AT237

Maintenance
and Parts Manual

www.altec.com

Altec Industries, Inc. reserves the right to improve models and change specifications without notice.
749-20195
2016
Copyright  2016 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, engi-
neering, 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 main-
tenance.

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, magnaflux 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 con-
ductors, 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..................................................................................................... 9
Oil Condition............................................................................................................ 9
Changing Oil and Flushing the System................................................................. 11
Lubrication................................................................................................................... 12
Lubrication Chart and Diagram.............................................................................. 14
Structures..................................................................................................................... 15
Care of Exterior Surfaces...................................................................................... 15
Welds .................................................................................................................... 16
Fasteners..................................................................................................................... 16
Rotation Bearing Cap Screws............................................................................... 19
Slide Pad Bearing Cap Screws............................................................................. 21
Rotation Gearbox Mounting Cap Screws.............................................................. 21
Pins and Pin Retainers................................................................................................ 21
Pin Installation Into Self-Lubricating Bearings ...................................................... 22
Bearings....................................................................................................................... 22
Spherical Bearings................................................................................................ 22
Self-Lubricating Bearings...................................................................................... 22
Tapered Roller Bearings........................................................................................ 23
Slide Pad Bearings................................................................................................ 23
Rotation Bearing ................................................................................................... 24
Cylinders...................................................................................................................... 26
Hydraulic Lines............................................................................................................ 26
Manual Lowering System............................................................................................. 27
Fiberglass and Plastic Components............................................................................ 27
Cleaning................................................................................................................ 27
Inspection.............................................................................................................. 27
Repair.................................................................................................................... 28
Covers................................................................................................................... 28
Platform Leveling......................................................................................................... 29
Hydraulic................................................................................................................ 29
Accident Prevention Signs........................................................................................... 29
Accident Prevention Signs Diagram...................................................................... 30

Section 5 — Hydraulic System

Oil Reservoir................................................................................................................ 35
Pump............................................................................................................................ 35
Secondary Stowage DC Pump.................................................................................... 35
 Valves.......................................................................................................................... 36
Outrigger Control Valve......................................................................................... 36
Ground Level Functions/Machine and Outrigger Valve......................................... 36
Outrigger Interlock Valve....................................................................................... 36
Main Control Valve, Variable Speed...................................................................... 36
Main Control Valve, Proportional Speed................................................................ 37
Speed Control Valve.............................................................................................. 37
System Relief Valve............................................................................................... 37
Outrigger Relief Valve............................................................................................ 38
Manual Lowering Valve......................................................................................... 38
Flow Control Valves............................................................................................... 38
Holding Valves....................................................................................................... 38
Cavitation and Aeration................................................................................................ 39
Air Bleeding.................................................................................................................. 40
Leakage....................................................................................................................... 40
Heat Generation........................................................................................................... 40
Hydraulic Lines............................................................................................................ 41
Fittings and Valve Cartridges....................................................................................... 44
Torque and Tightening Procedures........................................................................ 44
Valve Cartridges.................................................................................................... 45
Cylinders...................................................................................................................... 45
Outrigger Vertical Leg Cylinder ............................................................................. 46
Articulating Arm Cylinder....................................................................................... 47
Lower Boom Cylinder............................................................................................ 48
Extension Cylinder................................................................................................. 48
Lower Platform Leveling Cylinder.......................................................................... 49

Section 6 — Mechanical Systems

Rotation System........................................................................................................... 51
Rotation Bearing.................................................................................................... 52
Rotation Bearing Cap Screws .............................................................................. 54
Rotation Gearbox.................................................................................................. 54
Lower Boom................................................................................................................. 55
Slide Pad Bearings................................................................................................ 57
Lower Boom Tip Slide Pad Bearing....................................................................... 58
Upper Boom................................................................................................................. 58
Slide Pad Bearings ............................................................................................... 59
Platform........................................................................................................................ 60
Stabilizer Bars.............................................................................................................. 61
Rear Axle Stabilizer Bar......................................................................................... 61
Front Axle Stabilizer Bar........................................................................................ 62

Section 7 — Electrical System

On/Off Circuit............................................................................................................... 63
Relays.......................................................................................................................... 63
Truck/Machine Selector Switch.................................................................................... 63
Proportional Circuit...................................................................................................... 64
Multiplexed Controls.................................................................................................... 64
Control System............................................................................................................ 64
Cable Assemblies........................................................................................................ 65
Multiplex Cable Connectors................................................................................... 65
Electrical Harness Assemblies..................................................................................... 65
Electrical Harness Connectors.............................................................................. 66
Valve Driver Assembly................................................................................................. 66
Lower Controls Assembly............................................................................................ 66
Upper Controls Assembly............................................................................................ 66
Joystick.................................................................................................................. 67
 CADI............................................................................................................................ 68
Remote Start/Stop Control Box.................................................................................... 68
Throttle Control............................................................................................................ 69
Outrigger Interlock System.......................................................................................... 69

Section 8 — Troubleshooting, Testing, and Adjustments

Troubleshooting Procedure.......................................................................................... 71
Hydraulic System......................................................................................................... 71
Cycle Times........................................................................................................... 71
System Pressure................................................................................................... 71
Relief Valve............................................................................................................ 72
Pump Flow............................................................................................................. 72
Outriggers.............................................................................................................. 74
Articulating Arm Cylinder....................................................................................... 75
Main Control Valve (Proportional).......................................................................... 75
Lift Cylinder............................................................................................................ 76
Extension Cylinder................................................................................................. 76
Leveling Cylinders................................................................................................. 77
Upper Tool Circuit.................................................................................................. 77
Holding Valves....................................................................................................... 77
Mechanical System...................................................................................................... 79
Rotation Gearbox.................................................................................................. 79
Electrical System......................................................................................................... 81
Failure Identification.............................................................................................. 81
Circuit Protection................................................................................................... 81
Pin and Circuit Identification.................................................................................. 82
CADI Programming............................................................................................... 82
Remote Start/Stop Control Box............................................................................. 82
Engine Throttle Control — Manual Throttle System.............................................. 83
Engine Throttle Control — Automatic Throttle System.......................................... 83
Outrigger Interlock System.................................................................................... 86
Manually Lowering/Stowing the Unit............................................................................ 87
Lowering the Lower Boom..................................................................................... 88
Auxiliary Power Source................................................................................................ 89

Section 9 — Structural and Stability Testing

Structural...................................................................................................................... 91
Stability........................................................................................................................ 91

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
Stability Test Form
 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, re- interface with the vehicle.
pair, troubleshoot, and test the unit. Charts and figures
are provided to support the text. Because options vary Additional copies of this manual may be ordered through
from 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 located on the serial number placard and the
manual part number from the front cover to assure that
Knowledge of the information in this manual combined the correct manual will be supplied.
with proper skills and training in hydraulic, electrical, and
mechanical systems, provide a basis for safely maintaining This symbol is used throughout this manual to
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 infor- damage.
mation.
The terms danger, warning, caution, and notice repre-
• American National Standards Institute (ANSI) sent varying degrees of personal injury and/or property
A92.2 for aerial devices; A10.31 for digger derricks damage that could result if the preventive instructions
• American Public Power Association (Safety Manual are not followed. The following paragraphs from ANSI
for an Electric Utility) publications 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, could result in minor or moderate injury.

The Appendix contains reference items to help maintain Notice

the unit. A glossary of industry terms is provided for your Indicates information considered important, but
convenience. The glossary provides an understanding of not hazard related.
the industry terms and phrases used in Altec manuals.

Section 1 — Introduction • 1
2 • Section 1 — Introduction
 Section 2 — Unit Specifications
The basic structural components are the outriggers,
General Specifications pedestal, turntable, lower boom, and upper boom. The
The unit is an extendible/articulating aerial device and steel structures are made in the form of a closed box.
is not insulating. This structural style resists torsional loading as well as
tension, compression, and bending loads that may be
Unit height specifications are based on 40″ (101.60 cm) applied to the unit. Careful consideration has been given
frame height, but common frame heights vary from 36″ to the design and manufacturing process to minimize the
to 44″ (91.44 to 111.76 cm). Figure 2.1 provides unit possibility of fatigue cracks.
specifications.

Item Specification
Maximum ground to bottom of platform 37′ 6” (11.43 m)
Maximum working height 42’ 6” (12.95 m)
Maximum side reach 28’ 4” (8.64 m)
Travel height 9’ 10” (3.00 m)
Articulating arm articulation -7° to 90°
Boom articulation in degrees -25° to 75°
Upper boom extension 9’ 8” (2.95 m)
Rotation Noncontinuous
Maximum hydraulic system pressure 2,400 psi (165.47 bar)
Hydraulic flow requirement: aerial device 31/2 gpm (13.25 lpm)
Oil reservoir capacity 7 gallons (26.50 l)
Platform capacity 400 pounds (188 kg)

Figure 2.1 — Unit Specifications

Section 2 — Unit Specifications • 3

Component Identification

Lower Extension Upper

Leveling Cylinder Cylinder Upper Boom Tip Upper
Lower Boom Pin Boom Controls
Riser

Platform Mounting
Lift Lower Boom Bracket Pin
Cylinder
Platform
Link
Leveling Cylinder
Platform
Articulating Arm Platform
Arm Mounting Bracket

Articulating Arm
Cylinder

Mechanical Turntable Boom Rest

Rotation Stop Bracket

Pedestal
Lower Controls

4 • Section 2 — Unit Specifications

 Section 3 — Safety
General Maintenance Information
Safety Instructions • Read and understand the complete procedure before
It is essential that all personnel involved in the care of beginning.
the unit read and understand the Operator’s and Main-
tenance Manuals. Safety alerts throughout the manuals • Remove the pressure in a hydraulic circuit before
highlight situations in which accidents can occur. Give disconnecting its components.
special attention to all safety alerts.
• Use lifting devices of suitable capacity to support
The safety information in this manual applies only to the and handle components.
maintenance of the unit. Although procedures have been
written to protect the mechanic and other personnel, • Use a test block to adjust the relief setting on coun-
there is no safety system to account for human error or terbalance holding valves.
negligence.
• Be aware of the surroundings.
DANGER • Fully open all shutoff valves after servicing the unit.
Death or serious injury will result from unprotected
contact with energized conductors. The unit does not • Complete the required procedures before returning
provide protection from contact with or proximity to an the unit to operation.
electrically charged conductor when in contact with
or proximity to another conductor or any grounded • After completing a procedure, check the oil level in
device, material, or equipment. Maintain safe clear- the hydraulic reservoir, and add oil if necessary.
ances from energized conductors.
• Many inspections require the removal of covers.
After the inspection is complete, replace the covers
WARNING
before returning the unit to service.
Death or serious injury can result from careless or
improper use of the unit. The mechanic bears ultimate
responsibility for following all regulations and safety Disclaimer of Liability
rules of their employer and/or any state or federal law. Altec Industries, Inc. will not be liable for unauthorized
alterations or modifications of the unit. Altec Industries,
NOTICE Inc. will not be liable for improper or abusive operation
of the unit.
Maintenance personnel must be trained in safe ser-
vice procedures. Do not alter or modify the unit in any way that might affect
its structural integrity, dielectric integrity, or operational
Work practices may expose maintenance personnel to characteristics without specific written approval from
hazardous materials. Before using any chemical, read Altec Industries, Inc.
and understand the manufacturer’s label and the mate-
rial safety data sheet (MSDS). These sheets explain Unauthorized alterations or modifications will void the
emergency and first aid procedures and waste disposal warranty. However, of a greater concern is the possibility
methods. Properly dispose of oil and hazardous materials. that unauthorized changes could adversely affect the unit’s
operation that could endanger personnel and/or damage
CAUTION property. Altec will not be responsible for unauthorized
alterations or modifications that cause death, serious
Injury can result from slipping and falling. Be careful
injury, and/or property damage.
and use suitable work platforms during maintenance.
Altec Industries, Inc. assumes no liability for any personal
Maintenance procedures may require the use of ladders,
injury and/or property damage related to the use of this
platforms, scaffolding, etc. to access the unit. Provide suit-
manual when performing testing, operating, maintenance
able work surfaces clear of obstructions for maintenance
and/or repair procedures on this Altec unit.
procedures. Do not stand or walk on surfaces that are
not intended as such.

Section 3 — Safety • 5
6 • Section 3 — Safety
 Section 4 — Preventive Maintenance and Inspection
Proper unit maintenance will reduce downtime, lower generally has a number of heavy, cylindrical actuators.
operating and repair costs, and extend equipment life. As those components are allowed to rest in one position
Safety alone justifies a preventive maintenance program. for a period of time, the seals on the piston will tend to
flatten along the loaded side. Since the seal material is
This section contains information on properly inspecting synthetic, its elasticity is limited and it may not resume
the hydraulic system, structures, individual unit compo- its original shape completely. At best, there will be some
nents and lubrication. Use the Lubrication Chart and failure to seal well for a short period of time after putting
Diagram in this section when lubricating the unit. the equipment back into use. At worst, the seal will never
resume its original shape and will have to be replaced.
A Preventive Maintenance and Inspection Checklist is
provided in the Appendix. Use this checklist when per- Protective Measures
forming routine maintenance and inspections to ensure If it is known that equipment will be stored for a month
that no areas are overlooked. Components may be or more, some steps, as applicable, should be taken to
installed on the unit that require additional maintenance preserve the equipment.
at different intervals outside the scope of the Preventive
Maintenance and Inspection and Accessory Checklists. • The best preservative is to fully cycle (operate) the
Refer to those component manuals for more information. equipment once weekly.
Keep permanent, written, and dated records of all service
performed on the unit. • Coat exposed ferrous (iron or steel) bare metal
surfaces with a light grease or heavy oil compatible
Routine maintenance is performed on different compo- with system hydraulic oil. This includes cylinder rods,
nents of the unit at different times (refer to the Preventive shafts, gears, linkages, and unpainted parts.
Maintenance and Inspection Checklist in the Appendix).
More frequent maintenance may be necessary if the unit • Top off fluid reservoirs to allow as little air space as
is operated under severe conditions. In addition to the possible to limit the effects of condensation. Remove
Preventive Maintenance and Inspection Checklist recom- excess oil before operating to limit the chance of
mendations, follow these recommendations on new units. overflow when cylinders are cycled.

• Measure the turntable tilt before using a new unit. • Cover or wrap exposed rubber or neoprene parts
with an ultraviolet resistant covering to shield the
• Change the return line filter after the first 15 to 25 parts from sun exposure.
hours of operation.
• Unplug electrical connectors and apply a dielectric
grease or an aerosol product designed for protect-
Equipment Storage
ing electrical connectors. Plug the connectors back
Mobile hydraulic equipment needs maintenance when together.
stored or not used for extensive periods of time. Depend-
ing upon the climate, lack of use can begin to have a • Cover switch and control panels to prevent direct
negative effect in as little as two weeks. Storage for a intrusion of rain or moisture while still allowing air to
period of several months will almost certainly produce circulate over the panel.
some deterioration of the equipment.
• Cover personnel platforms to prevent water accu-
Rust will form on unprotected ferrous metal surfaces very mulation.
quickly, and water will collect inside unit structures. In dry
climates, gaskets will begin to shrink during long periods • Shield fiberglass components from the sun and other
of non-use, and lubricants will lose their ability to provide elements.
lubrication. In cold climates, condensation may occur in
fluid reservoirs and other components.
Hydraulic System
Even when protective measures have been taken prior Maintaining the hydraulic system is critical to the proper
to storage, some degradation of performance must be operation of the unit. Using the proper type and grade of
expected when the equipment is put back into use. oil helps to prevent hydraulic system problems. Maintain-
ing the oil is important. If the oil is dirty or contaminated,
One of the most noticeable effects of prolonged periods components may be damaged.
of non-use is seal deformation. Hydraulic equipment

Section 4 — Preventive Maintenance and Inspection • 7

 NOTICE Filler Breather Cap and Strainer Basket
Only use hydraulic oil as recommended. Other fluids The filler breather cap is on top of the fill hole of the reser-
added to the hydraulic system can increase compo- voir (refer to Figure 4.1). The cap allows air to flow in and
nent wear and affect the lubricating characteristics out of the reservoir as the oil level changes. It contains a
of the oil. filter that cleans the air as it enters the hydraulic system.
The cap strainer basket keeps large particles from enter-
Check the oil level in the reservoir with the vehicle level, ing the reservoir when oil is poured into the reservoir.
the booms in the boom rest, and all cylinders retracted.
Under these conditions, the proper oil level is approxi-
Filler Breather Cap Strainer Basket
mately 2″ (5.08 cm) from the top of the reservoir or use
the sight gauge on the reservoir.

Cleanliness Precautions
Contamination will ruin any hydraulic system. It is very
important that no contaminants enter the system. Dirt,
water, and air are types of contaminants. They can enter
the hydraulic system in many ways. Contaminants can
enter the system when filling the reservoir or changing
filters. They can also enter when changing components Return
Line Filter
or performing other service procedures.
Shutoff Valve
The following precautions will help protect the cleanliness Suction Strainer
of the hydraulic system.
Figure 4.1 — Reservoir
• Filter new oil with a 10 micron filter as it is added to
the reservoir. Replace the filler breather cap annually. If the unit is
operated in an extremely dusty environment, it may be
• Clean hydraulic connections before opening them. necessary to replace the filler breather cap more often.

• Plug or cap ports and lines opened for service. Remove and flush out (or replace) the strainer basket
any time it has collected dirt or other contaminants. Flush
• Keep replacement hoses, tubes and other compo- the strainer basket when the hydraulic oil is changed.
nents plugged while stored.
Suction Strainer
• Make sure components are clean before installation. Hydraulic oil passes through a suction filter or suction
strainer on its way to the pump. The suction filter or
• Clean the reservoir and return line filter covers before strainer is located inside the reservoir and contains a 100
opening them. micron wire mesh element. Although the element may
be cleaned, it is available as a service part.
• Clean the filler breather cap before opening it.
It is important to clean the strainer regularly. Clean the
• After servicing the inside of the reservoir immediately screen no more than four times before replacing it. Clean
replace the cover. it when the hydraulic oil is changed (at least once a year).
Oil will not flow into the pump fast enough if the filter be-
• Make sure quick disconnect couplers are clean before comes clogged. If the pump does not receive sufficient
connecting them. oil flow, pump damage will result.

• Do not spray water on the reservoir filler breather Removal

cap. This could force contaminants into the reservoir. Use the following procedure to remove the suction strainer
from the 7 gallon (26.50 l) reservoir.
Filtration
The unit is equipped with a complete filtration system. 1. Wipe off the suction hose fittings at the bottom of the
When properly maintained, this system will reduce con- reservoir.
tamination of the hydraulic system. The filtration system
must be serviced regularly to be effective. 2. Remove the suction hose and drain the reservoir.

8 • Section 4 — Preventive Maintenance and Inspection

 3. Remove the shutoff valve and fitting from the outside filter housing, but they may not have the same micron
of the reservoir (refer to Figure 4.1) and remove the rating. Also, other filters may allow oil to bypass at a
suction strainer. Do not crush the screen. different rate.

Oil Specifications
WARNING
NOTICE
Death or serious injury can result from improper
use of solvents. Follow the manufacturer’s label for Only use hydraulic oil as recommended. Other fluids
proper use and disposal. added to the hydraulic system can increase compo-
nent wear and affect the lubricating characteristics
of the oil.
CAUTION
Injury can result from airborne particles entering the Using a hydraulic fluid outside the temperature range
eyes. Wear appropriate safety equipment. it was prescribed for may cause system damage.

Eye protection must be worn at all times to prevent par- Only use oils meeting the viscosity rating for military
ticles of dirt, metal, or hydraulic oil from entering the eyes. specification MIL-5606 in extremely cold climates.
These oils have fewer antiwear characteristics and
4. Clean the filter screen by flushing it with solvent. are not recommended for full time use.
Blow it dry with an air hose from the inside of the
screen to the outside. Replace the filter screen if it Use high quality oil in the hydraulic system. The hydraulic
is damaged. oil should contain rust, oxidation, and corrosion inhibitors,
and antifoam and antiwear additives.
5. Install the filter and refill the reservoir.
Hydraulic oil is classified by viscosity, which changes
Return Line Filter with temperature. The higher the viscosity index of an
The return line filter cleans the oil as it enters the reservoir. oil, the less the viscosity will change as the temperature
It is mounted on a bracket on the side of the pedestal changes. A multiviscosity oil contains additives which
(refer to Figure 4.1). increase the viscosity index. Multiviscosity oils should
have high shear stability to maintain oil performance by
The return line filter is equipped with a bypass valve. The avoiding excessive change in viscosity.
bypass valve opens when there is a pressure drop of 25
psi 1.72 bar (or more) across the filter cartridge. When The ability of hydraulic oil to provide adequate fluid at
the valve is open, oil flows directly into the reservoir. low temperatures is measured by its pour point. If the
This prevents the cartridge from collapsing during cold pour point is not low enough, oil will not flow into the
oil start-ups or if it is clogged. pump at a fast enough rate when the pump is operated
at low temperatures. This will cause cavitation, which
If the filter becomes clogged, oil will flow directly into the can quickly destroy the pump.
reservoir through the bypass valve. The lack of oil filtra-
tion will eventually cause serious damage to hydraulic Figure 4.2 shows hydraulic oil recommendations for differ-
components. ent temperatures. The requirements are for mineral based
and biodegradable hydraulic fluids. Most companies can
During the initial break-in period of a new unit, the hy- supply equivalent oils. The oil selected for the hydraulic
draulic components will deposit break-in wear particles system depends on the temperature during unit operation.
in the return line filter cartridge. Change the return line
cartridge after the first 15 to 25 hours of operation. Then, When refilling or changing hydraulic fluids, it is recom-
change the cartridge at periodic maintenance intervals mended the replacement fluid meet oil cleanliness re-
as recommended in the Preventive Maintenance and quirement 21/17/14 as specified by ISO 4406.
Inspection Checklist. If the unit is operated in very dusty
conditions, replace the return line filter more often. Also, Oil Condition
replace the cartridge after new oil has circulated through An important part of hydraulic system preventive mainte-
the system for the first time. nance includes checking the condition of the hydraulic oil.

Replace the return line filter cartridge with a genuine Periodic laboratory analysis is the most accurate method
Altec replacement part. Other filters may screw into the of determining the condition of the hydraulic oil and de-

Section 4 — Preventive Maintenance and Inspection • 9

 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 -67° F (-55° C) -76° F (-60° C) -49° F (-45° C)
Flash point (min) 302° F (150° C) 302° F (150° C) 302° F (150° 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 4.2 — Hydraulic Oil Viscosity Recommendations

termining when it should be changed. A visual inspection Once the report is received, compare it to previous oil
may also be useful to check oil condition. analysis reports for the same unit. This information will
provide trends toward deterioration of the oil. It may give
A hydraulic oil supplier should be able to do this testing early warnings of a problem developing within hydraulic
or recommend a test laboratory. The laboratory should system components.
provide the following information.
NOTICE
• Particle count
• Trace element analysis (component wear, outside Change the oil if the sample has any of the charac-
contaminants and oil additive concentrations) teristics listed in Figure 4.3.
• Viscosity test
• Water content test If making a visual inspection, compare the sample of oil
• Dielectric strength test to a sample of new oil of the same type. Also, compare
it to previous samples taken from the same unit. Look for
Before taking a sample of oil, operate the unit to circulate the signs of oil deterioration listed in Figure 4.3.
the oil. Warm it to operating temperature. Take the sample
from the middle level of the reservoir by using a clean There are fluid contamination detector kits available
hand pump, such as a disposable syringe and a piece of which allow for rapid, on-the-spot analysis of the hydraulic
plastic tubing. If this is not available, the sample can be system’s condition.
drained from the bottom of the reservoir. Allow several
quarts of oil to flow out before collecting the sample. This Oxidation produces varnishes that bake onto hot sur-
will remove any dirt and water that has collected in the faces. These oxidation products are acidic and tend to
bottom of the reservoir. attack metal surfaces. This can cause damage to parts
in pumps, motors, and valves.
If a sample container has not been provided by the labora-
tory, use a wide mouth, screw top, clear glass container. High operating temperatures will increase the rate of
Clean it with hot water and detergent. Rinse it thoroughly oxidation of the oil. The presence of water or air in the
and let it air dry before putting oil into it. hydraulic oil also causes oxidation.

10 • Section 4 — Preventive Maintenance and Inspection

 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 4.3 — Hydraulic Oil Conditions

The presence of water may cause rust and corrosion and The following equipment and supplies are necessary to
reduces the dielectric capability of the oil. properly flush the hydraulic system.

If laboratory analysis or visual inspection indicate that • Hydraulic oil of the proper type and grade
the oil is deteriorating prematurely, determine the cause — 12 gallons (45.42 l) for a 7 gallon (26.50 l) reservoir
of the problem and correct it. • Three return line filter cartridges
• Clean, lint-free rags
Changing Oil and Flushing the System • Reservoir cover O-ring
Properly maintained, the filtration system greatly extends • Filler breather cap and strainer basket (if component
the useful life of the hydraulic oil. However, the oil will has not been replaced within one year)
eventually need to be replaced due to contaminants that
form during normal operation of the unit. CAUTION
It is impossible to recommend an exact time interval for Spilled hydraulic oil creates slick surfaces and can
oil changes due to varying conditions of unit use. Use cause personnel to slip and/or fall. Keep the unit and
the following guidelines to determine when the hydraulic work areas clean.
oil should be changed.
Use the following procedure to flush the hydraulic system.
• Change the oil at the intervals recommended in the
Preventive Maintenance and Inspection Checklist. 1. If the oil is being changed because of contamination
due to hydraulic component failure, proceed to step
• If a hydraulic component fails and contaminates the 2. Otherwise, operate the unit to circulate the oil and
system with metallic particles, change the component warm it to operating temperature. This will allow many
and the oil immediately. of the impurities to drain off in suspension.

• In climates with a wide variation in operating tempera- 2. Drain the oil reservoir completely.
tures between summer and winter months, change
to the appropriate weight oil each spring and fall. 3. Wipe off the top of the reservoir, reservoir cover, and
filler breather cap.
Replace the return line filter cartridge and filler breather
cap every time the hydraulic oil is changed. Also, clean 4. Remove the strainer basket. If the filler breather
or replace the suction filter. cap and strainer basket have not been replaced in
one year, or are damaged, replace them when reas-
A significant quantity of oil remains in the cylinders and sembling the reservoir. If the filler breather cap and
lines of the hydraulic system when the reservoir is drained. strainer basket is less than one year old and is not
Flush the system when the oil is changed. This is espe- damaged, clean the basket.
cially important if the system is heavily contaminated
with metal particles. 5. Remove the reservoir cover and the suction strainer.
Disassemble and clean it as described under Filtra-
If the oil is heavily contaminated with water, it may not be tion in this section.
necessary to change the oil and flush the system. Follow
the instructions in this section.

Section 4 — Preventive Maintenance and Inspection • 11

 WARNING 15. Fill the reservoir to approximately 2” (5.08 cm) from
the top with new hydraulic oil or until the hydraulic
Death or serious injury can result from improper
oil level sight gauge is filled with oil. Make sure the
use of solvents. Follow the manufacturer’s label for
oil is the proper type and grade. Filter the oil through
proper use and disposal.
a 10 micron filter as it is put into the reservoir.
6. Inspect the inside of the reservoir. If sludge or other
16. If the new oil was not filtered as it was put into the
contamination is found, clean it using solvent and
reservoir, circulate the oil through the tool circuit as
lint-free rags. Disconnect the pump suction line from
described in step 11.
the bottom of the reservoir to prevent contamination
while cleaning. Reconnect the suction line immedi-
17. Change the return line filter cartridge after approxi-
ately after cleaning.
mately 25 hours of operation.
7. Install the suction strainer and strainer basket.
Water Removal
If the hydraulic system was heavily contaminated with
8. Install the filler breather cap. If the filler breather cap
water, special water removal filtration may be necessary.
has not been replaced in one year or is damaged,
An oil supplier or a qualified laboratory can determine
replace it. Check the reservoir cover O-ring. If it is
whether water has caused excessive oil oxidation or
not in good condition, replace it. Install the reservoir
additive deterioration.
cover.
If analysis shows oil deterioration beyond an acceptable
9. If hydraulic component failure has contaminated the
level, drain the reservoir and flush the system as described
system, change the return line filter cartridge (refer
under Changing the Oil and Flushing the System in this
to Figure 4.1).
section. Use a water removal filter cartridge during the
flushing process to remove any residual water from the
NOTICE system. When the flushing process is complete, replace
Only use hydraulic oil as recommended. Other fluids the water removal filter cartridge with a regular cartridge.
added to the hydraulic system can increase compo-
nent wear and affect the lubricating characteristics If the condition of the oil is acceptable except for the water
of the oil. content, allow time for it to separate from the oil. Then
drain the water off the bottom of the reservoir. Circulate
10. For a 7 gallon (26.50 l) reservoir, add 5 gallons (18.93 the oil in the reservoir through a separate water removal
l) of new hydraulic oil of the proper type and grade to filter cartridge. This may require two or more water re-
the reservoir. Filter the oil through a 10 micron filter moval filter cartridges, depending on the amount of water
as it is put into the reservoir. content. The cartridge’s capacity is approximately one
cup of water. Once the cartridge has accumulated this
amount of water, it needs to be replaced. Change the
NOTICE water removal cartridge a minimum of every other day.
Damage to the pump or return line filter can result if
the unit is operated with either or both of the shutoff Continue this process until the water content in the oil is
valves closed. Fully open the shutoff valves before reduced to an acceptable level. The preferred method
engaging the hydraulic system. of determining the water content in the oil is laboratory
testing. Another method is a dielectric test. Once the
11. If the new oil was not filtered as it was put into the water has been reduced to an acceptable level, replace
reservoir, allow the new oil to circulate through the the cartridge with a new return line filter cartridge.
tool circuit for 15 minutes by connecting an open-
center tool or service hose to the tool circuit. Lubrication
12. Slowly cycle all the cylinders and the rotation mo- Proper lubrication will extend the life of the equipment
tor to flush the contaminated oil from the lines and and reduce maintenance problems. The frequency of
components of the hydraulic system. lubrication required will depend on the amount of use
and the conditions the unit is operated in. Operation in
13. Change the return line filter cartridge. extremely dusty, sandy, or rainy environments will require
more frequent lubrication. Lubricate the unit as recom-
14. Drain the reservoir completely. mended by the Preventive Maintenance and Inspection
Checklist.

12 • Section 4 — Preventive Maintenance and Inspection

The Lubrication Chart and Diagram identifies each com- It is very important to grease this type of bearing regularly.
ponent, type of lubricant, and method of application. Any If they are not greased properly, the normal usable life of
brand of lubricant that meets or exceeds the specifications the bearing will be greatly reduced. These bearings can
of the products listed is acceptable. Select the appropri- produce enough twisting force on the mounting pins to
ate interval and lubricate the components identified by break the pin retainers and make removal difficult if they
the symbol(s). are not properly lubricated.

Components may be installed on the unit that require Self-lubricating bearings require no lubrication. This type
additional lubrication. Refer to those component manuals of bearing is used at the platform mounting bracket pin
for more information. and the lower boom pin.

Always wipe grease fittings clean before and after greasing Rotation Bearing
to keep contaminants from entering the points of lubrica- The rotation bearing ball path is lubricated for the life of
tion. To avoid bearing damage, use manually operated the bearing and requires no further lubrication.
grease guns. Air-driven grease guns can have enough
force to cause bearing damage. Rotation Gear Teeth
Apply an open face gear lubricant to the rotation gear
If the unit is not used or is stored for any length of time, and pinion teeth at the intervals recommended in the
apply fresh lubricant at all points shown on the Lubrica- Preventive Maintenance and Inspection Checklist.
tion Chart and Diagram. This will help prevent corrosion
during the idle period. CAUTION
Outriggers Injury can result from contact with pinion and rota-
Pin connections on the outriggers have been made with tion bearing gear teeth. Keep hands clear.
zinc plated pins that have been coated with anti-seize
compound to prevent corrosion. These connections do Injury can result from being pinched or trapped be-
not require additional lubrication unless they are disas- tween moving components. Keep hands clear.
sembled.
Use caution when covers have been removed to ser-
Use the following procedure to lubricate the inner legs at vice the unit. Pinch points and shear points may exist
the intervals recommended in the Preventive Maintenance between moving parts. Replace the covers immediately
and Inspection Checklist. after servicing.

1. Position the unit on a level surface, apply the parking Remove the pinion cover from the turntable to lubricate
brake, and chock the wheels. Engage the hydraulic the rotation gear teeth. Replace the cover after lubrica-
system, and extend the outrigger legs. Disengage tion has been completed.
the hydraulic system, and turn off the engine.
WARNING
2. Wipe the exposed inner leg surfaces to remove any
dirt, moisture, etc. Death or serious injury can result from being trapped
between moving components. Maintain a safe dis-
3. Wipe on a coating of moly grease. tance while components are in motion.

4. Start the engine, and engage the hydraulic system. Do not lubricate the gear teeth while operating the unit.
Retract and extend the outrigger legs several times Stop turntable movement before lubricating. Rotate the
to spread the grease evenly on the surface. turntable slowly through a complete 360 degree revolution.

5. Extend the outrigger legs, and wipe off the excess Rotation Gearbox
grease to prevent buildup of dust and other particles. The lubricant in the gearbox is fluid and requires periodic
inspection.
6. Retract the outrigger legs.
Lubricant on the outside of the gearbox or the need to
Bearings add lubricant regularly to the rotation gearbox is a sign
Spherical bearings are used in several places on the of leaks. Determine the cause of the leak and correct
unit. All spherical bearings require periodic lubrication it. If the leak is ignored, the internal components of the
with a chassis lubricant. gearbox could be damaged by the low lubricant level. If

Section 4 — Preventive Maintenance and Inspection • 13

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 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.

L White Lithium Grease Spray

M Moly Grease — Multipurpose lithium base grease with good water resistance, Brush/grease gun
rust inhibition, oxidation stability, and extreme pressure properties with or
without molybdenum disulfide additive.

O AGMA 7 Compounded Oil Pour

Gearbox
Lubricant
O

Input A
Shaft Splines

Rotation Gearbox Hydraulic Pump

A Cylinder Pins

M Inner Leg
Outer Surface Outriggers

L Bonded Hose Assembly Platform Shaft A

Lift Cylinder C
Spherical Bearing
Rotation Gearbox G Rotation Pinion Gear Teeth
A
Eccentric Ring Rotation Bearing Gear Teeth

14 • Section 4 — Preventive Maintenance and Inspection

the lubricant level appears to be increasing, this could Periodic inspection of the structures is recommended
be a sign of an internal hydraulic leak from a defective to be certain there is no deformation, abnormal wear or
motor shaft seal. If a gearbox is overheated and the lu- abrasion, interference between moving parts, or cracking
bricant smells burned, change the lubricant immediately. of the welds on structural members.
Change the lubricant if it becomes diluted with hydraulic
oil from a leaking seal. Inspect the structures and welds as recommended by
the Preventive Maintenance and Inspection Checklist.
Booms
The internal and external surfaces of the lower boom do Care of Exterior Surfaces
not require lubrication. They should remain clean and dry Altec units are manufactured out of structural steel, gal-
to operate properly. vanized steel, and/or aluminum components with differing
resistance to corrosion. While Altec uses components,
Bonded Hose Assembly designs, and coatings that maximize corrosion resistance,
Use the following procedure to lubricate the bonded hose regular cleaning and maintenance is necessary to pre-
assembly at the intervals recommended in the Preventive serve the finish over the life of the equipment.
Maintenance and Inspection Checklist.
Frequent and regular washing will lengthen the life of the
1. Position the unit on a level surface, apply the parking new equipment’s painted finish and components. Wash
brake, and chock the wheels. Engage the hydraulic the equipment and vehicle frequently with water to remove
system and extend the outrigger legs. Use the lower dirt and preserve the original luster of the paint. Never
controls to raise the riser assembly over the bed of wash the equipment in direct sunlight or when the metal
the vehicle. surfaces are hot to the touch as it may cause streaks on
the finish. Do not select detergents and degreasers that
2. Extend the boom 4′ to 6′ (1.22 to 1.83 m) while spray- can damage the finish. Use only commercially available
ing white lithium grease inside of the boom at the automotive grade cleaners. Use high pressure washing
rear access holes. Lubricate the sides and bottom systems with caution, with the tip of the nozzle maintained
of the lower boom. at a distance of 12” (30.48 cm) or more from the surface.

3. Retract and extend the boom to distribute the lubri- It is particularly important to wash the unit and body during
cant. winter months as salt and other ice melting products are
extremely corrosive and can damage the vehicle. Other
4. Retract the boom. Lower the riser assembly. Stow corrosive environments that would necessitate additional
the boom. washing may include coastal areas, farming communi-
ties where chemicals are sprayed, or mining operations.
5. Retract the outrigger legs. Disengage the hydraulic
system, and turn off the engine. Waxing of the exterior is typically not required; however,
waxing will provide additional protection and help restore
the finish to the original luster. This may not only improve
Structures appearance, but will likely extend the service life of the
The structural components of the unit are identified in the vehicle and equipment.
Component Identification in Section 2. The unit has been
designed to meet or exceed the ANSI specifications for It is important to repair any chips or scratches that occur
vehicle-mounted rotating and elevating aerial devices. to prevent further corrosion. If the paint damage exposes
primer, a liquid touch up paint may be used. Damage
Regular inspection of the welds and structures is required that extends to unpainted metal must be primed prior to
to ensure that components maintain their strength. Peri- applying a top coat. Touch up paint for standard Altec
odic cleaning of the structures is also recommended. This colors can be ordered by calling 1-877-GO ALTEC. A local
will prevent damage that can occur from dirt accumulation. auto body shop can assist with matching a custom color.

Equipment that is used in harsh environments and off road

CAUTION
needs to have more routine washing and maintenance to
Injury can result from slipping and falling. Be careful the under body area. When the equipment is washed, it
when accessing and exiting the unit. Keep access should be washed on the underside as well and routinely
areas clear of debris and obstructions. Use three checked for any damage to the paint/undercoat. Any
points of contact and the handles and steps provided. damage discovered should be touched up accordingly
with a good rust preventative material and/or undercoat.

Section 4 — Preventive Maintenance and Inspection • 15

This will help prevent corrosion that could spread from ible cracks in the weld and at the weld-to-parent material
these areas that are not easily seen. joint. Use a bright light to provide adequate visibility of
the inspection area.
Accumulated dirt can damage the unit and cause it to
malfunction. Dirt buildup also accelerates wear on the Pay close attention to welds that are located where
components. changes in cross section take place and near the attach-
ment points of highly loaded components. To assist in
the inspection of the welds on the unit, Figure 4.4 shows
CAUTION
these areas. If any cracks or unacceptable conditions
Spilled hydraulic oil creates slick surfaces and can are discovered, report them to your Altec representative.
cause personnel to slip and/or fall. Keep the unit and
work areas clean. Any welds added in the field should be done by qualified
personnel and conform to AWS standards.
Keep the platform clean of debris. The weight of the
operator and the debris may overload the platform. After doing repair work on the unit, such as weld repair,
some testing of the unit may be required.
If a pressure washer or steam cleaner is used to clean
the unit, be careful where the spray is directed. Do not Refer to Section 6 for information on repairing mechani-
direct the spray where the cleaning liquid might get into cal components.
electrical components such as electrical connections,
switches, or lights. Even though all electrical components
on the unit are designed for all weather use, it is possible Fasteners
for water pressure from the nozzle to push a seal out of A variety of fasteners are used on the unit. Different fasten-
position. Do not direct the spray at the filler breather cap ers have different inspection and installation requirements
of the reservoir. The high pressure can force water and depending on their use and design. This section explains
cleaning liquid into the reservoir and contaminate the different fasteners used on the unit, torque specifications,
hydraulic oil. Do not clean the spool ends of any hydraulic and the use of thread locking and anti-seize compounds.
valve with direct pressure from a pressure washer. Limit
the water pressure to 500 psi (34.47 bar) and keep the The standard grade of fastener used on the unit is a zinc
spray tip at least 18″ (45.72 cm) away from these com- plated, SAE Grade 5, steel cap screw. SAE Grade 8 cap
ponents while washing. After washing and cleaning the screws, or special high strength cap screws, are used
unit, lubricate as necessary. in highly loaded areas. A variety of other fasteners such
as socket head, flat countersunk head, and button head
Refer to Fiberglass and Plastic Components in this section cap screws are also used on the unit.
for information on cleaning the fiberglass components.
Check all fasteners for tightness as recommended by
Welds the Preventive Maintenance and Inspection Checklist.
All welds on the unit are originally applied in conformance
to AWS standards. Every weld on the unit is important Figure 4.5 represents general locations of fasteners to
and should be periodically inspected. inspect. When inspecting fasteners, pay particular atten-
tion to the following fasteners.
WARNING
• Rotation bearing mounting cap screws
Death or serious injury can result from improper • Rotation gearbox mounting cap screws
use of solvents. Follow the manufacturer’s label for • All pin retainer cap screws
proper use and disposal. • Arm insulator attachment cap screws
• Link insulator attachment cap screws
If paint has lifted off the weld or if rust is found, a closer • Boom tip attachment cap screws
inspection is required. Remove any loose paint or rust • Platform mounting cap screws
with a wire brush. Clean the area with a solvent such
as acetone. Closely inspect the area for cracks in the A properly installed cap screw applies a clamping force
welds. Dye penetration and magnetic particle testing are equal to or greater than the load applied to it. A cap screw
simple processes that can be used to verify or disprove installed at less than the recommended torque value
a suspected problem. does not provide enough clamping force. The cap screw
may fatigue, causing it to loosen or fail. If the cap screw
Visual inspections can be very effective if conducted is torqued beyond the recommended torque value, the
properly. Clean the area to be inspected. Look for vis-

16 • Section 4 — Preventive Maintenance and Inspection

Pin Boss Platform
Boom Structure Attachment Boss
Cylinder
Attaching Structure
Boom

Cylinder Boss

Pedestal
Top Plate

Base
Base Plate Attaching
Both Sides Area

Mounting Bracket Turntable Pedestal

Eye
Weldment

Vertical
Plates

Platform Mounting Boss

Upper Boom Riser Cylinder

End Weldment End Weldment

Articulating
Arm Link

Articulating
Arm
Cylinder Base Cylinder Cylinder Boss
and Stiffener Attachment Boss and Stiffener

Figure 4.4 — Weld Inspection Areas

Section 4 — Preventive Maintenance and Inspection • 17

 Platform Mounting
Pin Retainer Cap Screws Cap Screws

Rotation
Gearbox Mounting
Rotation
Bearing

Interface Front or Rear

and Outrigger Torsion Bar Attachment

Figure 4.5 — Fasteners

elastic range of the cap screw may be exceeded. This Many general application fasteners do not normally
may result in premature failure of the cap screw. require an installation torque or lubrication, but instead
are installed using sound mechanical practices. If it is
When checking fastener torque value, check at 90 percent desired to more closely control the fastener clamp load it is
of the original value. For example, if the torque value for recommended that a copper-based anti-seize compound
a cap screw is 100 foot-pounds (136 N•m), check the cap be applied. Refer to Torque Values in the Appendix as a
screw for tightness at 90 foot-pounds (122 N•m). guide to determine the proper cap screw torque value.

Some fasteners require torque values that differ from Inspection Marks
common torque charts. Refer to Figure 4.6 for the proper Nuts or cap screws with locking patch element used
tightening torque for these fasteners. in combination with inspection marks may be used at
specific locations on the unit. Many are visible to the
Foot-Pounds (N•m) operator during daily inspections.
Pedestal mounting cap screws 300 (407)
If any inspection marks are found to be cracked or broken
Subbase shear plate cap screws 220 (298) during inspection, the original mark must be totally re-
Rotation bearing cap screws and washers 150 (203) moved. If no damage is evident, the fastener torque must
Rotation gearbox mounting cap screws 115 (156) be checked. If damage is evident, the fastener must be
replaced and torqued and the inspection mark reapplied.
Platform mounting cap screws 55 (75)
Upper boom tip attachment cap screws 31 (42) The inspection lacquer (refer to Service Tools and Supplies
Velocity fuse 22 (30) in the Appendix) should not be used after the expiration
date printed on the container.
Inch-Pounds (N•m)
Use the following procedure to apply a new inspection
Slide pad bearings 50 (5.65)
mark.
Figure 4.6 — Torque Values

18 • Section 4 — Preventive Maintenance and Inspection

 1. Remove the majority of the original inspection mark Eye protection must be worn at all times to prevent par-
by chipping it off with a chisel or other cutting method. ticles of dirt, metal, or hydraulic oil from entering the eyes.
Do not damage the surface on the nut, fastener,
washer, and part or structure being attached to. If the threads of the fasteners and the tapped holes are
not clean and free of grease and oil, the effectiveness
WARNING of the thread locking adhesive will be reduced. Clean
the threads of the fasteners and the tapped holes with
Death or serious injury can result from improper solvent and blow dry with compressed air before applying
use of solvents. Follow the manufacturer’s label for the thread locking adhesive. Follow all manufacturers
proper use and disposal. instructions on the thread locking adhesive container.

2. Be sure the cleaning operation is performed in a well Anti-seize compound can be used to prevent rust and
ventilated area. Remove the remaining residue using corrosion from forming on the metal-to-metal and metal-
inspection lacquer cleaner (refer to Service Tools and to-fiberglass contact areas between a connecting pin and
Supplies in the Appendix). Apply the cleaner to a rag its boss. It is also recommended for certain fasteners to
and completely remove the inspection stripe. reduce friction during torquing to increase clamping load.
Apply anti-seize compound to the following components.
3. Properly torque the fastener.
• Platform bracket pin
4. Clean the area where the inspection stripe is to be • Outrigger cylinder pins
applied with a soft clean cloth and acetone. • Pump output shaft splines
• Rotation gearbox mounting cap screws
5. Start at the center of the cap screw and apply a 1/32″ • Rotation drive adjustment eccentric ring
to 1/16″ (0.79 to 1.59 mm) thick stripe of inspection • Rotation bearing mounting cap screws
lacquer to the head of the cap screw, across the • Extension cylinder anchor pins
washer, and onto the surface of the parent material.
The stripe should extend 1/8″ to 1/4″ (3.18 to 6.35 mm) The area on which the anti-seize is applied must be
onto the parent material. clean and dry for the anti-seize to be effective. Proper
application of anti-seize will make future disassembly of
6. The stripe must be continuous across the surfaces. the component much easier.
If it is not, remove the stripe with cleaner and reapply
the inspection lacquer properly. Chrome pins used with self-lubricating bearings require
special attention. Apply anti-seize compound to the sur-
Thread Locking Adhesives face of the pin only where the pin and steel pin bosses
and Anti-Seize Compounds make contact. This pin installation procedure is described
Anaerobic thread locking adhesives work in the absence under Pins and Pin Retainers in this section.
of air. When a fastener is removed, clean it thoroughly
and apply the adhesive before reinserting. Properly torque Rotation Bearing Cap Screws
the fastener before the adhesive cures, which occurs Special high strength cap screws secure the rotation
within 15 minutes of application. bearing to the pedestal and the turntable. These cap
screws are coated with anti-seize compound and have a
Apply anaerobic thread locking adhesive on the threads patch lock material permanently bonded to the threads.
of all pivot pin retainer cap screws (medium strength) to They are torqued to 150 foot-pounds (203 N•m). To help
provide additional security against loosening. identify the fasteners, green paint is applied to the cap
screw heads. Placards alerting personnel of the torque
WARNING value are attached to the pedestal weldment by each
access hole. The cap screws require special inspection
Death or serious injury can result from improper procedures.
use of solvents. Follow the manufacturer’s label for
proper use and disposal.
NOTICE
CAUTION Only use Altec supplied cap screws and washers to
install the rotation bearing.
Injury can result from airborne particles entering the
eyes. Wear appropriate safety equipment. When rotation bearing cap screws or washers are re-
moved, they must be replaced with new ones. Contact
your Altec representative for replacement fasteners.

Section 4 — Preventive Maintenance and Inspection • 19

Insufficient or uneven cap screw tightness can contribute Retorquing Procedure
to reduced life of the bearing. Perform this procedure on the entire bearing race (outer,
inner, or both) if any cap screws were found loose at the
CAUTION visual or annual inspections.
Injury can result from being pinched or trapped be- Some components may need to be removed to make
tween moving components. Keep hands clear. the rotation bearing cap screws accessible for retorqu-
ing. It is important that experienced, trained mechanics
Use caution when covers have been removed to ser- perform this procedure.
vice the unit. Pinch points and shear points may exist
between moving parts. Replace the covers immediately 1. Retorque according to the appropriate pattern shown
after servicing. in Figure 4.7. Understand the entire procedure before
starting the torque inspection.
NOTICE
Use an accurate, click-type manual torque wrench for 1
the inspection of these cap screws. Torque the cap 11 16
screws. Torque the cap screws by a smooth pull on 8 6
the torque wrench without jerking. Do not overtighten
the cap screws. 13 9

3 4
If any cap screws are broken or missing, replace all the
fasteners in that race (refer to Section 6 under Rotation
10 14
Bearing Cap Screws). If a cap screw will not remain
properly torqued between normal inspections, further 5 7
inspection may be required. 15 12
2
Impacts to and excessive forces on the unit due to ve- Pedestal
hicular accidents, rollovers, and excessive loading may
result in structural damage not obvious during a visual
2 17 5
inspection. A more detailed inspection by a qualified
12 15
individual may be required to determine if replacement
of the rotation bearing and fasteners is required. 7 10
14 3
Visual Inspection Procedure
Perform this visual inspection procedure at intervals
recommended in the Preventive Maintenance and In-
spection Checklist. 4 13
9 8
Visually inspect all rotation bearing cap screws, looking for
18 11
any evidence that a cap screw is loose. Check for loose 6 1
16
washers under the heads of the cap screws by trying
to turn each washer by hand. If movement is indicated, Rotation Gearbox
retorque all of the cap screws and nuts as described in
this section.
Turntable
Annual Torque Inspection Procedure
Figure 4.7 — Cap Screw Torque Pattern
Check the cap screws to be sure they are torqued to 90
percent of the normal installation torque. Use a regularly
2. Begin with cap screw number 1 on the outer race,
calibrated, accurate torque wrench. If one or more of
and torque it to 150 foot-pounds (203 N•m).
these cap screws turns before the wrench clicks, check
the torque on all the cap screws as described in this sec-
3. Continue around the pattern, torquing each cap screw
tion. If the rotation bearing is replaced or removed, the
to 150 foot-pounds (203 N•m).
same inspection intervals must be followed.
4. Beginning at number 1, torque all cap screws to 150
foot-pounds (203 N•m) again. Go around in a circular
pattern instead of in the numbered order.

20 • Section 4 — Preventive Maintenance and Inspection

 5. Repeat steps 1 through 4 on the inner race cap Visual Inspection Procedure
screws, torquing each cap screw to 150 foot-pounds Perform this visual inspection procedure as recommended
(203 N•m). in the Preventive Maintenance and Inspection Checklist.

Slide Pad Bearing Cap Screws Visually inspect all rotation gearbox cap screws, looking
The lower boom and outriggers are equipped with slide for any evidence that a cap screw is loose. Check for loose
pad bearings. The slide pad bearings are mounted with washers under the heads of the cap screws by trying to
either hex head or flat countersunk head cap screws. The turn each washer by hand. If movement is indicated, all
flat countersunk head cap screws have a nylon insert or the cap screws must be retorqued.
nylon patch imbedded in the threads. These fasteners
must be installed using medium strength thread locking Annual Torque Inspection Procedure
adhesive. Check the cap screws to be sure they are torqued to 90
percent of the normal installation torque. Use a regularly
Do not reuse the flat countersunk head cap screws if they calibrated, accurate torque wrench. If one or more of
are removed. Once a cap screw is removed, the nylon these cap screws turns before the wrench clicks, retorque
insert or nylon patch on the threads of the cap screw all the cap screws to the normal installation torque. If
will be distorted. This distortion may not allow the cap the rotation gearbox is replaced or removed, the same
screw to tighten properly if it is reused. They should be inspection intervals must be followed.
replaced with new cap screws of the proper length and
thread locking adhesive to ensure a clean and secure fit.
Properly torque the cap screws to prevent the bearings Pins and Pin Retainers
from splitting (refer to Torque Values in the Appendix). A variety of pins and pin retainers are used on the unit.
The type of pin or pin retainer used depends on the
Slide pad bearings mounted with flat countersunk cap particular application.
screws must have the heads of the mounting screws
located below the sliding surface of the bearing. This Chrome plated pins are used in critical areas, such as
prevents the cap screw head from damaging the upper the lower boom pivot pin. The chrome plating provides
boom surface. long wear for pins used with self-lubricating bearings.
It also prevents rust. Proper pin lubrication will protect
Rotation Gearbox Mounting Cap Screws pins from corrosive wear. However, do not lubricate pins
Special cap screws are used to secure the rotation gear- used with self-lubricating bearings (refer to Bearings in
box to the turntable. The torque value for the cap screws this section).
is 115 foot-pounds (156 N•m). The cap screws require
special inspection procedures. Use a dead blow hammer to remove or install pins.
Striking the pin with a steel hammer may distort the pin
Insufficient or uneven cap screw tightness can contribute or close the retaining ring groove. This may make pin
to reduced life of the gearbox. installation difficult or cause the retaining ring to come
out of its groove.
CAUTION
Inspect all pivot and mounting pins at intervals recom-
Injury can result from being pinched or trapped be- mended in the Preventive Maintenance and Inspection
tween moving components. Keep hands clear. Checklist. Inspect pins if removed for signs of wear. If
a pin has a noticeable step worn in it or if a chrome pin
Use caution when covers have been removed to ser- has flakes, cracks, or is galled replace it.
vice the unit. Pinch points and shear points may exist
between moving parts. Replace the covers immediately Retaining Rings
after servicing. Retaining rings are used as a backup retaining system
for some pins and as the primary retaining system for
NOTICE other pins.
Only use Altec supplied cap screws and washers to
When inspecting retaining rings, check that they are
install the rotation gearbox.
properly installed and undamaged.
Use an accurate, click-type manual torque wrench
Install retaining rings with the sharp edge out (refer to
for the inspection of these cap screws. Torque the
Figure 4.8). This makes it more difficult for the retaining
cap screws by a smooth pull on the torque wrench
without jerking. Do not overtighten the cap screws.

Section 4 — Preventive Maintenance and Inspection • 21

ring to come off the pin if the pin is being forced out the
First Boss Second Boss
other side.
Pin Bearing

Sharp
Edge

Section A-A

Figure 4.8 — Retaining Ring Anti-Seize Compound

Flange and Cap Screws Pin Retainer Figure 4.9 —

The mounting pins of many cylinders and other major Pin Installation Into Self-Lubricating Bearings
components are made with a chrome plated pin with a
welded flange on one end of the pin. The flange is drilled
for two cap screws. On the opposite end of the pin is a
Bearings
groove cut for the retaining ring. This provides a very The unit is equipped with a variety of bearings. The type
dependable retainer system for the component. The pin of bearing used depends on the particular application.
flange is secured with two cap screws.
Spherical Bearings
This type of pin retainer system is used on the lower A spherical bearing is used at the base end of the lift
boom pivot, the articulating arm cylinder, the lift cylinder, cylinder. Self-aligning bearings such as these are used
and the platform leveling cylinder on the lower boom. in areas where perfect alignment is difficult to maintain.
This type of bearing allows the component to follow the
When inspecting this type of pin, check cracking of the movements of the structure without applying a side load
flange weld. Make sure the cap screws are tight. Any to the internal components of the cylinder.
cracks or looseness of the cap screws can mean the
bearings are binding on the pin. Make sure the retain- Periodic lubrication of these bearings is required. Lubrica-
ing ring is in place, properly installed, and undamaged. tion prevents the inner rim that maintains the alignment
from seizing to the outer rim of the bearing. Lubrication
Pin Installation Into in this section describes how to properly lubricate these
Self-Lubricating Bearings bearings.
When installing a pin into a self-lubricating bearing, only
lubricate the area where the pin and the boss make con- Self-Lubricating Bearings
tact (refer to Figure 4.9). Self-lubricating bearings are used at the mounting points
of the following components.
Use the following procedure to install the pin.
• Platform bracket pin
1. Slide the pin through the first boss and bearing until • Arm pivot pins
it reaches the second boss. • Link pivot pins
• Boom pin
2. Apply an anti-seize compound to the second pin • Leveling cylinders
boss, and pin surface that is still exposed. • Lift cylinder rod end pin
• Articulating arm cylinder
3. Slide the pin completely into the second pin boss
and install the appropriate retaining system. Self-lubricating bearings are designed for long life. Under
normal use, this type of bearing will provide many years
of service with little maintenance. These bearings resist
impact and shock loads, and abrasive contaminants.

Self-lubricating bearings are made with a braided cord

liner containing Teflon fibers. The liner is bonded to the

22 • Section 4 — Preventive Maintenance and Inspection

outer shell of the bearing with epoxy resin. The epoxy 2. Use a screwdriver and needle nose pliers to collapse
resin has a self-lubricating filler added to it. A chrome the bearing and pull it out of the bearing boss.
plated pin is used with this bearing.
3. Clean the bearing boss. Do not remove any metal
The inside diameter of a fiberglass self-lubricating bear- from the boss surface. If metal is removed, the new
ing contains Teflon fibers. Once a pin is installed in the bearing may not fit properly in the boss.
bearing, some of the Teflon transfers to the pin surface
and provides lubrication. Applying anti-seize compound 4. Place the new bearing on a bearing driver. Line it
to the entire surface of the pin will prevent the Teflon from up with the bearing boss and drive the bearing into
transferring. This may shorten bearing life. place using a dead blow hammer. An old pin can be
used as a driver (refer to Figure 4.10).
Replace these bearings if the components are disas-
sembled for other purposes. Replacement of this type 5. Inspect the pin before installing it into the bearing.
of bearing due to wear is not a normal consideration. Use a new pin if the chrome is flaked, cracked, or
galled.
If it is desirable to measure the bearing to determine
when it is worn, consider several factors. The accurate 6. Slide the pin through the first pin boss and bearing
way to measure bearing wear is to keep a record of the until it reaches the second pin boss.
clearance between the chrome pin and the bearing.
Place the magnetic base of a dial indicator in a position 7. Apply an anti-seize compound to the second pin boss
that allows the clearance between the pin and the bear- and pin surface that is still exposed.
ing to be measured while under load. Take a measure-
ment when the unit is new to provide a reference point. 8. Slide the pin completely into the second pin boss,
Monitor the change in bearing clearance with subsequent and install the appropriate retaining system.
measurements.
Tapered Roller Bearings
For self-lubricating bearings, clearance wear on the bear- Tapered roller bearings are often used in gearboxes.
ing of 0.005” (0.13 mm) may suggest that the bearing This bearing type may be used at high speeds and will
needs to be replaced. This figure takes into account only support radial and axial loading. Depending on the ap-
the wear of the bearing. Over time, there may also be plication, the tapered roller bearing may be installed with
pin and pin boss wear. An overall change in the clear- several thousandths inch end clearance, no clearance,
ance between the pin and the bearing of 0.020” (0.51 or with a preload.
mm) or more indicates the pin and bearing both need
to be replaced. A preload is 0.000″ (0.00 mm) clearance minus a few
thousandths. Preload is sometimes checked with a torque
Replacement wrench (stall torque) or with a line and scale (rolling
Use the following procedure to remove and install self- torque). Shaft load and speed of the particular application
lubricating bearings. will determine the method of installation. Light loads and
high speeds call for a specific amount of end clearance.
1. Drive out the old bearing. If this is not possible, re- Heavy loads and low speeds call for a specific amount
move it with a die grinder, cut point chisel, or hacksaw of preload on the bearing. Proper installation and lubri-
blade (refer to Figure 4.10). Do not damage the inside cation of the tapered roller bearing are very important in
diameter of the bearing boss. determining the useful life of the bearing.

Slide Pad Bearings

Removal Boom
Tool Slide pad bearings on the booms provide a smooth
surface for extension and retraction of the upper boom.

The most highly loaded slide pad bearings are made of

Bearing
molybdenum disulfide impregnated nylon. Other slide
Driver pad bearings are made of a type of polyethylene. Both
Removal Installation types of bearings will last indefinitely when run against
Figure 4.10 — Removal and smooth surfaces.
Installation of Self-Lubricating Bearings

Section 4 — Preventive Maintenance and Inspection • 23

The internal sliding surface of the lower boom is sanded constant for many years if the bearing is properly lubricated
smooth and may be lightly lubricated with moly grease or and not overloaded. As the bearing raceway begins to
assembled with the powder paint coating during factory wear, clearance will increase. It should increase steadily
assembly. The lower boom and slide pads require no at first and accelerate toward the end of bearing life.
further lubrication unless the booms are disassembled
for major maintenance. An increase in bearing clearance is one sign of bearing
wear. Periodic bearing tilt measurements will help deter-
Keep the external surface of the upper boom smooth. mine when bearing replacement is necessary. Perform
If the external surface becomes rough, the upper boom bearing inspection and turntable tilt measurements at
may not extend and retract smoothly. intervals recommended in the Preventive Maintenance
and Inspection Checklist. When the total increase in
Allow paint applied to the upper boom to cure thoroughly. turntable tilt measurement reaches 0.050″ (1.27 mm),
After the paint has cured, lubricate the surface before perform more frequent inspections until the bearing re-
extending or retracting the upper boom over the slide placement criteria is reached at intervals recommended
pad bearings. in the Preventive Maintenance and Inspection Checklist.

Bearing replacement kits that contain slide pad bear- Take an initial turntable tilt measurement when the unit is
ings and mounting screws are available from your Altec delivered. This will provide a baseline for future bearing
representative. tilt measurements. Future bearing tilt measurements will
be compared to this baseline to determine how much the
Shimming bearing tilt has increased since the initial (new bearing)
Thin gauge steel shims are used with slide pad bearings measurement. To minimize measurement variations,
on the top and sides of the upper boom. The shims are the measurement should be done by the maintenance
used to obtain the proper clearance between the upper team responsible for all future bearing tilt measurements
and lower booms. The shims also aid in maintaining the so a consistent, repeatable method of measurement is
proper alignment of the extension cylinder and other developed and documented. The greatest portion of the
components. measured turntable tilt results from structural deflection
rather than the actual bearing internal clearance. Varia-
If it becomes necessary to change the clearance, shims tions in the tilt measurement can be caused by differ-
should be added or removed only from the bearings on ences in the exact measurement location, the method of
the top and sides. Do not add shims to the slide pad attaching the measurement equipment, and the way the
bearings on the bottom. boom load is applied. Due to these potential variations
in measurement, use the same documented measure-
If new slide pad bearings are installed, use shims where ment procedure each time a bearing tilt measurement is
needed (top and/or sides) to obtain proper fit and align- taken. The initial bearing tilt measurement is not taken at
ment. the manufacturing plant since all subsequent measure-
ments need to be done identically to the first one. Keep
Outrigger a maintenance log to monitor bearing inspections and
Vertical leg outriggers are used to assist the stability while turntable tilt measurements and to document the exact
operating the unit. Hydraulic cylinders on each side of the measurement procedure used during the life of the unit.
outrigger assembly extend the inner leg to the ground.
The cylinders are held in place by dual pilot operated Bearing Replacement Criteria
check valves. These check valves also trap the oil in the The rotation bearing must be inspected and evaluated.
cylinder in cases of hydraulic line breakage. The recommended bearing inspection procedures include
the following items.
Rotation Bearing
The turntable rotates on a large ball bearing called the • Monitoring the trend of turntable tilt measurements
rotation bearing. The inner race is mounted to the turntable Bearing inspections and turntable tilt measurements
and the outer race is mounted to the pedestal. The outer can be used to determine when a bearing should be
race has gear teeth that mesh with teeth on the rotation replaced. Generally, an increase in turntable tilt of
pinion. Properly maintained, the bearing should provide 0.065″ (1.65 mm) above the initial tilt measurement
many years of satisfactory service. indicates that the bearing may be reaching the end
of its useful life. Other factors related to the condition
Monitoring Bearing Wear of the bearing must also be considered. Determine
The internal bearing clearance will increase slightly dur- if the increase in the turntable tilt measurements
ing the break-in period. It should then remain essentially has been steady or if it shows a trend of acceler-

24 • Section 4 — Preventive Maintenance and Inspection

 ated wear (refer to Figure 4.11). Example 1 shows termine if bearing noise is due to internal or external
a steady increase in wear, which is normal. Example problems.
2 shows an accelerated increase in wear, which
indicates bearing replacement may be necessary. If • Inspecting the condition of the purged bearing grease
the tilt measurement has reached 0.065″ (1.65 mm) Grease from a well worn, poorly maintained or dam-
above the initial (new bearing) tilt measurement and aged bearing will typically contain fairly large rust or
periodic measurements show a trend of accelerated metal particles instead of metal dust specks which
wear, replace the bearing. might be found in any bearing. Fairly large rust or
metal particles indicate the bearing has reached an
500 Hour/6 Month accelerated wear condition, and immediate bear-
Inspections Example 1 Example 2 ing replacement is required. The presence of rust
1 0.112″ (2.84 mm) 0.110″ (2.79 mm) indicates inadequate lubrication. Rust is commonly
indicated by extremely dirty grease. This situation
2 0.114″ (2.90 mm) 0.114″ (2.90 mm) must be corrected to optimize the performance of
3 0.116″ (2.95 mm) 0.122″ (3.10 mm) the new bearing. Always check the purged bearing
grease at each inspection and turntable tilt mea-
Figure 4.11 — Turntable Tilt Measurements
surement procedure even if there is no presence of
roughness, noise in the bearing or significant change
Because the major portion of the measured turn-
in turntable tilt measurement.
table tilt results from structural deflection, the total
tilt measurement varies from model to model. For
One or more of these evaluation criteria should detect the
example, overall turntable tilt measurements ap-
need for rotation bearing replacement long before there
proaching 0.200″ (5.08 mm) are not uncommon on
is any threat of failure. By maintaining proper rotation
some models, even on bearings which have not yet
bearing lubrication and avoiding overload conditions,
reached the end of their usable life. Severely worn
the replacement rotation bearing should provide many
bearings could have a measured turntable tilt as
years of service.
much as 0.500″ (12.70 mm) or more in addition to
other prominent symptoms of wear such as unusual
Bearing Inspection and Turntable Tilt Measurement
noise and roughness. Therefore, the total turntable
1. Position the unit on a level surface where the booms
tilt measurement itself should not be used to gauge
can be elevated and rotated. Apply the parking brake,
a bearing’s remaining useful life. The change in
and chock the wheels. Engage the hydraulic system,
turntable tilt and the trend toward accelerated wear
and properly set the outriggers.
is more important than the total tilt measurement
itself.
2. Position the booms in a position of near maximum
side reach. Exact boom position is not critical. Slowly
• Evaluating the “feel” of the unit
rotate the turntable 360 degrees using the lower
If there is no trend toward accelerated wear, consider
controls while checking for roughness or noise in
the “feel” of the unit during load reversals (such as
the rotation bearing. Repeat using the upper controls
moving the booms up and down). Operators may
since roughness may be felt more accurately from
notice an increase in the tilting or rocking of the
the platform. Record in the maintenance log whether
turntable.
unusual noise or roughness was encountered.
• Checking for rotation bearing noise and roughness
3. Rotate the turntable to the position to be used for
Determine whether there is any presence of rough-
the turntable tilt measurement. If the aerial device is
ness or noise in the rotation bearing during rotation.
normally operated within a particular zone of rotation,
Severely worn bearings commonly exhibit grinding,
measure the tilt with the turntable rotated to this posi-
snapping, and popping noises during rotation. These
tion. For consistent measurement, always use the
noises may indicate the bearing has broken ball
same rotational position with no load in the platform
spacers, split ball bearings, or excessive galling,
each time the tilt measurement is done. Record the
which would require immediate bearing replacement.
rotational position in the maintenance log.
Popping or clicking noises might also be caused by
broken or improperly torqued bearing fasteners, a
4. Position the boom as in Figure 4.12. For reference,
warped mounting surface, or worn teeth. A check of
this position is called Position A.
the fastener torque and the rotation bearing grease
purged during lubrication because it will usually de-

Section 4 — Preventive Maintenance and Inspection • 25

 Boom Fully Retracted
and Fully Raised
Boom Fully
Extended and Horizontal
Articulating
Arm Vertical

Figure 4.14 — Position B

Articulating
Arm Horizontal
8. Repeat steps 6 and 7 twice more to obtain an ac-
Figure 4.12 — Position A curate reading.

5. Attach the magnetic base of the dial indicator to the 9. Remove the dial indicator to prevent damage.
pedestal, positioning the pointer at either the front
or rear of the turntable. Position the pointer of the 10. Refer to Bearing Replacement Criteria to determine
dial indicator against the underside of the turntable if bearing replacement is required.
base plate, as close as possible to the bearing gear
cover. Figure 4.13 shows possible positions for the
dial indicator pointer. Any of these positions may be
Cylinders
used. It may be difficult to position the dial indicator Inspect all cylinders at intervals recommended in the
and pointer in some zones of rotation without inter- Preventive Maintenance and Inspection Checklist.
ference with the turntable or pedestal. In this case,
position the dial indicator and pointer to the area
WARNING
as close as possible to the recommended position.
Once a correct indicator pointer position is chosen, Death or serious injury can result from cylinder
it is important that the same pointer position is used failure. Do not operate a cylinder that has a dented
for each subsequent tilt measurement. Record the barrel or a damaged rod.
pointer position in the maintenance or service log
where the tilt measurements are recorded. Some Visually inspect the cylinders for leaks, loose or missing
inspectors prefer to permanently mark the location pin retainers, broken bearings, bent rods, and dents in
where the dial indicator pointer contacts the bearing the rod or barrel.
base plate to ensure that subsequent measurements
are made in exactly the same spot. Check for proper operation of the cylinder holding valves
by positioning the boom or outrigger so a load is ap-
plied to the cylinder to put pressure against the holding

A • •B Pinion Gear Cover valves. Disengage the hydraulic system. Fully shift the
manual lever for the function being tested. Hold the lever
momentarily to allow oil flow from the holding valve to
tank. If the cylinder does not move, the retract holding
valve is operating properly. If the cylinder retracts slowly,
the holding valve may be leaking. Determine the cause
Rotation Bearing
•
C Gear Cover
of the problem and correct it before operating the unit.

Figure 4.13 — Pointer Positions Hydraulic Lines

Hydraulic hoses and tubes transmit hydraulic oil through-
6. Set the dial indicator at zero with the booms in Posi-
out the hydraulic system.
tion A (refer to Figure 4.12).
Inspect all hoses and tubes for wear and/or physical
7. Position the booms to Position B as shown in Figure
damage at intervals recommended in the Preventive
4.14. Do not rotate the turntable. Record the indicator
Maintenance and Inspection Checklist. Make sure the
reading.
hoses are properly routed to avoid sharp edges, kinking,

26 • Section 4 — Preventive Maintenance and Inspection

and scuffing. Inspect the tubes for dents or other damage Purging
that may restrict oil flow. Make sure all hoses and tubes 1. Lower the lower boom into the rest and apply down
are held firmly in their support brackets. pressure for three to five seconds to unlock the ve-
locity fuse.
Manual Lowering System
2. Raise the lower boom about 24” (60.96 cm) above
The manual lowering system allows the platform operator horizontal and support the booms with a sling and
to lower the booms if the hydraulic system fails. Lowering hoist.
is accomplished by opening the manual lowering valve
on the upper boom tip to bleed off oil from the lift cylinder. 3. Turn the manual lowering system control knob coun-
The valve may be adjusted to control the rate of platform terclockwise to open the needle valve.
lowering. Figure 4.15 shows the manual lowering system.
4. Slowly lower the booms about 12” (30.48 cm) using
This lowering system uses a 1/2 gpm (1.89 lpm) pres- the hoist. This will allow oil in the base of the cylinder
sure compensated flow control to regulate the maximum to flow to the reservoir, purging the system of any
lowering speed. A velocity fuse is also used to isolate air.
the system if the hose to the manual lowering valve at
the boom tip malfunctions. If the flow through the veloc- 5. Close the needle valve and test the manual lowering
ity fuse becomes greater than 1.7 gpm (6.44 lpm) it will system for proper operation.
close, stopping the hydraulic oil flow.

Test the manual lowering system as recommended by

Fiberglass and Plastic Components
the Preventive Maintenance and Inspection Checklist. Cleaning
The outside of the platform can be cleaned (as necessary)
Testing using a pressure washer and a mild detergent. Rinse with
Use the following procedure to test the manual lowering clean water to remove any detergent residue. Be careful
system. not to spray water into platforms equipped with electric
heaters. Water entering under pressure may damage
1. Fully raise the lower boom. the heater unit.

2. Turn the manual lowering system control knob

CAUTION
counterclockwise to lower the platform. If the lower
boom does not lower using the system, close the Injury can result from electric shock. Turn off and
lowering valve and lower the lower boom using the unplug the electric heater before cleaning the plat-
unit’s hydraulic system. form with water.

NOTICE Inspection
If there is air in the line when the lower boom is The fiberglass platform should be inspected for any visible
raised, the fuse will close and disable the manual damage such as scratches, cracks, or chips. Repair of
lowering system. these defects is easy and should be maintained to retain
the cosmetic appearance of the platform.

Hoses in Booms

Manual
Lowering Valve
Velocity Fuse

Figure 4.15 — Manual Lowering System

Section 4 — Preventive Maintenance and Inspection • 27

Repair CAUTION
The first step in successful repair is to analyze the dam-
Injury can result from airborne particles entering the
age and determine the cause. Cracks in the gelcoat or
eyes and lungs. Wear appropriate safety equipment.
outer surface of the platform are easily repaired. Dam-
age to the fiberglass structure can be more serious and
2. While wearing the dust mask for breathing protection
should be carefully evaluated before attempting to repair
and the safety glasses, grind the area within the box
the platform.
to a depth of approximately 1/8″ (3.18 mm).
The structural integrity of the platform rim or lip, door
3. Cut strips of fiberglass cloth to fit the box area.
frame and bottom is critical in determining whether the
platform can be successfully repaired. The platform bot-
4. Clean the area thoroughly with cleaning solvent.
tom, door frame, part way up the sides from the bottom,
and the rim are substantially thicker than the rest of the
5. While wearing rubber gloves, mix the approximate
platform to provide structural support. These factors must
amount of polyester resin and catalyst according to
be considered when determining whether a successful
the directions in the gelcoat repair kit.
repair can be made on or near the platform bottom, door
frame, or rim.
6. While wearing the rubber gloves, saturate the fiber-
glass cloth with the mixed resin, and apply it to the
Altec cannot determine if the platform is repairable in the
damaged area. Work the area to squeeze out any
field. Evaluate the platform and determine whether or not
trapped air bubbles.
it can be repaired and safely used for future service. Altec
does not recommend that repairs be made to platforms
7. After the resin has set up completely, grind off any
which have the following damage.
rough area or high spots.
• Cracks through the fiberglass of the rim, lip, or door
8. Measure an additional cup of resin and catalyst ac-
frame
cording to the directions in the gelcoat repair kit and
apply smoothly to completely cover the affected area.
• Cracks on the floor of the platform around the mount-
ing point to the L-bracket or mounting bracket
9. Sand the area with the dual acting sander and 320
grit sandpaper.
Altec only assumes responsibility for platform repair
performed by Altec personnel.
10. Paint the area to match the platform.
The equipment and materials listed below are required
Damage to the gelcoat layer may be repaired using the
to perform field repair of the platform.
instructions that accompany the gelcoat repair kit. This
kit can be ordered from your Altec representative. The
• Circular grinder with 24 grit sandpaper
gelcoat is for cosmetic purposes as well as providing a
• Dual acting sander with 320 grit sandpaper
protective layer of ultraviolet inhibitors. The gelcoat layer
• Cleaning solvent (acetone)
has no inherent strength.
• Fiberglass cloth or mat
• Gelcoat repair kit
More specific repair information for a particular situation
• Good quality rubber gloves
should be requested from your local Altec representative.
• Dust mask
Before making any repair, keep in mind the structural
• Safety glasses
integrity of the platform and the safety of the operator.
• Nonmetallic spray paint (to match the platform)
Covers
The following procedure may be used as a guide in mak-
Covers on various areas of the unit are made of plastic.
ing a quality field repair.
Plastic
1. Outline the damage with a box that is 1″ (2.54 cm)
Plastic covers at the boom tip are covered with an acrylic
wider on all sides of the damaged area. If the dam-
surface to protect the plastic from ultraviolet damage.
age is 1″ x 3″ (2.54 x 7.62 cm), the box would be 3″
Use a pressure washer and mild detergent to clean
x 5″ (7.62 x 12.70 cm).
plastic covers. Rinse with clean water to remove any
detergent residue.

28 • Section 4 — Preventive Maintenance and Inspection

 NOTICE To test the upper leveling cylinder, with the hydraulic
Using solvents (such as acetone, MEK, or lacquer system disengaged, place a load on the cylinder using
thinner) can damage plastic covers. Use only isopro- a come-along to pull on the lower end of the L-bracket. If
pyl alcohol (rubbing alcohol) to clean plastic covers. the cylinder moves, the seals are leaking and the cylinder
needs to be repaired or replaced. If the cylinder does
In some situations, pressure washing may not remove all not move, have someone move the control handle on
of the contaminants from plastic covers. Use isopropyl the main control valve for the platform leveling function,
(rubbing) alcohol to clean this type of contamination. while pulling on the L-bracket and watching for cylinder
movement. A change in cylinder position indicates that
After the covers are clean and dry, hand polish using an the holding valves are not functioning properly.
automotive type wax.
Accident Prevention Signs
Platform Leveling The unit was equipped with accident prevention signs
Hydraulic at the time of manufacture. If any of these are lost or
A walk-around inspection can be done to visually check become illegible, replacements may be obtained from
for leaks and loose or missing mounting pin fasteners. your Altec representative.
Inspect the cylinders for obvious damage such as bro-
ken bearings, dented rod or cylinder barrel, or a bent The location, part numbers, and descriptions of all plac-
cylinder rod. ards are listed in the Parts Manual.

WARNING
Death or serious injury can result from cylinder
failure. Do not operate a cylinder that has a dented
barrel of a damaged rod.

Section 4 — Preventive Maintenance and Inspection • 29

Accident Prevention Signs Diagram

3 4 2 4

8
7
11 1

* Both sides 1* 6*
Street Side

13
8 Without Outriggers

12
Chassis

Curb Side Access

5

Without
8 Outriggers
9 With
Outriggers 2 7

4
10

30 • Section 4 — Preventive Maintenance and Inspection

 1

Section 4 — Preventive Maintenance and Inspection • 31

 5

32 • Section 4 — Preventive Maintenance and Inspection

10

11
12

13

Section 4 — Preventive Maintenance and Inspection • 33

34 • Section 4 — Preventive Maintenance and Inspection
 Section 5 — Hydraulic System
The unit uses a full-flow, open-center hydraulic system.
Pump
Hydraulic oil flow is provided by a fixed displacement
pump. Hydraulic oil flows continually from the pump, The hydraulic pump can be driven by the vehicle engine,
through the valves and back to the reservoir whenever or an auxiliary engine. The hydraulic system has been
the pump is turning. When the pump is engaged and all designed for a pump delivery of 5 gpm (18.93 lpm) at 2,400
valves are in neutral, the only pressure in the system psi (165.47 bar). In case of catastrophic pump failure,
is that required to overcome the resistance to oil flow the hydraulic system must be flushed. This procedure is
through the hoses and valves. described in Section 4 under Changing Oil and Flushing
the System. Flushing the hydraulic system will remove
Hydraulic schematic drawings are an important tool in most of the metallic contamination from the system.
understanding the operation of a hydraulic system. The
symbols identify the flow paths and operation of the Before servicing the pump, close the shutoff valve in the
components in the system. A thorough understanding of suction line between the reservoir and the pump. Clos-
these symbols can reduce downtime and increase the ing the shutoff valve allows the pump to be serviced or
accuracy of diagnosing malfunctions. Basic hydraulic removed without draining the reservoir.
schematic symbols are identified in the Appendix.

This section includes a description of the hydraulic

components and an illustration of the components. Hy-
draulic schematics of the components can be found in
the Appendix.

Oil Reservoir Figure 5.2 — Pump

The capacity of the reservoir is 7 gallons (26.50 l). It uses

NOTICE
an external spin on cartridge type return line filter. The
reservoir is shown in Figure 5.1. Damage to the pump or return line filter can result
if the unit is operated with either or both the shutoff
valves closed. Fully open the shutoff valves before
Filler Breather Cap Strainer Basket engaging the hydraulic system.

When service is completed, open the shutoff valve before

operating the unit.

Secondary Stowage DC Pump

The secondary stowage DC pump and motor assembly
has two hydraulic connections: inlet and outlet. It also has
Return an internal check valve. The pump is a fixed displace-
Line Filter ment pump with output less than 1.2 gpm (4.54 lpm).
The motor receives its power from the vehicle battery
Shutoff Valve or an auxiliary battery.
Suction Strainer
Figure 5.1 — Hydraulic Oil Reservoir

A removable 150 micron mesh suction strainer is located Motor

at the outlet of the reservoir. A filler breather cap is located Pump
on top of the fill hole of the reservoir. The cap contains a
filter that cleans the air as it enters the hydraulic system.
A strainer basket in the fill hole keeps large particles from
entering the reservoir when oil is poured into it. Refer to
Section 4 under Filtration for information on filters.

Figure 5.3 — Secondary Stowage DC Pump

Section 5 — Hydraulic System • 35

 The ground level functions/machine spool of the valve
Valves has two detent positions. The positions are Ground Level
When describing hydraulic valves, “position” identifies Functions and Machine.
the number of operating positions of the valve spool. A
two-position blocking valve has two operating positions: When the ground level functions/machine selector handle
open and closed. is in the Ground Level Functions position, hydraulic oil
flow is directed to the outrigger control valves.
The word “way” identifies the number of ports in a valve
section. A four-way control valve has four ports. One port After the outriggers have been properly set, the selector
is for a pressure connection, one is for a return line con- may be positioned in the Machine position. When the
nection, and the other two ports are the working ports. ground level functions/machine selector handle is in the
Machine position, hydraulic oil flow is directed through the
Outrigger Control Valve rotary joint to the station selector valve in the turntable.
The outrigger control valve is a three-position, four-way
valve. The three positions of the valve spool are extend, The second spool of the valve is a three-position, four-
neutral, and retract. The four connections are pressure, way, manually operated spool with a switch to energize
return, and work ports A and B. The valve spools are spring the outrigger motion alarm. This spool directs hydraulic
centered and are operated by a manual control handle. oil flow to the outrigger valves.

Outrigger Interlock Valve

The outrigger interlock valve is a normally open, two-
position, two-way, solenoid operated, poppet-type valve.
It allows hydraulic oil in the pressure line to bleed back
to the reservoir instead of reaching the above rotation
control valves until the outriggers have been lowered.

Figure 5.4 — Outrigger Control Valve

Ground Level Functions/

Machine and Outrigger Valve
The ground level functions/machine and outriggers Figure 5.6 — Outrigger Interlock Valve
valve (refer to Figure 5.5) is located on the tailshelf of
the vehicle. One spool of the valve is a three-position, Electrical switches are located on each outrigger leg and
four-way, manually operated valve. are connected to the outrigger interlock control module.
Lowering the outriggers activates the electrical switches,
sending voltage to the solenoid on the outrigger interlock
valve. The interlock valve spool then shifts, blocking flow
to the reservoir. All hydraulic oil is then directed to the
main control valve to operate the unit.

Main Control Valve, Variable Speed

The main control valve module (refer to Figure 5.7) pro-
vides for directional control of the boom functions. The
control valve has five valve spools and is located on the
side of the turntable. The valve spools are spring-centered
and solenoid actuated in both directions.

The valve module contains a system pressure relief

valve. This relief valve is factory set to deliver a system
Figure 5.5 — Ground Level pressure of 2,200 to 2,250 psi (151.68 to 155.32 bar). A
Functions/Machine and Outrigger Valve bypass valve is also located in the valve inlet section to
prevent hydraulic oil flow from reaching the valve spools
until a function is operated.

36 • Section 5 — Hydraulic System

 Lower Boom Articulating Platform
Articulating Arm Lower Boom (Lower) Arm (Lower) (Stow/
(Raise) (Raise)
Upper Boom Rotation Unstow)
Rotation (CW) Upper Boom Platform (Retract) (CCW)
(Extend) (Unstow)

System Rotation Upper Boom Platform

Relief (CCW) (Retract) Stow
Upper Boom Rotation
Variable Unloader Articulating Lower Boom Lower Boom (Extend) (CW)
Inlet Valve Arm (Lower) (Lower) (Raise) Articulating Platform
Arm (Raise) Stow/Unstow
Variable Speed Proportional Control

Figure 5.7 — Main Control Valve

Main Control Valve, Proportional Speed the balance to flow into the system. Once the solenoid is
The main control valve module (refer to Figure 5.7) pro- fully energized, the spool is held in the closed position
vides for directional control of the boom functions. The and the full 5 gpm (18.93 lpm) from the pump is allowed
control valve has five valve spools and is located on the to flow into the system.
side of the turntable. The valve spools are spring centered
and solenoid actuated in both directions. System Relief Valve
The main system relief valve is located in the main con-
The valve module contains a system pressure relief trol valve (refer to Figure 5.8). The relief valve limits the
valve. This relief valve is factory set to deliver a system maximum pressure in the hydraulic system to 2,400 psi
pressure of 2,400 psi (165.47 bar). (165.47 bar).

Blocking Valve
The blocking valve is located at the turntable. It is a
normally open, two-way, solenoid operated valve which
prevents hydraulic oil flow from reaching the main valve
until a function is operated.

Speed Control Valve

The speed control valve is a variable speed inlet valve.
In the normally open position, full flow is allowed to pass
and the 5 gpm (18.93 lpm) from the pump is returned to
the reservoir.
Relief Valve
When the solenoid is energized by the variable speed Variable Speed Proportional
control at the upper controls, the spool gradually shifts to
the closed position, restricting oil flow to tank and allowing Figure 5.8 — System Relief Valve

Section 5 — Hydraulic System • 37

Outrigger Relief Valve Two flow control valves limit the hydraulic oil flow in the
The outrigger relief valve is located in the pressure line rotation circuit. They are factory set to limit the speed
between the pump and the turntable on units that are of the rotation function for the 90 degree rotator. These
equipped with this option. The purpose of the relief valve are located in the valve block for the double pilot oper-
is to limit the maximum pressure in the outrigger circuit ated check valves. The flow control valves for the 180
to 2,500 psi (172.37 bar). degree rotator are located in a valve block mounted on
the rotator actuator.
Manual Lowering Valve
The manual lowering valve (refer to Figure 5.9) is an Holding Valves
adjustable needle valve. Located at the boom tip, this The unit uses holding valves to ensure that various
valve may be manually opened to allow hydraulic oil to actuators maintain their position under load or if there
bleed off the oil in the base of the lift cylinder. The valve is hydraulic line failure. These holding valves block the
is used with two other components. A 1.7 gpm (6.44 lpm) hydraulic oil in the actuators to prevent movement. The
velocity fuse is used to isolate the system if the hose to types of holding valves used are pilot operated check
the needle valve breaks. A 1/2 gpm (1.89 lpm) pressure valves and counterbalance valves.
compensated flow control is used to control the maximum
lowering speed. Testing of pilot operated check valves and counterbal-
ance valves is described in Section 8 under Hydraulic
Manual Lowering System.
Valve
Pilot Operated Check Valves
Pilot operated check valves block flow out of the follow-
ing actuators.

• Outrigger cylinders
• Upper platform leveling cylinder
• Platform rotation cylinder

A pilot operated check valve allows free flow into the

actuator and blocks return flow. The valve has an inter-
Figure 5.9 — Manual Lowering Valve nal pilot piston that allows it to be hydraulically opened,
allowing flow out of the actuator.
Velocity Fuse
The velocity fuse (refer to Figure 5.10) acts as a flow The pilot operated check valves are installed in pairs and
limiting valve. When hydraulic oil flow through this valve are cross-ported (refer to Figure 5.11). Oil sent to one
reaches 1.7 gpm (6.44 lpm) with a pressure difference work port of the actuator is used to pilot open the check
of 50 psi (3.45 bar) across it, the valve will close. valve for the other work port of the actuator.

Figure 5.10 — Velocity Fuse

Figure 5.11 —
Flow Control Valves Cross-Ported Pilot Operated Check Valve
Flow control valves are used in the platform leveling,
manual lowering and platform rotator circuits. Counterbalance Valves
Counterbalance valves block flow out of the following
In the platform leveling circuit, the flow control valve limits actuators.
the hydraulic oil flow to control the speed of tilt. The flow
control in the manual lowering circuit controls the speed • Lift cylinder
of the boom lowering. • Boom cylinder
• Articulating arm cylinder
• Hydraulic platform leveling function of leveling system

38 • Section 5 — Hydraulic System

A counterbalance valve is a combination of a check valve not entirely fill the cavities that open during the intake
and a relief valve. The check valve allows free flow into part of the pumping cycle and the pump tries to draw a
the actuator and blocks the flow from coming back out. vacuum. The characteristic sound of cavitation is a high
pitched scream. This sound increases with the degree
The relief valve function can be pilot operated to allow of cavitation and increased flow. The following items are
flow out of the function. It also allows the valve to relieve possible causes of cavitation.
excessive pressure and prevents damage from thermal
expansion of the oil. • Excessive pump operating speed
• Clogged suction filter
The counterbalance valves are installed in pairs and are • Excessive oil viscosity (thickness)
cross-ported. Oil sent to one side of the actuator is used • Restrictions or sharp bends in hose
to pilot open the counterbalance valve on the other side • Excessive inlet hose length
of the actuator. • Pump inlet too high above reservoir level
• Shutoff valve in suction line not fully open

NOTICE
Cavitation can quickly destroy the pump. If signs of
pump cavitation are noticed, determine the cause
Figure 5.12 — Counterbalance Valve and repair the problem.

Load Holding and Regenerative Valves If pump cavitation is due to excessive oil viscosity caused
A valve block is mounted to the upper boom extension by cold temperatures, allow the oil to warm up before
cylinder. This block contains a counterbalance holding operating the unit.
valve, a check valve, and a pilot operated check valve.
The counterbalance valve is installed in the system on Aeration occurs when air bubbles are introduced into the
the extend side of the cylinder. This valve protects the hydraulic oil and carried along as the oil flows through
system from rapid lowering in the event of a hydraulic the pump. Aeration can be caused by the following
hose failure. The pilot operated check valve is used to conditions.
prevent the extension cylinder from extending while the
unit is in motion. • Low oil level in the reservoir can cause a whirlpool
at the suction line opening, which sucks air into the
The check valve allows hydraulic oil exhausted from the system along with the oil.
rod end of the cylinder, back into the pressure line to help
extend the cylinder. Regenerative systems such as this, • Leaking connections in the suction line between the
allow extension and retraction speeds to be approximately reservoir and the pump can cause aeration.
the same even though the area of the piston on the extend
side is greater than the area on the retract side. • If the return line outlet is located above the oil level
in the reservoir, turbulence can be caused as the
return oil stream discharges above the surface of
the oil.

NOTICE
Air circulating through the pump can cause unit
malfunctions or pump damage. Determine the cause
and repair the problem.

An air leak in the suction line can occur even if there

Figure 5.13 — is no oil leak when the system is shut down. A leak in
Load Holding and Regenerative Valve the suction line can often be located by slowly squirting
clean hydraulic oil around each connection in the suction
line. Do this with the pump running at normal operating
Cavitation and Aeration speed. A suction leak will suck oil in, and the pump may
Cavitation and aeration are two problems that can cause temporarily run quietly as the air leak is sealed by the
pump damage. Pump cavitation occurs when inlet oil does oil. The leak can then be eliminated.

Section 5 — Hydraulic System • 39

When aeration occurs, the oil in the reservoir is likely to Seek immediate medical attention if injured by escap-
become foamy. The pump may also become noisy. ing hydraulic oil. Serious infection or reaction can re-
sult if medical treatment is not given immediately.
Air Bleeding
Spilled hydraulic oil creates slick surfaces and can
The presence of air in the hydraulic system will cause cause personnel to slip and/or fall. Keep the unit and
abnormal operation, noise, and damage to the pump. work areas clean.
The presence of air in the hydraulic system can usually
be traced to one of the following. If a connection is properly tightened but continues to leak,
disassemble the connection. Seal the necessary parts
• If the oil level in the reservoir gets too low, the pump and/or replace the part that is the source of the leak.
suction can cause a whirlpool to form in the reservoir
which will allow air to be sucked into the system. Worn or damaged parts can also cause leaks. For ex-
ample, scratched cylinder rods or a worn or scratched
• A leak in the plumbing between the reservoir and output shaft on a hydraulic motor can cause leaks. Such
the pump can suck air in and not leak out when the conditions must be repaired or replaced. A new seal
system is shut down. should also be installed.

• Loose connections in the pressure system will nor- An internal leak allows pressurized hydraulic oil to es-
mally leak externally during unit operation, but can cape to tank or another hydraulic circuit. Most hydraulic
suck air into the system after the unit is shut down components have a small amount of internal leakage
as the oil tries to find its way to the low points of the due to machining tolerances.
system.
An internal leak can cause a variety of problems in a hy-
• Hydraulic lines taken loose during maintenance draulic system. Internal leakage in a cylinder can cause
operations can allow air to enter the system. drifting or malfunction of a cylinder. Replacing seals in
the leaking component will usually stop internal leakage.
NOTICE
A leaking holding valve in a cylinder can cause drifting
Air circulating through the pump can cause unit or malfunction of the cylinder. It can be stopped by re-
malfunctions or pump damage. Determine the cause placing the holding valves in the component. However,
and repair the problem. some types of damage, such as scoring of the inside of
a cylinder barrel, require more extensive repair.
Air entering the system due to low oil levels or leaks in
the suction line will cause the most problems and should
be corrected immediately. Heat Generation
Heat is the result of pressurized fluid escaping to the
Leakage reservoir. Most hydraulic components have a some in-
ternal leakage due to machining tolerances. This type of
If components and connections are installed properly, leak generates a small amount of heat that is taken into
leaks can be kept to a minimum. Small external leaks account when the component is designed.
are usually easy to find because dust will collect on the
hydraulic oil film. Internal leaks in the system can be caused by internal
housing cracks, bad relief valves, or leaking seals. This
External leakage is the escape of hydraulic oil outside type of leak allows a large volume of pressurized oil to
the hydraulic system. Improperly tightened fittings are a return to tank. This creates excessive heat in the hydraulic
primary cause of external leakage. Follow the torque and system. Continuous operation with excessive heat will
tightening specifications under Fittings and Valve Car- damage the hydraulic oil, seals and O-rings throughout
tridges in this section to properly tighten hydraulic fittings. the system.

WARNING The following conditions cause heat generation.

Death or serious injury can result from hydraulic • Excessive pump speed
oil being injected into the flesh. Do not use hands • Worn or defective pump
or other body parts to check hydraulic lines and fit- • Defective relief valve cartridges
tings for leaks.

40 • Section 5 — Hydraulic System

 • Contaminated spool in a control valve When replacing a hose, use one the same size, length,
• Low hydraulic oil level and pressure rating. If hose size is doubled, four times
• Improper hydraulic oil the amount of oil will flow at the same pressure. If hose
• Internal component leakage size is decreased, the flow in the circuit will decrease and
back pressure will increase. The increase in back pres-
Refer to Section 8 under Hydraulic System for more sure will cause heat to build up and system malfunction.
information about troubleshooting specific components
for internal leakage.
WARNING
Death or serious injury can result from uncontrolled
Hydraulic Lines movement. Purge the air from the actuator before
Hoses and tubes connect various components of the operating the unit.
hydraulic system.
Death or serious injury can result from hydraulic
Most hoses have a lay line on them. The lay line contains oil being injected into the flesh when loosening or
the following information about the hose. disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic
• Manufacturer’s name components.
• Manufacturer’s part number
• SAE rating Seek immediate medical attention if injured by escap-
• Working pressure ing hydraulic oil. Serious infection or reaction can
• Burst pressure (sometimes) result if medical treatment is not given immediately.
• “Nonconductive” appears on nonconductive hoses
Spilled hydraulic oil creates slick surfaces and can
Hoses transport hydraulic oil through the boom to the cause personnel to slip and/or fall. Keep the unit and
boom tip. The ribbon hose connects with the hoses at work areas clean.
the platform (refer to Figure 5.14).
After removing a hydraulic line from a cylinder, do not
operate the unit from the upper controls until all air is
DANGER purged from the cylinder after the hydraulic lines are
Death or serious injury will result from unprotected reinstalled. The presence of air in the cylinder can cause
contact with energized conductors. Never replace a inadvertent retraction or extension of the cylinder.
nonconductive hose with a conductive hose.
CAUTION
The hoses in the boom and at the platform are non-pin
perforated, nonconductive, thermoplastic hoses. Replace Injury can result from airborne particles entering the
the hoses with hoses of the same type. Do not use wire eyes and lungs. Wear appropriate safety equipment.
braid hoses in the boom or the control bundle.

Ribbon Hose

Figure 5.14 — Ribbon Hose Routing

Section 5 — Hydraulic System • 41

Injury can result from being pinched or trapped be- 2. Turn the vehicle engine start switch to the on position
tween moving components. Keep hands clear. without starting the engine.

Use caution when covers have been removed to ser- 3. While engaging the green master button, move the
vice the unit. Pinch points and shear points may exist switches for each function in both directions several
between moving parts. Replace the covers immediately times to release the pressure from each circuit in
after servicing. the hydraulic system. Also, shift the control handles
at the platform for the upper tool circuit functions in
Remove all fluid pressure from a hydraulic circuit before both directions several times.
disconnecting lines or fittings.
4. Remove the covers from the bottom of the boom
Mark all hydraulic line fittings before disconnecting them (refer to Figure 5.15).
to ease installation later. Place a container under the
hoses to catch the hydraulic oil. Cap or plug all open 5. Disconnect the ribbon hoses from the turntable hy-
ports, hoses, and fittings to prevent contamination. draulic hoses at the end of the boom where the cover
was removed in step 3 (refer to Figure 5.16). When
Warranty will be denied on components returned to Altec if disconnecting the leveling system hoses, unscrew
ports are not plugged and cylinder rods are not retracted. the hoses very slowly to release the hydraulic pres-
sure. Disconnect all hoses.
Properly torque all connections (refer to the Torque and
Tightening Procedures in this section). 6. Remove the ribbon hose clamp that is accessed
through the cover removed in step 4.
After completing a procedure, check the oil level in the
hydraulic oil reservoir, and add oil if necessary. 7. Disconnect the ribbon hoses from the platform hoses
at the boom tip.
Two ribbon hoses are used to transmit hydraulic oil to
the boom while allowing the boom to move relative to 8. Remove the ribbon hose clamp in the base end of the
the articulating arm. A ribbon hose consists of several upper boom (refer to Figure 5.17). Note any shims
single hoses bonded together. that are installed between the hose clamp and the
inner surface of the fiberglass boom as well as slide
Removal pad bearings that are on the outside of the fiberglass
1. Position the unit on a level surface, apply the parking boom. These shims and slide pad bearings must be
brake, and chock the wheels. Disengage the hydraulic oriented the same way during installation as they
system, and turn off the engine. were when they were removed.

Cover

Figure 5.15 — Boom Cover

42 • Section 5 — Hydraulic System

 Figure 5.16 — Hose Routing and Identification

portion of the clamp. The clamp must be oriented the

same way during installation as it was when it was
removed.

4. Install all shims between the hose clamp and inside

surface of the fiberglass boom.
Ribbon Hose
Clamp Fasteners
5. Install the slide pad bearings and cap screws on the
Figure 5.17 — Access Hole outside of the upper boom (refer to Section 4 under
Slide Pad Bearing Cap Screws). The shims and
9. Before pulling the ribbon hoses out of the boom, note wear pads must be oriented the same way during
how the hoses are routed in the boom for proper installation as they were when they were removed.
installation. Pull the ribbon hoses out of the base
end of the boom. 6. Lubricate the lower inside surface of the lower boom
(refer to Section 4 under Lubrication).
10. Remove the cap screws from the lower portion of the
ribbon hose clamp from step 8 and open the clamp 7. Lubricate the inner surfaces of the two ribbon hoses
up. Remove the ribbon hoses from the ribbon hose where they contact each other.
clamp. Note the orientation of the clamp on the hoses
so it can be installed the same way during installa- 8. Route the ribbon hoses into the lower boom. The
tion. ribbon hoses must be oriented the same way during
installation as they were when removed.
Installation
1. Route the ribbon hose into the fiberglass boom as it 9. With the upper boom fully retracted, adjust the rib-
was before removing it. bon hoses so there is 1″ (25.40 mm) of clearance
between the inner radius of the hoses and the rear
2. Use markings of the removal procedure to connect edge of the fiberglass boom. Adjust so there is 1/4”
the ribbon hoses to the hydraulic hoses at the boom to 1″ (6.35 to 25.40 mm) of clearance between the
tip. 2 ribbon hoses at the center of the radius and also
1
/2” (12.70 mm) clearance between the rear of the
3. Slide the ribbon hose clamp that goes in the base end outer hose radius and the boom pivot boss (refer to
of the upper boom onto the ribbon hoses. Continue Figure 5.18).
to slide the clamp onto the hoses until it is inside the
upper boom and the holes in the clamp line up with 10. Install the ribbon hose clamp at the end of the hose
the holes in the side of the boom. Install the lower channel.

Section 5 — Hydraulic System • 43

 1
/4” (6.35 mm) Minimum Use the proper torque and tightening specifications when
to 1″ (25.40 mm) Maximum installing a hydraulic fitting to reduce the likelihood of leaks
in the system. Use caps and plugs during the handling
and storage of hydraulic components to prevent damage
to sealing surfaces and fitting threads.

When installing a valve cartridge into a valve body,

properly torque the cartridge. Tightening the cartridge
less than the specified torque value may cause a leak.
Overtorquing a cartridge can damage the valve, valve
body, or bind internal parts.

Torque and Tightening Procedures

1″ (25.40 mm) Minimum Overtorquing a component can distort the part and cause
1
/2” (12.70 mm) leakage. When a leaking fitting is found, check to see
Minimum if it is tight. If it is not tight, torque it to the proper value.
Replace the fitting if it will not stay tight.
Figure 5.18 — Clearance Measurements
If the fitting is tight, stop the unit, determine the cause
11. Use the markings of the removal procedure to connect of the leak, and take corrective action. When making a
the ribbon hoses to the turntable hydraulic hoses. connection that uses a swivel nut, use one wrench to hold
Note there are multiple sets of mounting holes for the hose, tube, or fitting and another wrench to turn the
the bulkhead brackets at the tip of the hose channel nut. This is necessary to prevent damage to the sealing
(refer to Figure 5.19). Relocate the bulkhead brackets surface of the JIC connections.
to an alternate set of holes, if needed, to remove
slack from the new ribbon hoses and maintain the The following procedures describe proper torque and
alignment adjusted in step 9. tightening procedures for various types of hydraulic
fittings. Refer to Torque Values in the Appendix for the
appropriate torque chart.

WARNING
Bulkhead Death or serious injury can result from improper
Mounting Holes use of solvents. Follow the manufacturer’s label for
Figure 5.19 — Mounting Holes proper use and disposal.

12. Extend the boom from the lower controls. While the Tapered Pipe Thread Fittings
boom is extended, generously lubricate the lower 1. Clean the male threads of the fitting with a cleaning
surface of the extension cylinder, the surface of the solvent.
ribbon hose assembly that is accessible, and the
lower inside surface of the outer boom using spray 2. Apply pipe sealant to the male threads of the fitting.
lubricant (refer to Service Tools and Supplies in the Do not get sealant on the first two male threads.
Appendix). Apply enough sealant to form a ring of sealant on
the outside of the connection when the threads are
13. Operate each unit function from the lower controls. tightened into the mating body.
If the functions operate properly, test each function
from the upper controls, checking for leaks and proper 3. Screw the fitting into the mating part and finger
operation. tighten.

14. Replace all covers. 4. Turn the fitting with a wrench the appropriate turns
from finger tight (T.F.F.T.), taking the final position of
the tube end into consideration.
Fittings and Valve Cartridges
Most hydraulic ports and fittings are SAE straight thread 5. Follow the sealant manufacturer’s directions for cure
O-ring or 37 degree flared JIC straight thread. These types time. The ring of sealant described in step 2 will not
of fittings provide a good seal and resist vibration. completely harden due to its exposure to air.

44 • Section 5 — Hydraulic System

SAE O-Ring Fittings With Locknuts 3. With the threaded end of the compression nut facing
1. Lubricate the O-ring and threads with hydraulic oil the fitting body, slide the nut onto the nylon tubing,
or light grease, such as petroleum jelly. followed by the compression sleeve.

2. Screw the fitting into the SAE straight thread boss

NOTICE
until the backup washer bottoms on the boss face
with the O-ring squeezed into the boss cavity. To prevent damaging the nut and threads, do not
overtighten compression fittings.
3. Unscrew the fitting (maximum of one full turn) to align
the fitting with the mating part. 4. Insert the tubing into the fitting body. Make sure
the tubing rests firmly on the shoulder of the fitting,
4. Tighten the lock nut with a wrench and torque to the and hand tighten the compression nut. Tighten the
proper value for the size and material (stainless steel compression nut the proper number of turns.
or steel) so the backup washer contacts the boss
face. Valve Cartridges
1. Clean the male threads of the cartridge with a clean-
SAE O-Ring Fittings Without Locknuts ing solvent.
1. Lubricate the O-ring and threads with hydraulic oil
or light grease, such as petroleum jelly. 2. Lubricate the threads and O-ring with hydraulic oil.

2. Turn the fitting in full length until finger tight. 3. Turn the cartridge in until it is finger tight.

3. Tighten the fitting with a wrench to the proper 4. Tighten the cartridge with a wrench to the proper
value. value.

Tube and JIC Fittings Cylinders

1. Clean the male threads of the fitting with a cleaning
solvent. Hydraulic cylinders operate the articulating arm, boom,
leveling system, and outriggers. All cylinders used on the
2. Tighten the nut until first wrench resistance [approxi- unit are double-acting cylinders.
mately 30 inch-pounds (3.39 N•m)].
Holding valves are often used to maintain cylinder posi-
3. Using a felt tip pen or marker, mark a line lengthwise tion if there is hydraulic line failure. The lower and upper
on the nut and extend it onto the adapter body (refer boom and leveling system/platform tilt cylinders use
to Torque Values in the Appendix). counterbalance holding valves. The outrigger, jib tilt, jib
extension, platform rotate, and platform tilt cylinders use
4. Determine the proper number of hex flats the nut pilot operated check valves.
must be turned with a wrench. Using a wrench to
hold the adapter body, rotate the nut with another Holding valves may be installed in cavities machined
wrench the proper number of hex flats from wrench directly into the cylinders. They may also be installed
resistance (F.F.W.R.). in a valve block in the hydraulic lines connected to the
cylinder or directly mounted on the cylinder.
5. Use the marks to count the correct number of hex flats
to turn the nut. The marks also serve as a visual in- All cylinder rods are chrome plated to prevent rust and
dicator that the fitting has been properly tightened. corrosion. The chrome plating also provides a smooth
surface for the end gland bearing and seal.
Compression Fittings
1. Cut the tubing to length, allowing for bend, equipment WARNING
movement, etc.
Death or serious injury can result from uncontrolled
2. Fit the brass insert into the nylon pilot tubing with movement. Use a sling and hoist of adequate capacity.
the flanged end out. The insert should fit snug in the
pilot tubing. The color coded tubing requires the use Death or serious injury can result from cylinder
of an insert. failure. Do not operate a cylinder that has a dented
barrel or a damaged rod.

Section 5 — Hydraulic System • 45

Death or serious injury can result from cylinder be done in a clean, properly equipped shop. The Parts
failure. Never reuse a self-locking piston nut or re- Manual contains a drawing of each cylinder. The drawing
tention device. lists the Altec part numbers for the seal kits and provides
torque specifications for piston nuts and end glands.
Death or serious injury can result from cylinder fail-
ure. Properly install and torque a piston nut or gland Hydraulic cylinder piston nuts and end glands must be
retention device. torqued to the proper values at assembly. Many piston
nuts and end glands have retention devices, such as
Death or serious injury can result from hydraulic oil cotter pins and set screws. These retention devices must
being injected into the flesh. Properly cap or connect be installed properly.
hydraulic lines before operating the unit.
If the internal size tolerance of the cylinder barrel is ex-
Death or serious injury can result from hydraulic ceeded, the piston seal could be pushed out when the
oil being injected into the flesh when loosening or cylinder is put under a load. This will cause cylinder failure.
disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic After reconnecting a hydraulic line from any cylinder,
components. extend and retract the cylinder five to six times to purge
the air out of the cylinder and to check for hydraulic leaks.
Seek immediate medical attention if injured by escap-
ing hydraulic oil. Serious infection or reaction can Mark all hydraulic line fittings before disconnecting them
result if medical treatment is not given immediately. to ease installation later. Place a container under the
hoses to catch the hydraulic oil. Cap or plug all open
Spilled hydraulic oil creates slick surfaces and can ports, hoses, and fittings to prevent contamination.
cause personnel to slip and/or fall. Keep the unit and
work areas clean. Warranty will be denied on components returned to Altec if
ports are not plugged and cylinder rods are not retracted.
Death or serious injury can result from uncontrolled
movement. Purge the air from the actuator before Properly torque all connections and cap screws (refer
operating the unit. to Torque and Tightening Procedures in this section).

Death or serious injury can result from uncontrolled After completing a procedure, check the oil level in the
movement. Position the lower boom horizontal and hydraulic oil reservoir, and add oil if necessary.
restrain the upper boom before removing the exten-
sion cylinder retaining or trunnion pin. After replacing a major component, such as a lift cylinder,
perform a structural test.
CAUTION
Outrigger Vertical Leg Cylinder
Injury can result from airborne particles entering the A sling and hoist are needed to perform the following
eyes and lungs. Wear appropriate safety equipment. procedures.

Injury can result from being pinched or trapped be- Removal

tween moving components. Keep hands clear. 1. Position the unit on a level surface, apply the parking
brake, and chock the wheels.
Pinch points exist at both ends of the cylinder. Be extremely
careful when removing or installing cylinders. 2. Engage the hydraulic system, and lower the outrig-
gers near the ground.
Use caution when covers have been removed to ser-
vice the unit. Pinch points and shear points may exist 3. Remove the pin retainers and pin connecting the rod
between moving parts. Replace the covers immediately end of the cylinder to the inner leg of the outrigger
after servicing. (refer to Figure 5.20).

Never install a cylinder with side pressure on the rod. Do 4. Secure the cylinder with a sling and hoist. Carefully
not operate a cylinder if the cylinder barrel is dented or retract the cylinder to avoid scratching the rod. With
if the rod is damaged. the cylinder fully retracted, disengage the hydraulic
system, and turn off the engine.
Altec does not recommend repairing cylinders in the field.
Most repairs require cylinder disassembly which should

46 • Section 5 — Hydraulic System

 6. Extend and retract the outrigger leg five to six times
Pilot Operated Check Valve to purge any air in the cylinder while checking for
hydraulic leaks and proper operation.

7. Perform a structural test.

Articulating Arm Cylinder

Two slings and hoists are necessary to perform the fol-
lowing procedures.

Removal
1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the hydraulic
system, and properly set the outriggers.

2. Raise the boom so it is out of the way. Raise the

articulating arm approximately 30 to 40 degrees
above horizontal. Disengage the hydraulic system.
Figure 5.20 — Outrigger Cylinder
3. Use a sling and hoist to support the riser end of the
5. Release any pressure in the hoses connected to the arm.
cylinder by shifting the outrigger control handle for
the cylinder in both directions several times. 4. Move the articulating arm lower control handle in
both directions several times to release trapped
6. Remove the hoses from the cylinder. pressure.

7. Remove the pin retainer and pin connecting the base 5. Remove the hoses connected to the cylinder.
end of the cylinder to the outer leg of the outrigger.
6. The articulating arm cylinder is held in place by a flanged
8. On some units, it may be necessary to use a puller pin at each end (refer to Figure 5.21). Use a sling and
threaded into a 1/2″-13 UNC tapped hole in the end hoist to support the rod end of the cylinder.
of the pin to remove the pin.
Lower Boom Articulating Arm
9. With the hoist, carefully lift the cylinder out of the
outrigger weldment.

Installation
1. Secure the cylinder to the hoist. Lift the cylinder
above the outrigger leg weldment. Carefully guide the
cylinder as it slides into the outrigger leg weldment.

2. Install the pin that secures the base end of the cylinder Boom Lift Articulating
Cylinder Arm Cylinder
in the weldment. Install the pin retainer that secures
the pin.

3. Reconnect the hoses to the cylinder.

4. Start the engine, and engage the hydraulic system.

With the cylinder properly secured, extend the cyl-
Figure 5.21 — Articulating Arm Cylinder
inder. Do not scratch the rod. Line up the pin hole in
the rod end with the bosses in the outrigger leg and
7. At the rod end, remove the pin retainers and the pin.
fold-up shoe. Make sure the bearings for the outrig-
ger leg and fold-up shoe are in place.
8. Adjust the sling and hoist to support the entire cylinder.
At the base end, remove the pin retainers and pin.
5. Install the pin connecting the cylinder and the leg.
Install the pin retainer that secures the pin.
9. Immediately lower the cylinder to the ground.

Section 5 — Hydraulic System • 47

Installation 8. At the base end of the cylinder, remove the pin re-
1. Lift the cylinder between the turntable and arm weld- tainers and the pin.
ments. Align the pin mounting holes in the base end
with the cylinder mounting bracket on the arm weld- 9. Immediately lower the cylinder to the ground.
ment. Install the cylinder pin through the pin boss,
base end of the cylinder, and the second pin boss Installation
in the boom. 1. With the new cylinder on the ground, secure the sling
around the cylinder. Position the cylinder so that the
2. Install the pin retainers to secure the cylinder pin. counterbalance holding valve is in the down position.
Torque the cap screws to the proper value.
2. Lift the cylinder with the hoist and align the base
3. Connect the hydraulic hoses to the cylinder. end of the cylinder with the mounting bracket on
the turntable. Install the cylinder pin through the pin
4. Engage the hydraulic system. From the lower controls, boss, the base end of the cylinder, and the second
extend the articulating arm cylinder until the cylinder pin boss.
rod end is aligned with the mounting holes in the
articulating arm. Install the cylinder rod pin through 3. Install the retaining ring and cap screws. Torque the
the pin boss, rod end of the cylinder, and the second cap screws to the proper value.
pin boss in the arm weldment.
4. Connect the hydraulic hoses to the cylinder.
5. Install the pin retainers to secure the cylinder pin.
Torque the cap screws to the proper value. 5. Start the engine, and engage the hydraulic system.
From the lower controls, extend and retract the rod
6. Use the lower controls to raise and lower the articulat- several times to purge the air from the cylinder.
ing arm five to six times to purge any air in the cylinder
while checking for leaks and proper operation. 6. Extend the rod and align the rod end of the cylinder
with the bracket on the lower boom. Install the cylinder
7. Perform a structural test. pin at the rod end of the cylinder.

Lower Boom Cylinder 7. Install the pin retainers to secure the cylinder pin.
Two slings and hoists are necessary to perform the fol- Torque the cap screws to the proper value.
lowing procedures.
8. Perform a structural test.
Removal
1. Position the unit on a level surface, apply the parking Extension Cylinder
brake, and chock the wheels. Engage the hydraulic A sling and hoist will be necessary to remove or install
system, and raise the boom to easily access the the extension cylinder.
cylinder. Disengage the hydraulic system, and turn
off the engine. Removal
1. Position the unit on a level surface, apply the parking
2. Use a sling and hoist to support the lower boom. brake, and chock the wheels. Engage the hydraulic
system, and properly set the outriggers.
3. Use a sling and hoist to support the cylinder.
2. Remove the side slide pad bearings from the base
4. At the rod end, remove the pin retainers and pin. end of the lower boom (refer to Section 6 under Up-
Start the engine, and engage the hydraulic system. per Boom).

5. Completely retract the cylinder using the hydraulic 3. Extend the upper boom about 30″ to 36″ (76.20 to
system. Disengage the hydraulic system, and turn 91.44 cm) until the trunnion pin connecting the rod
off the engine. end of the extension cylinder to the upper boom can
be seen. Rotate the boom to allow the best work posi-
6. Release any pressure in the hoses connected the tion on the boom. Disengage the hydraulic system,
lower boom cylinder by shifting the lower boom control and turn off the engine.
in both directions several times.
4. Move the upper boom extend/retract lower controls
7. Remove the hydraulic hoses from the cylinder. in both directions several times to release any pres-
sure.

48 • Section 5 — Hydraulic System

 WARNING 6. Start the engine, and engage the hydraulic system.
Raise the lower boom using the lower controls. Ex-
Death or serious injury can result from uncontrolled
tend the upper boom fully. Lower the boom as low as
movement. Position the lower boom horizontal and
possible and retract the boom. Do this several times
restrain the upper boom before removing the exten-
to release any air in the cylinder while checking for
sion cylinder retaining or trunnion pin.
leaks and proper operation.
5. Remove the hoses from the extend and retract ports
7. Install the cover at the lower side of the upper boom.
of the cylinder at the base end of the lower boom.
8. Perform a structural test.
6. Remove the self-locking nut from the pin from the
base end of the extension cylinder (refer to Figure
Lower Platform Leveling Cylinder
5.22). Use a brass drift to drive the pin out.
A sling and hoist will be necessary to remove or install
the lower tilt cylinder.
7. Remove the trunnion pins from the rod end of the
extension cylinder with a socket wrench.
Removal
1. Position the unit on a level surface, apply the parking
8. Using a sling and hoist to support the extension
brake, and chock the wheels. Engage the hydraulic
cylinder, slide the extension cylinder out of the base
system, and properly set the outriggers.
end of the lower boom.
2. Raise the boom approximately 20 to 30 degrees above
Installation
horizontal to gain clearance between the articulating
1. Secure the cylinder in a position on the floor and pull
arm and the boom.
the rod out about 30″ (76.20 cm). Apply anti-seize
compound to the base end pin bores.
3. Use a sling and hoist to support the platform.
2. Use a sling and hoist to support the extension cylinder.
4. Disengage the hydraulic system, and turn off the
Slide the extension cylinder into the base end of the
engine.
lower boom. Have a helper push up on the cylinder,
using the access hole in the center of the lower boom
to align the cylinder with the trunnion holes. WARNING
Death or serious injury can result from hydraulic oil
3. Apply red thread lock adhesive to the trunnion threads being injected into the flesh. Support the platform
and install into the cylinder. Torque to 100 foot-pounds and slowly disconnect the leveling system hoses to
(136 N•m). relieve the pressure.

4. Align the pin bore and the pin hole at the base end Seek immediate medical attention if injured by escap-
on the cylinder. Apply anti-seize compound to the ing hydraulic oil. Serious infection or reaction can re-
pin and install. Attach the self-locking nut to the pin sult if medical treatment is not given immediately.
and torque to the proper value.
Spilled hydraulic oil creates slick surfaces and can
5. Install the slide pad bearings inside the base end cause personnel to slip and/or fall. Keep the unit and
of the lower boom (refer to Section 6 under Upper work areas clean.
Boom). Properly connect the hydraulic hoses to the
cylinder. 5. When disconnecting the lower platform leveling cyl-
inder hoses, unscrew the connections very slowly to
release the hydraulic pressure in the hoses.

Extension Cylinder Upper Boom

Pin

Lower Boom
Figure 5.22 — Extension Cylinder

Section 5 — Hydraulic System • 49

 6. At the base end of the cylinder, remove the pin re- Installation
tainers and pin (refer to Figure 5.23). 1. Align the base end of the cylinder with the cylinder
attachment bracket on the boom.
Lower Leveling Cylinder
2. Install the cylinder base end pin and pin retainers.
Torque the cap screws to the proper value.

3. Install the rod end pin and pin retainers. Torque the
cap screws to the proper value.

4. Connect the hydraulic hoses to the cylinder.

5. Start the engine, and engage the hydraulic system.

Raise and lower the boom several times to purge
air from the cylinders while checking for leaks and
proper operation.

6. Perform a structural test.

Figure 5.23 — Lower Platform Leveling Cylinder

7. At the rod end of the cylinder, remove the pin retain-

ers and pin. Remove the cylinder.

50 • Section 5 — Hydraulic System

 Section 6 — Mechanical Systems
A mechanical system consists of unit components ar- 5. Mark all hydraulic line fittings before disconnecting
ranged so the motion of one mechanically moves the them to ease installation later. Place a container
other. Examples of mechanical components are the under the hoses to catch the hydraulic oil. Cap or
rotation bearing, rotation gearbox, and the booms. Me- plug all open ports immediately.
chanical components may be moved by each other or
by hydraulic or electrical actuators. 6. After reconnecting a hydraulic line, operate the con-
trols in the system five to six times to purge the air
When welding on the unit, a welding ground clamp must out of the system and to check for hydraulic leaks.
be attached to the same structure on which the welding is
being performed. This is necessary to prevent electrical 7. Properly torque all connections and cap screws
current from being sent through components. (refer to Section 5 under Torque and Tightening
Procedures).
Components such as the rotation bearing, wire braid
hoses, and hydraulic cylinders can be damaged by 8. Perform a structural test after replacing a major
electrical current. Electrical current flowing through a component. Hydraulic cylinders, pivot pins, rotation
component can be very intense, causing serious internal bearing, and leveling system components are ex-
damage to the component. amples of items that require testing after installation.

Follow this list of safety procedures when servicing the

CAUTION
unit.
Injury can result from being pinched or trapped be-
1. Select a work site large enough to operate the re- tween moving components. Keep hands clear.
quired functions.
Use caution when covers have been removed to ser-
2. Position the unit on a level surface, apply the parking vice the unit. Pinch points and shear points may exist
brake, and chock the wheels. Check the hydraulic between moving parts. Replace the covers immediately
oil level. Engage the hydraulic system, and properly after servicing.
set the outriggers.
Rotation System
WARNING The turntable rotates on a large shear ball bearing referred
Death or serious injury can result from uncontrolled to as the rotation bearing. The inner race of the bearing
movement. Use a sling and hoist of adequate capacity. is fastened to the turntable. The outer race of the bearing
is fastened to the pedestal. It has gear teeth cut on the
3. Use a hoist to safely support heavy components outside surface of the outer race.
before loosening the fasteners on that component.
Rotation is accomplished by a worm gearbox mounted
on the turntable (refer to Figure 6.1). The gearbox is
WARNING
driven by a hydraulic motor. The rotation gearbox pinion
Death or serious injury can result from hydraulic meshes with the teeth on the rotation bearing.
oil being injected into the flesh when loosening or
disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic
components.

Seek immediate medical attention if injured by escap-

ing hydraulic oil. Serious infection or reaction can re-
sult if medical treatment is not given immediately.
Rotation
Gearbox
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
work areas clean.
Rotation
4. Never loosen or remove a pressurized hose or fit- Bearing
ting.
Figure 6.1 — Rotation System

Section 6 — Mechanical Systems • 51

When the rotation function is operated, hydraulic oil 4. Support the turntable and articulating arm (and boom,
flows to the rotation motor for the direction of operation if still attached) to prevent them from coming off of
(clockwise or counterclockwise). The motor powers the the pedestal after the cap screws are removed.
worm, which in turn drives the worm gear. The worm gear
is attached to the rotation pinion. As the rotation pinion 5. More than one lifting device may be required to ad-
travels around the rotation bearing, the turntable rotates. equately support the turntable and booms. Remove
the inner race cap screws and washers. The cap
The worm gear is self-locking, assuring that the turntable screws are accessible from the turntable side of the
will remain in position when hydraulic pressure is not rotation bearing.
being applied to the hydraulic motor.
6. Use a sling and hoist to lift the turntable, articulating
Rotation Bearing arm, and boom from the rotation bearing.
The rotation bearing provides for very low torque rotation.
The bearing should provide many years of satisfactory 7. Remove the cap screws and washers from the outer
service if properly maintained. race of the rotation bearing. They are accessible from
the pedestal side of the rotation bearing.
The unit is equipped with a rotation bearing lubricated
for the life of the bearing. It does not require lubrication 8. Using a sling and hoist, lift the bearing off of the
except at the time of a major overhaul of the unit. pedestal weldment.

Refer to Section 4 under Rotation Bearing for procedures Installation

for measuring turntable tilt and inspecting the rotation New rotation bearing kits shipped from Altec include
bearing cap screws. cap screws, hardened washers, anaerobic adhesive
compound, cleaning solvent, and installation instructions.
WARNING
Death or serious injury can result from uncontrolled WARNING
movement. Use a sling and hoist of adequate capacity. Death or serious injury can result from improper
use of solvents. Follow the manufacturer’s label for
Removal proper use and disposal.
1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the hydraulic 1. Clean the rotation bearing mounting surfaces on
system, and properly set the outriggers. Fully raise the pedestal, turntable, and the bearing with a cloth
the articulating arm. Disengage the hydraulic system, and solvent to remove any dirt or grease. Allow the
and turn off the engine. surfaces to completely dry.

2. Relieve the pressure by moving all the handles at 2. Remove the grease tube from the old rotation bearing
the lower controls in each direction several times. and install it on the new bearing.

3. Position the new rotation bearing on the pedestal with

WARNING
the high tooth, marked by yellow or blue paint, in the
Death or serious injury can result from uncontrolled proper position (refer to Figure 6.2). Align the mounting
movement. Secure the booms before removing the holes with the cap screw holes in the bearing.
rotation gearbox.

3. Remove the gearbox (refer to Rotation Gearbox in High Tooth

this section).

WARNING
Death or serious injury can result from uncontrolled
movement. Properly support the component before
loosening fasteners and removing hydraulic com-
ponents.

Figure 6.2 — Rotation Bearing High Tooth Location

52 • Section 6 — Mechanical Systems

 NOTICE
Only use Altec supplied cap screws and washers to
install the rotation bearing. 4 14
9 7
If a rotation bearing cap screw is removed, it must be 18 12
replaced with a new cap screw. Contact your Altec repre- 6 2
sentative for replacement rotation bearing cap screws. 16 17

4. Install the cap screws with washers in the outer race 1 5

of the bearing. The washer has a more rounded edge 11 15
on one side. Install the washer with the rounded edge 8 10
13 3
toward the cap screw head. Do not torque the cap
screws until all of them have been installed on the
outer race.

NOTICE Figure 6.4 — Inner Race Cap Screw Torque Pattern

Use an accurate, click-type manual torque wrench for 8. Install the cap screws in the inner race of the bearing
the installation of the rotation bearing cap screws. in the same manner as the outer race cap screws.
Torque the cap screws by a smooth pull on the
torque wrench without jerking. Do not overtighten 9. Torque the cap screws in three phases with the same
the cap screws. procedure used on the outer race in step 5. Follow
the alternating star pattern shown in Figure 6.4.
5. Torque the cap screws in three phases.
10. Install the rotation gearbox (refer to Rotation Gearbox
a. Torque the cap screws to 75 foot-pounds (102 in this section).
N•m) using the alternating star pattern in Figure
6.3. 11. Adjust the backlash between the rotation pinion and
rotation bearing gear teeth as described in Section
b. Set the torque wrench to 150 foot-pounds (203 8 under Rotation Gearbox.
N•m). Follow the same alternating star pattern.
12. Reconnect the grease tube, all hydraulic lines, and
c. Keep the torque wrench set for 150 foot-pounds electrical wires.
(203 N•m). Torque each cap screw using a circular
pattern starting with cap screw number one. 13. From the lower controls, operate each function
through five or six cycles to purge any air that may
16 4 have entered the system.
1
11 6
14. Lubricate the rotation bearing raceway and gear teeth
8 9 as described in Section 4 under Lubrication.
13 14
15. Conduct a rotation system seating procedure. Posi-
3 7 tion the booms and apply the appropriate test weight
for a level surface stability test. Provide a suitable
10 12
restraint that is securely anchored to the ground to
5 15 2
prevent overturning. Rotate the turntable through
three complete revolutions to properly seat the bear-
Figure 6.3 — Outer Race Cap Screw Torque Pattern ing and fasteners.

6. Rotate the inner race to position the grease fitting 16. Using a circular pattern, torque the rotation bearing
as shown in Figures 6.4. fasteners (both inner and outer race) to 100 percent
of the normal installation torque. Torque the rotation
7. Use a sling and a hoist to position the turntable on top gearbox fasteners again to 100 percent of the normal
of the rotation bearing. Align the turntable mounting installation torque.
holes with the mating cap screw holes in the bearing.

Section 6 — Mechanical Systems • 53

17. Inspect the rotation bearing cap screws as recom- as described in Section 4 under Rotation Bearing Cap
mend by the Preventive Maintenance and Inspec- Screws.
tion Checklist. Use the inspection procedures as
described in Section 4 under Rotation Bearing Cap Rotation Gearbox
Screws. Only qualified service personnel should service the
rotation gearbox. Read and understand the complete
Rotation Bearing Cap Screws procedure before starting.
Use this procedure when only the rotation bearing cap
screws are being replaced. Removal
Use the following procedure to remove the rotation
gearbox.
NOTICE
Only use Altec supplied cap screws and washers. 1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the hydraulic
When rotation bearing cap screws or washers are re- system, and properly set the outriggers.
moved, they must be replaced with new ones. Contact
your Altec representative for replacement fasteners. 2. Fully raise the articulating arm, disengage the hy-
draulic system, and turn off the engine.
1. Position the unit on a level surface, apply the parking
brakes, and chock the wheels. Engage the hydraulic
system, and properly set the outriggers. Disengage WARNING
the hydraulic system, and turn off the engine. Death or serious injury can result from uncontrolled
movement. Secure the booms before removing the
rotation gearbox.
WARNING
Death or serious injury can result from uncontrolled 3. Secure the boom with a strap so the turntable cannot
movement. Replace only one cap screw at a time. rotate when the gearbox is removed.

2. Loosen and replace only one cap screw at a time.

CAUTION
3. Install the new cap screw and washer. The washer Injury can result from contact with pinion and rota-
has a more rounded edge on one side. Install the tion bearing gear teeth. Keep hands clear.
washer with the rounded edge toward the cap screw
head. Injury can result from airborne particles entering the
eyes. Wear appropriate safety equipment.
4. Torque the cap screw to 100 percent of the normal
installation torque value. Wear eye protection while adjusting the eccentric ring to
prevent particles of metal or dirt from entering the eyes.
5. Using a circular pattern, repeat steps 2 through 4 for
each cap screw or nut in the race. 4. Remove any wiring, control lines, hoses, or tubes
that are in the way of the gearbox removal. Cap or
6. Conduct a rotation system seating procedure. Posi- plug all open connections to prevent contaminants
tion the booms and apply the appropriate test weight from entering the system.
for a level surface stability test. Provide a suitable
restraint that is securely anchored to the ground to 5. Remove the pinion cover. Loosen the eccentric ring
prevent overturning. Rotate the turntable through lock and the cap screws securing the gearbox.
three complete revolutions to properly seat the bear-
ing and fasteners. 6. Engage a suitable bar or drift pin, preferably of a soft
material such as brass, in a drive slot of the eccen-
7. Using a circular pattern, torque the rotation bearing tric ring. Rotate the eccentric ring using light blows
cap screws and nuts to 100 percent of the normal from a hammer against a bar or drift pin. Rotate the
installation torque value. eccentric ring to position the gearbox the maximum
distance from the rotation bearing gear teeth.
Resume regular inspection of the rotation bearing cap
screws as recommended by the Preventive Maintenance 7. Manually operate the rotation control valve spool
and Inspection Checklist. Use the inspection procedures to release pressure from the rotation function lines.

54 • Section 6 — Mechanical Systems

 Close the shutoff valve at the hydraulic reservoir. Tag 10. Inspect the rotation gearbox mounting cap screws
the ignition key or hydraulic system’s switch with a as recommended by the Preventive Maintenance
warning note alerting the operator to open the shutoff and Inspection Checklist.
valve before engaging the hydraulic system.
Lower Boom
8. Remove the rotation motor hydraulic hoses. Plug
and cap the openings. Two hoists (or suitable lifting devices) are necessary for
removal and installation of the lower boom.
9. Place a nylon sling around the gearbox. The sling
can be tied together to make a basket under the Removal
gearbox. WARNING
10. Connect the sling to a hoist. Remove the eccentric Death or serious injury can result from uncontrolled
ring lock and the four gearbox mounting cap screws. movement. Properly support the component before
Lift the gearbox out of the turntable and lower it to loosening fasteners and removing components.
the ground.
Death or serious injury can result from hydraulic
Installation oil being injected into the flesh when loosening or
1. Position the boom and hoist as instructed during the disconnecting hydraulic components. Remove the
removal procedure. pressure before loosening or disconnecting hydraulic
components.
2. Clean the mounting surface and eccentric ring. Ap-
ply anti-seize compound to the inside and outside Seek immediate medical attention if injured by escap-
surface of the eccentric ring and boss. Install the ing hydraulic oil. Serious infection or reaction can
eccentric ring in a position so that adjusting 1/4 turn result if medical treatment is not given immediately.
one way will produce full adjustment and 1/4 turn the
other way will completely loosen the gearbox. Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
3. Position the nylon sling on the gearbox as before and work areas clean.
connect it to the hoist. Position the gearbox inside
the turntable. CAUTION
4. Install the gearbox mounting cap screws loosely. Injury can result from being pinched or trapped be-
tween moving components. Keep hands clear.
5. Adjust the rotation pinion to the rotation bearing
following the procedure in Section 8 under Rotation 1. Position the unit on a level surface, apply the parking
Gearbox. brake, and chock the wheels. Engage the hydraulic
system, and properly set the outriggers.
6. Reconnect the rotation motor hoses. Reconnect any
other hoses, tubes and control lines that may have 2. Position the boom horizontal. Keep the articulating
been removed for this procedure. Remove the sling arm in the rest. Disengage the hydraulic system and
used to secure the boom. Fully open the shutoff valve turn off the engine.
on the reservoir and remove the ignition warning tag.
3. Use a sling and hoist to support the boom. Use
7. Position the unit on a level surface with sufficient another sling and hoist to support the rod end of the
clearance for full boom movement. Apply the parking lift cylinder barrel.
brake and chock the wheels. Engage the hydraulic
system, and properly set the outriggers. 4. Bleed the hydraulic pressure from the hydraulic
system by shifting the control handles at the lower
8. Operate the unit through all boom angles and rotation control station in both directions several times. Shift
from the lower controls while checking for leaks and the control handle at the platform for the upper tool
proper operation. circuit functions in both directions several times if
the platform is left on the boom.
9. Operate the unit through all boom angles and rotation
from the upper controls. Fully extend the articulating 5. Remove the two hoses connected to the base end
arm cylinder and the lift cylinder while checking for of the lift cylinder.
smoothness of rotation.

Section 6 — Mechanical Systems • 55

 6. Remove the pin retainers from the pin attaching the 10. Use a sling and hoist to carefully lift the boom from
lift cylinder to the boom. While supporting the cylinder, the unit.
use a brass drift to remove the pin. Lower the cylinder
so it rests on the rotation gearbox or turntable. Installation
1. Using the sling and hoist, position the boom assembly
7. At the rod end of the lower platform leveling cylinder, on the riser or turntable. Install the boom pivot pin.
remove the cap screws from the flange on the rod
end pin. Remove the pin. Tie the leveling cylinder to 2. Install the pin retainers. Install the lock washers and
the boom with cable ties or a rope. cap screws. Torque the cap screws to the proper
value.
CAUTION
3. Install the ribbon hoses in the boom to the turntable
Injury can result from airborne particles entering the hoses (refer to Section 5 under Hydraulic Lines).
eyes. Wear appropriate safety equipment.
4. Remove the cable ties or rope used to support the
8. Mark the individual hose connections at the end of lower platform leveling cylinder to the boom. Align
the boom. Disconnect the ribbon hoses from the the rod end of the lower platform leveling cylinder
turntable hydraulic hoses (refer to Figures 6.5 and with the cylinder holes in the riser. Install the rod end
6.6). Unscrew the hoses very slowly to release the pin and pin retainers. Torque the cap screws to the
hydraulic pressure. proper value.

9. Support the boom assembly. Remove the boom pin 5. Use a sling and hoist to position the lift cylinder on
retainers and pin. the unit. Align the rod end of the lift cylinder with the

Boom Lower Boom Upper Boom

Cover Pivot Pin

Cover
Lower Tilt
Cylinder

Figure 6.5 — Boom

Figure 6.6 — Hose Routing and Identification

56 • Section 6 — Mechanical Systems

 cylinder attachment bracket on the boom. Install the
cylinder pin and the pin retainers.

6. Connect the two hydraulic hoses to the lift cylinder.

WARNING
Backer Plate
Death or serious injury can result from uncontrolled
movement. Purge the air from the actuator before
operating the unit.
Slide Pad
7. Start the engine, and engage the hydraulic system.
Operate the unit through all boom angles and rotation
from the lower controls while checking for leaks and
proper operation.
Bottom Pad
8. Operate the unit through all boom angles and rotation
from the upper controls.

9. Replace all covers.

10. Perform a structural test.

Figure 6.8 — Lower Boom Tip Slide Pad
Slide Pad Bearings
Slide pad bearings are mounted in the center of the lower
boom, and at the lower boom tip to protect the upper WARNING
boom (refer to Figures 6.7 and 6.8). Replace worn or Death or serious injury can result from being trapped
damaged slide pads with new pads. between moving components. Maintain a safe dis-
tance while components are in motion.

Mid-Boom Slide Pad Bearing Removal

1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the hydraulic
system, and properly set the outriggers.

2. Extend the upper boom fully and retract 12″ to 15″

(30.48 to 38.10 cm). Disengage the hydraulic system.

3. Remove the cover on the bottom center of the lower

boom.

4. Remove the nuts from the slide pad bearing at the

center of the lower boom. Use a piece of wire to reach
behind the bearing and remove it and the fasteners
Slide Pad (refer to Figure 6.8).
Bearing
Installation
1. Use a piece of wire to position the new slide pad
bearing in the proper position in the lower boom.

2. Install the fasteners with the heads on the inside of

Figure 6.7 — Mid-Boom Slide Pad Bearing the boom. Install the nuts on the outside of the boom
and torque to the proper value.

3. Engage the hydraulic system, and operate the boom

extend and retract functions several times, checking
for smooth operation of the boom.

Section 6 — Mechanical Systems • 57

 4. Replace all covers. should be no more than 0.060″ (1.52 mm) between
the top slide pad bearing and the top of the upper
Lower Boom Tip Slide Pad Bearing boom or the middle slide pad bearing and the side
Six slide pad bearings are mounted at the tip of the lower of the upper boom.
boom. One top and four side bearing pads are mounted
on backer plates and attached from the outside of the
boom using cap screws. A single pad is held by the upper
Upper Boom
boom in a recess built in the bottom of the lower boom. A sling and hoist are needed to perform the following
procedures.
A sling and hoist are needed for these procedures.
Removal
Removal
WARNING
1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the hydraulic Death or serious injury can result from uncontrolled
system, and properly set the outriggers. movement. Use a sling and hoist of adequate capacity.

2. Raise the lower boom to a horizontal position. Extend Failure to support the platform and upper boom during
the upper boom about 12″ (30.48 cm). Disengage this procedure can cause uncontrolled movement.
the hydraulic system.
1. Position the unit on a level surface, apply the parking
3. Remove the cap screws holding the top slide pad brake, and chock the wheels. Engage the hydraulic
bearing assembly. Remove the top slide pad bearing system, and properly set the outriggers.
(refer to Figure 6.7).
2. Remove the platform (refer to Platform Assembly in
4. Remove the cap screws holding the slide pad bearing this section).
assembly on each side of the boom. Remove each
assembly and label each so it can be reinstalled in 3. Place the lower boom in a horizontal position to the
the correct side of the boom. rear of the vehicle with the platform in the end posi-
tion. Extend the upper boom about 30″ to 36″ (76.20
5. Attach a sling and hoist to the upper boom. Raise the to 91.44 cm) until the pin connecting the rod end of
upper boom to allow the bottom slide pad bearing the extension cylinder to the upper boom can be
to be removed. Use a piece of wire to reach in and seen. Disengage the hydraulic system.
remove the lower pad. There are no shims with the
lower slide pad bearing. WARNING
6. Slide pad bearings can now be removed from the Death or serious injury can result from uncontrolled
backer plate. Use the original shims on each pad to movement. Position the lower boom horizontal and
maintain the correct clearance between the upper restrain the upper boom before removing the exten-
and lower booms. sion cylinder retaining or trunnion pin.

Installation CAUTION
1. Using the sling and hoist, lift the upper boom to allow
Injury can result from being pinched or trapped be-
installation of the bottom bearing. Use a piece of wire
tween moving components. Keep hands clear.
to slide it into the recess in the lower boom.
4. Bleed the pressure from the hydraulic system by
2. Install the correct slide pad bearing assembly on
moving the control handles at the lower control sta-
each side of the boom. Install the cap screws and
tion in both directions several times.
torque to the proper value.
5. Remove the cover at the bottom center of the lower
3. Lower the upper boom to rest on the bottom bearing.
boom. Loosen the clamp over the hoses. Disconnect
Install the top bearing. Fasten the top bearing with
the hoses between the end of the upper boom and
the cap screws and torque to the proper value.
the lower boom.
4. Push the upper boom to the side and check the clear-
6. Remove the slide pad bearings at the lower boom
ance between the slide pad bearings and the upper
tip (refer to Lower Boom Tip Slide Pad Bearings in
boom. Use a feeler gauge to measure the gap. There
this section).

58 • Section 6 — Mechanical Systems

 7. Remove the retaining rings attaching the rod end upper boom as it extends from and retracts into the lower
of the extension cylinder to the upper boom. Use a boom. One pad is mounted on the top of the inner boom.
brass drift to remove the pin. Four pads are mounted on the outer sides and three pads
are mounted inside the inner boom to help support the
8. Use a sling and hoist to pull the upper boom out of extension cylinder.
the lower boom.
Thin gauge shims are used on the slide pad bearings on
Installation the top and bottom of the base end of the upper boom.
1. Lubricate the inside surface of the lower boom with When removing slide pad bearings in the upper boom,
a light coat of chain and cable lube or moly grease. keep track of these shims so they can be replaced in
the original positions to obtain proper fit and alignment
2. Position the upper boom and slide it into the lower between the lower and upper booms.
boom until the barrel of the extension cylinder contacts
the inner slide pad bearings in the upper boom.
WARNING
3. The extension cylinder must be aligned with the slide Death or serious injury can result from being trapped
pad bearings inside the upper boom. Using a blunt between moving components. Maintain a safe dis-
lever through the hole in the center of the lower boom, tance while components are in motion.
push up slightly on the base end of the extension
cylinder while sliding the upper boom in the lower Removal
boom. Align the rod of the cylinder with the hole in 1. Position the unit on a level surface, apply the parking
the upper boom. brake, and chock the wheels. Engage the hydraulic
system and properly set the outriggers.
4. Install the pin and pin retainers securing the exten-
sion cylinder rod to the upper boom. 2. Place the lower boom in a horizontal position to the
rear of the vehicle with the platform in the end posi-
5. Install the slide pad bearings at the lower boom tip tion. Fully retract the upper boom. Disengage the
(refer to Lower Boom Tip Slide Pad Bearings in this hydraulic system.
section).
CAUTION
6. Install the platform (refer to Platform in this section).
Injury can result from being pinched or trapped be-
7. Attach the hoses from the boom to the hoses in the tween moving components. Keep hands clear.
turntable or articulating arm. Position the hoses so
that any slack is toward the lower boom base end. 3. Remove the cover at the base end of the lower boom
Install the hose clamp. (refer to Figure 6.9).

WARNING
Death or serious injury can result from uncontrolled
movement. Purge the air from the actuator before
operating the unit. Cover

8. Engage the hydraulic system. Operate the unit through

all boom angles and rotation from the lower controls
while checking for leaks and proper operation. Repeat
this step from the upper controls.

9. Install the cover on the bottom center of the lower

boom.
Figure 6.9 — Boom Cover
10. Perform a structural test.
4. Remove the cap screws from the top slide pad bear-
Slide Pad Bearings ing. Remove the bearing.
Eight slide pad bearings are mounted to the base end
of the upper boom. The slide pad bearings support the 5. Using the slots and holes on the sides of the base
end of the lower boom, remove one of the cap screws

Section 6 — Mechanical Systems • 59

 from each of the four slide pad bearings on the side or the upper boom is removed from the lower boom.
of the upper boom (refer to Figure 6.10). Refer to Section 6 under the appropriate topic for
these procedures. This slide pad bearing should only
need replacement at the time of a major overhaul. It
is held in place with two flat head cap screws. These
Top Pad cap screws are removed from inside the upper boom.

Installation
When installing slide pad bearings in the upper boom,
Extension
Cylinder place the shims in their original position. This will help
obtain proper fit and alignment between the lower and
upper booms.
Cap Screws
1. Position the two inner slide pad bearings on each
Inner side of the extension cylinder with the longer portion
Slide Pad of the curved lip on the bottom. Install a cap screw
in each pad in only the bottom hole. Torque to the
proper value.

Slide 2. Engage the hydraulic system and extend the upper

Pad
boom slowly about 2″ (5.08 cm) until the access slot
in the lower boom is aligned with the upper mounting
hole for the slide bearing pad.
Hose
Bracket 3. Disengage the hydraulic system. Install the cap
screws for the inner slide pad bearings through the
access holes and torque to the proper value.

4. Install the four side slide pad bearings in the proper

positions on the upper boom. Use one cap screw for
each bearing pad in the holes closest to the base
Figure 6.10 — Slide Pad Bearings end of the boom. Tighten to the proper torque.

6. Engage the hydraulic system, and extend the upper 5. Engage the hydraulic system and retract the upper
boom about 2″ (5.08 cm) until the second set of cap boom about 2″ (5.08 cm) or until the access slots and
screws securing the slide pad bearings are aligned the cap screw holes align. Install the cap screws, and
with the access holes on each side of the lower boom. tighten them to the proper torque.
Disengage the hydraulic system and remove the cap
screws. 6. Install the top slide pad bearing and the cap screws.
Tighten to the proper torque.
7. Remove the bearings on each side of the upper boom
and mark their position for later installation. A piece 7. Engage the hydraulic system, and operate the boom
of wire may be used to reach behind the bearing for extend and retract functions several times, checking
removal. for smooth operation of the boom.

8. The two inner slide pad bearings have one additional 8. Replace the cover at the base end of the lower boom.
mounting cap screw holding them in the boom. To
remove these cap screws, engage the hydraulic
Platform
system, and fully retract the upper boom. Disengage
the hydraulic system, and remove the cap screws A sling and hoist are needed for the following procedures.
from the lower access hole. Remove the two inner
slide pad bearings and mark their position for later Removal
installation. 1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the hydraulic
9. The top inner wear pad can only be replaced if the system, and properly set the outriggers. Position the
extension cylinder is removed from the upper boom boom horizontal. Keep the articulating arm in the rest

60 • Section 6 — Mechanical Systems

 CAUTION Inspect for radial and circumferential splits around the
rubber bushings. Surface dry cracks are acceptable and
Injury can result from being pinched or trapped be-
do not adversely effect the performance of the stabilizer
tween moving components. Keep hands clear.
bar. Inspect the bushing bolts for correct preload. There
should be 5/8″ (15.88 mm) of thread showing beneath
2. Support the platform with the sling and the hoist.
the self-locking nut. Inspect the cups for deformation
or corrosion. Inspect the frame mounting bolts for tight-
WARNING ness. The axle U-bolts should be inspected for tightness.
Death or serious injury can result from hydraulic If unusual tilting of the unit is noted, contact your Altec
oil being injected into the flesh when loosening or representative before placing the unit in service.
disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic Rear Axle Stabilizer Bar
components. Removal
1. Position the unit on a level surface, apply the parking
Seek immediate medical attention if injured by escap- brake, and chock the wheels.
ing hydraulic oil. Serious infection or reaction can re-
sult if medical treatment is not given immediately. 2. Disengage the hydraulic system, and turn off the
engine.
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and 3. Use a floor jack to support the stabilizer bar.
work areas clean.
CAUTION
3. Disconnect the hydraulic hoses connecting the boom
Injury can result from being pinched or trapped be-
tip to the upper controls.
tween moving components. Keep hands clear.
4. Remove the fasteners holding the platform to the
Use caution when removing the stabilizer bar from the
platform mounting bracket.
unit. Pinch points and shear points may exist between
moving parts.
5. Remove the platform.
4. Note the order in which the cups and bushings are
Installation
removed to ensure proper installation of the new
1. Position the platform on the platform bracket and
bushings. Remove all self-locking nuts, lower cups,
align the holes for the fasteners.
and bushings from the pivot bolts. Discard the self-
locking nuts.
2. Install the fasteners and torque to the proper value.
5. Use the floor jack to slowly lower the stabilizer bar.
3. Connect the hydraulic hoses to the upper controls.
6. Remove the remaining cups and bushings.
4. Start the engine, and engage the hydraulic system.
Operate each function from the upper controls while
7. Replace the cups or pivot bolts if they show any sign
standing outside the platform checking for proper func-
of deformation or corrosion.
tion and any leaks. If all functions operate properly,
test again while standing inside the platform.
Installation
1. Use a floor jack to support the stabilizer bar.
5. Perform a structural test.
2. Install the new bushings and original cups (if not
Stabilizer Bars deformed or corroded) on the pivot bolts.
Stabilizer bars are used on the rear and/or front axle
3. Use the floor jack to slowly raise the stabilizer bar
to enhance the stability of the unit. Due to changes in
onto the pivot bolts.
chassis specifications by the chassis manufacturers and
specific customer requests, the stabilizer bars supplied
4. Install the lower bushings, cups, and new self-locking
with a particular unit may not reflect the descriptions given
nuts onto the pivot bolts.
in this procedure. If this is the case, contact your Altec
representative for the applicable procedures.
5. Remove the floor jack from under the stabilizer
bar.

Section 6 — Mechanical Systems • 61

 6. Tighten each pivot bolt until 5/8″ (15.88 mm) of thread 5. Use the floor jack to slowly lower the stabilizer bar.
shows from beneath the self-locking nut.
6. Remove the remaining cups and bushings.
7. Perform a stability test before placing the unit back
into service. 7. Replace the cups or pivot bolts if they show any sign
of deformation or corrosion.
Front Axle Stabilizer Bar
Removal Installation
1. Position the unit on a level surface, apply the parking 1. Use a floor jack to support the stabilizer bar.
brake, and chock the wheels.
2. Install the new bushings and original cups (if not
2. Disengage the hydraulic system, and turn off the engine. deformed or corroded) on the pivot bolts.

3. Use a floor jack to support the stabilizer bar. 3. Use the floor jack to slowly raise the stabilizer bar
onto the pivot bolts.
CAUTION
4. Install the lower bushings, cups, and new self-locking
Injury can result from being pinched or trapped be- nuts onto the pivot bolts.
tween moving components. Keep hands clear.
5. Remove the floor jack from under the stabilizer bar.
Use caution when removing the stabilizer bar from the
unit. Pinch points and shear points may exist between 6. Tighten each pivot bolt until 5/8″ (15.88 mm) of thread
moving parts. is exposed from beneath the self-locking nut.

4. Note the order in which the cups and bushings are 7. Perform a stability test before placing the unit back
removed to ensure proper installation of the new into service.
bushings. Remove all self-locking nuts, lower cups,
and bushings from the pivot bolts. Discard the self-
locking nuts.

62 • Section 6 — Mechanical Systems

 Section 7 — Electrical System
Electrical power is supplied from the vehicle battery. A closed. When the circuit is opened the power is removed.
comparison may be made between electrical and hydrau- All of the circuits on the unit are on/off electrical circuits.
lic components that may be more familiar to a hydraulic
mechanic (refer to Figure 7.1). Electrical power is used to operate the remote engine
start/stop system, secondary stowage DC pump, and
CAUTION outrigger interlock system. Electrical power is supplied
from the vehicle battery.
Injury can result from electric shock. Severe arching
can occur even when working with low voltage vehicle
electrical systems. Use caution when working with Relays
any electrical device. A relay is an automatic switch with contacts that can be
closed or opened by current in the relay coil. The relay
Voltage levels of this system are based on a constant acts as a control so that two separate functions have to
vehicle power source. Voltage may vary from 10 to 15.5 be performed before the desired output can occur. The
volts and still be considered normal. relays are single-pole, double-throw, and operate with
a 12 volt coil.
The electrical system uses on/off circuits. The major
electrical components and their operation are described
in this section. Wiring Line Diagrams in the Appendix Truck/Machine Selector Switch
illustrate the component wiring. Refer to Section 8 for The truck/machine selector switch is located in the cab
troubleshooting information. of the vehicle. The center terminals of the truck/machine
selector switch are connected to an ignition switch. If
On/Off Circuit the switch is placed in the Truck position, the center
and lower terminals are connected, which sends power
The on/off circuit supplies low voltage constant power to to terminal 5 in the remote start/stop control box. If the
a solenoid or other component when a switch or relay is switch is placed in the Machine position, the center and

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 • 63

top terminals are connected, which sends power to ter- Using this method, and time-domain multiplexing, two
minal 4 in the remote start/stop control box. wires are all that is required for two-way communications
between two different places.
Proportional Circuit A time-domain multiplexing circuit acts like two rotary
A proportional circuit supplies a varying electrical signal switches (or distributors) connected by a single wire (or
that corresponds to a controlling movement. In this way, lead). These switches are used to electronically select
the operating speed of a selected function is proportional from a number of different data channels and synchro-
to the movement of the controlling device. The unit uses nously connect them together for a brief moment in time.
a type of digital proportional electrical signal called PWM A multiplexer can be viewed as a programmable switch.
to vary the signal to electrohydraulic valves. The selected Refer to Figure 7.2 for a representation of the process.
function will continue to operate until the control is returned
to neutral, the function reaches its maximum travel, or On the unit, the multiplexer exists as software controlled
the interlock is released. coding (or input) and decoding (or output) microproces-
sors located on circuit boards inside the control and driver
Proportional circuits are used to control the following assemblies. Refer to Control System in this section for
functions. information about the control and driver assemblies.

• Upper controls
Control System
— Joystick
– Boom (up/down) The unit’s electronic control system consists of the fol-
– Boom (extend/retract) lowing three major components (refer to Figure 7.3).
– Rotation (clockwise/counterclockwise)
• Lower controls
• Upper controls
Multiplexed Controls • Valve driver
Each of the control inputs produce a command word that
contains information to drive a simple on/off signal or a A CADI (calibration and diagnostics instrument) is used to
proportional digital signal. In a non-multiplexed system, a set certain operating parameters and check the operation
dedicated signal path (wire) is required for each function. of the control system. The CADI does not come with the
Simply put, additional controls require additional wires, unit, but it is available from your service representative
which leads to less available space, more weight, greater (refer to Service Tools and Supplies in the Appendix).
complexity, and higher costs.
Each of these components have specific functions within
Multiplexing is the best method to answer these chal- the control system. The lower controls and upper controls
lenges by simultaneously providing greater reliability and are input devices that allow the operator to input control
functionality. Multiplexing is the art of interleaving signals selections and commands to the system. The valve driver
(or data) so that the data is channeled (or processed) into is an output device that interprets the multiplexed com-
a communications signal that can be transmitted over a munications signals received and sends the appropriate
single communications channel (or wire) in one direction. digital signals to relays and solenoid-operated hydraulic

Output Input
No. 3 No. 3
2 3 2 3

1 4 1 4

Multiplex Cable
6 5 6 5
Rotary Switch Rotary Switch
(Transmit End) (Receive End)
Figure 7.2 — Equivalent Multiplexing Circuit

64 • Section 7 — Electrical System

valves to operate the various functions of the unit. The
CADI is the only component that is both an input and Cable Assemblies
output device. Cable assemblies made up of electrical conductors
are used to send and receive all the multiplexed com-
munication signals (and some analog signals) between
Multiplex Cables
the various control system components. All multiplexed
communication is accomplished with two wires that serve
as the communications channel.

Two multiplex cable assemblies are used on the unit. Each

of these cable assemblies establish a common ground
between the various control system components.

• A five-wire multiplex cable assembly is used to route

Upper Controls the circuit wiring between the upper controls and the
valve driver.
Valve Driver
Assembly • A six-wire multiplex cable assembly is used to route
Lower Controls the circuit wiring between the lower controls and the
valve driver.

The CADI also uses a permanently attached, multiplex

cable. The CADI can be connected to a receptacle pro-
vided on either the lower or upper controls.

Multiplex Cable Connectors

Six and 12-pin weatherproof quick connectors are used
Figure 7.3 — Control System Components to connect the multiplex cable assemblies to each other
and the control system components.
The upper control panel uses a single handle control
(joystick) to operate the booms and turntable rotation. As When connecting a multi-pin connector, make sure it is
the joystick is moved to operate a function, a proportional properly aligned before pushing the plug fully into the
electrical device in the hand control assembly varies an receptacle. Make sure the rubber insulating ring between
analog voltage signal proportional to the amount of move- the connector and receptacle is in place and is in good
ment. The circuit board in the upper control assembly condition.
converts the varying voltage signal into an on/off digital
signal. The grouping and length of time between pulses Immediately after disconnecting one of these connec-
in the digital signal indicates which function is selected tors, cap the plug or wrap it in a plastic bag to prevent
and the amount of movement requested. contamination.

Data and instructions from the multiplexed upper con-

trols are routed through the multiplex cable to the valve Electrical Harness Assemblies
driver assembly. Electrical harness assemblies are used to send analog
control outputs from the valve driver to the solenoids on
After a signal is processed within the valve driver assem- the blocking valve and aerial control valve on the side
bly it is routed through a wire harness to the appropriate of the turntable.
solenoid operated control valve. Pulsars (pilot valves)
on the control valve regulate the pilot system hydraulic One multi-wire electrical harness assembly is used on
pressure to shift the appropriate valve spool and oper- the unit. The control harness above rotation connects
ate the selected function at a speed proportional to the to one 12-pin connector on the valve driver. The other
amount of joystick movement. end splits into eight pulsar two-pin connectors that are
connected to the aerial control valve. Two wires separate
Output signals for the above rotation functions are gener- from one of the connectors at the upper valve driver to
ated in the valve driver. connect to blocking valves.

Section 7 — Electrical System • 65

Electrical Harness Connectors
Weatherproof connectors are used to make the con- Lower Controls Assembly
nections between the control harnesses and solenoid- The lower controls assembly is stored inside a compart-
operated valves. ment on the curb side of the vehicle near the tailshelf.

Two, 6, and 12-pin weatherproof quick connectors are The lower controls consist of up to eight switches, one
used to connect the electrical harness assemblies to master push button, and one emergency stop push but-
each other and the control system components. The wire ton. To disengage the emergency stop button, pull the
terminals on the connectors are labeled numerically for red button up.
identification purposes.
A 10′ (3.05 m) cable is permanently attached to the box
Valve Driver Assembly and attaches to a connector inside the storage compart-
ment. An extension cable connects the lower controls
The valve driver assembly is located on the side of the connector inside the storage compartment to the valve
turntable. It drives the valves for all functions above driver assembly located on the side of the turntable.
rotation. The unit contains one circuit board with micro-
processors, three status LEDs, three connectors, and
specialized electronics to drive hydraulic valves. Upper Controls Assembly
The upper controls assembly is mounted on the platform.
The cover of the valve driver assembly must be removed The upper controls consist of up to three switches, an
to view the status LEDs (refer to Figure 7.4). A separate emergency stop button, and a joystick. To disengage the
LED is provided next to each of the microprocessors. Refer emergency stop button, pull the red button up. The joystick
to Figure 7.5 for an explanation of the LED functions. will not cause boom movement until the interlock trigger
is engaged. The trigger must also be engaged before the
platform tilt switch will cause platform motion.

Status LED Status LED Status LED

Indicator (INTR) Clock Battery Indicator (MO-5) Indicator (MO-4)

Valve Driver
TB3 TB2 TB1 Circuit Board

Figure 7.4 — Valve Driver Assembly

66 • Section 7 — Electrical System

 LED Condition Possible Cause Corrective Action

On Operating properly. None.

Blinking slowly A cable(s) is not properly connected. Check the appropriate diagnostics display. Make sure
all of the cable connectors are properly connected
A cable(s) has a broken wire. and there are no opens or shorts in the wires. Turn
the power off and on to reset the electronics. If the
No communications on one or more problem persists, replace the cable(s) and/or the ap-
multiplexed circuits. propriate controls or driver assembly.

Blinking quickly Partial or one-way communications Check the appropriate diagnostics display. Make sure
on one or more multiplexed circuits. all of the connectors on the other end of the cable
are properly connected. Turn the power off and on to
The A and B communications wires reset the electronics. If the problem persists, replace
are reversed. the cable(s).

Off A microprocessor(s) is not operating Check the appropriate diagnostics display. Turn power
properly. off and on to reset the electronics. If the problem persists,
replace the appropriate controls or driver assembly.

Figure 7.5 — Status LED Indications

The upper controls cable is permanently attached to Pin Color Function

the box, connects to one extension cable inside the 1 N/A No connection
booms, and attaches to a connector on the valve driver
assembly. 2 N/A No connection
3 Black Joystick grounding wire
Joystick 4 N/A No connection
The upper controls box is equipped with a joystick to
operate each proportional boom function. The joystick 5 N/A No connection
is connected to the circuit board inside the box by a 14 6 Violet Thumb rollers (boom extend/retract)
pin connector. The electrical connection for each pin on 7 White/black Thumb rollers (arm raise/lower)
the nine pin connector is labeled in Figure 7.6.
8 Orange X axis (boom cw/cww)
When the interlock trigger on the joystick is engaged a 9 Yellow Y axis (boom up/down)
microswitch is activated. The microswitch sends electrical 10 Red +12 volts joystick
power to close the boom functions diverter valve. The
microswitch also directs power to the circuit board in the 11 Red +12 volts joystick
upper controls assembly. 12 White Trigger interlock
13 Blue Trigger interlock
When operated, the joystick sends analog electrical
signals to the control system, where the signals are 14 N/A No connection
converted to PWM signals and multiplexed. The control Figure 7.6 —
system drives the aerial valve pulsars (a special type of Joystick Connector Wiring Identification
solenoid-operated pilot valve). The pulsars control pilot
pressure to the aerial valve spools, which controls the Analog and digital electrical signals are shown in Figure
hydraulic oil flow delivered to the boom function actuator. 7.7. An analog electrical signal is a smooth variation of
This system allows boom function movement speed to be electrical current or voltage. The digital PWM electrical
proportional to the distance the joystick is moved. signal is a pulsing voltage changing from 0 VDC (off) to
12 VDC (on) at a preprogrammed rate. Proportionality at
the actuator is achieved by varying the percent of time
the signal is off and the time percentage the signal is on.
The percent of time that the signal is on is referred to as
the modulation ratio (MR) or percentage of PWM.

Section 7 — Electrical System • 67

 LCD
Analog

Digital
Push Button
Figure 7.7 — Electrical Signals Keypad

As the joystick is moved, the PWM MR increases. The

solenoid-operated pilot valve responds to the digital PWM
signal by varying the pilot pressure applied to the valve
spool proportionally to the signal MR. The valve spool
movement and the hydraulic oil flow rate exiting the valve
work port is proportional to the pilot pressure.
Figure 7.8 — CADI
CADI
Remote Start/Stop Control Box
The CADI (refer to Figure 7.8) is a separate, self-contained
component of the control system. The CADI does not The remote start/stop control box is the central connection
come with the unit, but is available from your service point between the remote engine start/stop system and the
representative (refer to Service Tools and Supplies in vehicle electrical system. With suitable electrical controls
the Appendix). It can be temporarily connected to the for the engine and starter, the engine may be stopped
control system using the connector provided on the top or started at the platform with an air-operated cylinder
of the lower controls assembly or on the top of the upper or an Altec ROACS-3 radio control system. If both the
controls assembly. start/stop system and the secondary stowage DC pump
options are ordered, there will be a toggle switch at the
A Quick Reference Guide is included with the CADI turntable and tailshelf. The toggle switches and the air
containing full instructions for its operation. cylinder at the platform make the same connection.

The control box wiring information is shown in the wiring

line diagrams. Troubleshooting information for the remote
start/stop control box can be found in Section 8 under
Remote Start/Stop Control Box.

CAUTION
Injury can result from electrical shock. Severe arch-
ing can occur even when working with low voltage
vehicle electrical systems. Use caution when working
with any electrical device.

The control box uses low voltage components. This

makes problems easy to troubleshoot with a voltmeter
or a test light.

68 • Section 7 — Electrical System

 circuit, if the unit is so equipped. Refer to the Wiring Line
Throttle Control Diagrams in the Appendix for circuit information.
The normal hydraulic oil flow for the unit is 3.5 gpm (13.25
lpm). When the throttle control is operated, the flow rate For GM 6.5 diesel engines, the pressure switch is wired
is increased to approximately 5 gpm (18.93 lpm). Two to provide a ground completion circuit to the engine
throttle controls are available: a manually controlled electronic control unit. The pressure switch is wired to
throttle and an automatic throttle. terminal B8 of the engine ECU. The engine speed is
increased only when the pressure switch is energized.
Manual Throttle Control The pressure switch is adjustable to compensate for dif-
The manual throttle control consists of an air cylinder at ferent hydraulic pressure requirements for various aerial
the platform, an air activated switch in the turntable, a configurations and options.
remote start/stop control box, and a throttle control sole-
noid mounted on the engine. The remote start/stop control The Ford 7.3 diesel engine speed is also controlled by
box is used to supply voltage to the throttle controllers. an electronic control system. The engine throttle control
Refer to the Wiring Line Diagrams in the Appendix for system requires a positive 12 volt input signal to the load
circuit information. sensing throttle input terminal of the throttle control unit.
The power for the input signal is supplied from terminal 4
The manual throttle is controlled by the air cylinder at the of the Altec supplied remote start/stop control box located
platform. When the cylinder is engaged, the air switch in the cab. The Ford automatic control system requires a
in the pedestal is grounded completing the circuit that relay. The relay is energized when the pressure switch is
supplies power to the remote start/stop control box. The activated, which in turn causes a ground completion. As
remote start/stop box converts this input into output with the GM engine control system, the engine speed is
electrical signals at terminals 8 and 9. The signal to increased only when hydraulic pressure is needed and
terminal 8 is zero volts (or grounded) when energized. engine speed returned to idle when all functions and/or
Connecting this to the General Motors 6.5 turbo diesel tool circuit are not in use.
terminal B8 on the ECU will increase engine speed to
a level preset by GM. The engine speed increases the For gasoline fueled engines that require a throttle control
pump flow providing a higher rate than 5 gpm (18.93 solenoid, the wiring arrangement is shown in Wiring Line
lpm). Engaging the air cylinder a second time returns Diagrams in the Appendix. This circuit requires a relay
the engine to idle speed. that receives power from both the terminal 4 of the Altec
supplied remote start/stop control box and the ignition
The output signal at terminal 9 is a positive 12 volts when terminal of the vehicle ignition switch. The engine speed
the throttle is increased. This signal can be used to en- is increased when the pressure switch is activated, a
ergize the throttle control on an earlier model gasoline ground completion circuit is completed, and the relay is
fueled engine that is not equipped with electronic controls energized. When the relay is activated, power from the
The signal can also be used for the Ford 7.3 diesel engine ignition is applied to the throttle control solenoid that
electronic control. This will raise the engine speed to a increases engine speed. When the function is shut off,
level preset by Ford. Engaging the air cylinder a second the relay is deactivated, the throttle control solenoid is
time returns the engine to idle. deenergized, and the engine returns to idle speed.

Automatic Throttle Control

Outrigger Interlock System
On units equipped with the automatic throttle control,
the engine speed will be automatically increased to pro- The outrigger interlock system is a combination of
vide a higher oil flow rate when the boom, elevator arm, electrical and hydraulic components. There is one out-
platform functions, outriggers or tool circuit are in use. rigger interlock electrical switch for each outrigger leg.
The automatic throttle control will slow the engine speed The switches (refer to Figure 7.9) are mounted on the
when all functions are shut off. The throttle is controlled outrigger outer legs. When the outriggers are extended,
by a pressure switch located in or below the pedestal. the switches close. The switches are connected to the
The switch is activated by an increase in pressure when outrigger interlock control module. When the switches
either boom functions or the tool circuit are in use. The are closed, electrical power is sent to the solenoid of
pressure switch is adjustable and should be set so that the interlock valve. The solenoid energizes and shifts
the function requiring the lowest pressure will energize the valve closed. This allows the pressure port for the
the automatic control switch. The engine returns to idle main control valve to receive hydraulic oil from the pump.
when the function is not in use. The lowest pressure
function is usually the rotation drive or it can be the tool

Section 7 — Electrical System • 69

 Troubleshooting information can be found in Section 8
under Outrigger Interlock System.

Removal
Remove the fasteners that secure the switch assembly
to the outrigger frame. Remove the two fasteners that
secure the switch to the cover. At the end of the switch
wiring, disconnect the connector. Remove the switch
Figure 7.9 — Outrigger Interlock Electrical Switch and wiring.

When the outriggers are raised, the outrigger interlock Installation

switches open and the solenoid for the outrigger interlock Connect the electrical connector of the new switch. Se-
valve is deenergized. The valve opens and the hydraulic cure the switch to the cover with the fasteners. Secure
oil flows through the path of least resistance back to the the switch assembly to the outrigger frame.
reservoir.

70 • Section 7 — Electrical System

 Section 8 — Troubleshooting, Testing, and Adjustments
Pressure is a measure of the pounds of force applied on
Troubleshooting Procedure a one square inch area. The amount of pressure deter-
Establish a troubleshooting procedure to be followed any mines whether or not the actuator will move. Movement
time there is a malfunction. This procedure will provide occurs when sufficient pressure is applied to the movable
a starting point for determining the root cause of the component of an actuator. If an actuator does not move,
malfunction and increase troubleshooting accuracy. Use the cause may be insufficient pressure.
the following procedure.
Flow is a measure of the amount of fluid displaced dur-
1. Position the unit on a level surface, apply the parking ing a specified amount of time. The flow rate determines
brake, and chock the wheels. Check the oil level in the speed of actuator movement. The more fluid that is
the reservoir. displaced, the faster the actuator will move. If an actuator
moves slowly, the cause may be low flow.
2. Engage the hydraulic system, warm the hydraulic
oil to operating temperature, and properly set the The Hydraulic System Schematic (refer to the Appendix)
outriggers. identifies the paths of oil flow in the system and the operation
of every hydraulic component. A thorough understanding
3. Before testing each function through its full travel of JIC symbols and their meanings is helpful in trouble-
capabilities, try small movements to be certain the shooting (refer to Basic JIC Symbols in the Appendix).
function is operating properly. Test each function for
full travel capabilities. Use an accurately calibrated gauge to test the pressure.
A calibrated gauge will provide an accurate reading which
is essential for proper hydraulic adjustments.
WARNING
Death or serious injury can result from falling from Before testing or adjusting unit functions, position the
the platform. All platform occupants must properly unit on a level surface, apply the parking brake, and
use an appropriate OSHA approved personal fall chock the wheels.
protection system.
Cycle Times
4. Operate the unit from the lower controls and then Figure 8.1 shows average cycle times.
the upper controls to identify the malfunction.
Function Seconds
5. Use the Hydraulic System Schematic and Wiring Line
Diagrams in the Appendix to determine the flow path Articulating arm raise 15 to 22
required to operate the failed function. Make a list of Articulating arm lower 8 to 13
the components used to operate the failed function.
Lower boom raise 15 to 21
Cross off components used to operate other func-
tions that are operating properly. This should leave Lower boom lower 15 to 21
only three or four items to check. Upper boom extend 9 to 18
Upper boom retract 15 to 21
6. Check the easiest component first. Verify the proper
operation of each component remaining on the list Rotate left or right (360°) 40 to 65
until the bad component is found. Do not activate throttle control to operate the pump at a
faster speed when testing cycle times. These times do
7. Use accurate test equipment to verify flow, pressure, not apply to units with automatic throttle system.
voltage, and current. Figure 8.1 — Average Cycle Times

Once the symptom has been positively identified, use System Pressure
the Troubleshooting Chart in the Appendix for suggested System pressure is controlled by an adjustable pressure
causes and corrective actions. relief valve in the main control valve (refer to Figure 8.2).
The relief valve limits the maximum pressure in the hy-
Hydraulic System draulic system to 2,400 psi (165.47 bar).

Hydraulic fluid pressure and flow are required to operate

the hydraulic system functions.

Section 8 — Troubleshooting, Testing and Adjustments • 71

 Testing
1. Position the unit on a level surface, apply the parking
brake, and chock the wheels.

2. Disengage the hydraulic system, and turn off the

engine.

3. Install a pressure gauge [3,000 psi (206.84 bar)

minimum] on the quick disconnect.

4. Start the engine, and engage the hydraulic system.

Relief Valve
Variable Speed Proportional 5. Using the outrigger controls, fully retract an outrigger
cylinder. Hold the control handle in the retract posi-
Figure 8.2 — Relief Valve tion while reading the pressure gauge. The pressure
gauge should indicate 2,500 psi (172.37 bar). If the
Testing pressure reading is above or below this value, the
1. Position the unit on a level surface, apply the parking pressure needs to be adjusted.
brake, and chock the wheels. Engage the hydraulic
system, and properly set the outriggers. Adjustment
Use the following procedure to adjust the relief valve.
2. Disengage the hydraulic system, and turn off the
engine. 1. Disengage the hydraulic system, and turn the engine
off.
3. Install a pressure gauge of 3,000 psi (206.84 bar)
minimum on the quick disconnect. 2. Turn the adjusting screw clockwise to increase system
pressure. Turn the adjusting screw counterclockwise
4. Start the engine, and engage the hydraulic system. to decrease system pressure. Use small adjustment
increments.
5. Using the lower controls, fully retract the articulating
arm cylinder. Hold the control handle in the arm Lower 3. Test the pressure.
position while reading the pressure gauge. The pres-
sure gauge should indicate 2,400 psi (165.47 bar). 4. Repeat the adjustment procedure until the gauge
If the pressure reading is above or below this value, indicates 2,500 psi (172.37 bar).
adjust the main system pressure.
Pump Flow
Adjustment A slow down in unit movement may indicate a worn or
1. Disengage the hydraulic system, and turn off the defective pump. If a worn or defective pump is suspected,
engine. perform the following procedure to determine if full flow
can be generated.
2. Turn the adjusting screw clockwise to increase system
pressure. Turn the adjusting screw counterclockwise
to decrease system pressure. Use small adjustment
WARNING
increments. Death or serious injury can result from hydraulic
oil being injected into the flesh when loosening or
3. Test the pressure. disconnecting hydraulic components. Remove the
hydraulic pressure before loosening or disconnect-
4. Repeat the adjustment procedure until the gauge ing hydraulic components.
indicates 2,400 psi (165.47 bar).
Seek immediate medical attention if injured by escap-
Relief Valve ing hydraulic oil. Serious infection or reaction can re-
The outrigger and/or tool system pressure is controlled sult if medical treatment is not given immediately.
by an adjustable pressure relief valve in the pressure line
between the pump and the turntable. The relief valve limits Spilled hydraulic oil creates slick surfaces and may
the maximum pressure to 2,500 psi (172.37 bar). cause personnel to slip and/or fall. Keep the unit and
work areas clean.

72 • Section 8 — Troubleshooting, Testing and Adjustments

Testing WARNING
1. Position the unit on a level surface, apply the parking
Death or serious injury can result from pump or hy-
brake, and chock the wheels.
draulic system failure. Do not perform this procedure
without a pressure relief installed.
2. Disengage the hydraulic system, and turn off the
engine.
7. Install a pressure relief to bypass the pump flow
around the flowmeter and shutoff valve. Refer to
3. Disconnect the pump pressure line from the pump.
Figure 8.3 for relief placement. The relief should
be set no more than 200 psi (13.79 bar) above the
DANGER required unit system pressure. System pressure is
Death or serious injury will result from contact with stamped on the unit serial number placard. Cap and
rotating components in the pump driveline. Keep plug any open connections.
hands and clothing clear of the pump driveline.
8. Start the engine, and engage the hydraulic system.
4. Connect the inlet of the flowmeter (refer to Figure 8.3)
to the pump using a long section of hydraulic hose. NOTICE
The hose diameter must be the same size or larger
If the pump is equipped with a compensator, test full
than the hose used on the unit and long enough to
flow at 500 psi (34.47 bar) below the pressure listed
allow reading the flowmeter without possible contact
in the following step.
with the pump driveline.
9. The flowmeter will indicate the flow from the pump.
5. If the pump is equipped with a compensator, con-
Increase the load on the pump by slowly closing
nect the pump sense line to the pump pressure line
the load inducing shutoff valve. Do not exceed the
entering the flowmeter (refer to variable displacement
unit system pressure as indicated on the unit serial
pump in Figure 8.3).
number placard. The flowmeter should indicate ap-
proximately 5 gpm (18.93 lpm) at 2,400 psi (165.47
6. Connect the outlet of the flowmeter to a reservoir
bar). If the pump flow is less than required for unit
return line. Fully open any shutoff valves on the
operation, the pump may be defective or worn.
flowmeter.

Fixed Displacement Pump Variable Displacement Pump

Figure 8.3 — Pump Flow Test Connections

Section 8 — Troubleshooting, Testing and Adjustments • 73

10. If the pump flow is correct, disengage the hydraulic 5. Hold the open end of the hose over a container and
system, and turn off the engine. start the hydraulic system. Shift the outrigger control
handle to the Raise position. There may be an initial
11. Open the load inducing shutoff valve. Remove the surge of oil out of the open end of the hose as pres-
flowmeter, temporary lines, and fittings. Reconnect sure is first applied to the cylinder.
the unit lines to their original positions.
6. If a heavy stream of oil drains from the hose, with the
Outriggers control handle in the Raise position, the cylinder is
Outrigger cylinders and holding valves must operate leaking internally. Reconnect the hose to the outrig-
properly to assure unit stability. Any leakage must be ger control valve. Repair or replace the cylinder.
corrected before placing the unit in service.
Testing — Piston Seal and Check Valve
WARNING A vehicle jack, a clean liquid container, and the ability to
let the unit sit overnight are required to perform this test.
Death or serious injury can result from hydraulic
oil being injected into the flesh when loosening or 1. Position the unit, apply the parking brake, and chock
disconnecting hydraulic components. Remove the the wheels. Start the engine, and engage the hydraulic
pressure before loosening or disconnecting hydraulic system.
components.
2. Extend the outrigger cylinder completely. Disengage
Seek immediate medical attention if injured by escap- the hydraulic system.
ing hydraulic oil. Serious infection or reaction can re-
sult if medical treatment is not given immediately. 3. Raise the unit with a jack so the outrigger does not
carry its own weight.
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and 4. Shift the outrigger control handle in both directions
work areas clean. several times to relieve any pressure in the hoses.

Use the appropriate test to determine the cause of out- 5. Disconnect the retract hose from the control valve.
rigger drift. Place the hose in a clean liquid container. Disconnect
the extend hose from the valve and place the hose
Drift Up in another clean liquid container.
If an outrigger drifts up several inches when it is loaded,
the pilot operated check valve in the extend circuit may 6. Let the jack down, so the outrigger carries its own
be leaking. If the outrigger drifts up a little and stops, weight. Let the unit sit overnight.
there is an internal leak in the piston seal.
a. If the retract hose container has oil in it, the pilot
Testing — Internal Cylinder Leakage operated check valve is defective.
A liquid container is required to perform this test.
b. If the cylinder moved a few inches and stopped,
1. Position the unit on a level surface, apply the parking the cylinder piston seal is leaking.
brake, and chock the wheels. Start the engine, and
engage the hydraulic system. c. If the cylinder retracts all the way in and there is oil
in the extend hose container, the cylinder piston
2. Retract the cylinder completely. Disengage the hy- seal is leaking and the pilot operated check valve
draulic system. is defective.

3. Shift the outrigger control handle in both directions 7. The pilot operated check valve port marked V1 con-
several times to relieve any pressure in the hoses. trols cylinder extension. The port marked V2 controls
cylinder retraction. Both ports are located in the valve
4. Disconnect the outrigger cylinder hose from the or cylinder housing. This housing is mounted on the
extend port of the outrigger control valve. Cap the base end of the outrigger cylinder (refer to Figure
fitting at the valve. Allow the oil remaining in the hose 8.4). Replace the appropriate valve cartridge as
to drain into a clean liquid container. described in this section under Holding Valves and
repeat the test.

74 • Section 8 — Troubleshooting, Testing and Adjustments

 If the components controlling the cylinder are working
Pilot Operated
Check Valves properly, the problem may be caused by leakage past
the counterbalance valve. It may also be caused by an
internal cylinder leak.

Testing
1. Start the engine, engage the hydraulic system, and
properly set the outriggers.

2. Position the articulating arm with the cylinder rod

extended approximately half way.

3. Rotate the turntable to a position that allows the lower

boom to be lowered as far as possible.

4. Disengage the hydraulic system, and turn off the

Figure 8.4 — Outriggers engine.

Drift Down a. If the arm drifts down, manually shift the main
If the outrigger drifts down from the raised position over- control valve spool for that function. If movement
night or over the weekend, the cylinder may be leaking increases, the counterbalance holding valve is
internally or the pilot operated check valve in the retract leaking.
circuit may be leaking.
b. If the arm drifts down slightly and stops, there is
Testing — Internal Cylinder Leakage and Check Valve an internal cylinder leak.
A vehicle jack, a clean liquid container, and the ability to
let the unit sit overnight is required to perform this test. Main Control Valve (Proportional)
Two adjusting screws are provided on each main control
1. Place a jack under the outrigger shoe to support the valve segment (refer to Figure 8.5). These screws limit the
outrigger. Disengage the hydraulic system. maximum spool travel in each direction, thereby limiting
the maximum hydraulic flow from each work port. The
2. Shift the outrigger control handle in both directions adjusting screws are factory preset and are not part of the
several times to relieve any pressure in the hoses. normal servicing of the main control valve. If a problem
with hydraulic oil flow is suspected, the spool stop adjust-
3. Disconnect the retract hose from the control valve ment should be regarded as the last adjustment attempt.
and place the hose in a liquid container. Remove the
jack, and let the unit sit overnight. Testing
Before testing the speed of any function, use a flow meter
a. If the outrigger extended and there is liquid in the to verify that the pump is delivering the proper hydraulic
container, the retract pilot operated check valve is oil flow. Refer to the appropriate procedure in this section.
leaking. Place a jack under the outrigger shoe to
support the outrigger. Replace the pilot operated Testing the main control valve functions requires an open
check valve in the V2 port of the pilot operated area with sufficient clearance for full boom elevation,
check valve housing (refer to Holding Valves in articulating arm elevation, rotation, and extension.
this section).
1. Position the unit on a level surface, apply the parking
b. If the outrigger is extended but there is no liquid brake, and chock the wheels. Engage the hydraulic
in the container, the cylinder is leaking internally. system, and properly set the outriggers.
Replace or repair the cylinder.
2. Move the station selection switch on the lower con-
Articulating Arm Cylinder trols to the Upper position. Position the booms such
If the articulating arm drifts down under load or its own that the full travel of all boom functions is possible
weight, first rule out external causes such as a control without encountering obstacles.
valve malfunction.
3. Using the upper controls, fully retract the articulat-
ing arm cylinder. Hold the control in the arm Lower

Section 8 — Troubleshooting, Testing and Adjustments • 75

 Adjusting Screw
for C2 Port
Adjusting Screw
for C1 Port

Valve Section C1 Port Function C2 Port Function

Boom Up Down
Rotate Counterclockwise Clockwise
Extend/retract Extend Retract
Articulating arm Up Down
Platform Stow Unstow
Platform rotation Counterclockwise Clockwise

Figure 8.5 — Main Control Valve Adjustment

position to warm the oil in the hydraulic system to Lift Cylinder

operating temperature. Cold oil can result in an im- Testing
proper function time. If the boom drifts down under load or under its own
weight, rule out external causes such as a control valve
4. From the upper controls, operate the aerial device malfunction.
functions, timing the functions throughout the full
range of motion. In the case of rotation, time the 1. Position the unit, apply the parking brake, and chock
function for one full rotation cycle. Compare the the wheels. Start the engine, engage the hydraulic
measured times with the times in Figure 8.1. system, and properly set the outriggers (if equipped).

5. If the cycle times are not within the ranges listed in 2. Place the rated load in the platform.
Figure 8.1 and cannot be properly adjusted with the
CADI (refer to the CADI Quick Reference Guide), ad- 3. Fully extend the lift cylinder.
justment of the valve spool stops must be performed.
Proceed to the adjustment portion of this section. 4. Rotate the turntable to a position that allows the
boom to be lowered as far as possible.
6. If the times are within specifications, stow the unit,
and disengage the hydraulic system. Turn off the 5. Disengage the hydraulic system, and turn off the
engine. engine.

Adjustment a. If the boom drifts down, move the lower control

If adjustment is required, refer to Figure 8.5 to determine handle for that function. If the movement increases,
which screw to adjust and the identification of the C1 the counterbalance holding valve is leaking.
and C2 ports for each valve section. For example, the
C1 screw on each valve section controls the function b. If the boom drifts down slightly and stops, there
attached to the C1 port on the same valve section. is an internal cylinder leak.

1. Loosen the jam nut and turn the adjusting screw. Extension Cylinder
Clockwise screw rotation will decrease the function Testing
speed and counterclockwise rotation will increase If the upper boom retracts under load or its own weight,
the speed. Use care when making adjustment. The first rule out external causes such as a control valve
adjusting screw and threads are easily damaged. malfunction.

2. After making the adjustment, tighten the jam nut and 1. Start the engine, engage the hydraulic system, and
test the function again. properly set the outriggers.

2. Place the rated load in the platform.

76 • Section 8 — Troubleshooting, Testing and Adjustments

 3. Fully raise the lower boom, and extend the upper WARNING
boom.
Death or serious injury can result from uncontrolled
movement. Fully unload the actuator or position it
4. Disengage the hydraulic system, and turn off the
so it cannot move, before removing a holding valve.
engine.
Death or serious injury can result from hydraulic
a. If the upper boom drifts in, manually shift the main
oil being injected into the flesh when loosening or
control valve spool for that function. If movement
disconnecting hydraulic components. Remove the
increases, the counterbalance holding valve is
pressure before loosening or disconnecting hydraulic
leaking.
components
b. If the arm drifts down slightly and stops, there is
Seek immediate medical attention if injured by escap-
an internal cylinder leak.
ing hydraulic oil. Serious infection or reaction can re-
sult if medical treatment is not given immediately.
Leveling Cylinders
To test the upper platform leveling cylinder, disengage
Spilled hydraulic oil creates slick surfaces can cause
the hydraulic system, and push down on the platform lip
personnel to slip and/or fall. Keep the unit and work
to place force on the cylinder. If the cylinder moves, the
areas clean.
seals in the cylinder or the pilot operated check valve
may be leaking. Determine the cause of the leak and
correct it before operating the unit. CAUTION
Injury can result from airborne particles entering the
There is no practical way to remove all the hydraulic pres- eyes. Wear appropriate safety equipment.
sure from the leveling system hoses. The platform must
be supported to relieve some of the hydraulic pressure in Pilot Operated Check Valves
the leveling system hydraulic hoses. Unscrew the leveling A pilot operated check valve provides a positive lock
system hoses very slowly to release the pressure in the against hydraulic flow or leakage until it is opened by
hydraulic leveling system. pressure from a control valve. The following actuators
use pilot operated check valves.
Upper Tool Circuit
Pressure • Outrigger cylinders
The upper tool circuit pressure is adjustable and is set • Upper platform leveling cylinder
at 2,000 psi (137.90 bar).
Pilot operated check valves assure a cylinder will maintain
Flow its position if there is hydraulic line failure.
Hydraulic oil flow for the upper tool circuit is controlled
by the flow in the hydraulic system. This should be 5
gpm (18.93 lpm). NOTICE
Pilot operated check valves are not adjustable and
Holding Valves must be replaced if defective.
The unit uses holding valves to ensure that various
actuators maintain their position under load or if there Testing
is hydraulic line failure. These holding valves block the There are two methods for testing pilot operated check
hydraulic oil in the actuators to prevent movement. The valves.
types of holding valves used are pilot operated check
valves and counterbalance valves. Switching Valve Cartridges
1. Position the unit on a level surface, apply the parking
If the valve stops holding the load, or malfunctions in brake, and chock the wheels. Start the engine, and
some other way, it is most likely contaminated. Do not engage the hydraulic system. Stow the booms.
disassemble a cartridge in the field. Holding valves should
only be disassembled by the manufacturer. 2. When testing the outriggers, extend the outriggers
1″ (2.54 cm) from the ground, turn off the engine,
When removing a holding valve cartridge, do not allow and disengage the hydraulic system.
dirt, water, or other contaminants to enter the holding
valve cavity when the cartridge is removed.

Section 8 — Troubleshooting, Testing and Adjustments • 77

 3. Relieve any fluid pressure from the pilot operated 3. Disengage the hydraulic system, and turn off the
check valve by shifting the control handle for that engine.
function in both directions several times.
4. Locate the plugs in the extend and retract test ports
4. Support the structure (such as the outrigger leg) the at the base end of the cylinder. Use an Allen wrench
pilot operated check valve supports. Switch the car- to slowly unscrew the test plugs. Allow the pressure
tridges with those of another outrigger. Make sure not to bleed off before completely removing the plugs.
to switch the location of the cartridges in the block. If the cylinder is under pressure and the plugs are
unscrewed quickly, hydraulic oil may spray out of the
5. If the problem moves to the other location, replace test ports. Replace the test plugs.
the valve cartridge. If the problem does not move,
the pilot operated check valve is not the cause of the 5. Switch the position of the two valve cartridges.
malfunction.
6. If the problem moves to the other location, replace
Loading the Function the valve. If the problem does not move, the coun-
1. Load the function protected by the pilot operated terbalance valve is not the cause of the malfunction.
check valve.
Loading the Function
2. Disengage the hydraulic system, and turn off the 1. Load the function protected by the counterbalance
engine. valve.

3. Move the control selector handle to the Lower Con- 2. Disengage the hydraulic system, and turn off the
trols position. engine.

4. Move the lower control handle for the function to 3. Move the control selector to the Lower Controls
connect the function to tank. If the function moves, position.
the pilot operated check valve is leaking and must
be replaced. 4. Move the lower control handle for the function to
connect the function to tank. If the function moves,
Counterbalance Valves the counterbalance valve is leaking and must be
A counterbalance valve provides a positive lock against replaced.
hydraulic flow or leakage until it is opened by pressure
from a control valve. Counterbalance valves are used to Relief Pressure
block flow out of the following actuators. Counterbalance valves are set to relieve pressure at dif-
ferent settings (refer to the Hydraulic System Schematics
• Lift cylinder in the Appendix). Do not adjust counterbalance valves in
• Articulating arm cylinder the field. The only exception is adjusting the counterbal-
• Hydraulic platform stow/unstow function of the level- ance valves as described in Manually Lowering/Stowing
ing system the Unit in this section. If the setting on a counterbalance
valve has been changed, remove the cartridge and adjust
Counterbalance valves assure a cylinder or motor will with a test block or replace it.
maintain its position if there is hydraulic line failure.
WARNING
Testing
There are two methods for testing counterbalance valves. Death or serious injury can result from unexpected
movement. Counterbalance valves that have had the
Switching Valve Cartridges relief setting changed must be replaced or reset to
1. Position the unit on a level surface, apply the parking the proper setting using an Altec test block before
brake, and chock the wheels. Engage the hydraulic the unit is operated.
system, and properly set the outriggers. Stow the
booms. Do not adjust a counterbalance valve without a test
block. Using a test block and pressure gauge is the only
2. Move the control selector to the Lower Controls posi- accurate way to determine that the proper setting has
tion, and remove the hydraulic load from the valves been obtained.
by shifting the lower control handle in both directions
until the cylinder can be rocked by hand. A test block and instruction sheet for 11/8″ hex cartridges
and 7/8″ hex cartridges are available from your Altec

78 • Section 8 — Troubleshooting, Testing and Adjustments

representative (refer to Service Tools and Supplies in begins to flow from port 2. Note this pressure read-
the Appendix). ing, and remove the pressure from port 1.

Removal 5. If the relief setting is correct, turn off the pressure

Before removing a counterbalance valve, unload the source and move the control several times in both
cylinder. The following steps describe how to remove a directions to relieve pressure.
counterbalance valve.
6. Disconnect the pressure source from port 1 and
1. Position the unit on a level surface, apply the parking remove the counterbalance valve cartridge.
brake, and chock the wheels. Engage the hydraulic
system, and properly set the outriggers. Stow the 7. If the relief setting is incorrect, adjust the relief setting
booms. as described in the following procedure.

2. Shift the lower control handle for the function until Adjustment
the cylinder can be rocked by hand. Disengage the 1. Loosen the jam nut, and turn the adjusting screw
hydraulic system, and turn off the engine. clockwise to decrease the setting or counterclockwise
to increase the setting.
3. Locate the plugs in the extend and retract test ports
at the base end of the cylinder or counterbalance 2. Hold the adjusting screw from turning, and tighten
valve block. Use an Allen wrench to slowly unscrew the jam nut.
the test plugs. Allow the pressure to bleed off before
completely removing the plugs. If the test ports are 3. Repeat the test procedure until the correct relief
not available, slowly screw the counterbalance valve setting is obtained.
cartridge from its housing.
4. Repeat the test procedure at least three more times
Testing to confirm the correct setting.
1. Lubricate the O-rings on the counterbalance valve
cartridge, and install the cartridge in the test block. 5. Turn off the pressure source and move the control
several times in both directions to relieve pressure.
2. Connect a hydraulic pressure source and an accurate
pressure gauge to port 1 (refer to Figure 8.6). The 6. Disconnect the pressure source from port 1, and
pressure source and gauge must be adequate for remove the counterbalance valve cartridge.
a pressure greater than the desired counterbalance
valve relief setting.
Mechanical System
Rotation Gearbox
Adjusting Screw Jam Nut Adjustment
Counterbalance The rotation pinion can be adjusted to mesh properly
Valve Cartridge with the rotation bearing. Proper adjustment minimizes
Port 2 backlash, or mesh, between the pinion and rotation
bearing gear teeth. Adjustment is accomplished with the
eccentric ring and eccentric ring lock.

Excessive backlash will appear as excessive side-to-

side boom movement when the rotation function is
stopped. Adjustment of the backlash may be necessary
to compensate for wear after extended operation. It is
Port 1
also necessary if a new rotation gearbox and/or rotation
Figure 8.6 — Counterbalance Valve Test Block bearing is installed.

3. Install a straight adapter in port 2 to aid in observing Use the following procedure to check and adjust the mesh
the oil flow from this port during the procedure. between the rotation pinion and the rotation bearing.

4. Gradually increase the pressure at port 1 with the 1. Position the unit on a level surface, apply the parking
pressure source. The counterbalance valve relief brake, and chock the wheels. Engage the hydraulic
setting is the pressure at which a fine stream of oil system, and properly set the outriggers.

Section 8 — Troubleshooting, Testing and Adjustments • 79

 2. Remove the pinion cover under the turntable base
plate. Eccentric
Ring

CAUTION
Injury can result from contact with pinion and rota- Eccentric
tion bearing gear teeth. Keep hands clear. Ring Lock

Injury can result from being pinched or trapped be-

tween moving components. Keep hands clear.
Figure 8.8 — Eccentric Ring
3. Rotate the booms to the position that has the least
amount of movement between the rotation pinion and 6. Loosen, but do not remove, the four cap screws that
the rotation bearing. This position is normally the high mount the rotation gearbox to the turntable base
tooth location (refer to Figure 8.7). The high tooth is plate. If installing a new gearbox, install the washer
the point on the bearing where the rotation pinion with the rounded edge of the washer hole toward the
meshes with the rotation bearing when the booms cap screw head. Start the cap screws and washers
are stowed. On a new rotation bearing, it is painted in the gearbox mounting holes.
blue or yellow. Disengage the hydraulic system, and
turn off the engine. The eccentric ring is located on top of the turntable
base plate, under the gearbox. Since the bore of
the eccentric ring is 1/16″ (1.59 mm) off center from
High Tooth the 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″ (3.18 mm) oversize to accommodate this
movement.

7. Engage a suitable bar or drift pin, preferably of a soft

material such as brass, in a drive slot of the eccentric
ring. Rotate the eccentric ring using light blows from
Figure 8.7 — Rotation Bearing High Tooth Location a hammer against a bar or drift pin. Should the gear
mesh become looser, the ring must be turned in the
4. With another person rocking the boom tip back and opposite direction. Rotate the eccentric ring until the
forth, observe the movement of the pinion. If side- pinion bottoms out in the rotation gear teeth. At this
to-side movement between the pinion and rotation point, the ring will stop rotating. Do not use excessive
gear teeth occurs at the point of gear mesh, the force to drive the eccentric ring past this point.
mesh between the pinion and rotation bearing is
not properly adjusted. Do not confuse backlash with 8. Align the lock to the eccentric ring so one of the
slight lost motion within the rotation gearbox. Internal holes lines up with the hole in the turntable plate. It
gearbox backlash will cause the pinion to rotate back may be necessary to rotate the eccentric ring slightly
and forth slightly. This cannot be reduced externally. to install the lock. Install the cap screw through the
If adjustment is necessary to bring the pinion into eccentric ring lock, lock washer, and turntable plate.
closer mesh with the rotation bearing, continue with Install the nut and torque it to the proper value.
the following steps.
9. Tighten the gearbox mounting cap screws firmly.
Rotate the turntable slowly through at least two revo-
CAUTION lutions. If it rotates smoothly, go to step 11. If rotation
Injury can result from airborne particles entering the binds or hesitates in any position, the backlash may
eyes. Wear appropriate safety equipment. have been set too tight. Loosen the gearbox mount-
ing cap screws. Rotate the eccentric ring to loosen
5. Remove the eccentric ring lock (refer to Figure 8.8). the adjustment one locking increment (refer to step
8). Repeat step 9.

10. Torque each gearbox mounting cap screw to 115

foot-pounds (156 N•m).

80 • Section 8 — Troubleshooting, Testing and Adjustments

11. If a new gearbox was installed, or if the rotation teeth • Wire pulled from a connection
are dry, apply an open face gear lubricant as recom- • Poor contact where an electrical component is
mended in Section 4 under Lubrication. grounded

12. Install the pinion cover. Begin the search for an open circuit at a point closest
to the component that is not operating. Trace the wiring
from the component and look for a broken connection,
Electrical System corrosion, or other visible damage to the cable or wires.
If the component is grounded to the unit structure, make
CAUTION
sure the ground connection is good. If the wiring looks
Injury can result from electric shock. Severe arching good and the ground contact is good, disconnect the
can occur even when working with low voltage vehicle leads to the component and check the resistance reading
electrical systems. Use caution when working with through the component with an ohmmeter. A very high or
any electrical device. infinite resistance indicates an open circuit.

A basic understanding of electrical system components Component Failure

and system failures will aid in troubleshooting the unit’s A component malfunction is sometimes the most difficult
electrical system. problem to locate. It may appear as an open or a short
circuit, or the component may not perform to its design
Failure Identification capacity. Determine what functions are affected and what
A short circuit, an open circuit, or component failure can components in the system could be the cause of the
cause the electrical system to operate improperly. problem. If no open or short circuits can be located, and
the proper voltage is being applied to the component’s
Short Circuit electrical connections, the problem may be hydraulic or
High current flow through a short circuit will usually inter- mechanical.
rupt 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 wire
• Worn insulation Relay
• Defective component If it is believed that a relay is not operating properly, a
• Loose connection touching a ground few simple tests can be performed to see if the relay is
the problem.
To find the location of a short circuit, first analyze the
location of the circuit breaker or fuse that is opening and Testing
what is operating when it opens. To test the relay switch, place a jumper wire between
relay terminals 30 and 87. The jumper wire will complete
It may be necessary to progressively isolate the loca- the circuit to operate the function. Operate the function
tion of a short by disconnecting circuits until the short following the normal operating procedures. If the function
disappears. operates with the jumper wire in place, the relay switch
is defective and the relay will need to be replaced.
A short can also be detected by turning off power to the
unit and using an ohmmeter to check the resistance to To see if there is electrical power at the relay, connect
ground at connections and terminals that would have a the leads of a voltmeter to relay terminals 85 and 86
voltage applied during normal operation. Zero resistance while operating the disabled function. The voltmeter
between ground and one of these locations indicates a should indicate approximately 12 volts if there is power
short circuit. This checking procedure should begin clos- at the relay.
est to the power source.
Another method of testing would be to swap the suspected
Open Circuit relay with a good one. If the function operates, the sus-
An open circuit prevents normal current flow through pected relay is defective and will need to be replaced.
components of the electrical system. An open circuit may
be caused by the following items. Circuit Protection
Self-resetting thermal circuit breakers are used in the
• Broken wire electrical system to protect wiring and components from
• Corrosion

Section 8 — Troubleshooting, Testing and Adjustments • 81

excessive current flow. These circuit breakers reset within function operates, but does not start or stop smoothly,
a few minutes after the electrical overload is removed. or operate at the proper speed, the functions threshold
and max out may require adjustment. The CADI allows
each function direction to be adjusted independent of
NOTICE
the opposite function direction. Changing the threshold
Damage to the electrical system can result if a circuit or max out for boom up has no effect on boom down. Do
breaker trips repeatedly. not change the settings for the frequency, speed curve,
ramp, or lower speed from those shown in the CADI
A 20 amp thermal circuit breaker is normally used to Quick Reference Guide. If they are different than those
protect the ignition splice in the remote start/stop circuit. shown, use the CADI to return them to their proper value.
The wire from the ignition switch to the truck/machine
selector has a five amp thermal circuit breaker in it. The LCD provides four rows of information. The last two
rows are broken up into six columns. The mode selected
Pin and Circuit Identification is shown in the first row of the display. The function and
To troubleshoot the electrical system, the truck/machine parameter selected are shown in the second row. The
switch must be placed in the Machine position to engage third row lists all the parameters that can be adjusted.
the hydraulic system and provide electrical power to op- The fourth row lists all current values. The value that is
erate the unit. The station selection switch on the lower currently selected for change will be flashing in the display.
controls must be placed in the Lower Controls position
to troubleshoot the lower control functions and placed The calibration mode allows the technician to set or fine
in the Upper Controls position to troubleshoot the upper tune the operating parameters for the programmable
control functions. control functions. The left and right menu push buttons
allow the technician to scroll through all the programmable
The unit’s control system consists of three electronic con- functions. The display wraps around to the first function
trol boxes, two multiplex cable assembles, and two control after the last function is selected when scrolling in either
harnesses. The lower controls, upper controls, and valve direction. The select push button provides the technician
driver are mounted in the control boxes. Each control box with a means of scrolling through all the parameters dis-
contains one circuit board. Refer to the Parts Manual for played. The display wraps around to the first parameter
component wiring information and illustrations. after the last parameter is selected. The up and down
value push buttons allow the technician to incrementally
Multiplex cable assemblies are used to connect the increase or decrease the value of the parameter selected.
electronic control boxes to each other. The lower controls Once a value is selected, the controls can be used to
multiplex cable assembly is used to connect the lower test the operation of the function without unplugging the
control panel to the valve driver box. CADI. When all the parameters are properly set, unplug
the CADI. There is no Enter button. Settings are entered
The upper controls multiplex cable assembly is used to into the system as soon as they are changed.
connect the upper control panel to the valve driver box.
Refer to the Parts Manual for component wiring informa- Refer to the CADI Quick Reference Guide for instruction
tion and illustrations. on calibrating the system.

Control harnesses are used to connect the valve driver box Remote Start/Stop Control Box
to the solenoid operated valves. The upper control har- The remote start/stop control box controls the stop/start
ness connects the upper valve driver box to the blocking system and the throttle and manual lowering systems.
valve and aerial control valve. Refer to the Parts Manual Refer to Figure 8.9 for wiring identification. The remote
for component wiring information and illustrations. start/stop control box should not be opened for service.
There are no user replaced parts inside the control
CADI Programming box. Contact the Altec representative for replacement
All of the unit’s programmable functions are set at the information.
factory. If the aerial control valve is to be replaced, follow
the procedures in this section for adjusting the function The control box uses low voltage components. This
speeds and operating pressures before making adjust- makes problems easy to troubleshoot with a voltmeter
ments to the control system parameters. The factory or a test light.
control system parameters are shown in the CADI Quick
Reference Guide. The parameters for threshold and max To troubleshoot the remote start/stop control box for the
out are adjusted with the CADI to the individual unit for start/stop system, a jumper wire and a test light will be
optimum performance. For example, if an aerial device needed.

82 • Section 8 — Troubleshooting, Testing and Adjustments

 Testing
The truck/machine selector must be in the Machine posi-
tion to troubleshoot the throttle control. Use a voltmeter
to test terminals 4 and 14 to be sure that the appropriate
vehicle voltage is reaching the control box. If there is no
voltage reading at terminals 4 and 14, the problem may
be in the components that supply electrical power to it.

Connect the voltmeter between terminals 1 and 8. If there

is a voltage reading, use a jumper wire to momentarily
connect a good ground source and terminal 3. This will
bypass the air switch in the pedestal. If the engine throttles
up or down, the relay is operating properly. The problem
is most likely the air switch or the wires that normally
ground terminal 3.

When grounding terminal 3 does not cause the throttle to

operate, the problem is most likely the control box or the
throttle control servo. To further test the control box, use
a voltmeter to test the voltage out of terminals 8 and 9.
While watching the voltmeter, have a partner momentarily
ground terminal 3 as previously explained. If the voltmeter
reading is 12 volts on terminal 8 and 0 volts on terminal
Figure 8.9 — Remote Start/Stop 9, the problem is not the control box.
Control Box Wiring Identification
Engine Throttle Control —
To test for an open circuit to ground, connect a jumper Automatic Throttle System
wire from terminal 14 to a suitable ground. If the unit This information applies to the automatic throttle system
operates, there is a bad ground. Repair the appropriate used on GM 6.5 turbo diesels, Ford 7.3 diesels, and some
circuit. gasoline fueled engines. The automatic control system
uses the control box and a power relay. To troubleshoot
If the start/stop circuit will not operate, connect a jumper the throttle circuit, a jumper wire, and a voltmeter will be
wire from terminal 1 or 2 to terminal 14. If the remote needed. Refer to Figure 8.11 for wiring identification.
start/stop system is now operable, the remote start/stop
control box is not the problem. Check the air cylinder, air Connect the voltmeter to terminal 4 of the start/stop
hoses, and the pressure switch. control box and terminal 14. There should be a 12 volt
reading if the truck/machine switch is in the Machine
Connect a jumper wire from terminal 1 to 4, 5, or 7 to position. If no voltage is present, the control box and the
troubleshoot a malfunction. Connect a jumper wire from wiring supplying voltage to it must should be checked as
terminal 1 to 4 or 5 to bypass the cab switch. If this explained earlier.
restores operation, the control box is not the problem.
Check the wiring between the remote start/stop control Non-Electronically Controlled Gasoline Engines
box and the cab switch, if the wiring and connections are These engines require a relay, pressure switch, and a
good, the remote start/stop control box is the source of throttle control solenoid to adjust the engines mechani-
the problem. cal control (refer to Figure 8.11). If voltage is present
at terminal 4 of the control box, check terminal 85 of
Connect a jumper wire from terminal 1 to terminal 7 to the relay for 12 volts. The relay is usually located in the
bypass the control box. If this restores operation, the ap- engine compartment near the throttle control solenoid.
propriate relay is the problem. If it does not restore opera- The pressure switch is commonly located in the area of
tion, the remote start/stop control box is the problem. the pump.

Engine Throttle Control — The gasoline engine will also have 12 volts at the relay
Manual Throttle System terminal 30 that comes from the ignition terminal of the
This information applies to the captive air throttle system. vehicle ignition switch. If there are 12 volts at both relay
To troubleshoot the throttle circuit, a jumper wire and a terminals 30 and 85, put a temporary jumper between
voltmeter will be needed. Refer to Figure 8.10 for wiring relay terminals 30 and 87 to bypass the relay in the circuit.
identification.

Section 8 — Troubleshooting, Testing and Adjustments • 83

 Figure 8.10 — Engine Throttle Wiring Identification

If the engine speed increases the relay may be defective, ring. Looking at the switch from the wiring end, turn the
which can be confirmed by temporarily jumping from relay adjusting ring clockwise to increase the pressure.
terminal 86 to a known grounding point. If the relay does
not close and the engine speed does not increase, the To adjust the pressure switch, position the unit on a
relay is defective and needs to be replaced. level surface, apply the parking brake, and chock the
wheels. Engage the hydraulic system and properly set
If the engine speed increases when jumping from terminal the outriggers. Fully retract the upper boom and operate
86 to a known ground, there may be damaged wiring the rotation function. Adjust the pressure switch until the
or a bad connection in the wiring assembly between throttle increases during normal operation, but idles back
relay terminal 86 through the pressure switch to point of when the rotation function stops. Replace the pressure
grounding near the switch. Run a jumper wire from the switch if it fails to function properly.
ground terminal of the switch to a good ground. If the
engine speed increases, the switch ground is not mak- The Ford 7.3 Ford Power Stroke Diesel
ing good contact. If it does not increase, connect the These engines use the throttle control box, a relay, and
jumper between the two pressure switch connections. a pressure switch to control the electronic throttle (refer
If the engine speed increases, the pressure switch may to Figure 8.11). The relay is usually located in the engine
be out of adjustment or not functioning. compartment near the engine electronic throttle control.
The pressure switch is commonly located in the area of
Adjust the pressure switch by sliding the cover in the the pump.
center of the switch toward the wiring end of the switch.
Use a small flat blade screwdriver to turn the adjusting The relay terminals 30 and 86 both receive 12 volts from
terminal 4 of the start/stop control box when the truck/

84 • Section 8 — Troubleshooting, Testing and Adjustments

 Figure 8.11 — Automatic Throttle Option

machine switch is in the Machine position. To test the Use a small flat blade screwdriver to turn the adjusting
circuit first move the truck/machine switch to the Machine ring. Looking at the switch from the wiring end, turn the
position. Use the voltmeter to see if there are 12 volts at adjusting ring clockwise to increase the pressure.
both relay terminals 30 and 86. If 12 volts are present,
connect a jumper between relay terminals 30 and 87 to To adjust the pressure switch, position the unit on a
bypass the relay in the circuit. level surface, apply the parking brake, and chock the
wheels. Engage the hydraulic system and properly set
If the engine speed increases with the jumper in place, the outriggers. Fully retract the upper boom and operate
the relay may be defective. Remove the jumper from the rotation function. Adjust the pressure switch until the
terminals 30 and 87 and place it from relay terminal 85 to throttle increases during normal operation, but idles back
a known grounding point. If the relay does not close and when the rotation function stops. Replace the pressure
the engine speed does not increase, replace the relay. switch if it fails to function properly.

If the engine speed increases when jumping from terminal GM 6.5 Turbo Diesel
85 to a known ground, there may be damaged wiring This electronic throttle uses a pressure switch to increase
or a bad connection in the wiring assembly between the engine speed (refer to Figure 8.11). To test this circuit
relay terminal 85 through the pressure switch to point connect a temporary jumper between terminal B8 of
of grounding near the switch. Run a jumper wire from engine ECU and a known grounding point. If the engine
the ground terminal of the switch to a good ground. If speed increases, there may be damaged wiring or a bad
engine speed increases, the switch ground is not mak- connection in the wiring assembly between the ECU and
ing good contact. If it does not increase, connect the the pressure switch to point of grounding near the switch.
jumper between the two pressure switch connections. Run a jumper wire from the ground terminal of the switch
If engine speed increases, the pressure switch may be to a good ground. If engine speed increases, the switch
out of adjustment or not functioning. ground is not making good contact. If it does not increase,
connect the jumper between the two pressure switch con-
Adjust the pressure switch by sliding the cover in the nections. If engine speed increases, the pressure switch
center of the switch toward the wiring end of the switch. may be out of adjustment or not functioning.

Section 8 — Troubleshooting, Testing and Adjustments • 85

Adjust the pressure switch by sliding the cover in the steps 5 through 7 to determine if the cartridge is the
center of the switch towards the wiring end of the switch. problem.
Use a small flat blade screwdriver to turn the adjusting
ring. Looking at the switch from the wiring end, turn the 5. Turn off the engine, and disengage the hydraulic
adjusting ring clockwise to increase the pressure. system. Move the outrigger control handles in each
direction several times.
To adjust the pressure switch, position the unit on a
level surface, apply the parking brake, and chock the WARNING
wheels. Engage the hydraulic system and properly set
the outriggers. Fully retract the upper boom and operate Death or serious injury can result from hydraulic
the rotation function. Adjust the pressure switch until the oil being injected into the flesh when loosening or
throttle increases during normal operation, but idles back disconnecting hydraulic components. Remove the
when the rotation function stops. Replace the pressure pressure before loosening or disconnecting hydraulic
switch if it fails to function properly. components.

Outrigger Interlock System Seek immediate medical attention if injured by escap-

If the outrigger interlock system is defective, the outrigger ing hydraulic oil. Serious infection or reaction can re-
interlock valve will not shift closed when the outriggers sult if medical treatment is not given immediately.
are lowered. This will cause the functions above rotation
to be inoperable. If this problem occurs, first check the Spilled hydraulic oil creates slick surfaces and can
outrigger interlock switches. If this does not solve the cause personnel to slip and/or fall. Keep the unit and
problem, perform the following test procedure. work areas clean.

Testing 6. The outrigger interlock valve must be hydraulically

The following procedure will determine if the defective bypassed. To do this, disconnect the hydraulic lines
component is in the electrical system or if it is the outrig- connected to the outrigger interlock valve. Use an
ger interlock valve. appropriate fitting to connect the hydraulic lines.

1. Locate the outrigger interlock valve in the pressure 7. Start the engine and engage the hydraulic system.
line between the pump and the turntable. There are Operate a function above rotation. If the function oper-
two wires connected to the outrigger interlock valve. ates, the outrigger interlock valve cartridge, ground
One is the ground wire. The other wire provides wire, or solenoid coil is the problem. If the function
electrical power. Locate the electrical wire providing does not operate, the outrigger interlock valve is
power to the solenoid. Use a jumper wire to connect not the problem. Disengage the hydraulic system.
this wire to the vehicle’s electrical system. Release the pressure from the outrigger circuit by
moving the outrigger control handles in both direc-
2. Operate a boom function. If the function operates, tions several times. Disconnect the hydraulic hoses
proceed to step 3. If the function does not operate, and connect them to the outrigger interlock valve.
follow steps 4 through 7. Troubleshoot the hydraulic components located below
rotation, such as the machine/ground level functions
3. Remove the jumper wire. If the outriggers were selector valve.
operational in step 2, the defective component is in
the electrical system. Troubleshoot the portion of the Electrical Switch Adjustment
electrical system from the electrical wire connected The interlock switches are not adjustable. The proxim-
to the solenoid to the wires connected to the remote ity switches are equipped with two LED lights (refer to
start/stop control box located in the vehicle cab. Also Figure 8.12). The green light indicates there is power
check the outrigger interlock electrical switches and to the switch and the yellow light indicates the leg is
the wiring connected to these switches. extended. Depending upon the unit, the lights may be
visible through the hole in the cover or the cover and
4. Remove the jumper wire. If all the functions above switch may have to be removed to access the lights. If
rotation are not operational in step 2, the source the assembly is removed to access the lights, the yellow
of the problem is most likely a defective outrigger light will be out. Move the assembly to within 3/4″ (19.05
interlock valve cartridge. It could also be a defective mm) of a flat metal object. If the yellow light comes on,
solenoid coil or a defective ground connection. Follow the switch is working properly.

86 • Section 8 — Troubleshooting, Testing and Adjustments

 DANGER
Death or serious injury will result from improper use
Lights of the unit. Do not manually operate the unit without
proper training.

WARNING
Death or serious injury can result from being trapped
Figure 8.12 — Outrigger Interlock Electrical Switch between moving components while adjusting the
holding valve. Allow an exit path from the area.
Pulsar Valves (Proportional Speed)
If one direction of a function stops working the problem
may be the solenoid operated pulsar valve. If it is deter- CAUTION
mined that the pulsar is the problem use the following Injury or property damage can result from contact of
procedure to replace the pulsar. the booms or platform with fixed objects. Make sure
there is sufficient clearance before operating the unit.
1. Turn off the hydraulic and electrical systems.
In an emergency situation, the platform may be lowered
2. Disconnect the electrical wire connector from the to rescue personnel by following the manual procedures
pulsar. for rotating the turntable and lowering the lower boom. It
will then be necessary to manually raise the lower boom
3. Loosen and remove the pulsar from the cavity in the above horizontal to stow the unit.
main control valve. Remove the loose O-ring from
the bottom of the pulsar mounting cavity. Support the lower boom with a strap connected to a
lifting device. Press the correct manual override pin on
NOTICE the upper boom valve section. Refer to Figure 8.13 for
the manual override pin identification on the main control
Properly seat the O-ring when installing a new pulsar. valve sections.

There is an O-ring in the bottom of the pulsar cavity that

has to be replaced with the new O-ring that comes with Articulating Lower Boom
each new pulsar. Torque the new pulsar at 60 to 78 inch- Arm (Raise) (Raise)
pounds (6.78 to 8.81 N•m). Rotation Upper Boom Platform
(CW) (Extend) (Unstow)
4. Install the new O-ring in the bottom of the pulsar
cavity. Make sure the new O-ring sets flat on the
bottom of the opening.

5. Install the new pulsar. Torque the pulsar at 60 to 78

inch-pounds (6.78 to 8.81 N•m).

6. Connect the electrical connector to the pulsar.

7. Engage the hydraulic system, and operate the unit.

Check for leaks and proper operation.

Manually Lowering/Stowing the Unit System Rotation Upper Platform

The following text explain a method that may be used to Relief (CCW) Boom (Stow)
(Retract)
manually rotate the turntable and to retract the hydraulic
cylinders that operate the upper and lower boom, and Variable Unloader Articulating Lower Boom
the articulating arm. Inlet Valve Arm (Lower) (Lower)
Figure 8.13 — Main Control Valve Manual
Override Pin Identification (Variable Speed Valve)

Section 8 — Troubleshooting, Testing and Adjustments • 87

If the unit is equipped with an manual lowering valve,
refer to the Maintenance Manual for proper procedures Counterbalance Valve
for purging air from that system.

Rotating the Turntable

After determining that there is no danger in contacting
the unit from the ground, the turntable may be rotated
manually. The rotation worm gear shaft is provided with
an extension shaft that may be hand operated. The most
convenient means of doing this is with a socket and ratchet
wrench. For the worm gear to turn, the valve spool on the
main control valve will have to be manually shifted. This
can be done by pushing in on the correct manual override
pin on the rotation valve section. A manual override pin
is located in the center of each end cap on the valve for
each function. Refer to Figure 8.13 for the manual over-
ride pin identification on the main control valve sections. Figure 8.14 —
Boom Counterbalance Holding Valve Location
By turning the extension shaft while holding the manual
override pin in, the unit may be rotated to a position above
the boom stow bracket. The booms can then be lowered WARNING
into the travel position. Death or serious injury can result from being trapped
between moving components while adjusting the
Retracting the Upper Boom holding valve. Allow an exit path from the area.
Retracting the upper boom is accomplished by adjusting
the counterbalance holding valve in the upper boom cylin- After the manual stowing or lowering procedure is com-
der to the open position and pressing the correct manual plete, it is necessary to replace or properly adjust the
override pin on the upper boom valve section. Refer to counterbalance valve in the upper boom cylinder to its
Figure 8.13 for the manual override pin identification on original setting.
the main control valve sections.
WARNING
If the booms have been positioned at a high enough
angle, the upper boom will retract by gravity after adjusting Death or serious injury can result from unexpected
the counterbalance valve and while pressing the correct movement. Counterbalance valves that have had the
manual override pin. relief setting changed must be replaced or reset to
the proper setting using an Altec test block before
If the boom angle is too low, it may be necessary to use the unit is operated.
a come-along to manually retract the upper boom after
adjusting the counterbalance valve and while pressing Lowering the Lower Boom
the correct manual override pin. The come-along may Lowering the lower boom is accomplished by adjusting
be attached with one end connected to the upper boom the counterbalance holding valve in the lower boom lift
lanyard attachment loop and the other to a sling placed cylinder to the open position and pressing the correct
around the base end of the lower boom. manual override pin on the lower boom valve section.
Refer to Figure 8.13 for the manual override pin identifi-
The counterbalance holding valve is located in the base end cation on the main control valve sections.
of the upper boom cylinder as shown in Figure 8.14.
The lower boom will lower by gravity after adjusting the
To adjust the counterbalance holding valve, it is necessary counterbalance valve and while pressing the correct
to unlock the lock nut with a socket wrench and screw the manual override pin.
adjusting screw inward (clockwise) with a hex wrench.
Turn the adjusting screw until the boom begins to move The counterbalance holding valve is located on the
downward. The boom should then slowly retract by grav- manifold at the base end of the lower boom cylinder as
ity. The rate of descent can be controlled by turning the shown in Figure 8.15.
counterbalance valve adjusting screw.
To adjust the counterbalance holding valve, it is necessary
to unlock the lock nut with a socket wrench and screw the

88 • Section 8 — Troubleshooting, Testing and Adjustments

adjusting screw inward (clockwise) with a hex wrench. If the articulating arm is in a position of full extension, it may
Turn the adjusting screw until the boom begins to move not lower under its own weight when the counterbalance
downward. The boom should then slowly lower by grav- valve is adjusted to the open position. In this situation, it
ity. The rate of descent can be controlled by turning the will be necessary to connect a rope or cable from another
counterbalance valve adjusting screw. device to the articulating arm to initiate movement.

The counterbalance holding valve is located in the valve

Articulating Arm block near the base end of the articulating arm cylinder
Cylinder as shown in Figure 8.15.

To adjust the counterbalance holding valve, it is neces-

Counterbalance sary to unlock the lock nut with a wrench and screw the
Valves adjusting screw inward (clockwise) with a hex wrench.
Turn the adjusting screw until the articulating arm begins
to move downward. The arm should then slowly lower by
gravity. The rate of descent can be controlled by turning
the counterbalance valve adjusting screw.

WARNING
Death or serious injury can result from being trapped
Manifold between moving components while adjusting the
holding valve. Allow an exit path from the area.
Figure 8.15 — Articulating Arm
Counterbalance Holding Valve Location
Death or serious injury can result from being trapped
between moving components. Maintain a safe dis-
WARNING tance while components are in motion.
Death or serious injury can result from being trapped
between moving components while adjusting the After the manual stowing or lowering procedure is
holding valve. Allow an exit path from the area. complete, it is necessary to replace or properly adjust
the articulating arm cylinder counterbalance valve to its
Death or serious injury can result from being trapped original setting.
between moving components. Maintain a safe dis-
tance while components are in motion. WARNING
Death or serious injury can result from unexpected
After the manual stowing or lowering procedure is com-
movement. Counterbalance valves that have had the
plete, it is necessary to replace or properly adjust the
relief setting changed must be replaced or reset to
counterbalance valve in the lower boom lift cylinder to
the proper setting using an Altec test block before
its original setting.
the unit is operated.

WARNING
Auxiliary Power Source
Death or serious injury can result from unexpected
movement. Counterbalance valves that have had the If the unit is disabled by engine or pump failure, it can be
relief setting changed must be replaced or reset to stowed for travel by using hydraulic power from another
the proper setting using an Altec test block before unit. The operating unit must have a hydraulic system with
the unit is operated. similar pressure and flow rates and a lower tool circuit.

Lowering the Articulating Arm WARNING

Lowering the articulating arm is accomplished by adjust-
Death or serious injury can result from being trapped
ing the counterbalance holding valve in the valve block
between moving components. Maintain a safe dis-
to the open position and pressing the correct manual
tance while components are in motion.
override pin on the articulating arm sectional valve. Refer
to Figure 8.13 for the manual override pin identification
Death or serious injury can result from hydraulic
on the main control valve sections.
oil being injected into the flesh when loosening or
disconnecting hydraulic components. Remove the

Section 8 — Troubleshooting, Testing and Adjustments • 89

pressure before loosening or disconnecting hydraulic Quick disconnect couplings may be mounted at the
components. tailshelf for future use.

Seek immediate medical attention if injured by escap- After the required plumbing connections are made, use
ing hydraulic oil. Serious infection or reaction can re- the following procedure to stow the unit.
sult if medical treatment is not given immediately.
1. Bring a pressure outlet from the operable unit to the
Spilled hydraulic oil creates slick surfaces and can disabled unit. To do this, use the lower tool circuit
cause personnel to slip and/or fall. Keep the unit and hose reel or an extension hose from a pressure
work areas clean. outlet on the operable unit. Connect this pressure
hose to the pressure line quick disconnect coupling
Use the following procedure to make the required plumb- previously installed.
ing connections.
2. Bring a return inlet from the operable unit to the dis-
1. Install a return line connection between the main con- abled unit. To do this, use the lower tool circuit hose
trol valve and the return line filter as shown in Figure reel or an extension hose from a return inlet on the
8.16. If the unit does not have a secondary stowage operable unit. Connect this return inlet or extension
DC pump, install a check valve in the pressure line hose to the return line quick disconnect coupling
between the pump and the point of connection for previously installed. Make sure the manual shutoff
the auxiliary power source. valve in the return line is closed to divert the return
oil flow to the operable unit.

3. Start the engine and pump on the operable unit and

move the tools control handle to the On position. Stow
the disabled unit using its lower controls or manual
override on the main control valve, as necessary.

4. For units that have lost 12 volt power to the aerial

device, use manual override pins on the main control
valve to operate the boom, elevator arm, and platform
stow/unstow functions (refer to Figure 8.13). Press
the manual override pin for the dump valve and then
press the manual override pin to operate the desired
function. Follow the boom storage procedure under
Figure 8.16 — Auxiliary Power Source Plumbing Boom Storage in this section.

2. Install a manual shutoff valve between the return line 5. Move the tools control handle to the Off position.
connection and the return line filter. Turn off the engine and pump on the operable unit.

3. Install the pressure line between the pump control

valve and the main control valve. The check valve NOTICE
(shutoff valve) will divert oil from the disabled unit The return line can rupture, causing a large quantity
to the operable unit and prevent back flow to the of oil to spill under pressure. Open the manual shutoff
pump. valve before starting a disabled unit.

4. Close the manual shutoff valves to divert the return 6. Open the manual shutoff valves on the disabled
oil flow to the operable unit and preserve oil to the unit. Return all hydraulic connections to their normal
disabled unit. positions on both units.

90 • Section 8 — Troubleshooting, Testing and Adjustments

 Section 9 — Structural and Stability Testing
The unit has been factory tested and, at the time of NOTICE
delivery, all applicable ANSI requirements were met or Carefully load the test weight to prevent damage to
exceeded. Any time an alteration is made that can affect the platform or liner.
the unit’s stability, testing must be performed to confirm
that the unit operates safely and in compliance with all 6. Place a sling around the platform to suspend the
governing organizations. weight directly under its centerline. Use a forklift
(or other lifting device) to slowly apply the weight.
If the test is being performed with the lower boom
Structural
below horizontal, the test weight may be placed in
After replacing any major component, perform a 1.5 to the platform without the use of a lifting device.
1 structural test to verify structural soundness before
putting the unit back into service. 7. Apply the test weight for five minutes. During that
time, do not operate any function of the unit. This is
WARNING a static test only.

Death or serious injury can result if the unit becomes 8. Remove the weight from the platform. Inspect the unit
unstable. Maintain stability of the unit while perform- for structural soundness if any cracking or popping
ing a structural test by following proper procedures. was heard during the test.

NOTICE 9. Operate the unit through its full range of movement

before returning it to service.
Carefully load the test weight to prevent damage to
the platform.
Stability
Use the following procedure to perform a structural Due to the possible affect on stability, the unit and/or
test. vehicle should never be altered or modified without
the specific written approval from Altec Industries, Inc.
1. The area where the test is performed should be level Component replacement with original equipment parts
and free from any overhead obstructions. Position will not affect the stability of the unit.
the unit in the test area so the platform may be ac-
cessed by a forklift (or other lifting device) to place ANSI A92.2 requires a level surface test and a five de-
the test weight. gree slope test when the unit mounting is complete on
the vehicle. These stability tests are not required to be
2. Apply the parking brake, and chock the wheels. performed again unless significant changes are made
Engage the hydraulic system, and properly set the in the original vehicle and body mounting or the unit is
outriggers. remounted on another vehicle.
3. The position of the booms for the test is dependent
upon the component(s) that have been replaced. If WARNING
the lift cylinder is replaced, lower the lower boom Death or serious injury can result from uncontrolled
below horizontal and fully extend the upper boom. If movement. Do not permit anyone to occupy the
a component of the articulating arm and/or turntable platform until the unit has passed applicable tests.
is replaced, perform a test with the arm fully raised
and a test with the arm fully lowered. During both of Death or serious injury can result if the mobile unit
these tests, position the lower boom horizontal and becomes unstable. Provide a suitable restraint while
fully extend the upper boom. If any other compo- the stability tests are performed.
nents have been replaced, position the unit so the
lower boom is horizontal and the upper boom is fully
extended. NOTICE
Carefully load the test weight to prevent damage to
4. Position the platform in the end-mounted position. the platform or liner.

5. Calculate the test weight for the platform by multiplying Test Forms
1.5 times the platform capacity shown on the serial Stability test forms are provided in the Appendix. The
number placard. forms designate the proper boom and jib positions and the
proper test loads to be used. They show the unit loading

Section 9 — Structural and Stability Testing • 91

configuration(s) that would most likely cause overturning. • Choose Test A or Test B depending on the location
Completed forms should be dated and signed by the test of the weight for the test. Test B can only be used
technician after conducting the stability tests and should if the jib can structurally carry both the jib load and
be retained as part of the original unit documentation. the platform load.

Additional test forms may be needed to show appropri- • The unit must pass the level surface test before
ate stability tests for units equipped with special lifting conducting the five degree slope test.
features such as a lower boom lifting eye or a gin pole
socket. If Altec Engineering determines that special lift- Level Surface Test
ing features will always produce less tendency toward During the level surface test, the test technician must
overturning than would normal platform and jib stability determine which side of the vehicle, curb side or street
test loads, stability tests using special lifting features are side, is the least stable. This information will be used in
not required. the five degree slope test.

General Test Conditions 1. Position the unit on a level, hard surface, apply the
• Remove all tools and material including removable parking brake, and chock the wheels. Engage the
boom supports, extra platforms (not attached to the hydraulic system.
unit), and all removable cargo.
2. Properly set the outriggers (if equipped) as directed
• Restrict the amount of total fuel in all tanks to 20 in the Operator’s Manual.
gallons (75.71 l) or less.
3. Move the booms and jib into a position to most likely
• Inflate tires to tire manufacturer’s recommended cause overturning (refer to the test form).
pressure settings (unless customer specified).
4. Apply a load at the center of the platform(s) equal
• Chock the wheels during all testing. to 1.5 times the rated platforms load. The load can
be applied either into the platform(s) or suspended
• Only the test technician can be on the unit during by a load line from the center of the platform(s). The
the test. platform test load may be suspended on the jib line
in addition to the jib test load if the unit is equipped
• Do not use outrigger pads unless a special case with a material handling jib structurally capable of
such as customer request exists. In such cases, the carrying the added load.
test technician must note on the test form that pads
were used, the reason pads were used, and the 5. Apply a load to the material handling jib, if equipped,
thickness of the pads. When pads are used during equal to 1.5 times its rated load.
the five degree slope test, the test technician must
prevent the pads from sliding down the slope or the 6. Rotate the turntable in a full rotation cycle, watching
outrigger shoe from sliding off the pad. for any evidence of instability. Outriggers and tires may
lift off the surface during the test without indicating
• Perform the test only while operating from the lower a condition of instability as long as the mobile unit
controls. does not tend to overturn. For cable placers rated
for mobile use only, tires shall not lift off the surface
• Provide a suitable restraint during all stability tests to during the test.
prevent the mobile unit from overturning in the event
a condition of instability is reached. A typical restraint 7. For cable placers equipped with a side load rating,
method is a loose loop of chain around each side refer to the serial number placard to determine the
of the rear axle [allows the axle to raise off the test side load rating. Position the booms with test weights
surface at least 8″ to 10″ (20.32 to 25.40 cm) before still attached in what was observed to be the least
tightening the chain] near the wheel, that is securely stable position in step 6. Apply the rated side load
anchored to the ground. Increase the length of the to the pulling arms in a direction pulling toward the
chain to allow further movement if there is any doubt rear of the vehicle. Watch for evidence of instability.
about whether the mobile unit has reached a condi- During this test, no tires shall lift off the ground.
tion of instability. Raising of outriggers or tires does
not necessarily indicate a condition of instability. 8. Add permanent counterweight if it is determined that
the mobile unit will not pass the test as originally built.

92 • Section 9 — Structural and Stability Testing

 Use temporary counterweight to determine how much the mobile unit does not tend to overturn. For cable
permanent counterweight is needed and where the placers rated for mobile use only, tires shall not lift
counterweight should be added. Rotate the turntable off the surface during the test.
in a full rotation cycle, watching for any evidence of
instability after adding the temporary counterweight. 7. For cable placers equipped with a side load rating,
If the unit passes the test with the temporary coun- refer to the serial number placard to determine the
terweight, remove the temporary weight and add the side load rating. Position the booms with test weights
permanent counterweight. Perform the test again. still attached in what was observed to be the least
The unit must pass this test before moving on to the stable position in step 6. Apply the rated side load
five degree slope test. to the pulling arms in a direction pulling toward the
rear of the vehicle. Watch for evidence of instability.
Five Degree Slope Test During this test, no tires shall lift off the ground.
1. Position the unit on a constant five degree hard
surface with the centerline of the vehicle positioned 8. Add permanent counterweight if it is determined that
approximately perpendicular to the direction of the the mobile unit will not pass the test as originally built.
slope. If the level surface test showed the mobile unit Use temporary counterweight to determine how much
has a greater tendency to overturn about one side permanent counterweight is needed and where the
than another, position the least stable side on the counterweight should be added. Rotate the turntable
low side of the slope. Apply the parking brake, and in a full rotation cycle, watching for any evidence of
chock the wheels. Engage the hydraulic system. instability after adding the temporary counterweight.
If the unit passes the test with the temporary coun-
2. Properly set the outriggers (if equipped) as directed terweight, remove the temporary weight and add the
in the Operator’s Manual. If this is a recertification permanent counterweight. Perform the test again.
of the stability test with proper outrigger setup, the The mobile unit must pass this test.
side-to-side slope indicator should indicate the value
stamped on the slope indicator placard. If the reading 9. After the test has been completed, stamp the side-to-
cannot be attained or if another customer specified side slope indicator placard with the slope indicator
angle is desired, contact Altec Engineering on how to reading. This is only required following the stability
proceed. test at the time of initial installation of the unit on the
chassis. Take the reading while the outriggers are still
3. Move the booms and jib into a position to most likely set from the five degree test with the loads removed
cause overturning (refer to the test form). and the booms stowed in the travel position. Stamp
the front-to-back slope indicator placard with a 5 un-
4. Apply a load at the center of the platform(s) equal to less the unit has a requirement for a specific angle,
1.33 times the rated platform load. The load can be in which case the placard shall be stamped with its
applied either into the platform(s) or suspended by appropriate angle.
a winch line from the center of the platform(s). The
platform test load may be suspended on the jib line 10. After the test has been completed, torque all acces-
in addition to the jib test load if the unit is equipped sible rotation bearing cap screws to 100 percent of
with a material handling jib structurally capable of the normal installation torque value using a circular
carrying the added load. pattern. This is only required following the stability
test at the time of initial installation of the unit on the
5. Apply a load to the material handling jib, if equipped, chassis.
equal to 1.33 times its rated load.
11. After the test has been completed, torque the rota-
6. Rotate the turntable in a full rotation cycle, watch- tion gearbox mounting cap screws to 100 percent
ing for any evidence of instability. Outriggers and of the normal installation torque value. This is only
tires may lift off the surface during the stability test required following the stability test at the time of initial
without indicating a condition of instability as long as installation of the unit on the chassis.

Section 9 — Structural and Stability Testing • 93

94 • Section 9 — Structural and Stability Testing
Appendix
 Glossary
2nd stage boom — see intermediate boom. arm — 1: the primary load-carrying structure of an articulating arm. 2:
3rd stage boom — see upper boom. the primary load-carrying structure of a single elevator. 3: the articulat-
ing structure which supports the arbor bar for reel lifting.
A-frame outrigger — an extendible outrigger having two diagonal
members which are connected at the top and joined near the midsection arm cylinder — the hydraulic cylinder that moves the arm of a single
by a horizontal cross piece. Resembles a broad based “A.” elevator up and down.
above rotation — in reference to a position on or about a unit that is articulating arm — a system located between the turntable and lower
vertically above the rotation bearing. boom of an aerial device which is used for lifting the boom assembly
to increase the platform working height. This system includes the arm,
absolute — a measure having as its zero point or base the complete link(s), riser and articulating arm cylinder.
absence of the item being measured.
articulating arm cylinder — the hydraulic cylinder that moves an
absolute pressure — a pressure scale with the zero point at a perfect articulating arm up and down.
vacuum.
articulating-boom aerial device — an aerial device with two or more
access hood ― hinged part of the disc housing used to access the boom sections that are connected at joint(s) which allow one boom to
cutter disc. pivot with respect to the adjacent boom.
accumulator — a container used to store fluid under pressure as ASTM — American Society for Testing and Materials.
a source of hydraulic power or as a means of dampening pressure
surges. ATB — see anti-two-block (ATB) system.
actuator — a device for converting hydraulic energy into mechanical atmosphere (one) — a pressure measure equal to 14.7 psi.
energy, such as a motor or cylinder. atmospheric pressure — pressure on all objects in the atmosphere
adapter — a device used to connect two parts of different type or because of the weight of the surrounding air. At sea level, about 14.7
diameter. psi absolute.
adhesion promoter — surface prepping solvent for UV coating. atmospheric vents — a vacuum prevention device designed to allow
air to enter a hydraulic line that has encountered an internal pressure
adjusting stud — a component of a cable drive system that is threaded below that of the atmosphere (vacuum).
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 auger — the hole boring tool of the digger, consisting of a hollow tube
of the drive cable. 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
aeration — the entrapment of air in hydraulic fluid. Excessive aeration to the tube to carry the loose material away from the teeth.
may cause the fluid to appear milky and components to operate errati-
cally because of the compressibility of the air trapped in the fluid. auger extension shaft — a shaft which fits into the auger tube to
connect the digger output shaft to the auger.
aerial control valve — the control valve on the turntable of an elevator
unit which operates the movement functions of the aerial device. auger rotation hydraulic system — the hydrostatic system on a pres-
sure digger which operates the auger transmission gearbox.
aerial device — a vehicle-mounted device with a boom assembly
which is extendible, articulating, or both, which is designed and used auger stow bracket — the bracket on a digger derrick lower boom
to position personnel. The device may also be used to handle material, which stores the digger and auger assembly when it is not in use.
if designed and equipped for that purpose. auger stow switch — a limit switch which is actuated by the auger
Allen wrench — a six-sided wrench that fits into the hex socket of a to shut off digger operation in the stowing direction when the auger
cap screw or set screw. reaches its fully stowed position in the auger stow bracket.
American National Standards Institute (ANSI) — a self-governing auger transmission gearbox — the gearbox mounted on the mast
body of professionals whose primary objective is to prevent accidents weldment of a pressure digger that is used to rotate the kelly bar.
by establishing requirements for design, manufacture, maintenance, auger tube — the hollow tube at the centerline of an auger to which
performance, use and training for manufactured goods including aerial the auger flighting is welded.
devices and digger derricks. auger windup sling — the cable or strap attached to the auger stow
anaerobic adhesive — a bonding agent or adhesive that cures in bracket which is used to store the digger and auger.
the absence of air. auxiliary engine — a separately mounted engine that is used to provide
analog signal — an electrical signal that communicates information power for the unit’s hydraulic system.
by the continuous variation of voltage or current level within a defined auxiliary hydraulic system — the secondary hydraulic system of a
range, in proportion to an input parameter such as pressure or control pressure digger that operates all the hydraulic functions except auger
lever position. rotation.
annular area — a ring shaped area. Usually refers to the piston area AWS — American Welding Society.
minus the cross-sectional area of the rod of a hydraulic cylinder.
back pressure — pressure existing in the discharge flow from an ac-
ANSI — see American National Standards Institute. tuator or hydraulic system. It adds to the pressure required to operate
anti-two-block (ATB) system – the system that helps prevent dam- an actuator under a given load.
age to the winch line or boom by preventing a two-blocking condition backlash — the clearance at the tooth contact point between the
from occurring, by shutting off certain functions when the load hook, adjacent gear teeth of two or more meshing gears.
overhaul ball, hook block, or other lifting component that is attached
to the winch line approaches near the boom tip. baffle — a device, usually a plate, installed in a reservoir to separate
the return line inlet from the suction line outlet.
antirotation fork — a two-pronged retainer which is fastened to the
inside of the turntable and used to prevent movement of the rotary band of arrows — decals used on extendible and articulating upper
joint outer housing. booms to define the boom tip area and the insulating portions of the
upper boom and lower boom insert.
antifoam additive — an agent added to hydraulic fluid to inhibit air
bubbles from forming and collecting together on the surface of the bare-hand work — a technique of performing live line maintenance on
fluid. energized conductors and equipment whereby one or more authorized
persons work directly on an energized part after having been raised
antiwear additive — an agent added to hydraulic fluid to improve and bonded to the energized conductors or equipment.
the ability of the fluid to prevent wear on internal moving parts in the
hydraulic system. barrel — the hollow body of a hydraulic cylinder into which the piston
and rod are assembled.
anvil — the stationary blade on a chipper cutting mechanism.
base boom — see lower boom.
arbor bar — the shaft or spindle that is used to support a cable reel.
base end — 1: the closed end of a hydraulic cylinder, opposite from the
arbor bar collar — a cylindrical device that is used to secure a cable end that the rod extends from. 2: the end of an extendible boom that is
reel on an arbor bar. closest to the turntable. 3: the end of an articulating boom that remains
positioned closest to the turntable when the boom is fully unfolded.

1 Appendix — Glossary
basket — see platform. from the winch to the load. 2: the lower sheave in a digger derrick up-
battery charger — a device used to restore the electrical charge in per boom tip containing two sheaves, which carries the winch line as it
a battery. travels from the upper sheave (boom tip idler sheave) to the load.
bearing — a machine part that is installed between two adjacent machine boom tip tools — see upper tool circuit.
parts to allow those parts to rotate or slide with respect to each other. boom tip winch — a winch located at the tip of a boom.
Commonly used to decrease friction or wear on components. bore — the inside diameter of a pipe, tube, cylinder barrel, or cylindrical
behind cab mount — a pedestal mounting position located immediately hole in any of various other components.
behind the vehicle cab on the longitudinal centerline of the chassis. boss — protruding material on a part which adds strength, facilitates
below rotation — in reference to a position on or about a unit that is assembly, provides for fastenings, etc.
vertically below the rotation bearing. brake — a device used to slow or stop the rotation or movement of a
below rotation controls — controls that are located on the chassis, component such as a rotation gearbox, winch, gravity leveled platform,
used for operating some or all of the functions of the unit. or arbor bar.
blade — the replaceable component on the rotating cutting implement brake caliper — mechanical assembly that houses the brake pads
that cuts wood to produce wood chips. and piston used to apply stopping force on the brake rotor.
bleed-off — to reduce the trapped pressure in a hydraulic system, brake controller — interface between tow vehicle and electric trailer
line, or component, to a zero state by allowing fluid to escape under brakes. Can be inertia activated or based on time delay from activation
controlled conditions through a valve or outlet. of vehicle brakes. Typically in the tow vehicle’s driving compartment
blocking valve — a two-position, two-way valve that blocks pump flow with electrical line running to the trailer wiring connector. Most require
to a hydraulic circuit or system when it is not actuated, and opens to the user to adjust brake gain to compensate for varying trailer load.
allow fluid when actuated. Necessary for the use of electric trailer brakes.
body — a structure containing compartments for storage of tools, brake rotor — rotating disk attached to a shaft that transfers the force
materials, and/or other payload which is installed on a vehicle frame from the brake caliper to the shaft.
or subbase. break-away switch — a device which automatically activates the
body belt — a component in a personal fall protection system consisting breaking system of a towed unit when unintentionally separated from
of a strap which is secured about the waist of a person, with a means the towing vehicle.
for attaching it to a lanyard. (As of January 1, 1998, the use of a body breather — a device that permits air to move in and out of a container
belt for personal fall protection is prohibited by OSHA.) or component to maintain atmospheric pressure.
body harness — a component in a personal fall protection system bridge mount — a unit mounting configuration in which the turntable
consisting of an assembly of straps which are secured about the waist, is mounted on a pedestal structure which forms a bridge over the
chest, shoulders, and legs of a person, with a means for attaching the cargo area.
assembly to a lanyard. broadband — a high speed telecommunication system utilizing fiber
bolt — a cylindrical fastener with external screw threads at one end optic and/or coaxial cable.
and a head configuration such hexagonal, square, or round at the other bucket — see platform.
end, which conforms to the dimensional and material specifications
published for bolts. (These specifications are different from those for buckeye — see forged pin retainer.
cap screws.) bullwheel assembly — an assembly of steel rollers used as a portion
boom — a movable, mechanical structure that is used to support a of a cable stringing system.
platform, material handling components and/or other attachments on burst pressure — the minimum internal pressure that will cause a
a unit. hose, tube, cylinder, or other hydraulic or pneumatic component to
boom angle indicator — a device which indicates the angle between rupture or split open.
the boom centerline and a horizontal plane. button head — a type of cap screw with a rounded head containing a
boom flares — steel structures mounted on the boom tip of a digger socket into which a tool can be inserted to turn the cap screw.
derrick which are used to protect the boom tip from loads and support bypass — a secondary passage for fluid flow.
poles carried on the winch line.
bypass valve — a hydraulic valve that allows for an alternate pas-
boom functions valve — the control valve on a digger derrick that sage for fluid flow.
directs hydraulic pressure and flow to the boom functions (boom, rota-
tion, intermediate boom, upper boom) hydraulic circuits. cable — 1: a wire or wire rope by which force is exerted to control or
operate a mechanism. 2: an assembly of two or more electrical conduc-
boom limiting system — the system of hydraulic cylinders or a tors or optical fibers laid up together, usually by being twisted around a
combination of switches that prevent the platform from moving into a central axis and/or by being enclosed within an outer covering.
non-working position.
cable chute — a device used to guide cable into strand for lashing
boom pin — the horizontal pin that connects the lower boom to the the cable to the strand when placing cable. A trolley allows the device
turntable or riser. to ride on the strand as cable is fed through the chute.
boom rest — the structural member attached to the chassis or body cable drive system — an upper boom drive mechanism which utilizes
to support the lower boom in the travel or rest position. cables to produce upper boom movement.
boom stow switch — a limit switch which is actuated to shut off the cable guide — a bracket which is mounted on a boom to guide the
boom lower function when the boom reaches its stowed position in winch line.
the boom rest.
cable keeper — 1: a mechanical device attached to a cable that is used
boom stow valve — a mechanically actuated hydraulic valve that limits to maintain the position of the cable on a sheave. 2: a component used
the downward pressure of a boom as it is placed in its rest. to prevent a cable or winch line from coming off a sheave.
boom tip — the area at the end of an extendible or articulating upper cable lasher — a mechanical device which wraps lashing wire in a
boom that is farthest from the turntable when the boom assembly is spiral configuration around a length of suspension strand and adjacent
extended or unfolded. This area includes all components at the end communication cable.
of the boom above the band of arrows.
cable lug — a mechanical device attached to a cable that is used to
boom tip idler sheave — the upper sheave in a digger derrick upper maintain the position of the cable on a sheave.
boom tip containing two sheaves, which carries the winch line as it
travels from the winch to the lower sheave (boom tip sheave). cable placer — a type of aerial device which contains a cable string-
ing system and associated components for use in erecting overhead
boom tip pin — a horizontal pin at the upper boom tip. Platform mounting communication cable.
bracket(s) and material handling devices are fastened to this pin.
cable slug — the steel end fitting at each end of the drive cable in an
boom tip sheave — 1: the sheave in a digger derrick upper boom tip upper boom drive system. One end is attached to the cylinder rod and
containing only one sheave, which carries the winch line as it travels the other is secured in a pocket on the elbow sheave.

Appendix — Glossary 2
cable stringing system — the group of steel rollers, bullwheel as- charge pump — the hydrostatic hydraulic system pump that provides
semblies, strand sheave assemblies and fairlead which directs com- fluid at low pressure to make up for internal leakage, provides cooling
munication cable or suspension strand from the reel it is stored on to fluid flow, and tilts the hydrostatic pump swash plate.
the working position of the operator. chassis — a vehicle on which a unit is mounted, such as a truck,
CADI — see calibration and diagnostic instrument. trailer, or all-terrain vehicle.
calibrate — to check, adjust, or determine by measurement in com- check valve — a valve that permits flow of fluid in one direction, but
parison with a standard, the proper value of each scale reading or not in the reverse direction.
setting on a meter or other device. chip curtain — rubberized deflection curtain attached to the infeed
calibration and diagnostic instrument (CADI) — a hand-held instru- chute.
ment that can be temporarily connected to the control system of a unit chip deflector — directs chip discharge.
to adjust various system control parameters.
circuit — the complete path of flow in a hydraulic or electrical sys-
caliper — a measuring instrument with two legs or jaws that can be tem.
adjusted to determine the distance between two surfaces.
circuit breaker — a form of electrical switch which opens (trips) to
cam — a rotating or sliding piece that imparts motion to a roller moving interrupt a circuit when it senses excessive current flow that may be
against its edge or to a pin free to move in a groove on its face or that caused by a short circuit, to protect wiring and components from damage.
receives motion from such a roller or pin. Some types of circuit breakers reset automatically when the excessive
candling — a method of inspecting filament wound fiberglass booms current discontinues and others must be reset manually.
by slowly passing a light through the inside of the boom in a darkened clean out — clean out area under the lower feed roll.
area. Cracks, crazing, and other damage show up as dark spots or
shadows. clevis — a U-shaped fastening device secured by a pin or bolt through
holes in the ends of two arms.
cap — a device located on the hand of a reel lifter that is used to
retain the arbor bar. closed center — a directional valve design in which pump output is
blocked by the valve spool(s) when the valve spool(s) is in the center
cap end — see base end. or neutral operating condition.
cap screw — a cylindrical fastener with external screw threads at clutch — 1: the device on a reel lifter which allows the connection and
one end and a head configuration such as hexagonal, hex socket, flat disconnection of the arbor bar and the driver. 2: controlled transfer of
countersunk, round, or slotted at the other end, which conforms to the rotational power from engine to output PTO shaft.
dimensional and material specifications published for cap screws.
coaxial cable — a type of shielded cable used for conducting tele-
capacitive coupling — the transfer of electrical energy from one communication signals, in which the signal carrier is a single wire at
circuit to another through a dielectric gap. the core, surrounded by a layer of insulating material, which is in turn
capacity chart — a table or graph showing the load capacity, rated surrounded by a metallic, conductive layer which serves as a shield,
capacity, or rated load capacity figures for a unit or accessory. with an overall outer layer of insulation.
captive air system — a closed circuit, low pressure pneumatic system combined digger derrick and platform use — the stability criteria
used to actuate a pressure switch by means of a manually operated for a digger derrick mobile unit which indicates that the load capacity
air plunger. chart and stability requirements apply to the use of the derrick for lifting
cartridge — 1: the replaceable element of a fluid filter. 2: the replace- of loads with the winch line at the upper boom tip or material handling
able pumping unit of a vane pump, composed of the rotor, ring, vanes jib tip, with the platform occupied.
and side plates. 3: A removable hydraulic valve that is screwed into come-along — a device for gripping and putting tension into a length
place in a cavity in a hydraulic manifold or cylinder. of cable, wire, rope, or chain by means of two jaws or attaching devices
catrac — see hose carrier. which move closer together when the operator pulls on a lever.
caution — indicates a hazardous situation which, if not avoided, could communication cable — a copper wire, coaxial, or fiber optic cable
result in minor or moderate injury. used for conducting telecommunication signals.
cavitation — the formation of gaseous voids in hydraulic fluid caused compensating link — a mechanical linkage that serves as a connector
by a low pressure condition which typically occurs when inlet starvation between the turntable and the upper boom drive mechanism. As the
prevents the pump from filling completely with fluid. The characteristic lower boom is raised or lowered, this linkage causes the upper boom
sound of cavitation is a high pitched scream. to maintain its relative angle in relationship to the ground.
center mount — see behind cab mount. compensator — a valve spool that is used to maintain a constant
pressure drop regardless of supply or load pressure.
center of gravity — the point in a component or assembly around
which its weight is evenly balanced. compensator control — a control for a variable displacement pump
that alters displacement in response to pressure changes in the system
centerline of rotation — the vertical axis about which the turntable as related to its adjusted pressure setting.
of a unit rotates.
component — a single part or self-contained assembly.
centrifugal pump — a pump in which motion and force are applied
to fluid by a rotating impeller within a housing. compressibility — the change in volume of a unit volume of a fluid
when it is subjected to a unit change in pressure.
chain — a series of identical rigid segments connected to each other
at joints which allow each segment to pivot with respect to adjacent conductive — having the ability to act as a transmitter of electricity.
segments, used to transmit mechanical force. Electricity will flow through metal, therefore metal is conductive.
chain extension system — a mechanical system consisting of a mo- conductive shield — a device used to shield the lower test electrode
tor, gearbox, chains, and sprockets that is used to extend and retract system from capacitive coupling.
an extendible upper boom. conductor — a wire, cable, or other body or medium that is suitable
chain sling — an inverted Y-shaped length of chain used for lifting a for carrying electric current.
strand reel with an aerial device and placing it in a strand carrier. constant resistivity monitor — device used to continuously measure
chamber — a compartment within a hydraulic component that may the electrical resistance of the wash water in the tank of an insulator
contain elements to aid in operation or control, such as a spring cham- washer.
ber or drain chamber. contaminate — to render unfit or to soil by introduction of foreign or
channel — a fluid passage that has a large length dimension compared unwanted material.
to the dimension of the cross-section. continuous rotation — a rotation system in which the turntable is
charge — to fill an accumulator with fluid under pressure. able to rotate an unlimited number of revolutions about the centerline
of rotation without restriction.
charge pressure — the pressure, above atmospheric pressure, at
which replenishing fluid is forced into the hydraulic system. control — a device, such as a lever or handle, which is actuated by
the operator to regulate the direction and speed of one or more func-
tions of a unit.

3 Appendix — Glossary
control bar — when manually activated, controls the movement of detent — a device for positioning and holding one mechanical part in
feed roll(s) on a chipper. relation to another so that the device can be released by force applied
control feed — a wood chipper which controls the infeed rate to the to one of the parts.
cutting mechanism. diagnostic — relating to the practice of investigation or analysis of the
control station — a position where controls for unit operation are cause or nature of a condition, situation, or problem.
located. These positions may include the platform, upper boom tip, diagonal brace — the structural member attached near the top of a
turntable, pedestal or vehicle tailshelf. corner mount pedestal and extending downward and forward to a point
control valve — a directional valve controlled by an operator, used to of attachment on the subbase or vehicle frame between the pedestal
control the motion or function of an actuator or system. and the vehicle cab.
cooler — a heat exchanger used to remove heat from hydraulic fluid. dial indicator — a meter or gauge with a calibrated circular face and
a spring-loaded plunger, used as a measuring device.
corner mount — a pedestal mounting position located behind the
rear axle(s) with the centerline of rotation located to one side of the diegrinder — a small, hand held, rotary grinding tool.
chassis. dielectric — nonconductive to electrical current.
corona ring — see gradient control device. differential cylinder — any cylinder that has two opposed piston
counterbalance valve — a load holding valve that can be opened areas that are not equal.
to allow flow in the normally blocked direction by applying hydraulic digger — the mechanism which drives the auger.
pressure to a pilot port, and which contains a relief capability to allow digger bail — a tubular housing attached to the gearbox portion of a
flow from the blocked direction if the blocked pressure exceeds a digger, which surrounds the motor and provides an attachment point
certain value. to the digger link.
courtesy cut — partial cut through limbs so as to allow limbs to fold digger derrick — a multipurpose, vehicle-mounted device with an
towards tree trunks and allow ease of feeding chipper. extendible boom which may accommodate components that dig
cracking pressure — the pressure at which a pressure actuated valve, cylindrical holes, set utility poles, and position materials, apparatus,
such as a relief valve, begins to pass fluid. and/or personnel.
crane — a machine used for hoisting and moving objects by means digger derrick use — the stability criteria for a digger derrick mobile
of cables attached to a movable boom. unit which indicates that the load capacity chart and stability require-
crazing — a network of fine cracks on or below the fiberglass surface. ments apply to the use of the derrick for lifting of loads with the winch
Crazing often occurs when the fiberglass is struck with a blunt object, line at the upper boom tip or material handling jib tip, with the platform
sometimes causing deformation and breakdown of the fiberglass resin. stowed or removed, if so equipped.
crosstalk — a form of interference in which one circuit or channel digger hanger bracket — the structural member on a digger derrick
receives some unintentional signal from another. which supports the digger link on the extendible boom.
cross-ported — a hydraulic path connected between the two opposite digger latch mechanism — a mechanism which secures the digger
flow paths of a hydraulic circuit that allows a route for flow between to the lower boom when it is stowed and to the extendible boom when
the two paths in lieu of flow thru an actuator. To allow sensing of the it is unstowed.
pressure in one path by a component installed in the other path. digger link — the structural member which attaches the digger to the
cSt (centistoke) — a metric unit of kinematic viscosity. In customary digger hanger bracket.
use, equal to the kinematic viscosity of a fluid having dynamic viscosity digger/winch valve — the control valve on a digger derrick that
of one centipose and a density of one gram per cubic centimeter. directs hydraulic pressure and flow to the digger and winch hydraulic
curb side — the side of a vehicle which is opposite from oncoming circuits.
traffic when the vehicle is traveling forward in the normal direction in digital signal — an electrical signal that communicates information
a lane of traffic. by the use of two distinct levels of voltage or current, a high “on” level
cushion — a device built into a hydraulic cylinder that restricts the flow and a low “off” level, which are sent in a series of pulses. The timing
of fluid at the outlet port to slow the motion of the rod as it reaches of the pulses is used to indicate the level of an input parameter such
the end of its stroke. as control lever position, or information such as the address setting of
a radio control transmitter linking it to its receiver.
custom option — an option which is not shown on a standard order
form and which requires additional engineering work to supply. diode — an electrical component that allows current flow in one direc-
tion but not in the reverse direction.
cylinder — a device that converts fluid power into linear mechanical
force and motion. It usually consists of a movable piston and rod, or directional valve — a valve that selectively directs or prevents fluid
plunger, operating within a cylindrical bore. flow through desired passages.
danger — indicates a hazardous situation which, if not avoided, will disc — the rotating component, housing the blades on a disc chipper.
result in death or serious injury. This signal word is to be limited to the disc chipper — a wood chipper which utilizes a disc shaped, rotating
most extreme situations. cutter mechanism.
DC pump — a pump which is powered by a direct current electric motor. disc housing — weldment housing the cutting disc, comprising of the
dead band — the area or range near the center rest position of a base, stationary hood and access hood.
hand control where the function does not respond to movement of discharge chute — directs chip discharge from the cutter mechanism
the lever or handle. in the desired direction.
decal — a thin sheet of flexible material which is attached to another displacement — the quantity of fluid that can pass through a pump,
surface by adhesive, and is used to convey instructions, information motor or cylinder in a si­ngle revolution or stroke.
and warnings. docking station — a device used to mount a radio remote control
deenergize — to remove electrical power from a device, as from the transmitter on a platform.
coil of a solenoid valve. dog clutch — see drum clutch.
delivery — the volume of fluid discharged by a pump in a given time, double-acting cylinder — a cylinder in which fluid pressure can be
usually expressed in gallons per minute (gpm). applied to either side of the piston to move the rod in either direction.
demulsibility — the ability of a liquid to expel another type of liquid. double elevator — an elevator lift with two load carrying arms. The
Commonly used to describe a fluid’s ability to cause water to separate double elevator system includes a lower pedestal, lower arm, lower arm
out rather than being held in suspension. cylinder(s), riser, upper arm, upper arm cylinder(s), and upper pedestal,
design voltage — the maximum rated line voltage for which an aerial plus parallel links in both the lower and upper sections.
device has been designed, and for which it can be qualified. double-pole, double-throw (DPDT) switch — a six-terminal electrical
desolve — surface prepping solvent for low voltage coating. switch or relay that connects, at the same time, one pair of terminals
to either of two other pairs of terminals.

Appendix — Glossary 4
double-pole, single-throw (DPST) switch — a four-terminal electrical end gland — a hollow, cylindrical part that screws into or is retained
switch or relay that, at the same time, opens or closes two separate in the open end of a hydraulic cylinder barrel, through which the rod
circuits or both sides of the same circuit. protrudes.
down load — the downward force created when an external force is ex- end-mounted platform — a platform which is attached to a mounting
erted on the boom, such as a winch pulling cable on a cable placer. bracket that extends beyond the boom tip, positioning the platform
drain — a passage or a line from a hydraulic component that returns (and platform rotation pivot, if so equipped) beyond the end of the
leakage fluid to the reservoir. upper boom.
drift — 1: a gradual, uncontrolled change from a set position of an energize — to send electrical power to a device, as to the coil of a
actuator or component. 2: a tool for ramming or driving something. solenoid valve.
driver — the gearbox and motor assembly on a reel lifter which is energized conductor — an apparatus that is transmitting electric
connected to and disconnected from the arbor bar through the clutch current.
assembly. energy — the ability or capacity to do work, measured in units of
drop pocket — an open top tool storage area on the chassis of a work.
unit. engine protection system — a system which detects when the
drum — the rotating component, housing the blades on a drum chipper. auxiliary engine oil pressure or temperature is out of the proper range
and shuts the engine off.
drum chipper — a wood chipper which utilizes a drum shaped, rotat-
ing cutter mechanism. extendible — capable of linear movement of one or more portions of
an assembly to increase the overall length or reach of the assembly.
drum clutch — a clutch consisting of two or more drive lugs that engage
similar driven lugs to transmit torque. Commonly used between the extendible-boom aerial device — an aerial device with a telescopic
gearbox and cable drum on front or bed mounted winches. or extendible boom assembly.
dump valve — a normally open, two-position, two-way valve that sends extension cylinder — a hydraulic cylinder which extends and retracts
pump flow through a path going directly to the reservoir or bypassing an extendible boom(s).
hydraulic circuit when it is not actuated, preventing operation of the fairlead — the group of steel rollers at the platform of a cable placer which
hydraulic system or circuit. When it is actuated, it closes off this path, guide the cable or suspension strand during the placing process.
redirecting flow to the hydraulic system or circuit to allow operation. fairlead receptor tube — part of the pulling arms used to support
dynamometer — an instrument for measuring mechanical force or the fairlead.
power. fall protection system — a system consisting of a body harness or
earth anchor — see screw anchor. body belt, a decelerating lanyard, connectors, and an anchor point at
eccentric ring — a ring with the center hole located in a position off the the boom tip, used to catch and hold a person who falls from a plat-
geometric center, commonly used to adjust the position of the rotation form. (As of January 1, 1998, the use of a body belt for personal fall
pinion with respect to the rotation bearing gear teeth. protection is prohibited by OSHA.)
eccentric ring lock — a device which engages a hole or notch in an fan — part of the disc or drum chipper which propels chipped debris
eccentric ring to prevent the ring from rotating. and increases airflow into the discharge chute.
efficiency — the ratio of output to input. Volumetric efficiency of a pump feed box — assembly housing the feed roll(s).
is the actual output in gpm divided by the theoretical or design output. feed roll — a mechanical controlled roll or rollers used to control the
The overall efficiency of a hydraulic system is the output power divided feed rate to the cutter mechanism.
by the input power. Efficiency is usually expressed as a percent. feed table — folding or fixed position guard which restricts operators
elbow — the structure on an articulating-boom aerial device that con- access to the cutter mechanism.
nects the upper boom to the lower boom. The elbow allows the upper feedback (feedback signal) — the return of part of an output signal to
boom to pivot relative to the lower boom. the input for the purpose of modification and control of the output.
elbow bearing — the rotating member that allows the upper boom to feeder tube — a telescopic hydraulic tube assembly mounted on an
rotate around the end of the lower boom. Used on aerial devices with extendible boom which carries pump flow to a device mounted on the
the upper and lower booms mounted side by side. extendible portion of the boom such as a digger or boom tip winch.
elbow pin — the horizontal pin that attaches the upper boom to the FeedSense® — Automatically maintains cutter mechanism speed.
lower boom on an articulating-boom aerial device. Used on aerial
devices with the upper boom mounted over the lower boom. fiber optic cable — a type of cable used for conducting control or
telecommunication signals, in which the signal carrier(s) is one or more
electrical harness — an assembly of electrical wires that is used to optical fibers, enclosed within an outer covering.
deliver electrical current between components.
fiber optic receiver — an electronic module that collects fiber optic
electrocution — receiving an electrical shock resulting in death. signals and converts them into electrical signals.
electrohydraulic — a combination of electric and hydraulic control fiber optic transmitter — an electronic module that converts elec-
mechanisms in which an electrically controlled actuator is used to shift trical signals into fiber optic signals and sends them through a fiber
the spool in a hydraulic control valve. optic cable.
electrohydraulic control system — a control system in which the fiber optics — the use of transparent fibers of glass or plastic which
function control handles are connected to electric controls. The elec- transmit light signals throughout the length of the fiber. Commonly used
tric controls actuate electrohydraulic valves to operate the functions to transmit signals from a remote control.
of the unit.
fiberglass — glass in fibrous form added as a reinforcement to a plastic
electrohydraulic valve — a directional valve that receives a vari- for use in making various products.
able or controlled electrical signal which is used to control or meter
hydraulic flow. filler breather cap — the component on the top of a reservoir that
allows air to enter and exit the reservoir as the fluid level changes,
elevator lift — a system located between the turntable and subbase and which can be removed to access a fill hole when adding hydraulic
of an aerial device which is used for lifting the aerial device to increase fluid to the reservoir.
the platform working height. This system may be configured as a single
elevator or a double elevator. filter — a device through which fluid is passed to remove and retain
insoluble contaminants from a fluid.
elevator unit — the overall device including the subbase, elevator lift
and the aerial device. 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
emergency operating DC pump — see secondary stowage DC hydraulic system fluid.
pump.
filter cartridge — a component containing filtration material which is
emergency operating system — see secondary stowage system. installed within a filter housing or attached to a filter receptacle for use,
and can be removed and replaced as a self-contained unit.

5 Appendix — Glossary
firm footing — outrigger placement and extension in accordance with gradient control device — a device at the upper end of an insulating
the instructions in a unit’s operator’s manual to ensure proper leveling boom that reduces electrical stress level(s) below that considered to
of the vehicle and adequate stability when operating the unit. be disruptive.
fixed displacement pump— a pump in which displacement is con- gravity leveling system — a system which uses the force of gravity
stant, so that the output flow can be changed only by varying the to keep the bottom of a platform parallel to level ground as the boom
drive speed. is raised or lowered. One means of accomplishing this is by allowing
flange — on a flange and lug pin retaining system, an end plate that is the platform to pivot freely about a horizontal shaft attached above the
welded to one end of the pin. The purpose of the flange is to position platform’s center of gravity.
the pin in the connection. grease fitting — a small fitting that acts as the connection between a
flange and lug pin retaining system — a connecting pin retention grease gun and the component to be lubricated.
system in which an end plate is welded to one end of the pin and a gripper tool — a component used for grasping an object or electrical
retaining plate is attached with cap screws to the other end to hold lines through the use of an articulated mechanism.
the pin in position. ground — 1: a large conducting body with a potential of zero volts
flashover — a disruptive electrical discharge at the surface of electrical used as a common current return for an electric circuit. 2: an object that
insulation or in the surrounding medium, which may or may not cause makes an electrical connection with a ground or with the earth.
permanent damage to the insulation. ground fault interrupter (GFI) — a fast acting form of circuit breaker
flats from finger tight (F.F.F.T.) — a method of counting the number that opens to interrupt an electrical circuit if it senses a very small
of wrench flats when tightening a hydraulic adapter to establish a current leakage to ground, to protect personnel against a potential
torque value. shock hazard from defective electrical tools or wiring. It does this by
flat-shoe outrigger — an outrigger which has a shoe that is fixed in monitoring for any difference in current flow between the hot and neu-
a horizontal position. tral wires in the circuit. An imbalance exceeding a very small preset
value indicates that current is finding an improper path to ground, and
flighting — a curved plate or series of curved plates welded together, causes the breaker to trip.
spiraling along the axis of an auger tube or screw anchor rod.
guard ring — see conductive shield.
flow — the movement of fluid generated by pressure differences.
hand — an extension of the reel lifter arm that allows for loading the
flow control valve — a valve that regulates the rate of fluid flow. arbor bar.
flow rate — the volume, mass or weight of a fluid passing through any hand control — a hand operated control lever or handle located at a
conductor per unit of time. control station used to regulate a function of a unit, where the speed of
flow straightener — a component part of a nozzle used to straighten the function is proportional to the distance the control is moved.
or remove any swirling motion of fluid going through the nozzle. hand latch — mechanical device used to retain the arbor bar in the
flowmeter — an instrument used to measure the flow rate of fluid in reel lifter or strand carrier hand.
a hydraulic tube or hose. heat — the form of energy that has the capacity to create warmth or
fluid — a liquid that is specially compounded for use as a power to increase the temperature of a substance. Any energy that is wasted
transmitting medium in a hydraulic system. or used to overcome friction is converted to heat. Heat is measured in
calories or British thermal units (Btu). One Btu is the amount of heat
fold — to move a pivoting structure such an articulating upper boom required to raise the temperature of one pound of water one degree
toward its stowed position. Fahrenheit.
fold-up shoe outrigger — an outrigger which has a shoe that pivots heat exchanger — a device that transfers heat through a conducting
into a vertical position when the outrigger is fully retracted. wall from one fluid to another or into the atmosphere.
force — any push or pull measured in units of weight. hertz (Hz) — a unit of frequency equal to one cycle per second.
forged pin retainer — a pin retainer made from forged steel, consisting high tooth — the individual tooth out of all the gear teeth on a rotation
of a slender, cylindrical body with a flattened, circular head at one end, bearing at which the minimum backlash occurs with the rotation pinion.
with a mounting hole through the head perpendicular to the body. The This is because of a slight difference between the actual and theoretical
body is inserted through a hole in the pin to be retained, and the head tooth pitch lines due to manufacturing tolerances.
is fastened to the adjacent structure with a cap screw.
HLIW — hot line insulator washer.
four-way valve — a valve that has four ports, normally a pressure
(inlet) port, a return (tank) port, and two work ports. Used to change holding valve — see load holding valve.
direction of a cylinder or other output device. hood pin — in conjunction with bolts, secures the two top halves of
FPS — Fluid Power Society. the disc housing together.
frequency — the number of times an action occurs in a unit of time. HOP — see hydraulic overload protection system.
gasket — a packing made of a deformable material, usually in the horsepower (HP) — the power required to lift 550 pounds one foot in
form of a sheet or ring, used to make a pressure tight fit between one second or 33,000 pounds 1 foot in one minute. One horsepower
stationary parts. is equal to 746 watts or to 42.4 British thermal units per minute.
gate valve — see shutoff valve. hose carrier — a flexible component which contains hydraulic, elec-
trical, and/or air lines, usually mounted inside or along the side of an
gauge pressure — a pressure scale that ignores atmospheric pres- extendible boom. As the boom is extended, the hose carrier unfolds in
sure by establishing atmospheric pressure as its zero point. Its zero a rolling motion to allow the lines to extend with the boom.
point is 14.7 psi absolute.
hose carrier tube — a rigid, enclosed tube which contains hydraulic,
gauge snubber — see snubber valve. electrical, and/or air lines, and may contain components for upper
gearbox — an assembly with internal speed changing gears; a transmis- controls. It is usually attached to a hose carrier on the side of an
sion. Gearboxes are commonly used to transmit power from a hydraulic extendible boom.
motor to operate a function through an output shaft. hot line insulator washer (HLIW) — a vehicle-mounted device which
gelcoat — a protective coating used on fiberglass components to is designed and used for cleaning pole and structure mounted transmis-
prevent the wicking of moisture into the fiberglass strands and to retard sion and distribution insulators.
the degrading effect of ultraviolet light on the fiberglass. HTMA — Hydraulic Tool Manufacturer’s Association.
GFI — ground fault interrupter. Huck bolt — a bolt-like fastener that is placed in position and then
gib assembly — secures cutter blades in place on drum chippers. stretched while an end fitting is swaged on. Commonly used to attach
gin pole — a vertical phase-holding apparatus which is attached to a a pedestal, subbase, and/or outriggers to a vehicle frame.
platform or upper boom tip. hydrant — a discharge pipe with a valve and spout at which water
gpm — gallons per minute. may be drawn from a water main.
hydraulic control — a control that is actuated by hydraulically induced
forces.

Appendix — Glossary 6
hydraulic leveling system — an automatic hydraulic control system keyway — a groove that is cut in a shaft or bore for a key to fit into.
which keeps the bottom of a platform parallel to or at a fixed angle to kilovolts (kV) — a unit of potential difference equal to 1,000 volts.
the turntable base plate as the boom is raised or lowered. One means
of accomplishing this is by transferring hydraulic fluid between a lower knife — see blade.
leveling cylinder actuated by movement of the lower boom and an upper knuckle — see elbow.
leveling cylinder mounted between the platform and the upper boom.
L-bracket — an L-shaped weldment that is used to connect a splicer
hydraulic overload protection (HOP) system — the system on a platform to the upper boom tip.
digger derrick that shuts off certain functions to help prevent damage
to the digger derrick structure when an overload is applied to the boom lanyard — a component in a personal fall protection system consisting
in the downward direction. of a flexible, nonmetallic strap or rope with a connector at each end
for connecting a body harness or body belt to a specified anchor point
hydraulic schematic — a drawing that uses common hydraulic symbols provided at the boom tip, used to catch and decelerate a person in a
to represent the hydraulic system of the unit. fall from the platform. (As of January 1, 1998, the use of a body belt
hydraulic swivel — a fluid conducting fitting having two joined parts for personal fall protection is prohibited by OSHA.)
that are capable of pivoting freely about each other to accommodate lashing wire — a thin, solid wire which is wrapped in a helix configura-
motion of an attached hydraulic line. tion around a length of suspension strand and adjacent communication
hydraulically extendible jib — a jib boom that may be extended or cable so that the suspension strand carries the weight of the cable.
retracted by hydraulic power. lay — the length of wire rope in which one strand makes one complete
hydraulics — an engineering science pertaining to liquid pressure spiral around the rope.
and flow. layer — all wraps of winch line on a winch drum which are on the same
hydrostatic hydraulic system — any hydraulic drive in which a posi- level between drum flanges.
tive displacement pump and motor transfer rotary power by means of leakage monitor system — a means by which current leakage is
fluid under pressure. measured through the insulating section(s) of a boom to confirm of
individual address setting — the code that identifies a specific dielectric integrity.
transmitter as the one emitting the signal corresponding to a specific leveling cable — the wire rope portion of a mechanical leveling system
receiver’s reception address. that passes over the sheaves.
infeed chute — tapered weldment attached prior to the feed/cutter leveling chain — the chain portion of a mechanical leveling system
mechanisms, assisting in the centering of the tree canopy. that passes over the sprockets.
in-line — the installation of a component in series between two por- leveling cylinder — 1: a cylinder that is used in an arrangement in
tions of a hydraulic line or electrical conductor so that flow in the line a hydraulic leveling system to hydraulically level the platform. 2: the
or conductor toward the component passes through the component hydraulic cylinder that is used to tilt the pivot and mast weldments of
and continues on in the line or conductor on the other side. a pressure digger to either side of the vertical position.
instability — a condition of a mobile unit where the sum of the mo- leveling rod — a slender, round, fiberglass rod used in a mechani-
ments tending to overturn the mobile unit is equal to or exceeds the cal leveling system that passes through a unit’s boom to connect the
sum of the moments tending to resist overturning. leveling chains or cables at each end of the boom.
insulating aerial device — an aerial device with dielectric components leveling system — see platform leveling system.
designed and tested to meet the specific electrical insulating rating
consistent with the manufacturer’s name plate. leverage — a gain in output force over input force; mechanical advan-
tage or force multiplication.
insulating digger derrick — a digger derrick designed for and manu-
factured with a fiberglass boom(s) for use around energized conductors lift cylinder — the hydraulic cylinder that moves the lower boom up
at a maximum of 46 kV phase to phase. and down on a digger derrick or extendible-boom aerial device.
insulating liner — see platform liner. lifter cylinder — the hydraulic cylinder that moves the reel lifter
arms.
insulating portions — those sections which are designed, main-
tained, and tested in accordance with the electrical requirements of lifting eye — a shackle or weldment used for attaching chain, cable,
ANSI A92.2. rope, etc. to a boom for material handling.
insulator — a device that isolates the energized conductor of a power light emitting diode (LED) — a semiconductor diode that emits light
line from the support structure. when subjected to an applied voltage. LEDs are used for electronic
display.
intercom system — a transmitter and receiver system that allows
two-way verbal communication between a platform operator and a line — a tube, pipe, or hose used as a passageway to move hydraulic
person at ground level. fluid.
interference — any energy that inhibits the transmission or reception linear — in a straight line.
of electrical or radio signals. linear actuator — a device for converting hydraulic energy into linear
intermediate boom (INT BOOM) — an extendible boom section motion such as a cylinder or ram.
which is located between the upper boom and the lower boom in an linear position transducer — an extendible length measuring device
extendible boom assembly. which produces a variable electrical signal that is proportional to the
ISO — International Standards Organization. length to which the device is extended.
jam nut — a nut that is screwed down firmly against another nut to liner — see platform liner.
prevent loosening. link — the secondary load-carrying structure of an articulating arm.
jaw clutch — see drum clutch. LMAP — see load moment and area protection.
jib — an auxiliary boom which attaches to the upper boom tip to extend LML — see load moment limiter (LML) system.
the reach of the boom. load capacity — (as defined by ANSI for digger derricks) the maximum
JIC — Joint Industry Conference. load, specified by the manufacturer, that can be lifted by the mobile unit
joystick — a two or three axis control lever which allows the operator at regular intervals of load radius or boom angle, through the specified
to simultaneously control multiple functions. ranges of boom elevation, extension and rotation, with options installed
and inclusive of stability requirements.
junction box — an enclosed central connecting point for electrical
wiring. load holding valve — a hydraulic valve which blocks fluid flow from
a hydraulic actuator, such as a cylinder or motor, to prevent motion
kelly bar — 1: for derricks see auger extension shaft. 2: the auger drive when the control valve is not being operated or in case of a hydraulic
shaft of a pressure digger which is extendible from the ram cylinder. line failure.
key — a parallel-sided piece that fits into grooves in two adjacent parts load moment — the moment that acts in the direction to attempt
to prevent movement between the parts. Often used as the driving to overturn the unit, consisting of the total moment produced by the
member between a shaft and a sheave or winch drum. weights of the boom, boom attachments, and load on the winch line.

7 Appendix — Glossary
load moment and area protection (LMAP) — monitors load on the material handling — having the ability to use the boom or attachments
unit and also monitors the working area. on the boom to lift and position materials.
load moment limiter (LML) system — the system on a digger derrick material handling system — the system on an aerial device that
that shuts off certain functions to help prevent overturning of the unit consists of a jib and winch used to lift material to the upper boom tip.
when the load moment reaches a value that could cause instability if mechanical leveling system — a mechanical system which keeps
increased further. the bottom of a platform parallel to or at a fixed angle to the turntable
load radius — the horizontal distance from the centerline of rotation base plate as the boom is raised or lowered. One means of accom-
to the winch line load attachment point. plishing this is by utilizing a parallelogram arrangement of leveling rods
load sensing — (see sense line) the signal when a function is operated attached to cables or chains operating around sheaves or sprockets
that tells the hydraulic pump to stroke up from a non-stroked (neutral) at boom pivot points.
position to supply oil to that function. mercury switch — a switch that is closed or opened when an inter-
lock washer — a solid or split washer that is placed underneath a nut nal globule of mercury moves to or away from the contacts when the
or cap screw to help prevent loosening by exerting pressure against switch is tilted.
the fastener. meter — to regulate the amount of fluid flow.
locknut — see self-locking nut. meter-in — to regulate the amount of fluid flow into an actuator or
lockwire — a wire that is installed to prevent loosening of fasteners system.
or components. meter-out — to regulate the flow of the discharge fluid from an actua-
low voltage coating — a sprayed on layer that provides low voltage tor or system.
insulating properties. micron (micrometer) — one-millionth of a meter or about 0.00004″.
lower arm — the primary load-carrying structure of a double elevator micron rating — the minimum size of the particles that a filter is
which is located between the lower pedestal and the riser. designed to remove.
lower arm cylinder — the hydraulic cylinder that moves the lower arm microswitch — a small electrical device that is used to turn an electrical
of a double elevator up and down. current on or off, or to change the connections in a circuit.
lower boom (LWR BOOM) — the boom section in a boom assembly minimum approach distance — the three dimensional area sur-
which is attached to the turntable or riser, and which supports the upper rounding a conductor into which a person may not enter nor bring any
boom or intermediate boom. conductive object unless they are: qualified electrical workers, wearing
lower boom cylinder — the hydraulic cylinder that moves the lower insulating gloves (and sleeves when required), protected against contact
boom about its pivot point on an articulating-boom aerial device. with any other objects at a different electrical potential.
lower boom insulator — the part of the lower boom made of high mobile operation — the use of the aerial device or digger derrick while
dielectric strength material (usually fiberglass reinforced plastic or the mobile unit is traveling.
equivalent) to interrupt the conductive path for electricity through the mobile unit — the combination of a unit, its chassis and related per-
lower boom. manently attached equipment.
lower boom winch — a winch that is located on the lower boom. modified A-frame outrigger — an extendible outrigger that is config-
lower control valve — the hydraulic valve on the vehicle, turntable, ured like a large broad based “A” with an open top.
or pedestal of an aerial device used for operating some or all of the modulation ratio — the “on” time vs. the “off” time of a pulse width
functions of the aerial device. modulated digital signal. This ratio is determined by dividing the on
lower controls — the controls on the vehicle, turntable, or pedestal, time during one cycle by the total cycle time.
used for operating some or all of the functions of the unit. moly — see molybdenum disulfide.
lower pedestal — the structure within an elevator lift that connects molybdenum disulfide — a black inorganic chemical that is used as
the elevator lift to the subbase. a dry lubricant and as an additive for grease and oils. Molybdenum
lower test electrode system — a system on an insulating aerial disulfide has a very high melting point and is insoluble in water.
device utilizing conductive bands installed permanently on the inside molydisulfide — see molybdenum disulfide.
and outside surfaces of the insulating portion of the upper boom and moment — a force multiplied by the perpendicular distance from the
conductive connections to components inside that portion of the boom line of action of the force to an axis or point. The force may be the
such as leveling rods and hydraulic lines. All the bands and component weight of an item, with the vertical line of action located at the item’s
connections are connected to a common pickup point for use in mea- center of gravity. Moment is measured in units of force times distance;
suring current leakage to confirm of dielectric integrity. for example, pound-feet or foot-pounds.
lower tool circuit — a hydraulic tool circuit with quick disconnect monitor head — remotely controlled articulated assembly with a nozzle,
couplings located on the pedestal or on the vehicle. mounted at the upper end of an HLIW.
lug — a metal part which serves as a cap, handle, support, or fitting motor — a device that converts hydraulic or electrical energy into
connection. continuous rotary motion and torque.
lunette eye — a round metal ring used in place of a ball coupler on a multiple-part line — the arrangement of the winch line in which the
trailer. It attaches to a pintle hook on the towing vehicle. winch line is routed between the boom tip and the load two or more
magnetic suction separator filter — see magnetic suction strainer. times. A snatch block is used at the load and a snatch block or additional
magnetic suction strainer — a suction filter consisting of a strainer boom tip sheave(s) is used on the boom to reverse the direction of
which contains one or more magnets to trap ferrous metallic contami- the winch line. The end of the winch line is connected to a stationary
nants that are small enough to pass through the strainer. attachment point on the boom or lower snatch block. A multiple-part
line is used to reduce the tension in the winch line to a value below
mainframe — see pedestal. the winch line rated working load when a lifting load that exceeds the
man-and-a-half platform — an oversized one-man platform. winch line rated working load.
manifold — a fluid conductor that provides multiple connection multiplexing — a process by which signals from multiple inputs are
ports. combined and transmitted simultaneously over a single channel.
manual lowering valve — a manually operated hydraulic valve used multiviscosity — the viscosity characteristic of a fluid which contains
to lower the boom in the event of power failure. additives that increase the viscosity index. The fluid does not become
as thin at high temperatures or as thick at low temperatures as a fluid
manual override — a means of manually actuating an automatically without these additives. This allows the fluid to be used over a wider
or remotely controlled device. temperature range.
manually extendible jib — a jib that is capable of being extended and nonconductive — the characteristic of a substance that allows it to
retracted by human force. transmit electricity only in a very small degree when it is clean, dry and
mast — the structure on a pressure digger which supports the auger properly maintained.
transmission gearbox, ram cylinder, kelly bar, and pole setter.

Appendix — Glossary 8
noncontinuous rotation — a rotation system in which the turntable is outrigger controls — the controls for operating the outriggers.
prevented from rotating more than approximately one revolution about outrigger cylinder — the hydraulic cylinder which extends and retracts
the centerline of rotation. or unfolds and folds an outrigger leg.
non-insulating aerial device or digger derrick — an aerial device outrigger interlock system — a system which requires all outriggers
or digger derrick which is not designed, manufactured, or tested to to be extended to a specified position before other unit functions are
meet any dielectric rating. allowed to operate.
nonmetallic — formed of materials which are not any type of metal. outrigger interlock valve — a valve which prevents above rotation
non-overcenter aerial device — a type of articulating-boom aerial sense line signals from reaching the pump until the outriggers have
device on which the upper boom will not unfold from the stored posi- been lowered.
tion to beyond a vertical position regardless of the position of the outrigger leg — 1: the movable structural component of an outrigger
lower boom. which extends or unfolds to position the outrigger shoe on the ground,
nontransferable boom flares — boom flares that are permanently and which retracts or folds to return the outrigger shoe to the stored
attached to the boom tip of a digger derrick. position. 2: the stationary structural component of an extendible outrig-
nontransferable upper controls — an upper control panel on a digger ger from which the movable outrigger leg extends.
derrick that is permanently attached to the upper boom tip. outrigger motion alarm — an audible warning system to alert person-
normally closed switch — a switch which is closed to allow current nel that outriggers are being lowered or moved.
to flow through it when it is not actuated, and opens to interrupt current outrigger pad — a portable piece of rigid material which is placed
flow when actuated. under an outrigger shoe to increase the contact area with the ground
normally closed valve — a two-way valve which is closed to block surface when the ground surface is not firm enough to support direct
fluid from flowing through it when it is not actuated, and opens to allow contact from the outrigger shoe.
flow when actuated. outrigger shoe — the component of an outrigger that is attached
normally open switch — a switch which is open to prevent current to the movable leg and that contacts the ground or outrigger pad to
from flowing through it when it is not actuated, and closes to allow stabilize the mobile unit.
current flow when actuated. outrigger signal valve — a valve used to provide a signal to the pump
normally open valve — a two-way valve which is open to allow fluid when the outriggers are being operated and to allow a separate signal
to flow through it when it is not actuated, and closes to block flow system to control the aerial device operation.
when actuated. outrigger spread — the distance between the outer edges on fixed
notice — indicates information considered important, but not hazard shoes, or between pin centerlines on pivoting shoes, of opposite outrig-
related. gers which have been extended or deployed to a given position.
nozzle — a tube-like device for accelerating and directing the discharge over travel — movement of a mechanism beyond its normal stop-
flow of fluid. ping point.
NPT — National Pipe Thread. overcenter aerial device — a type of articulating-boom aerial device
on which the upper boom can unfold from the stored position to beyond
NPTF — National Pipe Thread Fluid, a pipe thread form which is a vertical position.
modified from the NPT form to improve the resistance to fluid leakage
through the threads in a connection. overframe — an outrigger weldment mounting position located above
the vehicle chassis frame.
O-ring — a ring of material with a circular cross section that is used
as a gasket, usually made of synthetic rubber. overload — the condition existing when a load greater than the rated
capacity or design lead is applied to a unit or component.
ohmmeter — an instrument used to measure the resistance in ohms
between two points in an electrical component or circuit. override — the takeover of boom movement control functions from
the platform controls by the activation of the lower control station
on/off circuit — circuit that supplies constant electrical power to a controls.
solenoid or other component when a relay or switch is closed and
removes the power when the relay or switch is opened. overtighten — to torque a threaded fastener beyond the recommended
torque value.
one-man platform — a platform designed to carry one person. It is
usually 24″ wide x 30″ wide or 24″ wide x 24″ wide. oxidation — the reaction of a substance with oxygen.
open center — a directional valve design in which pump output re- paddle — part of the disc assembly which propels chipped debris into
turns freely to the reservoir when the valve spool(s) is in the center the discharge chute.
or neutral position. panic bar — a safety system which when manually activated stops
open circuit — an electric circuit that has infinitely high resistance, movement of the feed roll(s) on a chipper.
resulting in no current flow. An open circuit may be caused by a loose parallel link — the secondary load-carrying structure of an elevator
connection, broken wire, corrosion or poor contact where an electrical lift.
component is grounded to the unit structure. particle count — a visual count of the numbers of particulate contami-
operational area — the area surrounding a chipper effected by chip nants in a quantity of a hydraulic fluid.
discharge, noise, or any chipper operations. passage — a machined or cored fluid conducting path that lies within
operator — a person trained, authorized and engaged in the opera- or passes through a component.
tion of the unit. payload — any tools, materials, fuel and occupants carried by the
optical fiber — a thin strand of transparent glass or plastic used to mobile unit that are not permanently attached.
transmit signals using light throughout the length of the strand. pedestal — the stationary base of a unit that supports the turntable
orifice — a restriction in a hydraulic or pneumatic circuit, the length of and is attached to the subbase or vehicle frame.
which is small in respect to its diameter. pedestal mount — a mounting configuration for an aerial device in
OSHA — Occupational Safety and Health Administration. which the turntable is mounted on a pedestal consisting of a box-like
out and down outrigger — an outrigger that has independently- structure.
controlled horizontal and vertical extendible outrigger legs. penetration — the distance the vehicle frame is lifted from the point
outboard bearing — a bearing which supports the end of a gearbox the outriggers contact the ground surface until extension of the outrig-
output shaft farthest from the gearbox. ger cylinders is stopped.
output signal — a radio wave intended to pass communication from phase — a conductive wire or cable used for transmitting high voltage
a source to a destination. electrical current. The phrase “phase to phase” can be referenced
as any two conductors of a three-phase electrical power line system.
outrigger — a structural member, which when properly extended or
deployed on firm ground or outrigger pads, assists in stabilizing the pilot operated — condition in which a valve is actuated by hydraulic
mobile unit. fluid pressure.

9 Appendix — Glossary
pilot operated check valve — a check valve that can be opened apply to the use of the derrick with the platform occupied, with no lifting
to allow flow in the normally blocked direction by applying hydraulic of loads with the winch line.
pressure to a pilot port. plunger — a cylindrically shaped part that is used to transmit thrust;
pilot pressure — auxiliary pressure used to actuate or control hydraulic a ram.
components. pole — a long cylindrical piece of material such as wood, metal, or
pilot valve — an auxiliary valve used to control the operation of concrete which is installed in a vertical position for use as a support
another valve. structure for power and communication lines.
pin — a cylindrical structural device used to allow a pivoting joint or pole guide — a mechanism at the tip of a boom used for guiding and
to connect mating parts. stabilizing a utility pole while using the winch line to raise or lower
pin retainer — a device which is used to hold a pin in place in an the pole.
assembly. pole guide tilt cylinder — the hydraulic cylinder which is used to tilt
pinch point — a particular location in which a human body or a part (raise or lower) the pole guide.
of the body may become pinched or pinned between moving mechani- pole guide tong cylinder — the hydraulic cylinder which opens and
cal parts. closes the pole guide tongs.
pinion — a gear with a small number of teeth that has been designed pole guide tongs — movable arms on a pole guide used to stabilize and
to mesh with a larger gear. guide a utility pole as it is being raised or lowered with the winch line.
pintle hitch — a common heavy duty coupling type which utilizes a pintle pole puller — an apparatus consisting of a hydraulic cylinder, chain
hook attached to a tow vehicle to pull a trailer having a lunette eye. and other components used to loosen a utility pole from the ground.
pintle hook — the “jaw” portion of a pintle hitch which attaches to pole setter — an assembly attached to the mast of a pressure digger
the tow vehicle. that is used to pick up, position, and set a pole.
piston — a cylindrically shaped part that fits within a cylinder or cy- polyethylene — a moisture proof plastic.
lindrical bore and transmits or receives linear motion by means of a poppet — that part of certain valves that prevents flow when it closes
connecting rod or other component. against a seat and allows flow when it moves away from the seat.
piston pump — a pump in which motion and force are applied to fluid port — an internal or external opening for intake or exhaust of fluid
by a reciprocating piston(s) in cylindrical bore(s). in a component.
pivot weldment — the structure located above the slide frame on a portable resistivity tester — a device used for testing the electrical
pressure digger which supports the mast. resistance of water. Commonly used for testing the wash water for
placard — 1: a thin sheet of rigid material which is attached to another insulator washers.
surface by adhesive and/or mechanical fasteners, and is used to convey position — identifies the number of operating positions of a valve
instructions, information and warnings. 2: May also refer to a decal. spool; i.e. a two-position valve has two operating positions.
planetary gear set — an assembly of meshed gears consisting of a post mount — a mounting configuration for an aerial device in which
central gear (sun gear), a coaxial internal tooth ring gear and several the turntable is mounted on a pedestal which utilizes a round vertical
intermediate pinions (planet gears) supported on a revolving carrier. tube as its primary load-carrying structure.
planetary gearbox — a gearbox containing one or more planetary potentiometer — a variable resistor that is connected to act as an
gear sets. electrical voltage divider.
platform — the personnel-carrying component of a unit, mounted at pour point — the lowest temperature at which a fluid will flow or pour
the upper boom tip. under specific conditions.
platform elevator — a mechanism, at the boom tip, to which the plat- power — work per unit of time, measured in horsepower (HP) or
form is mounted, allowing vertical motion of the platform with respect watts.
to the rest of the boom tip.
power distribution module — the central connection point between
platform heater — an electrically powered device mounted in a splicer the chassis and unit electrical systems. This device is used to provide
platform which is used to warm the occupant. battery power to the unit when the PTO is engaged or the truck/machine
platform leveling system — a system which keeps the bottom of a selector is in the machine position.
platform parallel to or at a fixed angle to the base plate of the turntable, power take-off (PTO) — a supplementary mechanism enabling ve-
or parallel to level ground, as the boom is raised or lowered. The system hicle engine power to be used to operate non-automotive apparatus
may be mechanically, hydraulically, or gravity operated. such as a pump.
platform liner — a component made of material having a high dielectric precharge pressure — the pressure of compressed gas in an ac-
strength which is designed to be inserted into a platform to cover the cumulator before any fluid is added.
walls and bottom of the platform.
pressure — the force applied in a given area. It can be expressed in
platform pin — the horizontal pin that is used to fasten a platform pounds per square inch (psi).
mounting bracket to the upper boom tip. The mounting bracket pivots
about this pin for platform leveling or positioning. pressure compensator — a device on a variable displacement
pump that adjusts pump output flow to develop and maintain a preset
platform rest — the structural member attached to the chassis or body maximum pressure.
to support and cushion the platform in the travel or rest position.
pressure differential — the difference in pressure between two points
platform ring — a metal band around the lip of a splicer platform in a system or component.
which supports and guides the platform as it is rotated about its verti-
cal centerline. pressure drop — the reduction in pressure between two points in a
line or passage due to the energy required to maintain flow.
platform rotation override system — a system which allows the
zone of platform rotation to extend beyond a predetermined limit when pressure gauge — an instrument which displays the hydraulic or
actuated by the operator. pneumatic pressure sensed at a port on the device.
platform rotator — a system which allows the operator to rotate the pressure line — the line carrying fluid from a pump outlet to the pres-
platform about a vertical axis. This permits the position of the platform surized port of a valve or actuator.
to be changed with respect to the boom tip. pressure override — the difference between the cracking pressure of
platform tilt system — a system which allows the operator to adjust a valve and the pressure reached when the valve is passing full flow.
the orientation of the platform about a horizontal axis. Some systems pressure reducing valve — a pressure control valve whose primary
allow the operator to adjust the working position of the platform floor function is to limit its outlet pressure.
and tilt the platform for cleaning. Other systems allow tilting of the
platform for cleaning but do not provide for operator adjustment of the pressure switch — an electric switch which is actuated when the hy-
working position. draulic or pneumatic pressure applied to a port on the switch reaches
a specified value.
platform use — the stability criteria for a digger derrick mobile unit
which indicates that the load capacity chart and stability requirements

Appendix — Glossary 10
pressure transducer — a pressure measuring device which produces all possible configurations of lower boom angle, boom extension, upper
a variable electrical signal that is proportional to the hydraulic pressure boom angle, articulating arm travel, and/or elevator lift travel.
applied to a port on the device. rear jack stand — adjustable rear support used when the chipper is
primary control panel — the derrick lower control panel which con- in operation and not coupled to the tow vehicle.
tains the electrical connections between the derrick control system and rear mount — a pedestal mounting position located over or near the
components such as the power distribution module and the dump or rear axle(s) on the longitudinal centerline of the chassis.
blocking valve. The primary control panel is used in conjunction with
a secondary panel to provide dual station lower controls. 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 reel brake — a component of the reel driver which prevents the over-
by a hand control. running of cable reels carried by a strand carrier and reel lifter. The
brake is used to maintain tension in the cable or suspension strand
psi — pounds per square inch. when used with the reel driver.
PTO — see power take-off. reel driver — a component of a strand carrier and reel lifter used for
pulling arms — mechanical structure used to attach the platform to paying in or paying out cable or suspension strand.
the boom tip and supports the fairlead receptor tube. reel lifter — a device used to support and move cable reels from the
pullout upper controls — an upper control panel on a digger derrick ground to the vehicle.
which is mounted on a housing that can be extended from inside an reel lifter arms — the structure on a reel lifter used to lift and store
outer housing when additional length is needed, such as to attach the reels of cable or suspension strand on the chassis.
control panel to a personnel jib with the outer housing attached to the
upper boom tip, or to attach the upper control panel to the upper boom reengage — to repeat the activation of a function after it has been
tip with the outer housing attached to the transferable boom flares. momentarily halted.
pulse width modulation (PWM) — a means of transmitting a digital relay — an automatic switch with contacts that can be closed or opened
signal in continuous cycles of pulses where the total length of time for by electrical current in a coil.
a cycle of one “on” pulse and the following “off” period is constant, and relief valve — a pressure operated valve that bypasses pump delivery
the length of time (width) of the “on” pulse within each cycle is varied to the reservoir to limit system pressure to a predetermined maximum
(modulated) in proportion to the level of an input parameter such as value.
control lever position.
remote arm — a remotely operated jib used to handle equipment or
pump — a device that converts mechanical force and motion into electrical lines.
hydraulic flow and pressure.
remote assist — a vehicle-mounted device with a boom assembly
purge system — a system of check valves that allows hydraulic which is extendible, articulating, or both, which is designed and used to
fluid flow in a reverse manner through the hydraulic system, usually accommodate attachments for performing operations such as supporting
from the lower control valve to the upper controls. This actions frees or cutting electrical conductors, lifting or holding objects, or cutting tree
or purges the control system of any trapped air and restores a solid branches. It is operated by remote control from the ground or from the
column of fluid for precise control. The purge system may also be used platform of an adjacent personnel lifting device. It may be mounted on
to warm up the control system in cold weather conditions if the fluid the vehicle by itself or in addition to a personnel lifting device.
in the reservoir is warm.
remote control system — a system used for operating some or all
purge/upper/lower controls selector valve — a valve which is used of the functions of a unit from a portable control station. The control
to direct hydraulic fluid to the purge system, the upper control valve, station may be a transmitter which sends signals by radio waves to a
or the lower control valve. receiver on the unit, or a control module which sends signals through
PWM — pulse width modulation. a fiber optic or electrical cable to the unit.
quick disconnect couplings — hydraulic fittings designed for fast remote operated auxiliary control system (ROACS) — a radio
and easy attachment and separation. controlled system for starting and stopping certain functions of the
mobile unit.
radial ball bearing — an antifriction bearing with rolling ball contact
in which the direction of action of the load transmitted is perpendicular remote start/stop system — the components used to actuate a
to the axial centerline of the bearing. function of the unit from a location other than for normal operation.
The most common functions controlled are engine start/stop and the
radial outrigger — an outrigger in which the movable outrigger leg secondary stowage DC pump.
pivots in an arc around a pin connection between the leg and a sup-
porting structure as the leg is lowered and raised. reservoir — a container for storage of liquid in a fluid power system.
radio communication — communication by means of radio waves. resistance — the opposition to the flow of electricity or hydraulic
fluid.
ram — 1: a single-acting cylinder with a single diameter plunger rather
than a piston and rod. 2: the plunger in a ram-type cylinder. restriction — a reduced cross-sectional area in a line or passage that
produces a pressure drop.
ram cylinder — the hydraulic cylinder that is used to retract and extend
the kelly bar on a pressure digger. retaining ring — a hardened, washer-like ring that may be spread
apart or compressed and installed into a groove or recess to serve
ramp — an adjustable delay to govern the response of the hydraulic as a retaining device.
valve when a unit is operated from the electronic controls.
return line — a hydraulic line used to carry discharge flow from a
range diagram — a diagram which shows the load radius and sheave hydraulic system or actuator back to the reservoir at low pressure.
height of a digger derrick at all the configurations of boom extension
and boom angle covered by the corresponding load capacity chart. return line filter — a filter located in a hydraulic system return line or
at the inlet of a hydraulic reservoir which cleans fluid flowing from the
rated capacity — (as defined by ANSI for digger derricks) the maximum hydraulic system to the reservoir.
load, specified by the manufacturer, that can be lifted by the digger
derrick at regular intervals of load radius or boom angle, through the reversing valve — a four-way directional valve used to change the di-
specified ranges of boom elevation and extension, with specified op- rection of movement of a double-acting cylinder or reversible motor.
tions installed, and exclusive of stability requirements. ribbon hose — a group of hoses that are attached side by side to
rated line voltage — the nominal voltage, phase to phase, at which produce a flat bundle. Commonly used to carry hydraulic fluid, air and/
electrical systems are rated. or electrical cable(s) to the boom tip or upper controls.
rated load capacity — (as defined by ANSI for aerial devices) the riding seat — an operator’s control station attached to the side of the
maximum loads, specified by the manufacturer, which can be lifted turntable, with a seat on which the operator rides with the rotation of
by the aerial device through the specified range of boom elevation the unit.
and extension with specified options installed and in consideration of riser — 1: the structure on a double elevator that connects the lower
stability requirements. elevator arm to the upper elevator arm. 2: the structure within an ar-
reach diagram — a drawing that shows the horizontal and vertical ticulating arm to which the lower boom is connected.
limits of travel of the platform, upper boom tip, and/or jib tip throughout ROACS — see remote operated auxiliary control system.

11 Appendix — Glossary
rod — the cylindrically shaped part of a cylinder which extends and secondary stowage DC pump — a low flow hydraulic pump driven by
retracts from the barrel to actuate or move a component. a direct current electric motor. This pump is used to provide hydraulic
rod end — the end of a cylinder that the extending component or flow to stow the unit when the system for normal operation has failed.
rod is on. secondary stowage system — those components used to stow the
roller — a cylindrical device which spins freely about a pin or shaft, unit when the system for normal operation has failed.
used to guide the motion of another component. selector switch — a switch which is used to direct electrical current
rollover protection structure (ROPS) — operator compartment to one of two or more electrical circuits.
structure (usually cab or frame) intended to protect equipment opera- selector valve — a valve which is used to direct hydraulic fluid to one
tors from injuries caused by overturns or rollovers. of two or more hydraulic circuits.
rollpin — a pin that has been formed by rolling up a thin, flat strip of self feed — a wood-chipper with no control of the infeed rate to the
metal to form a cylinder. Commonly used by being driven into a hole cutting mechanism.
to serve as a retaining device. self-locking nut — a nut which contains a built-in device or shape to
rope — a stout, flexible cord, which consists of many strands of wire increase thread friction so as to resist loosening due to vibration or
or fibers that are twisted or braided together. repeated loading.
ROPS — see rollover protection structure. self-lubricating bearing — an antifriction bearing in which lubricating
rotary actuator — a device for converting hydraulic energy into rotary material is incorporated in the bearing.
motion and torque in which the rotary motion is restricted to within sense line — a line that carries a hydraulic pressure signal from a
certain angular limits. valve or actuator to the compensator control on a variable displace-
rotary joint — a multiple port manifold that has a rotating portion and ment pump.
a stationary portion, used to provide a continuous hydraulic connection sense selector valve — a valve which prevents hydraulic fluid in
between rotating and stationary hydraulic lines. Commonly used at the the sense line from reaching the pump until a certain function(s) is
centerline of rotation of units equipped with continuous rotation. operated.
rotate frame — the structure located above the stationary frame on a sequence — 1: the order of a series of operations or movements. 2:
pressure digger that is used to support and rotate the slide frame. to divert flow to accomplish a subsequent operation or movement.
rotating platform — a platform which can be rotated about a vertical sequence valve — a pressure operated valve that diverts flow to a
axis to change its position in relationship to the boom tip. secondary actuator while holding pressure on the primary actuator at
rotation bearing — the rotating member, usually a shear ball bear- a predetermined minimum value after the primary actuator completes
ing, located between the pedestal and the turntable which allows the its travel.
turntable to rotate and which contains gear teeth that mesh with the sequential extension — the operation by which one boom section
rotation pinion. in an extendible boom assembly reaches full extension or retraction
rotation chain — a chain attached to the stationary frame of a pressure before the next boom section begins movement.
digger that is used by the rotation gearbox to rotate the rotate frame. set screw — a short screw, typically with an Allen type head, that is
rotation gearbox — the gearbox which drives the rotational motion used as a clamp to bind parts together.
of the turntable. shackle — see clevis.
rotation pinion — the gear on the output shaft of the rotation gearbox shear — an action or stress resulting from opposing applied forces that
which meshes with the rotation bearing gear teeth and drives the attempt to separate a part into two pieces that would then slide along
turntable rotational motion. each other in opposite directions along the plane of separation.
rotation resistant wire rope — wire rope which is constructed to resist shear ball bearing — an antifriction bearing with rolling ball contact
the tendency to untwist or rotate when carrying a suspended load. This in which the direction of load transmitted through the balls is parallel
is accomplished by laying the outer strands in the opposite direction to the axial centerline of the bearing, producing shear loading on the
to the lay of the inner strands or core. balls. The bearing can support axial, radial, and tilt loading. Commonly
rotation system — the system which drives the rotation of the turntable used as a rotation bearing.
about the centerline of rotation. It typically consists of a rotation bearing, shear pin — a replaceable pin which prevents motion between two
rotation gearbox, hydraulic motor, and load holding valve. adjacent parts by the production of shear loading in the pin, and which
rpm — revolutions per minute. may be designed to fail under overload to protect other parts.
running torque — the torque produced by a rotating device such as shear stability — resistance of a hydraulic fluid viscosity index improver
a motor or gearbox at a specified rotational speed. additive to shearing.
SAE — Society of Automotive Engineers. shearing — molecular damage or breakdown of the viscosity index
improver additive in hydraulic fluid. Shearing can occur when the fluid
safety belt — see body belt. flows through fine clearances at high velocity. Shearing can cause
safety chains — the chains that are attached to the trailer tongue with permanent loss in fluid viscosity.
hooks on their free ends. These chains keep the trailer connected to sheave — a grooved wheel used to support and guide a winch line
the tow vehicle should the coupler or hitch ball detach from the tow or leveling cable at a point of change in the direction of motion of the
vehicle. Safety chains must be secured every time you tow. line or cable.
saybolt universal viscosity — A measure of viscosity equal to the time sheave height — the vertical distance from ground level to the centerline
it takes in seconds for 60 milliliters of fluid to flow through a capillary of the boom tip sheave in a digger derrick upper boom tip.
tube in a Saybolt universal viscosimeter at a given temperature.
short circuit — an inadvertent path of low resistance established
scissor link — the mechanical linkage on a reel lifter used to connect between two points of an electrical circuit. A short circuit will result in
the lifter cylinder to the arm. excessive current flow.
screw anchor — a rod with an eye on one end and auger flighting on shutoff valve — a device which is used to stop hydraulic fluid flow.
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. shuttle valve — a three-port valve that accepts hydraulic fluid pres-
sure from two inlets and allows only the highest pressure fluid to pass
seating in — an initial microscopic surface deformation of components through it to a single outlet while keeping the inlet fluid pressure isolated
that are clamped together with threaded fasteners. This causes a slight from one another.
reduction in the dimension of the components, reducing the clamping
force applied by the fasteners. side gun — a hand held water nozzle and hose that can be used from
the ground for washing or fire fighting.
secondary control panel — a derrick lower control panel that is
configured as a remote terminal of the primary panel. The secondary side load — an external horizontal load placed on a boom from one
panel is used in conjunction with a primary panel to provide dual sta- side.
tion lower controls.

Appendix — Glossary 12
side load protection system — the system on a digger derrick that sprocket — a wheel with teeth along the circumference which are
helps prevent damage to the digger derrick structure when excessive shaped so as to engage with a chain, used to support and guide the
side loads are applied to the booms. Can be electronic or hydraulic. chain at a point of change in the direction of motion of the chain.
side-mounted platform — a platform which is attached to a mount- SSU (Saybolt Second Universal) — the unit of measure for Saybolt
ing bracket that extends from one side of the boom tip, positioning universal viscosity.
the platform (and platform rotation pivot, if so equipped) beside the stability — a condition of a mobile unit in which the sum of the mo-
boom tip. ments which tend to overturn the mobile unit is less than the sum of
sideslip — sideways motion of a component caused by an externally the moments tending to resist overturning; the mobile unit’s ability to
applied sideways force which overcomes resistive forces from hy- resist tipping.
draulics, friction, etc. Commonly used to describe rotation of a digger stabilize — to provide adequate stability for a mobile unit to allow
derrick boom caused by side loading which exceeds the side load operation of the vehicle-mounted device(s).
protection setting.
stabilizer — a device used to assist in stabilizing a mobile unit, such
signal — a command or indication of a desired position, velocity, flow as an outrigger, torsion bar or spring lockout.
or pressure.
stake — to slightly deform the threads of a fastener or material at the
signal line — see sense line. joint between two components by placing the blade of punch or chisel
single-acting cylinder — a cylinder in which fluid pressure can be ap- on the threads or joint and tapping on the handle with a hammer. The
plied to move the rod in only one direction. Return motion is produced deformed material serves to prevent loosening of the components.
by an external force such as a spring or gravity. stall torque — the torque produced by a rotating device such as a
single elevator — an elevator lift with one load carrying arm. The motor or gearbox at zero rotational speed.
single elevator system includes a lower pedestal, arm, arm cylinder(s), standard option — an option which can be ordered from a standard
parallel links, and upper pedestal. order form and can be supplied without additional engineering work.
single handle control — a control, with an interlock trigger incorpo- start/stop control module — an electrical device that relays sig-
rated in the handle, which allows the operator to simultaneously control nals from the unit’s remote start/stop system to the component(s) or
multiple functions of the booms and turntable from the platform. system(s) being controlled, such as the secondary stowage DC pump
single-pole, double-throw (SPDT) switch — a three-terminal electri- and/or vehicle ignition system.
cal switch or relay that connects one terminal to either of two other stationary frame — the structure attached to the subbase of a pressure
terminals. digger that supports the outriggers and rotate frame.
single-pole, single-throw (SPST) switch — a two-terminal electrical stationary hood — normally non-removable part of the disc housing
switch or relay that opens or closes one circuit. in which the discharge chute attaches.
slide frame — the structure on a pressure digger used to support the stationary platform — a platform which can not be rotated about a
auxiliary engine, hydraulic reservoir, control station, and pivot weld- vertical axis to change its position in relationship to the boom tip.
ment. The slide frame can be extended horizontally from its stowed
position to adjust the distance of the kelly bar from the rotate frame. stow — to place a component such as a boom or digger derrick auger
in its rest position.
slide pad — a rectangular block used as a bearing between extend-
ible boom or outrigger sections, usually composed of a non-metallic strainer — a coarse filter.
material. strainer basket — a coarse, basket shaped filter which is mounted in
slip ring — an assembly of one or more conductive, rotating rings and the fill hole of a reservoir and projects into the reservoir.
stationary brushes used to provide a continuous electrical connection strand — 1: one of the groups of individual fibers or wires within a
between rotating and stationary conductors. Commonly used at the synthetic winch line or wire rope. 2: see suspension strand.
centerline of rotation of units equipped with continuous rotation.
strand carrier — a device used to support and transport strand reels
slug face — the extreme end of the cable slug which is secured to the on a vehicle.
cylinder rod or adjusting stud.
strand reel — a reel or spool used for carrying suspension stand.
SMA connector — metal connector used for connecting fiber optic
components. street side — the side of a vehicle toward oncoming traffic when the
vehicle is traveling forward in the normal direction in a lane of traffic.
snatch block — a device which has a means of attachment to connect
it to a boom or load, and which can be opened to receive a winch line stroke — 1: total linear movement in either direction of a piston or
around an internal sheave. plunger. 2: to change the displacement of a variable displacement
pump or motor.
snubber valve — a two-port valve with a manually adjustable orifice
that restricts the flow of fluid through the valve. subbase — a structural mounting interface between the pedestal and
the vehicle frame. It provides torsional stiffness and strength in addition
socket head — a cylindrical cap screw head design containing a to that which would be provided from the vehicle frame alone.
hexagonal (six-sided) female socket into which an Allen wrench can
be inserted to turn the cap screw. subweldment — a smaller welded subassembly used within a more
complex welded structure.
solenoid — a coil of insulated wire that produces a magnetic field within
the coil when electrically energized. When attached to a hydraulic valve, suction filter — a filter located in a hydraulic system suction line or at
the magnetic field acts upon the valve to move internal valve parts. the outlet of a hydraulic reservoir which cleans fluid flowing from the
reservoir to the pump inlet.
solenoid valve — a valve which is actuated by a solenoid to controlling
the flow of hydraulic fluid. suction line — the hydraulic line connecting the pump inlet port to
the reservoir outlet.
speed reducer — see gearbox.
surge — a momentary rise of pressure in a circuit.
spherical bearing — a bearing with a spherically shaped inner race
that is allowed to move freely inside a stationary outer race to accom- surge brake system — a surge brake system is entirely self-contained
modate misalignment. on the trailer and is activated when the tow vehicle decelerates. The
momentum of the trailer pushes the surge brake housing forward. This
splicer platform — a fiberglass platform equipped with a door and drives the push rod that is connected to the coupler into the master
latch. cylinder. Brake fluid is then forced out of the master cylinder into the
spline — one of a number of equally spaced, load carrying teeth that wheel cylinders or pistons that apply the trailer brakes. The entire
have been cut on the outside diameter of a shaft or inside diameter of activation process is completed in less than one second.
a bore, parallel to the shaft or bore centerline. suspension strand — a type of wire rope which is used to support
spool — a moving, cylindrically shaped part of a hydraulic valve that the weight of an attached communication cable suspended between
moves to direct flow through the valve. poles or other overhead support structures.
spring lockouts — a mechanical system which is engaged to keep swage — to taper or reduce the diameter of a rod, tube, or fastener
a vehicle’s suspension system from flexing during operation of the by forging, squeezing, or hammering.
unit.

13 Appendix — Glossary
synthetic winch line — a winch line made from nonmetallic synthetic transferable upper controls — an upper control panel on a digger
fibers which are formed into strands that are then braided together to derrick that can be attached to either the upper boom tip or the trans-
make a complete rope. ferable boom flares by the use of a detent pin.
T-stand — a “T” shaped weldment for mounting lower controls to the transition — the area between the feed box and the cutter mecha-
vehicle. nism.
tachometer — an instrument used for displaying the speed of rotation transmitter — a device used to generate and emit a radio frequency
of an engine output shaft. carrier signal. The signal is sent to a receiver which translates the
tailshelf — the rear portion of the mobile unit above and behind the signal into usable information.
rear axle. trim pot — a potentiometer which is used to make fine adjustments
tailshelf tools — see lower tool circuit. in a circuit during manufacture or calibration, typically by turning a
slotted adjusting screw.
tank — see reservoir.
troubleshoot — to locate and diagnose problems in a system or a
telescopic — having sections that slide within or over one another to component.
change overall length.
trunnion — a mounting device consisting of a pair of opposite, projecting
tension spring — springs controlling downward force of the upper cylindrical pivots on which something can be rotated or tilted.
feed roll.
trunnion bearing — a bearing that a trunnion pin pivots in.
terminal block — an insulating mounting used for making electrical
terminal connections. trunnion pin — a cylindrical pivot pin that is a part of a trunnion.
test block — a manifold with ports for connecting a hydraulic pressure turnbuckle — a link with screw threads at both ends that is turned to
source, pressure gauge and a cartridge valve such as a counterbalance bring the ends closer together for tightening purposes.
valve or relief valve used for testing and adjusting the relief setting of turns from finger tight (T.F.F.T.) — a method of counting the number
the valve. of turns of a hydraulic adapter to establish a torque value.
thimble — a metal ring around which a rope is passed and spliced to turntable — the structure located above the rotation bearing which
make a loop or eye. supports the lower boom or articulating arm, and rotates about the
thread locking adhesive — an anaerobic adhesive that is applied centerline of rotation.
to fastener threads to prevent loosening due to vibration or repeated turntable winch — a winch located on the turntable.
loading. turret — see turntable.
three-phase — a system for transmitting high voltage, alternating cur- two-blocking — a condition in which the load hook, overhaul ball, hook
rent, electrical power along three separate conductors, with 120 degrees block, or other lifting component that is attached to the winch line comes
between the voltage waveform cycles of any two conductors. in contact with the boom tip during winch or boom operation.
three-position valve — a valve having three positions for direction two-man platform — a platform designed to carry two people. It is
of fluid flow, such as neutral, flow in one direction, and flow in the op- usually 24″ wide x 48″ wide.
posite direction.
two-part line — a multiple-part line on a digger derrick in which the
three-way valve — a valve that has three ports, normally a pressure winch line is routed from the boom tip sheave down to a snatch block
(inlet) port, a normally closed port, and a normally open port. Used to at the load and then back up to a stationary attachment point on the
block or open a common flow passage. boom.
threshold — the amount of signal (starting power) given to a control two-position valve — a valve having two positions for direction of
valve when the control is just moved from neutral position. fluid flow, such as open and closed.
throttle control — a manual, hydraulic, or electrical device used to two-speed motor — a motor which has two operating speed and torque
regulate vehicle or auxiliary engine speed. modes (a low-speed, high-torque mode, and a high-speed, low-torque
toggle switch — an electrical switch operated by a short projecting mode) that can be selected by the operator.
lever combined with a spring to quickly open or close a circuit when two-way valve — a valve that has two ports, normally a pressure (inlet)
the lever is pushed through a small arc. port and an outlet port. Used to open or close a flow passage. May be
tongue weight — the downward weight applied by the towable equip- configured as normally closed or normally open.
ment on the hitch ball. Generally tongue weight should not be more ultraviolet inhibitor coating — a sprayed or brushed on layer that
than 10 percent of the gross trailer weight. provides ultraviolet light resistant properties.
topping cylinder — see lift cylinder. UNC — Unified National Coarse, a thread description.
torque — 1: a rotational twisting force. 2: to preload a threaded fastener underframe — an outrigger weldment mounting position located
by application of a rotational twisting force. beneath the unit subbase or vehicle chassis frame.
torque converter — a rotary device for transmitting and amplifying undertighten — to torque a threaded fastener below the recom-
torque, especially by hydraulic means. mended value.
torsion bar — a rod-like spring which is flexed by being twisted about UNF — Unified National Fine, a thread description.
its axis, used to assist in stabilizing a mobile unit.
unfold — to move a pivoting structure such as an articulating upper
tow line winch — a winch located on a cable placer which is used boom away from its stowed position.
for tensioning suspension strand or self-supporting cable or towing a
cable lasher. unit — the Altec device(s), subbase, outriggers, body and associated
interface items mounted on a chassis, but not including the chassis
tow vehicle (towing vehicle) — the vehicle that pulls a trailer or itself.
towed vehicle.
unload — to release hydraulic flow, usually directly to the reservoir, to
trace element analysis — analysis of a small sample of hydraulic fluid prevent pressure buildup.
to determine contamination level and condition of additives.
unloaded vehicle weight — the total weight of the completed mobile
tracking — a current leakage path created across the surface of unit without payload.
insulating material when a high-voltage current forms a carbonized
path within a foreign material on the surface. unloading valve — a valve that bypasses flow to the reservoir when
a set pressure is maintained on its pilot port.
transducer — a device that converts input energy of one form into
output energy of another, such as hydraulic pressure into an electri- upper arm — the primary load-carrying structure of a double elevator
cal signal. which is located between the riser and the upper pedestal.
transferable boom flares — boom flares, on which a pole guide may upper arm cylinder — the hydraulic cylinder that moves the upper
be mounted, that can be pinned to either the intermediate boom tip or arm of a double elevator up and down.
the upper boom tip of a digger derrick. upper boom (UPR BOOM) — the boom section in a boom assembly
which is farthest from the turntable when the boom assembly is fully

Appendix — Glossary 14
extended or unfolded, and which supports the boom tip sheave and/ vortex — a whirlpool of liquid.
or platform(s). waist harness — a belt device worn by the operator of a radio remote
upper boom cylinder — the hydraulic cylinder that moves the upper control system to which the transmitter is attached.
boom about its pivot point on an articulating-boom aerial device. walking beam outrigger — an extendible outrigger which has a pivot
upper boom drive mechanism — the components used to produce point at the top of the nonextending leg and a linkage attached to the
upper boom movement on an articulating boom-aerial device, such as extending leg, so that the leg assembly rotates about the pivot point
linkage, cables, sheaves and/or gears. to increase the outrigger spread as it is extended.
upper boom rest — the structural member that supports the upper warning — indicates a hazardous situation which, if not avoided, could
boom in the rest or travel position. result in death or serious injury.
upper boom tip — the boom tip of an upper boom. water monitor — an articulating mechanism that is used to direct the
upper control valve — the hydraulic valve on or beside the platform flow of a high pressure water stream.
of an aerial device used for operating some or all of the functions of water removal filter cartridge — a special filter cartridge designed
the aerial device. to absorb and remove water from hydraulic fluid. It is not intended
upper controls — the controls located on or beside the platform used for use during normal operation, but is for use when water removal
for operating some or all of the functions of the unit. is required.
upper controls primary battery — the preferred source of power for way — describes how many ports are in a valve or valve section. See
fiber optic upper controls. two-way valve, three-way valve, or four-way valve.
upper controls secondary battery — the backup power source for weldment — a structural unit formed by welding together an assembly
fiber optic upper controls. of pieces.
upper pedestal — the structure within an elevator lift that connects wheel chock — a wedge or block placed on the ground in front of or
the elevator lift to the aerial device rotation bearing. behind the wheel of a vehicle to block the movement of the wheel.
upper tool circuit — a tool hydraulic circuit with quick disconnect winch — a mechanism consisting of a gearbox with a cylindrical rotating
couplings located at the upper boom tip. drum on which to coil a line for load hoisting or line tensioning.
vacuum — the absence of pressure. A perfect vacuum is the total winch capacity — the maximum load, specified by the manufacturer,
absence of pressure; a partial vacuum is some condition less than that can be pulled on the first layer of line on the winch drum at rated
atmospheric pressure. Vacuum is measured in inches of mercury system pressure.
(in. Hg.). winch line — a load hoisting line consisting of a synthetic or wire
valve — a device that controls fluid flow direction, pressure or flow rope.
rate. winch line rated working load — the average breaking strength of
vane pump — a type of pump with a rotor and several sliding vanes in a winch line (as specified by the line manufacturer) divided by the ap-
an elliptical chamber. Hydraulic fluid enters the expanding area and is propriate design factor as specified by ANSI.
forced out as the fluid is moved to the decreasing chamber area. wire rope — a rope made from steel wires which are formed into strands
variable displacement pump — a pump in which the size of the that are then twisted about each other in a spiral configuration.
pumping chamber(s) can be changed, so that the output flow can wood chipper — reduces above ground tree materials to uniform
be changed by moving the displacement control or varying the drive chips.
speed or both. work — the exertion of a force moving through a definite distance.
vehicle — a carrier for a unit. Work is measured in units of force multiplied by distance; for example,
velocity — the speed of linear motion in a given direction. pound-feet.
velocity fuse — a hydraulic valve that is used to stop fluid flow through worm gearbox — a gearbox that utilizes a gear which has a continuous
it when the flow rate reaches a predetermined cut-off value. helix tooth or teeth similar to a large screw thread along shaft (worm),
that drives a gear which has teeth cut at an angle along a its outside
vent — an air breathing device on a fluid reservoir or hydraulic line. diameter (worm gear). The rotational axis of the worm is perpendicular
VI — see viscosity index. to the rotational axis of the worm gear.
viscosity — a measure of the internal friction or resistance to flow wrap — a single coil of winch line on a winch drum.
of a fluid. X-frame outrigger — an extendible outrigger having two diagonal
viscosity index (VI) — a measure of the resistance to change in vis- members which are connected at the top in an overlapping manner.
cosity of a fluid with change in temperature. The higher the number, Resembles a broad based “X”.
the less the viscosity will change as the temperature changes. Y-cable — an electrical cable assembly which contains three branches
voltmeter — an instrument used to measure the potential difference joined at a common point, similar to a “Y.”
in volts between two points in an electrical circuit. zerk — see grease fitting.
volume — 1: the size of a space or chamber in cubic units. 2: loosely
applied to the output flow of a pump in gallons per minute (gpm).

15 Appendix — Glossary
Appendix — Glossary 16
 Service Tools and Supplies
Most routine maintenance and service of the unit can be their corresponding Altec part number. The list contains
performed with common hand tools and shop supplies items for both aerial devices and derricks. An Accessory
available from a tool supply company. Some special tools and Replacement Parts Catalog is also available for
and supplies are available from your Altec representative ordering other items that may not be shown in the Parts
that may be useful or required to perform certain main- Manual. This catalog can be obtained through your Altec
tenance procedures. These items are categorized with representative.

Product Purpose/Use Part Number

Fiberglass Care

Gelcoat kit Repair fiberglass platforms and booms 041-90001

Formula Five Clean ’N Glaze Clean and polish 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

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

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

Chain Lube Lubricate ribbon hose and boom at installation 400-00007

Fasteners

Thread locking adhesive Low strength thread locking and sealing agent for small diameter 099-00019
(purple 50 ml) 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 diameter 099-00037
(red 50 ml) 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 prior 099-00039
to bonding; leaves no residue

Appendix — Service Tools and Supplies

 Product Purpose/Use Part Number
Fasteners (cont.)

Primer (Grade N — 6 oz) Chlorinated solvent reduces cure time on thread locking adhesive 099-00040

Primer (Grade T — 6 oz) Nonchlorinated solvent reduces cure time on thread locking 099-00041
adhesive

Wire twisting pliers Lockwiring fasteners 099-60007

Hydraulic System Care

Pipe sealant (50 ml) General purpose pipe sealant for use on pipes to 2″ 099-00038

Flowmeter Test hydraulic system 099-00034

Test block — small bore (7/8″ hex) Test counterbalance valve 352-79006

Test block — large bore (11/8″) Test 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 Test 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

FD Electrical Contact Cleaner Clean and degrease electrical systems 970176850

Appendix — Service Tools and Supplies

 AT237

Preventive Maintenance and Inspection Checklist

Vehicle No. ________________________ Location __________________________ Date _________________

Service Request # ____________________ Model # ____________________ Serial # ______________________

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 tracking PTO hours using an approved method or device, follow the recommended hourly maintenance intervals.
If performing maintenance based upon a calendar-based schedule, follow the recommended monthly intervals. The
required items apply to both tracking methods.

Intervals
 Prior to placing the unit in service  85 hours/1 month  500 hours/6 months
 1,000 hours/1 year  2,000 hours/2 years  4,000 hours/4 years
 Required maintenance
Symbols
/O = 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 Hours/1 Month
Perform the Daily Preoperational Inspection Lubrication
(refer to the Operator’s Manual) Lift cylinder spherical bearing
Hydraulic Reservoir Outrigger inner leg outer surface
Oil level Rotation pinion and bearing gear teeth
Hydraulic System
Manual lowering system operation
500 Hours/6 Months
Perform the 85 hour/1 month inspection Axle U-bolts secure
Supplemental Brake Lock Filters
Operation (holding, bleed off) Change return line filter
Hydraulic Reservoir/Pump/Hydraulic System Outriggers
Mounting (cap screws secure, welds intact, no cracks) Mounting (welds intact, no deformation or cracks)
No leaks Machine/ground level functions selector operation
Operation, noise level Outrigger interlock system operation
Unit Mounting Outrigger extend warning system operation
Pedestal mounting (fasteners secure, welds intact, Operation (holding without drift)
no cracks) Structures (welds intact, no deformation or cracks)
Stabilizer Bars Pins and retainers secure
Structure (welds intact, no cracks or deformation) No leaks
Bushing bolts secure to manufacturer’s specifications Lower Controls
Bushing condition Operation (metering, proper direction)
Mounting cap screws secure Engine start/stop switch operation

sep 15 Appendix — Preventive Maintenance and Inspection Checklist

 Lower/upper control operation Lower Boom
Pedestal Structure (welds intact, no deformation or cracks)
Structure (welds intact, no deformation or cracks) Fasteners secure
No leaks Covers (in place and secure)
Covers No leaks
Slip ring mounting cap screws secure Upper Boom
Turntable Fasteners secure
Structure (welds intact, no deformation or cracks) Structure (welds intact, no deformation or cracks)
Boom pin and retainers secure Covers (in place and secure)
Lift cylinder pivot pin and retainers secure No leaks
Covers Extension Cylinder
No leaks Trunnion pins secure
Rotation Bearing and Gearbox Pin and retaining rings secure
Motor mounting cap screws secure Operation
Gearbox mounting cap screw visual inspection No leaks
Eccentric ring lock in place and secure Chromed rod condition
No leaks Upper Boom Tip
Operation (smoothness and noise level) Structure (welds intact, no deformation or cracks)
Pinion gear teeth Platform mounting pin secure
Rotation bearing gear teeth Leveling cylinder operation
Rotation bearing inspection and measurement [after Leveling cylinder mounting (welds intact, no
0.050″ (1.27 mm) increased wear from initial deformation or cracks)
measurement]2 Leveling bracket cover (in place and secure)
Rotation bearing cap screw visual inspection Upper Controls
Articulating Arm Cylinder Operation (metering, proper direction)
Pin retainers secure Emergency stop operation
Operation No operation in Lower Controls position
No leaks Platform
Holding valves (operation, leaks) Mounting secure
Chromed rod Platform (condition, clean)
Articulating Arm Liner (condition, clean, nylon cap screws secure)
Riser (welds intact, deformation, cracks) Fall protection system condition
Link (welds intact, deformation, cracks) Covers (in place and secure)
Arm (welds intact, deformation, cracks) Placards
Leveling cylinder operation No leaks
Link pivot pins Platform Leveling System
Lift Cylinder Operation
Pivot bearings secure within cylinder eyes No leaks
Pin retainers secure Lubrication
Operation Outrigger valve handle linkage
No leaks Rotation bearing and pinion gear teeth
Holding valves (operation, leaks) Bonded hose assembly
Chromed rod condition

Appendix — Preventive Maintenance and Inspection Checklist

 1,000 Hours/1 Year
Perform the 500 hour/6 month inspection Turntable
Chassis Underside Hoses and tubes (routing, condition)
Hoses (routing, condition) Rotation Bearing and Gearbox
Exhaust shields Rotation bearing cap screw annual torque inspection
Pump/Hydraulic System Rotation gearbox mounting cap screw annual
Operation torque inspection
Mounting cap screws secure Extension Cylinder
Drive line condition Hoses (routing, condition)
Noise level Articulating Arm
Unit Mounting Fasteners secure
Utility body mounting and structure (cap screws Upper Boom
secure, welds intact, no cracks) Slide pad bearings and fasteners
Boom rest (welds intact, no deformation or cracks) Upper Boom Tip
Hydraulic Reservoir Mounting to upper boom secure
Collect oil sample for analysis 1
Upper Controls
Outriggers Electrical cable (routing, condition)
Hoses and tubes (routing, condition) Placards (condition, readable)
Placards (condition, readable) Platform
Hydraulic System Pressure Liner (condition, cleanliness, nylon bolts tight)
System pressure ______ Placards (condition, readable)
Lower Controls Lubrication
Placards (condition, readable) Pump input shaft splines
Pedestal
Hoses and tubes (routing, condition)
2,000 Hours/2 Years
Perform the 1,000 hour/1 year inspection Rotation Bearing and Gearbox
Hydraulic Reservoir and System Pinion to rotation bearing gear backlash
Change hydraulic oil Gearbox internal lost motion
Clean suction filter element Rotation bearing inspection and measurement [before
Clean or change filler hole strainer 0.050″ (1.27 mm) increased wear from initial
Change filler/breather cap measurement]2
Reservoir cover gasket condition
4,000 Hours/4 Years
Perform the 2,000 hour/2 year inspection Clean inside of reservoir
Hydraulic Reservoir and System
Flush hydraulic system
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 a 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″ (1.27 mm) increased wear
from initial measurement. After reaching 0.050″ (1.27 mm) increased wear, measure every 6 months. Refer to the Maintenance Manual for the
procedure.

Comments __________________________________________________________________________________

___________________________________________________________________________________________

Appendix — Preventive Maintenance and Inspection Checklist

Appendix — Preventive Maintenance and Inspection Checklist
 Accessory Checklist
Vehicle No. ________________________ Location __________________________ Date _________________

Model Number _________________ Serial Number ___________________ Inspector ____________________

Symbols
/O = 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

Optional Unit Accessories Beacons
Platform liners Wheel chocks and holders
Platform covers Mud flaps
Tool holders (mounting and condition) Cones and holders
Scabbard (mounting and condition) Inverters (operation and mounting)
Spare augers Generators (operation and mounting)
Screw anchor wrench Platform rest (condition and mounting)
Lifting slings and chains Fire extinguishers*
Hydraulic cooler (mounting, condition and fan operation) First aid kit
Hydraulic oil heater (operation and condition) Flare kit*
ROACS system (operation) Grounding reel
Radio controls Power cord reel
Optional Body Accessories Hotstick tube or box
Outrigger pads and holders Ladder rack
Hose reel Spare fuse pack
Hoses Optional Chassis Accessories
Quick disconnects Front winch (mounting and operation)
Hydraulic tools and hoses PTO and driveline
Impact Bed winch
Chain saw Capstan
Tamp Collapsible reel
Pole puller, chain and base Secondary brake system
Quick disconnects Pintle hitch
Pole rack mounting Safety chain eyebolts
Body (structure, mounting) Trailer plug
Access steps (condition and mounting) Tow hooks
Cargo area retention (mounting and condition) Cab guard
Dump operation Brake controller (mounting and operation)
Spotlights and work lights Back up alarm (mounting and operation)
* 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 applica-
tions 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″ 2 to 2 /2
1 3
/4″ 1 /2 to 2
1
7
/8″ -8 20 (27)
3
/16″ 2 to 2 /2
1 7
/8″ 1 /2 to 2
1
1″ -10 25 (34)
1
/4″ 2 to 2 /2
1
1″ 1 /2 to 2
1
1 /8″
1
-10 25 (34)
5
/16″ 2 to 2 /2
1
1 /8″
1
1 /2 to 2
1
1 /4″
1
-12 35 (48)
3
/8″ 1 /2 to 2
1
1 /2″
1
1 /2 to 2
1
1 /2″
1
-16 50 (68)
1
/2″ 2 to 2 /2
1
2″ 1 /2 to 2
1
2″ -20 65 (88)
5
/8″ 2 to 2 /2
1

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 /4
1
3
/4″ 3
/8″-16 250 to 350 (28 to 40)
5
/16″ 5 1 /4
3
1″ 3
/8″-16 325 to 425 (37 to 48)
3
/8″ thru 1″ 6 thru 16 2 /4
1
1 /4″
1 7
/16″-14 425 to 550 (48 to 62)
1 /2″
1 1
/2″-13 550 to 700 (62 to 79)

SUN Counterbalance Valves 2″ 1

/2″-13 650 to 800 (73 to 90)

Wrench Size Torque ft-lbs (N•m)

7
/8″ 30 to 35 (41 to 47)
11/8″ 45 to 50 (61 to 68)
11/4″ 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.
-4 7
/16-20 2 2
-5 1
/2-20 2 2
-6 9
/16-18 1 /2
1
11/4
-8 3
/4-16 11/2 1
-10 1-16 1 /2
1
1
-12 1 /16-12
1
1 /4
1
1
-16 1 /16-12
5
1 1
-20 1 /8-12
5
1 1
-24 1 /8-12
7
1 1
-32 2 /2-12
1
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
Pressurized
Pressure reducing

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

Hydraulic motor Variable displacement

Two-position, in transition

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

Appendix — Basic JIC Symbols

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

Appendix — Basic JIC Symbols

Appendix — Basic JIC Symbols
Hydraulic System Schematics

& &

 
36, 36,

9 9

Variable Speed

Appendix — Hydraulic System Schematics

 81672:

672:
75 
36, & &
5

 
36, 36,

9 9
(

36,
7(

7( (


36,

7( 75

& &
5


36,
 
9+ 95 36, 36,
&8,1 9
9

5(75$&7

81672:
(;7(1'
/2:(5

/2:(5
5$,6(

5$,6(

672:
&&:
&:
33 /2:(5%220 & & 7(/(6&23( & & $57$50 & & 527$7( & & /(9(/,1* & &
5$,6(/2:(5 (;75(7 5$,6(/2:(5 &:&&: 3/$7)250
672:81672:

3*


36,

527$7,21

$
3% % 
36,


9'&

$
*30
0 %
&

36,

%
$

3
0,&521
36,%<3$66 0(6+

5(6(592,5$66(0%/<

'

Proportional Control

Appendix — Hydraulic System Schematics

 Pump Flow Manual Outrigger
Control Valve Lowering Valve Interlock Valve

Cross-Ported Pilot Load Holding and

Outrigger Control Valve Operated Check Valve Regenerative Valve

Secondary Stowage Counterbalance Velocity Fuse Speed Control Valve

DC Pump Valve
5(75$&7

81672:
(;7(1'
/2:(5

/2:(5
5$,6(

5$,6(

672:
&&:
&:

33 /2:(5%220 & & 7(/(6&23( & & $57$50 & & 527$7( & & /(9(/,1* & &
5$,6(/2:(5 (;75(7 5$,6(/2:(5 &:&&: 3/$7)250
672:81672:

3*


36,

Proportional Control Valve

Appendix — Hydraulic System Schematics

 Variable Speed Valve

Appendix — Hydraulic System Schematics

 Proportional Speed
AT237
Appendix — Hydraulic System Schematics
Appendix — Hydraulic System Schematics
 Variable Control
AT237
Appendix — Hydraulic System Schematics
Appendix — Hydraulic System Schematics
 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

Upper Control and Valve Wiring

Appendix — Wiring Line Diagrams
 Lower Control and Vehicle Wiring

Appendix — Wiring Line Diagrams

Multiplex Wiring
Appendix — Wiring Line Diagrams
Appendix — Wiring Line Diagrams
 Troubleshooting Chart
Symptom Possible Cause Test Procedure/­Corrective Action

Nothing Truck/machine selector switch Place the truck/machine selector switch in the Machine position.
operates. in the cab is in the Truck position.

Hydraulic oil is not reaching pump. Check oil reservoir. If oil is low, add hydraulic oil to the proper level.

Hydraulic system is not engaged. Check hydraulic system. If it is not engaged, properly engage it.

No system pressure. If there is no pressure at the main control valve, check for loss of prime to
pump, which may be caused by a leak in the suction line to the pump.

Pump is not operating properly. Check for proper plumbing.

Connect a flowmeter to the pump and check the flow. At idle speed, the
flowmeter should indicate 3.5 gpm (13.25 lpm) at 2,400 psi (165.47 bar). If
the unit is equipped with an automatic throttle, the flowmeter should indicate
5 gpm (18.93 lpm) at 2,400 psi (165.47 bar). If the flow is less than this,
determine the cause of the malfunction. Repair or replace the pump.

Shutoff valve between pump Check the shutoff valve. If the shutoff valve is closed, open it. On belt-driven
and reservoir closed. pumps, check for belt damage. On PTO driven pumps, check for hydraulic
system component damage.

Cylinder drifts. Internal leakage in cylinder. Test the cylinder for internal leakage. If internal leakage is determined,
replace the seals in the cylinder or replace the cylinder.

Leakage past holding valve. Replace the holding valve O-ring seal.

Make certain the boom is not being overloaded, causing counterbalance

valves to open.

Test the cylinder to determine if the holding valve is the source of the leakage.
If the holding valve is a counterbalance valve, test and adjust the valve by
using an Altec test block or replace the valve cartridge. If the holding valve
is a pilot operated check valve, replace the check valve cartridge.

No functions Control selector not in upper position. Place control selector in the Upper position.
from upper
control panel. Main system bypass (dump) valve Test by connecting flowmeter at valve input and back to reservoir. Replace
not shifting. blocking valve if necessary.

Loss of electrical power. Test upper control electrical cable starting at terminal blocks on turntable
to determine where power is lost.

Electronic communications failure Remove the aerial control valve access cover from the side of the
or microprocessor output error. turntable. Use the manual control levers to stow the unit. Diagnose the
electronic system and repair as required.

No function System pressure relief valve is Adjust the system pressure relief valve.
above rotation set too low.
operates.
Outriggers are not properly set. Properly set the outriggers. All outrigger interlock switches must be activated
for machine functions to operate.

Outrigger interlock valve is not Troubleshoot the outrigger interlock system. Determine if problem is in the
opening. electrical or hydraulic portion of the system. Replace defective component.

Check the outrigger interlock electrical switches.

Excessive Many possibilities. Isolate and repair the problem.

heat buildup.

Unit operates Station selector is in the Lower Check the station selector. Place in the Upper Controls position.
from lower Controls position.
controls, but
no boom func- Loss of electrical power. Test lower control electrical cable starting at terminal blocks to determine
tions operate where power is lost.
from upper
controls.

Appendix — Troubleshooting Chart

Symptom Possible Cause Test Procedure/Corrective Action
(continued) Electronic communications failure or Remove the aerial control valve access cover from the side of the
microprocessor output error. turntable. Use the manual control levers to stow the unit. Diagnose
the electronic system and repair as required.

All functions oper- Restriction in pressure line. Check for hot spots in the pressure line. The restricted area will
ate slow from the feel warmer than the rest of the hydraulic system. If a restriction is
lower and upper found, remove it.
controls.
Control valve spools do not fully shift. Check for damaged control valve handle linkage or for contamination
in the spool end cap.

Low pump flow. Check the pump with a flowmeter. Replace the pump if defective.

The throttle is not set properly. Adjust the engine throttle to achieve 3.5 gpm (13.25 lpm) or 5 gpm
(18.93 lpm) (all units with automatic throttle) pump flow.

Main control valve spools do not fully Electrical solenoid not fully shifting valve spool (may be caused by
shift. low voltage to the solenoid).

Boom or arm Counterbalance valve is contaminated. Replace the counterbalance valve.

cylinder does not
hold under load. Counterbalance valve malfunction, Remove the counterbalance valve and adjust using a test block.
out of adjustment.
Replace counterbalance valve with a new factory adjusted valve.

Internal cylinder leakage. Replace the seals in the cylinder or replace cylinder.

Cannot achieve full System pressure relief valve is set Adjust the system pressure relief valve.
system pressure. too low.

Upper boom Restriction in hydraulic hose. Remove kink or replace the hose.
extend slowly.

Upper boom ex- Internal leakage in cylinder. Test the cylinder. If there is an internal leak in the cylinder, replace
tends during travel. seals in the cylinder or replace the cylinder.

Engine throttle Component malfunction. Refer to Section 8 under Throttle Control.

control is not func-
tioning properly.

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.

Pump is noisy. Reservoir oil level is too low. Fill the reservoir to the proper level.

Restriction in the pump suction line. Suction line shutoff valve is not fully open.

Suction hose is kinked or plugged.

Suction hose too is small (15/8″ minimum).

Air entering suction line. Low oil level (fill reservoir to the proper level).

Loose hydraulic fitting (tighten or replace if necessary).

Hydraulic System/pump connection Correct misalignment.

misaligned.

Cavitation. Restriction in the suction line (remove kink or replace hose).

Improper hydraulic oil viscosity (replace oil with that of proper

viscosity).

Air entering hydraulic lines (fix defective hydraulic fittings).

Severe hydraulic Hose, tube, fitting, seal failure, etc. Excessive pump speed.
leak.
Replace defective component.

Appendix — Troubleshooting Chart

 Stability Test Form

Conduct tests with the booms fully extended

and the articulating arm fully raised as shown
Test
Weight

F-550

Level Surface Stability Test Chart Five Degree Slope Stability Test Chart
Capacity Platform Capacity Platform
Per Platform Test Weight Per Platform Test Weight
Platform Option Pounds (kg) Pounds (kg) Platform Option Pounds (kg) Pounds (kg)
One man, end-mounted 400 (181) 600 (272) One man, end-mounted 400 (181) 533 (242)

Procedure

1. Perform the stability test on a level surface and on a five degree slope in accordance with applicable ANSI/
CSA requirements.
2. Fill out all information on this form as a record of a completed stability test.
3. Position the booms horizontal tot he ground. Extend the upper boom to the full extend position. If the unit is
equipped with an articulating arm, raise the arm to the full raise position.
4. If the unit is equipped with a platform rotator, the platform must be rotated to the position furthest from the
centerline of rotation.
5. Find the option being tested in the chart for the test being performed.
6. Refer to the serial number placard for rated capacities. Subtract the weight of tools, etc. from the test weight
shown in the stability charts. For platform capacities 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.
7. Perform the test on both sides of the chassis.
8. After the test has been completed, torque all accessible rotation bearing cap screws to 150 foot-pounds (203
N•m) using a circular pattern. This is only required following the stability test at the time of initial installation of
the unit on the chassis.
9. After the test has been completed, torque the rotation gearbox mounting cap screws to 115 foot-pounds (156
N•m). This is only required following the stability test at the time of initial installation of the unit on the chassis.

General Information

Model number ____________________________ Serial number _____________________________________

Platform type _____________________________ Platform capacity __________________________________

Counterweight added to unit ____________________________________________________________________

Location of counterweight relative to rear axle _____________________________________________________

Level Surface Test

Platform test weight __________________________________________________________________________

Thickness of outrigger pads (0 if not used) ________________________________________________________

1 of 2 Appendix — Stability Test Form
Five Degree Slope Test

Platform test weight __________________________________________________________________________

Side of vehicle on low side of slope __________ Thickness of outrigger pads (0 if not used) _________________

Allowable slope indicator limits: Front-to-back _____________________ Side-to-side _____________________

Conclusion

Rotation bearing cap screws torqued __________ Rotation gearbox mounting cap screws torqued __________

Pass _____ Fail (reason) _____________________________________________________________________

Comments _________________________________________________________________________________

__________________________________________________________________________________________

Signature of technician ______________________________________ Date of test ______________________

Appendix — Stability Test Form 2 of 2