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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 specifcations without notice.
2013
www.altec.com
749-10067
D2000B/3000B
Maintenance
and Parts Manual
Preface
This unit is the result of Altecs advanced technology and quality awareness in design, engi-
neering, and manufacturing. At the time of delivery from the factory, this unit met or exceeded
all applicable requirements of the American National Standards Institute. All information,
illustrations, and specifcations 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 main-
tenance.
The scope of this manual is limited to periodic maintenance. It does not cover methods that
may be required to inspect and repair major damage to the unit. Impacts to and excessive
forces on the hydraulic utility equipment, through vehicular accidents, rollovers, excessive
loading, and the like, may result in structural damage not obvious during a visual inspection.
If the hydraulic utility equipment is subjected to such impacts or forces, a qualifed person
may need to perform additional testing such as acoustic emissions, magnafux 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 specifc written approval of Altec Industries, Inc. Unauthorized
alterations or modifcations will void the warranty. Of greater concern, is the possibility that
unauthorized modifcation could adversely affect the safe operation of this unit, resulting in
personal injury and/or property damage.
Danger
Death or serious injury will result from unprotected contact with energized conductors.
Non-insulating units have no dielectric rating. Maintain safe clearances, as defned by
federal, state, and local authorities, and your employer, from energized conductors.
No unit can provide absolute safety when in proximity to energized conductors. No unit is
designed or intended to replace or supersede any protective device or safe work practice
relating to work in proximity to energized conductors. When in proximity to energized con-
ductors, this unit shall only be used by trained personnel using their 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.
Table of Contents
Section 1 Introduction
About This Manual..................................................................................................... 1
Section 2 Unit Specifcations
General Specifcations .................................................................................................. 3
Component Identifcation .............................................................................................. 5
Section 3 Safety
Safety Instructions ........................................................................................................ 7
Disclaimer of Liability .................................................................................................... 7
Section 4 Preventive Maintenance and Inspection
Equipment Storage ....................................................................................................... 9
Protective Measures ............................................................................................... 9
Hydraulic System .......................................................................................................... 9
Cleanliness Precautions ....................................................................................... 10
Filtration ................................................................................................................ 10
Oil Specifcations .................................................................................................. 12
Oil Condition ......................................................................................................... 13
Changing Oil and Flushing the System ................................................................ 14
Electrical System ........................................................................................................ 16
Slip Ring ............................................................................................................... 16
Lubrication .................................................................................................................. 16
Lubrication Chart and Diagram ............................................................................. 18
Structures .................................................................................................................... 23
Care of Exterior Surfaces ..................................................................................... 23
Welds .................................................................................................................... 24
Fasteners .................................................................................................................... 24
Rotation Bearing Cap Screws .............................................................................. 28
Rotation Gearbox Mounting Cap Screws ............................................................. 30
Digger Motor Cap Screws .................................................................................... 31
Auger and Auger Extension Shaft Cap Screws and Nuts ..................................... 31
Slide Pad Bearing Cap Screws ............................................................................ 31
Pins and Pin Retainers ............................................................................................... 31
Pin Installation Into Self-Lubricating Bearings ...................................................... 33
Pin Installation Into Lubricated Joints ................................................................... 34
Bearings ...................................................................................................................... 34
Spherical Bearings ............................................................................................... 34
Pressure Cast Cylindrical Bearings ...................................................................... 34
Self-Lubricating Bearings ..................................................................................... 34
Tapered Roller Bearings ....................................................................................... 35
Slide Pad Bearings ............................................................................................... 35
Rotation Bearing ................................................................................................... 36
Cylinders ..................................................................................................................... 39
Hydraulic Lines ........................................................................................................... 39
Atmospheric Vents ...................................................................................................... 39
Fiberglass and Plastic Components ........................................................................... 39
Cleaning ............................................................................................................... 39
Plastic ................................................................................................................... 40
Determining the Degree of Boom Damage........................................................... 40
Repair ................................................................................................................... 41
Winch Line .................................................................................................................. 43
Synthetic Winch Line ............................................................................................ 43
Wire Rope Winch Line .......................................................................................... 44
Auger Windup Sling .................................................................................................... 45
Wire Rope Sling .................................................................................................... 46
Synthetic Sling ...................................................................................................... 46
Auger Stow Bracket Clevis ................................................................................... 46
Accident Prevention Signs .......................................................................................... 46
Accident Prevention Signs Diagram ..................................................................... 47
Section 5 Hydraulic System
Protection Systems ..................................................................................................... 57
Hydraulic Overload Protection (HOP) ................................................................... 57
Hydraulic Side Load Protection (HSLP) System .................................................. 58
Electronic Side Load Protection (ESLP) System .................................................. 59
Boom Stow Protection .......................................................................................... 61
Auger Stow Protection .......................................................................................... 61
Load Moment Limiter .................................................................................................. 62
Anti-Two-Block (ATB) .................................................................................................. 62
Oil Reservoir ............................................................................................................... 63
Pump ........................................................................................................................... 64
Hydraulic Shock Absorber ........................................................................................... 64
Rotary Joint ................................................................................................................. 64
Valves.......................................................................................................................... 65
Outrigger Control Valve and Outrigger/Tools Control Valve ................................. 65
Lower Tool Circuit Flow Control Valve .................................................................. 66
Selector Valve ....................................................................................................... 66
Lower Control Valve ............................................................................................. 67
Auxiliary Functions Valve ...................................................................................... 68
Rotation Float Valve ............................................................................................. 69
Rotation Float Brake Release Valve ..................................................................... 69
Holding Valves ...................................................................................................... 70
Cavitation and Aeration ............................................................................................... 70
Air Bleeding ................................................................................................................. 71
Leakage ...................................................................................................................... 71
Heat Generation .......................................................................................................... 72
Hydraulic Lines ........................................................................................................... 72
Fittings and Valve Cartridges ...................................................................................... 73
Torque and Tightening Procedures ....................................................................... 73
Cylinders ..................................................................................................................... 74
Radial Outrigger Cylinder ..................................................................................... 76
A-Frame, X-Frame, and Modifed A-Frame Outrigger Cylinder ........................... 76
Out and Down Outrigger Vertical Leg Cylinder ..................................................... 78
Out and Down Outrigger Horizontal Leg Cylinder ................................................ 79
Lift Cylinder ........................................................................................................... 80
Intermediate Boom Cylinder ................................................................................. 80
Upper Boom Cylinder ........................................................................................... 82
Auger Latch Cylinder ............................................................................................ 84
Digger Shift Cylinder ............................................................................................. 84
Pole Guide Cylinders ............................................................................................ 85
Thermal Compensation Cylinder .......................................................................... 85
Section 6 Mechanical Systems
Rotary Joint ................................................................................................................. 87
Rotation System .......................................................................................................... 88
Rotation Bearing ................................................................................................... 89
Rotation Bearing Cap Screws ............................................................................. 91
Rotation Gearbox ................................................................................................. 92
Upper Boom ................................................................................................................ 94
Winch .......................................................................................................................... 95
Drum ..................................................................................................................... 95
Platform Brake ............................................................................................................ 96
Digger Transfer Mechanism ........................................................................................ 96
Section 7 Electrical System
On/Off Circuit .............................................................................................................. 99
Proportional Circuit ..................................................................................................... 99
Multiplexed Controls ................................................................................................. 100
Below Rotation Valve Driver...................................................................................... 100
Above Rotation Valve Driver ..................................................................................... 100
Cable Assemblies ..................................................................................................... 100
Multiplex Cable Connectors ...................................................................................... 100
Calibration and Calibration Diagnostic Instrument (CADI) ........................................ 104
Power Distribution Module (PDM) ............................................................................. 105
Outrigger Interlock System ....................................................................................... 105
A-Frame, X-Frame, Modifed A-Frame, Out and Down, or
Corner Mount Street Side Outriggers .......................................................... 105
Radial or Corner Mount Curb Side Outriggers ................................................... 105
Lower Control Panel ................................................................................................. 106
Dual Lower Control Panels ................................................................................. 106
Hand Controls ..................................................................................................... 106
Joysticks ............................................................................................................. 107
Slip Ring .................................................................................................................... 107
Upper Controls .......................................................................................................... 108
Operation ............................................................................................................ 108
Pole Guide Interlock System ..................................................................................... 109
Section 8 Troubleshooting, Testing, and Adjustments
Troubleshooting Procedure ........................................................................................111
Hydraulic System .......................................................................................................111
Cycle Times .........................................................................................................111
Pilot System Pressure ........................................................................................ 112
Standby Pressure ............................................................................................... 113
System/Compensator Pressure .......................................................................... 113
Secondary System Relief Pressure .................................................................... 114
Outrigger System Pressure ................................................................................ 115
Lower Tools System Pressure ............................................................................ 115
Pump Flow .......................................................................................................... 116
Outriggers ........................................................................................................... 117
Lower Tool Circuit ............................................................................................... 118
Upper Tool Circuit ............................................................................................... 120
Derrick Blocking Valve (DS1) ............................................................................. 121
Outrigger/Tool Blocking Valve (DS2) .................................................................. 122
Outrigger/Tool Sense Dump Valve (DS4) ........................................................... 123
Selector Valve Orifce ......................................................................................... 124
Outrigger/Tool Pressure Selector Valve (DS3) ................................................... 124
Sense Lines and Sense Shuttle Valves ............................................................. 125
Outrigger Interlock System ................................................................................. 128
Rotary Joint ........................................................................................................ 128
Pulsar Valves and Hand Controls ....................................................................... 129
Lift Cylinder ......................................................................................................... 131
Intermediate and Upper Boom Extension Cylinders ........................................... 132
Holding Valves .................................................................................................... 134
Mechanical System ................................................................................................... 136
Rotation Gearbox ............................................................................................... 136
Rotation Brake With Hydraulic Side Load Protection ......................................... 139
Rotation Brake With Electronic Side Load Protection ........................................ 139
Platform Brake .................................................................................................... 139
Digger Shift Cylinder ........................................................................................... 140
Electrical System ...................................................................................................... 140
Failure Identifcation ........................................................................................... 140
Short Circuit ........................................................................................................ 141
Pin and Circuit Identifcation ............................................................................... 142
Circuit Protection ................................................................................................ 142
Proximity Switches ............................................................................................. 142
Tilt Switches........................................................................................................ 143
Outrigger Interlock System ................................................................................. 144
Programmable Settings ...................................................................................... 144
Boom Functions Speeds .................................................................................... 146
Upper Control Sequential Boom Extension ........................................................ 147
Pole Guide Interlock System .............................................................................. 148
Protection Systems ................................................................................................... 150
Hydraulic Overload Protection (HOP) ................................................................. 150
Load Indicator Gauge ......................................................................................... 151
Hydraulic Side Load Protection (HSLP) ............................................................. 152
Electronic Side Load Protection (ESLP) ............................................................. 156
Boom Stow Protection ........................................................................................ 159
Auger Stow Protection ........................................................................................ 159
Rotation Pressure Limiter ................................................................................... 160
Lower Boom Pressure Limiter ........................................................................... 161
Extension Pressure Limiter ................................................................................. 162
Load Moment Limiter .......................................................................................... 163
Anti-Two-Block (ATB) ........................................................................................ 163
Manually Lowering/Stowing the Unit ......................................................................... 164
Rotating the Turntable ........................................................................................ 165
Lowering the Booms ........................................................................................... 165
Manually Raising the Outriggers ........................................................................ 166
Auxiliary Power Source ............................................................................................. 166
Bypassing the Derrick Blocking Valve ....................................................................... 169
Bypassing the Outrigger/Tool Blocking Valve............................................................ 169
Section 9 Dielectric and Stability Testing
Dielectric ................................................................................................................... 173
Stability ..................................................................................................................... 173
Load Moment Limiter ................................................................................................ 176
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
Dielectric Test Forms
Stability Test Forms
Section 1 Introduction 1
Section 1 Introduction
Throughout the manual, the term unit is used to describe
the Altec device, subbase, outriggers, and the associated
interface with the vehicle.
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, caution, and notice repre-
sent varying degrees of personal injury and/or property
damage that could result if the preventive instructions
are not followed. The following paragraphs from ANSI
publications explain each term.
Danger
Indicates a 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 hazardous situation which, if not
avoided, could result in death or serious injury.
Caution
Indicates a hazardous situation which, if not
avoided, may result in minor or moderate in-
jury. It may also be used to alert against unsafe
practices.
Notice
The preferred signal word to address practices
not related to personal injury.
About This Manual
This manual provides instruction to safely inspect, re-
pair, troubleshoot, and test the unit. Charts and fgures
are provided to support the text. Because options vary
from one model to another, some fgures 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 maintaining
the unit. Read and understand the applicable procedure
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, renters,
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.
2 Section 1 Introduction
Section 2 Unit Specifcations 3
Section 2 Unit Specifcations
General Specifcations
This unit has a lower boom with telescoping intermediate
and upper booms. The lower and intermediate booms are
steel. The upper boom is fberglass. Figure 2.1 provides
general unit specifcations.
The basic structural components are the outriggers, sub-
base, pedestal, turntable, lower boom, intermediate boom,
and upper boom. The steel structures are manufactured in
the form of a closed box or tubular construction. This con-
struction resists torsional loading. It also resists tension,
compression, and bending loads. Careful consideration
has been given to the design and manufacturing process
to minimize the possibility of fatigue cracks.
The round upper boom is made of centrifugally cast
fberglass. The inner fberglass surface is impregnated
with a wax compound, providing a smooth surface for
moisture to bead. The outer surface has a smooth gelcoat
fnish to protect the fberglass.
The nonconductive components, when properly main-
tained, clean, dry, free from tracking, and in good condi-
tion as established by dielectric testing, will meet the
dielectric requirements of ANSI in effect at the time of
unit manufacture. The ratings of the unit must be known
and understood by its users.
This unit shall be used near energized conductors only by
qualifed operators who are fully trained and profcient as
electrical linemen. Personnel using this equipment must
be familiar with the hazards of contact with energized
conductors, for the protection of themselves, their co-
workers, and the public. The nature of electrical hazards
is described in the Operators Manual.
4 Section 2 Unit Specifcations
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Section 2 Unit Specifcations 5
Component Identifcation
Lower Boom
Lift Cylinder
Outrigger
Cylinder
Outrigger Controls
Pedestal
Rotation Bearing
Boom Pin
Boom Angle Indicator
Auger Stow
Bracket
Extension
Cylinder
Auger
Auger
Extension Shaft
Digger
Digger Link
Boom Tip Winch
Upper Boom
Platform
Jib
Upper
Boom Tip
Platform Pin
Capacity
Chart
Turntable
Rotation
Gearbox
Turntable
Winch
Lower
Controls
Intermediate Boom
Digger Hanger
Bracket
Pole Guide Tong
Cylinder
Pole Guide
Outriggers
Anti-
Two-Block
Switch
6 Section 2 Unit Specifcations
Section 3 Safety 7
Section 3 Safety
Maintenance procedures may require the use of ladders,
platforms, scaffolding, etc., to access the unit. Provide
suitable work surfaces clear of obstructions for mainte-
nance procedures. Do not stand or walk on surfaces that
are not intended as such.
General Maintenance Information
Read and understand the complete procedure
before 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
counterbalance 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.
Many inspections require the removal of covers.
After the inspection is complete, replace the covers
before returning the unit to service.
Disclaimer of Liability
Altec Industries, Inc. will not be liable for unauthorized
alterations or modifcations 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 specifc written approval from
Altec Industries, Inc.
Unauthorized alterations or modifcations 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 unauthorized
alterations or modifcations that cause death, serious
injury, and/or property damage.
Altec Industries, Inc. assumes no liability for any personal
injury and/or property damage related to the use of this
manual when performing testing, operating, maintenance
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 Main-
tenance 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 in proximity to another conductor or
any grounded device, material, or equipment. Maintain
safe clearances from energized conductors.
Warning
Death or serious injury can result from careless
or improper use of the unit. The mechanic bears
ultimate responsibility for following all regulations
and safety rules of their employer and/or any state
or federal law.
Notice
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 frst aid procedures and waste disposal
methods. Properly dispose of oil and hazardous materi-
als.
Caution
Injury can result from slipping and falling. Use care
and suitable work platforms during maintenance.
8 Section 3 Safety
Section 4 Preventive Maintenance and Inspection 9
Section 4 Preventive Maintenance and Inspection
Proper unit maintenance will reduce downtime, lower op-
erating and repair costs, and extend equipment life. Safety
alone justifes a preventive maintenance program. This
section contains information on properly inspecting the
hydraulic system, structures, individual unit components
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. Components may be installed
on your unit that require additional maintenance at
different intervals outside the scope of the Preventive
Maintenance and Inspection and Accessory Checklists.
Refer to these component manuals for more information.
Keep permanent, written, and dated records of all service
performed on the unit.
Routine maintenance is performed on different com-
ponents of the unit at different times (refer to the Pre-
ventive 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
recommendations, follow these recommendations on
new units.
Check oil level and collect sample for analysis.
Measure the turntable tilt before using a new unit.
Change the return line flter cartridge after the frst
15 to 25 PTO hours
Gearbox manufacturers recommend an initial oil
change after the frst 15 to 25 PTO hours.
Equipment Storage
Mobile hydraulic equipment needs maintenance when
stored, or not used, for extensive periods of time. De-
pending 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 nonuse, and lubricants will lose their ability to provide
lubrication. In cold climates, condensation may occur in
fuid reservoirs and other components.
Even when protective measures have been taken prior
to storage, some degradation of performance must be
expected when the equipment is put back into use.
One of the most noticeable effects of prolonged periods
of nonuse 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 fatten 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
surfaces 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 fuid 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
overfow 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 protect-
ing electrical connectors. Plug the connector back
together.
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 fberglass components from the sun and other
elements, if stored outside.
Hydraulic System
Warning
Death or serious injury can result if the recommended
hydraulic oil is not used. Other fuids added to the
10 Section 4 Preventive Maintenance and Inspection
hydraulic system can affect the insulating capability
of the unit.
Notice
Only use hydraulic oil as recommended. Other fuids
added to the hydraulic system can increase compo-
nent wear and affect the lubricating characteristics
of the oil.
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 can be damaged.
Check the oil level in the reservoir with the vehicle level
and the booms and outriggers stowed. Under these
conditions, the proper oil level is between the Add and
Full marks on the dipstick.
Cleanliness Precautions
Contamination will ruin any hydraulic system. It is very
important that no contaminants enter the system. Dirt,
water, and air are types of contaminants. They can enter
the hydraulic system in many ways. Contaminants can
enter the system when flling the reservoir or changing
flters. 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 flter 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 installa-
tion.
Clean the reservoir and return line flter covers
before opening them.
Clean the fller 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 fller breather cap.
This could force contaminants into the reservoir.
Filtration
The unit is equipped with a complete fltration system.
When properly maintained, this system will reduce con-
tamination of the hydraulic system. The fltration system
must be serviced regularly to be effective.
Filler Breather Cap and Strainer Basket
The fller breather cap is located on top of the fll hole of
the reservoir (refer to Figure 4.1).
Figure 4.1 Reservoir
The cap allows air to fow in and out of the reservoir as
the oil level changes. It contains a flter that cleans the
air as it enters the hydraulic system. The fll hole strainer
basket keeps large particles from entering the reservoir
when oil is poured into it. The cap has a built-in dipstick
with Full and Add marks. Use the marks to determine the
oil level of the reservoir as described under Hydraulic Oil
Specifcations in this section.
Replace the fller breather cap flter (refer to Service Tools
and Supplies in the Appendix) as recommended by the
Preventive Maintenance and Inspection Checklist. If the
unit is operated in an extremely dusty environment, the
flter may need to be changed more often.
Remove and fush 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.
Suction Filter
A magnetic suction separator flter is located in the bottom
of the reservoir at the outlet (refer to Figure 4.1).
The magnetic suction separator flter has a pleated wire
mesh screen. This screen prevents particles that are 250
Filler Breather
Cover
Assembly
Suction
Filter
Return Line Filter
Outlet
Pipe
Section 4 Preventive Maintenance and Inspection 11
micron or larger from entering the pump. One micron is
0.00039. Magnets located inside the flter attract and
collect iron and steel particles in the hydraulic oil.
Clean the flter whenever the hydraulic oil is changed. Oil
will not fow into the pump fast enough if the flter becomes
clogged. If the pump does not receive suffcient oil fow,
pump damage will result.
Use the following procedure to remove and clean the
flter.
1. Drain the reservoir and wipe the top of the reservoir
cover. Loosen the cap screw in the center of the
cover two to three turns. Slide the cover assembly
to one side. Lift up on the other side and slide the
assembly back to remove it from the reservoir.
2. Reach down into the reservoir with a wrench which
will ft the 3.15 (80 mm) hex at the bottom of the
flter. Unscrew the flter by using the wrench to turn
the flter counterclockwise. Do not grip the wire mesh
screen by hand or with the wrench. This will crush
the screen.
3. Disassemble the flter and remove the magnet as-
sembly out of the suction flter.
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.
Eye protection must be worn at all times to prevent particles
of dirt, metal, or hydraulic oil from entering the eyes.
4. Clean the flter screen by fushing it with clean sol-
vent. Blow it dry with an air hose from the inside of
the screen to the outside. Check for holes or other
damage. Replace the suction flter if the screen is
damaged.
5. Clean the magnets by fushing them with solvent.
Blow them off with an air hose and wipe them dry
with a lint-free rag.
6. Assemble the flter screen and magnet assembly.
7. Inspect the inside of the reservoir. If necessary, clean
it as described under Changing Oil and Flushing the
System in this section.
8. Install the suction flter in the reservoir by turning the
hex at the bottom clockwise with a wrench. Clean the
flter no more than four times before replacing it.
9. Install the cover assembly.
Return Line Filter
The return line flter is a 10 micron flter that cleans the oil
as it enters the reservoir. It is mounted in the reservoir.
Particles trapped by the flter are collected in the flter
cartridge. This cartridge is disposable and is available
from your Altec representative (refer to Service Tools and
Supplies in the Appendix).
The return line flter is equipped with a bypass valve in
the flter head. The bypass valve opens when there is
a pressure drop of 25 psi (1.72 bar) or more across the
flter cartridge. When the valve is open, oil fows directly
into the reservoir. This prevents the cartridge from col-
lapsing during cold weather or if it is clogged.
If the flter becomes clogged, oil will fow directly into the
reservoir through the bypass valve. The lack of oil fltration
will eventually damage hydraulic components.
During the break-in period of a new unit, the hydraulic com-
ponents will deposit break-in wear particles in the return
line flter cartridge. Change the return line flter cartridge
after the frst 15 to 25 hours. Then, change the cartridge
as recommended by the Preventive Maintenance and
Inspection Checklist. If the unit is operated in very dusty
conditions, replace the return line flter cartridge more
often. Also, replace the flter cartridge after new oil has
circulated through the system for the frst time.
Use the following procedure to change the return line
flter cartridge.
1. Wipe off the cover on the flter head (refer to Figure
4.1). Remove the cover and bypass valve.
2. Lift the cartridge out of the flter housing.
3. Inspect the inside of the flter housing for dirt buildup.
Wipe the housing out if necessary. Do not drop any
dirt through the outlet hole at the bottom of the flter
housing.
4. Insert the new cartridge in the housing. Do not clean
and reuse the old cartridge.
12 Section 4 Preventive Maintenance and Inspection
5. At the bottom end of the cartridge there is a sealing
grommet. Fit the raised portion of the outlet tube
through the grommet. Push the cartridge down until
it sits against the bottom of the housing.
6. Install the bypass valve and flter cover. Tighten the
cover cap screws. Do not overtighten the cover cap
screws. Excessive torque will strip the threads in the
aluminum flter housing.
Cold Oil/Change Filter Light
A cold oil/change flter light is located on the lower control
panel (refer to Figure 4.2). This light alerts the operator
when the return line flter needs changing or when the
hydraulic oil is cold. The cold oil/change flter light is
operated by the flter switch on the rotary joint.
When the return line flter becomes contaminated, a pres-
sure drop is created across the return line flter cartridge.
When the pressure drop reaches 25 psi (1.72 bar), oil
begins to fow through the bypass valve in the return line
flter instead of through the flter cartridge. When the pres-
sure at the rotary joint is 38 psi (2.62 bar), the cold oil/
change flter light will turn on to warn of the condition.
The cold oil/change flter light will also be on when the
hydraulic oil is cold. Cold oil increases back pressure in
the return line. Excessive pump speed also increases
back pressure. Even if the flter cartridge is in good con-
dition, the light will turn on if the back pressure exceeds
the pressure switch setting of 38 psi (2.62 bar).
Use the cold oil/change flter light as an indicator of flter
condition only when the oil is warm and the pump is run-
ning at no more than maximum rated fow.
Oil Specifcations
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 in insulated equipment must possess
high demulsibility to allow the oil to separate from the
water in the reservoir. These oils must pass the ASTM
D877 test for dielectric breakdown voltage of insulating
oils at 35 kilovolts or higher for new oil.
Hydraulic oil is commonly classifed 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 fow at low
temperatures is measured by its pour point. If the pour
point is not low enough, oil will not fow into the pump
at a fast enough rate when the pump is operated at low
temperatures. This will cause cavitation, which can very
quickly destroy the pump.
Warning
Death or serious injury can result if the recommended
hydraulic oil is not used. Other fuids added to the
hydraulic system can affect the insulating capability
of the unit.
Figure 4.2 Lower Control Panel
Cold Oil/Change Filter Light
Section 4 Preventive Maintenance and Inspection 13
Notice
Only use hydraulic oil as recommended. Other fuids
added to the hydraulic system can increase compo-
nent wear and affect the lubricating characteristics
of the oil.
Using a hydraulic fuid outside the temperature range
it was prescribed for may cause system damage.
Only use oils meeting the viscosity rating for military
specifcation MIL-5606 in extremely cold climates.
These oils have fewer antiwear characteristics and
are not recommended for full time use.
Figure 4.3 shows hydraulic oil recommendations for dif-
ferent temperatures. The requirements are for mineral
based and biodegradable hydraulic fuids. Most compa-
nies can supply equivalent oils. The oil selected for the
hydraulic system depends on the temperature during
unit operation.
When reflling or changing hydraulic fuids it is recom-
mended the replacement fuid meet oil cleanliness re-
quirement 21/17/14 as specifed by ISO 4406.
Oil Condition
An important part of hydraulic system preventive main-
tenance includes checking the condition of the hydraulic
oil.
Periodic laboratory analysis is the most accurate method
of determining the condition of the hydraulic oil and de-
termining when it should be changed. A visual inspection
may also be used to check oil condition.
A hydraulic oil supplier should be able to do testing or
recommend a test laboratory. The laboratory should
provide the following information.
Particle count
Trace element analysis (component wear, outside
contaminants and oil additive concentrations)
Viscosity test
Water content test
Dielectric strength test (when requested)
Before taking a sample of oil, operate the unit to circu-
late 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 fow 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 labora-
tory, 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 in it.
Specifcation All Weather Oil Cold Weather Oil Warm Weather Oil
ISO grade 22 15 32
Ambient temperature range -10 to 95 F (-23 to 35 C) -50 to 60 F (-46 to 16 C) 40 F (4 C) and above
Viscosity @ 104 F (40 C) 24 cSt 15 cSt 32 cSt
Viscosity @ 212 F (100 C) 4.6 cSt 4.4 cSt 6.0 cSt
Pour point, biodegradable -31 F (-35 C) -58 F (-50 C) -31 F (-35 C)
Pour point, mineral based -48 F (-55 C) -76 F (-60 C) -49 F (-45 C)
Flash point (min) 302 F (150 C) 302 F (150 C) 302 F (150 C)
Dielectric strength (min) 35 kV 35 kV 35 kV
Four-ball wear, scar (max) 0.028 (0.70 mm) 0.028 (0.70 mm) 0.028 (0.70 mm)
Oxidation stability, TOST (min) 2,000 hours 2,000 hours
Oxidation stability, RPVOT (min) 250 minutes 177 minutes 250 minutes
Water content (max) 63 ppm 38 ppm 63 ppm
Demulsibility, minutes to pass 15 10 15
Copper corrosion 1A 1A 1A
Rust test, pass/fail Pass Pass Pass
Foam test, pass/fail Pass Pass Pass
Figure 4.3 Hydraulic Oil Viscosity Recommendations
14 Section 4 Preventive Maintenance and Inspection
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.
Notice
Change the oil if the sample has any of the charac-
teristics listed in Figure 4.4.
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 4.4.
There are fuid contamination level 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 oxi-
dation 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 fltration system greatly extends the
useful life of the hydraulic oil. However, the hydraulic oil
will eventually need to be replaced due to contaminants
that form during the 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.
If a hydraulic component fails and contaminates the
system with metallic particles, change the component
and the oil immediately.
In climates with a wide variation in operating tempera-
tures between summer and winter months, change
to an appropriate weight oil each spring and fall.
Replace the return line flter cartridge and fller breather
cap flter every time the hydraulic oil is changed. Also,
clean or replace the magnetic suction separator flter.
A signifcant 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 contami-
nated with metal particles.
If the oil is contaminated with water, it may not be neces-
sary to change the oil and fush the system. Follow the
instructions under Water Removal in this section.
The following equipment and supplies are necessary to
properly fush the hydraulic system.
Approximately 85 gallons (322 l) of proper grade
hydraulic oil
Two return line flter cartridges
Clean, lint-free rags
Four seals for the return line flter housing
Filler breather cap flter (if the component has not
been replaced within one year)
Figure 4.4 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 fuids; presence of water
Decrease in viscosity Addition of improper fuids; additive deterioration
Separation of water or other fuids from the oil Presence of water; addition of improper fuids
Foreign particles or other visible contamination Contamination; emulsion of water with oil additives
Section 4 Preventive Maintenance and Inspection 15
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 fush the hydraulic sys-
tem.
1. If the oil is being changed because of contamination
due to a 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, reservoir cover, fller
breather cap, and return line flter.
4. Remove the reservoir cover and the magnetic suc-
tion separator flter. Disassemble and clean it as
described under Suction Filter in this section.
Warning
Death or serious injury can result from improper
use of solvents. Follow the manufacturers label for
proper use and disposal.
5. Inspect the inside of the reservoir. If sludge or other
contamination is found, clean it using solvent and
lint-free rags. Remove the return line flter to provide
an additional access hole for cleaning. Disconnect
the pump suction line from the bottom of the reservoir
while cleaning. This will keep dirt and solvent out of
the suction line.
6. Reconnect the suction line immediately after cleaning.
Install the return line flter using new seals on the cap
screws that clamp the flter head to the reservoir.
7. Install the clean magnetic suction separator flter in
the reservoir. Install a new flter in the fller breather
cap.
8. Install the reservoir cover assembly.
9. If hydraulic component failure has contaminated the
system, change the return line flter cartridge.
10. Add approximately 25 gallons (95 l) of new hydraulic
oil of the proper grade to the reservoir. If possible,
the new oil should be pumped through a 10 micron
flter as it is put into the reservoir.
11. If the new oil was not fltered as it was put into the
reservoir, connect a service hose to the tool outlets
and allow the new oil to circulate through the tool
circuit for about 15 minutes.
12. Use a slow engine speed, cycle all the cylinders and
motors to fush the contaminated oil from the lines
and components of the hydraulic system.
13. Change the return line flter cartridge.
14. Drain the reservoir completely.
15. Fill the reservoir with new hydraulic oil of the proper
grade to the Full mark on the dip stick. Filter the oil
through a 10 micron flter as it is put into the reser-
voir.
16. If the new oil was not fltered as it was put into the
reservoir, circulate the oil through the tool circuit as
described in step 12.
17. Change the return line flter cartridge after approxi-
mately 25 hours of operation.
Water Removal
If the hydraulic system was contaminated with water,
special water removal fltration may be necessary. An oil
supplier or a qualifed laboratory can determine whether
water has caused excessive oil oxidation or additive
deterioration.
If analysis shows that oil deterioration beyond an accept-
able level, drain the reservoir and fush the system as
described earlier in this section. Use a water removal flter
cart during the fushing process to remove any residual
water from the system.
If the condition of the oil 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 water removal flter cart.
While doing this, occasionally start the unit and cycle
all the functions. This will fush contaminated oil back
to the reservoir. Continue this process until the water
content in the oil is reduced to an acceptable level. The
preferred method of determining the water content in the
oil is laboratory testing. Another method of determining
water content in the oil is a dielectric test.
Do not attempt to use a water removal cartridge in the
return line flter to remove water from the system. The
fow rate of the pump, even at engine idle, exceeds the
fow at which effcient water absorption occurs.
16 Section 4 Preventive Maintenance and Inspection
Electrical System
Maintaining the electrical system is critical for proper
operation of the unit.
Slip Ring
This unit uses an electrical slip ring assembly to transmit
electrical signals between the pedestal and the turntable.
It protects the electrical wiring that passes through the
centerline of rotation. Failure to properly maintain the slip
ring may result in corrosion or degradation of contacting
surfaces, which may lead to malfunction and eventual
need for replacement of the slip ring.
This unit may be equipped with a serviceable slip ring.
The procedure outlined in this section should only be
performed on a serviceable slip ring. Attempting to
perform this procedure on any other slip ring may void
the manufacturers warranty. A serviceable slip ring is
identifed by the presence of fasteners which hold the
metal cover over the slip ring circuit assembly (refer to
Figure 4.5).
Figure 4.5 Slip Ring Identifcation
1. Position the unit on a level surface where the booms
can be elevated and rotated 360 degrees without
contact with fxed objects. Apply the parking brake
and chock the wheels. Engage the PTO and properly
set the outriggers. Disengage the PTO and turn off
the engine.
2. Remove any turntable or pedestal covers required
to access the slip ring assembly. Disconnect any
plumbing necessary to allow removal of the cover
from the slip ring assembly.
3. Remove the cover from the slip ring assembly. Re-
connect any plumbing which was disconnected in
step 2.
Caution
Injury can result from being pinched or trapped be-
tween moving components. Keep hands clear.
4. Spray the slip ring surfaces with DeoxIT cleaner/
protectant (refer to Service Tools and Supplies in
the Appendix). Normally one to two bursts of spray
is suffcient. If access to the slip ring is limited, rotate
the turntable to access all areas. Use care when
rotating the unit, as removed covers may expose
pinch points or other hazards.
5. Following treatment of all contact surfaces, start the
engine, engage the PTO, and rotate the turntable a
minimum of three full revolutions in both directions.
If contact surfaces appear clean and discoloration
from oxidation is greatly reduced, or no oxidation
residue is noted when the slip ring contact surfaces
are wiped with a clean white rag, proceed to step
8.
6. If the slip ring is heavily oxidized (discoloration of the
contact surfaces), spray the slip ring contact surfaces
again and allow it to sit overnight.
7. After sitting overnight, rotate the turntable three full
turns, then wipe all contact surfaces with a clean white
rag or blow off contact surfaces with compressed air
until dry.
8. Spray all contact surfaces again (one to two bursts)
with DeoxIT.
9. Reinstall the slip ring cover and turntable or pedestal
covers that were removed.
10. Test all functions that use the slip ring to conduct
electrical power between the turntable and pedes-
tal.
11. Following a successful test, return unit to service.
Lubrication
Proper lubrication will extend the life of the equipment
and reduce maintenance problems. The frequency of
lubrication 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. After washing and cleaning the unit,
relubricate as necessary.
The Lubrication Chart and Diagram identifes each com-
ponent, type of lubricant, and method of application. Any
brand of lubricant that meets or exceeds the specifca-
tions of the products listed is acceptable. There are fve
Fasteners
Section 4 Preventive Maintenance and Inspection 17
intervals of lubrication. Select the appropriate interval and
lubricate components identifed by the symbol(s).
Components may be installed on your unit that require
additional lubrication. Refer to these component manuals
for more information.
Always wipe grease fttings clean before and after greasing
to keep contamination from entering the points of lubrica-
tion. To avoid bearing damage, use manually operated
grease guns. Air-driven grease guns may have enough
force to cause bearing damage.
If the unit is not used, or is stored for any length of time,
apply fresh lubricant at all points shown on the Lubrica-
tion Chart and Diagram. This will help prevent corrosion
during the idle period.
Outriggers
Non-rotating pin connections on the outriggers have
been made with zinc plated pins coated with anti-seize
compound to prevent corrosion. These connections do
not require additional lubrication unless they are disas-
sembled.
Lubricate the inner legs of extendible outriggers as recom-
mended by the Preventive Maintenance and Inspection
Checklist. If the outrigger legs have three stages, lubricate
the inner leg and the second stage.
Use the following procedure to lubricate the outrigger
legs.
1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the PTO and
extend the outrigger legs. Disengage the PTO and
turn off the engine.
2. Wipe the exposed inner leg surfaces to remove any
dirt, moisture, etc.
3. Wipe on a coating of moly grease.
4. Start the engine and engage the PTO. Retract and
extend the outrigger legs several times to spread the
grease evenly on the surface.
5. Extend the outrigger legs and wipe off the excess
grease to prevent buildup of dust and other par-
ticles.
6. Retract the outrigger legs.
Bearings
Spherical bearings are used in several places on the
unit. They require regular lubrication with a chassis
lubricant.
It is very important to grease this type of bearing regu-
larly. 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 diffcult if they
are not properly lubricated.
Self-lubricating bearings require no lubrication when they
contact plated shafts. This type of bearing is used at the
boom pin but must be lubricated regularly to protect the
housing from corrosion.
The outboard bearing for the winch output shaft is a
self-lubricating bearing. The output shaft is not plated,
requiring regular lubrication to prevent rust. There is a
grease ftting in the end of the output shaft.
Rotation Bearing
The rotation bearing ball path is lubricated by a grease
ftting on the front of the turntable.
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
turntable slowly through at least 2 complete 360 degree
revolutions, stopping every 30 to 45 degrees to lubricate.
Operate the manual grease gun three to fve times at
each stop.
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 rota-
tion 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
immediately after servicing.
Remove the pinion cover from the turntable to lubricate
the rotation gear teeth. Replace the cover after the lu-
brication has been completed.
18 Section 4 Preventive Maintenance and Inspection
85 hours/ 500 hours/ 1,000 hours/ 2,000 hours/
1 month 6 months 1 year 2 years If disassembled
Letter Lubricant Application Method
A Anti-Seize Compound Extreme pressure lubricant that prevents seizure, Brush
corrosion, rust, and galvanic pitting.
C Chassis Grease Multipurpose lithium base grease with good water Grease gun
resistance, rust inhibition, oxidation stability, and extreme pressure properties.
E EP 80W-90 Gear Oil API Service Designation GL-5. Pour
F ATF, Type F Pour
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 good water resistance, Brush/grease gun
rust inhibition, oxidation stability and extreme pressure properties, with or
without molybdenum disulfde additive.
R Wire Rope Lubricant Penetrating, cleaning, nongumming protective spray; Spray
must minimize friction and eliminate rust.
S General Purpose Spray Lubricant Spray
T AGMA 4EP ISO 150 Industrial Gear Oil (do not use API GL-5 oil) Pour
V Conoco Gear Oil GP460 AGMA Grade 7 compounded with proprietary additives. Pour
W SAE 140 Worm Gear Oil AGMA Grade 7 compounded or 7EP, must be Pour
noncorrosive to bronze.
Lubrication Chart and Diagram
Service items identifed by the symbol(s) at the appropriate level.
Radial Outriggers
Cylinder, Shoe,
and Leg Pins
A
A
Cylinder, Shoe,
and Leg Pins
Section 4 Preventive Maintenance and Inspection 19
Corner Mount Outriggers
Cylinder and
Shoe Pins
A
C
M
Outrigger Inner
Leg Surface
Leg and Link
Pivot Pins
A-Frame Outriggers
Outer Surface
M
Cylinder and
Shoe Pins
A
A
Cylinder and
Shoe Pins
Outer Surface M
Out and Down Outriggers
Turntable With Hydraulic Side Load Protection
Cylinder Pin A
Turntable With Electronic Side Load Protection
Lift Cylinder
Spherical
Bearing
C
Fill Plug
Oil Level
Oil Fill
T
Change Oil T
Worm
Bearing
C
Oil Level V
Change Oil V
Lift Cylinder
Spherical
Bearing
C
Fill Plug
Gearbox Oil Level, Oil Fill E
Gearbox Change Oil E
Worm Bearing C
Brake Oil Level F
Brake Change Oil F
Oil Level V
Change Oil V
20 Section 4 Preventive Maintenance and Inspection
C
Boom Pin (2)
Lift Cylinder
Spherical Bearing
Trunnion Pin
Heads (2)
A Cylinder Pins
Intermediate Boom
Outer Surface
M
Intermediate Boom
Extension Cylinder Pin
Transferable Flares Retaining
Pin and Bosses
Upper Boom
Slide Bearing
Pivot Pin
C
A
C
Angle Indicator(s)
S
A
Booms
Platform
Mounting Pin
and Socket (2)
M
G
Pole Guide Tong
and Gear Teeth
A
Worm Bearing C
Change Oil V
Winch
Line
Winch Drum
Shaft
Keys
Set Screws
Line Anchor
A
R
Winch Line
Rollers (1 or 2)
C
Fill Plug
Worm Bearing C
C
Outboard Bearing
(Opposite End)
Boom Tip Winch
Platform
Brake Linkage
Brake
Detent
Pin
S
S
Pole Guide Tong and Tilt
Cylinder Trunnions (4)
A
Oil Level V
Winch
Outboard
Bearing
C
Rotation
Gearbox
Eccentric
Ring
A
Rotation Pinion
and Bearing
Gear Teeth
G
Turntable
Rotation Bearing
Ball Race
C
Turntable
Winch Line
Winch Drum
Shaft
Keys
Set Screws
Line Anchor
A
R
Rotary Joint
(If Equipped With
Grease Fitting
on this Side)
C
Section 4 Preventive Maintenance and Inspection 21
7
Two-Speed
Mechanically Shifted Digger
E
Change Oil E
Oil Level
Two-Speed
Hydraulically Shifted Digger
Fill Plug
Oil Level
Change Oil
E
E
Auger Stow Bracket
Wire Rope
Windup Sling
Latch
R
C
Ground
Fill Plug
Outrigger Valve Handle
S
Hydraulic Pump
A
Input Shaft
Splines
Digger Hanger Link
Digger Link
Pivot Pin
Digger Link Pivot Tube
C
C
22 Section 4 Preventive Maintenance and Inspection
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 revolu-
tion.
Gearboxes
The need to add oil regularly to any of the gearboxes
(rotation, digger, or winch) 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 reflling 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 Preventive 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 defec-
tive motor shaft seal. If this occurs in a rotation gearbox,
it may also be a sign of a bad brake piston seal.
Wipe the gearbox clean before removing the plug from
the fll or check hole. Do not overfll the gearbox with oil.
Overflling will cause the gearbox to leak. Tighten the
plugs securely after checking or flling. Wipe excess oil
off of the gearbox to prevent dirt buildup.
The winch 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.
The boom tip winch oil level is checked with the boom
fully lowered or as low as possible.
For a mechanically shifted two-speed digger, the oil
should be even with the bottom of the check hole with
the digger tilted at a seven degree angle.
For a hydraulically shifted two-speed digger, the oil level
should be 1
3
/4 to 2
1
/4 (4.45 to 5.72 cm) below the top of
the fll hole with the digger hanging vertically.
For the rotation gearbox used with hydraulic side load
protection, the oil level should be 1
1
/4 to 1
1
/2 (3.18 to
3.81 cm) below the top of the fll hole. It may be neces-
sary to use a slim object such as a plastic wire tie as a
dip stick to check the oil level.
Rotation Brake With Hydraulic Side Load Protection
If the rotation motor leaks into the brake on the rotation
gearbox used with hydraulic side load protection, the
brake fuid will be contaminated. This contamination will
reduce the holding capability of the friction discs inside
the brake. Thus, the holding capacity of the rotation brake
will be reduced.
If the rotation motor has leaked into the rotation brake,
remove the brake from the rotation gearbox. Disassemble
it and discard the friction discs. They must be replaced
with new friction discs. Wash the remaining brake com-
ponents including the separator plates with solvent. Soak
the new friction discs in Type F automatic transmission
fuid for ten minutes before installing them. After installing
the discs, pour Type F automatic transmission fuid over
the discs until the fuid level is even with the top friction
disc. Finish reassembling the brake. Bleed the air from
the rotation brake as described in Section 6 under Rota-
tion Gearbox, Installation. Then adjust the rotation brake
and side load settings as described in Section 8 under
Hydraulic Side Load Protection.
Notice
Proper fuid must be used in the rotation brake. The
use of improper fuid will reduce the holding capac-
ity of the brake.
The rotation brake is permanently lubricated. The fuid
does not replacement beyond the initial fll under normal
conditions. However if the brake has been subjected to
a great amount of slippage over a long period of time,
the fuid can become deteriorated and cause reduced
holding capacity of the brake which cannot be restored
by adjusting the brake. In this case, the fuid in the brake
should be drained and replaced with new fuid. Then
adjust the brake and side load settings as described in
Section 8 under Hydraulic Side Load Protection.
Booms
The internal surfaces of the lower and intermediate
booms are lubricated at the factory. They only need to
be lubricated during a major overhaul of the unit.
The external surface of the intermediate boom is exposed
to the weather and to cleaning. Lubricate this surface
as recommended by the Preventive Maintenance and
Inspection Checklist to keep the boom sliding freely on
the slide pad bearings.
Use the following procedure to lubricate the intermedi-
ate boom.
Section 4 Preventive Maintenance and Inspection 23
1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the PTO and
extend the intermediate boom. Disengage the PTO
and turn off the engine.
2. Wipe the exposed boom surfaces to remove any dirt,
moisture, etc.
3. Wipe on a coating of moly grease.
4. Start the engine and engage the PTO. Retract and
extend the boom several times to spread the grease
evenly on the surface.
5. Extend the boom and wipe off the excess grease to
prevent buildup of dust and other particles.
6. Retract the intermediate boom.
Structures
The structural components of the unit are identifed in the
Component Identifcation in Section 2. The unit has been
designed to meet or exceed the ANSI specifcations for
vehicle-mounted rotating and elevating derricks.
Regular inspection of the welds and structures is required
to insure that components maintain their strength. Periodic
cleaning of the structures is also recommended. This will
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.
Care of Exterior Surfaces
Altec units are manufactured out of structural steel, gal-
vanized steel and/or aluminum components with differing
resistance to corrosion. While Altec uses components,
designs and coatings that maximize corrosion resistance,
regular cleaning and maintenance is necessary to pre-
serve the fnish over the life of the equipment.
Frequent and regular washing will lengthen the life of your
new equipments painted fnish and components. Wash
your equipment and truck body frequently with warm or
cold water to remove dirt and preserve the original luster
of the paint. Never wash the equipment in direct sunlight
or when the metal surfaces are hot to the touch as it may
cause streaks on the fnish. Caution must be used in se-
lecting detergents and degreasers that may damage the
fnish. Use only commercially available automotive grade
cleaners. High pressure washing systems should be used
with caution, with the tip of the nozzle maintained at a
distance of 12 (30.5 cm) or more from the surface.
It is particularly important to wash the unit and body during
winter months as salt and other ice melting products are
extremely corrosive and can damage the vehicle. Other
corrosive environments that would necessitate additional
washing may include coastal areas, farming communities
where chemicals are sprayed, or mining operations.
Waxing of the exterior is typically not required, however
waxing will provide additional protection and help restore
the fnish to the original luster. This may not only improve
appearance, but will likely extend the service life of your
truck body and equipment.
It is important to repair any chips or scratches that occur
to prevent further corrosion. If the paint damage exposes
primer, then a liquid touch up paint may be used. Dam-
age that extends to unpainted metal must be primed
prior to applying a top coat. Touch up paint for standard
Altec colors may be ordered by calling 1-877-GO ALTEC.
Your local auto body shop can assist you with matching
a custom color.
Equipment that is used in harsh environments and off road
use needs to have more routine washing and maintenance
to the under body area. When the equipment is washed
it should washed on the underside as well and routinely
checked for any damage to the paint/undercoat. Any
damage discovered should be touched up accordingly
with a good rust preventative material and/or undercoat.
This will help prevent corrosion that could spread from
these areas that are not easily seen.
Accumulated dirt can damage the unit and cause it to
malfunction. Dirt buildup also accelerates wear on the
components.
Caution
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
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
24 Section 4 Preventive Maintenance and Inspection
on the unit are designed for all weather use, it is possible
for water pressure from the nozzle to push a seal out of
position. Do not direct the spray at the fller breather cap
of the reservoir. The 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 pres-
sure washer. Limit the water pressure to 500 psi (34.47
bar) and keep the spray tip at least 18 (45.72 cm) away
from these components while washing. After washing and
cleaning the unit, relubricate as necessary.
Refer to Fiberglass Care in this section for information
on cleaning the fberglass 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
Death or serious injury can result from improper
use of solvents. Follow the manufacturers label for
proper 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. Look for vis-
ible cracks in the weld and at the weld-to-parent material
joint. Use a bright light to provide adequate visibility of
the inspection area.
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 4.6 illustrates
these areas. If any cracks or unacceptable conditions are
discovered, report them to your Altec representative.
Any welds added in the feld should be done by qualifed
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 mechani-
cal components.
Fasteners
A variety of fasteners are used on the unit. Different
fasteners have different inspection and installation
requirements depending on their use and design. This
section explains different fasteners used on the unit,
torque specifcations, 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, fat 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.
Figure 4.7 represents general locations of fasteners to
inspect. When inspecting fasteners, pay particular atten-
tion to the following fasteners.
Subbase and pedestal shear plate fasteners
Outrigger attachment fasteners
Corner mount Huck bolts
Rotation bearing mounting cap screws
Rotation gearbox mounting cap screws
Riding seat platform mounting cap screws
All pin retainer cap screws at pivot pins
Winch mounting cap screws
Hydraulic motor mounting cap screws on all gear-
boxes
Rotary joint drive bar mounting cap screws
Digger link pin nuts
Auger and auger extension shaft cap screws and
nuts
Upper boom cylinder trunnion pins
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
elastic range of the cap screw may be exceeded. This
may result in premature failure of the cap screw.
When checking fastener torque value, 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).
Some fasteners require torque values that differ from
common torque charts. Refer to Figure 4.8 for the proper
tightening torque for these fasteners on this unit.
Section 4 Preventive Maintenance and Inspection 25
Figure 4.6 Weld Inspections
Bearing Mounting Plate
(Top and Bottom)
Tie Plate Welds
to Pedestal
and Subbase
Across Subbase Top
Plate (Front and Rear)
Across Top of
Subbase Tubes
(Front and Rear)
Corner Mount Pedestal (Back View)
Bearing Mounting Plate
(Top and Bottom)
Outrigger
Mounting Area
Pedestal Weld to
Horizontal Plates
Outrigger
Link Pivot
Tubes
Rear Mount or Behind
Cab Mount Pedestal
Diagonal
Brace Areas
Subbase Area
Vertical Plates
(Inside Pedestal)
Corner Mount Pedestal (Side View)
Boom Pin
Tube Area
Lift Cylinder
Mounting Area
Lower Boom
26 Section 4 Preventive Maintenance and Inspection
Side and Rear Plate
Welds to Base Plate
Lift Cylinder
Mount Area
Boom Pivot
Pin Bosses
Winch Bracket Area
Boom Pivot
Pin Flange
Turntable
Digger Link Tube
Digger Attachment
Digger Hanger Bracket
Area (Both Sides)
Boom Tip
Attachment Area
Steel Boom Tip
Section 4 Preventive Maintenance and Inspection 27
Pole Guide
Pivot Pin
Retainers
Digger Link
Pin Nuts
Auger and Auger
Extension Shaft
Cap Screws
Hydraulic
Motor Mounting
Cap Screws
Figure 4.7 Fasteners
All Pin Retainers at Pivot Pins
Pedestal
and Subbase
Mounting Fasteners
Rotation Gearbox
Mounting
Cap Screws
Rotation Bearing
Mounting
Cap Screws
Hydraulic Motor
Mounting Cap
Screws
Winch Mounting
Cap Screw
All Pin Retainers
at Pivot Pins
Rotary Joint Drive
Bar Mounting
Cap Screws
Upper Boom
Cylinder Trunnion
Pins
Many general application fasteners would not normally
require an installation torque or lubrication but instead
would be installed using sound mechanical practices. If
it is desired to more closely control the fastener clamp
load it is recommended that a copper based anti-seize
compound be applied. Refer to Torque Values in the
Appendix as a guide to determine the proper cap screw
torque value.
Inspection Marks
Nuts or cap screws with locking patch element used in
combination with inspection marks are used at specifc
locations on the unit. Many are visible to the operator
during daily inspections.
If any inspection marks are found to be cracked or bro-
ken during inspection, totally remove the original mark.
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.
The inspection lacquer (refer to Service Tools and Supplies
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
Death or serious injury can result from improper
use of solvents. Follow the manufacturers label for
proper use and disposal.
2. Be sure the cleaning operation is performed in a well-
ventilated area. Remove the remaining residue using
Foot-Pounds (Nm)
Rotation bearing cap screws 325 (441)
Rotation gearbox mounting cap screws 325 (441)
Digger motor mounting cap screws 55 (75)
Boom pivot pin nut 225 (305)
Intermediate boom extension mounting nut 225 to 250 (305 to 339)
Upper boom cylinder trunnion pins 150 (203)
Platform mounting cap screws 55 (75)
Riding seat mounting cap screws 75 (102)
Figure 4.8 Torque Values
28 Section 4 Preventive Maintenance and Inspection
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
/32 to
1
/16 (0.8 to 1.6 mm) 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
/8 to
1
/4 (3.2 to 6.4 mm) 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 fastener is removed, it must be cleaned
thoroughly. The adhesive must be applied before rein-
serting. Properly torque the fastener before the adhesive
cures (within 15 minutes of application). When installing
trunnion pins, apply thread locking adhesive only to the
frst two or three threads of the male portion. Refer to
Trunnion Pins in this section for proper installation.
Apply high strength anaerobic thread locking adhesive
on the threads of the upper boom cylinder trunnion pins
(male portion) to provide additional security against
loosening.
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.
If the threads of the fasteners are not clean and free of
grease and oil, the effectiveness of the thread locking
adhesive will be reduced. Clean the threads of the fasten-
ers with solvent and blow dry with compressed air before
applying the thread locking adhesive.
For optimum thread locking, follow the manufacturers
label for proper use and disposal.
Anti-seize compound 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
recommended for certain fasteners to reduce friction dur-
ing torquing to increase clamping load. Apply anti-seize
compound to the following components.
Pump input shaft splines
Outrigger cylinder and shoe pins
Radial outrigger pivot pins
Rotation gearbox eccentric ring
Winch drum shaft/keys/set screws/line anchor
Intermediate boom cylinder pins
Upper boom cylinder pins
Transferable boom fares and pole guide assembly
retaining pin and bosses
Platform mounting pin and boss
Upper boom cylinder trunnion pin heads
The area on which the anti-seize is applied must be clean
and dry for the anti-seize to be effective.
Chrome pins used with self-lubricating bearings require
special attention. Apply anti-seize compound to the sur-
face of the pin only where the pin and steel bin bosses
make contact. This pin installation procedure is described
under Pins and Pin Retainers in this section.
Rotation Bearing Cap Screws
Special high strength
3
/4 cap screws are used to secure
the rotation bearing to the pedestal and turntable. The
cap screws are coated with a dry flm lubricant and
have a patch lock material permanently bonded to the
threads. The torque value for the cap screws is 325
foot-pounds (441 Nm). They require special inspection
procedures.
Notice
Only use Altec supplied cap screws and washers to
install the rotation bearing.
When rotation bearing cap screws or washers, or nuts
removed, they must be replaced with new ones. Contact
your Altec representative for replacement fasteners.
Insuffcient or uneven cap screw tightness can contribute
to reduced life of the bearing.
Caution
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
Section 4 Preventive Maintenance and Inspection 29
exist between moving parts. Replace the access covers
immediately after servicing.
Notice
Use an accurate
3
/4 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.
If any cap screws are broken or missing, replace all the
fasteners in that race (refer to Section 6 under Rotation
Bearing Cap Screws). If a cap screw will not remain
properly torqued between normal inspections, further
inspection may be required.
Impacts to and excessive forces on the unit due to ve-
hicular accidents, rollovers, and excessive loading may
result in structural damage not obvious during a visual
inspection. A more detailed inspection by a qualifed
individual may be required to determine if replacement
of the rotation bearing and fasteners is required.
Visual Inspection Procedure
Perform this visual inspection procedure as recom-
mended by the Preventive Maintenance and Inspection
Checklist.
Visually inspect all 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 using the Retorquing
Procedure.
Annual Torque Inspection Procedure
Check the cap screws to be sure they are torqued to
295 foot-pounds (400 Nm), or 90 percent of the normal
installation torque of 325 foot-pounds (441 Nm). Use a
regularly calibrated, accurate torque wrench. If one or
more of these cap screws turns before the wrench clicks,
check the torque on the cap screws as described under
Retorquing Procedure in this section. If the rotation bear-
ing is replaced or removed, the same inspection intervals
must be followed.
Retorquing Procedure
Perform this procedure on the entire bearing race (outer,
inner, or both) if any cap screws were found loose at the
visual or annual inspections.
If all the cap screws have been removed from one or
both races of the rotation bearing, refer to Section 6
under Rotation System for the installation and torquing
procedure.
Some components may need to be removed to make
the rotation bearing cap screws accessible for retorqu-
ing. It is important that experienced, trained mechanics
perform this procedure.
1. Retorque according to the appropriate pattern shown
in Figure 4.9 for the inner race and Figure 4.10 for
the outer race.
Figure 4.9
Inner Race Cap Screw Torque Patterns
Figure 4.10
Outer Race Cap Screw Torque Patterns
2. Begin with cap screw number 1 on the outer race
and torque it to 325 foot-pounds (441 Nm).
8
13
14
4
23
24
9
10
19
20
2
25
26
5
6
15
16
3
X
12
11
22
21
Gearbox
Here
1 27
28
7
18
17
Number one cap screw can be at any
location on the bearing with the remainder
of the pattern shifted accordingly
1
23 14
13 24
6
9
10
4
19
20
7
15
16
8
18
17
3
12
11
5
22
21
2
30 Section 4 Preventive Maintenance and Inspection
3. Continue around the pattern, torquing each cap screw
to 325 foot-pounds (441 Nm).
4. Retorque all cap screws to 325 foot-pounds (441
Nm) again beginning at number 1. Go around in a
circular pattern this time instead of the numbered
order.
5. Repeat steps 1 through 4 on the inner race cap
screws, torquing each cap screw to 325 foot-pounds
(441 Nm).
Rotation Gearbox Mounting Cap Screws
Special
3
/4 cap screws are used to secure the rotation
gearbox to the turntable. The torque value for the cap
screws is 325 foot-pounds (441 Nm). The cap screws
require special inspection procedures.
Insuffcient or uneven cap screw tightness can contribute
to reduced life of the gearbox.
Caution
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
immediately after servicing.
Notice
Only use Altec supplied cap screws and washers to
install the rotation gearbox.
Use an accurate
3
/4 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.
For the rotation gearbox used with hydraulic side load
protection, a torque wrench adapter (included with unit,
refer to Service Tools and Supplies in the Appendix) must
be used when removing or installing the rotation gearbox
mounting cap screws or performing the annual torque
inspection (refer to Figure 4.11). The adapter may be
oriented at any angle on the torque wrench when tight-
ening or loosening the cap screws but not torquing them
to a specifc value. It must be oriented at 90 degrees to
the handle of the torque wrench when torquing the cap
screws to a specifc value.
Visual Inspection Procedure
Perform this visual inspection procedure as recom-
mended by the Preventive Maintenance and Inspection
Checklist.
Visually inspect all rotation gearbox cap screws, look-
ing 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, retorque all the cap screws.
Annual Torque Inspection Procedure
Make sure the cap screws are torqued to 292 foot-pounds
(396 Nm), or 90 percent of the normal installation torque
of 325 foot-pounds (441 Nm). Use a regularly calibrated,
accurate torque wrench. For the rotation gearbox used with
hydraulic side load protection, a torque wrench adapter
(included with unit, refer to Service Tools and Supplies
in the Appendix) must be used. The adapter must be
oriented at 90 degrees to the handle of the torque wrench
when torquing the cap screws to a specifc value (refer to
Figure 4.11). If any of these cap screws turns before the
wrench clicks, retorque all the cap screws to 325 foot-
Top View
Figure 4.11 Torque Wrench Adapter
Side View
Rotation
Gearbox
Used With
Side Load
Protection
Turntable Rotation Gearbox
Mounting Cap
Screw
Torque
Wrench
Adapter
Torque Wrench
Angle Between Adapter and Torque Wrench:
= Any Angle When Tightening or
Loosening, But Not Torquing,
= 90 Degrees When Torquing to Specifc Value
Section 4 Preventive Maintenance and Inspection 31
pounds (441 Nm). If the rotation gearbox is replaced or
removed, follow the same inspection intervals.
Digger Motor Cap Screws
The digger motor mounting cap screws are
5
/8 -11 UNC.
Install the cap screws without any lubrication and torque
them to 55 foot-pounds (75 Nm). The upper housing of
the digger gearbox is made of aluminum. Overtightening
the motor mounting cap screws this may damage the
threads in the aluminum housing.
Auger and Auger Extension
Shaft Cap Screws and Nuts
The cap screws and nuts used to retain the auger and
the auger extension shaft do not utilize a specifc torque
value. Install the standard nut on the cap screw with a
slight clearance from the hub of the auger or extension
shaft. Install the jam nut on the cap screw fnger tight
against the standard nut. Then using two wrenches,
hold the standard nut and tighten the jam nut against
it securely.
Slide Pad Bearing Cap Screws
The lower boom, intermediate boom, and the digger
hanger bracket are equipped with slide pad bearings.
They are installed with either hex head or fat countersunk
head, nylon patch cap screws.
Do not reuse the cap screws if they are removed. Replace
them with new cap screws to insure a secure ft.
Overtightening the bearing mounting screws can damage
or split slide pad bearings. Boom Slide Pad Bearings in
this section describes this type of bearing.
Pins and Pin Retainers
A variety of pins and pin retainers are used on the unit.
The type of pin or pin retainer used depends upon the
particular application.
Chrome plated pins are used in many areas such as the
lower boom pivot pin. The chrome plating reduces the
likelihood of rust and provides long wear for pins used
with self-lubricating bearings.
Use a dead blow hammer to remove or install pins. Use
of a steel hammer may distort the pin or close the retain-
ing ring groove. This may make pin installation diffcult or
cause the retaining ring to come out of its groove.
Trunnion Pins
The upper boom cylinder is mounted inside the upper
boom with trunnion pins (refer to Figure 4.12).
Side View
Retaining Rings
Section A-A
Section B-B
Trunnion
Pins
Figure 4.12 Booms
Boom Slide
Bracket
Bearing Bracket
Weldment
Section C-C
C
C
B
B
A
A
32 Section 4 Preventive Maintenance and Inspection
Torque Inspection
Visually check the trunnion pins for looseness as recom-
mended by the Preventive Maintenance and Inspection
Checklist.
Use the following procedure to check the trunnion pins.
1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the PTO and
properly set the outriggers.
2. From the lower controls, raise the boom out of the
rest and rotate the turntable to a position where the
intermediate and upper booms can be accessed
when fully extended.
Caution
Injury can result from being pinched or trapped be-
tween moving components. Keep hands clear.
Keep hands clear while extending and retracting the
booms.
3. Extend the upper and intermediate booms to allow
access to the trunnion pins through the access hole
in the intermediate boom (refer to Figure 4.13). Dis-
engage the PTO and turn off the engine.
Figure 4.13 Intermediate Boom
4. Check the trunnion pins with a torque wrench to be
sure they are torqued to 135 foot-pounds (183 Nm)
or 90 percent of the normal installation torque of 150
foot-pounds (203 Nm).
5. If a trunnion pin is loose, torque it to 150 foot-pounds
(203 Nm).
Warning
Death or serious injury can result from uncontrolled
movement. Secure the booms before removing the
cylinder mounting pins.
6. Start the engine, engage the PTO, and stow the unit.
Forged Pin Retainers
Forged pin retainers are used to retain and prevent ro-
tation of the pivot pins. A forged pin retaining system is
shown in Figure 4.14.
Figure 4.14 Forged Pin Retaining System
During inspection, look for bent or broken stems. A bent
or broken stem may indicate that the bearings within the
joint are worn out. Also, if the pin binds within the joint
and tries to turn, the stem could bend or break. This may
indicate a lack of lubrication. Make sure the cap screw
through the eye of the retainer is tight.
If a forged pin retainer is damaged, determine the cause
of damage. Relubricate or take the connection apart and
replace the necessary parts.
Retaining Rings
Retaining rings are used as a backup retaining system for
some pins and as the only retaining system for others.
Figure 4.14 illustrates how retaining rings are used as a
backup retainer on lift cylinder pivot pins. If the forged pin
retainer should fail or fall out, the retaining rings will hold
the pin in place. However, they will not prevent the pin from
rotating. Immediately determine the cause of the problem
and replace and/or repair the necessary parts.
When inspecting retaining rings, check that they are
properly installed and undamaged.
Install retaining rings with the sharp edge out (refer to
Figure 4.15). This makes it more diffcult for the retain-
ing ring to come off the pin if the pin is being forced out
the other side.
Access Hole
Intermediate Boom
Stem
Forged Pin
Retainer
Retaining Ring
Cylinder Eye
Retaining
Ring
Section 4 Preventive Maintenance and Inspection 33
Figure 4.15 Retaining Ring
Lower Boom Pin Retaining System
Figure 4.16 shows the boom pin retaining system. This
pin has an end plate welded to one end. A button head
cap screw and spacer are installed through the hole in the
pivot pin end plate. The tube and button head cap screw
prevent the pin from turning. The other end is retained by
a self-locking nut torqued to 225 foot-pounds (305 Nm).
The nut has a nylon insert that grips the threads on the
pin to prevent the nut from loosening.
Figure 4.16 Boom Pin Retaining System
When inspecting the boom pin, check for cracking of the
end plate weld or elongation of the hole in the end plate.
Make sure the cap screw is tight and the head of the cap
screw is not broken off. The washers under the nut can
be turned by hand if it is loose. Any of these conditions
are signs that the bearings are binding and that the pin
was trying to turn. If any of these conditions are found,
take the connection apart and replace parts as necessary.
The self-locking nut is not reusable. If the nut is removed
from the pin, it must be replaced with a new nut.
Radial Outrigger Pin Retainers
Some pivot pins for the radial outrigger cylinders are re-
tained by two
3
/8 x 4 cap screws (refer to Figure 4.17).
The cap screws are positioned through the midsection of
the pivot pin and secured with a self-locking nut.
When inspecting the pivot pin, check the nuts for proper
tightness. If they are loose, determine the cause of the
problem and replace the necessary parts. Torque the
nuts to the proper value.
Figure 4.17 Radial Outrigger Pin Retainers
Pin Installation Into
Self-Lubricating Bearings
When installing a pin into a self-lubricating bearing, only
lubricate the area where the pin and the boss make
contact (refer to Figure 4.18).
Figure 4.18
Pin Installation Into Self-Lubricating Bearings
Use the following procedure to properly install the pin.
1. Slide the pin through the frst boss and through the
bearing until it reaches the second boss.
2. Apply an anti-seize compound to the second pin boss
and pin surface that is still exposed.
3. Slide the pin completely into the second pin boss
and install the appropriate retaining system.
Pin
End
Plate
Bearing
Weld
Nut
Flat Washer
Button Head
Cap Screw and
Spacer Tube
Section A-A
Cap Screw
A
A
First Boss Second Boss
Bearing
Anti-Seize Compound
Pin
Sharp
Edge
Section A-A
34 Section 4 Preventive Maintenance and Inspection
Pin Installation Into Lubricated Joints
When installing a pin into a joint that has a rotating member
which contains a grease ftting, lubricate the area where
the pin and the non-rotating bosses make contact with
anti-seize compound (refer to Figure 4.19).
Figure 4.19 Pin Installation Into Lubricated Joint
Bearings
The unit is equipped with a variety of bearings. The type
of bearing used depends on the particular application.
Spherical Bearings
Spherical bearings are used at both ends of the lift cyl-
inder. Self-aligning bearings such as these are used in
areas where perfect alignment is diffcult to maintain.
This type of bearing allows the component to follow the
movements of the structure without applying a side load
to the internal components of the cylinder.
Periodic lubrication of these bearings is required to pre-
vent the inner rim that maintains alignment from seizing
to the outer rim of the bearing. Lubrication in this section
describes how to properly lubricate these bearings.
Pressure Cast Cylindrical Bearings
A pressure cast bearing is used to connect the outrigger
pad to the rod end of the cylinder on some radial outrig-
gers. This bearing is designed for high strength, high
load situations. Excellent impact, wear, and corrosion
resistance are characteristics of this bearing. Particles of
molybdenum disulfde solid lubricant have been dispersed
throughout the bearing material. This type of bearing
requires no additional lubrication.
Self-Lubricating Bearings
Self-lubricating bearings are designed for long life. Un-
der normal use this type of bearing will provide many
years of service with virtually no maintenance. These
bearings resist impact and shock loads and abrasive
contaminants.
Self-lubricating bearings are made with a braided cord
liner containing Tefon fbers. The liner is bonded to the
outer shell of the bearing with epoxy resin. The epoxy
resin has a self-lubricating fller added to it. A chrome
plated pin is used with this bearing.
The inside diameter of a self-lubricating bearing contains
Tefon fbers. Once a pin is installed in the bearing, some
of the Tefon transfers to the pin surface and provides
lubrication. Applying anti-seize compound to the entire
surface of the pin will prevent the Tefon from transferring.
This may shorten bearing life.
Replace these bearings if the components are disas-
sembled for other purposes. Replacement of this type of
bearing due to wear is not a normal consideration.
If it is desirable to measure the bearing to determine
when it is worn, several factors must be considered. The
only accurate way to measure bearing wear is to keep a
record of the clearance between the chrome pin and the
bearing. Place the magnetic base of a dial indicator in a
position that allows the clearance between the pin and
the bearing to be measured under load. Take an initial
measurement when the unit is new. This will provide a
reference point. Monitor the change in bearing clearance
with subsequent measurements.
For self-lubricating bearings, clearance wear on the bear-
ing of 0.005 (0.13 mm) may suggest that the bearing
needs to be replaced. This fgure takes into account only
the wear of the bearing. Through the course of time, there
may also be pin and pin boss wear. An overall change in
the clearance between the pin and the bearing of 0.020
(0.51 mm) or more indicates the pin and bearing both
need to be replaced.
Replacement
Use the following procedure to remove and install self-
lubricating bearings.
1. Drive out the old bearing. If this is not possible, remove
it with a die grinder, cut point chisel, or hacksaw blade
(refer to Figure 4.20). Be careful not to damage the
inside diameter of the bearing boss.
Figure 4.20 Removal and
Installation of Self-Lubricating Bearings
First Boss Second Boss Grease
Fitting
Pin
Anti-Seize Compound
Removal
Bearing
Installation
Driver
Removal
Tool
Section 4 Preventive Maintenance and Inspection 35
method of installation. Light loads and high speeds will
call for a specifc amount of end clearance. Heavy loads
and low speeds will call for a specifc amount of preload
on the bearing. Proper installation and lubrication of the
tapered roller bearing are very important in determining
the useful life of the bearing.
Slide Pad Bearings
The lower and intermediate steel booms and the out-
rigger legs are equipped with slide pad bearings. Slide
pad bearings provide a smooth surface for extension
and retraction.
The most highly loaded slide pad bearings are made of
molybdenum disulfde impregnated nylon. Other slide
pad bearings that are not as heavily loaded are made
of a type of polyethylene. Both types of bearings will last
indefnitely when run against smooth surfaces.
The internal sliding surfaces are lubricated with moly
grease during factory assembly. The internal surfaces and
their mating slide pads require no additional lubrication
unless they are disassembled for major maintenance.
Keep the external surfaces of the intermediate boom and
outrigger smooth and lightly lubricated. The Lubrication
Chart and Diagram in this section specifes the proper
lubrication interval. If the outside surface becomes rusty
or rough, the boom or outrigger may not extend and
retract smoothly. Also, the digger hanger bracket may
bind against the boom.
Allow paint applied to a boom or outrigger to cure thor-
oughly. After the paint has cured, lubricate the surface
before retracting or extending the boom or outrigger over
the slide pad bearings.
The slide pad bearings that the fberglass portion of
the upper boom slides on require no lubrication. They
should last the life of the unit, if abrasive particles are
not allowed to accumulate on the boom or the bearings.
Keeping the fberglass clean will minimize the wear on
the bearings and boom surface. Fiberglass Care in this
section describes how to clean the fberglass.
The slide pad bearings are mounted with either hex head
cap screws or fat countersunk head cap screws. The cap
screws have a nylon patch embedded in the threads.
Slide pad bearings mounted with the fat countersunk
cap screws must have the heads of the mounting screws
located below the sliding surface of the bearing (refer
to Figure 4.22). This prevents the cap screw head from
damaging the boom surface.
2. Use a screwdriver and needle nose pliers to collapse
the bearing and pull it out of the bearing boss.
3. Clean the bearing boss. Do not remove any metal
from the boss surface. If metal is removed, the new
bearing may not ft properly in the boss.
4. Place the new bearing on a bearing driver. Line it
up with the bearing boss and drive the bearing into
place using a dead blow hammer. An old pin may be
used as a driver (refer to Figure 4.20).
5. Inspect the pin before installing it into the bearing.
Use a new pin if the chrome is faked, cracked, or
galled.
6. Slide the pin through the frst pin boss and through
the bearing until it reaches the second pin boss.
7. Apply an anti-seize compound to the second pin boss
and pin surface that is still exposed (refer to Figure
4.18).
8. Slide the pin completely into the second pin boss
and install the appropriate pin retaining system.
9. Pins equipped with fange and lug fasteners require
from 0.010 to 0.080 (0.254 to 2.032 mm) pin play
(end clearance between the bushing and the boss).
This is accomplished by adding or subtracting ma-
chine bushings to obtain the desired dimensions.
Figure 4.21 Machine Bushings Clearance
Tapered Roller Bearings
Tapered roller bearings are often used in gearboxes. This
bearing type can be used at high speeds and will support
radial and axial loading. Depending on the application,
this bearing may be installed with several thousandths
inch end clearance, no clearance, or with a preload.
A preload is 0.000 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
Lug
Pin
Bearing
Machine Bushing
Measure Clearance Here
36 Section 4 Preventive Maintenance and Inspection
Figure 4.22 Slide Pad Bearing Cap Screws
Slide pad bearings mounted with hex head cap screws
have steel nuts embedded into the bearing itself (refer to
Figure 4.22). The cap screws are installed with the head
located on the opposite side of the steel plate from where
the bearing is located. When replacing a hex head cap
screw on a slide pad bearing, make sure to replace it
with a cap screw of the proper length as specifed in the
Parts Manual. Cap screws that are too short will not fully
engage the nut embedded in the bearing. Cap screws
that are too long will protrude beyond the bearing and
damage the boom or leg surface.
When replacing a slide pad bearing, do not reuse the cap
screws. Once a cap screw is removed, the nylon patch
on the threads of the cap screw will be distorted. This
distortion may not allow the cap screw to tighten properly
if it is reused. Use new nylon patch cap screws of the
proper length when replacing a slide pad bearing. Do not
apply excessive torque when tightening the cap screws.
This will prevent the bearings from splitting.
Shimming
Thin gauge steel shims are used with slide pad bearings
on the top, sides, and bottom of the booms. Shims are
used to obtain the proper ft between the boom sections.
The shims also aid in maintaining the proper alignment
of the extension cylinders and other components.
If new slide pad bearings are installed, use shims where
needed (top, sides, and/or bottom) to obtain proper ft
and alignment.
Rotation Bearing
The turntable rotates on a shear ball bearing called the
rotation bearing. The inner race is mounted to the turn-
table. The outer race is mounted to the pedestal. The outer
race has gear teeth that mesh with the rotation pinion.
The bearing provides for very low torque rotation.
Monitoring Bearing Wear
The internal bearing clearance will increase slightly
during the break-in period. It should then remain essen-
tially constant for many years if the bearing is properly
lubricated and not overloaded. As the bearing raceway
begins to wear, the clearance will increase. It should
increase steadily at frst and accelerate toward the end
of bearing life.
An increase in bearing clearance is one sign of bear-
ing wear. Periodic bearing tilt measurements will help
determine when bearing replacement is necessary.
Perform bearing inspection and turntable tilt measure-
ments as recommended by the Preventive Maintenance
and Inspection Checklist. More frequent inspections are
required when the total increase in turntable tilt measure-
ment 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 defection rather than
bearing internal clearance. It is important that the defec-
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 4.23). 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.
Flat Countersunk Head Cap Screw
Bearing
Hex Head Cap Screw
Boom
Bearing
Boom
Nut
Section 4 Preventive Maintenance and Inspection 37
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 4.23 Turntable Tilt Measurements
Because the major portion of the measured turntable tilt
results from structural defection, the total tilt measurement
varies from model to model. For example, overall turntable
tilt measurements approaching 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. Therefore, the total turntable tilt measurement
itself should not be used to gauge a bearings remain-
ing 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 bear-
ing fasteners, a warped mounting surface, or worn
teeth. 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
accelerated wear condition and immediate bear-
ing replacement 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 mea-
surement procedure even if there is no presence of
roughness, noise in the bearing, or signifcant 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 replacement 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. Engage the PTO and properly
set the outriggers.
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
(if so equipped) as roughness may be felt more ac-
curately from the platform. Note in the maintenance
log whether unusual noise or roughness was en-
countered.
3. Test the system pressure and adjust if necessary as
described in Section 8. Record the system pressure
in the maintenance log. The system pressure must
be correct because changes in the system pressure
will affect the structural defection and change the
turntable tilt measurements.
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 each time the tilt
measurement is done. Record the rotational position
in the maintenance log.
5. Remove the platform(s), if so equipped. Fully retract
the upper boom and fully extend the intermediate
boom. Lower the boom to determine if the boom tip
can be placed on the ground (refer to Figure 4.24). If
the boom tip cannot be easily placed on the ground,
an alternate setup using the auger is acceptable.
Retract the intermediate boom, unstow the auger,
and fully extend the intermediate boom.
38 Section 4 Preventive Maintenance and Inspection
6. Attach the magnetic base of the dial indicator to the
pedestal, positioning the contact point at the cor-
rect position. The contact point of the dial indicator
should be positioned against the underside of the
turntable base plate under the lift cylinder, as close
as possible to the bearing gear cover. Figure 4.25
shows the position for the dial indicator contact
point. It may be diffcult to position the dial indicator
and contact point in some zones of rotation without
interference with the turntable or pedestal. In this
case, position the dial indicator and contact point to
the area as close as possible to the recommended
position. Once a correct indicator contact point po-
sition is chosen, it is very important that the same
contact point position is used for each subsequent
tilt measurement. Therefore, record the contact point
position in the maintenance or service log where the
tilt measurements are recorded. Some inspectors
prefer to permanently mark the location where the
dial indicator contact point contacts the bearing base
plate to ensure that subsequent measurements are
made in exactly the same spot.
Figure 4.25 Pointer Position
7. Position the boom tip or auger tip a few inches above
the ground. Place a thick wooden plank or similar
material under the boom tip to protect it from dam-
age (refer to Figure 4.24). Operate the boom lower
function until the boom tip contacts the protective
material on the ground or the auger tip contacts the
ground. Continue to operate the boom lower function
until the hydraulic system reaches maximum pres-
sure and the lift cylinder stops retracting. Make sure
the lift cylinder does not bottom out before maximum
system pressure is reached. Set the dial indicator
at zero while holding the system at maximum pres-
sure.
8. Slowly raise the boom until the boom tip is raised off
the protective material or the auger is raised off the
ground. Read and record the indicator reading.
9. Repeat steps 7 and 8 two more times to ensure an
accurate consistent reading.
10. Remove the dial indicator to prevent accidental dam-
age.
Notice
There may be metal particles in the grease. Use a
putty knife to collect and wipe the grease.
11. Stow the auger if it was unstowed for the procedure.
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, insignifcant particles will not
normally be felt under the straight edge. Also, look
for signs of rust which would indicate poor lubrica-
tion. 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.
Protective Material
Under Boom Tip
Boom Tip
Upper Boom Fully
Retracted
Intermediate Boom
Fully Extended
Figure 4.24 Setup
Dial Indicator Pointer
C
Section 4 Preventive Maintenance and Inspection 39
b. If there are any signs of rust in the grease, lubri-
cate the bearing more frequently to purge the old
grease out.
12. Refer to Bearing Replacement Criteria to determine
if bearing replacement is required.
Cylinders
Inspect all cylinders as recommended by the Preventive
Maintenance and Inspection Checklist.
Warning
Death or serious injury can result from cylinder
failure. Do not operate a cylinder that has a dented
barrel or a damaged rod.
Visually inspect the cylinders for leaks, loose or missing
pin retainers, broken bearings, bent rods, and dents in
the rod or barrel.
Check for proper operation of the cylinder holding valves
by positioning the boom or outrigger so a load is applied
to the cylinder to put pressure against the holding valves.
Disengage the PTO. Fully shift the manual lever for the
function being tested. Hold the lever momentarily to allow
oil fow from the holding valve to tank. If the cylinder does
not move, the extend holding valve is operating properly.
If the cylinder retracts slowly, the holding valve may be
leaking. Determine the cause of the problem and correct
it before operating the unit.
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 Inspection Checklist for
wear and/or physical damage. Make sure the hoses
are properly routed to avoid sharp edges, kinking, and
scuffng. Inspect the tubes for dents or other damage
that may restrict oil fow. Make sure all hoses and tubes
are held frmly in their support brackets.
Atmospheric Vents
Atmospheric vents (refer to Figure 4.26) are located at
the boom tip, on the pole guide and tools circuits. Inspect
these vents as recommended by the Preventive Mainte-
nance and Inspection Checklist.
Figure 4.26 Atmospheric Vent
Fiberglass and Plastic Components
The fberglass components are covered with gelcoat to
protect the fberglass and resin composite. The gelcoat
contains ultraviolet inhibitors to retard the effect of ul-
traviolet light on the fberglass. With minimal care, the
sealing and ultraviolet properties of the fberglass can be
maintained for many years. The following sections include
information on the cleaning and repair of fberglass and
plastic components.
Inspect the fberglass components for cleanliness and
any visible damage such as scratched, cracked, or
chipped gelcoat. Surface irregularities may trap dirt and
contaminants, which over time may reduce the dielectric
properties of the fberglass. Of particular concern are
irregularities running lengthwise on the boom. Trapped
contaminants, such as dust particles and water, may
cause tracking, providing a path to ground or possible
dielectric failure.
Search for signs of looseness or movement at the bond
areas (fberglass to steel or fberglass to fberglass con-
nections) at the boom tip and end of the upper boom. If
the fasteners are properly tightened and the chemical
bond is good, it is unlikely damage will be found. If a
chemical bond has failed and the unit is operated using
the mechanical backup fasteners, cracks or elongation
of the holes may develop around the fasteners. The
fasteners will then begin to show frictional wear.
Other fberglass components have a variety of mechani-
cal fasteners that require inspection.
Cleaning
Keep fberglass and plastic components clean and in
good condition to preserve the dielectric properties and
appearance. Clean all components passing through the
boom fberglass section.
Notice
Do not spray water from a high pressure washer
directly at hydraulic or electrical components.
The fberglass upper boom interior may be cleaned (as
necessary) using a pressure washer and directing the
stream of soapy water inside the boom. Rinsing with clean
water will then remove any detergent residue. Elevate
-4 -8
40 Section 4 Preventive Maintenance and Inspection
the booms for draining and drying. Allow the booms to
dry thoroughly before operating the unit.
Warning
Death or serious injury can result from improper
use of solvents. Follow the manufacturers label for
proper use and disposal.
In some situations, pressure washing may not remove
all of the contaminants from the upper boom interior. A
solvent may be used to clean this type of contamination
with some type of swab device. Suitable solvents, such
as acetone or MEK (Methyl Ethyl Ketone), may be used
to clean these stubborn areas. Refer to the precau-
tions and instructions on the solvent selected for this
cleaning procedure. This may require removal of some
interior boom components. After the contaminated area
is swabbed, use the pressure washer and follow up with
a thorough rinsing with clean water.
The exterior of the upper boom, and other fberglass
components, may be washed with a mild detergent. When
washing these components, take care not to create any
surface scratches.
Notice
Do not coat a fberglass surface with any product
that will reduce its dielectric characteristics or cause
surface fashover.
Do not use petroleum based products to clean the fber-
glass components. Petroleum based products will leave
an oily residue that attracts dust.
Do not use steel wool to clean fberglass components. Re-
tained metallic particles can provide a conductive path.
Surface fashover occurs when a substance causes an
arcing of electricity between two points on the boom. If
this occurs, the dielectric integrity of the boom can be
permanently damaged.
Notice
When using a power buffer to polish fberglass, do
not damage or overheat the gelcoat surface.
After the exterior surfaces are clean and dry, polish with
Formula Five Clean N Glaze. For the best results, polish
fberglass surfaces by hand.
Plastic
Plastic covers on the unit are covered with an acrylic
surface to protect the plastic from damage from ultraviolet
damage. Use a pressure washer and mild detergent to
clean plastic covers. Rinse with clean water to remove
any detergent residue.
Notice
Using solvents (such as acetone, MEK, or lacquer thin-
ner) can damage plastic covers. Use only isopropyl
alcohol (rubbing alcohol) to clean plastic covers.
In some situations, pressure washing may not remove all
of the contaminants from plastic covers. Use isopropyl
(rubbing) alcohol to clean this type of contamination.
After the covers are clean and dry, hand polish using an
automotive type wax.
Determining the Degree of Boom Damage
Minor damage (scratches on the upper boom, the boom
tip, and fberglass control covers) is repairable. If no f-
berglass cloth fbers are cut or damaged, determine if the
scratch or nick affects only the gelcoat or if it is through
to the resin. To do this, look at the color at the bottom of
the scratch. If the color is white, the damage is on the
surface. This damage is minor and can be sanded out as
described under Surface Damage in this section.
Notice
If the fberglass is damaged past the gelcoat and
shows up black, and/or the fberglass cloth fbers
are damaged, contact Altec before any repairs are
started.
If the color at the bottom of the scratch or nick is dark,
and there is no visible damage to the layers of fberglass
cloth, the damage is through the gelcoat and just into the
resin. This requires a more thorough repair of the gelcoat
and is described under Gelcoat in this section.
Any time there is doubt regarding damage to the boom,
use the following procedure to accurately describe the
damage before calling Altec.
1. Identify the quadrant in which the damage has oc-
curred (refer to Figure 4.27).
2. Identify the exact area along the booms length where
the damage is. To do this, measure from the boom
tip to the damage site [example 46 (1,168.4 mm)
from the upper boom tip].
3. Defne the type, size, and the cause of the damage
[example 2 long x 1 wide x
1
/8 deep (50.8 x 25.4
x 3.18 mm); gouge caused by a chain saw].
Section 4 Preventive Maintenance and Inspection 41
Figure 4.27 Boom Damage Location
4. When calling Altec to describe the damage in ques-
tion, be sure to explain where you are in relation to
the unit (example front of the unit, facing the boom
tip with the unit in the stowed position).
If the boom has several damaged or cut inner fberglass
cloth layers, it may not be repairable. At this point, the
booms strength may be reduced and repairs will not
restore the boom strength. If such damage is discovered,
contact your Altec representative. They can evaluate the
affect of the damage on the structural integrity of the
boom and determine if the damage is repairable or if the
boom must be replaced.
If it is determined that the extent and location of the dam-
age will not reduce the safety factor of the boom, it may
be acceptable to repair the damaged area with gelcoat
to seal it and place the unit back into service.
Repair
Minor Surface Damage
Minor scratches in the surface of the gelcoat may be
easily repaired. If the bottom of the scratch is the same
color as the gelcoat pigment, repair according to the
following procedure.
Caution
Injury can result from airborne particles entering
the eyes and lungs. Wear appropriate safety equip-
ment.
1. Use a dual acting sander with 320 grit sandpaper to
sand the scratched area. Move the sander to sand
around the circumference of the boom. Do not sand
lengthwise on the boom.
2. When the scratch has almost disappeared, sand by
hand with a 600 grit wet or dry sandpaper until the
scratch is no longer visible.
3. Use Formula Five Clean N Glaze to polish the
area.
Gelcoat
Use an Altec gelcoat repair kit (refer to Service Tools and
Supplies in the Appendix) with the following procedure.
Any scratch that is dark at the bottom is through the
gelcoat and into the resin below.
In order for gelcoat repairs to cure properly, the following
special temperature considerations must be understood.
The highest quality gelcoat repairs are accomplished
indoors in a heated and well ventilated area.
Notice
The gelcoat can be burned during the warming pro-
cess. Continually move the heat gun or paint stripper
during warming.
If the unit has been outside and the temperature is
less than 70 degrees Fahrenheit (21 degrees Cel-
sius), or if this is a feld repair, the boom area must
be warmed before proceeding. Warm the fberglass
using a heat gun until it is warm to the touch. It will
take approximately 40 minutes to do this. A paint
stripper gun will provide a faster method. Do not
concentrate the heat of the gun in one specifc area
for any length of time.
If the outside temperature is below 60 degrees Fahr-
enheit (16 degrees Celsius), a feld gelcoat repair is
not suggested. Makeshift tents over the repair area will
not hold suffcient heat, preventing proper curing.
Caution
Injury can result from airborne particles entering
the eyes and lungs. Wear appropriate safety equip-
ment.
Use the following procedure to repair the gelcoat.
1. Use a die grinder to widen the scratch to
1
/8 (3.18
mm). Do not grind into the fberglass cloth.
2. Inspect the scratch. If the fberglass cloth is cut,
contact your Altec representative. If no fberglass
cloth is damaged, bevel the edges of the
1
/8 (3.18
mm) cut to about 45 degrees.
3. Lightly sand the damaged area by hand to roughen
it up. This will help the resin bond to the surface.
Quadrant 2
Quadrant 3
Quadrant 4
Quadrant 1
12
3
6
9
42 Section 4 Preventive Maintenance and Inspection
Warning
Death or serious injury can result from improper
use of solvents. Follow the manufacturers label for
proper use and disposal.
4. Use a solvent such as acetone to clean the area and
remove any dust.
5. The Altec gelcoat repair kit contains a can of resin, a
can of fumed silica powder, and a bottle of hardener.
Refer to the material safety data sheet included with
the kit for special precautions and recommendations
for use with this product. Mix the resin, powder, and
hardener according to the kit instructions.
6. Apply the mixture to the damaged area with a plastic
spatula. Work the spatula back and forth to remove
any air bubbles. Build up the area so it is slightly
above the boom surface. The mixture will shrink
slightly as it cures.
7. When the area has cured, sand the area by hand
with 600 grit wet or dry sandpaper. Sand until the
patch is no longer visible.
8. Use Formula Five Clean N Glaze to polish the
area.
Platform and Fiberglass Covers
The frst step in successful repair is to analyze the dam-
age and determine the cause. Cracks in the gelcoat or
outer surface of the platform or cover are easily repaired.
Damage to the fberglass structure can be more serious
and should be carefully evaluated before attempting to
repair the platform.
Structural components of the platform include the rim,
mounting ribs, platform sides, and the bottom (refer to
Figure 4.28). The platform is constructed similar to a
basketball hoop and net. The rim supports the sides
in the same way that the basketball hoop supports the
net. The structural integrity of the platform rim is critical
in determining whether or not the platform can be suc-
cessfully repaired. The platform bottom and the side
with the mounting ribs are substantially thicker than the
other three sides. The mounting ribs are the area where
the platform mounting bracket fastens to the platform.
Consider these factors when determining whether a
successful repair can be made on the platform bottom
or mounting rib side.
Figure 4.28 Platform
Altec cannot determine if the platform is repairable in the
feld. Evaluate the platform and determine whether or not
it can be repaired and safely used for future service. Altec
does not recommend that repairs be made to platforms
which have the following damage.
Cracks through the fberglass of the mounting ribs
Cracks through the fberglass of the rim
A hole through the foor or mounting rib side of the
platform
Altec only assumes responsibility for platform repair
performed by Altec personnel.
Warning
Death or serious injury can result from contact with
energized conductors. Do not operate the unit with
a hole in the platform or liner.
The following items are required to perform feld repair
of the platform or fberglass covers.
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 to match the platform
Use the following procedure as a guide in making a
quality feld repair.
1. Outline the damage with a box that is 1 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).
Rim
Mounting
Ribs
Sides
Section 4 Preventive Maintenance and Inspection 43
Caution
Injury can result from airborne particles entering
the eyes and lungs. Wear appropriate safety equip-
ment.
2. While wearing safety glasses and a dust mask for
breathing protection, grind the area within the box
to a depth of approximately
1
/8 (3 mm).
3. Cut strips of fberglass cloth to ft the box area.
Warning
Death or serious injury can result from improper
use of solvents. Follow the manufacturers label for
proper 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 rubber gloves, saturate the fberglass
cloth with the mixed resin and apply it to the dam-
aged area. Work the area to squeeze out any air
bubbles.
7. After the resin has set up completely, grind off any
rough areas 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.
Notice
Do not coat a fberglass surface with any product
that will reduce its dielectric characteristics or cause
surface fashover.
10. Paint the area to match the platform. Do not apply
metallic paint to 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 provides a protective layer of ultraviolet inhibitors.
The gelcoat layer has no inherent strength.
Before making any repair, the structural integrity of the
platform and the safety of the operator must be kept in
mind. More specifc repair information for a particular
situation should be requested from your Altec repre-
sentative.
Winch Line
The winch drum is designed to accommodate either wire
or synthetic winch line. Inspect the winch line as recom-
mended by the Preventive Maintenance and Inspection
Checklist.
Synthetic Winch Line
Warning
Death or serious injury can result when the synthetic
winch line contacts an energized conductor and the
ground. Do not allow the winch line to contact an
energized conductor.
The synthetic winch line is not to be considered an in-
sulator. Contact between an energized conductor and
the ground may result when the winch line is extended
to the ground.
Normal use will gradually reduce the strength of synthetic
winch line. The entire length of the line must be inspected
as recommended by the Preventive Maintenance and
Inspection Checklist.
Keep a permanent, written, and dated report of the lines
condition and any corrective action taken during the
inspection on fle.
Follow the instructions of the line manufacturer when
splicing a synthetic winch line. A properly made splice is
a strong and effcient means of attachment.
When inspecting the synthetic winch line, use the following
guidelines to determine the condition of the line.
A few damaged strands spaced out along the length
of the line are acceptable. List the location of the
damaged strands in the report. Check these strands
carefully in future inspections.
To determine wear, compare an individual strand in
an area where it is exposed and subjected to wear
with an area of the same strand where it has been
protected from wear. If individual cover strands have
worn to within 50 percent of their original bulk over
an extended area of the line, replace the line.
If half of the cover strands are cut at a given point,
replace the line or cut out the damaged section and
splice the line back together.
44 Section 4 Preventive Maintenance and Inspection
Replace a spliced line if it does not meet the length
requirements under Replacement in this section.
If a damaged section is removed near the eye of the
line, put in a new eye splice. Use a standard end-
for-end splice to rejoin the line in other areas.
Knots can reduce rope strength. A winch line should
never have a knot tied in it.
Wash the line with a mild detergent and warm water.
Strong cleaning agents or bleaches may be harmful to
the line and must not be used.
Rinse the line thoroughly after washing. Squeeze out
the water by placing the line under tension. Allow line
to air dry.
Rotate the winch line end-for-end on a periodic basis.
This will vary the high stress and wear points, extending
the useful life of the line. This is not possible if a closed
thimble is spliced into the lifting eye.
Wire Rope Winch Line
Normal use will gradually reduce the strength of wire rope
winch line. The entire length of the line must be inspected
as recommended by the Preventive Maintenance and
Inspection Checklist.
Keep a permanent, written, and dated report of the lines
condition and any corrective action taken during the
inspection on fle.
Caution
Injury can result from handling wire rope. Wear ap-
propriate safety equipment.
Be careful when using wire rope. Wire rope can be dan-
gerous if not handled properly.
If the wire rope is caked with grease and dirt, clean it with
a wire brush before inspecting it. During the inspection,
the line should be fexed as much as possible and not
be under tension. Wiping the line with a soft cloth may
be helpful in detecting broken wires.
Replace the wire rope if any of the following conditions
exist.
Two or more broken wires at an end connection.
Kinking, crushing, twisting, or other damage that re-
sults in permanent distortion of the rope structure.
Evidence of heat damage or excessive corrosion.
Wear that has reduced the thickness of individual outer
wires to
2
/3 or less of the original wire diameter.
If a damaged section of a wire line is cut off of one
end, the new length of line must meet the winch line
length requirements under Winch in Section 6. If is
does not, replace the winch line.
Reduction in the rope diameter of more than
1
/32 (0.8
mm) for
3
/8 to
1
/2 (9.5 to 12.77 mm) rope diameter
or
3
/64 (1.2 mm) for
9
/16 to
3
/4 (14.3 to 19 mm) rope
diameter.
Three or more broken wires in one strand within one
lay (refer to Figure 4.29).
Figure 4.29 Wire Rope
Six or more randomly broken wires in one lay.
Measure the diameter of wire rope with calipers, across
the crowns of opposite strands (refer to Figure 4.30).
Rotate the caliper around the rope when taking the mea-
surement to obtain the maximum reading. On new wire
rope, initial loading and operation will allow for seating
in of the strands and initial diameter pull down. After the
initial loading, the frst measurements should be made
and recorded for future reference.
Figure 4.30 Wire Rope Measurement
Inspect the rope If it has not been used for a month or
more. The rope must be approved for use before putting
the unit back in service.
One Rope Lay
One Strand
Correct Incorrect
Section 4 Preventive Maintenance and Inspection 45
Rotate the winch line end-for-end on a periodic basis.
This will vary the high stress and wear points extending
the useful life of the line.
Proper lubrication is important in extending the life of wire
rope winch line. Periodic lubrication with a spray-on wire
rope lubricant such as Chain and Cable Fluid (refer to
Service Tools and Supplies in the Appendix) will prevent
corrosion. It will also reduce internal friction and wear as
the wires move in relationship to each other.
Replacement
When replacing a synthetic winch line, the replacement
synthetic winch line must be of the same size and at
least the same rated working load as the rope originally
furnished with the unit. The winch line rated working load
of the originally furnished line is shown on the capacity
placard at the lower controls. ANSI requires that the de-
sign factor of synthetic-type ropes shall not be less than
5:1 and that the winch drum diameter be in a ratio of no
less than 8:1 to the rope diameter (d <
D
/8, where D is the
diameter of the drum and d is the diameter of the rope)
for turntable winches. For boom tip winch replacement
line consult your Altec representative. The replacement
winch line must be long enough to provide at least fve
full wraps of the line on the winch drum. This is with the
load hook on the ground and the booms and any jib at
full extension and elevation.
When replacing a wire rope with a synthetic rope, the
synthetic rope must meet the requirements for diameter,
length, and strength stated in the previous paragraph.
Remove any sharp edges that the synthetic rope may
contact. Repair or replace any hardware that is scored
or damaged by the wire rope. This will help to prevent
damage to the new synthetic rope. The fbers of synthetic
ropes can be cut and damaged by sharp edges and burrs
on winch drums, sheaves, shackles, wire slings, etc.
Warning
Death or serious injury can result from loss of load
control. Install the winch line in the proper direction
of the drum rotation.
The winch line must be installed in the proper direction
of drum rotation for the holding valve to be effective.
When spooling new line on the drum, make sure the frst
wrap that exits the anchor pocket is fush with the drum
fange to achieve even spooling of the winch line.
Put the frst layer of line close and tight around the winch
drum. The line should be under a tension of at least 50
pounds (22.68 kg). This will help prevent subsequent
wraps from slipping down between the frst layer of wraps
when a load is applied to the winch.
When replacing a wire rope winch line, the replacement
wire rope winch line must be of the same size and at
least the same rated working load as the rope originally
furnished with the unit. The rated working load of the
winch line originally furnished with the unit is shown on the
load capacity placard at the lower controls. ANSI requires
that the design factor of steel wire ropes be not less than
3.5:1, and the design factor for rotation-resistant-type steel
wire ropes be not less than 5:1. It is also required that
the winch drum shall provide a frst layer wire rope pitch
diameter of no less than 18 times the nominal diameter
of the wire rope for turntable winches. This means that
the sum of the diameter of the drum and the diameter
of the rope divided by the diameter of the rope must be
greater than or equal to 18 [(D+d)/d greater than or equal
to 18 which is equivalent to d less than or equal to D/17,
where D is the diameter of the drum and d is the diameter
of the rope] for turntable winches. For boom tip winch
replacement line consult your Altec representative.
Follow the recommendations of the rope manufacturer
when storing, unreeling, cutting, and installing new wire
rope. The replacement winch line must be long enough
to provide at least fve full wraps of the line on the winch
drum. This is with the load hook on the ground and the
booms and any jib at full extension and elevation.
Warning
Death or serious injury can result from loss of load
control. Install the winch line in the proper direction
of the drum rotation.
The winch line must be installed in the proper direction
of drum rotation for the holding valve to be effective.
When spooling new rope on the drum, make sure the
frst wrap that exits the anchor pocket is fush with the
drum fange. This will help achieve even spooling of the
winch line.
Auger Windup Sling
The unit may be equipped with a wire rope or synthetic
auger windup sling.
Warning
Death or serious injury can result if the auger sling
breaks. Replace a worn or damaged auger sling.
If any of the conditions given in this section are found,
replace the sling with an Altec replacement part to insure
that the proper rope is used.
46 Section 4 Preventive Maintenance and Inspection
Wire Rope Sling
Replace the wire rope auger windup sling if any of the
following conditions exist.
Four or more broken wires.
Any signs of wear, kinking, crushing, or corrosion.
If the welded lug (refer to Figure 4.31) that secures
the sling during auger stowage appears to be cutting
wires or strands on the sling. This condition requires
repair or replacement of the lug also.
Lubricate wire rope windup slings regularly as recom-
mended by the Preventive Maintenance and Inspection
Checklist. This will extend the life of the wire rope by
preventing corrosion and reducing wear on the wires.
Synthetic Sling
Replace the synthetic auger windup sling if any of the
following conditions exist.
Cuts, snags, holes, punctures, tears, or excessive
abrasive wear in the webbing.
Broken or worn threads in the stitching.
Signifcant bleaching of the webbing from sunlight
exposure.
Any knots in the sling.
If the welded lug (refer to Figure 4.31) that secures the
sling during auger stowage appears to be cutting strands
on the sling, repair or replace the lug.
Auger Stow Bracket Clevis
The auger stow bracket is equipped with a pivoting clevis
attached to the auger windup sling (refer to Figure 4.31).
The clevis is held in its normal position by a shear pin.
If the windup sling is overloaded while stowing the auger,
the shear pin will fail before the sling is damaged. When
the shear pin fails, the clevis tilts to a vertical position
(refer to Figure 4.31). This drops the auger slightly with a
jolt to alert the operator that too much tension is being put
on the auger windup sling. If the shear pin fails, promptly
replace it with a genuine Altec replacement part.
The following may cause the sling to overload while
stowing the auger.
Excessive digger speed
A bent auger or auger extension shaft
Improper adjustment or malfunctioning of the auger
stow switch
When inspecting the shear pin, make sure it is intact. If the
shear pin is broken, replace it with a new one. Determine
the cause of the shear pin failure and correct it.
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
representative.
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.
Auger Windup
Sling
Welded Lug
Clevis
Figure 4.31 Auger Mechanism
Shear Pin Intact
Clevis
Shear Pin Clevis
Shear Pin Failed
Section 4 Preventive Maintenance and Inspection 47
Accident Prevention Signs Diagram
Radio Controls Without Hard Wired Lower Control
37 33 22 2
26 15 6
5
3
23
19
30
31
4
10
17
36
2
Riding Seat (Full View)
26
15
6
4
2
10
17
30 3
36
23
5
31
19
18 28
or On Side
15
6
17
30
36
23 31 5 19 26
4
2
3
10
Riding Seat
48 Section 4 Preventive Maintenance and Inspection
9
13
Chassis
13
9 1
1
1
29
Auger Stow Bracket
Control Pedestal
Rear Mount or Corner Mount Pedestal
Both Sides Rear Mount
One Side Corner Mount
27
Turntable
32
16
Out and
Down Outrigger
24
7
Curb and
Street Side
Curb and
Street Side
Personnel
Jib Boom
Platform Stepside
2 4 6 30
31
14
10
17 16
5
Both Sides
25
26
On Tailshelf Near
Control Station
Jib Bracket
33
Behind Cab Mount
Pedestal (Both Sides)
4
37
6 30 27 35 31
3
10
2
19
17
15
5
33
34
2 3 32 19
33
15
17 30 5 6 4
34 35
10
36
37
23
36
7
7
A-Frame,
X-Frame, or Corner
Mount Outrigger
Radial
Outrigger
Section 4 Preventive Maintenance and Inspection 49
Units With
Platform Mounting Tubes
With Pullout Section
37
16
Boom Tip Power Package
and/or Upper Controls
Boom Tip Winch
Turntable With Riding Seat
33
31
21
37
34
30
Turntable Winch
Turntable With Riding Seat
Both
Sides
22
Boom Tip
22
34
37
30
31
33
18 28
Control Panels
STANDARD
RASE
CCW CW
ROTATE
LOW SPEED
AUGER
RELEASE
SHFT DGGER
LOWER
BOOM
DG
DIGGER
OPERATE PUSH TO
ROTAFLOAT
CLOSE OPEN
POLE GUIDE
CLEAN
UPPER BOOM
RETRACT EXTEND
E
N
G
N
E Stop
ON
OFF
T
O
O
L
S
T
H
R
O
T
T
L
E
STOP
START
WINCH RASE
BACK FWD
LOWER
POLE GUIDE
U
N
T
RET EXT
INTERM BOOM
STOP
Radio Controls
11
12
8
20
50 Section 4 Preventive Maintenance and Inspection
2
4
3
1
Section 4 Preventive Maintenance and Inspection 51
5
6
7
9
8
52 Section 4 Preventive Maintenance and Inspection
14
13
12
10
11
16
15
Section 4 Preventive Maintenance and Inspection 53
20
17
18
19
21
22
54 Section 4 Preventive Maintenance and Inspection
25
23
24
26
Death or serious injury may result from
unintended downhill rotation of boom if
rotation float is operated when unit is
located on a slope and screw anchor is
not engaged in soil.
Operate rotation float only while installing
screw anchors.
Operate rotation float only after screw anchor
has engaged soil.
Discontinue operation of unit and refer to
manual for instructions if audible alarm stays on
constantly.
Rotation Float System Operating nstructions:
With screw anchor engaged in soil and digger
operating, activate rotation float to allow
derrick rotation to follow screw anchor
automatically.
When rotation float is activated, audible alarm
will beep once and light will come on.
UNNTENDED MOTON HAZARD
WARNNG
Section 4 Preventive Maintenance and Inspection 55
30
32
31
27
29
28
56 Section 4 Preventive Maintenance and Inspection
35
33 34
36
37