A-A28d M

Copyright 2005 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.
Altec Industries, Inc. reserves the right to improve models and change specifications without notice.
749-20182
June 2005
A-A28D
Maintenance
and Parts Manual
Preface
This unit is the result of Altecs advanced technology and quality awareness in design,
engineering, and manufacturing. At the time of delivery from the factory, this unit met or
exceeded all applicable requirements of the American National Standards Institute. All
information, illustrations, and specifications contained within this manual are based on the
latest product information available at the time of publication. It is essential that all personnel
involved in the use and/or care of this unit read and understand the Operators Manual.
Given reasonable care and operation, according to the guidelines set forth in the manuals
provided, this unit will provide many years of excellent service before requiring major
maintenance.
The scope of this manual is limited to periodic maintenance. It does not cover methods that
may be required to inspect and repair major damage to the unit. Impacts to and excessive
forces on the hydraulic utility equipment, through vehicular accidents, rollovers, excessive
loading, and the like, may result in structural damage not obvious during a visual inspection.
If the hydraulic utility equipment is subjected to such impacts or forces, a qualified person may
need to perform additional testing such as acoustic emissions, magnuflux or ultrasonic testing
as applicable. If structural damage is suspected or found, contact Altec for additional
instructions.
Warning
Death or serious injury can result from component failure. Continued use of a mobile
unit with hidden damage could lead to component failure.
Never alter or modify this unit in any way that might affect the structural integrity or operational
characteristics without the specific written approval of Altec Industries, Inc. Unauthorized
alterations or modifications will void the warranty. Of greater concern, is the possibility that
unauthorized modification could adversely affect the safe operation of this unit, resulting in
personal injury and/or property damage.
Danger
Death or serious injury will result from unprotected contact with energized conductors.
Non-insulated units have no dielectric rating. Maintain safe clearances, as defined by
federal, state, and local authorities, and your employer, from energized conductors.
No unit can provide absolute safety when in proximity to energized conductors. No unit is
designed or intended to replace or supersede any protective device or safe work practice
relating to work in proximity to energized conductors. When in proximity to energized
conductors, this unit shall only be used by trained personnel using their companys 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.
7-04
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 .......................................................................................................... 10
Changing Oil and Flushing the System ................................................................. 10
Lubrication ................................................................................................................... 12
Lubrication Chart and Diagram .............................................................................. 13
Structures .................................................................................................................... 14
Cleaning ................................................................................................................ 14
Welds .................................................................................................................... 14
Fasteners ..................................................................................................................... 16
Methods of Lockwiring........................................................................................... 17
Pins and Pin Retainers ................................................................................................ 18
Pin Installation Into Self-Lubricating Bearings ....................................................... 19
Bearings ....................................................................................................................... 19
Spherical Bearings ................................................................................................ 19
Self-Lubricating Bearings ...................................................................................... 19
Tapered Roller Bearings ........................................................................................ 19
Shear Ball Bearings ............................................................................................... 20
Radial Ball Bearing ................................................................................................ 20
Slide Pad Bearings ................................................................................................ 20
Rotation Bearing .................................................................................................... 20
Rotation Gearbox Mounting Cap Screws ............................................................... 24
Lift Mounting Cap Screws ..................................................................................... 24
Cylinders ...................................................................................................................... 24
Lift Cylinder ........................................................................................................... 24
Extension Cylinder ................................................................................................ 25
Leveling Cylinders ................................................................................................. 26
Hydraulic Lines ............................................................................................................ 26
Manual Lowering System............................................................................................. 26
Fiberglass Platform Care ............................................................................................. 26
Cleaning ................................................................................................................ 26
Inspection.............................................................................................................. 26
Repair .................................................................................................................... 26
Accident Prevention Signs........................................................................................... 27
Accident Prevention Signs Diagram...................................................................... 28
Section 5 Hydraulic System
Oil Reservoir ................................................................................................................ 31
Pump ........................................................................................................................... 31
Secondary Stowage DC Pump..................................................................................... 31
Valves .......................................................................................................................... 31
Main Control Valve ................................................................................................ 32
Manual Lowering Valve ......................................................................................... 32
Holding Valves ...................................................................................................... 32
Load Holding and Regenerative Valve ................................................................... 33
Cavitation and Aeration ................................................................................................ 33
Air Bleeding ................................................................................................................. 34
Platform Leveling Bleeding Procedure................................................................... 34
Leakage ....................................................................................................................... 34
Heat Generation ........................................................................................................... 35
Hydraulic Lines ............................................................................................................ 35
Fittings and Valve Cartridges ....................................................................................... 36
Torque and Tightening Procedures ........................................................................ 36
Cylinders ...................................................................................................................... 37
Extension Cylinder ................................................................................................ 38
Extension Cylinder Holding Valve ......................................................................... 39
Lift Cylinder ........................................................................................................... 40
Elevation Cylinder Holding/Emergency Lower Valves ........................................... 40
Section 6 Mechanical Systems
Rotation System .......................................................................................................... 41
Rotation Bearing .................................................................................................... 41
Rotation Drive Gearbox ......................................................................................... 42
Booms ......................................................................................................................... 42
Upper Boom .......................................................................................................... 42
Upper Boom .......................................................................................................... 43
Platform Assembly ...................................................................................................... 44
End-Mounted Platform........................................................................................... 44
Side-Mounted Platform.......................................................................................... 44
Plastitrack/Boom Cables ............................................................................................. 44
Section 7 Electrical System
Circuit Protection ......................................................................................................... 47
Lower Control Panel ..................................................................................................... 48
Solenoids ..................................................................................................................... 48
Boom Function Solenoids ..................................................................................... 48
Upper Control Panel ..................................................................................................... 48
Ground Fault Interrupter ............................................................................................... 48
Section 8 Troubleshooting, Testing, and Adjustments
Troubleshooting Procedure .......................................................................................... 49
Hydraulic System ........................................................................................................ 49
Cycle Times .......................................................................................................... 49
Relief Valve Adjustment ........................................................................................ 49
Elevation System .................................................................................................. 50
Extension System................................................................................................. 51
Positive Leveling ................................................................................................... 51
Mechanical System ..................................................................................................... 51
Rotation Backlash Adjustment .............................................................................. 51
Electrical System ........................................................................................................ 52
Failure Identification .............................................................................................. 52
Section 9 Structural and Stability Testing
Structural ..................................................................................................................... 55
Stability ........................................................................................................................ 55
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
Stability Test Form
Section 1 Introduction 1
Section 1 Introduction
Additional copies of this manual may be ordered through
your Altec representative. Supply the model and serial
number found on the serial number placard and the
manual part number from the front cover to assure that
the correct manual will be supplied.
This symbol is used throughout this manual to
indicate danger, warning, and caution instruc-
tions. These instructions must be followed to
reduce the likelihood of personal injury and/or property
damage.
The terms danger, warning, and caution represent vary-
ing degrees of personal injury and/or property damage
that could result if the preventive instructions are not
followed. The following paragraphs from ANSI publica-
tions explain each term.
Danger
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury. This signal word is to be limited to
the most extreme situations.
Warning
Indicates a potentially hazardous situation which,
if not avoided, could result in death or serious
injury.
Caution
Indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe
practices.
The term attention is used to alert personnel of special
information to assist in the maintenance of the unit or
instructions that must be followed to prevent the possibil-
ity of damage to structures, components, or other prop-
erty.
About This Manual
This manual provides instruction to safely inspect, repair,
troubleshoot, and test the unit. Charts and figures are
provided to support the text. Because options vary from
one model to another, some figures may only be a
representation of what is actually on the unit.
Knowledge of the information in this manual combined
with proper skills and training in hydraulic, electrical, and
mechanical systems, provide a basis for safely maintain-
ing the unit. Read and understand the applicable proce-
dure before beginning. Carefully follow each procedure.
Contact the following organizations for additional infor-
mation.
American National Standards Institute (ANSI)
A92.2 for aerial devices; A10.31 for digger derricks
American Public Power Association
(Safety Manual for an Electric Utility)
American Society for Testing and Materials (ASTM)
American Welding Society (AWS)
Canadian Standards Association (CSA)
European Committee for Standardization (CEN)
Fluid Power Society (FPS)
Hydraulic Tool Manufacturers Association (HTMA)
International Electrotechnical Commission (IEC)
International Organization for Standardization (ISO)
Occupational Safety and Health Administration
(OSHA)
Dealers, installers, owners, users, operators, rentors,
lessors, and lessees must comply with the appropriate
sections of the applicable ANSI standard.
The Appendix contains reference items to help maintain
the unit. A glossary of industry terms is provided for your
convenience. This glossary provides an understanding
of the industry terms and phrases used in Altec manuals.
Throughout the manual, the term unit is used to describe
the Altec device, subbase, outriggers, and the associ-
ated interface with the vehicle.
2 Section 1 Introduction
Section 2 Unit Specifications 3
Section 2 Unit Specifications
General Specifications
This unit uses a telescopic upper boom.
Unit height specifications are based on a 40 inch (101.6)
frame height, but common frame heights vary from 36 to
44 inches (91.4 to 111.8 cm). Figure 2.1 provides general
unit specifications. This unit is not insulated.
The basic structural components are the pedestal, the
turntable, the lower boom and the aluminum upper boom.
The structures are made in the form of a box. This
structural style resists torsional loading, as well as ten-
sion, compression, and bending loads that may be applied
to the unit. Careful consideration has been given to the
design and manufacturing process to minimize the possi-
bility of fatigue cracks.
Item A-A28D A-A28D Van*
Maximum ground to bottom of platform height
Side-mounted platform 29.5 (9 m) 28.5 (8.7 m)
End-mounted platform 29.3 (8.9 m) NA
Working height
Side-mounted platform 34.5 (10.5 m) 33.5 (10.2 m)
Maximum side reach
Side-mounted platform 21.1 (6.4 m) 21.1 (6.4 m)
Travel height 10.67 (3.3 m) 9.75 (3.0 m)
Maximum hydraulic pressure setting 2,400 psi (165 bar) 2,400 psi (165 bar)
Rotation 360 degrees, noncontinuous 360 degrees, noncontinuous
Boom articulation -11 to +74 -11 to +74
Upper boom extension 9.92 (3.02 m) 9.92 (3.02 m)
Maximum platform capacity
Side-mounted platform 350 lb (159 kg) 350 lb (159 kg)
End-mounted platform 300 lb (136 kg) NA
* 22 inch (56 cm) frame height
Figure 2.1 Unit Specifications
4 Section 2 Unit Specifications
Component Identification
Upper Boom
Pedestal
Turntable
Lower Controls
Boom Pin
Lower Boom
Platform
Upper Controls
Upper Boom Tip
Platform Pin
Lift Cylinder
Boom
Rest Bracket
Section 3 Safety 5
Section 3 Safety
General Maintenance Information
Read and understand the complete procedure be-
fore beginning.
Remove the pressure in a hydraulic circuit before
disconnecting its components.
Use lifting devices of suitable capacity to support and
handle components.
Use a test block to adjust the relief setting on coun-
terbalance holding valves.
Be aware of your surroundings.
Fully open all shutoff valves after servicing the unit.
Complete the required procedures before returning
the unit to operation.
After completing a procedure, check the oil level in
the hydraulic reservoir and add oil if necessary.
Disclaimer of Liability
Altec Industries, Inc. will not be liable for unauthorized
alterations or modifications of the unit. Altec Industries,
Inc. will not be liable for improper or abusive operation of
the unit.
Do not alter or modify this unit in any way that might affect
its structural integrity, dielectric integrity, or operational
characteristics without specific written approval from
Altec Industries, Inc.
Unauthorized alterations or modifications will void the
warranty. However, of a greater concern is the possibility
that unauthorized changes could adversely affect the
units operation that could endanger personnel and/or
damage property. Altec will not be responsible for unau-
thorized alterations or modifications that cause death,
serious injury, and/or property damage.
Altec Industries, Inc. assumes no liability for any per-
sonal injury and/or property damage related to the use of
this manual when performing testing, operating, mainte-
nance and/or repair procedures on this Altec unit.
Safety Instructions
It is essential that all personnel involved in the care of this
unit read and understand the Operators and Mainte-
nance Manuals. Safety alerts throughout the manuals
highlight situations in which accidents can occur. Give
special attention to all safety alerts.
The safety information in this manual applies only to the
maintenance of this unit. Although procedures have
been written to protect the mechanic and other person-
nel, there is no safety system to account for human error
or negligence.
Danger
Death or serious injury will result from unprotected
contact with energized conductors. This unit does
not provide protection from contact with or proximity
to an electrically charged conductor when you are in
contact with or proximity to another conductor or
any grounded device, material, or equipment. Main-
tain safe clearances from energized conductors.
Warning
Death or serious injury can result from careless or
improper use of the unit. The mechanic bears ulti-
mate responsibility for following all regulations and
safety rules of their employer and/or any state or
federal law.
Attention
Maintenance personnel must be trained in safe ser-
vice procedures.
Work practices may expose maintenance personnel to
hazardous materials. Before using any chemical, read
and understand the manufacturers label and the mate-
rial safety data sheet (MSDS). These sheets explain
emergency and first aid procedures and waste disposal
methods. Properly dispose of oil and hazardous materi-
als.
6 Section 3 Safety
Section 4 Preventive Maintenance and Inspection 7
Section 4 Preventive Maintenance and Inspection
Proper unit maintenance will reduce downtime, lower
operating and repair costs, and extend equipment life.
Safety alone justifies a preventive maintenance program.
This type of program is less expensive than making major
repairs.
This section contains information on properly inspecting
the hydraulic system, structures, individual unit compo-
nents, and lubrication. Use the Lubrication Chart and
Diagram in this section when lubricating the unit.
A Preventive Maintenance and Inspection Checklist is
provided in the Appendix. Use this checklist when per-
forming routine maintenance and inspections to insure no
areas are overlooked. Keep permanent, written, and dated
records of all service performed on the unit.
Routine maintenance is performed on different compo-
nents of the unit at different times (refer to the Preventive
Maintenance and Inspection Checklist in the Appendix).
More frequent maintenance may be necessary if the unit
is operated under severe conditions. In addition to the
Preventive Maintenance and Inspection Checklist recom-
mendations, follow these recommendations on new units.
Measure the turntable tilt before using a new unit.
Change the return line filter after the first 15 to 25 PTO
hours.
Gearbox manufacturers recommend an initial oil
change after the first 15 to 25 PTO hours.
Torque the lift mounting cap screws to the recom-
mended torque specification after the first 30 days of
use.
Equipment Storage
Mobile hydraulic equipment needs maintenance when
stored, or not used, for extensive periods of time. Depend-
ing upon the climate, lack of use may begin to have a
negative effect in as little as two weeks. Storage for a
period of several months will almost certainly produce
some deterioration of the equipment.
Rust will form on unprotected ferrous metal surfaces very
quickly and water will collect inside unit structures. In dry
climates, gaskets will begin to shrink during long periods
of non-use, and lubricants will lose their ability to provide
lubrication. In cold climates, condensation may occur in
fluid reservoirs and other components.
Even when protective measures have been taken prior to
storage, some degradation of performance must be ex-
pected when the equipment is put back into use.
One of the most noticeable effects of prolonged periods of
non-use is seal deformation. By its nature, hydraulic
equipment generally has a number of heavy, cylindrical
actuators. As these components are allowed to rest in one
position for a period of time, the seals on the piston will
tend to flatten along the loaded side. Since the seal
material is synthetic, its elasticity is limited and it may not
resume its original shape completely. At best, there will be
some failure to seal well for a short period of time after
putting the equipment back into use. At worst, the seal will
never resume its original shape and will have to be
replaced.
Protective Measures
If it is known that equipment will be stored for a month or
more, some steps should be taken to preserve the
equipment.
1. The best preservative is to fully cycle (operate) the
equipment once weekly if even for a short time.
2. Coat exposed ferrous (iron or steel) bare metal sur-
faces with a light grease or heavy oil compatible with
system hydraulic oil. This includes cylinder rods,
shafts, gears, linkages, and unpainted parts.
3. Top off fluid reservoirs to allow as little air space as
possible, to limit the effects of condensation. Remove
excess oil before operating to limit the chance of
overflow when cylinders are cycled.
4. Cover or wrap exposed rubber or neoprene parts with
an ultraviolet resistant covering to shield the parts
from sun exposure.
5. Unplug electrical connectors and apply a dielectric
grease or an aerosol product designed for protecting
electrical connectors. Plug the connector back to-
gether.
6. Cover switch panels and control panels to prevent
direct intrusion of rain or moisture, while allowing air to
circulate over the panel.
7. Cover personnel platforms to prevent the accumula-
tion of water in the platform.
8. Shield fiberglass components from the sun and other
elements, if stored outside.
Hydraulic System
Maintaining the hydraulic system is critical to the proper
operation of the unit. Using the proper type of oil helps to
prevent many hydraulic system problems. Maintaining the
oil is also important. If the oil is dirty or contaminated,
components may be damaged.
8 Section 4 Preventive Maintenance and Inspection
Attention
Only use hydraulic oil as recommended. Other fluids
added to the hydraulic system can increase compo-
nent wear and affect the lubricating characteristics of
the oil.
Check the oil level in the reservoir with the vehicle level
and the booms stowed. Under these conditions, the proper
oil level is at the midpoint of the sight glass.
Cleanliness Precautions
Contamination will ruin any hydraulic system. It is very
important that no contamination 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 or
performing other service procedures.
The following precautions will help protect the cleanliness
of the hydraulic system.
Filter new oil with a 10 micron filter as it is added to the
reservoir.
Clean hydraulic connections before opening them.
Cap or plug ports and lines opened for service.
Keep replacement hoses, tubes, and other compo-
nents plugged while stored.
Make sure components are clean before installation.
Clean the reservoir and return line filter covers
before opening them.
Clean the filler breather cap before opening it.
After servicing the reservoir, immediately replace
the cover.
Make sure quick disconnect couplers are clean
before connecting them.
Do not spray water on the reservoir filler breather
cap. This could force contaminants into the reser-
voir.
Filtration
This unit is equipped with a complete filtration system.
When properly maintained, this system will reduce con-
tamination of the hydraulic system. The filtration system
must be serviced regularly to be effective.
Filler Breather Cap and Strainer Basket
The filler breather cap is located on top of the fill hole of the
reservoir (refer to Figure 4.1).
The cap allows air to flow in and out of the reservoir as the
oil level changes. It contains a filter that cleans the air as
it enters the hydraulic system. The fill hole strainer basket
keeps large particles from entering the reservoir when oil
is poured into it.
Replace the filler breather cap every year. If the unit is
operated in an extremely dusty environment, it may be
necessary to replace the filler breather cap more often.
Remove and flush (out or replace) the strainer basket any
time it has collected dirt or other contaminants. Flush the
strainer basket when the hydraulic oil is changed.
Return Line Filter
The return line filter is a 10 micron return line filter that
cleans the oil as it enters the reservoir. The return line filter
is inside the cap on top of the reservoir.
The return line filter is equipped with a bypass valve. The
bypass valve opens when there is a pressure drop of 25 psi
(or more) across the filter cartridge. When the valve is
Figure 4.1 Reservoirs
Strainer
Basket
Suction
Strainer
Post Mount
Strainer
Basket
Suction
Strainer
Bridge Mount
Fill Cap Return Line
Filter
Fill Cap/Return Line
Filter Assembly
open, oil flows directly into the reservoir. This prevents the
cartridge from collapsing during cold oil start-ups or if it is
clogged.
If the filter becomes clogged, oil will flow directly into the
reservoir through the bypass valve. The lack of filtration
will eventually damage hydraulic components.
During the initial break-in period of a new unit, the hydraulic
components will deposit break-in wear particles in the
return line filter cartridge. Change the return line cartridge
after the first 15 to 25 PTO hours. Then change the
cartridge as recommended in the Preventive Maintenance
and Inspection Checklist. If the unit is operated in very
dusty conditions, replace the return line filter more often.
Also, replace the cartridge after new oil has circulated
through the system for the first time.
Always replace the return line filter cartridge with a genuine
Altec replacement part. Other filters may screw into the
filter housing, but may not have the same micron rating.
Also, other filters may allow oil to bypass at a different rate.
Suction Strainer
As the hydraulic oil leaves the reservoir, it passes through
a suction strainer, located in the bottom of the reservoir.
This filter has a pleated wire mesh screen to prevent large
particles from entering the pump.
Warning
Death or serious injury can result from improper use
of solvents. Follow the manufacturers label for proper
use and disposal.
Caution
Injury can result from airborne particles entering the
eyes. Wear appropriate safety equipment.
The suction strainer should be removed from the reservoir
and cleaned when the hydraulic oil is changed. Do not
apply force to the screen as damage will occur. Clean the
screen by flushing it with solvent and blowing it out with an
air hose from the inside of the screen to the outside.
A clogged suction strainer may cause cavitation, resulting
in pump damage.
Oil Specifications
Use high quality oil in the hydraulic system. The oil should
contain rust, oxidation, and corrosion inhibitors. It should
also contain antifoam and antiwear additives.
Hydraulic oils used must possess high demulsibility to
allow the oil to separate from the water in the reservoir.
Hydraulic oil is commonly classified by viscosity. The
viscosity of hydraulic oil changes with temperature. The
higher the viscosity index of an oil, the less the viscosity
will change as the temperature changes. A multiviscosity
oil contains additives which increase the viscosity index.
Multiviscosity oils should have high shear stability to
maintain oil performance by avoiding excessive change in
viscosity.
The ability of hydraulic oil to provide adequate fluid at low
temperatures is measured by its pour point. If the pour
point is not low enough, oil will not flow into the pump at a
fast enough rate when the pump is operated at low
temperatures. This will cause cavitation, which can quickly
destroy the pump.
Attention
the oil.
Only use oils meeting the viscosity rating for military
specification MIL-5606 in extremely cold climates. These
oils have fewer antiwear characteristics and are not
recommended for full time use.
Figure 4.2 shows hydraulic oil recommendations for differ-
ent temperatures. Most companies can supply equivalent
Specification Cold Weather Oil All Weather Oil Warm Weather Oil
Ambient temperature range -50 to 60F (-46 to 16C) -10 to 90F (-23 to 32C) 40F (4C) and above
Viscosity @ 100F (38C) 85 SSU (17 cSt) 90 SSU (20.2 cSt) 150 SSU (30 cSt)
Viscosity @ 210F (99C) 35 SSU (4.5 cSt) 43 SSU (5.0 cSt) 46 SSU (5.5 cSt)
Pour point -80F (-62C) -55F (-48C) -30F (-34C)
Maximum oil temperature 160F (71C)
Minimum pump start-up temperature -15F (-26C)
Figure 4.2 Hydraulic Oil Viscosity Recommendations
oils. The oil selected for the hydraulic system depends on
the temperature during unit operation.
Oil Condition
An important part of hydraulic system preventive mainte-
nance includes checking the condition of the hydraulic oil.
Periodic laboratory analysis is the most accurate method
of determining the condition of hydraulic oil and determin-
ing when it should be changed. A visual inspection may
also be useful to check oil condition.
A hydraulic oil supplier should be able to do testing or
recommend a test laboratory. The laboratory should pro-
vide the following information.
Particle count
Trace element analysis (component wear, outside
contaminants, and oil additive concentrations)
Viscosity test
Water content test
Before taking a sample of oil, operate the unit to circulate
the oil. Warm it to operating temperature. Take the sample
from the middle level of the reservoir using a clean hand
pump, such as a disposable syringe and a piece of plastic
tubing. If this is not available, the sample can be drained
from the bottom of the reservoir. Allow several quarts of oil
to flow out before collecting the sample. This will remove
any dirt and water that has collected in the reservoir near
the drain.
If a sample container has not been provided by the
laboratory, use a wide mouth, screw top, clear glass
container. Clean it with hot water and detergent. Rinse it
thoroughly and let it air dry before putting oil into it.
Once the report is received, compare it to previous oil
analysis reports for the same unit. This information will
provide trends toward oil deterioration. It may give early
warnings of a problem developing within hydraulic system
components.
Attention
Change the oil if the sample has any of the character-
istics listed in Figure 4.3.
If making a visual inspection, compare the sample of oil to
a sample of new oil of the same type. Also, compare it to
previous samples taken from the same unit. Look for the
signs of oil deterioration listed in Figure 4.3.
There are fluid contamination detector kits available which
allow for rapid, on-the-spot analysis of the hydraulic
systems condition. Contact your Altec representative for
further information.
Oxidation produces varnishes that bake onto hot sur-
faces. These oxidation products are acidic and tend to
attack metal surfaces. This can damage pumps, motors,
and valves.
High operating temperatures will increase the rate of
oxidation of the oil. The presence of water or air in hydraulic
oil also causes oxidation.
The presence of water may cause rust and corrosion. It
also reduces the dielectric capability of the oil.
If laboratory analysis or visual inspection indicate that the
oil is deteriorating prematurely, determine the cause of the
problem and correct it.
Changing Oil and Flushing the System
A properly maintained filtration system greatly extends the
useful life of the hydraulic oil. However, the oil will
eventually need to be replaced due to contaminants that
form during normal operation of the unit.
It is impossible to recommend an exact time interval for oil
changes due to varying conditions of unit use. Use the
following guidelines to determine when the hydraulic oil
should be changed.
Change the oil as recommended by the Preventive
Maintenance and Inspection Checklist.
Figure 4.3 Hydraulic Oil Conditions
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
If a hydraulic component fails and contaminates the
system with metallic particles, change the component
and the oil immediately.
In climates where there is a wide variation in operating
temperatures between summer and winter months,
change to the appropriate weight oil each spring and
fall.
Replace the return line filter cartridge and the filler breather
cap every time the hydraulic oil is changed. Also, clean or
replace the suction strainer.
A significant quantity of oil remains in the cylinders and
lines of the hydraulic system when the reservoir is drained.
Flush the system when the oil is changed. This is
especially important if the system is heavily contaminated
with metal particles.
If the oil is contaminated with water, it may not be
necessary to change the oil and flush the system. Follow
the instruction under Water Removal in this section.
The following equipment and supplies are necessary to
properly flush the hydraulic system.
Approximately 10 gallons of proper hydraulic oil
Three return line filter cartridges
Clean, lint-free rags
Reservoir cover gasket
Filler breather cap and strainer basket (if component
has not been replaced within one year)
Caution
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
work areas clean.
Use the following procedure to flush the hydraulic system.
1. If the oil is being changed because of contamination
due to hydraulic component failure, proceed to step 2.
Otherwise, operate the unit to circulate the oil and
warm it to operating temperature. This will allow many
of the impurities to drain off in suspension.
2. Drain the oil reservoir completely.
3. Wipe off the top of the reservoir and the filler breather
cap.
4. Remove and clean the strainer basket.
Warning
use and disposal.
5. Inspect the inside of the reservoir. If sludge or other
contamination is found, remove the reservoir and
flush it out with a small amount of hydraulic oil.
6. Change the return line filter and clean the suction
strainer.
7. Install the strainer basket.
8. If hydraulic component failure has contaminated the
system, change the return line filter cartridge.
Attention
the oil.
9. Fill the reservoir with new hydraulic oil of the proper
grade to the midpoint of the sight gauge. Filter the oil
through a 10 micron filter as it is put into the reservoir.
10. Install the filler breather cap. If the filler breather cap
has not been replaced in one year, or is damaged,
replace it.
Attention
Damage to the pump or return line filter can result if the
unit is operated with either or both of the shutoff valves
closed. Fully open the shutoff valves before engaging
the PTO.
11. Cycle all the cylinders and the rotation motor to flush
the contaminated oil from the lines and components of
the hydraulic system.
12. Change the return line filter cartridge and clean the
suction filter element.
13. Drain the reservoir completely.
14. Fill the reservoir with new hydraulic oil of the proper
grade to the midpoint of the sight gauge. Filter the oil
through a 10 micron filter as it is put into the reservoir.
15. Change the return line filter cartridge after approxi-
mately 25 PTO hours.
Water Removal
If the hydraulic system is heavily contaminated with water,
special water removal filtration may be necessary. An oil
supplier or a qualified laboratory can determine whether
water has caused excessive oil oxidation or additive
deterioration.
If analysis shows oil deterioration beyond an acceptable
level, drain the reservoir and flush the system as de-
scribed earlier in this section. Use a water removal filter
cartridge during the flushing process to remove any
residual water from the system. When the flushing pro-
cess is complete, replace the water removal filter cartridge
with a regular filter cartridge.
If the oil condition is acceptable except for the water
content, allow time for it to separate from the oil. Then drain
the water off the bottom of the reservoir. Circulate the oil
in the reservoir through a separate water removal filter
cartridge. This may require two or more water removal filter
cartridges, depending on the amount of water content. The
cartridges capacity is approximately one cup of water.
Once the cartridge has accumulated this amount of water,
it needs to be replaced. Change the water removal car-
tridge a minimum of every other day.
Continue this process until the water content is reduced to
an acceptable level. The preferred method of determining
the water content is laboratory testing. Once the water
content has been reduced to an acceptable level, replace
the cartridge with a new return line filter cartridge.
Lubrication
Proper lubrication will extend the life of the equipment and
reduce maintenance problems. The frequency of lubrica-
tion required will depend on the amount of use and the
conditions the unit is operated in. Operation in extremely
dusty, sandy, or rainy environments will require more
frequent lubrication. Lubricate the unit as recommended
by the Preventive Maintenance and Inspection Checklist.
The Lubrication Chart and Diagram identifies each compo-
nent, type of lubricant, and method of application. Any
brand of lubricant that meets or exceeds the specifications
of the products listed is acceptable. Select the appropriate
interval and lubricate the components identified by the
symbol(s).
Always wipe grease fittings clean before and after greas-
ing to keep contaminants from entering the points of
lubrication. To avoid bearing damage, use manually oper-
ated grease guns. Air-driven grease guns may have
enough force to cause bearing damage.
If the unit is not used, or it is stored for any length of time,
apply fresh lubricant at all points shown on the Lubrication
Chart and Diagram. This will help prevent corrosion during
the idle period.
Bearings
Spherical bearings are used in several places on the unit.
They require periodic lubrication with a molybdenum
lubricant. It is very important to grease this type of bearing
regularly. If they are not greased properly, the usable life
of the bearing will be greatly reduced. These bearings can
produce enough twisting force on the mounting pins to
break the pin retainers and make removal difficult if they
are not properly lubricated.
Self-lubricating bearings require no lubrication.
Rotation Gearbox
The need to add oil regularly to the rotation gearbox is a
sign of a leak. Determine the cause of the leak and correct
it. A low oil level can damage the internal components of
a gearbox.
The overall life expectancy of a gearbox may be extended
by regularly draining and refilling the oil. The best time to
drain a gearbox is right after it has been operating. At this
time, the oil is warm and the wear particles are suspended
in the oil. Change the oil as recommended by the Preven-
tive Maintenance and Inspection Checklist. If a gearbox is
overheated and the oil smells burned, change the oil
immediately.
If the oil level of a gearbox appears to be increasing, this
could be a sign of an internal hydraulic leak from a
defective motor shaft seal. Change the oil if it becomes
diluted with hydraulic oil from a leaking seal. The oil should
be level with the bottom of the fill hole.
The rotation gearbox has a vent plug that must be kept free
of paint and dirt. The vent prevents excessive pressure
buildup inside the gearbox as the oil expands during
operation.
Rotation Bearing
The rotation bearing ball path is lubricated by a grease
fitting on the inside of the bearing.
Warning
Death or serious injury can result from being trapped
between moving components. Maintain a safe dis-
tance while components are in motion.
Do not lubricate the bearing while operating the unit. Stop
turntable movement before lubricating. Rotate the turn-
table slowly through at least two complete 370 degree
revolutions, stopping periodically to lubricate. Operate the
manual grease gun three to five times in each position.
Lubrication Chart and Diagram
Service items identified by the symbol(s) at the appropriate level.
Letter Lubricant Application Method
A Silicone Lubricant Spray
B Mobil SHC634 Gear Oil or Equivalent Pour
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.
M Moly Grease Multipurpose lithium base grease with molybdenum disulfide Brush/grease gun
additive, good water resistance, rust inhibition, oxidation stability, and extreme
pressure properties.
C
C
B
A
85 hours/1 month 500 hours/6 months 1,000 hours/1 year 2,000 hours/2 years If disassembled
G
M
M
M
M
Lift Cylinder
Bearings
Leveling
Cylinder Pins
Leveling
Cylinder Pins
Rotation Gearbox
Pinion Shaft
Rotation Bearing
Rotation Gearbox
Upper Boom
Extension Cylinder
Rod End
Extension Cylinder
Anchor Bolt
Platform
Pivot Shaft
C
Rotation Gear Teeth
Apply an open face gear lubricant to the rotation gear and
pinion teeth.
Caution
Injury can result from contact with pinion and rotation
bearing gear teeth. Keep hands clear.
Injury can result from being pinched or trapped be-
tween moving components. Keep hands clear.
Use caution when access covers have been removed to
service the unit. Pinch points and shear points may exist
between moving parts. Replace the access covers imme-
diately after servicing.
Remove the pinion cover from the turntable to lubricate the
rotation and pinion gear teeth. Replace the cover after the
lubrication has been completed.
Warning
Death or serious injury can result from being trapped
between moving components. Maintain a safe dis-
tance while components are in motion.
Do not lubricate the gear teeth while operating the unit.
Stop turntable movement before lubricating. Rotate the
turntable slowly through a complete 360 degree revolution.
Booms
The internal surfaces of the lower boom are lubricated at
the factory and should only require additional lubrication at
times of major overhaul and after replacing the slide pads
on the base end of the upper boom.
To lubricate the external surface of the upper boom, fully
extend the upper boom. Apply lubricant to the exposed
boom surfaces. Extend and retract the boom several
times. Wipe the excess lubricant from the upper boom.
Structures
The structural components of the unit are identified in the
Component Identification in Section 2. The unit has been
designed to meet or exceed the ANSI for vehicle-mounted
rotating and elevating aerial devices.
Regular inspections of the welds and structures is required
to insure that components maintain their strength. Peri-
odic cleaning of the structures is also recommended to
prevent damage that can occur from dirt accumulation.
Caution
Injury can result from slipping and falling. Use care
and the handles and steps provided.
Periodic inspection of the structures is recommended to
be certain there is no deformation, abnormal wear or
abrasion, interference between moving parts, or cracking
of the welds on structural members.
Inspect the structures and welds as recommended by the
Preventive Maintenance and Inspection Checklist.
Cleaning
Accumulated dirt can damage the unit and cause it to
malfunction. Dirt buildup also accelerates wear on the
components.
Caution
work areas clean.
If a pressure washer or steam cleaner is used to clean the
unit, be careful where the spray is directed. Do not direct
the spray where the cleaning liquid might get into 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 for water
pressure to push a seal out of position. Do not direct the
spray at the filler breather cap of the reservoir. High
pressure can force water and cleaning liquid into the
reservoir and contaminate the hydraulic oil. Do not clean
the rotary joint or spool ends of any hydraulic valve with
direct pressure from a pressure washer. Limit the water
pressure to 500 psi (34.47 bar) and keep the spray tip at
least 18 inches (45.72 cm) away from these components
while washing. After washing and cleaning the unit,
relubricate as necessary.
Refer to Fiberglass Platform Care in this section for
information on cleaning the fiberglass components.
Welds
All welds on the unit are originally applied in conformance
to AWS standards. Every weld on the unit is important and
should be periodically inspected.
Warning
use and disposal.
If paint has lifted off the weld, or if rust is found, a closer
inspection is required. Remove any loose paint or rust with
a wire brush. Clean the area with a solvent such as
acetone. Closely inspect the area for cracks in the welds.
Dye penetration and magnetic particle testing are simple
processes that may be used to verify or disprove a
suspected problem.
Visual inspections can be very effective if conducted
properly. Clean the area to be inspected. Use a bright light
to look for visible cracks in the weld and at the weld-to-
parent material joint.
Pay close attention to welds that are located where
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 illustrates
these areas. If any cracks or unacceptable conditions are
discovered, report them to your Altec representative.
Any welds added in the field should be done by qualified
personnel and also conform to AWS standards.
After doing repair work on the unit, such as weld repair,
some testing of the unit may be required. Refer to Section
6 for information on repairing mechanical components.
Figure 4.4 Weld Inspections
Pedestal
Cylinders
End-Mounted
Platform Bracket
Interface Weldment for Bridge Mount
Turntable
Side Mount L-Bracket
Bridge Mount Pedestal
Upper Boom
Lower Boom
4 Sides
4 X
4 X
Fasteners
A variety of fasteners are used on the unit. Different
fasteners have different inspection and installation re-
quirements depending on their use and design. This
section explains fasteners used on the unit, torque speci-
fications, and the use of thread locking and anti-seize
compounds.
The standard grade of fastener used on the unit is a zinc
plated, SAE Grade 5, steel cap screw. SAE Grade 8 cap
screws or special high strength cap screws are used in
highly loaded areas. A variety of other fasteners such as
socket head, flat countersunk head, and button head cap
screws are also used on the unit.
Check all fasteners for tightness as recommended by the
Preventive Maintenance and Inspection Checklist.
Refer to Figure 4.5 for the general location of the fasteners
to inspect.
Figure 4.5 Fasteners
Platform Pivot
Unit Mounting
Rotation Bearing
Rotation Gearbox
All Pin Retainers
Boom Pivot
The following is a list of fasteners to which particular
attention should be given.
Rotation gearbox mounting cap screws
(110 foot-pounds)
Rotation bearing cap screws (170 foot-pounds)
Extension cylinder rod end anchor cap screw
(75 foot-pounds)
All pin retainer cap screws (refer to torque chart)
A properly installed cap screw, applies a clamping force
equal to or greater than the load applied to it. A cap screw
installed at less than the recommended torque value does
not provide enough clamping force. The cap screw may
fatigue, causing it to loosen or fail. If the cap screw is
torqued beyond the recommended torque value, the elas-
tic range of the cap screw may be exceeded. This may
result in premature failure of the cap screw.
When checking fastener torque, check at 90 percent of the
original value. For example, if the torque value for a cap
screw is 100 foot-pounds (136 Nm), check the cap screw
for tightness at 90 foot-pounds (122 Nm).
Methods of Lockwiring
Some critical fasteners on the aerial device must be
lockwired. This includes cap screws in pin retention
systems and certain other mounting or retaining cap
screws. Lockwiring is illustrated in Figure 4.6. If inspection
shows that the lockwires are broken or damaged, or if they
have been cut off for cap screw removal, the wires must
be replaced.
Figure 4.6 Lockwiring
A relatively soft, aircraft type safety wire such as the types
listed below must be used.
Stainless steel safety wire
Alloy 305, 0.043 diameter
Zinc coated carbon steel wire
MS20995F41, 0.041 diameter
Attention
Use only new wire for lockwiring. Never attempt to
reuse lockwires.
Special wire twister pliers that have smooth flat jaw
surfaces are available from tool manufacturers. Using this
type of pliers will minimize nicking and weakening the wire.
These pliers make it much easier to produce neat and
effective lockwires.
Before lockwiring, make sure that the cap screws are
properly tightened to their proper torque value. Do not
loosen cap screws or overtighten them to try to make it
easier to install the lockwire in the hole in the bolt head.
Handle the wire carefully during installation so that it does
not become kinked, nicked, scraped or flattened. Avoid
pulling the wire around sharp corners, twisting it exces-
sively, or gripping it too tightly with pliers.
Lockwiring Procedure
1. Install the lockwire so that it tends to pull the fastener
in the direction that would tighten it.
2. Twist the wires between the anchor point and the
fastener so that there is no slack. Twist the wire tightly
enough to secure the part, but not over twisted. Over
twisting can cause the wire to become brittle or
stressed to the point that it will break under a slight
load.
3. Install and twist the lockwires so that the loop around
the bolt head is snug. This will prevent the loop from
coming up over the bolt head, leaving a slack loop.
4. Make a pigtail of three to six twists at the end of the
wiring. Cut the wire ends off straight with a pair of wire
cutters.
5. Bend the end of the pigtail back or under the twisted
wire to prevent the sharp wire ends from being a
potential cause of injury.
Inspection Marks
Nuts or cap screws with locking patch element used in
combination with inspection marks are used at specific
locations on the unit that are visible to the operator during
daily inspections.
If any inspection marks are found to be cracked or broken
during inspection, the original mark must be totally re-
moved. The fastener torque must be checked (if no
damage is evident) or the fastener replaced and torqued (if
damage is evident), and the inspection mark reapplied.
Snug Loop Around Head
Snug Twists With no Slack
Pigtail
Retaining Plate Forged Pin Retainer
The inspection lacquer (refer to Service Tools and Sup-
plies in the Appendix) should not be used after the
expiration date printed on the container.
Use the following procedure to apply a new inspection
mark.
1. Remove the majority of the original inspection mark by
chipping it off with a chisel or other cutting method. Do
not damage the surface on the nut, fastener, washer,
and part or structure being attached to.
Warning
use and disposal.
2. Be sure the cleaning operation is performed in a well-
ventilated area. Remove the remaining residue using
inspection lacquer cleaner (refer to Service Tools and
Supplies in the Appendix). Apply the cleaner to a rag
and completely remove the inspection stripe.
3. Properly torque the fastener.
4. Clean the area where the inspection stripe is to be
applied with a soft clean cloth and acetone.
5. Start at the center of the cap screw and apply a
1
/16
to
1
/8 thick stripe of inspection lacquer to the head of
the cap screw, across the washer, and onto the
surface of the parent material. The stripe should
extend
1
/4 to
3
/8 onto the parent material.
6. The stripe must be continuous across the surfaces. If
it is not, remove the stripe with cleaner and reapply the
inspection lacquer properly.
Thread Locking Adhesives
and Anti-Seize Compounds
Anaerobic thread locking adhesives work in the absence
of air. When a cap screw is removed, it must be cleaned
thoroughly with a wire brush and cleaning solvent and the
adhesive must be reapplied before reinserting the cap
screw. The cap screw must be properly torqued before
curing of the adhesive, which occurs within 15 minutes of
application at room temperature.
The use of anaerobic thread locking adhesives is recom-
mended on the threads of the fasteners and connections
listed below to provide additional security against loosen-
ing.
Pin retaining fasteners Medium strength
Rotation stop pivot pin High strength
Warning
use and disposal.
Caution
eyes. Wear appropriate safety equipment.
If the threads of the fasteners and the tapped hole are not
clean and free of grease and oil, the effectiveness of the
thread locking adhesive will be reduced. The threads of the
fastener and the tapped hole should be cleaned with
solvent and blown dry with compressed air before applying
the thread locking adhesive.
Anti-seize compounds may be used to prevent rust and
corrosion from forming on the metal to metal contact areas
between a connecting pin and its boss. It is also recom-
mended for certain fasteners to reduce friction during
torquing to increase clamping load. The area to receive the
anti-seize compound must be clean and dry so the anti-
seize will be effective.
Pins and Pin Retainers
All pins on the aerial device have been plated to prevent
rusting and to provide wear resistance for those pins used
in conjunction with self-lubricating bearings.
Give particular attention to the lubrication information to
make sure that proper lubrication is given to those pins that
require it. It is also important to know which pins and parts
do not require lubrication. Pins used with self-lubricating
bearings do not require additional lubrication.
Retaining Rings
Retaining rings are used on several mounting pins. They
are installed in grooves that have been machined in the
pin. Retaining rings must be in place. Install retaining rings
with the sharp edge out (refer to Figure 4.7). This makes
it more difficult for the ring to come off the pin if the pin is
being forced out the other side.
Figure 4.7 Retaining Ring
Sharp
Edge
Section A-A
Welded Flange
The lower boom pivot pin (refer to Figure 4.8) and the pin
connection at the base end of the lift cylinder use a welded
flange that is held in position with two cap screws. A
retaining ring is installed on the other end of the pin.
Figure 4.8 Welded Flange
During inspection make sure the retaining ring is in place
and is properly installed. Make sure the cap screws are
tight and inspect for cracking of the flange weld.
Pin Installation Into
Self-Lubricating Bearings
When a pin is used in conjunction with a self-lubricating
bearing, only the areas of metal to metal contact between
the pin and the boss should receive an anti-seize com-
pound. Lubrication of the bearing will prevent the bearing
lubricant from transferring to the pin surface. To install the
pin properly, slide the pin through the first boss and through
the bearing until it reaches the second boss, as shown in
Figure 4.9. The anti-seize compound may now be applied
to the second pin boss and to the pin surface that is still
exposed. The pin may now be completely installed with the
appropriate fastener system.
Figure 4.9
Pin Installation Into Self-Lubricating Bearings
Bearings
A variety of bearing types are used on the unit. Each type
of bearing has characteristics that are required for that
particular application.
Spherical Bearings
Spherical bearings are used in all cylinders on the unit.
These bearings are used in areas where perfect alignment
is difficult to maintain. This bearing type allows the
cylinder to follow the movements of the structure, without
applying a side load to the internal components of the
cylinder. Periodic lubrication of this bearing type is re-
quired to prevent seizing. This bearing should be lubri-
cated as indicated on the Preventive Maintenance and
Inspection Checklist.
Self-Lubricating Bearings
Fiber wound self-lubricating bearings are installed without
any additional lubrication. This type of bearing is used in
conjunction with a chrome pin. When a load is applied to
the pin, some of the lubricant is transferred to the chrome
pin and forms a lubricant to lubricated pin and bearing
assembly.
Self-lubricated bearings are designed for long life and,
under normal use, will provide many years of trouble-free
service with virtually no maintenance. If this type of
bearing receives lubrication from an outside source, the
transfer of lubricant from the bearing to the chrome pin
surface will stop. In this case, the useful life of the bearing
would be reduced. Additional periodic lubrication would
then be required for the life of the bearing.
After many years of service, it may be desirable to replace
these bearings when the components are disassembled
for other purposes. Replacement of this type of bearing
due to wear is not a normal consideration.
Tapered Roller Bearings
Tapered roller bearings are often used in rotation gear-
boxes. This bearing type may be used at high speeds and
will support radial and axial loading. Depending on the
application, the tapered roller bearing may be installed with
several thousandths inch end clearance, no clearance, or
with a preload. A preload is .000 clearance minus a few
thousandths. Preload is sometimes checked with a torque
wrench (stall torque) or with a line and scale (rolling torque).
Shaft load and speed of the particular application will
determine the method of installation. Light loads and high
speeds will call for a specific amount of end clearance.
Heavy loads and low speeds will call for a specific amount
of preload on the bearing. Proper installation and lubrica-
tion of the tapered roller bearing are very important in
determining the useful life of the bearing.
First Boss Second Boss
Bearing
Anti-Seize Compound
Pin
Shear Ball Bearings
The rotation bearing is a shear ball bearing. This bearing
type will support axial and radial loads because of the
design of the inner race and outer race. Most of the ball
surface is enclosed in the shear ball bearing design while
only a small part of the ball surface is enclosed in a
standard ball bearing.
Proper installation and lubrication are very important
because of the high loads that this type of bearing is
subjected to. The mounting surface must be clean and flat,
with the fasteners applying the proper clamping force to
hold the bearing in position. Lubrication of the shear ball
bearing is specified in this section under Rotation Bearing.
Radial Ball Bearing
The platform ring on the lip of the side-mounted platform
rotates on two radial ball bearings (refer to Figure 4.10).
These bearings support the platform ring and allow for
smooth rotation of the platform. Lubrication is not required
on sealed bearings of this type.
Figure 4.10 Radial Ball Bearing
Slide Pad Bearings
There are two kinds of slide pad bearings used on the
booms. White polyethylene pads are used at the tip of the
lower boom to support the upper boom and to support the
extension cylinder as illustrated in Figure 4.11.
Figure 4.11 Polyethylene Slide Pad Bearings
Blue polyethylene filled bearings are used to support the
base end of the upper boom. The bearings are shown in
Figure 4.12.
Figure 4.12 Slide Pad Bearings
Rotation Bearing
The rotation bearing is a shear ball type bearing that allows
for low friction rotation. The mounting surfaces of the
turntable and pedestal are machined to very close toler-
ances to provide full and complete support for the rotation
bearing.
The rotation bearing is secured to the pedestal and
turntable with
5
/8 grade 8 cap screws. These cap screws
have a patch lock material permanently bonded to the
threads. The cap screw threads and special hardened flat
washers are coated with an anti-seize compound at the
time of assembly. The lubrication provided by the anti-
seize compound allows for proper tightening of the cap
screws when they are tightened with the proper torquing
procedure. This helps to provide the maximum life of the
rotation bearing and the cap screws when the unit is
operated in the proper manner as recommended in the
Operators Manual. The use of lubrication also reduces the
torque required to obtain the proper cap screw tightness
and makes possible an accurate check of the torque of the
cap screws when they are inspected during regular main-
tenance procedures.
When the cap screw fasteners are properly installed, each
bearing race is clamped securely and evenly, providing a
smooth and true ball bearing path that is critical to the life
span of the bearing. Distorted mounting surfaces, or
uneven clamping force of the cap screws, will cause the
bearing pathway to become distorted, shortening the life of
the bearing. As loads are applied and released, the mating
surfaces of the bearing, turntable and pedestal may seat
in enough to relax the clamping force of the cap screw
fasteners slightly. If this condition is not corrected, opera-
tion cycles of loading and relaxing of the fasteners could
lead to fatigue type failures of the cap screws.
Attention
Only use Altec supplied cap screws and washers to
install the rotation bearing.
Upper Boom
Support Pad
Extension Cylinder
Support Pad
Bearing
Monitoring Bearing Wear
The internal bearing clearance will increase slightly during
the break-in period. It should then remain essentially
constant for many years if the bearing is properly lubri-
cated and not overloaded. As the bearing raceway begins
to wear, the clearance will increase (steadily at first and
accelerate toward the end of bearing life).
An increase in bearing clearance is one sign of bearing
wear. Periodic bearing tilt measurements will help deter-
mine when bearing replacement is necessary. Perform
bearing inspection and turntable tilt measurements as
recommended by the Preventive Maintenance and In-
spection Checklist. More frequent inspections are re-
quired when the total increase in turntable tilt measurement
reaches 0.050 (1.27 mm).
Take an initial turntable tilt measurement when the unit is
delivered. This will provide a baseline for future bearing tilt
measurements. Future bearing tilt measurements will be
compared to this baseline to determine how much the
bearing tilt has increased since the initial (new bearing)
measurement. The greatest portion of the measured
turntable tilt results from structural deflection rather than
bearing internal clearance. It is important that the deflec-
tion be held constant by using the same measurement
procedure each time. Keep a maintenance log to monitor
the bearing inspections and turntable tilt measurements
during the life of the unit.
Bearing Replacement Criteria
The rotation bearing must be inspected and evaluated.
The recommended bearing inspection procedures include
the following items.
Monitoring the trend of turntable tilt measurements
Bearing inspections and turntable tilt measurements
can be used to determine when a bearing should be
replaced. Generally, an increase in turntable tilt of
0.065 (1.65 mm) above the initial tilt measurement
indicates that the bearing may be reaching the end of
its useful life. Other factors related to the condition of
the bearing must also be considered. Determine if the
increase in the turntable tilt measurements has been
steady or if it shows a trend of accelerated wear (refer
to Figure 4.13). Example 1 shows a steady increase
in wear, which is normal. Example 2 shows an
accelerated increase in wear which would indicate
bearing replacement may be necessary. If the tilt
measurement has reached 0.065 (1.65 mm) above
the initial (new bearing) tilt measurement, and periodic
measurements show a trend of accelerated wear,
replace the bearing.
500 Hour/6 Month
Inspections Example 1 Example 2
1 0.112 (2.84 mm) 0.110 (2.79 mm)
2 0.114 (2.89 mm) 0.114 (2.89 mm)
3 0.116 (2.95 mm) 0.122 (3.10 mm)
Figure 4.13 Turntable Tilt Measurements
Because the major portion of the measured turntable
tilt results from structural deflection, the total tilt
measurement varies from model to model. For ex-
ample, overall turntable tilt measurements approach-
ing 0.200 (5.08 mm) are not uncommon on some
models, even on bearings which have not reached the
end of their usable life. Severely worn bearings could
have a measured turntable tilt as much as 0.500 (12.7
mm) or more in addition to other prominent symptoms
of wear such as unusual noise and roughness. There-
fore, the total turntable tilt measurement itself should
not be used to gauge a bearings remaining usable life.
The change in turntable tilt and the trend toward
accelerated wear is more important than the total tilt
measurement itself.
Evaluating the feel of the unit
If there is no trend toward accelerated wear, consider
the feel of the unit during load reversals. Operators
may notice an increase in the tilting or rocking of the
turntable.
Checking for rotation bearing noise and roughness
Determine whether there is any presence of rough-
ness or noise in the rotation bearing during rotation.
Severely worn bearings commonly exhibit grinding,
snapping, and popping noises during rotation. These
noises may indicate the bearing has broken ball
spacers, split ball bearings, or excessive galling, the
presence of which would require immediate bearing
replacement. Popping or clicking noises might also be
caused by broken or improperly torqued bearing fas-
teners or a warped mounting surface. A check of the
fastener torque and the rotation bearing grease purged
during lubrication will usually determine if bearing
noise is due to internal or external problems.
Inspecting the condition of the purged bearing grease
Grease from a well worn, poorly maintained, or dam-
aged bearing will typically contain fairly large rust or
metal particles, instead of metal dust specks which
might be found in any bearing. Fairly large rust or metal
particles indicate the bearing has reached an acceler-
ated wear condition and immediate bearing replace-
ment is required. The presence of rust indicates
inadequate lubrication. Rust is commonly indicated
by extremely dirty grease. This situation must be
corrected to optimize the performance of the new
bearing. Always check the purged bearing grease at
each inspection and turntable tilt measurement proce-
dure even if there is no presence of roughness, noise
in the bearing, or significant change in the turntable tilt
measurement.
One or more of these evaluation criteria should detect the
need for rotation bearing replacement long before there is
any threat of failure. By maintaining proper rotation bearing
lubrication and avoiding overload conditions, the replace-
ment rotation bearing should provide many years of
service.
Bearing Inspection and Turntable Tilt Measurement
1. Position the unit on a level surface where the booms
can be elevated and rotated. Apply the parking brake
and chock the wheels.
2. Fully extend all boom sections with the booms near
horizontal. Exact boom position is not critical. Slowly
rotate the turntable 360 degrees using the lower
controls while checking for roughness or noise in the
rotation bearing. Repeat using the upper controls
since roughness may be felt more accurately from the
platform. Note in the maintenance log whether un-
usual noise or roughness was encountered.
3. Test the system pressure and adjust if necessary.
Record the system pressure in the maintenance log.
The system pressure must be correct because changes
in the system pressure will affect the structural
deflection and change the turntable tilt measure-
ments.
4. Rotate the turntable to the position to be used for the
turntable tilt measurement. If the unit is normally
operated within a particular zone of rotation, the tilt
should be measured with the turntable rotated to this
position. For consistent measurement, always use
the same rotational position with no load in the
platform each time the tilt measurement is done.
Record the rotational position in the maintenance log.
5. Fully retract the upper boom. Rotate the turntable to a
position where the boom tip is located under a hoist.
Position a sling and hoist around the boom tip to
support the boom (refer to Figure 4.14).
Figure 4.14 Setup
6. Attach the magnetic base of the dial indicator to the
pedestal, positioning the pointer at either the front or
rear of the turntable. The pointer of the dial indicator
should be positioned against the underside of the
turntable base plate, as close as possible to the
bearing gear cover. Figure 4.15 shows the position for
the dial indicator pointer. It may be difficult to position
the dial indicator and pointer in some zones of rotation
without interference with the turntable or pedestal. In
this case, position the dial indicator and pointer to the
area as close as possible to the recommended posi-
tion. Once a correct indicator pointer position is
chosen, it is very important that the same pointer
position is used for each subsequent tilt measure-
ment. Therefore, record the pointer position in the
maintenance or service log where the tilt measure-
ments are recorded. Some inspectors prefer to perma-
nently mark the location where the dial indicator
pointer contacts the bearing base plate to ensure that
subsequent measurements are made in exactly the
same spot.
Figure 4.15 Pointer Positions
7. With the boom tip supported by the sling and hoist,
slowly lower the boom until the hydraulic system goes
over relief or maximum system pressure is reached.
Set the dial indicator at zero while holding the system
at this pressure.
Boom Horizontal
Sling and Hoist
Rated 2,000 lbs
Upper
Boom Fully
Retracted
Dial Indicator Pointer
C
8. Slowly raise the aerial device until the weight of the
boom is removed from the sling. Record the indicator
reading.
9. Repeat steps 7 and 8 two more times to obtain an
accurate reading.
10. Remove the dial indicator to prevent damage.
Attention
There may be metal particles in the grease. Use a putty
knife to collect and wipe the grease.
11. Stow the booms. Lubricate the bearing to purge some
grease for inspection. Wipe some of the purged
bearing grease, which should be visible around the
inside ring of the bearing, on a piece of clean white or
light-colored paper. Smear the grease on the paper
into a very thin layer using a straight edge such as a
putty knife. Using a bright light, look for metal particles
which are larger than normal specks of metal dust.
Normally, particles large enough to be concerned
about will be felt as a rough spot when smearing the
grease. The smaller, insignificant particles will not
normally be felt under the straight edge. Also, look for
signs of rust which would indicate poor lubrication.
Record information about the condition of the purged
grease in the maintenance log.
a. If there are metal particles found in the grease that
exceed
1
/32 (0.79 mm), the bearing should be
replaced at the next maintenance interval.
b. If there are any signs of rust in the grease, lubricate
the bearing more frequently to purge the old grease
out.
12. Refer to Bearing Replacement Criteria to determine if
bearing replacement is required.
Visual Torque Inspection Procedure
This visual torque inspection is to be performed as
recommended in the Preventive Maintenance and Inspec-
tion Checklist.
Visually inspect both sets of rotation bearing cap screws,
looking for any evidence that a cap screw is loose. Check
for loose washers under the heads of the cap screws by
trying to turn each washer by hand. If movement is
indicated, all the cap screws must be retorqued as
described in the Annual Torque Inspection Procedure.
Insufficient or uneven cap screw tightness may also
contribute to reduced life of the rotation bearing.
Annual Torque Inspection Procedure
This inspection is to be performed annually, or if any cap
screws were found loose during the visual torque inspec-
tion.
Attention
Use an accurate
1
/2 drive click-type manual torque
wrench for the inspection of these cap screws. Torque
the cap screws by applying a smooth pull on the
torque wrench without jerking. Do not overtighten the
cap screws.
It is important that experienced, trained mechanics per-
form this procedure.
Rotation Bearing Torquing Procedure
1. Position the boom so that it is unsupported by boom
rest and as close to a horizontal position as possible.
2. Starting with cap screw number one (refer to Figure
4.16) remove one cap screw at a time. Inspect the
threads of the cap screw and bearing. Coat the cap
screw removed or the replacement cap screw with
thread locking adhesive.
Inner Race Outer Race
Figure 4.16 Cap Screw Torque Pattern
3
7
11
1
9
6
14
13
5
10
2
12
8
4
1 6
4 8
2
7 3
5
3. Torque the cap screw to 100 foot-pounds (136 Nm).
4. Continue until all cap screws have been removed,
inspected or replaced, and reinstalled. Repeat the
torque sequence, torquing each cap screw to 170 foot-
pounds (231 Nm).
Rotation Gearbox Mounting Cap Screws
Special
1
/2 cap screws are used to secure the rotation
gearbox to the turntable. The torque value for the cap
screws is 110 foot-pounds (149 Nm). The cap screws
require special inspection procedures.
Insufficient or uneven cap screw tightness can contribute
to reduced life of the gearbox.
Caution
Attention
Only use Altec supplied cap screws and washers to
install the rotation gearbox.
Use an accurate
1
/2 drive click-type manual torque wrench
for the inspection of these cap screws. Torque the cap
screws by a smooth pull on the torque wrench without
jerking. Do not overtighten the cap screws.
Visual Inspection Procedure
Perform this visual inspection procedure as recommended
in the Preventive Maintenance and Inspection Checklist.
Visually inspect all rotation gearbox cap screws, looking
for any evidence that a cap screw is loose. Check for loose
washers under the heads of the cap screws by trying to
turn each washer by hand. If movement is indicated, all the
cap screws must be retorqued.
Annual Torque Inspection Procedure
Check the cap screws to be sure they are torqued to 99
foot-pounds (134 Nm) or 90 percent of the normal instal-
lation torque of 110 foot-pounds (149 Nm). Use a regularly
calibrated, accurate torque wrench. If one or more of these
cap screws turns before the wrench clicks, retorque all the
cap screws to 110 foot-pounds (149 Nm) using the pattern
shown in Figure 4.17. If the rotation gearbox is replaced or
removed, the same inspection intervals must be followed.
Figure 4.17 Torque Pattern
Lift Mounting Cap Screws
Torque the lift mounting cap screws to the recommended
torque specification. Use the following procedure to check
the torque of the mounting cap screws after the first 30
days of use after the first six months of use, and then with
the annual inspection thereafter.
1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Position the booms in
the rest.
2. Remove and inspect one cap screw at a time.
3. Replace mounting cap screws if any distortion or
corrosion is found.
4. Lubricate the cap screw and torque to specification.
The correct mounting cap screw torque specification
for the unit will be listed on a decal at the pedestal.
5. Mounting cap screws must be replaced every second
inspection.
Cylinders
Lift Cylinder
A visual inspection should include checking for leaks,
loose or missing pin retainers, broken bearings, bent rod,
and dents in the rod or barrel. The counterbalance holding
valve should be checked as recommended in the Preven-
tive Maintenance and Inspection Checklist. This may be
accomplished by positioning the boom to load the cylinder
pressure against the counterbalance valve. Disengage the
hydraulic system and manually move the main control
valve spool manual override pin for the boom down
function to see if the lift cylinder moves.
If the boom does not move, the counterbalance holding
valve is good. If the booms move slowly, the counterbal-
ance holding valve is leaking. If the function moves
without manually pushing the manual override pin to move
the valve spool, the cylinder may be leaking internally.
1
4 2
3
Pivot Pins
At five year intervals, both lift cylinder pivot pins must be
removed, inspected for wear, lubricated, and reinstalled.
Each pivot pin is held in place with a welded flange style
retaining system (refer to Figure 4.18).
Figure 4.18 Pivot Pin Assembly
Warning
Death or serious injury can result from uncontrolled
movement. Properly support the component before
loosening fasteners and removing hydraulic compo-
nents.
Use the following procedure to inspect and lubricate the
pivot pins.
1. Using the lower controls, raise the boom to a position
that allows access to both pivot pins. Support the
boom with a sling and hoist.
2. Use a sling and hoist to support the cylinder
3. Remove the hex head cap screw and lock washer from
one pivot pin at a time.
4. With a large hammer and a brass drift pin, drive out the
pivot pin from the cylinder.
5. Clean and inspect the pivot pin. Measure the pivot pin
at 0.50 increments along the surface. It should
maintain between 0.9985 and 0.9990. If there are
variable readings, replace the pivot pin.
6. Lubricate the pivot pin surface with molybdenum
grease.
7. Install the pivot pin, making sure the welded flange
sets flush against the cylinder anchor. Replace the
cap screw and lock washer with new hardware and
torque to 30 foot-pounds (41 Nm).
8. Repeat the same procedure for the other pin. Only do
one pivot pin at a time.
9. Remove the sling and hoist from the cylinder. Lower
the sling and hoist supporting the boom and remove
the sling and hoist.
Extension Cylinder
A visual inspection should include checking for leaks and
loose or missing pin retainers. The counterbalance holding
valve should be checked as recommended in the Preven-
tive Maintenance and Inspection Checklist. This may be
accomplished by positioning the lower boom in a maxi-
mum up boom angle and then slightly extending the upper
boom. The weight of the upper boom on its extension
cylinder will load the base end of the cylinder and put
pressure against the counterbalance valve. Disengage the
PTO and manually move the main control valve manual
override pin for the upper boom retraction function to see
if the extension cylinder moves.
If the boom does not move, the counterbalance holding
valve is good. If the boom moves slowly, the counterbal-
ance holding valve is leaking. If the function moves
without manually pushing the manual override pin to move
the valve spool, the cylinder may be leaking internally.
Rod End Anchor Cap Screw
1. Extend the upper boom until the access hole on the
bottom of the boom clears the slide blocks.
Warning
movement. Secure the boom before removing the
cylinder mounting pin.
2. Secure the upper boom to restrain it from extending
when the cap screw is removed.
3. Remove the cap screw through the access hole.
4. Inspect the thread condition of the cap screw.
5. Use a new cap screw, or coat the old cap screw with
zinc chromate and allow it to dry.
6. Coat the cap screw with anti-seize compound.
7. Install and torque the cap screw to 75 foot-pounds
(102 Nm).
8. Remove the restraint from the upper boom.
Every second year, or if the clevis anchor cap screw is
found to be loose, the clevis anchor cap screw must be
removed and checked for corrosion. With a light, check the
threads of the anchor. If there is evidence of any interac-
Cylinder
Anchor
Fastener Pivot Pin
Cylinder
tion between the steel cap screw and the aluminum
anchor, both the cap screw and the upper boom must be
replaced.
Leveling Cylinders
A walk-around inspection can be used to visually check for
leaks, loose or missing mounting pin fasteners. Inspect
the cylinders for obvious damage such as broken bear-
ings, dented rod or cylinder barrel, or a bent cylinder rod.
Warning
Death or serious injury can result from cylinder fail-
ure. Do not operate a cylinder that has a dented barrel
or a damaged rod.
To test the upper leveling cylinder, with the hydraulic
system disengaged, place a load on the cylinder using a
come-along to pull on the lower end of the L-bracket. If the
cylinder moves, the seals are leaking and the cylinder
needs to be repaired or replaced. If the cylinder does not
move, push one of the manual override pins on the main
control valve for the stow/unstow function, while pulling on
the L-bracket and watching for cylinder movement. A
change in cylinder position indicates that the holding
valves are not functioning properly.
Hydraulic Lines
Hydraulic hoses and tubes transmit hydraulic oil through-
out the hydraulic system. Inspect all hoses and tubes as
recommended by the Preventive Maintenance and In-
spection Checklist for wear and/or physical damage.
Make sure the hoses are properly routed to avoid sharp
edges, kinking, and scuffing. Inspect the tubes for dents
or other damage that may restrict oil flow. Make sure all
hoses and tubes are held firmly in their support brackets.
Make sure that the hose carrier is firmly secured to the
bottom of the lower boom.
Manual Lowering System
The manual lowering system allows the platform operator
to lower the booms if the hydraulic system should fail.
Lowering is accomplished by operating the emergency
lowering switch at the upper or lower controls.
This system should be tested for proper operation daily.
Fiberglass Platform Care
Cleaning
The outside of the platform may be cleaned as necessary
using a pressure washer and a mild detergent. Rinsing with
clean water will remove any detergent residue. Be careful
not to spray water into platforms equipped with electric
heaters. Water entering under pressure may damage the
heater unit.
Caution
Injury can result from electric shock. Turn off and
unplug the electric heater before cleaning the platform
with water.
Inspection
The fiberglass platform should be inspected for any visible
damage such as scratches, cracks or chips. Repair of
these defects is easy and should be maintained to retain
the cosmetic appearance of the platform.
Repair
The first step in successful repair is to analyze the damage
and determine the cause. Cracks in the gelcoat or outer
surface of the platform are easily repaired. Damage to the
fiberglass structure can be more serious and should be
carefully evaluated before attempting to repair the plat-
form.
The structural integrity of the platform rim or lip, door frame
and bottom is critical in determining whether the platform
can be successfully repaired. The platform bottom, door
frame, part way up the sides from the bottom, and the rim
are substantially thicker than the rest of the platform to
provide structural support. These factors must be consid-
ered when determining whether a successful repair can be
made on or near the platform bottom, door frame, or to the
rim.
Altec cannot make a determination of the repairability of
platforms in the field. An evaluation of whether the platform
can be repaired and safely used for future service must be
determined. Altec does not recommend that repairs be
made to platforms which have any of the damages listed
below.
Cracks through the fiberglass of the rim or lip,
or door frame
Cracks on the floor of the platform around the
mounting point to the L-bracket
If a customer elects to make repairs in any of the non-
recommended areas, a careful evaluation must be per-
formed to assure that the repair will be sufficient to
maintain platform safety and integrity. Altec assumes no
responsibility for platform repair performed by persons
other than Altec personnel. Platforms that are returned to
Altec for repair are evaluated by Altec personnel and then
may either be repaired or scrapped, depending on the
extent of the damage.
The equipment and materials listed below are required to
perform field repair of the platform. Acetone and the
gelcoat repair kit part numbers can be found in Altec
Service Tools and Supplies in the Appendix.
Circular grinder with 24 grit sandpaper
Dual acting sander with 320 grit sandpaper
Cleaning solvent (acetone)
Fiberglass cloth or mat
Gelcoat repair kit
Good quality rubber gloves
Dust mask
Safety glasses
Nonmetallic spray paint (white to match the platform)
The following procedure may be used as a guide in making
a quality field repair.
1. Outline the damage with a box that is one inch wider
on all sides of the damaged area. Example If the
damage is 1 x 3 (25.4 x 76.2 mm), the box would be
3 x 5 (76.2 x 127 mm).
Caution
eyes and lungs. Wear appropriate safety equipment.
2. While wearing the dust mask for breathing protection
and the safety glasses, grind the area within the box
to a depth of approximately
1
/8 (3 mm).
3. Cut strips of fiberglass cloth to fit the box area.
Warning
use and disposal.
4. Clean the area thoroughly with solvent.
5. While wearing rubber gloves, mix the approximate
amount of polyester resin and catalyst according to
the directions in the gelcoat repair kit.
6. While wearing the rubber gloves, saturate the fiber-
glass cloth with the mixed resin and apply it to the
damaged area. Work the area to squeeze out any air
bubbles.
7. After the resin has set up completely, grind off any
rough area or high spots.
8. Mix an additional cup of resin and catalyst according
to the directions in the gelcoat repair kit and apply
smoothly to completely cover the affected area.
9. Sand the area with the dual acting sander and 320 grit
sandpaper.
10. Paint the area to match the platform.
Damage to the gelcoat layer may be repaired using the
instructions that accompany the gelcoat repair kit. This kit
may be ordered from your Altec representative. The
gelcoat is for cosmetic purposes as well as providing a
protective layer of ultraviolet inhibitors. The gelcoat layer
has no inherent strength.
More specific repair information for a particular situation
should be requested from your local Altec representative.
Before making any repair, the structural integrity of the
platform and the safety of the operator must be kept in
mind.
Accident Prevention Signs
This unit was equipped with accident prevention signs at
the time of manufacture. If any of these are lost or become
illegible, obtain replacements from your Altec representa-
tive.
The location, part numbers, and descriptions of all plac-
ards are listed in the Parts Manual. Refer to the Accident
Prevention Signs Diagram for examples of the placards
and their locations.
Accident Prevention Signs Diagram
1
10
9
4
7
6 2
5
7
2 6 4 2 6 4
7
7
2 6 4
8
2** 6** 3**
7**
1
2*
3*
7*
6*
Gravity Level Square
Platform With Access Hole
Square Platform
With Access Hole
End-Mounted
Splicer Platform
Side-Mounted Splicer Platform
Street Side,
Front
and Rear
* Pedestal mounted controls
** Compartment mounted controls
Both Sides
1
2
3
4
TORQUE ALL CAP SCREWS ANNUALLY. REFER TO
991002317 B
* USE FOR CHEVY C3500,60CA, STD & HD "ONLY"
UNIT MOUNTING CAP SCREWS
CLIP. USE CALIBRATED TORQUE WRENCH TO TORQUE NUTS
TURNS, THEN TIGHTEN NUTS UNTIL SNUG AGAINST "U" BOLT
NOTE: TO CHECK TORQUE LOOSEN NUTS 1 1/2 TO 2 FULL
* 3/4" DIA
U-BOLTS
DRY LUBRICATED
REQUIRED TORQUE
3/4" DIA
5/8" DIA
1/2" DIA
SIZE
110 FT-LBS
135 FT-LBS
105 FT-LBS.
60 FT-LBS.
45 FT-LBS.
101 FT-LBS
79 FT-LBS.
CAUTION
5
6
7
8
9
10
Section 5 Hydraulic System 31
Section 5 Hydraulic System
The hydraulic system of this unit is a full flow, open center
system. This system uses a fixed displacement gear-type
pump to provide the hydraulic oil flow. Hydraulic oil flows
continually from the pump, through the valves and back to
the reservoir whenever the pump is turning. A bypass
valve is used to direct the hydraulic oil back to the reservoir
when the pump is turning but no functions are being
operated.
Hydraulic schematic drawings are important tools in un-
derstanding the operation of a hydraulic system. The
symbols identify the flow paths and operation of every
component in the hydraulic system. A thorough under-
standing of these symbols can reduce downtime and can
increase the accuracy of diagnosing malfunctions. The
Appendix identifies basic hydraulic schematic symbols.
Oil Reservoir
The hydraulic oil reservoir holds approximately 7 gallons
(26.5 l) and uses an internal return line filter. The vented fill
cap contains a 10 micron filter element. A wire 30 mesh
strainer screen is located in the fill hole to filter oil being
added to the reservoir. A removable 150 mesh suction
strainer is located in the bottom of the reservoir to filter all
oil leaving the reservoir (refer to Figure 5.1).
Pump
The hydraulic gear type pump may be driven by the vehicle
engine, or an auxiliary engine. The hydraulic system has
been designed for a pump delivery of 2.5 gpm (9.5 lpm) at
2,400 psi (165 bar).
Regardless of how the pump is driven, the pump functions
the same to deliver the proper flow and pressure to the
hydraulic system.
Secondary Stowage DC Pump
The secondary stowage DC pump and motor assembly
has two hydraulic connections: inlet and outlet. The pump
is a fixed displacement pump with an output of 1.2 gpm
(4.5 lpm). The motor may receive its 12 volt DC power from
the vehicle battery or an auxiliary battery.
This pump and motor assembly are intended to be used for
stowing the unit only and are not intended to be used in
continuous normal operation.
Attention
Damage to the pump and motor can result if the DC
pump is operated more than three minutes continu-
ously.
Figure 5.2 Secondary Stowage DC Pump
Valves
When describing hydraulic valves, position identifies the
number of operating positions of the valve spool. A two-
position blocking valve has two operating positions, open
and closed.
Pump
Motor
Figure 5.1 Hydraulic Oil Reservoirs
Strainer
Basket
Suction
Strainer
Post Mount
Strainer
Basket
Suction
Strainer
Bridge Mount
Fill Cap Return Line
Filter
Fill Cap/Return Line
Filter Assembly
32 Section 5 Hydraulic System
The word way identifies the number of ports in a valve
section. A four-way control valve has four ports. One port
is for a pressure connection, one is for a return line
connection, and the other two ports are the working ports.
Main Control Valve
The main control valve module provides for directional
control of the aerial device boom functions and hydraulic
stow/unstow. The control valve has four valve spools and
is located on the side of the pedestal. The valve spools are
spring centered and solenoid actuated in both directions.
The inlet section contains a system pressure relief valve.
This relief valve is factory set to relieve pressure at 2,500
psi (172 bar). A bypass valve is also included in the inlet
valve section to prevent hydraulic oil flow from reaching
the valve spools until a function is operated.
Figure 5.3 Main Control Valve
Relief Valves
Cross-ported pressure relief valves are located in the
stow/unstow circuit of the main control valve. These
valves are used to limit the pressure that can be applied
to the stow/unstow system. Both of the relief valves in the
stow/unstow function have been factory adjusted at 1,000
psi (69 bar) for unstow and 2,000 psi (138 bar) for stow.
Bypass (Dump) Valve
Bypass (dump) valves are used to prevent hydraulic oil
from flowing to components until the flow is needed. The
position of the valve is maintained by spring pressure until
the controlling solenoid is energized to shift the spool.
The bypass (dump) valve is a normally open valve. As long
as the bypass valve is open, pump flow is directed back
to the reservoir. In this position, the aerial device control
valves can not operate because they have no oil flow.
When a function is operated with the control, the bypass
valve is energized. The bypass valve closes, diverting the
oil flow to the main control valve spools. Moving the control
to neutral causes the bypass valve and the control valves
to be deenergized and movement stops.
Figure 5.4 Main System Bypass Valve
Valve Spools
Four valve spools are contained in the main control valve
module and are used for the aerial device functions.
Hydraulic oil flow is controlled by the spool valves to
operate the aerial device rotation, lower boom, upper
boom, and stow/unstow functions.
Figure 5.5 Valve Spool
Manual Lowering Valve
The manual lowering valve is a solenoid operated valve.
Located on the lift cylinder, this valve may be opened to
allow hydraulic oil to bleed off the base of the lift cylinder.
An orifice in the manual lowering valve is used to control
the maximum lowering speed.
Holding Valves
This unit uses holding valves to insure that various
actuators maintain their position under load in the event of
hydraulic line failure. These holding valves block the
hydraulic oil in the actuators to prevent movement. The
types of holding valves used are pilot operated check
valves and counterbalance valves.
Testing of pilot operated check valves and counterbalance
valves is fully described in Section 8 under Hydraulic
System.
Pilot Operated Check Valves
Pilot operated check valves are used to block oil flow out
of the upper platform leveling cylinder. The purpose of the
valve is to allow free flow into the cylinder and block return
flow until an internal pilot piston is hydraulically opened.
Pilot operated check valves are installed in pairs and
cross-ported. Oil sent to one work port of the cylinder is
used to pilot open the check valve for the other work port
of the cylinder.
Counterbalance Valves
Counterbalance valves block flow out of the lift cylinder
(boom lower only).
A counterbalance valve is a combination check valve and
relief valve. The check valve allows free flow into the
actuator and blocks the flow from coming back out.
The relief valve function can be pilot operated to allow flow
out of the function. It also allows the valve to relieve
excess pressure and prevents damage from thermal
expansion of the oil, or from moving a cylinder without a
path for the oil to flow.
Counterbalance valves are installed in pairs and cross-
ported. Oil sent to one side of the cylinder is used to pilot
open the counterbalance valve on the other side of the
cylinder.
The dual counterbalance valves used in the leveling
system are installed in a manifold block mounted in the
turntable. These valves allow the operator to unstow the
boom without first tilting the platform down.
Load Holding and Regenerative Valve
A valve block is part of the upper boom extension cylinder.
This block contains a counterbalance holding valve and a
shuttle valve. The counterbalance valve is installed in the
system on the extend side of the cylinder. This valve
protects the system from rapid lowering in the event of a
hydraulic hose failure. The pilot operated check valve is
used to prevent the extension cylinder from extending
while the unit is in motion, such as during road travel.
The shuttle valve also allows hydraulic oil exhausted from
the rod end of the cylinder to be directed back into the
pressure line to help extend the cylinder. Regenerative
systems such as this, allow extension and retraction
speeds to be approximately the same even through the
area of the piston on the extend side is greater than the
area on the retract side.
Cavitation and Aeration
Cavitation and aeration are two conditions that can cause
pump and other component damage, as well as poor
hydraulic system performance. Pump cavitation occurs
as a result of inlet oil not entirely filling the cavities that
open during the intake part of the pumping cycle. When the
oil cannot completely flood the pump suction cavities, a
partial vacuum is formed in the pump. The characteristic
sound of cavitation is a high pitched scream. This sound
increases with the degree of cavitation and increased flow.
The primary cause of pump cavitation is insufficient flow
of oil to the pump inlet, which can be caused by the
following conditions.
Excessive pump operating speed
Clogged magnetic suction strainer
Excessive oil viscosity
Restrictions or sharp bends in inlet hose
Excessive inlet hose length
Reservoir level too low relative to the pump inlet
Shutoff valve in suction line not fully open
Attention
Cavitation can quickly destroy the pump. If signs of
pump cavitation are noticed, determine the cause and
promptly repair the problem.
If pump cavitation is due to excessive oil viscosity caused
by cold temperatures, allow the oil to warm up before
operating the unit. If pump cavitation occurs when the oil
is warmed, stop the pump immediately and check the
system carefully for any of the other conditions noted.
Correct the condition before operating the pump.
Aeration occurs when air bubbles are introduced into the
hydraulic oil and carried along as the oil flows through the
pump. Aeration can be caused by the following conditions.
Low oil level in the reservoir. This can cause a
whirlpool at the suction line opening, which can draw
air into the system along with the oil.
Leaking connections in the suction line between the
reservoir and the pump.
Return line outlet is located above the oil level in the
reservoir. This can cause aerating turbulence as the
return oil stream discharges above the surface of the
oil.
Loose connections in the pressure system will nor-
mally leak externally during unit operation The system
may draw air into the system after the unit is shut down
as the oil moves to the low points of the system.
Hydraulic lines, which have been taken loose during
maintenance operations, will contain air until it is
purged out of the system.
Attention
Air circulating through the pump can cause unit
malfunctions or pump damage. Determine the cause
and repair the problem.
An air leak in a suction line can occur even if there is no
oil leakage when the system is shut down. A suction line
leak can often be located by slowly squirting clean
hydraulic oil around each connection in the suction line,
with the pump running at normal operating speed. A
suction leak will draw oil in to the joint, and the pump may
temporarily run quietly as the oil seals the air leak.
Aeration may be indicated by a noisy pump, unusual
hissing noise in the hydraulic lines, or foamy oil in the
reservoir.
Air Bleeding
The presence of air in the hydraulic system will cause
abnormal operation, noise, and damage to the pump.
Attention
Air circulating through the pump can cause unit
malfunctions or pump damage. Determine the cause
and repair the problem.
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.
Platform Leveling Bleeding Procedure
1. Start with the boom fully lowered so the lift cylinder is
fully retracted.
2. Stow and unstow the platform three times.
3. Raise the unit approximately 20 degrees.
4. Stow and unstow the platform three times.
5. Repeat until the boom is fully raised. Lower the boom
and test for function.
If space limitations restrict raising the boom, the system
may be bled using the following procedure.
1. Start with the boom fully lowered so that the lift
cylinder is fully retracted.
2. Disconnect the master cylinder rod end from the
boom.
Warning
Death or serious injury can result from hydraulic oil
being injected into the flesh.
Seek immediate medical attention if injured by escap-
ing hydraulic oil. Serious infection or reaction can
result if medical treatment is not given immediately.
work areas clean.
3. Stow the platform fully. With the platform fully stowed
and the power unit still engaged, crack the pressure
line at the platform slave cylinder. Allow fluid to run
into a container until it runs clear with no air bubbles.
Tighten the fitting while the line is still under pressure.
4. Unstow the platform and crack the pressurized line on
the slave cylinder. Allow the fluid to drain into a
container until it runs clear. Tighten the line while it is
still under pressure.
5. Connect the master cylinder rod end to the boom. Fill
the reservoir fluid level up to the midpoint of the sight
glass.
Leakage
If components and connections are installed properly,
leakage can be kept to a minimum. Small external leaks
are usually easy to find because dust will collect on the
hydraulic oil film.
External leakage is the escape of hydraulic oil outside the
hydraulic system. Fittings that are improperly tightened
are the primary cause of external leakage. Follow the
torque and tightening specifications to properly tighten
hydraulic fittings.
Warning
being injected into the flesh. Do not use hands or other
body parts to check hydraulic lines and fittings for
leads.
Seek medical attention if injured by escaping hydrau-
lic oil. Serious infection or reaction can result if
medical treatment is not given immediately.
work areas clean.
If a connection is properly tightened but continues to leak,
disassemble the connection. Seal the necessary parts
and/or replace the defective part.
Worn or damaged parts can also cause leakage. For
example, scratched cylinder rods, worn or scratched
output shaft on hydraulic motors or pumps or scratched
fittings can cause leakage. Such conditions must be
repaired or replaced. New seals should always be installed
when repairing components.
Internal leakage allows pressurized hydraulic oil to escape
to tank or another hydraulic circuit. Most hydraulic compo-
nents have a small amount of internal leakage due to
machining tolerances.
An internal leak can cause a variety of problems in a
hydraulic system. An internal leak in a cylinder can cause
cylinder drifting or malfunction. Internal leakage can usu-
ally be stopped by replacing the seals in the leaking
component.
A leaking holding valve in a cylinder can cause cylinder
drifting or malfunction. It may be stopped by replacing the
holding valves in the component. However, some types of
damage, such as scoring of the inside of a cylinder barrel,
require more extensive repair.
Heat Generation
Heat is generated in the hydraulic system as pressurized
fluid moves through restrictions. Most hydraulic compo-
nents have a small amount of leakage due to machining
tolerances. This type of leak generates a small amount of
heat that is accounted for in the design of the hydraulic
system.
Internal leaks in the system may be caused by internal
housing cracks, malfunctioning or improperly adjusted
relief valves, or leaking seals. This type of leak allows a
large volume of pressurized oil to return to the reservoir,
creating excessive heat in the hydraulic system. Continu-
ous operation with excessive heat will damage the hydrau-
lic oil, seals, and O-rings throughout the system.
The following conditions cause heat generation.
Excessive pump speed
Worn or defective pump
Defective relief valve
Improperly adjusted relief valve
Contaminated control valve spool
Low hydraulic oil level
Improper hydraulic oil
Internal component leakage
Hydraulic Lines
Hoses and tubes (generally referred to as hydraulic lines)
connect various hydraulic system components.
Most hoses have a lay line on them. Hose manufacturers
apply the lay line to ribbon hose assemblies after the
bonding process is completed. The lay line contains the
following information about the hose.
Unit manufacturers name
Unit manufacturers part number
SAE rating
Working pressure
Burst pressure (sometimes)
For some hose assemblies, the hose manufacturer bonds
individual thermoplastic hydraulic hoses and electrical
conduit into ribbon hoses. These hose assemblies are
installed in the booms to conduct hydraulic oil and electri-
cal wires from the turntable through the booms to the upper
boom tip. Wires are installed in electrical conduit that is
made of the same jacket material as the hydraulic hoses,
but without the plastic hose core and braided reinforce-
ment. The hose assembly rolls and unrolls inside the
booms as the booms are extended and retracted, eliminat-
ing the need for hose carriers.
When replacing a hose or tube with a different diameter
part, consider the effect the change will have on the
hydraulic system. If hose size is doubled, four times the
amount of oil will flow at the same pressure. If the hose
size is decreased by half, four times less oil will flow at the
same pressure. If the flow remains the same for a smaller
hose an increase in back pressure will result. The increase
in back pressure will cause heat to build up in the system.
When replacing a hose or tube, it is best to use a
component of the same diameter and length.
Warning
movement. Purge the air from the actuator before
operating the unit.
being injected into the flesh when loosening or dis-
connecting hydraulic components. Remove the pres-
sure before loosening or disconnecting hydraulic
components.
work areas clean.
After removing a hydraulic line from a cylinder, do not
operate the unit from the upper controls until all air is
purged from the cylinder after the hydraulic lines are
reinstalled. The presence of air in the cylinder may cause
inadvertent retraction or extension of the cylinder, result-
ing in death or serious injury.
Caution
Remove all pressure from hydraulic circuits before discon-
necting lines or fittings.
Mark all hydraulic line fittings before disconnecting them
to ease installation later. Place a container under the
hoses to catch the hydraulic oil. Cap or plug all open ports,
hoses, and fittings to prevent contamination.
Warranty will be denied on components returned to Altec
if ports are not plugged and cylinder rods are not retracted.
Properly torque all connections. Refer to the Torque and
tightening procedures in this section.
After completing a procedure, check the oil level in the
hydraulic oil reservoir and add oil if necessary.
Fittings and Valve Cartridges
Most hydraulic ports and fittings are SAE straight thread
O-ring or 37 degree flared JIC straight thread. These types
of fittings provide a good seal and resist vibration.
Use the proper torque and tightening specifications when
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 to a
torque value less than the specified torque value may
cause a leak. Tightening the cartridge to a torque value
more than the specified torque value can damage the
valve, valve body, or bind internal parts. A damaged valve
may not function properly.
Torque and Tightening Procedures
Overtorquing a component can distort the part and cause
a leak. When a leaking fitting is found, determine if the
fitting is tight. If it is not, torque the fitting to the proper
value. Replace the fitting if it will not stay tight.
If the fitting is tight, stop the unit, determine the cause of
the leak and take corrective action. When making a
connection that uses a swivel nut, use one wrench to hold
the component to which the hose is connected and another
wrench to turn the nut. The use of two wrenches prevents
damage to the sealing surface of the JIC connections and
hose twisting. Subjecting a twisted hose to normal operat-
ing pressure can cause premature failure.
The following procedure describes proper torque and
tightening procedures for various types of hydraulic fit-
tings. Refer to Torque Values in the Appendix for the
appropriate torque chart.
Warning
use and disposal.
Tapered Pipe Thread Fittings
1. Clean the male fitting threads with a cleaning solvent.
2. Apply pipe sealant to the male threads of the fitting,
being careful not to get sealant on the first two male
threads. Apply enough sealant to form a ring of sealant
on the outside of the connection when the threads are
tightened into the mating body.
3. Screw the fitting into the mating part and finger tighten.
4. Turn the fitting with a wrench the appropriate turns
from finger tight (T.F.F.T.). Verify that the opposite
end of the fitting or component is properly oriented.
5. Follow the sealant manufacturers directions for cure
time. The ring of sealant described in step 2 will not
completely harden.
SAE O-Ring Fittings With Self-Locking Nuts
1. Lubricate the O-ring and threads with hydraulic oil or
light grease, such as petroleum jelly.
2. Screw the fitting into the SAE straight thread boss
until the backup washer bottoms out on the boss face
with the O-ring squeezed into the boss cavity.
3. Unscrew the fitting (maximum of one full turn) to align
the fitting with the mating part.
4. Tighten the self-locking nut with a wrench and torque
to the proper value for the size and material (stainless
steel or brass) so the backup washer contacts the
boss face.
SAE O-Ring Fittings Without Self-Locking Nuts
1. Lubricate the O-ring and threads with hydraulic oil or
2. Turn the fitting in full length until finger tight.
3. Tighten the fitting with a wrench to the proper torque
value.
Tube and JIC Fittings
1. Clean the male threads of the fitting with a cleaning
solvent.
2. Tighten the nut finger tight until it bottoms out on the
flare seat. It may be necessary to wiggle the hose or
component while turning the nut to verify that the
fitting contacts the flare seat.
3. Using a felt tip pen or marker, mark a line lengthwise
on the nut and extend it onto the adapter body.
4. Determine the proper number of hex flats the nut must
be turned with a wrench. Refer to Torque Values in the
Appendix for proper torque values and an illustration
of this procedure.
5. Using a wrench to hold the adapter body, rotate the nut
with another wrench the proper number of hex flats.
Use the marks to count the proper number of hex flats
to turn the nut. The marks also serve as a visual
indicator that the fitting has been properly tightened.
Four-Bolt Split Flange Assembly
SAE Code 61 (3,000 psi)
1. Clean the sealing surface of any burrs, scratches or
foreign particles.
2. Lubricate the O-ring with hydraulic oil or light grease.
3. Position the flange and clamp halves. Put the cap
screws with lock washers in place (refer to Figure 5.6)
and hand tighten the cap screws.
Figure 5.6 Four-Bolt Flange Assembly
4. Follow the pattern in Figure 5.4 to torque the cap
screws in place.
Figure 5.7 Four-Bolt Flange Torque Pattern
5. Tighten each bolt to half the final torque desired.
Finish the procedure by tightening all bolts to the final
value, following the sequence shown in Figure 5.7.
Valve Cartridges
1. Clean the male threads of the cartridge with a cleaning
solvent.
2. Lubricate the threads and O-ring with hydraulic oil or
3. Turn the cartridge by hand until finger tight.
4. Tighten the cartridge with a calibrated torque wrench
to the proper value.
Cylinders
Hydraulic cylinders operate the booms, and platform
leveling system.
Cylinders use holding valves to maintain their position in
the event of hydraulic line failure. The boom lift and upper
platform leveling cylinders use counterbalance valves.
Holding valves may be installed in cavities machined
directly into the cylinders or may be installed in valve
blocks connected to the cylinder or directly mounted on
the cylinder.
All cylinder rods are chrome plated to prevent rust and
corrosion. The chrome plating also provides a smooth
surface for the end gland bearing and seal.
Warning
movement. Use a sling and hoist of adequate capacity.
ure. Do not operate a cylinder that has a dented barrel
or a damaged rod.
O-Ring
Flange Clamping Bolt
Split
Clamp
Half
Lock
Washer
ure. Never reuse a self-locking piston nut or retention
device.
ure. Properly install and torque a piston nut or gland
retention device.
being injected into the flesh. Properly cap or connect
hydraulic lines before operating the unit.
components.
work areas clean.
movement. Purge the air from the actuator before
operating the unit.
Caution
Pinch points exist at both ends of the cylinder. Be
extremely careful when removing or installing cylinders.
Never install a cylinder with side pressure on the rod. Do
not operate a cylinder if the cylinder barrel is dented or if
the rod is damaged.
Altec does not recommend repairing cylinders in the field.
Most repairs require cylinder disassembly which should be
done in a clean, properly equipped shop. The Parts Manual
contains a drawing of each cylinder. The drawing lists the
Altec part numbers for the seal kits and provides torque
specifications for piston nuts and end glands.
Hydraulic cylinder piston nuts and end glands must be
torqued to the proper values at assembly. Many piston
nuts and end glands have retention devices, such as
cotter pins and set screws. These retention devices must
be installed properly.
If the internal size tolerance of the cylinder barrel is
exceeded, the piston seal could be pushed out when the
cylinder is put under a load. This will cause cylinder failure.
After reconnecting a hydraulic line from any cylinder,
extend and retract the cylinder five to six times to purge the
air out of the cylinder and to check for hydraulic leaks.
Mark all hydraulic line fittings before disconnecting them
to ease installation later. Place a container under the
hoses to catch the hydraulic oil. Cap or plug all open ports,
hoses, and fittings to prevent contamination.
Warranty will be denied on components returned to Altec
if ports are not plugged and cylinder rods are not retracted.
Properly torque all connections and cap screws. Refer to
Torque and Tightening Procedures in this section.
After completing a procedure, check the oil level in the
hydraulic oil reservoir and add oil if necessary.
After replacing a major component, such as a lift cylinder,
perform a structural test as described in Section 9.
Extension Cylinder
Removal
1. With the boom in a horizontal position, extend it until
the cylinder rod end mounting access hole in the
bottom of the upper boom is visible.
Warning
3. Remove the rod end cylinder attachment cap screw
through the access hole.
4. At the base of the lower boom, remove the hose guard.
Warning
components.
cause personnel to slip and/or fall. Deep the unit and
work areas clean.
5. Mark and remove the hoses attached to the extension
cylinder.
6. Remove the four mounting cap screws from the swivel
plate at the base of the lower boom.
7. Remove the restraint and slide the extension cylinder
out through the base of the lower boom.
Warning
Installation
1. Slide the extension cylinder through the back of the
lower boom. Align and guide the extension cylinder
slide block through the base of the upper boom.
2. Install the swivel plate mounting cap screws. Torque
the cap screws to 70 foot-pounds (95 Nm).
3. Connect the hydraulic lines to the extension cylinder
holding valve.
4. Install the hose guard.
5. Extend the extension cylinder until the rod end aligns
with the access hole.
Attention
The cylinder attachment cap screw has a special
coating to inhibit the fusion of the steel cap screw with
the aluminum upper boom. Never replace this cap
screw with untreated hardware.
6. Coat the cap screw with zinc chromate and allow to
dry. Coat the cap screw with anti-seize compound and
torque the cap screw to 75 foot-pounds (102 Nm).
Extension Cylinder Holding Valve
Removal
1. With the booms in a horizontal position, extend the
boom until the extension cylinder rod end mounting
access hole is visible under the upper boom.
2. At the rear of the lower boom remove the cable guard
plate.
Warning
components.
cause personnel to slip and/or fall. Deep the unit and
work areas clean.
3. Mark and remove the hoses from the holding valve
fittings.
Figure 5.8 Extension Cylinder Holding Valve
Warning
cylinder mounting fasteners.
when the cap screws are removed.
5. Remove the swivel plate mounting cap screws.
6. At the platform, push the upper boom in until the
holding valve clears the base end of the lower boom.
7. Remove the holding valves from the valve block on
the cylinder.
Installation
1. Install the holding valves into the valve block and
torque them to 30-35 foot-pounds (40-47 Nm).
Extension Cylinder
Holding Valve
2. At the platform, push out until the swivel plate seats
against the lower boom.
3. Install the swivel plate attachment cap screw and
torque to approximately 70 foot-pounds (95 Nm).
4. Connect the hoses and install the hose guard.
5. Purge the air from the system by extending and
retracting the boom fully. Check the hydraulic oil level
in the reservoir with the boom fully retracted and in the
boom rest. Check the hoses and valve for hydraulic
leaks.
Lift Cylinder
Removal
1. Raise the boom to approximately 45 degrees.
Warning
2. Support the boom with an overhead hoist or jack with
a minimum of a one ton (907 kg) rated capacity.
3. Remove the rod end pin.
4. Supporting the lift cylinder. Raise the boom with a
hoist or jack, or operate the Down function.
5. Disconnect the hoses from the cylinder.
6. Remove the pin at the base of the cylinder and remove
the cylinder.
Installation
1. Slide the cylinder into the attachment on the turntable.
2. Install the base end cylinder pin.
3. Connect the hydraulic hoses.
4. Align the rod end with the cylinder mounting weldment
of the lower boom. Either extend the cylinder by
actuating the out function or lower the boom with the
hoist or jack. Install the rod end pin.
5. Lubricate both pins.
6. Operate the unit for function.
Elevation Cylinder Holding/
Emergency Lower Valves
Removal
1. Raise the boom to approximately 45 degrees.
Warning
2. Support the boom with an overhead hoist or jack with
a minimum of one ton (907 kg) rated capacity.
Warning
nents.
Never remove the cylinder holding valve or emergency
lower valve if the lift is not supported by a jack or overhead
hoist.
3. If removing the emergency lower valve, disconnect
the wires from the solenoid.
4. Remove the valve cartridge from the cylinder.
Installation
1. Lubricate the valve cartridge O-ring liberally with
hydraulic oil.
2. Install the cartridge into the cylinder and torque to
approximately 30 foot-pounds (40 Nm).
3. Raise and lower the boom to achieve full stroke of the
elevation cylinder.
4. Inspect for leaks.
Section 6 Mechanical Systems 41
Section 6 Mechanical Systems
A mechanical system consists of the unit components
arranged so the motion of one mechanically moves the
other. Examples of mechanical components are the rota-
tion bearing, rotation gearbox, and the booms. Mechanical
components may be moved by each other or by hydraulic
or electric actuators.
When welding on the unit, a welding ground clamp must be
attached to the same structure on which the welding is
being performed. This is necessary to prevent electrical
current from being sent through components.
Components such as wire braid hoses, hydraulic cylin-
ders, electrical wires, and electronic assemblies can be
damaged by electrical current. Electrical current flowing
through a component can be very intense, causing serious
internal damage to the component.
Follow this list of safety procedures when servicing the
unit.
1. Select a work site large enough to operate the required
functions.
brake, and chock the wheels. Check the hydraulic oil
level with the vehicle engine turned off.
Warning
3. Use a hoist to safely support heavy components
before loosening the fasteners on that component.
Warning
components.
work areas clean.
4. Never loosen or remove a pressurized hose or fitting.
5. Mark all hydraulic hose fittings and electrical connec-
tors before disconnecting them to ease installation
later. Place a container under the hoses to catch the
hydraulic oil. Cap or plug all open hydraulic ports
immediately. Warranty will be denied if components
are received with open ports.
6. After reconnecting a hydraulic line, operate the con-
trols in the system five to six times to purge the air out
of the system and to check for hydraulic leaks.
7. Properly torque all hydraulic connections and compo-
nents. Refer to Section 5 under Torque and Tightening
Procedures.
8. Properly torque all cap screws. Refer to the Appendix
for proper torque values.
9. Perform a structural test as described in Section 9
after replacing a major component. Hydraulic cylin-
ders, pivot pins, rotation bearing, and leveling system
components are examples of items that require test-
ing after installation.
Caution
Use extreme caution when access covers have been
removed to service the unit. Pinch points and shear points
may exist between moving parts. Replace the access
covers immediately after servicing.
Rotation System
The turntable rotates on a shear ball bearing. The inner
race of the bearing is fastened to the turntable and the
outer race is fastened to the pedestal. Teeth have been cut
on the outer race of the bearing.
The rotation drive gearbox is a hydraulic motor driven
worm gear. This gearbox is mounted inside the turntable.
The gearbox output shaft or pinion passes through a hole
in the turntable and meshes with the teeth on the outer race
of the rotation bearing. The turntable is rotated as the
gearbox output shaft drives the outer race.
Rotation Bearing
The rotation bearing is fastened to machined surfaces of
the pedestal and turntable with high strength alloy cap
screws. This bearing will provide many years of service if
it is properly maintained.
The rotation bearing has been designed and manufactured
with tightly controlled internal clearances to provide smooth
rotation with low torque requirements. The useful life of the
bearing will be increased with proper lubrication, no over-
42 Section 6 Mechanical Systems
loading and by keeping the cap screws torqued to the
proper value. The area inside the turntable should be kept
free of debris to prevent a buildup of contaminants at the
seal area of the bearing. Bearing life will be severely
shortened if the seal is damaged.
Caution
A hoist or other lifting device of suitable capacity will
be required to support the turntable and booms during
this procedure.
Rotation Drive Gearbox
The rotation drive gearbox is a single reduction worm shaft
and worm gear that is driven by a hydraulic motor. The
gearbox may also be rotated with a wrench placed on the
extension shaft opposite the hydraulic motor.
During operation, the hydraulic motor drives the worm
shaft which in turn drives a worm gear that is keyed to the
output shaft. The output shaft is equipped with gear teeth
that mesh with the gear teeth on the rotation bearing.
The worm shaft is supported by a tapered roller bearing on
each end of the shaft assembly. The output shaft also has
a tapered roller bearing on both the output and opposite end
of the worm gear shaft assembly. Shaft seals are located
at the pinion output shaft and both ends of the worm gear
shaft. Also a gasket prevents leakage between the hy-
draulic motor and the gearbox.
The largest single cause of leaking seals in the rotation
gearbox is a plugged vent. The vent is designed to open
when the pressure inside the gearbox exceeds the spring
tension of the vent. If the vent becomes dirty and plugs up,
it may fail to open, causing the gearbox pressure to
increase enough to force the lubricating grease past the
seals. Improper installation of the tapered roller bearings
is also a major cause of seal and bearing failure.
Removal
Warning
movement. Secure the booms before removing the
gearbox.
1. With the boom in the rest and secured, disconnect and
remove the motor from the gearbox.
2. Remove the gearbox mounting cap screws and re-
move the gearbox.
Installation
1. Align the pinion gear with the ring gear and slide the
gearbox into place.
Warning
movement. Do not operate the rotation motor while the
hand crank is attached to the gearbox.
2. Align the gearbox with the mounting holes. Rotate
using the manual hand crank on the square stud if
necessary. Remove the crank when finished.
3. Remove the gear guard below the turntable.
4. Clean and coat the mounting cap screws with thread
locking adhesive. Turn all cap screws in until they
touch.
5. Using a spanner wrench apply enough tension to
insure full engagement of the gears.
Torque each mounting cap screw to 75 foot-pounds (102
Nm). Repeat the procedure and torque each cap screw to
110 foot-pounds (149 Nm).
Figure 6.1 Rotation Gearbox Bolt Torque Pattern
7. Lubricate the gears with an open face gear lubricant
and install the gear guard.
8. Install the motor.
9. Start the generator and test for proper rotation.
10. With the platform lowered to ground level, place a foot
at the center line of the platform. Applying approxi-
mately 30 pounds of pressure, rock the platform back
and forth. If the platform moves more than 12 inches
(30 cm) to one side from the center line, repeat steps
5 through 9.
Booms
Upper Boom
For normal maintenance practices the upper boom will not
need to be removed. If it does become damaged and
needs to be replaced, the following procedure may be
followed.
1
4 2
3
It is recommended that the platform be removed before
attempting to remove the upper boom. Refer to Platform
Assembly for instructions on removing the platform. A
hoist or suitable lifting device with a minimum of 1,000
pounds capacity is recommended for removing the upper
boom.
Upper Boom
Removal
brake, and chock the wheels.
2. Remove the platform.
3. Engage the hydraulic system. Fully extend the boom.
Disengage the hydraulic system and turn off the
engine.
Warning
5. Through the access hole on the bottom side of the
upper boom, remove the extension cylinder rod end
mount cap screw.
6. Retract the cylinder rod by operating the In function
switch.
7. Remove the slide blocks at the end of the lower boom.
8. Remove the cable guard from beneath the lower
boom.
9. Disconnect the cables, hydraulic and pneumatic
hoses, and the plastitrack cable guard anchor plate.
10. Pull the plastitrack cable guard, cables, and hoses
straight out to the rear inside the lower boom.
Warning
11. Remove the upper boom by sliding it out the front of
the lower boom.
Installation
1. Align the upper boom with the lower boom and insert
the plastitrack.
2. Slide the upper boom in until it is just short of the
extension cylinder.
3. Lift the extension cylinder up to a level where the
support slide block aligns with the opening in the rear
of the upper boom.
4. Slide the boom past the extension cylinder support
slide block.
5. Make the bend in the plastitrack cable guard and insert
the cables and hoses through the hole in the bottom
of the lower boom.
6. Install the plastitrack anchor nuts. Connect the cables
and hoses. Install the cable guard.
Attention
Do not exceed 70 inch-pounds of torque when install-
ing slide block retaining cap screws.
7. Install the slide blocks at the end of the lower boom.
8. Extend the extension cylinder until the rod end aligns
with the access hole in the upper boom.
Attention
The cylinder attachment cap screw has a special
coating to inhibit the fusion of the steel cap screw with
the aluminum upper boom. Never replace this cap
screw with untreated hardware.
Figure 6.2 Extension Cylinder Rod End Attachment Access Hole
Access Hole in the
Bottom of the Boom
Upper Boom
Extension Cylinder
9. Coat the cap screw with zinc chromate and allow to
dry. Coat the cap screw with anti-seize compound and
torque the cap screw to 75 foot-pounds (102 Nm).
10. Install the platform.
Platform Assembly
End-Mounted Platform
Removal
2. Extend and lower the boom to place the platform as
close to the ground as possible.
3. Remove all tools and equipment from platform.
4. Turn the master switch to the Off position.
5. Remove the covers from the platform attachment
weldment.
6. Disconnect and support the slave cylinder.
7. Remove the cotter pin and castle nut on the trunnion
shaft.
8. Supporting the platform, remove the trunnion shaft.
Installation
1. Lubricate the trunnion shaft with a light bearing grease.
2. Position the platform and insert the trunnion shaft.
3. Turn the castle nut onto the trunnion shaft until it
bottoms out against the retainer plate. Turn the castle
nut out until the second set of ears align with the cotter
pin hole. Make sure the platform retainer plate pivots
freely. If necessary, turn the castle nut out until the
next set of ears align with the cotter pin hole.
4. Install a new cotter pin.
5. Connect and lubricate the slave cylinder.
6. Install the covers.
7. Operate the upper controls for proper operation.
Side-Mounted Platform
Removal
2. Extend and lower the boom to place the platform as
close to the ground as possible.
3. Remove all tools and equipment from the platform.
4. Turn the master switch to the Off position.
5. Disconnect and support the slave cylinder.
6. Remove the cotter key and castle nut from the
platform trunnion shaft.
7. Remove the platform.
Installation
1. Lubricate the trunnion shaft with a light bearing grease.
2. Slide the platform trunnion shaft through the support
bearings of the upper boom.
3. Turn the castle nut onto the trunnion shaft until it
bottoms out against the retainer plate. Back the castle
nut out until the second set of ears align with the cotter
pin hole. Make sure the platform retainer plate pivots
freely. If necessary, turn the castle nut out until the
next set of ears align with the cotter pin hole.
4. Install a new cotter pin.
5. Connect and lubricate the slave cylinder.
6. Test the upper platform controls for proper operation.
Plastitrack/Boom Cables
Removal
2. Extend the boom fully. Turn the master switch to the
Off position.
3. Remove the cable guard beneath the lower boom.
4. Disconnect the cables, hydraulic and pneumatic
hoses, and the plastitrack anchor nuts.
5. Pull the plastitrack, cables, and hoses straight out to
the rear inside the lower boom.
Attention
Installation will be eased if all wire labels are intact. In
the event that the cables are to be replaced, cut each
wire so the wire label remains attached to each com-
ponent on the control pod. This provides markers to
install the new cable.
6. Remove the upper control assembly. Disconnect all of
the wires and hoses.
7. Remove the cable clamps. Attach a fish line to the
cables.
8. At the plastitrack attachment point on the base of the
upper boom, insert a screw driver and gently pry in
while twisting the plastitrack until the plastitrack
snaps loose.
Figure 6.3 Plastitrack Attachment Point
9. With the plastitrack on its side so that it will bend
toward you, remove it through the side of lower boom.
Installation
1. Before installing the plastitrack/boom cables, check
cable and hose position to be sure it conforms with
Figure 6.4. Failure to do so may result in shortening
the useful life of the cables. Tie wrap the cables and
hoses where they will lay in the upper boom. Failure to
do so may result in a pinched cable or hose between
the extension cylinder slide block and the guide track.
2. Tie the fish line around the upper control end of the
cables and wrap with tape.
Figure 6.4 Cable/Hose Alignment
(viewed at the upper boom attachment)
3. Pull the cables back through the boom, feeding the
cables and plastitrack through the same lower boom
access hole they were removed from.
4. Snap the plastitrack into the mount on the base of the
upper boom.
5. Look through the upper boom to assure that the
cables and hoses are not protruding over into the
extension cylinder slide block side of the upper boom.
Reposition the cable if necessary.
6. Replace the cable clamps securing the cables to the
upper boom.
7. Install the upper control assembly.
8. Feed the cables and hoses through the hole in the
bottom of the lower boom. Secure the plastitrack
anchor nuts, and connect the cables and hoses.
9. Install the cable guard.
10. Test all controls and receptacles for proper operation.
Upper Boom
Plastitrack
Attachment
UQ Cable
N Hydraulic
Hose
U Hydraulic Hose
Air Hose
UR Cable
Section 7 Electrical System 47
Section 7 Electrical System
Electrical power is used on the unit to operate the sole-
noids that in turn shift the hydraulic valve spools to operate
the unit. Electrical power is also used to operate the start/
stop system and the secondary stowage DC pump. Power
may be supplied from the vehicle battery while the vehicle
engine is running or from an auxiliary power source. A
comparison may be made between electrical and hydrau-
lic components that may be more familiar to a hydraulic
equipment mechanic (refer to Figure 7.1).
Caution
Injury can result from electric shock. Severe arcing
can occur when working with electrical systems.
Care must be taken when cleaning the unit, not to direct
high pressure steam or water spray directly on the relays,
terminal block assembly, control panels, etc. High pres-
sure washing or steam cleaning may damage the integrity
of electrical components.
After cleaning it is recommended that the relay and
terminal block contacts be cleaned with an electrical
contact cleaner and then sprayed with a protective silicon
based coating. Refer to Altec Service Tools and Supplies
in the Appendix for products to use when servicing
Function Performed
Source of energy or power
Creates a potential energy difference between two points in
a system
Allows potential energy to become kinetic and do useful
work
Transmits power from place to place
Protects system from overload
Allows power to flow in one direction but not the other
Blocks power or allows it to flow
Varies the amount of power which passes through it de-
pending upon the distance the control handle is moved
Restricts the flow of power
Allows power to flow through upon receiving a signal from
another source
Causes axial movement of its central element when power
is applied to it
Transmits power through a continuously rotating connection
Hydraulic Component
Pump
Pressure
Oil flow
Hose or tube
Relief valve
Check valve
Shutoff valve
Control valve
Orifice
Pilot operated
check valve
Cylinder
Rotary joint
Electrical Component
Battery
Voltage
Current
Wire
Fuse or circuit breaker
Diode
Switch
Controller
Resistor
Relay
Solenoid
Slip ring assembly
Figure 7.1 Electrical/Hydraulic Comparison
electrical components. Electrical system cleaners and
protectants should only be used in well ventilated areas
following the manufactures directions for their use.
A basic understanding of electrical system components
and system failures will aid in troubleshooting the units
electrical system.
Circuit Protection
Self-resetting thermal circuit breakers are used in the
electrical system to protect wiring and components from
excessive current flow. These circuit breakers reset within
a few minutes after the electrical overload is removed.
Attention
If a circuit breaker trips repeatedly, determine the
cause of the problem and correct it. If the problem is
not corrected, serious damage to the electrical system
could result.
A 30 amp thermal circuit breaker is normally used to
protect the ignition splice in the remote start/stop circuit.
The wire from the ignition switch to the truck/machine
selector has a five amp thermal circuit breaker in it.
48 Section 7 Electrical System
Lower Control Panel
The lower control panel is used to send electrical signals
to operate the unit from a below rotation position. Electrical
signals are sent from the lower control panel to the
electrically operated solenoid on the main control valve.
The electrical solenoid is used to shift both the hydraulic
dump and directional control valve spools to operate the
desired function.
Solenoids
An electric solenoid consists of a coil that surrounds a
movable iron core. When the coil is energized by sending
current through it, a magnetic field is produced within the
coil that moves the iron core or valve spool to a different
position.
Boom Function Solenoids
Electrically operated solenoids are used to control the
hydraulic valve spools in the main control valve module on
the turntable. The spool valves are spring centered and
remain so until the solenoid is electrically energized. As
electrical current is applied to the solenoid, the valve spool
shifts to operate the function (refer to Figure 7.6).
Upper Control Panel
The upper control panel is used to send electrical signals
to operate the unit from the platform. Electrical signals are
sent from the upper control panel to the terminal blocks
inside the lower control panel. From the terminal blocks,
the signal is directed to the electrically operated solenoid
that is used to shift the hydraulic valve spool and operates
the desired function.
Ground Fault Interrupter
The electrical outlet at the platform is equipped with an
internal ground fault interrupter. A ground fault interrupter
is a fast acting circuit breaker that senses very small
currents caused by accidental grounding of a conductor
that might flow through the body of a person.
Section 8 Troubleshooting, Testing, and Adjustments 49
Section 8 Troubleshooting, Testing, and Adjustments
Troubleshooting Procedure
Establish a troubleshooting procedure to be followed any
time there is a malfunction. This procedure will provide a
starting point for determining the root cause of the mal-
function and increase troubleshooting accuracy. Consider
using the following procedure.
brake, and chock the wheels. Check the oil level in the
reservoir.
2. Start the vehicle engine and move the unit on/off
switch to the On position. Warm the hydraulic oil to
operating temperature.
3. Before testing each function through its full travel
capabilities, try small movements to be certain the
function is operating properly.
Warning
Death or serious injury can result from falling from the
platform. All platform occupants must properly use an
appropriate OSHA approved personal fall protection
system.
4. Operate the unit from the lower controls and then the
upper controls. Test each function for full travel
capabilities. Note any indications of a malfunction.
5. Use the Hydraulic System Schematic and Wiring Line
Diagrams in the Appendix to determine the flow path
required to operate the failed function. Make a list of
the components used to operate the failed function.
Cross off components used to operate other functions
that are operating properly. This should minimize the
number of items to check.
6. Check the easiest component first. Verify the proper
operation of each component remaining on the list
until the bad component is found.
7. Use accurate test equipment to verify flow, pressure,
voltage, and current.
Once the symptom has been positively identified, use the
Troubleshooting Chart in the Appendix for suggested
causes and corrective actions.
Hydraulic System
The successful way to troubleshooting any hydraulic
system is to find the cause of the problem before making
any changes. Only one change at a time should be made,
in order to verify that the change either corrects or fails to
correct the problem.
In this system of electrohydraulic control, it should first be
determined if the problem is electrical or hydraulic. For
example, if the upper controls will operate the Rotate
function, but the lower controls will not, the problem may
be in the ability of the lower control panel to send an
electrical signal to the lower controls.
Hydraulic pressure applied to a surface inside an actuator
is the means by which mechanical force is generated. This
force may be in the form of torque (hydraulic motor) or
linear force (hydraulic cylinder). If a function does not
operate or does not operate properly, the malfunction may
be caused by a lack of pressure at the actuator.
Hydraulic oil flow controls the speed of a hydraulic actua-
tor. Both hydraulic flow and pressure are required to
operate a function properly. If a function operates slowly,
low oil flow may be the cause.
Cycle Times
Figure 8.1 shows average cycle times. The times indi-
cated are for the full range of motion for that function.
Warm the hydraulic oil to between 80 and 120 degrees
Fahrenheit (26.7 and 48.9 degrees Celsius) before mea-
suring cycle times. Cycle times may be slower than
indicated if the temperature of the oil is below or above this
range.
Function Seconds
Boom raise 20 to 28
Boom lower 31 to 39
Boom extend or retract 10 to 18
Turntable CW/CCW 360 degree rotation 42 to 50
Platform tilt up or down 5 to 10
Figure 8.1 Average Cycle Times
The Hydraulic System Schematic (refer to the Appendix)
identifies the paths of oil flow in the system. A thorough
understanding of JIC symbols and their meanings is
helpful in troubleshooting (refer to Basic JIC Symbols in
the Appendix).
Use an accurately calibrated gauge when measuring
pressure in the hydraulic system. A calibrated gauge will
provide an accurate reading, which is essential for proper
hydraulic adjustments.
Before testing or adjusting the units functions, position
the unit on a level surface, apply the parking brake, and
chock the wheels.
Relief Valve Adjustment
Tee in a hydraulic gauge to the P port of the selector valve
manifold. All relief valves are located on the selector valve
manifold.
50 Section 8 Troubleshooting, Testing, and Adjustments
Figure 8.2 Selector Valve Manifold
Main System Relief
1. With the boom fully retracted, engage the In function.
2. Loosen the locking nut on the RV1 relief valve.
3. Adjust the slotted screw of the RV1 relief valve until
the pressure is 2,500 psi (172 bar).
4. Tighten the locking nut on the RV1 valve.
Boom Raise Relief Pressure
1. Raise the unit until the lift cylinder is fully extended.
Continue to engage the Up function.
the pressure is 1,950 psi (134 bar).
Boom Lower Relief Pressure
1. Lower the unit until the lift cylinder is fully retracted.
Continue to engage the Down function.
the pressure is 900 psi (62 bar).
Rotation Relief Pressure
1. At the rotation hydraulic motor, disconnect the two
hoses. Plug each hose.
2. Loosen the locking nut on the RV4 valve.
3. Operate the clockwise function and adjust the slotted
screw of the RV4 relief valve until the pressure is
1,500 psi (103 bar).
6. Operate the counterclockwise function and adjust the
slotted screw of the RV5 relief valve until the pressure
reads 1,500 psi (103 bar).
7. Secure the locking nut on the RV5 valve.
8. Remove the plugs and connect the hoses to the
motor. Check the hydraulic fluid level, and test the unit
for proper function.
Elevation System
Booms Drifts Down
Testing
1. Raise the boom to a 45 degree angle.
Warning
nents.
Never loosen or remove the holding valve or emergency
lower valve from the cylinder while the boom is elevated
and unsupported.
2. Disconnect the hoses from the T and P1 ports of the
lift cylinder.
3. Allow the unit to sit for 10 minutes. If the unit continues
to leak from the P1 port, then the holding valve is
defective and must be replaced. If the unit continues
to leak from the T port, then the emergency lower
valve is defective and will have to be replaced. If the
unit does not leak from either P1 or T ports, then the
cylinder must be replaced or resealed. Failure to
reinstall the fitting before attempting to lower the boom
will result in severe hydraulic leak.
Warning
nents.
Do not loosen or remove the holding valve or emergency
lower valve from the cylinder while the boom is elevated
and unsupported.
Extension System
Upper Boom Drifts In
Testing
1. Extend the upper boom and raise the booms to a 45
degree angle.
Warning
nents.
Under no circumstances loosen or remove the holding
valve from the cylinder while the boom is elevated and the
unit extended.
2. Disconnect the hoses from the P1 and P2 ports.
3. Allow the unit to sit for 10 minutes. If the unit continues
to leak from the P1 port, then the holding valve is
defective and must be replaced. If the unit continues
to leak from the P2, then the cylinder must be replaced
or resealed.
Warning
nents.
Positive Leveling
Platform Will Not Track,
Drifts out of Position During Use
Testing
1. With the booms in the boom rest and the platform in
the working position, Tee-in a hydraulic gauge to both
of the G and H ports at the selector valve manifold.
2. Stow the platform fully. Bump the unstow control
momentarily to release system pressure.
3. Raise the boom to a 45 degree angle. One gauge will
pressurize, and the other will drop to 0.
Observe the pressurized gauge closely as the unit is
elevated. The pressure should relieve at approxi-
mately 2,000 psi (138 bar). If the pressure fails to
relieve before 2,500 psi (172 bar), stop raising imme-
diately, and adjust the CB2 valve to the proper relief
setting of 2,000 psi (138 bar).
4. When the boom reaches 45 degrees, stop and ob-
serve the gauge closely. The pressure will drop, but
should lockup and hold at approximately 1,500 to
1,700 psi (103 to 117 bar). If the pressure drops to 0,
the CB2 holding valve cartridge must be replaced. If
the pressure drops to approximately 100 to 300 psi (7
to 21 bar) and the other gauge that was at 0 now is
pressurizing to an equal level, then one or both master
or slave cylinder needs to be resealed or replaced. To
isolate the defective cylinder repeat steps one, three,
and four with the slave cylinder disconnected and the
lines capped.
5. Lower the platform to the fully lowered position. Bump
the stow switch momentarily to release system pres-
sure.
6. Lower the boom into the boom rest observing the
pressurized gauge. The gauge that was pressurized
will now read 0 and the other gauge will be pressurized.
If the pressure fails to relieve before 2,500 psi (172
bar), stop lowering immediately, and adjust the CB1
valve to 1,500 psi (103 bar).
7. When the boom reaches the boom rest, stop and
observe the gauges closely. The pressure will drop,
but should lockup and hold at approximately 1,000 to
1,200 psi (69 to 83 bar). If the pressure drops to 0, the
CB1 valve cartridge must be replaced.
The above test will isolate the failed component if the
platform is drifting out of position when in use or will not
track. Other causes may be air in the system, loose
mounts or worn mounting cap screws, bent hydraulic
rams, or a damaged check valve on the slave cylinder from
lifting excessive loads.
Repeated platform leveling failure is usually due to over-
loading the platform and/or using it as a derrick. This type
of use is abusive and dangerous, and should not be
condoned.
Mechanical System
Rotation Backlash Adjustment
Warning
movement. Secure the booms before removing the
gearbox.
1. To adjust backlash, extend the boom with no load in
the platform. Raise the boom to an unsupported
position, as close to horizontal as possible.
2. Remove the gear guard below the turntable.
3. Remove each rotation gearbox mounting cap screw.
Clean and coat with thread locking adhesive. Turn all
cap screws in until they touch.
4. Using a spanner wrench, apply enough tension to
insure full engagement of the gears.
5. Torque each mounting cap screw to 75 foot-pounds
(102 Nm) using the torque pattern illustrated in Figure
8.3. Torque each mounting cap screw to 110 foot-
pounds (149 Nm).
Figure 8.3 Rotation Backlash Adjustment
6. Lubricate the gears with an open face gear lubricant
and install the gear guard.
7. With the platform lowered to ground level, place a foot
at the center line of the platform. Applying approxi-
mately 30 pounds of pressure, rock the platform back
and forth. If the platform moves more than 12 inches
(30 cm) to one side from the center line, repeat the
adjustment procedure.
If excessive backlash develops in the working positions
and can not be adjusted out, extended gear life can be
obtained by rotating the gear 180 degrees.
Electrical System
A basic understanding of electrical system components
and system failure will aid in troubleshooting the units
electrical system. The electrical system includes the
electronic control system and the additional vehicle wiring
required to accommodate the installation of the unit.
Failure Identification
The following three types of failures in the electrical
system will cause the system to operate improperly or not
at all.
Short circuit
Open short
Defective component
Caution
Injury can result from electrical shock. Severe arcing
can occur when working with electrical systems.
Short Circuit
High current flow through a short circuit will usually
interrupt one or more circuit breakers or fuses.
A short circuit can be caused by the following items.
Pinched wire
Worn insulation
Defective component
Loose connection touching a ground
To find the location of a short circuit, first analyze the
location of the circuit breaker or fuse which is opening and
what is being operated when it opens.
It may be necessary to progressively isolate the location
of a short by disconnecting circuits until the short disap-
pears. A short can also be detected by turning off power
to the unit and using an ohmmeter to check the resistance
to ground at connections and terminals which would have
a voltage applied during normal operation. Zero resistance
between ground and one of these locations indicates a
short circuit. This checking procedure should begin clos-
est to the power source.
Open Circuit
An open circuit prevents normal current flow through
components of the electrical system. An open circuit may
be caused by the following items.
Broken wire
Corrosion
Poor contact where an electrical component is
grounded
Wire pulled from a connection
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, corro-
sion, or other visible damage to the cable or wires. If the
component is grounded to the unit structure, make sure
that the ground connection is good. If the wiring looks good
and the ground contact is good, disconnect the leads to the
component and check the resistance reading through the
component with an ohmmeter. A very high or infinite
resistance indicates an open circuit.
Component Failure
A component malfunction is sometimes the most difficult
problem to locate. It may appear as an open or a short
circuit, or the component may not perform to its design
1
4 2
3
capacity. Determined what functions are affected and
what components in the system could be the cause of the
problem. If no open or short circuits can be located, and the
proper voltage is being applied to the components electri-
cal connections, the problem may be hydraulic or me-
chanical rather than electrical.
Make every effort to locate the problem component before
installing new parts. Trial and error component replace-
ment to isolate the problem can be very costly.
Boom Function Solenoid Testing
The boom function solenoid coils may be swapped with
one another if one is suspected to be malfunctioning. If a
function that is known to work, stops working when a
suspected defective solenoid coil is used, the coil is
malfunctioning and will need to be replaced.
By removing the cap, the solenoid coil can be removed
from the main control valve module.
Swap the lower boom lift and the rotation solenoid assem-
blies to verify operation of the solenoids, realize that the
controls for the lower boom lift cylinder will now control the
operation of the rotation function. Be certain to switch the
solenoids back to their proper location so that the control
functions will operate properly.
Ground Fault Interrupter Testing
To test the ground fault interrupter, push in on the black
test button. The red reset button should pop outward from
its position and the red indicator lamp above the test button
should be unlit. With the buttons in this position, the power
should be off at the outlet. If the reset button does not
change positions or if the red indicator lamp remains lit, do
not use the electrical outlet until it has been repaired.
If the ground fault interrupter tests properly, push the reset
button to restore power to the outlet.
Section 9 Structural and Stability Testing 55
Section 9 Structural and Stability Testing
This unit has been factory tested and, at the time of
delivery, all applicable ANSI requirements were met or
exceeded. Any time an alteration is made that may affect
the units stability or dielectric insulation, testing must be
performed to confirm that the unit operates safely and in
compliance with all governing organizations.
Structural
After replacing any major component, perform a 1.5 to 1
structural test to verify structural soundness before put-
ting the unit back into service.
Warning
Death or serious injury can result if the unit becomes
unstable. Maintain stability of the unit while perform-
ing a structural test by following proper procedures.
Use the following procedure to perform a structural test.
1. The area where the test is performed should be level
and free from any overhead obstructions. Position the
unit in the test area so the platform may be accessed
by a forklift (or other lifting device) to place the test
weight.
2. Apply the parking brake and chock the wheels.
3. The position of the booms for the test is somewhat
dependent upon the component(s) which has been
replaced.
4. Calculate the test weight for the platform by multiply-
ing 1.5 times the platform capacity shown on the
serial number placard.
Attention
Carefully load the test weight to prevent damage to the
platform or liner.
5. Place a sling around the platform to suspend the
weight directly under its centerline.
6. Apply the test weight for five minutes. During that
time, do not operate any function of the unit. This is
a static test only.
7. Remove the weight from the platform. Inspect the unit
for structural soundness if any cracking or popping
was heard during the test.
8. Operate the unit through its full range of movement
before returning it to service.
Stability
Although stability testing is not required, a stability test
form can be found in the Appendix.
Due to the possible affect on stability, this unit and/or
vehicle should never be altered or modified without the
specific written approval from Altec Industries, Inc. Com-
ponent replacement with original equipment parts will not
affect the stability of this unit.
56 Section 9 Structural and Stability Testing
Appendix
1 Appendix Glossary
Glossary
2nd stage boom see intermediate boom.
3rd stage boom see upper boom.
A-frame outrigger an extendible outrigger having two diagonal
members which are connected at the top and joined near the midsec-
tion by a horizontal cross piece. Resembles a broad based A.
above rotation in reference to a position on or about a unit that is
vertically above the rotation bearing.
absolute a measure having as its zero point or base the complete
absence of the item being measured.
absolute pressure a pressure scale with the zero point at a perfect
vacuum.
accumulator a container used to store fluid under pressure as a
source of hydraulic power or as a means of dampening pressure
surges.
actuator a device for converting hydraulic energy into mechanical
energy, such as a motor or cylinder.
adapter a device used to connect two parts of different type or
diameter.
adjusting stud a component of a cable drive system that is threaded
on both ends and has a hex adjusting flat in the center. It secures the
drive cable to the cylinder rod and can be used to adjust the tension of
the drive cable.
aeration the entrapment of air in hydraulic fluid. Excessive aeration
may cause the fluid to appear milky and components to operate
erratically because of the compressibility of the air trapped in the fluid.
aerial control valve the control valve on the turntable of an elevator
unit which operates the movement functions of the aerial device.
aerial device a vehicle-mounted device with a boom assembly
which is extendible, articulating, or both, which is designed and used to
position personnel. The device may also be used to handle material, if
designed and equipped for that purpose.
Allen wrench a six-sided wrench that fits into the hex socket of a cap
screw or set screw.
American National Standards Institute (ANSI) a self-governing
body of professionals whose primary objective is to prevent accidents
by establishing requirements for design, manufacture, maintenance,
performance, use and training for manufactured goods including aerial
devices and digger derricks.
anaerobic adhesive a bonding agent or adhesive that cures in the
absence of air.
analog signal an electrical signal that communicates information by
the continuous variation of voltage or current level within a defined
range, in proportion to an input parameter such as pressure or control
lever position.
annular area a ring shaped area. Usually refers to the piston area
minus the cross-sectional area of the rod of a hydraulic cylinder.
ANSI see American National Standards Institute.
antirotation fork a two-pronged retainer which is fastened to the
inside of the turntable and used to prevent movement of the rotary joint
outer housing.
antifoam additive an agent added to hydraulic fluid to inhibit air
bubbles from forming and collecting together on the surface of the fluid.
antiwear additive an agent added to hydraulic fluid to improve the
ability of the fluid to prevent wear on internal moving parts in the
hydraulic system.
arbor bar the shaft or spindle that is used to support a cable reel.
arbor bar collar a cylindrical device that is used to secure a cable
reel on an arbor bar.
arm 1: the primary load-carrying structure of an articulating arm. 2:
the primary load-carrying structure of a single elevator. 3: the articulat-
ing structure which supports the arbor bar for reel lifting.
arm cylinder the hydraulic cylinder that moves the arm of a single
elevator up and down.
articulating arm a system located between the turntable and lower
boom of an aerial device which is used for lifting the boom assembly to
increase the platform working height. This system includes the arm,
link(s), riser and articulating arm cylinder.
articulating arm cylinder the hydraulic cylinder that moves an
articulating arm up and down.
articulating-boom aerial device an aerial device with two or more
boom sections that are connected at joint(s) which allow one boom to
pivot with respect to the adjacent boom.
ASTM American Society for Testing and Materials.
atmosphere (one) a pressure measure equal to 14.7 psi.
atmospheric pressure pressure on all objects in the atmosphere
because of the weight of the surrounding air. At sea level, about 14.7
psi absolute.
atmospheric vents a vacuum prevention device designed to allow
air to enter a hydraulic line that has encountered an internal pressure
below that of the atmosphere (vacuum).
attention information that must be followed to reduce the likelihood
of property damage. Property damage could include structural damage
to the unit, component failure, or damage to nearby property.
auger the hole boring tool of the digger, consisting of a hollow tube
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
to the tube to carry the loose material away from the teeth.
auger extension shaft a shaft which fits into the auger tube to
connect the digger output shaft to the auger.
auger rotation hydraulic system the hydrostatic system on a
pressure digger which operates the auger transmission gearbox.
auger stow bracket the bracket on a digger derrick lower boom
which stores the digger and auger assembly when it is not in use.
auger stow switch a limit switch which is actuated by the auger to
shut off digger operation in the stowing direction when the auger
reaches its fully stowed position in the auger stow bracket.
auger transmission gearbox the gearbox mounted on the mast
weldment of a pressure digger that is used to rotate the kelly bar.
auger tube the hollow tube at the centerline of an auger to which the
auger flighting is welded.
auger windup sling the cable or strap attached to the auger stow
bracket which is used to store the digger and auger.
auxiliary engine a separately mounted engine that is used to
provide power for the units hydraulic system.
auxiliary hydraulic system the secondary hydraulic system of a
pressure digger that operates all the hydraulic functions except auger
rotation.
AWS American Welding Society.
back pressure pressure existing in the discharge flow from an
actuator or hydraulic system. It adds to the pressure required to operate
an actuator under a given load.
backlash the clearance at the tooth contact point between the
adjacent gear teeth of two or more meshing gears.
baffle a device, usually a plate, installed in a reservoir to separate
the return line inlet from the suction line outlet.
band of arrows decals used on extendible and articulating upper
booms to define the boom tip area and the insulated portions of the
upper boom and lower boom insert.
bare-hand work a technique of performing live line maintenance on
energized conductors and equipment whereby one or more authorized
persons work directly on an energized part after having been raised and
bonded to the energized conductors or equipment.
barrel the hollow body of a hydraulic cylinder into which the piston
and rod are assembled.
base boom see lower boom.
base end 1: the closed end of a hydraulic cylinder, opposite from the
end that the rod extends from. 2: the end of an extendible boom that is
closest to the turntable. 3: the end of an articulating boom that remains
positioned closest to the turntable when the boom is fully unfolded.
basket see platform.
battery charger a device used to restore the electrical charge in a
battery.
bearing a machine part that is installed between two adjacent
machine parts to allow those parts to rotate or slide with respect to each
other. Commonly used to decrease friction or wear on components.
behind cab mount a pedestal mounting position located immedi-
ately behind the vehicle cab on the longitudinal centerline of the
chassis.
3-05
2 Appendix Glossary
below rotation in reference to a position on or about a unit that is
vertically below the rotation bearing.
below rotation controls controls that are located on the chassis,
used for operating some or all of the functions of the unit.
bleed-off to reduce the trapped pressure in a hydraulic system, line,
or component, to a zero state by allowing fluid to escape under
controlled conditions through a valve or outlet.
blocking valve a two-position, two-way valve that blocks pump flow
to a hydraulic circuit or system when it is not actuated, and opens to
allow fluid when actuated.
body a structure containing compartments for storage of tools,
materials, and/or other payload which is installed on a vehicle frame or
subbase.
body belt a component in a personal fall protection system consist-
ing of a strap which is secured about the waist of a person, with a means
for attaching it to a lanyard. (As of January 1, 1998, the use of a body
belt for personal fall protection is prohibited by OSHA.)
body harness a component in a personal fall protection system
consisting of an assembly of straps which are secured about the waist,
chest, shoulders, and legs of a person, with a means for attaching the
assembly to a lanyard.
bolt a cylindrical fastener with external screw threads at one end and
a head configuration such hexagonal, square, or round at the other end,
which conforms to the dimensional and material specifications pub-
lished for bolts. (These specifications are different from those for cap
screws.)
boom a movable, mechanical structure that is used to support a
platform, material handling components and/or other attachments on a
unit.
boom angle indicator a device which indicates the angle between
the boom centerline and a horizontal plane.
boom flares steel structures mounted on the boom tip of a digger
derrick which are used to protect the boom tip from loads and support
poles carried on the winch line.
boom functions valve the control valve on a digger derrick that
directs hydraulic pressure and flow to the boom functions (boom,
rotation, intermediate boom, upper boom) hydraulic circuits.
boom pin the horizontal pin that connects the lower boom to the
turntable or riser.
boom rest the structural member attached to the chassis or body to
support the lower boom in the travel or rest position.
boom stow switch a limit switch which is actuated to shut off the
boom lower function when the boom reaches its stowed position in the
boom rest.
boom stow valve a mechanically actuated hydraulic valve that limits
the downward pressure of a boom as it is placed in its rest.
boom tip the area at the end of an extendible or articulating upper
boom that is farthest from the turntable when the boom assembly is
extended or unfolded. This area includes all components at the end of
the boom above the band of arrows.
boom tip idler sheave the upper sheave in a digger derrick upper
boom tip containing two sheaves, which carries the winch line as it
travels from the winch to the lower sheave (boom tip sheave).
boom tip pin a horizontal pin at the upper boom tip. Platform
mounting bracket(s) and material handling devices are fastened to this
pin.
boom tip sheave 1: the sheave in a digger derrick upper boom tip
containing only one sheave, which carries the winch line as it travels
from the winch to the load. 2: the lower sheave in a digger derrick upper
boom tip containing two sheaves, which carries the winch line as it
travels from the upper sheave (boom tip idler sheave) to the load.
boom tip tools see upper tool circuit.
boom tip winch a winch located at the tip of a boom.
bore the inside diameter of a pipe, tube, cylinder barrel, or cylindrical
hole in any of various other components.
boss protruding material on a part which adds strength, facilitates
assembly, provides for fastenings, etc.
brake a device used to slow or stop the rotation or movement of a
component such as a rotation gearbox, winch, gravity leveled platform,
or arbor bar.
breather a device that permits air to move in and out of a container
or component to maintain atmospheric pressure.
bridge mount a unit mounting configuration in which the turntable
is mounted on a pedestal structure which forms a bridge over the cargo
area.
broadband a high speed telecommunication system utilizing fiber
optic and/or coaxial cable.
bucket see platform.
buckeye see forged pin retainer.
bullwheel assembly an assembly of steel rollers used as a portion
of a cable stringing system.
burst pressure the minimum internal pressure that will cause a
hose, tube, cylinder, or other hydraulic or pneumatic component to
rupture or split open.
button head a type of cap screw with a rounded head containing a
socket into which a tool can be inserted to turn the cap screw.
bypass a secondary passage for fluid flow.
bypass valve a hydraulic valve that allows for an alternate passage
for fluid flow.
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
conductors or optical fibers laid up together, usually by being twisted
around a central axis and/or by being enclosed within an outer covering.
cable chute a device used to guide cable into strand for lashing the
cable to the strand when placing cable. A trolley allows the device to ride
on the strand as cable is fed through the chute.
cable drive system an upper boom drive mechanism which utilizes
cables to produce upper boom movement.
cable guide a bracket which is mounted on a boom to guide the
winch line.
cable keeper 1: a mechanical device attached to a cable that is used
to maintain the position of the cable on a sheave. 2: a component used
to prevent a cable or winch line from coming off a sheave.
cable lasher a mechanical device which wraps lashing wire in a
spiral configuration around a length of suspension strand and adjacent
communication cable.
cable lug a mechanical device attached to a cable that is used to
maintain the position of the cable on a sheave.
cable placer a type of aerial device which contains a cable stringing
system and associated components for use in erecting overhead
communication cable.
cable slug the steel end fitting at each end of the drive cable in an
upper boom drive system. One end is attached to the cylinder rod and
the other is secured in a pocket on the elbow sheave.
cable stringing system the group of steel rollers, bullwheel assem-
blies, strand sheave assemblies and fairlead which directs communi-
cation cable or suspension strand from the reel it is stored on to the
working position of the operator.
calibrate to check, adjust, or determine by measurement in compari-
son with a standard, the proper value of each scale reading or setting
on a meter or other device.
caliper a measuring instrument with two legs or jaws that can be
adjusted to determine the distance between two surfaces.
cam a rotating or sliding piece that imparts motion to a roller moving
against its edge or to a pin free to move in a groove on its face or that
receives motion from such a roller or pin.
candling a method of inspecting filament wound fiberglass booms
by slowly passing a light through the inside of the boom in a darkened
area. Cracks, crazing, and other damage show up as dark spots or
shadows.
cap a device located on the hand of a reel lifter that is used to retain
the arbor bar.
cap end see base end.
cap screw a cylindrical fastener with external screw threads at one
end and a head configuration such as hexagonal, hex socket, flat
countersunk, round, or slotted at the other end, which conforms to the
dimensional and material specifications published for cap screws.
capacitive coupling the transfer of electrical energy from one circuit
to another through a dielectric gap.
3-05
3 Appendix Glossary
capacity chart a table or graph showing the load capacity, rated
capacity, or rated load capacity figures for a unit or accessory.
captive air system a closed circuit, low pressure pneumatic system
used to actuate a pressure switch by means of a manually operated air
plunger.
cartridge 1: the replaceable element of a fluid filter. 2: the
replaceable pumping unit of a vane pump, composed of the rotor, ring,
vanes and side plates. 3: A removeable hydraulic valve that is screwed
into place in a cavity in a hydraulic manifold or cylinder.
catrac see hose carrier.
caution information that indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury. It may also
be used to alert against unsafe practices.
cavitation the formation of gaseous voids in hydraulic fluid caused
by a low pressure condition which typically occurs when inlet starvation
prevents the pump from filling completely with fluid. The characteristic
sound of cavitation is a high pitched scream.
center mount see behind cab mount.
center of gravity the point in a component or assembly around
which its weight is evenly balanced.
centerline of rotation the vertical axis about which the turntable of
a unit rotates.
centrifugal pump a pump in which motion and force are applied to
fluid by a rotating impeller within a housing.
chain a series of identical rigid segments connected to each other
at joints which allow each segment to pivot with respect to adjacent
segments, used to transmit mechanical force.
chain extension system a mechanical system consisting of a
motor, gearbox, chains, and sprockets that is used to extend and retract
an extendible upper boom.
chain sling an inverted Y-shaped length of chain used for lifting a
strand reel with an aerial device and placing it in a strand carrier.
chamber a compartment within a hydraulic component that may
contain elements to aid in operation or control, such as a spring
chamber or drain chamber.
channel a fluid passage that has a large length dimension compared
to the dimension of the cross-section.
charge to fill an accumulator with fluid under pressure.
charge pressure the pressure, above atmospheric pressure, at
which replenishing fluid is forced into the hydraulic system.
charge pump the hydrostatic hydraulic system pump that provides
fluid at low pressure to make up for internal leakage, provides cooling
fluid flow, and tilts the hydrostatic pump swash plate.
chassis a vehicle on which a unit is mounted, such as a truck, trailer,
or all-terrain vehicle.
check valve a valve that permits flow of fluid in one direction, but not
in the reverse direction.
circuit the complete path of flow in a hydraulic or electrical system.
circuit breaker a form of electrical switch which opens (trips) to
interrupt a circuit when it senses excessive current flow that may be
caused by a short circuit, to protect wiring and components from
damage. Some types of circuit breakers reset automatically when the
excessive current discontinues and others must be reset manually.
clevis a U-shaped fastening device secured by a pin or bolt through
holes in the ends of two arms.
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
or neutral operating condition.
clutch the device on a reel lifter which allows the connection and
disconnection of the arbor bar and the driver.
coaxial cable a type of shielded cable used for conducting telecom-
munication signals, in which the signal carrier is a single wire at the core,
surrounded by a layer of insulating material, which is in turn surrounded
by a metallic, conductive layer which serves as a shield, with an overall
outer layer of insulation.
combined digger derrick and platform use the stability criteria for
a digger derrick mobile unit which indicates that the load capacity chart
and stability requirements apply to the use of the derrick for lifting of
loads with the winch line at the upper boom tip or material handling jib
tip, with the platform occupied.
come-along a device for gripping and putting tension into a length
of cable, wire, rope, or chain by means of two jaws or attaching devices
which move closer together when the operator pulls on a lever.
communication cable a copper wire, coaxial, or fiber optic cable
used for conducting telecommunication signals.
compensating link a mechanical linkage that serves as a connector
between the turntable and the upper boom drive mechanism. As the
lower boom is raised or lowered, this linkage causes the upper boom to
maintain its relative angle in relationship to the ground.
compensator a valve spool that is used to maintain a constant
pressure drop regardless of supply or load pressure.
compensator control a control for a variable displacement pump
that alters displacement in response to pressure changes in the system
as related to its adjusted pressure setting.
component a single part or self-contained assembly.
compressibility the change in volume of a unit volume of a fluid
when it is subjected to a unit change in pressure.
conductive having the ability to act as a transmitter of electricity.
Electricity will flow through metal, therefore metal is conductive.
conductive shield a device used to shield the lower test electrode
system from capacitive coupling.
conductor a wire, cable, or other body or medium that is suitable for
carrying electric current.
constant resistivity monitor device used to continuously measure
the electrical resistance of the wash water in the tank of an insulator
washer.
contaminate to render unfit or to soil by introduction of foreign or
unwanted material.
continuous rotation a rotation system in which the turntable is able
to rotate an unlimited number of revolutions about the centerline of
rotation without restriction.
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 functions
of a unit.
control station a position where controls for unit operation are
located. These positions may include the platform, upper boom tip,
turntable, pedestal or vehicle tailshelf.
control valve a directional valve controlled by an operator, used to
control the motion or function of an actuator or system.
cooler a heat exchanger used to remove heat from the hydraulic
fluid.
corner mount a pedestal mounting position located behind the rear
axle(s) with the centerline of rotation located to one side of the chassis.
corona ring see gradient control device.
counterbalance valve a load holding valve that can be opened to
allow flow in the normally blocked direction by applying hydraulic
pressure to a pilot port, and which contains a relief capability to allow
flow from the blocked direction if the blocked pressure exceeds a
certain value.
cracking pressure the pressure at which a pressure actuated valve,
such as a relief valve, begins to pass fluid.
crazing a network of fine cracks on or below the fiberglass surface.
Crazing often occurs when the fiberglass is struck with a blunt object,
sometimes causing deformation and breakdown of the fiberglass resin.
crosstalk a form of interference in which one circuit or channel
receives some unintentional signal from another.
cross-ported a hydraulic path connected between the two opposite
flow paths of a hydraulic circuit that allows a route for flow between the
two paths in lieu of flow thru an actuator. To allow sensing of the
pressure in one path by a component installed in the other path.
cSt (centistoke) a metric unit of kinematic viscosity. In customary
use, equal to the kinematic viscosity of a fluid having dynamic viscosity
of one centipose and a density of one gram per cubic centimeter.
curb side the side of a vehicle which is opposite from oncoming
traffic when the vehicle is traveling forward in the normal direction in a
lane of traffic.
cushion a device built into a hydraulic cylinder that restricts the flow
of fluid at the outlet port to slow the motion of the rod as it reaches the
end of its stroke.
3-05
4 Appendix Glossary
custom option an option which is not shown on a standard order
form and which requires additional engineering work to supply.
cylinder a device that converts fluid power into linear mechanical
force and motion. It usually consists of a moveable piston and rod, or
plunger, operating within a cylindrical bore.
danger information that indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury. This signal
word is to be used in the most extreme situations.
DC pump a pump which is powered by a direct current electric motor.
dead band the area or range near the center rest position of a hand
control where the function does not respond to movement of the lever
or handle.
decal a thin sheet of flexible material which is attached to another
surface by adhesive, and is used to convey instructions, information
and warnings.
deenergize to remove electrical power from a device, as from the coil
of a solenoid valve.
delivery the volume of fluid discharged by a pump in a given time,
usually expressed in gallons per minute (gpm).
demulsibility the ability of a liquid to expel another type of liquid.
Commonly used to describe a fluids ability to cause water to separate
out rather than being held in suspension.
design voltage the maximum rated line voltage for which an aerial
device has been designed, and for which it can be qualified.
detent a device for positioning and holding one mechanical part in
relation to another so that the device can be released by force applied
to one of the parts.
diagnostic relating to the practice of investigation or analysis of the
cause or nature of a condition, situation, or problem.
diagonal brace the structural member attached near the top of a
corner mount pedestal and extending downward and forward to a point
of attachment on the subbase or vehicle frame between the pedestal
and the vehicle cab.
dial indicator a meter or gauge with a calibrated circular face and
a spring-loaded plunger, used as a measuring device.
diegrinder a small, hand held, rotary grinding tool.
dielectric nonconductive to electrical current.
differential cylinder any cylinder that has two opposed piston areas
that are not equal.
digger the mechanism which drives the auger.
digger bail a tubular housing attached to the gearbox portion of a
digger, which surrounds the motor and provides an attachment point to
the digger link.
digger derrick a multipurpose, vehicle-mounted device with an
extendible boom which may accommodate components that dig cylin-
drical holes, set utility poles, and position materials, apparatus, and/or
personnel.
digger derrick use the stability criteria for a digger derrick mobile
unit which indicates that the load capacity chart and stability require-
ments apply to the use of the derrick for lifting of loads with the winch
line at the upper boom tip or material handling jib tip, with the platform
stowed or removed, if so equipped.
digger hanger bracket the structural member on a digger derrick
which supports the digger link on the extendible boom.
digger latch mechanism a mechanism which secures the digger to
the lower boom when it is stowed and to the extendible boom when it
is unstowed.
digger link the structural member which attaches the digger to the
digger hanger bracket.
digger/winch valve the control valve on a digger derrick that directs
hydraulic pressure and flow to the digger and winch hydraulic circuits.
digital signal an electrical signal that communicates information by
the use of two distinct levels of voltage or current, a high on level and
a low off level, which are sent in a series of pulses. The timing of the
pulses is used to indicate the level of an input parameter such as control
lever position, or information such as the address setting of a radio
control transmitter linking it to its receiver.
diode an electrical component that allows current flow in one
direction but not in the reverse direction.
directional valve a valve that selectively directs or prevents fluid
flow through desired passages.
displacement the quantity of fluid that can pass through a pump,
motor or cylinder in a single revolution or stroke.
docking station a device used to mount a remote control transmitter
on a platform.
dog clutch see drum clutch.
double-acting cylinder a cylinder in which fluid pressure can be
applied to either side of the piston to move the rod in either direction.
double elevator an elevator lift with two load carrying arms. The
double elevator system includes a lower pedestal, lower arm, lower arm
cylinder(s), riser, upper arm, upper arm cylinder(s), and upper pedestal,
plus parallel links in both the lower and upper sections.
double-pole, double-throw (DPDT) switch a six-terminal electrical
switch or relay that connects, at the same time, one pair of terminals to
either of two other pairs of terminals.
double-pole, single-throw (DPST) switch a four-terminal electrical
switch or relay that, at the same time, opens or closes two separate
circuits or both sides of the same circuit.
down load the downward force created when an external force is
exerted on the boom, such as a winch pulling cable on a cable placer.
drain a passage or a line from a hydraulic component that returns
leakage fluid to the reservoir.
drift 1: a gradual, uncontrolled change from a set position of an
actuator or component. 2: a tool for ramming or driving something.
driver the gearbox and motor assembly on a reel lifter which is
connected to and disconnected from the arbor bar through the clutch
assembly.
drop pocket an open top tool storage area on the chassis of a unit.
drum clutch a clutch consisting of two or more drive lugs that engage
similar driven lugs to transmit torque. Commonly used between the
gearbox and cable drum on front or bed mounted winches.
dump valve a normally open, two-position, two-way valve that sends
pump flow through a path going directly to the reservoir or bypassing
hydraulic circuit when it is not actuated, preventing operation of the
hydraulic system or circuit. When it is actuated, it closes off this path,
redirecting flow to the hydraulic system or circuit to allow operation.
dynamometer an instrument for measuring mechanical force or
power.
earth anchor see screw anchor.
eccentric ring a ring with the center hole located in a position off the
geometric center, commonly used to adjust the position of the rotation
pinion with respect to the rotation bearing gear teeth.
eccentric ring lock a device which engages a hole or notch in an
eccentric ring to prevent the ring from rotating.
efficiency the ratio of output to input. Volumetric efficiency of a pump
is the actual output in gpm divided by the theoretical or design output.
The overall efficiency of a hydraulic system is the output power divided
by the input power. Efficiency is usually expressed as a percent.
elbow the structure on an articulating-boom aerial device that
connects the upper boom to the lower boom. The elbow allows the
upper boom to pivot relative to the lower boom.
elbow bearing the rotating member that allows the upper boom to
rotate around the end of the lower boom. Used on aerial devices with
the upper and lower booms mounted side by side.
elbow pin the horizontal pin that attaches the upper boom to the
lower boom on an articulating-boom aerial device. Used on aerial
devices with the upper boom mounted over the lower boom.
electrical harness an assembly of electrical wires that is used to
deliver electrical current between components.
electrocution receiving an electrical shock resulting in death.
electrohydraulic a combination of electric and hydraulic control
mechanisms in which an electrically controlled actuator is used to shift
the spool in a hydraulic control valve.
electrohydraulic control system a control system in which the
function control handles are connected to electric controls. The electric
controls actuate electrohydraulic valves to operate the functions of the
unit.
3-05
5 Appendix Glossary
flange on a flange and lug pin retaining system, an end plate that is
welded to one end of the pin. The purpose of the flange is to position the
pin in the connection.
flange and lug pin retaining system a connecting pin retention
system in which an end plate is welded to one end of the pin and a
retaining plate is attached with cap screws to the other end to hold the
pin in position.
flashover a disruptive electrical discharge at the surface of electrical
insulation or in the surrounding medium, which may or may not cause
permanent damage to the insulation.
flats from finger tight (F.F.F.T.) a method of counting the number
of wrench flats when tightening a hydraulic adapter to establish a torque
value.
flat-shoe outrigger an outrigger which has a shoe that is fixed in a
horizontal position.
flighting a curved plate or series of curved plates welded together,
spiraling along the axis of an auger tube or screw anchor rod.
flow the movement of fluid generated by pressure differences.
flow control valve a valve that regulates the rate of fluid flow.
flow rate the volume, mass or weight of a fluid passing through any
conductor per unit of time.
flow straightener a component part of a nozzle used to straighten
or remove any swirling motion of fluid going through the nozzle.
flowmeter an instrument used to measure the flow rate of fluid in a
hydraulic tube or hose.
fluid a liquid that is specially compounded for use as a power
transmitting medium in a hydraulic system.
fold to move a pivoting structure such an articulating upper boom
toward its stowed position.
fold-up shoe outrigger an outrigger which has a shoe that pivots
into a vertical position when the outrigger is fully retracted.
force any push or pull measured in units of weight.
forged pin retainer a pin retainer made from forged steel, consisting
of a slender, cylindrical body with a flattened, circular head at one end,
with a mounting hole through the head perpendicular to the body. The
body is inserted through a hole in the pin to be retained, and the head
is fastened to the adjacent structure with a cap screw.
four-way valve a valve having four ports for direction of fluid flow.
FPS Fluid Power Society.
frequency the number of times an action occurs in a unit of time.
gasket a packing made of a deformable material, usually in the form
of a sheet or ring, used to make a pressure tight fit between stationary
parts.
gate valve see shutoff valve.
gauge pressure a pressure scale that ignores atmospheric pres-
sure by establishing atmospheric pressure as its zero point. Its zero
point is 14.7 psi absolute.
gauge snubber see snubber valve.
gearbox an assembly with internal speed changing gears; a trans-
mission. Gearboxes are commonly used to transmit power from a
hydraulic motor to operate a function through an output shaft.
gelcoat a protective coating used on fiberglass components to
prevent the wicking of moisture into the fiberglass strands and to retard
the degrading effect of ultraviolet light on the fiberglass.
GFI ground fault interrupter.
gin pole a vertical phase-holding apparatus which is attached to a
platform or upper boom tip.
gpm gallons per minute.
gradient control device a device at the upper end of an insulating
boom that reduces electrical stress level(s) below that considered to be
disruptive.
gravity leveling system a system which uses the force of gravity to
keep the bottom of a platform parallel to level ground as the boom is
raised or lowered. One means of accomplishing this is by allowing the
platform to pivot freely about a horizontal shaft attached above the
platforms center of gravity.
grease fitting a small fitting that acts as the connection between a
grease gun and the component to be lubricated.
electrohydraulic valve a directional valve that receives a variable
or controlled electrical signal which is used to control or meter hydraulic
flow.
elevator lift a system located between the turntable and subbase of
an aerial device which is used for lifting the aerial device to increase the
platform working height. This system may be configured as a single
elevator or a double elevator.
elevator unit the overall device including the subbase, elevator lift
and the aerial device.
emergency operating DC pump see secondary stowage DC pump.
emergency operating system see secondary stowage system.
end gland a hollow, cylindrical part that screws into or is retained in
the open end of a hydraulic cylinder barrel, through which the rod
protrudes.
end-mounted platform a platform which is attached to a mounting
bracket that extends beyond the boom tip, positioning the platform (and
platform rotation pivot, if so equipped) beyond the end of the upper
boom.
energize to send electrical power to a device, as to the coil of a
solenoid valve.
energized conductor an apparatus that is transmitting electric
current.
energy the ability or capacity to do work, measured in units of work.
engine protection system a system which detects when the
auxiliary engine oil pressure or temperature is out of the proper range
and shuts the engine off.
extendible capable of linear movement of one or more portions of
an assembly to increase the overall length or reach of the assembly.
extendible-boom aerial device an aerial device with a telescopic
or extendible boom assembly.
extension cylinder a hydraulic cylinder which extends and retracts
an extendible boom(s).
fairlead the group of steel rollers at the platform of a cable placer
which guide the cable or suspension strand during the placing process.
fall protection system a system consisting of a body harness or
body belt, a decelerating lanyard, connectors, and an anchor point at
the boom tip, used to catch and hold a person who falls from a platform.
(As of January 1, 1998, the use of a body belt for personal fall protection
is prohibited by OSHA.)
feedback (feedback signal) the return of part of an output signal to
the input for the purpose of modification and control of the output.
feeder tube a telescopic hydraulic tube assembly mounted on an
extendible boom which carries pump flow to a device mounted on the
extendible portion of the boom such as a digger or boom tip winch.
fiber optic cable a type of cable used for conducting control or
telecommunication signals, in which the signal carrier(s) is one or more
optical fibers, enclosed within an outer covering.
fiber optics the use of transparent fibers of glass or plastic which
transmit light signals throughout the length of the fiber. Commonly used
to transmit signals from a remote control.
fiberglass glass in fibrous form added as a reinforcement to a plastic
for use in making various products.
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, and
which can be removed to access a fill hole when adding hydraulic fluid
to the reservoir.
filter a device through which fluid is passed to remove and retain
insoluble contaminants from a fluid.
filter cart a portable device which can be connected to a units
hydraulic system to filter water and/or other contaminants out of the
hydraulic system fluid.
filter cartridge a component containing filtration material which is
installed within a filter housing or attached to a filter receptacle for use,
and can be removed and replaced as a self-contained unit.
firm footing outrigger placement and extension in accordance with
the instructions in a units operators manual to ensure proper leveling
of the vehicle and adequate stability when operating the unit.
fixed displacement pump a pump in which displacement is con-
stant, so that the output flow can be changed only by varying the drive
speed.
3-05
6 Appendix Glossary
hydraulically extendible jib a jib boom that may be extended or
retracted by hydraulic power.
hydraulics an engineering science pertaining to liquid pressure and
flow.
hydrostatic hydraulic system any hydraulic drive in which a
positive displacement pump and motor transfer rotary power by means
of fluid under pressure.
individual address setting the code that identifies a specific
transmitter as the one emitting the signal corresponding to a specific
receivers reception address.
in-line the installation of a component in series between two portions
of a hydraulic line or electrical conductor so that flow in the line or
conductor toward the component passes through the component and
continues on in the line or conductor on the other side.
instability a condition of a mobile unit where the sum of the moments
tending to overturn the mobile unit is equal to or exceeds the sum of the
moments tending to resist overturning.
insulated aerial device an aerial device with dielectric components
designed and tested to meet the specific electrical insulating rating
consistent with the manufacturers name plate.
insulated digger derrick a digger derrick designed for and manu-
factured with a fiberglass boom(s) for use around energized conductors
at a maximum of 46 kV phase to phase.
insulated liner see platform liner.
insulated portions those sections which are designed, maintained,
and tested in accordance with the electrical requirements of ANSI
A92.2.
insulator a device that isolates the energized conductor of a power
line from the support structure.
intercom system a transmitter and receiver system that allows two-
way verbal communication between a platform operator and a person
at ground level.
interference any energy that inhibits the transmission or reception
of electrical or radio signals.
intermediate boom (INT BOOM) an extendible boom section which
is located between the upper boom and the lower boom in an extendible
boom assembly.
ISO International Standards Organization.
jam nut a nut that is screwed down firmly against another nut to
prevent loosening.
jaw clutch see drum clutch.
jib an auxiliary boom which attaches to the upper boom tip to extend
the reach of the boom.
JIC Joint Industry Conference.
joystick a two or three axis control lever which allows the operator
to simultaneously control multiple functions.
junction box an enclosed central connecting point for electrical
wiring.
kelly bar 1: for derricks see auger extension shaft. 2: the auger drive
shaft of a pressure digger which is extendible from the ram cylinder.
key a parallel-sided piece that fits into grooves in two adjacent parts
to prevent movement between the parts. Often used as the driving
member between a shaft and a sheave or winch drum.
keyway a groove that is cut in a shaft or bore for a key to fit into.
kilovolts (kV) a unit of potential difference equal to 1,000 volts.
knuckle see elbow.
L-bracket an L-shaped weldment that is used to connect a splicer
platform to the upper boom tip.
lanyard a component in a personal fall protection system consisting
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
provided at the boom tip, used to catch and decelerate a person in a fall
from the platform. (As of January 1, 1998, the use of a body belt for
personal fall protection is prohibited by OSHA.)
lashing wire a thin, solid wire which is wrapped in a helix configu-
ration around a length of suspension strand and adjacent communica-
tion cable so that the suspension strand carries the weight of the cable.
lay the length of wire rope in which one strand makes one complete
spiral around the rope.
gripper tool a component used for grasping an object or electrical
lines through the use of an articulated mechanism.
ground 1: a large conducting body with a potential of zero volts used
as a common current return for an electric circuit. 2: an object that
makes an electrical connection with a ground or with the earth.
ground fault interrupter (GFI) a fast acting form of circuit breaker
that opens to interrupt an electrical circuit if it senses a very small
current leakage to ground, to protect personnel against a potential
shock hazard from defective electrical tools or wiring. It does this by
monitoring for any difference in current flow between the hot and neutral
wires in the circuit. An imbalance exceeding a very small preset value
indicates that current is finding an improper path to ground, and causes
the breaker to trip.
guard ring see conductive shield.
hand an extension of the reel lifter arm that allows for loading the
arbor bar.
hand control a hand operated control lever or handle located at a
control station used to regulate a function of a unit, where the speed of
the function is proportional to the distance the control is moved.
heat the form of energy that has the capacity to create warmth or to
increase the temperature of a substance. Any energy that is wasted 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
required to raise the temperature of one pound of water one degree
Fahrenheit.
heat exchanger a device that transfers heat through a conducting
wall from one fluid to another or into the atmosphere.
hertz (Hz) a unit of frequency equal to one cycle per second.
high tooth the individual tooth out of all the gear teeth on a rotation
bearing at which the minimum backlash occurs with the rotation pinion.
This is because of a slight difference between the actual and theoretical
tooth pitch lines due to manufacturing tolerances.
HLIW hot line insulator washer.
holding valve see load holding valve.
HOP see hydraulic overload protection system.
horsepower (HP) the power required to lift 550 pounds one foot in
one second or 33,000 pounds 1 foot in one minute. One horsepower is
equal to 746 watts or to 42.4 British thermal units per minute.
hose carrier a flexible component which contains hydraulic, electri-
cal, and/or air lines, usually mounted inside or along the side of an
extendible boom. As the boom is extended, the hose carrier unfolds in
a rolling motion to allow the lines to extend with the boom.
hose carrier tube a rigid, enclosed tube which contains hydraulic,
electrical, and/or air lines, and may contain components for upper
controls. It is usually attached to a hose carrier on the side of an
extendible boom.
hot line insulator washer (HLIW) a vehicle-mounted device which
is designed and used for cleaning pole and structure mounted transmis-
sion and distribution insulators.
HTMA Hydraulic Tool Manufacturers Association.
Huck bolt a bolt-like fastener that is placed in position and then
stretched while an end fitting is swaged on. Commonly used to attach
a pedestal, subbase, and/or outriggers to a vehicle frame.
hydrant a discharge pipe with a valve and spout at which water may
be drawn from a water main.
hydraulic control a control that is actuated by hydraulically induced
forces.
hydraulic leveling system an automatic hydraulic control system
which keeps the bottom of a platform parallel to or at a fixed angle to the
turntable base plate as the boom is raised or lowered. One means of
accomplishing this is by transferring hydraulic fluid between a master
cylinder actuated by movement of the lower boom and a slave cylinder
mounted between the platform and the upper boom.
hydraulic overload protection (HOP) system the system on a
digger derrick that shuts off certain functions to help prevent damage
to the digger derrick structure when an overload is applied to the boom
in the downward direction.
hydraulic schematic a drawing that uses common hydraulic
symbols to represent the hydraulic system of the unit.
hydraulic swivel a fluid conducting fitting having two joined parts
that are capable of pivoting freely about each other to accommodate
motion of an attached hydraulic line.
3-05
7 Appendix Glossary
layer all wraps of winch line on a winch drum which are on the same
level between drum flanges.
leakage monitor system a means by which current leakage is
measured through the insulated section(s) of a boom to confirm of
dielectric integrity.
leveling cable the wire rope portion of a mechanical leveling system
that passes over the sheaves.
leveling chain the chain portion of a mechanical leveling system that
passes over the sprockets.
leveling cylinder 1: a cylinder that is used in a master/slave
arrangement in a hydraulic leveling system to hydraulically level the
platform. 2: the hydraulic cylinder that is used to tilt the pivot and mast
weldments of a pressure digger to either side of the vertical position.
leveling rod a slender, round, fiberglass rod used in a mechanical
leveling system that passes through a units boom to connect the
leveling chains or cables at each end of the boom.
leveling system see platform leveling system.
leverage a gain in output force over input force; mechanical
advantage or force multiplication.
lift cylinder the hydraulic cylinder that moves the lower boom up and
down on a digger derrick or extendible-boom aerial device.
lifter cylinder the hydraulic cylinder that moves the reel lifter arms.
lifting eye a shackle or weldment used for attaching chain, cable,
rope, etc. to a boom for material handling.
light emitting diode (LED) a semiconductor diode that emits light
when subjected to an applied voltage. LEDs are used for electronic
display.
line a tube, pipe or hose used as a passageway to move hydraulic
fluid.
linear in a straight line.
linear actuator a device for converting hydraulic energy into linear
motion such as a cylinder or ram.
linear position transducer an extendible length measuring device
which produces a variable electrical signal that is proportional to the
length to which the device is extended.
liner see platform liner.
link the secondary load-carrying structure of an articulating arm.
load capacity (as defined by ANSI for digger derricks) the maximum
load, specified by the manufacturer, that can be lifted by the mobile unit
at regular intervals of load radius or boom angle, through the specified
ranges of boom elevation, extension and rotation, with options installed
and inclusive of stability requirements.
load holding valve a hydraulic valve which blocks fluid flow from a
hydraulic actuator, such as a cylinder or motor, to prevent motion when
the control valve is not being operated or in case of a hydraulic line
failure.
load radius the horizontal distance from the centerline of rotation to
the winch line load attachment point.
lock washer a solid or split washer that is placed underneath a nut
or cap screw to help prevent loosening by exerting pressure against the
fastener.
locknut see self-locking nut.
lockwire a wire that is installed to prevent loosening of fasteners or
components.
lower arm the primary load-carrying structure of a double elevator
which is located between the lower pedestal and the riser.
lower arm cylinder the hydraulic cylinder that moves the lower arm
of a double elevator up and down.
lower boom (LWR BOOM) the boom section in a boom assembly
which is attached to the turntable or riser, and which supports the upper
boom or intermediate boom.
lower boom cylinder the hydraulic cylinder that moves the lower
boom about its pivot point on an articulating-boom aerial device.
lower boom insulator the part of the lower boom made of high
dielectric strength material (usually fiberglass reinforced plastic or
equivalent) to interrupt the conductive path for electricity through the
lower boom.
lower boom winch a winch that is located on the lower boom.
lower control valve the hydraulic valve on the vehicle, turntable, or
pedestal of an aerial device used for operating some or all of the
functions of the aerial device.
lower controls the controls on the vehicle, turntable, or pedestal,
used for operating some or all of the functions of the unit.
lower pedestal the structure within an elevator lift that connects the
elevator lift to the subbase.
lower test electrode system a system on an insulated aerial device
utilizing conductive bands installed permanently on the inside and
outside surfaces of the insulated portion of the upper boom and
conductive connections to components inside that portion of the boom
such as leveling rods and hydraulic lines. All the bands and component
connections are connected to a common pickup point for use in
measuring current leakage to confirm of dielectric integrity.
lower tool circuit a hydraulic tool circuit with quick disconnect
couplings located on the pedestal or on the vehicle.
lug a metal part which serves as a cap, handle, support, or fitting
connection.
magnetic suction separator filter see magnetic suction strainer.
magnetic suction strainer a suction filter consisting of a strainer
which contains one or more magnets to trap ferrous metallic contami-
nants that are small enough to pass through the strainer.
mainframe see pedestal.
man-and-a-half platform an oversized one-man platform.
manifold a fluid conductor that provides multiple connection ports.
manual lowering valve a manually operated hydraulic valve used
to lower the boom in the event of power failure.
manual override a means of manually actuating an automatically or
remotely controlled device.
manually extendible jib a jib that is capable of being extended and
retracted by human force.
mast the structure on a pressure digger which supports the auger
transmission gearbox, ram cylinder, kelly bar, and pole setter.
master control panel the primary derrick lower control panel which
contains the electrical connections between the derrick control system
and components such as the power module and the dump or blocking
valve. The master control panel is used in conjunction with a slave panel
to provide dual station lower controls.
master cylinder a cylinder in which motion of the piston under an
external force transfers hydraulic fluid to a slave cylinder to produce
corresponding motion.
material handling having the ability to use the boom or attachments
on the boom to lift and position materials.
material handling system the system on an aerial device that
consists of a jib and winch used to lift material to the upper boom tip.
mechanical leveling system a mechanical system which keeps the
bottom of a platform parallel to or at a fixed angle to the turntable base
plate as the boom is raised or lowered. One means of accomplishing
this is by utilizing a parallelogram arrangement of leveling rods attached
to cables or chains operating around sheaves or sprockets at boom
pivot points.
mercury switch a switch that is closed or opened when an internal
globule of mercury moves to or away from the contacts when the switch
is tilted.
meter to regulate the amount of fluid flow.
meter-in to regulate the amount of fluid flow into an actuator or
system.
meter-out to regulate the flow of the discharge fluid from an actuator
or system.
micron (micrometer) one-millionth of a meter or about 0.00004.
micron rating the minimum size of the particles that a filter is
designed to remove.
microswitch a small electrical device that is used to turn an electrical
current on or off, or to change the connections in a circuit.
minimum approach distance the three dimensional area surround-
ing a conductor into which a person may not enter nor bring any
conductive object unless they are: qualified electrical workers, wearing
insulating gloves (and sleeves when required), protected against
contact with any other objects at a different electrical potential.
3-05
8 Appendix Glossary
NPT National Pipe Thread.
NPTF National Pipe Thread Fluid, a pipe thread form which is
modified from the NPT form to improve the resistance to fluid leakage
through the threads in a connection.
O-ring a ring of material with a circular cross section that is used as
a gasket, usually made of synthetic rubber.
ohmmeter an instrument used to measure the resistance in ohms
between two points in an electrical component or circuit.
on/off circuit circuit that supplies constant electrical power to a
solenoid or other component when a relay or switch is closed and
removes the power when the relay or switch is opened.
one-man platform a platform designed to carry one person. It is
usually 24 wide x 30 wide or 24 wide x 24 wide.
open center a directional valve design in which pump output returns
freely to the reservoir when the valve spool(s) is in the center or neutral
position.
open circuit an electric circuit that has infinitely high resistance,
resulting in no current flow. An open circuit may be caused by a loose
connection, broken wire, corrosion or poor contact where an electrical
component is grounded to the unit structure.
operator a person trained, authorized and engaged in the operation
of the unit.
optical fiber a thin strand of transparent glass or plastic used to
transmit signals using light throughout the length of the strand.
orifice a restriction in a hydraulic or pneumatic circuit, the length of
which is small in respect to its diameter.
OSHA Occupational Safety and Health Administration.
out and down outrigger an outrigger that has independently-
controlled horizontal and vertical extendible outrigger legs.
outboard bearing a bearing which supports the end of a gearbox
output shaft farthest from the gearbox.
output signal a radio wave intended to pass communication from a
source to a destination.
outrigger a structural member, which when properly extended or
deployed on firm ground or outrigger pads, assists in stabilizing the
mobile unit.
outrigger controls the controls for operating the outriggers.
outrigger cylinder the hydraulic cylinder which extends and retracts
or unfolds and folds an outrigger leg.
outrigger interlock system a system which requires all outriggers
to be extended to a specified position before other unit functions are
allowed to operate.
outrigger interlock valve a valve which prevents above rotation
sense line signals from reaching the pump until the outriggers have
been lowered.
outrigger leg 1: the moveable structural component of an outrigger
which extends or unfolds to position the outrigger shoe on the ground,
and which retracts or folds to return the outrigger shoe to the stored
position. 2: the stationary structural component of an extendible outrig-
ger from which the moveable outrigger leg extends.
outrigger motion alarm an audible warning system to alert person-
nel that outriggers are being lowered or moved.
outrigger pad a portable piece of rigid material which is placed
under an outrigger shoe to increase the contact area with the ground
surface when the ground surface is not firm enough to support direct
contact from the outrigger shoe.
outrigger shoe the component of an outrigger that is attached to the
moveable leg and that contacts the ground or outrigger pad to stabilize
the mobile unit.
outrigger signal valve a valve used to provide a signal to the pump
when the outriggers are being operated and to allow a separate signal
system to control the aerial device operation.
outrigger spread the distance between the outer edges on fixed
shoes, or between pin centerlines on pivoting shoes, of opposite
outriggers which have been extended or deployed to a given position.
over travel movement of a mechanism beyond its normal stopping
point.
overcenter aerial device a type of articulating-boom aerial device
on which the upper boom can unfold from the stored position to beyond
a vertical position.
mobile operation the use of the aerial device or digger derrick while
the mobile unit is traveling.
mobile unit the combination of a unit, its chassis and related
permanently attached equipment.
modified A-frame outrigger an extendible outrigger that is config-
ured like a large broad based A with an open top.
modulation ratio the on time vs. the off time of a pulse width
modulated digital signal. This ratio is determined by dividing the on time
during one cycle by the total cycle time.
moly see molybdenum disulfide.
molybdenum disulfide a black inorganic chemical that is used as
a dry lubricant and as an additive for grease and oils. Molybdenum
disulfide has a very high melting point and is insoluble in water.
molydisulfide see molybdenum disulfide.
moment a force multiplied by the perpendicular distance from the
line of action of the force to an axis or point. The force may be the weight
of an item, with the vertical line of action located at the items center of
gravity. Moment is measured in units of force times distance; for
example, pound-feet or foot-pounds.
monitor head remotely controlled articulated assembly with a
nozzle, mounted at the upper end of an HLIW.
motor a device that converts hydraulic or electrical energy into
continuous rotary motion and torque.
multiple-part line the arrangement of the winch line on a digger
derrick in which the winch line is routed between the boom tip and the
load two or more times. A snatch block is used at the load and a snatch
block or additional boom tip sheave(s) is used on the boom to reverse
the direction of the winch line. The end of the winch line is connected
to a stationary 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 the winch line rated working load when a lifting load that
exceeds the winch line rated working load.
multiplexing a process by which signals from multiple inputs are
combined and transmitted simultaneously over a single channel.
multiviscosity the viscosity characteristic of a fluid which contains
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
without these additives. This allows the fluid to be used over a wider
temperature range.
nonconductive the characteristic of a substance that allows it to
transmit electricity only in a very small degree when it is clean, dry and
properly maintained.
noncontinuous rotation a rotation system in which the turntable is
prevented from rotating more than approximately one revolution about
the centerline of rotation.
non-insulated aerial device or digger derrick an aerial device or
digger derrick which is not designed, manufactured, or tested to meet
any dielectric rating.
nonmetallic formed of materials which are not any type of metal.
non-overcenter aerial device a type of articulating-boom aerial
device on which the upper boom will not unfold from the stored position
to beyond a vertical position regardless of the position of the lower
boom.
nontransferable boom flares boom flares that are permanently
attached to the boom tip of a digger derrick.
nontransferable upper controls an upper control panel on a digger
derrick that is permanently attached to the upper boom tip.
normally closed switch a switch which is closed to allow current to
flow through it when it is not actuated, and opens to interrupt current flow
when actuated.
normally closed valve a two-way valve which is closed to block fluid
from flowing through it when it is not actuated, and opens to allow flow
when actuated.
normally open switch a switch which is open to prevent current from
flowing through it when it is not actuated, and closes to allow current
flow when actuated.
normally open valve a two-way valve which is open to allow fluid to
flow through it when it is not actuated, and closes to block flow when
actuated.
nozzle a tube-like device for accelerating and directing the dis-
charge flow of fluid.
3-05
9 Appendix Glossary
overframe an outrigger weldment mounting position located above
the vehicle chassis frame.
overload the condition existing when a load greater than the rated
capacity or design lead is applied to a unit or component.
override the takeover of boom movement control functions from the
platform controls by the activation of the lower control station controls.
overtighten to torque a threaded fastener beyond the recom-
mended torque value.
oxidation the reaction of a substance with oxygen.
parallel link the secondary load-carrying structure of an elevator lift.
particle count a visual count of the numbers of particulate contami-
nants in a quantity of a hydraulic fluid.
passage a machined or cored fluid conducting path that lies within
or passes through a component.
payload any tools, materials, fuel and occupants carried by the
mobile unit that are not permanently attached.
pedestal the stationary base of a unit that supports the turntable and
is attached to the subbase or vehicle frame.
pedestal mount a mounting configuration for an aerial device in
which the turntable is mounted on a pedestal consisting of a box-like
structure.
penetration the distance the vehicle frame is lifted after the outrig-
gers contact the ground surface.
phase a conductive wire or cable used for transmitting high voltage
electrical current. The phrase phase to phase can be referenced as
any two conductors of a three-phase electrical power line system.
pilot operated condition in which a valve is actuated by hydraulic
fluid pressure.
pilot operated check valve a check valve that can be opened to
allow flow in the normally blocked direction by applying hydraulic
pressure to a pilot port.
pilot pressure auxiliary pressure used to actuate or control hydrau-
lic components.
pilot valve an auxiliary valve used to control the operation of another
valve.
pin a cylindrical structural device used to allow a pivoting joint or to
connect mating parts.
pin retainer a device which is used to hold a pin in place in an
assembly.
pinch point a particular location in which a human body or a part of
the body may become pinched or pinned between moving mechanical
parts.
pinion a gear with a small number of teeth that has been designed
to mesh with a larger gear.
piston a cylindrically shaped part that fits within a cylinder or
cylindrical bore and transmits or receives linear motion by means of a
connecting rod or other component.
piston pump a pump in which motion and force are applied to fluid
by a reciprocating piston(s) in cylindrical bore(s).
pivot weldment the structure located above the slide frame on a
pressure digger which supports the mast.
placard 1: a thin sheet of rigid material which is attached to another
surface by adhesive and/or mechanical fasteners, and is used to
convey instructions, information and warnings. 2: May also refer to a
decal.
planetary gear set an assembly of meshed gears consisting of a
central gear (sun gear), a coaxial internal tooth ring gear and several
intermediate pinions (planet gears) supported on a revolving carrier.
planetary gearbox a gearbox containing one or more planetary gear
sets.
platform the personnel-carrying component of a unit, mounted at the
upper boom tip.
platform heater an electrically powered device mounted in a splicer
platform which is used to warm the occupant.
platform leveling system a system which keeps the bottom of a
platform parallel to or at a fixed angle to the base plate of the turntable,
or parallel to level ground, as the boom is raised or lowered. The system
may be mechanically, hydraulically, or gravity operated.
platform liner a component made of material having a high dielectric
strength which is designed to be inserted into a platform to cover the
walls and bottom of the platform.
platform pin the horizontal pin that is used to fasten a platform
mounting bracket to the upper boom tip. The mounting bracket pivots
about this pin for platform leveling or positioning.
platform rest the structural member attached to the chassis or body
to support and cushion the platform in the travel or rest position.
platform ring a metal band around the lip of a splicer platform which
supports and guides the platform as it is rotated about its vertical
centerline.
platform rotation override system a system which allows the zone
of platform rotation to extend beyond a predetermined limit when
actuated by the operator.
platform rotator a system which allows the operator to rotate the
platform about a vertical axis. This permits the position of the platform
to be changed with respect to the boom tip.
platform tilt system a system which allows the operator to adjust the
orientation of the platform about a horizontal axis. Some systems allow
the operator to adjust the working position of the platform floor and tilt
the platform for cleaning. Other systems allow tilting of the platform for
cleaning but do not provide for operator adjustment of the working
position.
platform use the stability criteria for a digger derrick mobile unit
which indicates that the load capacity chart and stability requirements
apply to the use of the derrick with the platform occupied, with no lifting
of loads with the winch line.
plunger a cylindrically shaped part that is used to transmit thrust; a
ram.
pole a long cylindrical piece of material such as wood, metal, or
concrete which is installed in a vertical position for use as a support
structure for power and communication lines.
pole guide a mechanism at the tip of a boom used for guiding and
stabilizing a utility pole while using the winch line to raise or lower the
pole.
pole guide tilt cylinder the hydraulic cylinder which is used to tilt
(raise or lower) the pole guide.
pole guide tong cylinder the hydraulic cylinder which opens and
closes the pole guide tongs.
pole guide tongs moveable arms on a pole guide used to stabilize
and guide a utility pole as it is being raised or lowered with the winch line.
pole puller an apparatus consisting of a hydraulic cylinder, chain
and other components used to loosen a utility pole from the ground.
pole setter an assembly attached to the mast of a pressure digger
that is used to pick up, position, and set a pole.
polyethylene a moisture proof plastic.
poppet that part of certain valves that prevents flow when it closes
against a seat and allows flow when it moves away from the seat.
port an internal or external opening for intake or exhaust of fluid in
a component.
portable resistivity tester a device used for testing the electrical
resistance of water. Commonly used for testing the wash water for
insulator washers.
position a term which describes the number of possible positions a
valve spool or mechanism can be shifted to.
post mount a mounting configuration for an aerial device in which
the turntable is mounted on a pedestal which utilizes a round vertical
tube as its primary load-carrying structure.
potentiometer a variable resistor that is connected to act as an
electrical voltage divider.
pour point the lowest temperature at which a fluid will flow or pour
under specific conditions.
power work per unit of time, measured in horsepower (HP) or watts.
power module the central connection point between the chassis
and unit electrical systems. This device is used to provide battery power
to the unit when the truck/machine selector is in the machine position.
power take-off (PTO) a supplementary mechanism enabling ve-
hicle engine power to be used to operate non-automotive apparatus
such as a pump.
3-05
10 Appendix Glossary
ram cylinder the hydraulic cylinder that is used to retract and extend
the kelly bar on a pressure digger.
range diagram a diagram which shows the load radius and sheave
height of a digger derrick at all the configurations of boom extension and
boom angle covered by the corresponding load capacity chart
.
rated capacity (as defined by ANSI for digger derricks) the maxi-
mum load, specified by the manufacturer, that can be lifted by the digger
derrick at regular intervals of load radius or boom angle, through the
specified ranges of boom elevation and extension, with specified
options installed, and exclusive of stability requirements.
rated line voltage the nominal voltage, phase to phase, at which
electrical systems are rated.
rated load capacity (as defined by ANSI for aerial devices) the
maximum loads, specified by the manufacturer, which can be lifted by
the aerial device through the specified range of boom elevation and
extension with specified options installed and in consideration of
stability requirements.
reach diagram a drawing that shows the horizontal and vertical
limits of travel of the platform, upper boom tip, and/or jib tip throughout
all possible configurations of lower boom angle, boom extension, upper
boom angle, articulating arm travel, and/or elevator lift travel.
rear mount a pedestal mounting position located over or near the
rear axle(s) on the longitudinal centerline of the chassis.
receiver a device that converts radio waves into electrical signals for
communication and/or control purposes.
reel brake a component of the reel driver which prevents the
overrunning of cable reels carried by a strand carrier and reel lifter. The
brake is used to maintain tension in the cable or suspension strand
when used with the reel driver.
reel driver a component of a strand carrier and reel lifter used for
paying in or paying out cable or suspension strand.
reel lifter a device used to support and move cable reels from the
ground to the vehicle.
reel lifter arms the structure on a reel lifter used to lift and store reels
of cable or suspension strand on the chassis.
reengage to repeat the activation of a function after it has been
momentarily halted.
relay an automatic switch with contacts that can be closed or opened
by electrical current in a coil.
relief valve a pressure operated valve that bypasses pump delivery
to the reservoir to limit system pressure to a predetermined maximum
value.
remote arm a remotely operated jib used to handle equipment or
electrical lines.
remote assist a vehicle-mounted device with a boom assembly
which is extendible, articulating, or both, which is designed and used to
accommodate attachments for performing operations such as support-
ing or cutting electrical conductors, lifting or holding objects, or cutting
tree branches. It is operated by remote control from the ground or from
the platform of an adjacent personnel lifting device. It may be mounted
on the vehicle by itself or in addition to a personnel lifting device.
remote control system a system used for operating some or all of
the functions of a unit from a portable control station. The control station
may be a transmitter which sends signals by radio waves to a receiver
on the unit, or a control module which sends signals through a fiber optic
or electrical cable to the unit.
remote operated auxiliary control system (ROACS) a radio
controlled system for starting and stopping certain functions of the
mobile unit.
remote start/stop system the components used to actuate a
function of the unit from a location other than for normal operation. The
most common functions controlled are engine start/stop and the sec-
ondary stowage DC pump.
reservoir a container for storage of liquid in a fluid power system.
resistance the opposition to the flow of electricity or hydraulic fluid.
restriction a reduced cross-sectional area in a line or passage that
produces a pressure drop.
retaining ring a hardened, washer-like ring that may be spread apart
or compressed and installed into a groove or recess to serve as a
retaining device.
precharge pressure the pressure of compressed gas in an accumu-
lator before any fluid is added.
pressure the force applied in a given area. It can be expressed in
pounds per square inch (psi).
pressure compensator a device on a variable displacement pump
that adjusts pump output flow to develop and maintain a preset
maximum pressure.
pressure differential the difference in pressure between two points
in a system or component.
pressure drop the reduction in pressure between two points in a line
or passage due to the energy required to maintain flow.
pressure gauge an instrument which displays the hydraulic or
pneumatic pressure sensed at a port on the device.
pressure line the line carrying fluid from a pump outlet to the
pressurized port of a valve or actuator.
pressure override the difference between the cracking pressure of
a valve and the pressure reached when the valve is passing full flow.
pressure reducing valve a pressure control valve whose primary
function is to limit its outlet pressure.
pressure switch an electric switch which is actuated when the
hydraulic or pneumatic pressure applied to a port on the switch reaches
a specified value.
pressure transducer a pressure measuring device which produces
a variable electrical signal that is proportional to the hydraulic pressure
applied to a port on the device.
proportional circuit a circuit that supplies a varying voltage to a coil
in a pilot valve as electrical current applied to the circuit is varied by a
hand control.
proximity alarm a system which measures the distance from a
detector to another object, and sounds an alarm when this distance is
less than a specified value. Commonly used to inform the operator of
an HLIW of the distance between the boom tip nozzle and a power line
insulator or support structure.
psi pounds per square inch.
PTO see power take-off.
pullout upper controls an upper control panel on a digger derrick
which is mounted on a housing that can be extended from inside an
outer housing when additional length is needed, such as to attach the
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
tip with the outer housing attached to the transferable boom flares.
pulse width modulation (PWM) a means of transmitting a digital
signal in continuous cycles of pulses where the total length of time for
a cycle of one on pulse and the following off period is constant, and
the length of time (width) of the on pulse within each cycle is varied
(modulated) in proportion to the level of an input parameter such as
control lever position.
pump a device that converts mechanical force and motion into
hydraulic flow and pressure.
purge system a system of check valves that allows hydraulic fluid
flow in a reverse manner through the hydraulic system, usually from the
lower control valve to the upper controls. This actions frees or purges
the control system of any trapped air and restores a solid column of fluid
for precise control. The purge system may also be used to warm up the
control system in cold weather conditions if the fluid in the reservoir is
warm.
purge/upper/lower controls selector valve a valve which is used
to direct hydraulic fluid to the purge system, the upper control valve, or
the lower control valve.
PWM pulse width modulation.
quick disconnect couplings hydraulic fittings designed for fast and
easy attachment and separation.
radial ball bearing an antifriction bearing with rolling ball contact in
which the direction of action of the load transmitted is perpendicular to
the axial centerline of the bearing.
radial outrigger an outrigger in which the moveable outrigger leg
pivots in an arc around a pin connection between the leg and a
supporting structure as the leg is lowered and raised.
radio communication communication by means of radio waves.
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.
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return line a hydraulic line used to carry discharge flow from a
hydraulic system or actuator back to the reservoir at low pressure.
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
hydraulic system to the reservoir.
reversing valve a four-way directional valve used to change the
direction of movement of a double-acting cylinder or reversible motor.
ribbon hose a group of hoses that are attached side by side to
produce a flat bundle. Commonly used to carry hydraulic fluid, air and/
or electrical cable(s) to the boom tip or upper controls.
riding seat an operators control station attached to the side of the
turntable, with a seat on which the operator rides with the rotation of the
unit.
riser 1: the structure on a double elevator that connects the lower
elevator arm to the upper elevator arm. 2: the structure within an
articulating arm to which the lower boom is connected.
ROACS see remote operated auxiliary control system.
rod the cylindrically shaped part of a cylinder which extends and
retracts from the barrel to actuate or move a component.
rod end the end of a cylinder that the extending component or rod
is on.
roller a cylindrical device which spins freely about a pin or shaft, used
to guide the motion of another component.
rollpin a pin that has been formed by rolling up a thin, flat strip of
metal to form a cylinder. Commonly used by being driven into a hole to
serve as a retaining device.
rope a stout, flexible cord, which consists of many strands of wire
or fibers that are twisted or braided together.
rotary actuator a device for converting hydraulic energy into rotary
motion and torque in which the rotary motion is restricted to within
certain angular limits.
rotary joint a multiple port manifold that has a rotating portion and
a stationary portion, used to provide a continuous hydraulic connection
between rotating and stationary hydraulic lines. Commonly used at the
centerline of rotation of units equipped with continuous rotation.
rotate frame the structure located above the stationary frame on a
pressure digger that is used to support and rotate the slide frame.
rotating platform a platform which can be rotated about a vertical
axis to change its position in relationship to the boom tip.
rotation bearing the rotating member, usually a shear ball bearing,
located between the pedestal and the turntable which allows the
turntable to rotate and which contains gear teeth that mesh with the
rotation pinion.
rotation chain a chain attached to the stationary frame of a pressure
digger that is used by the rotation gearbox to rotate the rotate frame.
rotation gearbox the gearbox which drives the rotational motion of
the turntable.
rotation pinion the gear on the output shaft of the rotation gearbox
which meshes with the rotation bearing gear teeth and drives the
turntable rotational motion.
rotation resistant wire rope wire rope which is constructed to resist
the tendency to untwist or rotate when carrying a suspended load. This
is accomplished by laying the outer strands in the opposite direction to
the lay of the inner strands or core.
rotation system the system which drives the rotation of the turntable
about the centerline of rotation. It typically consists of a rotation bearing,
rotation gearbox, hydraulic motor, and load holding valve.
rpm revolutions per minute.
running torque the torque produced by a rotating device such as a
motor or gearbox at a specified rotational speed.
SAE Society of Automotive Engineers.
safety belt see body belt.
saybolt universal viscosity A measure of viscosity equal to the time
it takes in seconds for 60 milliliters of fluid to flow through a capillary tube
in a Saybolt universal viscosimeter at a given temperature.
scissor link the mechanical linkage on a reel lifter used to connect
the lifter cylinder to the arm.
screw anchor a rod with an eye on one end and auger flighting on
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.
seating in an initial microscopic surface deformation of components
that are clamped together with threaded fasteners. This causes a slight
reduction in the dimension of the components, reducing the clamping
force applied by the fasteners.
secondary stowage DC pump a low flow hydraulic pump driven by
a direct current electric motor. This pump is used to provide hydraulic
flow to stow the unit when the system for normal operation has failed.
secondary stowage system those components used to stow the
unit when the system for normal operation has failed.
selector switch a switch which is used to direct electrical current to
one of two or more electrical circuits.
selector valve a valve which is used to direct hydraulic fluid to one
of two or more hydraulic circuits.
self-locking nut a nut which contains a built-in device or shape to
increase thread friction so as to resist loosening due to vibration or
repeated loading.
self-lubricating bearing an antifriction bearing in which lubricating
material is incorporated in the bearing.
sense line a line that carries a hydraulic pressure signal from a valve
or actuator to the compensator control on a variable displacement
pump.
sense selector valve a valve which prevents hydraulic fluid in the
sense line from reaching the pump until a certain function(s) is oper-
ated.
sequence 1: the order of a series of operations or movements. 2: to
divert flow to accomplish a subsequent operation or movement.
sequence valve a pressure operated valve that diverts flow to a
secondary actuator while holding pressure on the primary actuator at a
predetermined minimum value after the primary actuator completes its
travel.
sequential extension the operation by which one boom section in
an extendible boom assembly reaches full extension or retraction
before the next boom section begins movement.
set screw a short screw, typically with an Allen type head, that is
used as a clamp to bind parts together.
shackle see clevis.
shear an action or stress resulting from opposing applied forces that
attempt to separate a part into two pieces that would then slide along
each other in opposite directions along the plane of separation.
shear ball bearing an antifriction bearing with rolling ball contact in
which the direction of load transmitted through the balls is parallel to the
axial centerline of the bearing, producing shear loading on the balls.
The bearing can support axial, radial, and tilt loading. Commonly used
as a rotation bearing.
shear pin a replaceable pin which prevents motion between two
adjacent parts by the production of shear loading in the pin, and which
may be designed to fail under overload to protect other parts.
shear stability resistance of a hydraulic fluid viscosity index im-
prover additive to shearing.
shearing molecular damage or breakdown of the viscosity index
improver additive in hydraulic fluid. Shearing can occur when the fluid
flows through fine clearances at high velocity. Shearing can cause
permanent loss in fluid viscosity.
sheave a grooved wheel used to support and guide a winch line or
leveling cable at a point of change in the direction of motion of the line
or cable.
sheave height the vertical distance from ground level to the
centerline of the boom tip sheave in a digger derrick upper boom tip.
short circuit an inadvertent path of low resistance established
between two points of an electrical circuit. A short circuit will result in
excessive current flow.
shutoff valve a device which is used to stop hydraulic fluid flow.
shuttle valve a three-port valve that accepts hydraulic fluid pressure
from two inlets and allows only the highest pressure fluid to pass
through it to a single outlet while keeping the inlet fluid pressure isolated
from one another.
side gun a hand held water nozzle and hose that can be used from
the ground for washing or fire fighting.
3-05
side load an external horizontal load placed on a boom from one
side.
side load protection system the system on a digger derrick that
helps prevent damage to the digger derrick structure when excessive
side loads are applied to the booms.
side-mounted platform a platform which is attached to a mounting
bracket that extends from one side of the boom tip, positioning the
platform (and platform rotation pivot, if so equipped) beside the boom
tip.
sideslip sideways motion of a component caused by an externally
applied sideways force which overcomes resistive forces from hydrau-
lics, friction, etc. Commonly used to describe rotation of a digger derrick
boom caused by side loading which exceeds the side load protection
setting.
signal a command or indication of a desired position, velocity, flow
or pressure.
signal line see sense line.
single-acting cylinder a cylinder in which fluid pressure can be
applied to move the rod in only one direction. Return motion is produced
by an external force such as a spring or gravity.
single elevator an elevator lift with one load carrying arm. The
single elevator system includes a lower pedestal, arm, arm cylinder(s),
parallel links, and upper pedestal.
single handle control a control, with an interlock trigger incorpo-
rated in the handle, which allows the operator to simultaneously control
multiple functions of the booms and turntable from the platform.
single-pole, double-throw (SPDT) switch a three-terminal electri-
cal switch or relay that connects one terminal to either of two other
terminals.
single-pole, single-throw (SPST) switch a two-terminal electrical
switch or relay that opens or closes one circuit.
slave control panel a secondary derrick lower control panel that is
configured as a remote terminal of the master panel. The slave panel
is used in conjunction with a master panel to provide dual station lower
controls.
slave cylinder a cylinder in which motion of the piston is produced
by the transfer of hydraulic fluid from a master cylinder, resulting in
corresponding motion.
slide frame the structure on a pressure digger used to support the
auxiliary engine, hydraulic reservoir, control station, and pivot weld-
ment. The slide frame can be extended horizontally from its stowed
position to adjust the distance of the kelly bar from the rotate frame.
slide pad a rectangular block used as a bearing between extendible
boom or outrigger sections, usually composed of a non-metallic mate-
rial.
slip ring an assembly of one or more conductive, rotating rings and
stationary brushes used to provide a continuous electrical connection
between rotating and stationary conductors. Commonly used at the
centerline of rotation of units equipped with continuous rotation.
slug face the extreme end of the cable slug which is secured to the
cylinder rod or adjusting stud.
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
around an internal sheave.
snubber valve a two-port valve with a manually adjustable orifice
that restricts the flow of fluid through the valve.
socket head a cylindrical cap screw head design containing a
hexagonal (six-sided) female socket into which an Allen wrench can be
inserted to turn the cap screw.
solenoid a coil of insulated wire that produces a magnetic field within
the coil when electrically energized. When attached to a hydraulic
valve, the magnetic field acts upon the valve to move internal valve
parts.
solenoid valve a valve which is actuated by a solenoid to controlling
the flow of hydraulic fluid.
speed reducer see gearbox.
spherical bearing a bearing with a spherically shaped inner race
that is allowed to move freely inside a stationary outer race to accom-
modate misalignment.
splicer platform a fiberglass platform equipped with a door and
latch.
spline one of a number of equally spaced, load carrying teeth that
have been cut on the outside diameter of a shaft or inside diameter of
a bore, parallel to the shaft or bore centerline.
spool a moving, cylindrically shaped part of a hydraulic valve that
moves to direct flow through the valve.
spring lockouts a mechanical system which is engaged to keep a
vehicles suspension system from flexing during operation of the unit.
sprocket a wheel with teeth along the circumference which are
shaped so as to engage with a chain, used to support and guide the
chain at a point of change in the direction of motion of the chain.
SSU (Saybolt Second Universal) the unit of measure for Saybolt
universal viscosity.
stability a condition of a mobile unit in which the sum of the moments
which tend to overturn the mobile unit is less than the sum of the
moments tending to resist overturning; the mobile units ability to resist
tipping.
stabilize to provide adequate stability for a mobile unit to allow
operation of the vehicle-mounted device(s).
stabilizer a device used to assist in stabilizing a mobile unit, such as
an outrigger, torsion bar or spring lockout.
stake to slightly deform the threads of a fastener or material at the
joint between two components by placing the blade of punch or chisel
on the threads or joint and tapping on the handle with a hammer. The
deformed material serves to prevent loosening of the components.
stall torque the torque produced by a rotating device such as a motor
or gearbox at zero rotational speed.
standard option an option which can be ordered from a standard
order form and can be supplied without additional engineering work.
start/stop control module an electrical device that relays signals
from the units remote start/stop system to the component(s) or system(s)
being controlled, such as the secondary stowage DC pump and/or
vehicle ignition system.
stationary frame the structure attached to the subbase of a pressure
digger that supports the outriggers and rotate frame.
stationary platform a platform which can not be rotated about a
vertical axis to change its position in relationship to the boom tip.
stow to place a component such as a boom or digger derrick auger
in its rest position.
strainer a coarse filter.
strainer basket a coarse, basket shaped filter which is mounted in
the fill hole of a reservoir and projects into the reservoir.
strand 1: one of the groups of individual fibers or wires within a
synthetic winch line or wire rope. 2: see suspension strand.
strand carrier a device used to support and transport strand reels
on a vehicle.
strand reel a reel or spool used for carrying suspension stand.
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.
stroke 1: total linear movement in either direction of a piston or
plunger. 2: to change the displacement of a variable displacement
pump or motor.
subbase a structural mounting interface between the pedestal and
the vehicle frame. It provides torsional stiffness and strength in addition
to that which would be provided from the vehicle frame alone.
subweldment a smaller welded subassembly used within a more
complex welded structure.
suction filter a filter located in a hydraulic system suction line or at
the outlet of a hydraulic reservoir which cleans fluid flowing from the
reservoir to the pump inlet.
suction line the hydraulic line connecting the pump inlet port to the
reservoir outlet.
surge a momentary rise of pressure in a circuit.
suspension strand a type of wire rope which is used to support the
weight of an attached communication cable suspended between poles
or other overhead support structures.
swage to taper or reduce the diameter of a rod, tube or fastener by
forging, squeezing or hammering.
synthetic winch line a winch line made from nonmetallic synthetic
fibers which are formed into strands that are then braided together to
make a complete rope.
3-05
T-stand a T shaped weldment for mounting lower controls to the
vehicle.
tachometer an instrument used for displaying the speed of rotation
of an engine output shaft.
tailshelf the rear portion of the mobile unit above and behind the rear
axle.
tailshelf tools see lower tool circuit.
tank the hydraulic reservoir.
telescopic having sections that slide within or over one another to
change overall length.
terminal block an insulating mounting used for making electrical
terminal connections.
test block a manifold with ports for connecting a hydraulic pressure
source, pressure gauge and a cartridge valve such as a counterbalance
valve or relief valve used for testing and adjusting the relief setting of the
valve.
thimble a metal ring around which a rope is passed and spliced to
make a loop or eye.
thread locking adhesive an anaerobic adhesive that is applied to
fastener threads to prevent loosening due to vibration or repeated
loading.
three-phase a system for transmitting high voltage, alternating
current, electrical power along three separate conductors, with 120
degrees between the voltage waveform cycles of any two conductors.
three-position valve a valve having three positions for direction of
fluid flow, such as neutral, flow in one direction, and flow in the opposite
direction.
three-way valve a valve having three ports for direction of fluid flow.
throttle control a manual, hydraulic, or electrical device used to
regulate vehicle or auxiliary engine speed.
toggle switch an electrical switch operated by a short projecting
lever combined with a spring to quickly open or close a circuit when the
lever is pushed through a small arc.
topping cylinder see lift cylinder.
torque 1: a rotational twisting force. 2: to preload a threaded fastener
by application of a rotational twisting force.
torque converter a rotary device for transmitting and amplifying
torque, especially by hydraulic means.
torsion bar a rod-like spring which is flexed by being twisted about
its axis, used to assist in stabilizing a mobile unit.
tow line winch a winch located on a cable placer which is used for
tensioning suspension strand or self-supporting cable or towing a cable
lasher.
trace element analysis analysis of a small sample of hydraulic fluid
to determine contamination level and condition of additives.
tracking a current leakage path created across the surface of
insulating material when a high-voltage current forms a carbonized
path within a foreign material on the surface.
transducer a device that converts input energy of one form into
output energy of another, such as hydraulic pressure into an electrical
signal.
transferable boom flares boom flares, on which a pole guide may
be mounted, that can be pinned to either the intermediate boom tip or
the upper boom tip of a digger derrick.
transferable upper controls an upper control panel on a digger
derrick that can be attached to either the upper boom tip or the
transferable boom flares by the use of a detent pin.
transmitter a device used to generate and emit a radio frequency
carrier signal. The signal is sent to a receiver which translates the signal
into usable information.
trim pot a potentiometer which is used to make fine adjustments in
a circuit during manufacture or calibration, typically by turning a slotted
adjusting screw.
troubleshoot to locate and diagnose problems in a system or a
component.
trunnion a mounting device consisting of a pair of opposite,
projecting cylindrical pivots on which something can be rotated or tilted.
trunnion bearing a bearing that a trunnion pin pivots in.
trunnion pin a cylindrical pivot pin that is a part of a trunnion.
turnbuckle a link with screw threads at both ends that is turned to
bring the ends closer together for tightening purposes.
turns from finger tight (T.F.F.T.) a method of counting the number
of turns of a hydraulic adapter to establish a torque value.
turntable the structure located above the rotation bearing which
supports the lower boom or articulating arm, and rotates about the
centerline of rotation.
turntable winch a winch located on the turntable.
turret see turntable.
two-man platform a platform designed to carry two people. It is
usually 24 wide x 48 wide.
two-part line a multiple-part line on a digger derrick in which the
winch line is routed from the boom tip sheave down to a snatch block
at the load and then back up to a stationary attachment point on the
boom.
two-position valve a valve having two positions for direction of fluid
flow, such as open and closed.
two-speed motor a motor which has two operating speed and
torque modes (a low-speed, high-torque mode, and a high-speed, low-
torque mode) that can be selected by the operator.
two-way valve a valve having two ports for direction of fluid flow, with
one internal flow path which can be open or blocked.
UNC Unified National Coarse, a thread description.
underframe an outrigger weldment mounting position located
beneath the unit subbase or vehicle chassis frame.
undertighten to torque a threaded fastener below the recom-
mended value.
UNF Unified National Fine, a thread description.
unfold to move a pivoting structure such as an articulating upper
boom away from its stowed position.
unit the Altec device(s), subbase, outriggers, body and associated
interface items mounted on a chassis, but not including the chassis
itself.
unload to release hydraulic flow, usually directly to the reservoir, to
prevent pressure buildup.
unloaded vehicle weight the total weight of the completed mobile
unit without payload.
unloading valve a valve that bypasses flow to the reservoir when a
set pressure is maintained on its pilot port.
upper arm the primary load-carrying structure of a double elevator
which is located between the riser and the upper pedestal.
upper arm cylinder the hydraulic cylinder that moves the upper arm
of a double elevator up and down.
upper boom (UPR BOOM) the boom section in a boom assembly
which is farthest from the turntable when the boom assembly is fully
extended or unfolded, and which supports the boom tip sheave and/or
platform(s).
upper boom cylinder the hydraulic cylinder that moves the upper
boom about its pivot point on an articulating-boom aerial device.
upper boom drive mechanism the components used to produce
upper boom movement on an articulating boom-aerial device, such as
linkage, cables, sheaves and/or gears.
upper boom rest the structural member that supports the upper
boom in the rest or travel position.
upper boom tip the boom tip of an upper boom.
upper control valve the hydraulic valve on or beside the platform
of an aerial device used for operating some or all of the functions of the
aerial device.
upper controls the controls located on or beside the platform used
for operating some or all of the functions of the unit.
upper pedestal the structure within an elevator lift that connects the
elevator lift to the aerial device rotation bearing.
upper tool circuit a tool hydraulic circuit with quick disconnect
couplings located at the upper boom tip.
vacuum the absence of pressure. A perfect vacuum is the total
absence of pressure; a partial vacuum is some condition less than
atmospheric pressure. Vacuum is measured in inches of mercury (in.
Hg.).
3-05
valve a device that controls fluid flow direction, pressure or flow rate.
vane pump a type of pump with a rotor and several sliding vanes in
an elliptical chamber. Hydraulic fluid enters the expanding area and is
forced out as the fluid is moved to the decreasing chamber area.
variable displacement pump a pump in which the size of the
pumping chamber(s) can be changed, so that the output flow can be
changed by moving the displacement control or varying the drive speed
or both.
vehicle a carrier for a unit.
velocity the speed of linear motion in a given direction.
velocity fuse a hydraulic valve that is used to stop fluid flow through
it when the flow rate reaches a predetermined cut-off value.
vent an air breathing device on a fluid reservoir or hydraulic line.
VI see viscosity index.
viscosity a measure of the internal friction or resistance to flow of a
fluid.
viscosity index (VI) a measure of the resistance to change in
viscosity of a fluid with change in temperature. The higher the number,
the less the viscosity will change as the temperature changes.
voltmeter an instrument used to measure the potential difference in
volts between two points in an electrical circuit.
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).
vortex a whirlpool of liquid.
waist harness a belt device worn by the operator of a radio remote
control system to which the transmitter is attached.
walking beam outrigger an extendible outrigger which has a pivot
point at the top of the nonextending leg and a linkage attached to the
extending leg, so that the leg assembly rotates about the pivot point to
increase the outrigger spread as it is extended.
warning an instruction that indicates a potentially hazardous situa-
tion which, if not avoided, could result in death or serious injury.
water monitor an articulating mechanism that is used to direct the
flow of a high pressure water stream.
water removal filter cartridge a special filter cartridge designed to
absorb and remove water from hydraulic fluid. It is not intended for use
during normal operation, but is for use when water removal is required.
way a term which describes how many ports are in a valve or valve
section.
weldment a structural unit formed by welding together an assembly
of pieces.
wheel chock a wedge or block placed on the ground in front of or
behind the wheel of a vehicle to block the movement of the wheel.
winch a mechanism consisting of a gearbox with a cylindrical
rotating drum on which to coil a line for load hoisting or line tensioning.
winch capacity the maximum load, specified by the manufacturer,
that can be pulled on the first layer of line on the winch drum at rated
system pressure.
winch line a load hoisting line consisting of a synthetic or wire rope.
winch line rated working load the average breaking strength of a
winch line (as specified by the line manufacturer) divided by the
appropriate design factor as specified by ANSI.
wire rope a rope made from steel wires which are formed into
strands that are then twisted about each other in a spiral configuration.
work the exertion of a force moving through a definite distance. Work
is measured in units of force multiplied by distance; for example, pound-
feet.
worm gearbox a gearbox that utilizes a gear which has a continuous
helix tooth or teeth similar to a large screw thread along shaft (worm),
that drives a gear which has teeth cut at an angle along a its outside
diameter (worm gear). The rotational axis of the worm is perpendicular
to the rotational axis of the worm gear.
wrap a single coil of winch line on a winch drum.
Y-cable an electrical cable assembly which contains three branches
joined at a common point, similar to a Y.
zerk see grease fitting.
3-05
Service Tools and Supplies
Appendix Service Tools and Supplies
Most routine maintenance and service of the unit can be
performed with common hand tools and shop supplies
available from a tool supply company. Some special
tools and supplies are available from your Altec repre-
sentative that may be useful or required to perform
certain maintenance procedures. These items are cat-
egorized with their corresponding Altec part number. The
list contains items for both aerial devices and derricks. An
Accessory and Replacement Parts Catalog is also avail-
able for ordering other items that may not be shown in the
Parts Manual. This catalog can be obtained through your
Altec representative.
Part Number
099-00017
099-00018
099-00025
099-00033
099-00050
099-00019
099-00020
099-00037
099-00069
099-00123
099-00124
099-00021
099-00039
099-00040
099-00041
099-60007
Product
Lubrication
Gear Shield
Chain and Cable Fluid
Moly grease
Anti-seize compound (16 oz can)
Anti-seize compound (
1
/4 lb tube)
Fasteners
Thread locking adhesive
(Purple 50 ml)
(Blue 50 ml)
(Red 50 ml)
(Red 50 ml)
Inspection lacquer, blue (
1
/2 oz)
Cleaner for inspection lacquer (
1
/2 oz)
Stainless steel safety wire
(5 lb roll)
Cleaning solvent (12 oz)
Primer (Grade N 6 oz)
Primer (Grade T 6 oz)
Wire twisting pliers
Purpose/Use
Lubricate rotation gears and pinions.
Lubricate cables such as wire rope winch line, auger windup
sling, and leveling cables or chains.
Component lubrication.
Low strength thread locking and sealing agent for small
diameter screws.
Medium strength thread locking and sealing agent for bolts
and nuts.
High strength thread locking and sealing agent for large
diameter bolts and cap screws.
Medium/high strength thread locking agent.
Visual inspection stripe.
Visual inspection stripe removal.
Lockwiring fasteners.
Quick drying, nonflammable solvent used for cleaning parts
prior to bonding. Leaves no residue.
Anaerobic solvent reduces cure time on thread locking
adhesive.
Anaerobic solvent reduces cure time on thread locking
adhesive.
Lockwiring fasteners.
Part Number
041-90001
041-90002
099-00062
703-50039
099-00008
099-00038
099-00034
352-79006
352-79008
991002073
353-30016
356-90002
750-40039
099-00051
099-00042
099-00061
Product
Fiberglass Care
Gelcoat kit
Formula Five Clean N Glaze
Plastic Kleen #2 Polish
Bonding kit
White paint
Hydraulic System Care
Pipe sealant (50 ml)
Flowmeter
Test block small bore (
7
/8 hex)
Test block large bore (1
1
/8)
Return line filter cartridge
Water removal filter cartridge
Diagnostic test kit
Oil warming kit
Corrosion suppressant
Electrical System Care
Conformal coating (14 oz)
Lectra-Motive Electric
Parts Cleaner (19 oz)
Purpose/Use
Repair fiberglass platforms and booms.
Cleaning and polishing fiberglass.
Nontoxic plastic cleaner.
Rebond fiberglass booms.
Nonmetallic spray paint.
General purpose pipe sealant for use on pipes to two inches.
Testing hydraulic system.
Testing counterbalance valve.
Testing counterbalance valve.
Filters hydraulic oil before it is returned to the reservoir.
Removes water from the hydraulic system.
Testing hydraulic systems.
Warm hydraulic oil to operating temperature in cold weather.
Chrome cylinder rod protection.
Silicon based electrical component protection.
Clean and degrease electrical systems.
Appendix Service Tools and Supplies
Preventive Maintenance and Inspection Checklist
Appendix Preventive Maintenance and Inspection Checklist
Vehicle No. __________________________ Location ____________________________ Date __________________
Model Number _________________________________ Serial Number _____________________________________
Odometer _________________ Hours Meter _________________ Inspector _________________________________
Perform all inspections, adjustments, repairs, and lubrication according to Altec specifications in the Maintenance
Manual. Refer to any MABs, CSNs, or other applicable documents provided by Altec for servicing the unit.
If you are tracking PTO hours utilizing an approved method or device, follow the recommended hourly maintenance
intervals, or if you are performing maintenance based upon a calendar-based schedule, follow the recommended monthly
intervals. The required items apply to both interval-tracking systems.
Intervals
Prior to placing unit in service 85 PTO hours/1 month 500 PTO hours/6 months
1,000 PTO hours/1 year 2,000 PTO hours/2 years
Required maintenance
Symbols
= Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
Perform the Daily Preoperational Inspection
(refer to the Operators Manual)
Hydraulic Reservoir and System
Check oil and collect oil sample for analysis
1
Rotation Bearing
Turntable tilt measurement
2
: ___________
Prior to Placing Unit in Service
Perform the Daily Preoperational Inspection
(refer to the Operators Manual)
General Condition
Clean debris from turntable, cylinders, boom tip
Hydraulic Reservoir
Oil level
Hydraulic System
Pedestal (no leaks)
Turntable (no leaks)
Manual lowering system operation
Lubrication
Rotation bearing ball race
Lower boom lift cylinder spherical bearings
Rotation pinion and bearing gear teeth
85 PTO Hours/1 Month
Unit Mounting
Subbase mounting (fasteners secure, welds intact,
no cracks)
Subbase structure (welds intact, no cracks)
Pedestal mounting (fasteners secure, welds intact,
no cracks)
Boom rest (welds intact, no deformation or cracks)
Utility body mounting (cap screws secure, welds intact,
no cracks)
Hydraulic Reservoir
Mounting (cap screws secure, welds intact, no cracks)
No leaks
Shutoff valves fully open
Drain water from bottom
Perform the 85 hour/1 month inspection
DC Pump
Operation, noise level, no leaks
Mounting cap screws secure
Supplemental Brake Lock
Operation (holding, no bleed-off)
Chassis Underside
Hoses (routing, condition)
Exhaust shields
Pump
Mounting cap screws secure
4-bolt flange bolts secure
Drive line
Noise level, no leaks
500 PTO Hours/6 Months
Filters
Change return line filter
Hydraulic System Pressure
Main system pressure (_______ psi)
Lower Controls
Engine start/stop switch (operation)
Secondary stowage DC pump switch (operation)
Lower/emergency stop/upper control switch (operation)
Placards (condition, readable)
Pedestal
Structure (welds intact, no deformation or cracks)
Main control valve solenoid (operation)
Hoses and tubes (routing, condition)
No leaks
Turntable
Boom pin and retainers secure
Lift cylinder pivot pin and retainers secure
No leaks
Platform leveling cylinder (operation, fasteners
secure, no leaks)
Rotation Bearing and Gearbox
Gearbox mounting cap screw visual inspection
Motor mounting cap screws secure
Eccentric ring lock (in place, secure)
No leaks
Pinion gear teeth
Rotation bearing gear teeth condition
Pinion to rotation bearing gear backlash
Gearbox internal lost motion
Operation (smoothness, noise level)
Rotation bearing cap screws visual inspection
Rotation bearing inspection and measurement (after
0.050 increased wear from initial measurement)
2
Lower Boom Lift Cylinder
Pivot bearings secure within cylinder eyes
Pin retainers secure
Operation, no leaks
Holding valves (operation, no leaks)
Chromed rod condition
Extension Cylinder
Pins and retaining rings secure
Operation, no leaks
Holding valves (operation, no leaks)
Lower Boom
Lift cylinder pivot pin and retainers secure
Slide bearing nuts and cap screws secure
Remove any debris from inside lower boom
Boom slide blocks (cap screws secure, blocks not
excessively worn)
Upper Boom
Platform leveling cylinder mounting pins (flange weld
intact, cap screws secure and lockwired)
Hose assembly (no leaks, securely attached to
tension rod)
Covers in place
Ribbon hose (no leaks, hose routing)
Upper boom stow pad (condition, in place)
Boom tip weldment (welds intact, no deformation
or cracks)
Boom tip fasteners secure
Remove any debris from inside upper boom
Platform
Mounting secure (bracket, pins and fasteners)
Platform mounting cap screws secure
Platform (condition, clean)
Hoses (routing, not pinched or pulled, no leaks)
Lanyard attachment secure
Covers in place
Door latch (operation)
Upper Controls
Engine start/stop switch (operation)
Secondary stowage DC pump switch (operation)
Lower/emergency stop/upper control switch (operation)
Lubrication
Rotation gearbox oil level
Lift cylinder spherical bearing
Rotation gearbox upper bearing
Perform the 500 hour/6 month inspection
Clean suction filter
Change filler breather cap
Clean or change filler hole strainer
Perform the 1,000 hour/1 year inspection
Flush hydraulic system
Clean inside of reservoir
Clean magnetic suction separator filter
Change hydraulic oil
Manual lowering system operation
Rotation Bearing
Rotation bearing inspection and measurement (before
0.050 increased wear from initial measurement)
2
Lubrication
Change rotation gearbox oil
1
Periodic laboratory analysis is the most accurate method of determining the condition of the hydraulic oil and when it should be changed.
If laboratory analysis is used, take baseline sample. Compare future lab tests on subsequent samples to the original to establish a trend.
2
Initially measure turntable tilt as a baseline. Check rotation bearing wear every 2 years until it measures 0.050 increased wear from initial
measurements. After reaching 0.050 increased wear, measure every 6 months. Refer to the Maintenance Manual for the proper procedure.
Check oil and collect oil sample for analysis
1
Rotation Bearing and Rotation Gearbox
Annual torque inspection
Lubrication
Pump input shaft splines
1,000 PTO Hours/1 Year
2,000 PTO Hours/2 Years
Appendix Accessory Checklist
Accessory Checklist
Vehicle No. __________________________ Location ____________________________ Date __________________
Model Number ___________________ Serial Number ___________________ Inspector _______________________
Symbols
= Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
1,000 PTO Hours or as Recommended by the Manufacturer
* DOT items
Unit Accessories
Platform liners
Platform covers
Tool holders (mounting and condition)
Scabbard (mounting and condition)
Spare augers
Screw anchor wrench
Lifting slings and chains
Hydraulic cooler (mounting, condition and fan operation)
Hydraulic oil heater (operation and condition)
ROACS system (operation)
Radio controls
Auxiliary power unit (mounting, pump to bellhousing
bolts, exhaust system, cooling system, fuel system)
Body Accessories
Body (structure, mounting)
Outrigger pads and holders
Pole rack mounting
Access steps (condition and mounting)
Cargo area retention (mounting and condition)
Dump bed operation (dump hoist and body prop)
Spotlights and work lights
Beacons
Wheel chocks and holders
Mud flaps
Cones and holders
Inverters (operation and mounting)
Generators (operation and mounting)
Platform rest (condition and mounting)
Fire extinguishers*
First aid kit
Flare kit/warning triangles (3)*
Grounding reel
Power cord reel
Hotstick tube or box
Ladder rack
Spare fuse pack*
Chassis Accessories
Front winch (mounting and operation)
PTO and driveline
Bed winch
Capstan
Collapsible reel
Secondary brake system
Pintle hitch (condition and mounting)
Safety chain eyebolts
Trailer plug
Tow hooks
Cab guard
Brake controller (mounting and operation)
Back up alarm (mounting and operation)
Torsion bar
Hydraulic Tools and Hoses
Hose reel and hoses
Pole puller, chain and base
Impact
Chain saw
Tamp
Quick disconnects
Appendix Accessory Checklist
Appendix Torque Values
Fitting Size T.F.F.T. Fitting Size T.F.F.T.
1
/8 2 to 2
1
/2
3
/4 1
1
/2 to 2
3
/16 2 to 2
1
/2
7
/8 1
1
/2 to 2
1
/4 2 to 2
1
/2 1 1
1
/2 to 2
5
/16 2 to 2
1
/2 1
1
/8 1
1
/2 to 2
3
/8 1
1
/2 to 2 1
1
/2 1
1
/2 to 2
1
/2 2 to 2
1
/2 2 1
1
/2 to 2
5
/8 2 to 2
1
/2
Pipe Thread T.F.F.T. Valve Cartridges
Wrench Size Fitting Size Torque ft-lbs (Nm)
7
/8 -8 20 (27)
1 -10 25 (34)
1
1
/8 -10 25 (34)
1
1
/4 -12 35 (48)
1
1
/2 -16 50 (68)
2 -20 65 (88)
Compression Fittings
Tube Size Fitting Size T.F.F.T.
1
/8 thru
1
/4 2 thru 4 1
1
/4
5
/16 5 1
3
/4
3
/8 thru 1 6 thru 16 2
1
/4
Split Flanges
Flange Size Thread Torque in-lbs (Nm)
3
/4
3
/8-16 250 to 350 (28 to 40)
1
3
/8-16 325 to 425 (37 to 48)
1
1
/4
7
/16-14 425 to 550 (48 to 62)
1
1
/2
1
/2-13 550 to 700 (62 to 79)
2
1
/2-13 650 to 800 (73 to 90)
Torque Values
Size
SAE Grade 5
ft-lbs (Nm)
SAE Grade 8
Hex and Socket Head
ft-lbs (Nm)
Button and Flat Head
ft-lbs (Nm)
1
/4 0.2500 8 (11) 6 (8) 11 (15) 9 (12) 9 (12) 8 (11)
5
/16 0.3125 16 (22) 13 (18) 22 (30) 18 (24) 19 (26) 15 (20)
3
/8 0.3750 28 (38) 23 (31) 39 (53) 33 (45) 33 (45) 28 (38)
7
/16 0.4375 44 (60) 37 (50) 63 (85) 52 (71) 54 (73) 45 (61)
1
/2 0.5000 68 (92) 57 (77) 96 (130) 80 (108) 82 (111) 68 (92)
9
/16 0.5625 98 (133) 82 (111) 138 (187) 115 (156) 118 (160) 98 (133)
5
/8 0.6250 135 (183) 113 (153) 191 (259) 159 (216) 164 (222) 136 (184)
3
/4 0.7500 240 (325) 200 (271) 339 (460) 282 (382) 290 (393) 241 (327)
7
/8 0.8750 386 (523) 322 (437) 545 (739) 455 (617) 467 (633) 390 (529)
1 1.0000 579 (785) 483 (655) 818 (1,109) 681 (923) 701 (951) 583 (791)
Cap Screws
Torque values shown are for turning the nut while holding the head of the bolt with a wrench. If the application demands tightening by the bolt head,
increase the torque slightly (by 5-20 percent depending on the bolt length) to allow for the normal twist of the bolt shank.
Dry Lubed Dry Lubed Dry Lubed
Appendix Torque Values
Torque With Self-Locking Nuts Torque Without Self-Locking Nuts
Fitting Size in-lbs (Nm) in-lbs (Nm)
-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.
SAE O-Ring Fittings
Misalignment
of marks show
how much nut
was tightened
Tube and JIC Fittings
Rotate Number
Tube Size Fitting Size of Hex Flats
1
/4 -4 2
5
/16 -5 2
3
/8 -6 1
1
/2
1
/2 -8 1
1
/2
5
/8 -10 1
1
/2
3
/4 -12 1
1
/4
1 -16 1
1
1
/4 -20 1
1
1
/2 -24 1
Basic JIC Symbols
Appendix Basic JIC Symbols
Methods of Operation
Spring
Manual
Manual, rotary
Push button
Push/pull lever
Pedal or treadle
Mechanical
Detent
Pressure compensated
Solenoid, single winding
Servo motor
Pilot pressure
Lines
Remote supply
Internal supply
Line, pressure or tank
Line, sense (for control)
Component enclosure
Flow, direction of
Lines crossing
Lines joining
Line with fixed restriction
Flow control adjustable, non-compensated
Flow control adjustable
(temperature and pressure compensated)
Station, testing, measurement,
power take-off or plugged port
or
)
Hydraulic
Pneumatic
Double-acting
Single-acting, internal spring
Single-acting, external spring
Check
Counterbalance
On - off (manual shut-off)
Pressure relief
Pressure reducing
Two-position, two connection
Two-position, three connection
Two-position, four connection
Three-position, four connection
Two-position, in transition
Valves capable of infinite
positioning (horizontal bars
indicate infinite positioning ability)
Shuttle valve
Typical closed center spool
Typical open center spool
Cylinders Valves
Reservoir
Line, to reservoir
Vented manifold
Vented
Pressurized
Above fluid level
Below fluid level
Fluid Storage
Hydraulic oscillator
Hydraulic motor
Fixed displacement
Variable displacement
Bidirectional
Motors
Pumps
Hydraulic pump
Fixed displacement
Variable displacement
)
Variable component
(run arrow through symbol at 45 degrees)
Pressure compensated units
(arrow parallel to short side of symbol)
Direction of shaft rotation
(assume arrow on near side of shaft)
Flowmeter
Pressure switch
Pressure gauge
Pressure sensor
Temperature gauge
Quick disconnect
Internal combustion engine
Accumulator, spring loaded
Accumulator, gas charged
Weighted
Filter, strainer
Filter with adjustable bypass
Heater
Cooler
Temperature controller
Temperature cause or effect
Miscellaneous
(
(
Hydraulic System Schematics
Appendix Hydraulic System Schematics
Single Speed
Two Speed
Appendix Hydraulic System Schematics
Counterbalance
Valve
Pump Reservoir DC Pump
Control Valve Two-Speed Control Valve
Appendix Basic Electrical Symbols
Basic Electrical Symbols
Relays
Switches
Transistors
Motor
Circuit breaker
Fuse
Capacitor
Coil
Connection
No connection
Battery
Ground
Diodes
Resistors
Chassis or common return connected
to one side of voltage source
Chassis or common return not
connected to voltage source
Fixed
Variable
Rectifier
Photoemissive diode (LED)
Simple
Bistable
Latching
Logic
Single-pole, single-throw (SPST)
Single-pole, double-throw (SPDT)
Double-pole, single throw (DPST)
Double-pole, double-throw (DPDT)
NPN
PNP
Air-core
Iron-core
K A
K A
M
B
C
E
B
C
E
Appendix Basic Electrical Symbols
Wiring Line Diagrams
Appendix Wiring Line Diagrams
Chassis/Lower Controls/Main Junction Panel
Appendix Wiring Line Diagrams
Upper Controls
Stability Test Form
Appendix Stability Test Form
General Information
Perform the stability test on a level surface and on a five degree slope in accordance with ANSI requirements.
Find the model being tested in the chart for the test being performed.
Conduct test with booms horizontal and fully extended.
Subtract the weight of liners, tools, etc., from the test weight shown in the stability charts. For platform capaci-
ties not shown, use a test weight of 1.5 times rated load for the Level Surface Stability Test and 1.33 times
rated load for the Five Degree Slope Stability Test.
After the test has been completed, torque all accessible rotation bearing cap screws to 170 foot-pounds using a
circular pattern (only required at time of initial installation of unit on chassis).
After the test has been completed, torque the rotation gearbox mounting cap screws to 110 foot-pounds (only
required at time of initial installation of unit on chassis).
Model number ______________________________ Serial number _________________________________________
Platform capacity (lbs) _______________________ Counterweight added to unit (lbs) _________________________
Location of counterweight relative to rear axle __________________________________________________________
Level Surface Test
Platform test weight (lbs) __________________ Thickness of outrigger pads (0 if not used) ____________________
Five Degree Slope Test
Platform test weight (lbs) __________________ Thickness of outrigger pads (0 if not used) ____________________
Side of vehicle on low side of slope __________________________________________________________________
Conclusion
Rotation bearing cap screws torqued ____________ Rotation gearbox mounting cap screws torqued ____________
Pass _____ Fail (reason) __________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
Signature of Technician ________________________________________ Date of test ________________________
Test Weight (lbs)
Level Five Degree
Platform Capacity Surface Slope
End mount 300 450 400
Side mount 350 525 467
Test
Weight
Appendix Stability Test Form

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