic.
piston pump — a pump in which motion and force are applied to fluid poppet — that part of certain valves that prevents flow when it closes
by a reciprocating piston(s) in cylindrical bore(s). against a seat and allows flow when it moves away from the seat.
pivot weldment — the structure located above the slide frame on a port — an internal or external opening for intake or exhaust of fluid in
pressure digger which supports the mast. a component.
placard — 1: a thin sheet of rigid material which is attached to another portable resistivity tester — a device used for testing the electrical
surface by adhesive and/or mechanical fasteners, and is used to resistance of water. Commonly used for testing the wash water for
convey instructions, information and warnings. 2: May also refer to a insulator washers.
decal.
position — a term which describes the number of possible positions a
planetary gear set — an assembly of meshed gears consisting of a valve spool or mechanism can be shifted to.
central gear (sun gear), a coaxial internal tooth ring gear and several
intermediate pinions (planet gears) supported on a revolving carrier. post mount — a mounting configuration for an aerial device in which
the turntable is mounted on a pedestal which utilizes a round vertical
planetary gearbox — a gearbox containing one or more planetary gear tube as its primary load-carrying structure.
sets.
potentiometer — a variable resistor that is connected to act as an
platform — the personnel-carrying component of a unit, mounted at the electrical voltage divider.
upper boom tip.
pour point — the lowest temperature at which a fluid will flow or pour
platform elevator — a mechanism, at the boom tip, to which the under specific conditions.
platform is mounted, allowing vertical motion of the platform with
respect to the rest of the boom tip. power — work per unit of time, measured in horsepower (HP) or watts.
power module — the central connection point between the chassis radial outrigger — an outrigger in which the moveable outrigger leg
and unit electrical systems. This device is used to provide battery pivots in an arc around a pin connection between the leg and a
power to the unit when the truck/machine selector is in the machine supporting structure as the leg is lowered and raised.
position. radio communication — communication by means of radio waves.
power take-off (PTO) — a supplementary mechanism enabling ram — 1: a single-acting cylinder with a single diameter plunger rather
vehicle engine power to be used to operate non-automotive apparatus than a piston and rod. 2: the plunger in a ram-type cylinder.
such as a pump.
ram cylinder — the hydraulic cylinder that is used to retract and extend
precharge pressure — the pressure of compressed gas in an the kelly bar on a pressure digger.
accumulator before any fluid is added.
ramp — an adjustable delay to govern the response of the hydraulic
pressure — the force applied in a given area. It can be expressed in valve when a unit is operated from the electronic controls.
pounds per square inch (psi).
range diagram — a diagram which shows the load radius and sheave
pressure compensator — a device on a variable displacement pump height of a digger derrick at all the configurations of boom extension and
that adjusts pump output flow to develop and maintain a preset boom angle covered by the corresponding load capacity chart.
maximum pressure.
rated capacity — (as defined by ANSI for digger derricks) the maxi-
pressure differential — the difference in pressure between two points mum load, specified by the manufacturer, that can be lifted by the digger
in a system or component. derrick at regular intervals of load radius or boom angle, through the
pressure drop — the reduction in pressure between two points in a line specified ranges of boom elevation and extension, with specified
or passage due to the energy required to maintain flow. options installed, and exclusive of stability requirements.
pressure gauge — an instrument which displays the hydraulic or rated line voltage — the nominal voltage, phase to phase, at which
pneumatic pressure sensed at a port on the device. electrical systems are rated.
pressure line — the line carrying fluid from a pump outlet to the rated load capacity — (as defined by ANSI for aerial devices) the
pressurized port of a valve or actuator. maximum loads, specified by the manufacturer, which can be lifted by
pressure override — the difference between the cracking pressure of the aerial device through the specified range of boom elevation and
a valve and the pressure reached when the valve is passing full flow. extension with specified options installed and in consideration of
stability requirements.
pressure reducing valve — a pressure control valve whose primary
function is to limit its outlet pressure. reach diagram — a drawing that shows the horizontal and vertical
limits of travel of the platform, upper boom tip, and/or jib tip throughout
pressure switch — an electric switch which is actuated when the all possible configurations of lower boom angle, boom extension, upper
hydraulic or pneumatic pressure applied to a port on the switch reaches boom angle, articulating arm travel, and/or elevator lift travel.
a specified value.
rear mount — a pedestal mounting position located over or near the
pressure transducer — a pressure measuring device which produces rear axle(s) on the longitudinal centerline of the chassis.
a variable electrical signal that is proportional to the hydraulic pressure
applied to a port on the device. receiver — a device that converts radio waves into electrical signals for
communication and/or control purposes.
proportional circuit — a circuit that supplies a varying voltage to a coil
in a pilot valve as electrical current applied to the circuit is varied by a reel brake — a component of the reel driver which prevents the
hand control. overrunning of cable reels carried by a strand carrier and reel lifter. The
brake is used to maintain tension in the cable or suspension strand
proximity alarm — a system which measures the distance from a when used with the reel driver.
detector to another object, and sounds an alarm when this distance is
less than a specified value. Commonly used to inform the operator of reel driver — a component of a strand carrier and reel lifter used for
an HLIW of the distance between the boom tip nozzle and a power line paying in or paying out cable or suspension strand.
insulator or support structure. reel lifter — a device used to support and move cable reels from the
psi — pounds per square inch. ground to the vehicle.
PTO — see power take-off. reel lifter arms — the structure on a reel lifter used to lift and store reels
of cable or suspension strand on the chassis.
pullout upper controls — an upper control panel on a digger derrick
which is mounted on a housing that can be extended from inside an reengage — to repeat the activation of a function after it has been
outer housing when additional length is needed, such as to attach the momentarily halted.
control panel to a personnel jib with the outer housing attached to the relay — an automatic switch with contacts that can be closed or opened
upper boom tip, or to attach the upper control panel to the upper boom by electrical current in a coil.
tip with the outer housing attached to the transferable boom flares. relief valve — a pressure operated valve that bypasses pump delivery
pulse width modulation (PWM) — a means of transmitting a digital to the reservoir to limit system pressure to a predetermined maximum
signal in continuous cycles of pulses where the total length of time for value.
a cycle of one “on” pulse and the following “off” period is constant, and remote arm — a remotely operated jib used to handle equipment or
the length of time (width) of the “on” pulse within each cycle is varied electrical lines.
(modulated) in proportion to the level of an input parameter such as
control lever position. remote assist — a vehicle-mounted device with a boom assembly
which is extendible, articulating, or both, which is designed and used to
pump — a device that converts mechanical force and motion into accommodate attachments for performing operations such as support-
hydraulic flow and pressure. ing or cutting electrical conductors, lifting or holding objects, or cutting
purge system — a system of check valves that allows hydraulic fluid tree branches. It is operated by remote control from the ground or from
flow in a reverse manner through the hydraulic system, usually from the the platform of an adjacent personnel lifting device. It may be mounted
lower control valve to the upper controls. This actions frees or purges on the vehicle by itself or in addition to a personnel lifting device.
the control system of any trapped air and restores a solid column of fluid remote control system — a system used for operating some or all of
for precise control. The purge system may also be used to warm up the the functions of a unit from a portable control station. The control station
control system in cold weather conditions if the fluid in the reservoir is may be a transmitter which sends signals by radio waves to a receiver
warm. on the unit, or a control module which sends signals through a fiber optic
purge/upper/lower controls selector valve — a valve which is used or electrical cable to the unit.
to direct hydraulic fluid to the purge system, the upper control valve, or remote operated auxiliary control system (ROACS) — a radio
the lower control valve. controlled system for starting and stopping certain functions of the
PWM — pulse width modulation. mobile unit.
quick disconnect couplings — hydraulic fittings designed for fast and remote start/stop system — the components used to actuate a
easy attachment and separation. function of the unit from a location other than for normal operation. The
radial ball bearing — an antifriction bearing with rolling ball contact in most common functions controlled are engine start/stop and the
which the direction of action of the load transmitted is perpendicular to secondary stowage DC pump.
the axial centerline of the bearing.
reservoir — a container for storage of liquid in a fluid power system. saybolt universal viscosity — A measure of viscosity equal to the
resistance — the opposition to the flow of electricity or hydraulic fluid. time it takes in seconds for 60 milliliters of fluid to flow through a capillary
tube in a Saybolt universal viscosimeter at a given temperature.
restriction — a reduced cross-sectional area in a line or passage that
produces a pressure drop. scissor link — the mechanical linkage on a reel lifter used to connect
the lifter cylinder to the arm.
retaining ring — a hardened, washer-like ring that may be spread
apart or compressed and installed into a groove or recess to serve as screw anchor — a rod with an eye on one end and auger flighting on
a retaining device. the opposite end. It is designed to screw into the ground and serve
as an anchor to hold an attached cable such as a guy wire.
return line — a hydraulic line used to carry discharge flow from a
hydraulic system or actuator back to the reservoir at low pressure. seating in — an initial microscopic surface deformation of compo-
nents that are clamped together with threaded fasteners. This causes
return line filter — a filter located in a hydraulic system return line or a slight reduction in the dimension of the components, reducing the
at the inlet of a hydraulic reservoir which cleans fluid flowing from the clamping force applied by the fasteners.
hydraulic system to the reservoir.
secondary stowage DC pump — a low flow hydraulic pump driven
reversing valve — a four-way directional valve used to change the by a direct current electric motor. This pump is used to provide
direction of movement of a double-acting cylinder or reversible motor. hydraulic flow to stow the unit when the system for normal operation
ribbon hose — a group of hoses that are attached side by side to has failed.
produce a flat bundle. Commonly used to carry hydraulic fluid, air and/ secondary stowage system — those components used to stow the
or electrical cable(s) to the boom tip or upper controls. unit when the system for normal operation has failed.
riding seat — an operator’s control station attached to the side of the selector switch — a switch which is used to direct electrical current to
turntable, with a seat on which the operator rides with the rotation of the one of two or more electrical circuits.
unit.
selector valve — a valve which is used to direct hydraulic fluid to one
riser — 1: the structure on a double elevator that connects the lower of two or more hydraulic circuits.
elevator arm to the upper elevator arm. 2: the structure within an
articulating arm to which the lower boom is connected. self-locking nut — a nut which contains a built-in device or shape to
increase thread friction so as to resist loosening due to vibration or
ROACS — see remote operated auxiliary control system. repeated loading.
rod — the cylindrically shaped part of a cylinder which extends and self-lubricating bearing — an antifriction bearing in which lubricating
retracts from the barrel to actuate or move a component. material is incorporated in the bearing.
rod end — the end of a cylinder that the extending component or rod sense line — a line that carries a hydraulic pressure signal from a valve
is on. or actuator to the compensator control on a variable displacement
roller — a cylindrical device which spins freely about a pin or shaft, used pump.
to guide the motion of another component. sense selector valve — a valve which prevents hydraulic fluid in the
rollpin — a pin that has been formed by rolling up a thin, flat strip of sense line from reaching the pump until a certain function(s) is oper-
metal to form a cylinder. Commonly used by being driven into a hole to ated.
serve as a retaining device. sequence — 1: the order of a series of operations or movements. 2: to
rope — a stout, flexible cord, which consists of many strands of wire divert flow to accomplish a subsequent operation or movement.
or fibers that are twisted or braided together. sequence valve — a pressure operated valve that diverts flow to a
rotary actuator — a device for converting hydraulic energy into rotary secondary actuator while holding pressure on the primary actuator at a
motion and torque in which the rotary motion is restricted to within predetermined minimum value after the primary actuator completes its
certain angular limits. travel.
rotary joint — a multiple port manifold that has a rotating portion and sequential extension — the operation by which one boom section in
a stationary portion, used to provide a continuous hydraulic connection an extendible boom assembly reaches full extension or retraction
between rotating and stationary hydraulic lines. Commonly used at the before the next boom section begins movement.
centerline of rotation of units equipped with continuous rotation. set screw — a short screw, typically with an Allen type head, that is
rotate frame — the structure located above the stationary frame on a used as a clamp to bind parts together.
pressure digger that is used to support and rotate the slide frame. shackle — see clevis.
rotating platform — a platform which can be rotated about a vertical shear — an action or stress resulting from opposing applied forces that
axis to change its position in relationship to the boom tip. attempt to separate a part into two pieces that would then slide along
rotation bearing — the rotating member, usually a shear ball bearing, each other in opposite directions along the plane of separation.
located between the pedestal and the turntable which allows the shear ball bearing — an antifriction bearing with rolling ball contact in
turntable to rotate and which contains gear teeth that mesh with the which the direction of load transmitted through the balls is parallel to the
rotation pinion. axial centerline of the bearing, producing shear loading on the balls.
rotation chain — a chain attached to the stationary frame of a pressure The bearing can support axial, radial, and tilt loading. Commonly used
digger that is used by the rotation gearbox to rotate the rotate frame. as a rotation bearing.
rotation gearbox — the gearbox which drives the rotational motion of shear pin — a replaceable pin which prevents motion between two
the turntable. adjacent parts by the production of shear loading in the pin, and which
may be designed to fail under overload to protect other parts.
rotation pinion — the gear on the output shaft of the rotation gearbox
which meshes with the rotation bearing gear teeth and drives the shear stability — resistance of a hydraulic fluid viscosity index im-
turntable rotational motion. prover additive to shearing.
rotation resistant wire rope — wire rope which is constructed to resist shearing — molecular damage or breakdown of the viscosity index
the tendency to untwist or rotate when carrying a suspended load. This improver additive in hydraulic fluid. Shearing can occur when the fluid
is accomplished by laying the outer strands in the opposite direction to flows through fine clearances at high velocity. Shearing can cause
the lay of the inner strands or core. permanent loss in fluid viscosity.
rotation system — the system which drives the rotation of the turntable sheave — a grooved wheel used to support and guide a winch line or
about the centerline of rotation. It typically consists of a rotation bearing, leveling cable at a point of change in the direction of motion of the line
rotation gearbox, hydraulic motor, and load holding valve. or cable.
rpm — revolutions per minute. sheave height — the vertical distance from ground level to the
centerline of the boom tip sheave in a digger derrick upper boom tip.
running torque — the torque produced by a rotating device such as a
motor or gearbox at a specified rotational speed. short circuit — an inadvertent path of low resistance established
between two points of an electrical circuit. A short circuit will result in
SAE — Society of Automotive Engineers. excessive current flow.
safety belt — see body belt. shutoff valve — a device which is used to stop hydraulic fluid flow.
shuttle valve — a three-port valve that accepts hydraulic fluid speed reducer — see gearbox.
pressure from two inlets and allows only the highest pressure fluid to spherical bearing — a bearing with a spherically shaped inner race
pass through it to a single outlet while keeping the inlet fluid pressure that is allowed to move freely inside a stationary outer race to accom-
isolated from one another. modate misalignment.
side gun — a hand held water nozzle and hose that can be used from splicer platform — a fiberglass platform equipped with a door and
the ground for washing or fire fighting. latch.
side load — an external horizontal load placed on a boom from one spline — one of a number of equally spaced, load carrying teeth that
side. have been cut on the outside diameter of a shaft or inside diameter of
side load protection system — the system on a digger derrick that a bore, parallel to the shaft or bore centerline.
helps prevent damage to the digger derrick structure when excessive spool — a moving, cylindrically shaped part of a hydraulic valve that
side loads are applied to the booms. moves to direct flow through the valve.
side-mounted platform — a platform which is attached to a mounting spring lockouts — a mechanical system which is engaged to keep a
bracket that extends from one side of the boom tip, positioning the vehicle’s suspension system from flexing during operation of the unit.
platform (and platform rotation pivot, if so equipped) beside the boom
tip. sprocket — a wheel with teeth along the circumference which are
shaped so as to engage with a chain, used to support and guide the
sideslip — sideways motion of a component caused by an externally chain at a point of change in the direction of motion of the chain.
applied sideways force which overcomes resistive forces from hydrau-
lics, friction, etc. Commonly used to describe rotation of a digger derrick SSU (Saybolt Second Universal) — the unit of measure for Saybolt
boom caused by side loading which exceeds the side load protection universal viscosity.
setting. stability — a condition of a mobile unit in which the sum of the moments
signal — a command or indication of a desired position, velocity, flow which tend to overturn the mobile unit is less than the sum of the
or pressure. moments tending to resist overturning; the mobile unit’s ability to resist
tipping.
signal line — see sense line.
stabilize — to provide adequate stability for a mobile unit to allow
single-acting cylinder — a cylinder in which fluid pressure can be operation of the vehicle-mounted device(s).
applied to move the rod in only one direction. Return motion is produced
by an external force such as a spring or gravity. stabilizer — a device used to assist in stabilizing a mobile unit, such as
an outrigger, torsion bar or spring lockout.
single elevator — an elevator lift with one load carrying arm. The
single elevator system includes a lower pedestal, arm, arm cylinder(s), stake — to slightly deform the threads of a fastener or material at the
parallel links, and upper pedestal. joint between two components by placing the blade of punch or chisel
on the threads or joint and tapping on the handle with a hammer. The
single handle control — a control, with an interlock trigger incorpo- deformed material serves to prevent loosening of the components.
rated in the handle, which allows the operator to simultaneously control
multiple functions of the booms and turntable from the platform. stall torque — the torque produced by a rotating device such as a motor
or gearbox at zero rotational speed.
single-pole, double-throw (SPDT) switch — a three-terminal electri-
cal switch or relay that connects one terminal to either of two other standard option — an option which can be ordered from a standard
terminals. order form and can be supplied without additional engineering work.
single-pole, single-throw (SPST) switch — a two-terminal electrical start/stop control module — an electrical device that relays signals
switch or relay that opens or closes one circuit. from the unit’s remote start/stop system to the component(s) or system(s)
being controlled, such as the secondary stowage DC pump and/or
slave control panel — a secondary derrick lower control panel that is vehicle ignition system.
configured as a remote terminal of the master panel. The slave panel
is used in conjunction with a master panel to provide dual station lower stationary frame — the structure attached to the subbase of a pressure
controls. digger that supports the outriggers and rotate frame.
slave cylinder — a cylinder in which motion of the piston is produced stationary platform — a platform which can not be rotated about a
by the transfer of hydraulic fluid from a master cylinder, resulting in vertical axis to change its position in relationship to the boom tip.
corresponding motion. stow — to place a component such as a boom or digger derrick auger
slide frame — the structure on a pressure digger used to support the in its rest position.
auxiliary engine, hydraulic reservoir, control station, and pivot weld- strainer — a coarse filter.
ment. The slide frame can be extended horizontally from its stowed
position to adjust the distance of the kelly bar from the rotate frame. strainer basket — a coarse, basket shaped filter which is mounted in
the fill hole of a reservoir and projects into the reservoir.
slide pad — a rectangular block used as a bearing between extendible
boom or outrigger sections, usually composed of a non-metallic mate- strand — 1: one of the groups of individual fibers or wires within a
rial. synthetic winch line or wire rope. 2: see suspension strand.
slip ring — an assembly of one or more conductive, rotating rings and strand carrier — a device used to support and transport strand reels
stationary brushes used to provide a continuous electrical connection on a vehicle.
between rotating and stationary conductors. Commonly used at the strand reel — a reel or spool used for carrying suspension stand.
centerline of rotation of units equipped with continuous rotation. street side — the side of a vehicle toward oncoming traffic when the
slug face — the extreme end of the cable slug which is secured to the vehicle is traveling forward in the normal direction in a lane of traffic.
cylinder rod or adjusting stud. stroke — 1: total linear movement in either direction of a piston or
snatch block — a device which has a means of attachment to connect plunger. 2: to change the displacement of a variable displacement
it to a boom or load, and which can be opened to receive a winch line pump or motor.
around an internal sheave. subbase — a structural mounting interface between the pedestal and
snubber valve — a two-port valve with a manually adjustable orifice the vehicle frame. It provides torsional stiffness and strength in addition
that restricts the flow of fluid through the valve. to that which would be provided from the vehicle frame alone.
socket head — a cylindrical cap screw head design containing a subweldment — a smaller welded subassembly used within a more
hexagonal (six-sided) female socket into which an Allen wrench can be complex welded structure.
inserted to turn the cap screw. suction filter — a filter located in a hydraulic system suction line or
solenoid — a coil of insulated wire that produces a magnetic field within at the outlet of a hydraulic reservoir which cleans fluid flowing from the
the coil when electrically energized. When attached to a hydraulic reservoir to the pump inlet.
valve, the magnetic field acts upon the valve to move internal valve suction line — the hydraulic line connecting the pump inlet port to the
parts. reservoir outlet.
solenoid valve — a valve which is actuated by a solenoid to controlling surge — a momentary rise of pressure in a circuit.
the flow of hydraulic fluid.
suspension strand — a type of wire rope which is used to support trim pot — a potentiometer which is used to make fine adjustments
the weight of an attached communication cable suspended between in a circuit during manufacture or calibration, typically by turning a
poles or other overhead support structures. slotted adjusting screw.
swage — to taper or reduce the diameter of a rod, tube or fastener by troubleshoot — to locate and diagnose problems in a system or a
forging, squeezing or hammering. component.
synthetic winch line — a winch line made from nonmetallic synthetic trunnion — a mounting device consisting of a pair of opposite,
fibers which are formed into strands that are then braided together to projecting cylindrical pivots on which something can be rotated or tilted.
make a complete rope. trunnion bearing — a bearing that a trunnion pin pivots in.
T-stand — a “T” shaped weldment for mounting lower controls to the trunnion pin — a cylindrical pivot pin that is a part of a trunnion.
vehicle.
turnbuckle — a link with screw threads at both ends that is turned to
tachometer — an instrument used for displaying the speed of rotation bring the ends closer together for tightening purposes.
of an engine output shaft.
turns from finger tight (T.F.F.T.) — a method of counting the number
tailshelf — the rear portion of the mobile unit above and behind the rear of turns of a hydraulic adapter to establish a torque value.
axle.
turntable — the structure located above the rotation bearing which
tailshelf tools — see lower tool circuit. supports the lower boom or articulating arm, and rotates about the
tank — the hydraulic reservoir. centerline of rotation.
telescopic — having sections that slide within or over one another to turntable winch — a winch located on the turntable.
change overall length. turret — see turntable.
terminal block — an insulating mounting used for making electrical two-man platform — a platform designed to carry two people. It is
terminal connections. usually 24″ wide x 48″ wide.
test block — a manifold with ports for connecting a hydraulic pressure two-part line — a multiple-part line on a digger derrick in which the
source, pressure gauge and a cartridge valve such as a counterbalance winch line is routed from the boom tip sheave down to a snatch block
valve or relief valve used for testing and adjusting the relief setting of the at the load and then back up to a stationary attachment point on the
valve. boom.
thimble — a metal ring around which a rope is passed and spliced to two-position valve — a valve having two positions for direction of fluid
make a loop or eye. flow, such as open and closed.
thread locking adhesive — an anaerobic adhesive that is applied to two-speed motor — a motor which has two operating speed and
fastener threads to prevent loosening due to vibration or repeated torque modes (a low-speed, high-torque mode, and a high-speed, low-
loading. torque mode) that can be selected by the operator.
three-phase — a system for transmitting high voltage, alternating two-way valve — a valve having two ports for direction of fluid flow, with
current, electrical power along three separate conductors, with 120 one internal flow path which can be open or blocked.
degrees between the voltage waveform cycles of any two conductors.
UNC — Unified National Coarse, a thread description.
three-position valve — a valve having three positions for direction of
fluid flow, such as neutral, flow in one direction, and flow in the opposite underframe — an outrigger weldment mounting position located
direction. beneath the unit subbase or vehicle chassis frame.
three-way valve — a valve having three ports for direction of fluid flow. undertighten — to torque a threaded fastener below the recom-
mended value.
threshold — the amount of signal (starting power) given to a control
valve when the control is just moved from neutral position. UNF — Unified National Fine, a thread description.
throttle control — a manual, hydraulic, or electrical device used to unfold — to move a pivoting structure such as an articulating upper
regulate vehicle or auxiliary engine speed. boom away from its stowed position.
toggle switch — an electrical switch operated by a short projecting unit — the Altec device(s), subbase, outriggers, body and associated
lever combined with a spring to quickly open or close a circuit when the interface items mounted on a chassis, but not including the chassis
lever is pushed through a small arc. itself.
topping cylinder — see lift cylinder. unload — to release hydraulic flow, usually directly to the reservoir, to
prevent pressure buildup.
torque — 1: a rotational twisting force. 2: to preload a threaded fastener
by application of a rotational twisting force. unloaded vehicle weight — the total weight of the completed mobile
unit without payload.
torque converter — a rotary device for transmitting and amplifying
torque, especially by hydraulic means. unloading valve — a valve that bypasses flow to the reservoir when a
set pressure is maintained on its pilot port.
torsion bar — a rod-like spring which is flexed by being twisted about
its axis, used to assist in stabilizing a mobile unit. upper arm — the primary load-carrying structure of a double elevator
which is located between the riser and the upper pedestal.
tow line winch — a winch located on a cable placer which is used for
tensioning suspension strand or self-supporting cable or towing a cable upper arm cylinder — the hydraulic cylinder that moves the upper arm
lasher. of a double elevator up and down.
trace element analysis — analysis of a small sample of hydraulic fluid upper boom (UPR BOOM) — the boom section in a boom assembly
to determine contamination level and condition of additives. which is farthest from the turntable when the boom assembly is fully
extended or unfolded, and which supports the boom tip sheave and/or
tracking — a current leakage path created across the surface of platform(s).
insulating material when a high-voltage current forms a carbonized
path within a foreign material on the surface. upper boom cylinder — the hydraulic cylinder that moves the upper
boom about its pivot point on an articulating-boom aerial device.
transducer — a device that converts input energy of one form into
output energy of another, such as hydraulic pressure into an electrical upper boom drive mechanism — the components used to produce
signal. upper boom movement on an articulating boom-aerial device, such as
linkage, cables, sheaves and/or gears.
transferable boom flares — boom flares, on which a pole guide may
be mounted, that can be pinned to either the intermediate boom tip or upper boom rest — the structural member that supports the upper
the upper boom tip of a digger derrick. boom in the rest or travel position.
transferable upper controls — an upper control panel on a digger upper boom tip — the boom tip of an upper boom.
derrick that can be attached to either the upper boom tip or the upper control valve — the hydraulic valve on or beside the platform
transferable boom flares by the use of a detent pin. of an aerial device used for operating some or all of the functions of the
transmitter — a device used to generate and emit a radio frequency aerial device.
carrier signal. The signal is sent to a receiver which translates the
signal into usable information.
upper controls — the controls located on or beside the platform used extending leg, so that the leg assembly rotates about the pivot point
for operating some or all of the functions of the unit. to increase the outrigger spread as it is extended.
upper pedestal — the structure within an elevator lift that connects warning — an instruction that indicates a potentially hazardous
the elevator lift to the aerial device rotation bearing. situation which, if not avoided, could result in death or serious injury.
upper tool circuit — a tool hydraulic circuit with quick disconnect water monitor — an articulating mechanism that is used to direct the
couplings located at the upper boom tip. flow of a high pressure water stream.
vacuum — the absence of pressure. A perfect vacuum is the total water removal filter cartridge — a special filter cartridge designed
absence of pressure; a partial vacuum is some condition less than to absorb and remove water from hydraulic fluid. It is not intended for
atmospheric pressure. Vacuum is measured in inches of mercury (in. use during normal operation, but is for use when water removal is
Hg.). required.
valve — a device that controls fluid flow direction, pressure or flow rate. way — a term which describes how many ports are in a valve or valve
vane pump — a type of pump with a rotor and several sliding vanes section.
in an elliptical chamber. Hydraulic fluid enters the expanding area and weldment — a structural unit formed by welding together an assembly
is forced out as the fluid is moved to the decreasing chamber area. of pieces.
variable displacement pump — a pump in which the size of the wheel chock — a wedge or block placed on the ground in front of or
pumping chamber(s) can be changed, so that the output flow can be behind the wheel of a vehicle to block the movement of the wheel.
changed by moving the displacement control or varying the drive speed winch — a mechanism consisting of a gearbox with a cylindrical
or both. rotating drum on which to coil a line for load hoisting or line tensioning.
vehicle — a carrier for a unit. winch capacity — the maximum load, specified by the manufacturer,
velocity — the speed of linear motion in a given direction. that can be pulled on the first layer of line on the winch drum at rated
velocity fuse — a hydraulic valve that is used to stop fluid flow through system pressure.
it when the flow rate reaches a predetermined cut-off value. winch line — a load hoisting line consisting of a synthetic or wire rope.
vent — an air breathing device on a fluid reservoir or hydraulic line. winch line rated working load — the average breaking strength of a
VI — see viscosity index. winch line (as specified by the line manufacturer) divided by the
appropriate design factor as specified by ANSI.
viscosity — a measure of the internal friction or resistance to flow of a
fluid. wire rope — a rope made from steel wires which are formed into
strands that are then twisted about each other in a spiral configuration.
viscosity index (VI) — a measure of the resistance to change in
viscosity of a fluid with change in temperature. The higher the number, work — the exertion of a force moving through a definite distance. Work
the less the viscosity will change as the temperature changes. is measured in units of force multiplied by distance; for example, pound-
feet.
voltmeter — an instrument used to measure the potential difference in
volts between two points in an electrical circuit. worm gearbox — a gearbox that utilizes a gear which has a continuous
helix tooth or teeth similar to a large screw thread along shaft (worm),
volume — 1: the size of a space or chamber in cubic units. 2: loosely that drives a gear which has teeth cut at an angle along a its outside
applied to the output flow of a pump in gallons per minute (gpm). diameter (worm gear). The rotational axis of the worm is perpendicular
vortex — a whirlpool of liquid. to the rotational axis of the worm gear.
waist harness — a belt device worn by the operator of a radio remote wrap — a single coil of winch line on a winch drum.
control system to which the transmitter is attached. Y-cable — an electrical cable assembly which contains three branches
walking beam outrigger — an extendible outrigger which has a pivot joined at a common point, similar to a “Y.”
point at the top of the nonextending leg and a linkage attached to the zerk — see grease fitting.
Service Tools and Supplies
Most routine maintenance and service of the unit can be corresponding Altec part number. The list contains items
performed with common hand tools and shop supplies for both aerial devices and derricks. An Accessory and
available from a tool supply company. Some special tools Replacement Parts Catalog is also available for ordering
and supplies are available from your Altec representative other items that may not be shown in the Parts Manual.
that may be useful or required to perform certain mainte- This catalog can be obtained through your Altec represen-
nance procedures. These items are categorized with their tative.
Product Purpose/Use Part Number

Lubrication
Gear Shield Lubricate rotation gears and pinions. 099-00017
Chain and Cable Fluid Lubricate cables such as wire rope winch line, auger windup 099-00018
sling, and leveling cables or chains.
Moly grease Component lubrication. 099-00025
Anti-seize compound (16 oz can) Component lubrication. 099-00033
Anti-seize compound (1/4 lb tube) Component lubrication. 099-00050
Fasteners
Thread locking adhesive Low strength thread locking and sealing agent for small 099-00019
(Purple 50 ml) diameter screws.
Thread locking adhesive Medium strength thread locking and sealing agent for bolts 099-00020
(Blue 50 ml) and nuts.
Thread locking adhesive High strength thread locking and sealing agent for large 099-00037
(Red 50 ml) diameter bolts and cap screws.
Thread locking adhesive Medium/high strength thread locking agent. 099-00069

(Red 50 ml)
Inspection lacquer, blue (1/2 oz) Visual inspection stripe. 099-00123
Cleaner for inspection lacquer (1/2 oz) Visual inspection stripe removal. 099-00124
Stainless steel safety wire Lockwiring fasteners. 099-00021

(5 lb roll)
Cleaning solvent (12 oz) Quick drying, nonflammable solvent used for cleaning parts 099-00039
prior to bonding. Leaves no residue.
Primer (Grade N — 6 oz) Anaerobic solvent reduces cure time on thread locking 099-00040
adhesive.
Primer (Grade T — 6 oz) Anaerobic solvent reduces cure time on thread locking 099-00041
adhesive.
Wire twisting pliers Lockwiring fasteners. 099-60007
Appendix — Service Tools and Supplies

Product Purpose/Use Part Number
Fiberglass Care
Gelcoat kit Repair fiberglass platforms and booms. 041-90001
Formula Five Clean ’N Glaze Cleaning and polishing fiberglass. 041-90002
Plastic Kleen #2 Polish Nontoxic plastic cleaner. 099-00062
Bonding kit Rebond fiberglass booms. 703-50039
White paint Nonmetallic spray paint. 099-00008
Hydraulic System Care
Pipe sealant (50 ml) General purpose pipe sealant for use on pipes to 2″. 099-00038
Flowmeter Testing hydraulic system. 099-00034
Test block — small bore (7/8″ hex) Testing counterbalance valve. 352-79006
Test block — large bore (11/8″) Testing counterbalance valve. 352-79008
Return line filter cartridge Filters hydraulic oil before it is returned to the reservoir. 353-30007
Water removal filter cartridge Removes water from the hydraulic system. 353-30016
Diagnostic test kit Testing hydraulic systems. 356-90002
Oil warming kit Warm hydraulic oil to operating temperature in cold weather. 750-40039
Corrosion suppressant Chrome cylinder rod protection. 099-00051
Electrical System Care
Conformal coating (14 oz) Silicon based electrical component protection. 099-00042
Lectra-Motive Electric Clean and degrease electrical systems. 099-00061

Parts Cleaner (19 oz)
Miscellaneous
Leveling cable kit Parts for the mandatory leveling cable change. 750-40106
4,000 lb dynamometer Test side load protection system. 099-00022
Atmospheric vent valve tester Test atmospheric vents for proper operation. 356-90042
Brake torque adapter Winch brake adjustment. 415-08042
Appendix — Service Tools and Supplies

Preventive Maintenance and Inspection Checklist
Vehicle No. __________________________ Location ____________________________ Date __________________
Model Number _________________________________ Serial Number _____________________________________
Odometer _________________ Hours Meter _________________ Inspector ________________________________
Perform all inspections, adjustments, repairs, and lubrication according to Altec specifications in the Maintenance
Manual. Refer to any MABs, CSNs, or other applicable documents provided by Altec for servicing the unit.
If you are tracking PTO hours utilizing an approved method or device, follow the recommended hourly maintenance
intervals, or if you are performing maintenance based upon a calendar-based schedule, follow the recommended monthly
intervals. The required items apply to both interval-tracking systems.
Intervals
R Prior to placing unit in service R 85 PTO hours/1 month R 500 PTO hours/6 months
R 1,000 PTO hours/1 year R 2,000 PTO hours/2 years R Required maintenance
Symbols
= Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
Prior to Placing Unit in Service

Perform the Daily Preoperational Inspection Rotation Bearing
(refer to the Operator’s Manual) Turntable tilt measurement2: ___________
Hydraulic Reservoir and System
Check oil and collect oil sample for analysis1
85 PTO Hours/1 Month
Perform the Daily Preoperational Inspection Fiberglass Boom(s)
(refer to the Operator’s Manual) Upper boom (condition, clean)
General Condition Lower boom (condition, clean)
Clean debris from around upper boom cylinder/linkage Lubrication
Clean debris from around platform leveling sheaves Elevator base and pedestal cylinder pivot bearings
Hydraulic Reservoir Elevator arm link pivot pins
Oil level Rotation bearing ball race
Hydraulic System Lower boom cylinder pivot bearings
Pedestal (no leaks) Rotation pinion and bearing gear teeth
Turntable (no leaks) Elbow bearing ball race
Elbow (no leaks) Platform tilt pin
Boom tip (no leaks)
500 PTO Hours/6 Months
Perform the 85 hour/1 month inspection 4-bolt flange cap screws secure
PTO Drive line
Operation, noise level, no leaks Noise level
Mounting cap screws secure No leaks
Supplemental Brake Lock Unit Mounting
Operation (holding, no bleed-off) Subbase mounting (fasteners secure, welds intact,
Chassis Underside no cracks)
Hoses (routing, condition) Subbase structure (welds intact, no cracks)
Exhaust shields Pedestal mounting (fasteners secure, welds intact,
Pump no cracks)
Mounting cap screws secure Boom rest (welds intact, no deformation or cracks)
Appendix — Preventive Maintenance and Inspection Checklist

Utility body mounting (cap screws secure, welds intact, Hydraulic System Pressure
no cracks) Pump compensator (3,000 psi)
Hydraulic Reservoir Standby pressure (350 psi)
Mounting (cap screws secure, welds intact, no cracks) Pilot system (350 psi)
No leaks Tool system pressure (2,000 psi)
Shutoff valves fully open Lower Controls
Drain water from bottom Placards (condition, readable)
Filters Operation (metering, proper direction)
Change return line filter Pedestal
Clean or change purge line filter Structure (welds intact, no deformation or cracks)
Clean or change outrigger signal valve cartridge Hoses and tubes (routing, condition)
Outriggers No leaks
Mounting (welds intact, no deformation or cracks) Rotary joint mounting cap screws secure
Machine/outrigger selector operation Slip ring mounting cap screws secure
Operation (holding without drift, no leaks) Placards (condition, readable)
Structures (welds intact, no deformation or cracks) Turntable
Pins and retainers secure, retaining cap screws secure Structure (welds intact, no deformation or cracks)
Motion alarm Boom pin and retainers secure
Hoses and tubes (routing, condition) Lower boom cylinder pivot pin and retainers secure
Placards (condition, readable) Leveling chain anchor pin (retainer condition, in place)
Control valves (operation, leaks) Hoses and tubes (routing, condition)
Lower Tools Circuit No leaks
Operation, no leaks Placards (condition, readable)
Hoses (routing, condition) Rotary joint drive pin (condition, retainer in place)
Quick disconnect couplers (condition, operation, Boom stow valve (operation, condition, no leaks)
dust caps) Rotation Bearing and Gearbox
Below Rotation Controls Gearbox mounting cap screw visual inspection
Operation Motor mounting cap screws secure
Placards and decals (condition, readable) Eccentric ring lock (in place, secure)
Elevator control valve (operation, no leaks) No leaks
Emergency operating DC pump operation Rotation bearing and pinion gear teeth condition
Lift Arms Pinion to rotation bearing gear backlash
Structure (welds intact, no deformation or cracks) Gearbox internal lost motion
Pivot pin (retainer condition, no deformation, lockwired) Operation (smoothness, noise level)
Arm rest pads (condition, in place) Rotation bearing cap screw visual inspection
Parallel Links Rotation bearing inspection and measurement (after
Structure (welds intact, no deformation or cracks) 0.050″ increased wear from initial measurement)2
Pivot pin (retainer condition, no deformation, lockwired) Lower Boom Cylinder
Elevator Lift Cylinder Pivot bearings secure within cylinder eyes
Self-aligning pivot bearings secure within cylinder eyes Pin retainers secure
Operation Operation, no leaks
No leaks Holding valves (operation, no leaks)
Chromed rod condition Chromed rod condition
Barrel condition Lower Boom
Upper and Lower Pedestals and Riser Structure (welds intact, no deformation or cracks)
Welds intact (no deformation or cracks) Lift cylinder pivot pin and retainers secure

Insulator fasteners secure Platform angle (leveling system tension)
Insulator (condition, clean) Liner (condition, clean, fasteners secure)
Leveling rods/cables Placards (condition, readable)
Jam nuts on leveling cable turnbuckles (in place, secure, Hoses (routing, not pinched or pulled, no leaks)
lockwires in place) Lanyard attachment secure
Cable keepers (placement, clearance) Covers in place
Remove any debris from inside lower boom Upper Controls
Hose routing (condition, no leaks) Operation (metering, proper direction, no leaks)
Elbow Emergency stop operation
Elbow bearing cap screw initial torque inspection 4
Mechanical linkage (operation, adjustment)
Elbow bearing cap screw visual torque inspection Rubber boot (condition, in place)
Leveling shaft retainers Single handle control isolating links (condition, clean)
Upper boom drive mechanism (condition, cap screws Interlock linkage (condition, adjustment)
secure and lockwired, rollpin in place) Engine start/stop control
Cover (in place, condition) Placards (condition, readable)
Hoses (routing, condition, no leaks) Tools at Platform
Leakage monitor system (condition, secure) Quick disconnects (condition, operation, no leaks)
Upper Boom Quick disconnect dust caps (condition, in place)
Structure (welds intact, no deformation or cracks) Hoses (routing, condition, no leaks)
Fiberglass fasteners secure Material Handling Package
Fiberglass (condition, clean) Fiberglass condition
Jam nuts on leveling turnbuckles (in place, secure) Bracket and mounting pins (condition)
Leveling rod/cables Sheave (condition, turns freely)
Covers in place Sheave pin and retainer secure
Upper boom restraint (condition, operation) Placards (condition, readable)
Upper boom stow pad (condition, in place) Jib operation (tilt and extension)
Boom tip weldment (welds intact, no deformation Jib cylinders (condition, no leaks, chromed rod)
or cracks) Winch mounting (cap screws secure, welds intact,
Boom tip fasteners secure no deformation or cracks)
Remove any debris from inside upper boom Winch motor mounting cap screws
Lanyard attachment Winch brake operation
Hose routing (condition, no leaks) Gearbox outboard bearing secure
Upper Boom Cylinders Winch rope (condition, anchor point secure)
Cylinder attachment pins (condition, cap screws secure Control valve (condition, operation, no leaks)
and lockwired, retaining rings in place) Winch cover (condition, in place)
Pivot bearings secure within cylinder eyes Hoses (routing, condition, no leaks)
Operation, no leaks Lubrication
Holding valves (operation, no leaks) Leveling cables
Chromed rod condition Interlock linkage
Platform Upper control mechanical linkage
Mounting secure (bracket, pins and fasteners) Outrigger valve handle linkage
Platform mounting cap screws secure Top bearing on rotation gearbox
Tilt (operation, lock pins in place) Rotation gearbox oil level
Platform (condition, clean) Winch gearbox oil level

Required Maintenance (Regardless of Hours)
Annual Testing Atmospheric vents (visually inspect all, verify operation
Dielectric test unit on Category A units)
Dielectric test platform liner(s) Leveling Cables
Confirmation test of single handle control(s), Replace leveling system cables3
if so equipped
1,000 PTO Hours/1 Year
Perform the 500 hour/6 month inspection Elbow
Hydraulic Reservoir and System Elbow bearing cap screw annual torque inspection
Clean suction filter element Bearing clearance test
Change filler breather cap Rotation Bearing and Gearbox
Clean or change filler hole strainer Rotation gearbox mounting cap screw annual torque
Reservoir cover gasket condition inspection
1
Collect oil sample for analysis Rotation bearing cap screw annual torque inspection
Lubrication
Pump input shaft splines
2,000 PTO Hours/2 Years
Perform the 1,000 hour/1 year inspection Lubrication
Hydraulic Reservoir and System Change winch gearbox oil
Flush hydraulic system Change rotation gearbox oil
Clean inside of reservoir Rotation Bearing
Clean suction filter element Rotation bearing inspection and measurement (before
Change hydraulic oil 0.050″ increased wear from initial measurement)2
1
Periodic laboratory analysis is the most accurate method of determining the condition of the hydraulic oil and when it should be changed.
If laboratory analysis is used, take baseline sample. Compare future lab tests on subsequent samples to the original to establish a trend.
2
Initially measure turntable tilt as a baseline. Check rotation bearing wear every 2 years until it measures 0.050″ increased wear from initial
measurements. After reaching 0.050″ increased wear, measure every 6 months. Refer to the Maintenance Manual for the proper procedure.
3
Refer to the Maintenance Manual for inspection and replacement criteria.
4
Only required at first 500 PTO hours/6 months inspection and as part of annual inspection.

Accessory Checklist
Vehicle No. __________________________ Location ___________________________ Date ___________________
Model Number ___________________ Serial Number ___________________ Inspector _______________________
Symbols
= Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
1,000 PTO Hours or as Recommended by the Manufacturer

Unit Accessories First aid kit
Platform liners Flare kit/warning triangles (3)*
Platform covers Grounding reel
Tool holders (mounting and condition) Power cord reel
Scabbard (mounting and condition) Hotstick tube or box
Spare augers Ladder rack
Screw anchor wrench Spare fuse pack*
Lifting slings and chains Chassis Accessories
Hydraulic cooler (mounting, condition and fan operation) Front winch (mounting and operation)
Hydraulic oil heater (operation and condition) PTO and driveline
ROACS system (operation) Bed winch
Radio controls Capstan
Auxiliary power unit (mounting, pump to bellhousing Collapsible reel
bolts, exhaust system, cooling system, fuel system) Secondary brake system
Body Accessories Pintle hitch (condition and mounting)
Body (structure, mounting) Safety chain eyebolts
Outrigger pads and holders Trailer plug
Pole rack mounting Tow hooks
Access steps (condition and mounting) Cab guard
Cargo area retention (mounting and condition) Brake controller (mounting and operation)
Dump bed operation (dump hoist and body prop) Back up alarm (mounting and operation)
Spotlights and work lights Torsion bar
Beacons Hydraulic Tools and Hoses
Wheel chocks and holders Hose reel and hoses
Mud flaps Pole puller, chain and base
Cones and holders Impact
Inverters (operation and mounting) Chain saw
Generators (operation and mounting) Tamp
Platform rest (condition and mounting) Quick disconnects
Fire extinguishers*
* DOT items
Appendix — Accessory Checklist

Appendix — Accessory Checklist
Torque Values
Fasteners
Grade 8
Bolt Size - Grade 5 Hex Hex Head, Socket Head, Button Head Cap Screw
Thread Pitch Head Cap Screw and 12 Point Cap Screw and Flat Head Socket Screw
1
/4″ - 20 5 (7) 7 (10) 6 (8)
5
/16″ - 18 10 (14) 15 (20) 13 (17)
3
/8″ - 16 19 (25) 26 (35) 22 (30)
7
/16″ - 14 30 (40) 42 (57) 36 (49)
1
/2″ - 13 45 (61) 64 (87) 55 (74)
9
/16″ - 12 65 (89) 92 (125) 79 (107)
5
/8″ - 11 90 (122) 127 (172) 109 (148)
3
/4″ - 10 160 (217) 226 (306) 193 (262)
7
/8″ - 9 258 (349) 364 (493) 312 (422)
1″ - 8 386 (524) 545 (739) 467 (633)
1
Values are foot-pounds (N•m).
2
Values apply for both lubed and not lubed applications with any style nut or threaded hole.
3
Values apply for torque applied to either the head of the bolt or the nut.
4
This chart only applies for general application fasteners where a specific torque is not defined. Refer to the fastener section for special applications
where the torque is specifically defined.
Pipe Thread T.F.F.T. Valve Cartridges (Standard SAE Cavity)

Fitting Size T.F.F.T. Fitting Size T.F.F.T. Wrench Size Fitting Size Torque ft-lbs (N•m)
1
/8″ 1
2 to 2 /2 3
/4″ 1
1 /2 to 2 7
/8″ -8 20 (27)
3
/16″ 1
2 to 2 /2 7
/8″ 1
1 /2 to 2 1″ -10 25 (34)
1
/4″ 1
2 to 2 /2 1″ 1
1 /2 to 2 1 /8″
1
-10 25 (34)
5
/16″ 1
2 to 2 /2 1 /8″
1 1
1 /2 to 2 1 /4″
1
-12 35 (48)
3
/8″ 1
1 /2 to 2 1 /2″
1 1
1 /2 to 2 1 /2″
1
-16 50 (68)
1
/2″ 1
2 to 2 /2 2″ 1
1 /2 to 2 2″ -20 65 (88)
5
/8″ 1
2 to 2 /2
Compression Fittings Split Flanges

Tube Size Fitting Size T.F.F.T. Flange Size Thread Torque in-lbs (N•m)
1
/8″ thru /4″ 1
2 thru 4 1
1 /4 3
/4″ 3
/8″-16 250 to 350 (28 to 40)
5
/16″ 5 3
1 /4 1″ 3
/8″-16 325 to 425 (37 to 48)
3
/8″ thru 1″ 6 thru 16 1
2 /4 1 /4″
1 7
/16″-14 425 to 550 (48 to 62)
1 /2″
1 1
/2″-13 550 to 700 (62 to 79)
2″ 1
/2″-13 650 to 800 (73 to 90)
SUN Counterbalance Valves
Wrench Size Torque ft-lbs (N•m)
7
/8″ 30 to 35 (41 to 47)
1 /8″1
45 to 50 (61 to 68)
1 /4″1
150 to 160 (203 to 217)
Appendix — Torque Values

SAE O-Ring Fittings
Torque With Self-Locking Nuts Torque Without Self-Locking Nuts
Fitting Size in-lbs (N•m) in-lbs (N•m)
-2 60 to 70 (7 to 8) 85 to 95 (10 to 11)
-3 120 to 140 (14 to 16) 160 to 180 (18 to 20)
-4 180 to 200 (20 to 23) 205 to 235 (23 to 27)
-5 245 to 275 (28 to 31) 245 to 275 (28 to 31)
-6 300 to 340 (34 to 38) 300 to 340 (34 to 38)
-8 545 to 595 (62 to 67) 545 to 595 (62 to 67)
-10 690 to 750 (78 to 85) 1,010 to 1,110 (114 to 125)
-12 910 to 1,010 (103 to 114) 1,250 to 1,350 (141 to 153)
-14 1,675 to 1,825 (189 to 206) 1,675 to 1,825 (189 to 206)
-16 1,845 to 1,995 (208 to 225) 1,895 to 1,945 (214 to 220)
-20 2,550 to 2,850 (288 to 322) 2,550 to 2,850 (288 to 322)
-24 2,850 to 3,150 (322 to 356) 2,850 to 3,150 (322 to 356)
-32 3,700 to 4,100 (418 to 463) 3,700 to 4,100 (418 to 463)
Upper values are for stainless steel.
Tube and JIC Fittings
Misalignment of
marks show how much
nut was tightened
Tube Connection Swivel Nut or Hose

Size Thread Size F.F.W.R. Connection F.F.W.R.
7
-4 /16-20 2 2
1
-5 /2-20 2 2
9 1
-6 /16-18 1 /2 11/4
3
-8 /4-16 11/2 1
1
-10 1-16 1 /2 1
1 1
-12 1 /16-12 1 /4 1
5
-16 1 /16-12 1 1
5
-20 1 /8-12 1 1
7
-24 1 /8-12 1 1
1
-32 2 /2-12 1 1
Appendix — Torque Values

Basic JIC Symbols
Lines Methods of Operation
Line, pressure or tank Spring
Line, sense (for control) Manual
Component enclosure Manual, rotary )

Hydraulic
Flow, direction of Push button
Pneumatic
Lines crossing or Push/pull lever
Lines joining Pedal or treadle
Line with fixed restriction Mechanical
Flow control — adjustable, non-compensated Detent
Flow control — adjustable

Pressure compensated
(temperature and pressure compensated)
Station, testing, measurement,

Solenoid, single winding
power take-off or plugged port
Servo motor
Remote supply
Pilot pressure
Internal supply
Appendix — Basic JIC Symbols

Valves Cylinders
Check Double-acting
Counterbalance Single-acting, internal spring
On - off (manual shut-off) Single-acting, external spring
Pressure relief Fluid Storage

Vented
Reservoir
Pressure reducing Pressurized
Above fluid level

Line, to reservoir
Two-position, two connection Below fluid level
)
Vented manifold
Two-position, three connection
Motors
Two-position, four connection
Hydraulic oscillator
Three-position, four connection

Fixed displacement
Two-position, in transition Hydraulic motor Variable displacement
Bidirectional
Valves capable of infinite
positioning (horizontal bars
indicate infinite positioning ability) Pumps
Shuttle valve Fixed displacement

Hydraulic pump
Variable displacement
Typical closed center spool
Typical open center spool
Logic element, poppet type

Miscellaneous
Variable component
Internal combustion engine
(run arrow through symbol at 45 degrees)
Pressure compensated units

Accumulator, spring loaded
(arrow parallel to short side of symbol)
(
Accumulator, gas charged (
Direction of shaft rotation

Weighted
(assume arrow on near side of shaft)
Filter, strainer Flowmeter
Filter with adjustable bypass Pressure switch
Heater Pressure gauge
Cooler Pressure sensor
Temperature controller Temperature gauge
Temperature cause or effect Quick disconnect

Hydraulic System Schematics
AM855 Single Elevator
Appendix — Hydraulic System Schematics

AM855 Double Elevator

AM855 Single Elevator With Dual Upper Controls

AM855 Double Elevator With Dual Upper Controls

AM855 Single Elevator With Two-Man Platform and Hydraulic Extend Jib

AM855 Double Elevator With Two-Man Platform and Hydraulic Extend Jib

Outrigger Control Valve Outrigger/Tool Control Valve
Reservoir
Lower Elevator Control Valve Lower Elevator Control Valve Pump Control Valve
(Single Elevator) (Double Elevator)
Emergency Operating Lower Boom Upper Control

Pump DC Pump Rotary Joint Stow Valve Interlock Valve
Upper Elevator Control Upper Elevator Control Cross-Ported Pilot Counterbalance

Valve (Single Elevator) and Selector Valve Operated Check Valve Valve
(Double Elevator)
Jib/Winch Valve Jib/Winch/Tool Valve Platform Rotate/
Lower Control Valve (Hydraulic Extend Jib) (Manual Extend Jib) Tool/Tilt Valve
Platform Rotator Valve Upper Control Valve Tool Control Valve
Machine/Outrigger Lower Winch/Platform

Station Selector Valve Selector Valve Lower Winch Valve Rotate Valve
Elevator Selector (Double Elevator) Lower Controls Solenoid Pilot Control Valve

Basic Electrical Symbols
Relays
Circuit breaker
Simple
Fuse
Bistable
Capacitor
Air-core Latching
Coil
Iron-core
Logic
Connection
Switches
No connection
Single-pole, single-throw (SPST)
Battery
Single-pole, double-throw (SPDT)
Chassis or common return connected

Double-pole, single throw (DPST)
to one side of voltage source
Ground
Chassis or common return not Double-pole, double-throw (DPDT)
connected to voltage source
C
Rectifier A K Transistors
Diodes NPN B
Photoemissive diode (LED) A K
E
Fixed C
Resistors
Variable PNP B
Motor
M
Appendix — Basic Electrical Symbols

Appendix — Basic Electrical Symbols
Wiring Line Diagrams
DC Pump With Remote Start/Stop, Captive Air
Appendix — Wiring Line Diagrams

DC Pump With Remote Start/Stop, ROACS 3

Outrigger Interlock

Troubleshooting Chart
Symptom Possible Cause Test Procedure/Corrective Action
Pump is noisy. The reservoir oil level is too low. Fill the reservoir to the proper level.
Restriction in pump suction line. Fully open the suction line shutoff valve.
Check for kinked or plugged suction hose. Remove restriction.
Make sure suction hose is 11/4 minimum.
Air entering suction line. Fill the reservoir to the proper level.
Tighten loose hydraulic fittings.
PTO/pump connection misaligned. Correct misalignment.
Cavitation. Remove restriction or replace line.
Use hydraulic oil of proper viscosity.
Reduce pump speed.
Excessive heat The reservoir oil level is too low. Fill the reservoir to the proper level.
buildup (180°+).
The engine speed is set too high. Adjust the throttle cylinder.
Excessive internal system Check the outrigger power beyond plug seals for leaks.
leakage.
Make sure the relief valve settings are properly set.
Check the boom tip tool valve for leakage. Replace if necessary.
Power tools improperly sized for Change power tools or adjust the tool flow control.
gpm flow of tool circuit.
Boom functions Lower control valve spools do not Lubricate or replace as necessary.
operate slowly. fully shift.
Adjust the pilot pressure to 350 psi.
Adjust the forced opening on the upper control valve to the proper
value.
Make sure the lower control valve handles are not hitting the
turntable cover, hoses, etc.
Engine rpm is set too low or the Adjust the engine rpm.
throttle does not increase engine
speed.
Improperly adjusted lower control Properly adjust the valve spool stops.
valve spool stop(s).
Low pump flow. Check the pump with a flowmeter. Replace if defective.
Low pump standby pressure. Adjust the standby pressure to 350 psi.
Restriction in the pressure line. The restricted area will be warmer to the touch than the rest of the
system. Remove the restriction.
Blocking valve is not fully open. Test by connecting a flowmeter at valve input and back to reservoir.
Replace the blocking valve if necessary.
One boom function Purge check not seating. Operate the lower control handle to verify that function operates
operates slowly. properly from that control.
Clean or replace the check valve.
Appendix — Troubleshooting Chart

Tools, jib, winch Tool signal not working. Replace the tool signal pressure reducing valve.
operate slowly or
will not work under Tool pressure is set too low. Adjust the tool pressure reducing valve.
load.
Power tools improperly sized Change power tools or adjust the tool flow control.
for gpm flow of tool circuit.
Engine throttle does not work. Adjust or replace the engine throttle control.
Pump pressure Pump standby pressure is Adjust to 350 psi.

oscillates during too low.
operation.
The engine and Tool valve is on. Turn the lower or upper tool circuit valve off.
pump remain
loaded all the time. Tool blocking valve is defective. Replace the tool blocking valve cartridge.
The pump signal is not bleeding Open the signal drain line needle valve (in turntable or pedestal).
off. Readjust 11/2 turns open.
No functions from The control selector valve is in Place the control in the Upper Controls position.
the upper controls. the Lower Controls position.
The control selector valve is Check the operation of the upper/lower control selector valve.
not fully shifted. Replace if defective.
Air in the hydraulic line. Purge all air out of the lines.
Low or no pilot pressure. Test and/or adjust standby pressure to 350 psi.
Test and/or adjust pilot pressure to 350 psi.
Improper upper control interlock Adjust the cable.

valve cable adjustment.
Blocking valve of the upper Check the operation of the blocking section of the upper control
control valve is not fully shifted. valve. If defective, replace the spool for the blocking section.
Only the outriggers Outriggers are not properly set. Properly set the outriggers. All interlock switches must be activated
and power tools for unit functions to operate.
operate.
Improper pilot pressure. Test and/or adjust the pilot pressure to 350 psi.
Low system pressure. Test and/or adjust the system pressure to 3,000 psi.
Malfunctioning lower control Clean or replace the blocking valve.

blocking valve.
No signal at the lower control Check the relief valve in the lower control housing.
valve. Replace if necessary.
Check the blocking valve in the inlet manifold housing.

Replace if necessary.
Check the pilot pressure reducing valve at the test port

quick disconnect. Replace the valve if necessary.
No signal to the pump control The seals may be leaking in the rotary joint if the signal is reaching
manifold. the rotary joint but not the pump control manifold.
Check for blocked, plugged, or cut hydraulic lines. If necessary,

repair or replace.

All functions Tools are turned off. Turn the lower or upper tool circuit valve on.
operate except
power tools. The upper control interlock is Release the interlock trigger on the single handle control.
engaged.
The blocking valve is shifting Remove and cap the pilot port line of the tool control valve to
off or malfunctioning. determine if the blocking valve is malfunctioning.
The tool system is receiving an Remove and cap TP port line of the tool control valve to determine
external signal. if the system is receiving an external signal.
The pump is not receiving a Check for pressure at the signal port of the tool control valve.
signal from the tool control valve.
All functions Sticky outrigger valve spools. Lubricate or replace as necessary.

operate except
outriggers. Blocked or plugged hydraulic line. Remove the restriction or replace the line.
The outrigger leg Pilot operated check valve Clean the valve in solvent and blow it dry with compressed air.
does not hold contamination.
under load.
Pilot operated check valve Replace the valve.
malfunction.
Internal cylinder leakage. Replace the seals in the cylinder.
The lower boom Counterbalance valve Replace the counterbalance valve.

cylinder does not contamination.
hold under load.
Counterbalance valve Remove the valve and adjust using a test block.
malfunction — out of adjustment.
Replace the counterbalance valve.
Internal cylinder leakage. Replace the seals in the cylinder.
Nothing operates. PTO is not engaged. Check the PTO. If it is not engaged, properly engage it.
Hydraulic oil is not reaching the Open the shutoff valve in the suction line.
pump.
Fill the reservoir to the proper level.
Check for a blocked, plugged, or cut suction line. If necessary, repair

or replace.
Improperly plumbed pump. Check the Hydraulic Schematic. The signal port is port B, the drain
port is A. Check pump installation for proper shaft alignment. Side
loads on the pump drive shaft will cause complete loss of pressure.
No system pressure. If there is no pressure at the system pressure test port on the tool
control valve, check for loss of prime to pump. May be caused by a
leak in the pump suction line. Repair if necessary.
Pump is not operating properly. Connect a flowmeter to the pump and check flow.
Disassemble the pump compensator housing at the back of the

pump and check for excessive friction on the compensator spool or
contamination. Pump malfunction is usually caused by improper
installation, contamination, or lack of oil in the pump.
If the pump generates pressure when the signal line is connected

to the pump, the pump is not the problem.
Rebuild or replace the pump.
Severe hydraulic Hose, tube, fitting, seal failure, etc. Replace the defective component.
leak.

Dielectric Test Form for AM Series
Category C — 46 kV and Below
Upper Boom Test – – – – –
Lower Boom Test

Bonding
Jumper
Bonding
Jumper
High Voltage
Test Leads
Control Leads High Voltage

Transformer
Ground/Return Controls Ground

Polyethylene Pad Leads
Position A Position B
Procedure
1. Read and understand the dielectric test information in the Maintenance Manual and ANSI requirements.
2. Insulate the vehicle from ground by placing polyethylene pads beneath each tire and outrigger leg.
3. The preferred test is with the unit in Position A. Position B may be used for an inside facility with limited test
space. When using Position B place the bottom of the platform 15′ from the ground. Electrical connections are
the same for both positions.
4. Electrically bond all metal at the boom tip to ensure all possible current paths are considered. Include all
conductive brackets, air plunger switches, hydraulic valves, controls, cylinders, jib brackets, etc.
5. Attach the ground/return leads to the vehicle.
6. Attach the high voltage test lead (insulated from ground) and bonding jumpers to the lower boom for the lower
boom test and to the upper boom for the upper boom test as shown.
7. Do not use cancel (null) circuit if the tester is so equipped.
8. To test the upper boom, gradually increase the voltage to 100 kV. Hold at 100 kV (60 hertz) for 3 minutes
continuously. If flashover occurs or the leakage rate exceeds 1,000 microamps, the unit has failed the test.
Record leakage reading.
9. To test the lower boom, gradually increase the voltage to 50 kV. Hold at 50 kV (60 hertz) for 3 minutes continu-
ously. If flashover occurs or the leakage rate exceeds 3,000 microamps, the unit has failed the test. Record
leakage reading.
General Information
Model number __________________________________ Serial number ____________________________________

Test device number _____________________________ Test position _____________________________________
Conclusion
Upper boom leakage reading (microamp) ____________ Lower boom leakage reading (microamp) ______________
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
Signature of technician ________________________________________ Date of test ________________________

Appendix — Dielectric Test Forms
Category B — 46 kV and Below
Meter Receptacle
Lower Boom Test
Test Band
Bonding
Jumper
High Voltage
Ground/ Leads
Return
Leads
Transformer
Ground Controls Ground

Polyethylene Pad (for upper boom test)
Procedure
5. Attach the ground, test leads, and bonding jumpers for the upper boom test as shown.
7. Gradually increase the voltage to 27 kV. Hold at 27 kV (60 hertz) for 1 minute continuously. If flashover occurs
or the leakage rate exceeds 27 microamps, the unit has failed the test. Record leakage reading.
8. Gradually increase the voltage to 54 kV. Record leakage when 54 kV (60 hertz) is reached. If flashover occurs
9. Hold the voltage at 54 kV (60 hertz) for 1 minute continuously. If flashover occurs or the leakage rate exceeds
54 microamps, the unit has failed the test. Record leakage reading.
10. Gradually increase the voltage to 80 kV. Hold at 80 kV (60 hertz) for 2 seconds. If flashover occurs or the
leakage rate exceeds 80 microamps, the unit has failed the test. Record leakage reading.
11. Remove the ground and test leads from the upper boom. Attach the test leads for the lower boom test as
shown.
12. Gradually increase the voltage to 50 kV. Hold at 50 kV (60 hertz) for 3 minutes continuously. If flashover occurs
or the leakage rate exceeds 3,000 microamps, the unit has failed the test. Record leakage reading.
General Information
Upper Boom Test
Leakage reading (microamp) at: 27 kV ________ 54 kV ________ 54 kV after 1 minute ________ 80 kV ________

Lower Boom Test
Leakage reading (microamp) ______________________
Conclusion
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________

Category B — 69 kV
Meter Receptacle
Lower Boom Test
Test Band
Bonding
Jumper
High Voltage
Ground/ Leads
Return
Leads
Transformer
Ground Controls Ground

Polyethylene Pad (for upper boom test)
Procedure
5. Attach the ground, test leads, and bonding jumpers for the upper boom test as shown.
7. Gradually increase the voltage to 40 kV. Hold at 40 kV (60 hertz) for 1 minute continuously. If flashover occurs
8. Gradually increase the voltage to 80 kV. Record leakage when 80 kV (60 hertz) is reached. If flashover occurs
9. Hold the voltage at 80 kV (60 hertz) for 1 minute continuously. If flashover occurs or the leakage rate exceeds
80 microamps, the unit has failed the test. Record leakage reading.
10. Gradually increase the voltage to 120 kV. Hold at 120 kV (60 hertz) for 2 seconds. If flashover occurs or the
leakage rate exceeds 120 microamps, the unit has failed the test. Record leakage reading.
11. Remove the ground and test leads from the upper boom. Attach the test leads for the lower boom test as
shown.
12. Gradually increase the voltage to 50 kV. Hold at 50 kV (60 hertz) for 3 minutes continuously. If flashover occurs
or the leakage rate exceeds 3,000 microamps, the unit has failed the test. Record leakage reading.
General Information
Upper Boom Test
Leakage reading (microamp) at: 40 kV ________ 80 kV ________ 80 kV after 1 minute ________ 120 kV ________

Lower Boom Test
Leakage reading (microamp) ______________________
Conclusion
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________

DC Periodic Dielectric Test For All
Category A, B, and C Insulating Articulating Aerials
(For DC Test Device With Output Current Metering Only)
Lower Boom Test
High Voltage
2 Ft
Test Leads
2 Ft Minimum
Minimum
Ground
Post Control Box
Drawing not intended to represent a specific model

Discharge Stick
Procedure
1. Read and understand the dielectric test information in the Maintenance Manual, ANSI requirements, and the manual
for the test device being used.
2. This procedure is for a DC test device with output current metering only. Do not use this procedure when using a
DC test device that measures the return current instead of the output current. If equipped with a selector switch, set
the switch to Ground Return.
3. The test area should be dry and appropriately roped off to prevent bystanders from entering the test area.
4. Ground chassis, test device or control box, and discharge stick as shown.
5. No isolation pads are required under the vehicle tires or outriggers.
6. Set up booms to maintain at least 2′ of clearance between conductive components as shown.
7. Electrically bond all metal at the boom tip to ensure all possible current paths are considered. Include all conductive
brackets, air plunger switches, hydraulic valves, controls, cylinders, jib brackets, etc.
8. Attach the high voltage test lead and bonding jumpers as shown for the upper and lower boom test.
9. It is not necessary to use the meter receptacle on the upper boom of Category A and B machines for the upper boom
test. However, whether the meter receptacle is used or not, all internal connections to this receptacle must be
checked to verify that all current paths through the boom are properly connected to ensure proper function.
10. Voltage and maximum allowable leakage for the upper boom test are as follows.
a. Category C – 46 kV and below – 56 microamps at 56 kV after 3 minutes
b. Category A/B – 46 kV and below – 28 microamps at 56 kV after 3 minutes
c. Category A/B – 69 kV – 42 microamps at 84 kV after 3 minutes
d. Category A/B – 138 kV – 84 microamps at 168 kV after 3 minutes
11. Voltage and maximum allowable leakage for the lower boom test is 100 microamps at 50 kV.
12. To test the upper boom, gradually increase the voltage to the proper level. Hold for 3 minutes. If flashover occurs
or the leakage rate exceeds the maximum value, the unit has failed the test. Record leakage reading.
13. To test the lower boom, it may be helpful, though not required, to move the boom to a more vertical position to help
keep the high voltage lead from contacting the ground or other conductive components. Gradually increase the
voltage to 50 kV. Hold for 3 minutes. If flashover occurs or the leakage rate exceeds 100 microamps, the unit has
failed the test. Record leakage reading.

General Information
Model number _________________________________ Serial number ____________________________________
Test device number ____________________________ Category/voltage rating _____________________________
Conclusion
Upper boom leakage reading (microamp) ____________ Lower boom leakage reading (microamp) ______________
Pass _____ Fail (reason) __________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________

Confirmation Test of Upper Control
Components With High Electrical Resistance
Maximum
Test Microamp
High Voltage Lead Test Voltage Leakage
AC 40 kV 400
DC 56 kV 56
Tester
Control Lead
Ground/Return Lead
The purpose of this test is to verify the high electrical resistance components in the single handle control. In some cases
the high voltage test lead may short circuit to other nearby conductive components. First, verify that provided covers
in the control area are intact. Then, insulating material, such as a piece of insulating blanket or liner, may also be placed
under and to the sides of the spring which wraps the high voltage test connections, as needed during the test, to prevent
this from happening.
Procedure
3. Wrap a 0.375″ to 1.000″ diameter spring around the control handle as shown. Conductive aluminum foil may be
used in lieu of a spring.
4. Attach the high voltage lead (insulated from ground) to the spring on the control handle as shown.
5. Attach the ground/return lead to the control base or platform mounting bracket. This lead must contact a bare
metal surface. (The bellows must be in place for this test.)
6. Use the lower controls to raise or extend the upper boom the minimum distance as required on the unit dielec-
tric test form.
8. To test the control, gradually increase the voltage (refer to the chart). Hold at the appropriate voltage for three
minutes continuously. If flashover occurs or the leakage rate exceeds the appropriate microamps from the
chart, the control has failed the test. Record leakage reading.
General Information
Model number ______________________________ Serial number ____________________________________
Test device number _______________________________________________________________________________
Conclusion
Test conducted AC ___________________________________ DC ______________________________________
Curb side control leakage reading (microamp) ________ Street side control leakage reading (microamp) ________
Pass ______ Fail (reason) _________________________________________________________________________

Comments _______________________________________________________________________________________
________________________________________________________________________________________________

Periodic Dielectric Test Form for Platform Liners
Either method may be used.
Wet Method Setup
1. Connect a ground lead to the steel tank. High Voltage Lead 6″ (15.24 cm) Maximum
2. Immerse the liner in the tank and fill with conductive fluid until
Liner
the level around both the inner and outer surfaces of the liner
is within 6″ (15.24 cm) of the top of the liner. Conductive
Fluid
3. Suspend the high voltage lead in the fluid within the liner.
Ground Tank
Dry Method Setup
1. Refer to TRS-0001 to apply conductive foil to the liner and High Voltage Lead 6″ (15.24 cm) Maximum
conduct the test. Liner
2. Connect a ground to the outer conductive foil.
3. Connect the high voltage lead to the inner conductive foil. Conductive
Foil
Testing (Wet or Dry) Ground
1. Apply the test voltage to the conductive fluid or foil. Voltage may be either 35 kV (60 hertz) for 1 minute or 100
kV DC for 3 minutes.
2. If flashover occurs, or the liner wall punctures, the liner has failed the test.
3. Turn off the test voltage (be sure the voltage meter indicates zero voltage). Remove the high voltage lead.
Remove the liner from the tank or remove the foil covering.
4. The test for more than one liner may be recorded on the same form providing the same setup is used to
eliminate external variables.
Conclusion
Unit Serial No. Liner Part No. Liner Serial No. Pass (Initials) Fail (Reason)
_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________

_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________
Wet/dry ___________ Test voltage __________ Test device number ______________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________

ANSI Stability Test Form, AM Overcenter Series
Level Surface Stability Test Chart

Standard Test A Alternate Test B
Capacity Lower Boom Platform Jib Test Platform Jib Test
Model Platform Options Per Platform Angle (A) Test Weight Weight at D Test Weight Weight at D
AM855 with Single side-mtd. 350 lbs. 0° 525 lbs. 590 lbs. - 2′ 0 1,115 lbs. - 2′
material handling Double side-mtd. 300 lbs. 900 lbs. 245 lbs. - 2′ 0 1,145 lbs. - 2′
AM855 with Single two-man 700 lbs. 0° 1,050 lbs. 110 lbs. - 2′ 0 1,160 lbs. - 2′
material handling Side-to-end-mtd.
Five Degree Slope Stability Test Chart

AM855 with Single side-mtd. 350 lbs. 0° 465 lbs. 525 lbs. - 2′ 0 990 lbs. - 2′
material handling Double side-mtd. 300 lbs. 800 lbs. 220 lbs. - 2′ 0 1,020 lbs. - 2′
AM855 with Single two-man 700 lbs. 0° 935 lbs. 100 lbs. - 2′ 0 1,035 lbs. - 2′
Procedure
1. Perform the stability test on a level surface and on a five degree slope in accordance with applicable ANSI
requirements.
2. Fill out all information on this form as a record of a completed stability test.
3. Find the model being tested in the chart for the test being performed.
4. Position the lower boom at the angle (A) indicated in the chart and place the upper boom horizontal. Fully raise
the elevator.
5. Position the jib so the distance (D) from the center of the load line to the center of the jib pivot equals either one
or 2′, as designated in the stability charts.
6. If the unit is equipped with platform rotators, the platforms must be rotated to the position furthest from the
centerline of rotation.
7. Alternate Test B is a more conservative test that may be used instead of Standard Test A to reduce weight
handling time. On units which require counterweight, Standard Test A may be preferred to minimize counter-
weight.
8. Subtract the weight of liners, tools, etc., from the test weight shown in the stability charts. For platform capaci-
ties not shown, use a test weight of 1.5 times rated load for the Level Surface Stability Test and 1.33 times
rated load for the Five Degree Slope Stability Test.
Appendix — Stability Test Forms

9. Load the jib and the platform with the proper weight.
10. After the test has been completed, torque all accessible rotation bearing cap screws to 325 foot-pounds using a
circular pattern (only required following initial stability test at the time of initial installation of unit on chassis).
11. After the test has been completed, torque the rotation gearbox mounting cap screws to 225 foot-pounds (only
required following initial stability test at the time of initial installation of unit on chassis).
General Information
Model number ___________________________ Serial number ___________________________________________
Platform type ___________________________ Platform capacity (lbs) ____________________________________
Counterweight added to unit (lbs) _____________________________________________________________________
Location of counterweight relative to rear axle __________________________________________________________
Level Surface Test
Test conducted A _____ B _____ Platform test weight (lbs) ____________ Jib test weight (lbs) _____________
Thickness of outrigger pads (0 if not used) _____________________________________________________________
Five Degree Slope Test
Side of vehicle on low side of slope __________ Thickness of outrigger pads (0 if not used) ____________________
0
Allowable slope indicator limits: Front-to-back _______________________ 0
Side-to-side _______________________
Conclusion
Rotation bearing cap screws torqued ____________ Rotation gearbox mounting cap screws torqued ____________
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________

CSA Stability Test Form, AM Overcenter Series
Level Surface and Five Degree Slope Stability Test Chart

AM855 with Single side-mtd. 350 lbs. 0° 700 lbs. 785 lbs. - 2′ 0 1,485 lbs. - 2′
material handling Double side-mtd. 300 lbs. 1,200 lbs. 325 lbs. - 2′ 0 1,525 lbs. - 2′
AM855 with Single two-man 700 lbs. 0° 1,400 lbs. 140 lbs. - 2′ 0 1,540 lbs. - 2′
Procedure
1. Perform the stability test on a level surface and on a five degree slope in accordance with applicable CSA
requirements.
3. Find the model being tested in the chart for the test being performed.
4. Position the lower boom at the angle (A) indicated in the chart and place the upper boom horizontal. Fully raise
the elevator.
5. Position the jib so the distance (D) from the center of the load line to the center of the jib pivot equals either one
or 2′, as designated in the stability chart.
6. If the unit is equipped with platform rotators, the platforms must be rotated to the position furthest from the
centerline of rotation.
7. Alternate Test B is a more conservative test that may be used instead of Standard Test A to reduce weight
handling time. On units which require counterweight, Standard Test A may be preferred to minimize counter-
weight.
8. Subtract the weight of liners, tools, etc., from the test weight shown in the stability chart. For platform capaci-
ties not shown, use a test weight of two times rated load for the Level Surface and the Five Degree Slope
Stability Test.
9. Load the jib and the platform with the proper weight.
10. After the test has been completed, torque all accessible rotation bearing cap screws to 325 foot-pounds using a
circular pattern (only required following initial stability test at the time of initial installation of unit on chassis).
11. After the test has been completed, torque the rotation gearbox mounting cap screws to 225 foot-pounds (only
required following initial stability test at the time of initial installation of unit on chassis).

General Information
Model number ___________________________ Serial number ___________________________________________
Platform type ___________________________ Platform capacity (lbs) ____________________________________
Counterweight added to unit (lbs) ____________________________________________________________________
Level Surface Test
Thickness of outrigger pads (0 if not used) _____________________________________________________________
Side of vehicle on low side of slope __________ Thickness of outrigger pads (0 if not used) ____________________
0
Allowable slope indicator limits: Front-to-back _______________________ 0
Side-to-side _______________________
Conclusion
Rotation bearing cap screws torqued ____________ Rotation gearbox mounting cap screws torqued ____________
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________

ANSI Stability Test Form, AM Series (With Lower Boom Lifting Eye)
Procedure
1. Perform the stability test on a level surface and on a five degree slope in accordance with applicable ANSI
requirements.
3. Place both booms in a horizontal position with the upper boom near its rest. Fully raise the elevator.
4. Do not occupy or load the platform.
5. Lift eye test weight is 1,200 pounds for the Level Surface Stability Test and 1,065 pounds for the Five Degree
Slope Stability Test.
6. Perform an applicable unit stability test.
General Information
Model number __________________________ Serial number ____________________________________________
Platform capacity (lbs) ___________________ Counterweight added to unit (lbs) ____________________________
Level Surface Test
Lift eye test weight (lbs) _________________ Thickness of outrigger pads (0 if not used) _____________________
Side of vehicle on low side of slope __________________________________________________________________
Conclusion
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________

CSA Stability Test Form, AM Series (With Lower Boom Lifting Eye)
Procedure
1. Perform the stability test on a level surface and on a five degree slope in accordance with applicable CSA
requirements.
3. Place both booms in a horizontal position with the upper boom near its rest. Fully raise the elevator.
4. Do not occupy or load the platform.
5. Lift eye test weight is 1,600 pounds for the Level Surface and the Five Degree Slope Stability Test.
6. Perform an applicable unit stability test.
General Information
Model number __________________________ Serial number ____________________________________________
Platform capacity (lbs) ___________________ Counterweight added to unit (lbs) ____________________________
Level Surface Test
Side of vehicle on low side of slope __________________________________________________________________
Conclusion
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________

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Section 2 — Unit Specifications

Section 4 — Preventive Maintenance and Inspection

Section 6 — Mechanical Systems

Section 8 — Troubleshooting, Testing, and Adjustments

Section 9 — Dielectric, Structural, and Stability Testing

Throughout the manual, the term unit is used to describe

Dealers, installers, owners, users, operators, renters, Caution

is impregnated with a wax compound, providing a smooth

Item AM855-E68 AM855-E81

Section 2 — Unit Specifications • 3

Upper Boom Tip

Parallel Upper Arm Cylinder

4 • Section 2 — Unit Specifications

General Maintenance Information

Section 4 — Preventive Maintenance and Inspection • 7

8 • Section 4 — Preventive Maintenance and Inspection

4. Insert a new cartridge in the housing. Do not clean and

Section 4 — Preventive Maintenance and Inspection • 9

10 • Section 4 — Preventive Maintenance and Inspection

Figure 4.3 — Hydraulic Oil Viscosity Recommendations

Condition Possible Cause

Figure 4.4 — Hydraulic Oil Conditions

Section 4 — Preventive Maintenance and Inspection • 11

• In climates with a wide variation in operating tempera- Warning

12 • Section 4 — Preventive Maintenance and Inspection

Notice If analysis shows oil deterioration beyond an acceptable

Section 4 — Preventive Maintenance and Inspection • 13

Letter Lubricant Application Method

A Anti-Seize Compound — Extreme pressure lubricant that prevents seizure, Brush

R Wire Rope Lubricant — Penetrating, cleaning, nongumming protective spray; Spray

S General Purpose Spray Lubricant Spray

Lift Cylinder Link Pivot

Radial Outriggers Elevator

Drain Plug Input Shaft

Change Oil W W Oil Level Drain Plug

Rotation Gearbox Winch Gearbox Hydraulic Pump

14 • Section 4 — Preventive Maintenance and Inspection

R Lower Boom Leveling Cables

Lower Boom Cylinder

Section 4 — Preventive Maintenance and Inspection • 15

Rotation Bearing Warning

16 • Section 4 — Preventive Maintenance and Inspection

Section 4 — Preventive Maintenance and Inspection • 17

Upper and Lower

Pin Bosses Cylinder

Front and Rear

18 • Section 4 — Preventive Maintenance and Inspection

Rotation Gearbox Rotation Bearing

All Pin Retainers

Figure 4.6 — Fasteners

Section 4 — Preventive Maintenance and Inspection • 19

When checking fastener torque value, check at 90 percent Notice

Figure 4.7 — Torque Values

Many general application fasteners would not normally

20 • Section 4 — Preventive Maintenance and Inspection

Use the following procedure to apply a new inspection mark. Caution

Section 4 — Preventive Maintenance and Inspection • 21

Rotation Bearing Cap Screws Annual Torque Inspection Procedure