Am800-900 M

Copyright 2006 by Altec Industries, Inc.
All rights reserved. No part of this publication may be used or reproduced by any means, or stored in a
database or retrieval system, without prior written permission of the publisher. Making copies of any part
of this publication for any purpose other than personal use is a violation of United States copyright laws.
Altec Industries, Inc. reserves the right to improve models and change specifications without notice.
749-20009
March 2006
AM800/900
Maintenance
and Parts Manual
Preface
This unit is the result of Altecs advanced technology and quality awareness in design,
engineering, and manufacturing. At the time of delivery from the factory, this unit met or
exceeded all applicable requirements of the American National Standards Institute. All
information, illustrations, and specifications contained within this manual are based on the
latest product information available at the time of publication. It is essential that all personnel
involved in the use and/or care of this unit read and understand the Operators Manual.
Given reasonable care and operation, according to the guidelines set forth in the manuals
provided, this unit will provide many years of excellent service before requiring major
maintenance.
The scope of this manual is limited to periodic maintenance. It does not cover methods that
may be required to inspect and repair major damage to the unit. Impacts to and excessive
forces on the hydraulic utility equipment, through vehicular accidents, rollovers, excessive
loading, and the like, may result in structural damage not obvious during a visual inspection.
If the hydraulic utility equipment is subjected to such impacts or forces, a qualified person may
need to perform additional testing such as acoustic emissions, magnuflux or ultrasonic testing
as applicable. If structural damage is suspected or found, contact Altec for additional
instructions.
Warning
Death or serious injury can result from component failure. Continued use of a mobile
unit with hidden damage could lead to component failure.
Never alter or modify this unit in any way that might affect the structural integrity or operational
characteristics without the specific written approval of Altec Industries, Inc. Unauthorized
alterations or modifications will void the warranty. Of greater concern, is the possibility that
unauthorized modification could adversely affect the safe operation of this unit, resulting in
personal injury and/or property damage.
Danger
Death or serious injury will result from unprotected contact with energized conductors.
Non-insulated units have no dielectric rating. Maintain safe clearances, as defined by
federal, state, and local authorities, and your employer, from energized conductors.
No unit can provide absolute safety when in proximity to energized conductors. No unit is
designed or intended to replace or supersede any protective device or safe work practice
relating to work in proximity to energized conductors. When in proximity to energized
conductors, this unit shall only be used by trained personnel using their companys accepted
work methods, safety procedures, and protective equipment. Training manuals are available
from a variety of sources.
Set-up requirements, work procedures, and safety precautions for each particular situation
are the responsibility of the personnel involved in the use and/or care of this unit.
7-04
Table of Contents
About This Manual............................................................................................................ 1
Special Cautions .................................................................................................................. 1
Disclaimer of Liability ........................................................................................................... 2
Structures ............................................................................................................................. 2
Equipment Storage ............................................................................................................... 2
Protective Measures ...................................................................................................... 2
Cleaning the Unit and Fiberglass .......................................................................................... 3
Plastic ............................................................................................................................ 3
Tightening of Fasteners ........................................................................................................ 3
Lockwiring ............................................................................................................................ 4
Inspection Marks .................................................................................................................. 4
Pins ...................................................................................................................................... 5
Bearings ............................................................................................................................... 5
Inspections ........................................................................................................................... 5
Elbow Bearing Cap Screw Torque Inspection Procedure ............................................... 6
Rotation Bearing Cap Screw Inspection Procedure ....................................................... 7
Rotation Gearbox Mounting Cap Screws ....................................................................... 8
Lubrication ............................................................................................................................ 9
Lubrication Chart and Diagram..................................................................................... 10
Adjustment of Rotation Pinion to the Rotation Bearing....................................................... 12
Hydraulic Plumbing, Hoses, and Fittings............................................................................ 12
Single Handle Control and Control Handle Covers .............................................................. 13
Atmospheric Vents ............................................................................................................. 13
Oil Filtration ........................................................................................................................ 13
Oil Selection ....................................................................................................................... 13
Changing the Oil ................................................................................................................. 14
Visual Inspection of Hydraulic Oil ...................................................................................... 14
Flushing the Hydraulic System........................................................................................... 14
Air Bleeding ........................................................................................................................ 15
Troubleshooting Procedure ................................................................................................. 15
Engine Throttle Control ....................................................................................................... 15
Removing the Rotary Joint ................................................................................................. 16
Removal of Upper Boom Lift Cylinders............................................................................... 16
Leveling Cable Inspection, Replacement, and Adjustment ................................................. 17
Inspection of Leveling and Holdback Cables ............................................................... 17
Replacement of Leveling Cables.................................................................................. 18
Procedure for Removing Leveling Cables and Rods .................................................... 18
Installation of Cables and Rods ................................................................................... 19
Adjustment of Leveling Cable Tension......................................................................... 21
Non-Overcenter Cam Valve Adjustment ............................................................................. 22
Main System Pressure/Standby Pressure Adjustment ...................................................... 23
Standby Pressure ........................................................................................................ 23
Main System Pressure ................................................................................................ 23
Pilot System Pressure Adjustment .............................................................................. 24
Tool System Pressure Adjustment .............................................................................. 24
Setting Main Control Valve Flow Controls/Boom Function Speed ............................... 24
Upper Boom Stow .............................................................................................................. 25
Holding Valves ................................................................................................................... 25
Winch Brake ....................................................................................................................... 26
Upper Control Linkage ........................................................................................................ 27
Upper Controls Interlock Trigger ......................................................................................... 28
Outrigger Interlock Switches .............................................................................................. 28
Testing ............................................................................................................................... 29
Dielectric ...................................................................................................................... 29
Structural ..................................................................................................................... 29
Stability ........................................................................................................................ 30
Appendix
Glossary
Service Tools and Supplies
Preventive Maintenance and Inspection Checklist
Accessory Checklist
Torque Values
Basic JIC Symbols
Hydraulic System Schematics
Troubleshooting Chart
Dielectric Test Forms
Stability Test Forms
Maintenance Manual 1
The terms danger, warning, and caution represent 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 an imminently hazardous situation which,
if not avoided, will result in death or serious injury.
This signal word is to be limited to the most
extreme situations.
Warning
Indicates a potentially hazardous situation which,
if not avoided, could result in death or serious
injury.
Caution
Indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe
practices.
The term attention is used to alert personnel of special
information to assist in the maintenance of the unit or
instructions that must be followed to prevent the possibil-
ity of damage to structures, components, or other prop-
erty.
Special Cautions
Several operating cautions are pointed out in the Operators
Manual and a number of maintenance cautions are de-
scribed in this Maintenance Manual. Adherence to the
cautions will mean safer operating practices and better
service from unit.
The following is an additional list of special cautions and
reminders to assist maintenance personnel and service
men in doing their job most efficiently.
1. Most hydraulic ports and fittings on a unit are SAE or
JIC straight thread. Do not attempt to connect pipe
thread fittings to them without being certain it is
intended to be a pipe thread connection.
2. Cleanliness is extremely important in a hydraulic
system. When hydraulic lines are disconnected or
components are removed, the ports should be plugged
or other precautions taken to prevent oil dry or other
contaminants from entering the hydraulic system.
3. Even new hydraulic oil from a barrel or other container
from the petroleum company is highly contaminated
compared to the filtered oil of the hydraulic system. All
oil being added to the reservoir must be filtered before
About This Manual
This manual provides instruction to safely inspect, repair,
and troubleshoot the unit. Charts and figures are provided
to support the text. Because options vary from one model
to another, some figures may only be a representation of
what is actually on the unit.
Knowledge of the information in this manual combined with
proper skills and training in hydraulic, electrical, and
mechanical systems, provide a basis for safely maintain-
ing the unit. Read and understand the applicable procedure
before beginning.
Contact the following organizations for additional informa-
tion.
American National Standards Institute (ANSI)
A92.2 for aerial devices; A10.31 for digger derricks
American Public Power Association
(Safety Manual for an Electric Utility)
American Society for Testing and Materials (ASTM)
American Welding Society (AWS)
Canadian Standards Association (CSA)
European Committee for Standardization (CEN)
Fluid Power Society (FPS)
Hydraulic Tool Manufacturers Association (HTMA)
International Electrotechnical Commission (IEC)
International Organization for Standardization (ISO)
Occupational Safety and Health Administration
(OSHA)
Dealers, installers, owners, users, operators, rentors,
lessors, and lessees must comply with the appropriate
sections of the applicable ANSI standard.
The Appendix contains reference items to help maintain
the unit. A glossary of industry terms is provided for your
convenience. This glossary provides an understanding of
the industry terms and phrases used in Altec manuals.
Throughout the manual, the term unit is used to describe
the Altec device, subbase, outriggers, and the 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.
2 Maintenance Manual
using it to power the unit. This is most effectively done
by running the oil through a micron filter as it is put into
the reservoir. If this is not possible, allow the oil to
circulate through the system for approximately 15
minutes before operating the unit. Change the filter
cartridges soon after using them to filter any substan-
tial quantity of new hydraulic oil. A new barrel of oil is
moisture free, however, this may not be true of barrels
which have not been stored properly.
4. Always be certain that the shutoff valve between the
reservoir and the pump inlet and the shutoff valve at
the return line filter are completely open before oper-
ating the pump.
5. Inspect hoses and wire cables frequently to be certain
they are routed in such a way to avoid sharp edges,
kinking, scuffing, etc.
Disclaimer of Liability
Altec Industries, Inc. will not be liable for unauthorized
alterations or modifications of the unit. Altec Industries,
Inc. will not be liable for improper or abusive operation of
the unit.
Do not alter or modify this unit in any way that might affect
its structural integrity, dielectric integrity, or operational
characteristics without specific written approval from
Altec Industries, Inc.
Unauthorized alterations or modifications will void the
warranty. However, of a greater concern is the possibility
that unauthorized changes could adversely affect the
units operation that could endanger personnel and/or
damage property. Altec will not be responsible for unautho-
rized alterations or modifications that cause death, seri-
ous 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.
Structures
The basic structural components are the pedestal, turn-
table, lower boom, upper boom, and the outriggers. The
steel structures are made in the form of a closed box
structure in order to resist torsional loading as well as
tension, compression and bending loads to which the unit
may be subjected. Careful consideration has been given
to the elimination of stress risers caused by sharp cor-
nered openings and abrupt changes in section, to mini-
mize the possibility of fatigue cracks forming.
Periodic inspection of the structures is recommended to
be certain that there has been no deformation, abnormal
wear or abrasion, interference between moving parts, or
cracking of the welds on structural members. Any such
problem found should be brought to the attention of an
Altec representative so that the cause can be determined
and steps taken to prevent a recurrence.
Equipment Storage
Mobile hydraulic equipment needs maintenance when
stored, or not used, for extensive periods of time. Depend-
ing upon the climate, lack of use may begin to have a
negative effect in as little as two weeks. Storage for a
period of several months will almost certainly produce
some deterioration of the equipment.
Rust will form on unprotected ferrous metal surfaces very
quickly and water will collect inside unit structures. In dry
climates, gaskets will begin to shrink during long periods
of non-use, and lubricants will lose their ability to provide
lubrication. In cold climates, condensation may occur in
fluid reservoirs and other components.
Even when protective measures have been taken prior to
storage, some degradation of performance must be ex-
pected when the equipment is put back into use.
One of the most noticeable effects of prolonged periods of
non-use is seal deformation. By its nature, hydraulic
equipment generally has a number of heavy, cylindrical
actuators. As these components are allowed to rest in one
position for a period of time, the seals on the piston will
tend to flatten along the loaded side. Since the seal
material is synthetic, its elasticity is limited and it may not
resume its original shape completely. At best, there will be
some failure to seal well for a short period of time after
putting the equipment back into use. At worst, the seal will
never resume its original shape and will have to be
replaced.
Protective Measures
If it is known that equipment will be stored for a month or
more, some steps should be taken to preserve the
equipment.
1. The best preservative is to fully cycle (operate) the
equipment once weekly if even for a short time.
2. Coat exposed ferrous (iron or steel) bare metal sur-
faces with a light grease or heavy oil compatible with
system hydraulic oil. This includes cylinder rods,
shafts, gears, linkages, and unpainted parts.
3. Top off fluid reservoirs to allow as little air space as
possible, to limit the effects of condensation. Remove
excess oil before operating to limit the chance of
overflow when cylinders are cycled.
4. Cover or wrap exposed rubber or neoprene parts with
an ultraviolet resistant covering to shield the parts
from sun exposure.
5. Unplug electrical connectors and apply a dielectric
grease or an aerosol product designed for protecting
electrical connectors. Plug the connector back to-
gether.
6. Cover switch panels and control panels to prevent
direct intrusion of rain or moisture, while allowing air to
circulate over the panel.
7. Cover personnel platforms to prevent the accumula-
tion of water in the platform.
8. Shield fiberglass components from the sun and other
elements, if stored outside.
Cleaning the Unit and Fiberglass
Any piece of equipment which is kept clean and neat
looking is the reflection of a maintenance department
which has pride in its work. It will also have a positive effect
on the operators. They are more likely to treat the unit with
reasonable care if they see that the maintenance crew
cares enough to keep it looking good.
When washing inside the pedestal with the cover off, do
not spray water on or around the fill cap of the oil reservoir.
This could spray water inside the oil cap.
It is common for debris to accumulate in the bottom of the
platforms or liners. Regularly clean out all such material
because of the abuse to the platform or liner bottom
aggravated by the weight of the lineman standing on it.
Operators and maintenance personnel should make sure
there is no build-up of tree branches, etc. in the area of the
leveling cable sheave at the platform and the area of the
lower boom near the turntable. This is most likely to occur
on units used in tree-trimming work.
The interior and exterior of the fiberglass boom and lower
boom insert must be kept in good condition to preserve the
dielectric integrity of the insulating components. Clean the
interior as necessary using a pressure washer and mild
detergent. After pressure washing, thoroughly rinse the
interior to remove detergent and elevate the booms to the
vertical position for draining and drying. Wash the exterior
of the upper boom, lower boom insert, and the fiberglass
platform with a mild detergent, using care not to make
surface scratches. After the exterior surfaces are clean
and dry, polish them with Formula 5 Clean N Glaze
Compound or an equivalent. The booms should be pol-
ished by hand, not with a buffer. Nothing should be used
for coating a fiberglass component which will reduce the
dielectric strength or cause surface flashover.
In the event that cuts or deep scratches are discovered in
the fiberglass components, it is recommended that an
Altec representative be contacted to evaluate the effect of
the damage on structural integrity and to determine if the
damage is repairable. Surface nicks that only effect the
gelcoat can be filled with a gelcoat kit. Fill the nick and
sand smooth with a 600 grit wet or dry sandpaper. Clean
afterwards with Formula Five Clean n Glaze compound.
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.
Attention
Using solvents (such as acetone, MEK, or lacquer
thinner) can damage plastic covers. Use only isopro-
pyl 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.
Tightening of Fasteners
The standard quality fastener used on the unit is a zinc
plated, SAE Grade 5, steel cap screw. SAE Grade 8 cap
screws are used where the higher strength is required in
the design. Special cap screws are used at the elbow
bearing and the rotation bearing to handle the loads on
these components. A variety of other fasteners such as
flat head screws, socket head screws, and button head
screws are also used on the unit. It is good maintenance
practice to check all of the fasteners occasionally to make
certain they are tight. Use the Torque Values in the
Appendix as a guide to determine how tight the various
bolts should be tightened.
The following is a list of fasteners to which particular
attention should be given.
Pedestal mounting bolts
Rotation gearbox mounting bolts
All pin retainer bolts
Outrigger attachment bolts
Boom end attachment bolts
Boom insert attachment bolts
Elbow bearing attachment bolts
Attachment bolts for upper boom to elbow weldment
Platform mounting bolts
Lockwiring
All critical fasteners on the unit must be Iockwired. This
includes bolts through forged pin retainers in pins, all
turnbuckles on leveling cables and insulator rods, and
certain other mounting or retaining bolts. Lockwires must
be installed in a way that tends to pull the fastener in the
direction which would tighten it. An aircraft type wire
should be used. It should be relatively soft. This wire is
easy to work with and will produce neat and effective
Iockwires.
Twist lockwires between the fastener and the anchor point.
At least three full twists should remain on the standing end
of the Iockwire when it is trimmed off. Overtwisting a
Iockwire will tend to work harden the wire which may cause
it to break.
Pliers used in Iockwiring should have smooth, flat sur-
faces to minimize working or cutting the wire, thus weak-
ening it. With a small amount of practice, a mechanic can
become skilled at installing neat and effective Iockwires.
Figure 1 Forged Pin Retainer
Figure 2 Two Bolts
The Iockwires used to secure the turnbuckles and adjust-
ments on the Ieveling cables and Ieveling rods are
illustrated in the section on cable replacement and adjust-
ment.
Inspection Marks
Nuts or cap screws with locking patch element used in
combination with inspection marks are used at specific
locations on the unit that are visible to the operator during
daily inspections.
If any inspection marks are found to be cracked or broken
during inspection, the original mark must be totally re-
moved. The fastener torque must be checked (if no
damage is evident) or the fastener replaced and torqued (if
damage is evident), and the inspection mark reapplied.
The inspection lacquer (refer to Service Tools and Sup-
plies in the Appendix) should not be used after the
expiration date printed on the container.
Use the following procedure to apply a new inspection
mark.
1. Remove the majority of the original inspection mark by
chipping it off with a chisel or other cutting method. Do
not damage the surface on the nut, fastener, washer,
and part or structure being attached to.
Warning
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
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 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 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.
Pins
All pins on the unit have been plated to prevent rusting and
to provide long wear for those pins mating with self-
lubricating bearings.
Pins which are non-rotating or static connections are zinc-
plated to prevent rusting.
Pay particular attention to the lubrication information to
assure proper lubrication of those pins and parts which
require it. It is also important to know which pins and parts
do not require lubrication. Pins mated with self-lubricating
bushings do not require lubrication.
The pin retention means used on the unit are shown in
Figure 3. When inspecting the forged pin retainers, Iook for
bent or broken stems. The stem could bend or break if the
pin that it is retaining tries to turn. On the lower boom
cylinder, this might indicate a lack of Iubrication of the
spherical bearings. A bent pin retainer on the idler sheaves
would indicate that the sheave is binding up. The weld on
pins with welded caps must be inspected. A cracked weld
or an elongated bolt hole indicates that the pin may be
trying to turn. If this is the case, replace the pin and
bearings. A sheared pin would also indicate binding
bearings and the connection should be disassembled and
necessary parts replaced.
Figure 3 Pin Retainers
Other welds to inspect are anywhere a change in cross
section takes place on the booms, turntable, or pedestal.
Pay particular attention to where the lower boom cylinder
meets the turntable and lower boom.
Bearings
The main rotation bearing on the unit is a shear ball bearing
with integral bullgear machined on the outer race. The
outer race is solidly bolted to the pedestal top plate on a
machined surface and the inner race is bolted to the
machined bottom surface of the turntable. The mounting
bolts are
3
/4 -10 UNC alloy cap screws x 2
1
/2 long. A
hardened washer is used beneath the head of each cap
screw. The mounting bolts are tightened to 325 foot-
pounds torque and should be retorqued if any indication of
looseness appears. Properly lubricated, this bearing should
give many years of satisfactory service.
The lower boom cylinder is equipped with spherical bear-
ings to assure alignment.
The main hinge pin for the lower boom, the upper boom
cylinders, the platform shaft, and the links at the elbow are
equipped with self-lubricating bearings. Also the platform
rotator pins, platform rotator cylinders, jib tilt cylinders, jib
tilt support bracket, and fiberglass jib sleeve are equipped
with self-lubricating bearings.
The articulating elbow bearing on the unit is a shear ball
bearing. The outer bearing race bolts securely to the upper
boom end weldment. The inner race bolts to the lower
boom upper weldment. Both bearing mounting surfaces
are machined flat. The bearing is secured with
5
/8-11 UNC
Bowmalloy brand cap screws x 2
1
/2 long. A hardened
washer is used beneath the head of each fastener. The
mounting bolts are tightened to 225 foot-pounds torque
and should be retightened if any indication of looseness
appears. Properly lubricated, this bearing will provide
many years of dependable service.
Inspections
Proper unit maintenance will reduce downtime, lower
operating and repair costs, and extend equipment life.
Safety alone justifies a preventive maintenance program.
This type of program is less expensive than making major
repairs.
This section contains information on properly inspecting
the hydraulic system, structures, individual unit compo-
nents, and lubrication. Use the Lubrication Chart and
Diagram in this section when lubricating the unit.
Lockwire
Stem
Cylinder Eye
Retaining
Ring
Retaining
Ring
Forged Pin
Retainer
Lock
Washers
Weld
Pivot Tube
Lockwire
Retaining
Plate
Pin
Bearing
End Plate
Rollpin
A Preventive Maintenance and Inspection Checklist is
provided in the Appendix. Use this checklist when per-
forming routine maintenance and inspections to insure no
areas are overlooked. Keep permanent, written, and dated
records of all service performed on the unit.
Routine maintenance is performed on different compo-
nents of the unit at different times (refer to the Preventive
Maintenance and Inspection Checklist in the Appendix).
More frequent maintenance may be necessary if the unit
is operated under severe conditions. In addition to the
Preventive Maintenance and Inspection Checklist recom-
mendations, follow these recommendations on new units.
Measure the turntable tilt before using a new unit.
Change the return line filter after the first 15 to 25 PTO
hours.
Gearbox manufacturers recommend an initial oil
change after the first 15 to 25 PTO hours.
Elbow Bearing Cap Screw
Torque Inspection Procedure
The
5
/8-11 UNC X 2
1
/2 Bowmalloy brand cap screws
securing the elbow bearing have a patch lock material
permanently attached to the threads and are coated with
an anti-seize compound at installation. The lubrication
provided by the anti-seize compound allows for a consis-
tent torque when a calibrated click-type torque wrench is
used with the proper torquing procedure. This helps
maintain the clamping force of the cap screws and
prevents wear or damage to the elbow bearing. It also
makes possible an accurate check of the prevailing torque
of the cap screws when they are inspected during regular
maintenance procedures.
The torque value of these cap screws is 225 foot-pounds.
To identify the fasteners, the cap screw heads are painted
white. Plastic caps are installed over the heads to protect
them from being painted over at installation.
Check the torque of the elbow bearing cap screws as
recommended by the Preventive Maintenance and In-
spection Checklist. Check the cap screws at 90 percent of
the recommended torque or 200 foot-pounds. This allows
checking of the cap screws for the proper torque without
rotating all the cap screws.
Initial and Annual Torque Inspection Procedure
Use an accurately calibrated,
1
/2 drive click-type torque
wrench for the inspection of these cap screws.
Upper Boom Side Inspection
1. Remove and discard the protective plastic caps from
the cap screw heads.
2. Inspection should be done in a star or crisscross
pattern as shown in Figure 4.
Figure 4 Upper Boom
3. If 50 percent or more of the cap screws are found to
be loose on either side of the bearing, examine the
bearing for excessive wear.
4. Begin with cap screw number 1, torquing the elbow
bearing cap screw to 200 foot-pounds while watching
for any fastener movement.
5. Torque cap screw number 2 to 200 foot-pounds, again
watching for any fastener movement. Continue around
the pattern of fasteners shown in Figure 4 until all have
been torqued to 200 foot-pounds. If none of the
fasteners moved while retorquing, the inspection is
complete and the covers can be replaced. If any of the
cap screws moved when retorquing, retorque each
cap screw again. This torquing should de done at 225
foot-pounds in a circular pattern beginning with cap
screw number 1 instead of a star pattern.
6. If 50 percent or more of the elbow bearing cap screws
are found to be loose, see instructions for further
inspections in step 3.
6
14
10
12
1
3
13
5
11
8
17
18
4
9
16
2
7
15
Lower Boom Side Inspection
1. Remove the cover from the elbow area to gain access
to the elbow bearing cap screws inside the lower
boom. If the plastic caps are on the cap screw heads,
remove and discard them.
2. On the lower boom side, only inspect one cap screw
per quadrant (refer to Figure 5).
Figure 5 Lower Boom
3. Check the torque on a cap screw at 200 foot-pounds.
4. If any of the cap screws that are checked move, they
should be marked and all the remaining cap screws
checked in the pattern shown in Figure 5. To check the
torque on all the cap screws, it may be necessary to
remove the leveling cable sheave at the elbow.
5. The retorquing procedure, steps 4-6, on the upper
boom side, should be followed when loose cap screws
require all cap screws to be inspected on the lower
boom side.
Visual Inspection Procedure
Visually inspect both sets of cap screws retaining the
elbow bearing. Check for loose washers under the heads
of the cap screws. Also check for evidence of movement
between the bearing and boom weldment. Movement can
be checked by raising the upper boom a few feet out of the
boom rest and rocking the upper boom side to side. If there
is any indication or movement or a loose washer, retorque
the cap screws as described in the Annual Inspection
Procedure.
Rotation Bearing Cap Screw
Inspection Procedure
Special high-strength
3
/4 cap screws are used to secure
the rotation bearing to the pedestal and the turntable. The
rotation bearing cap screws are torqued at the factory to
325 foot-pounds. Rotation bearing cap screw heads may
be colored and/or plastic caps are installed over the heads
to help identify the new fasteners.
Attention
Use a
3
/4 drive click-type manual torque wrench,
accurately calibrated, for the installation of the rota-
tion bearing cap screws. Torque the cap screws by
applying a smooth pull on the torque wrench without
jerking. Do not overtighten the cap screws.
Depending on the particular unit this procedure is being
performed on, components will need to be removed to
make the rotation bearing cap screws accessible for
removal. It is important that experienced. Trained me-
chanics perform this procedure and are aware of the
process needed to make the rotation bearing accessible
for removal.
Caution
Failure to keep the rotation bearing cap screws prop-
erly tightened may lead to fatigue failure of the cap
screws and consequent damage to the unit. Insuffi-
cient or uneven cap screw tightness may also contrib-
ute to reduced life of the rotation bearing.
Visually inspect both sets of rotation bearing cap screws
looking for any evidence that a cap screw is loose. Check
for loose washers under the heads of the cap screws by
trying to turn each washer by hand. If movement is shown,
all the cap screws must be retorqued using the Retorquing
Procedure.
Annual Torque Inspection Procedure
Some seating in of the cap screw threads and mounting
surfaces may occur in any bolted joint during the initial
break-in period, causing a partial loss of cap screw
tightness without any cap screw rotation. Randomly select
four to five cap screws each on both the turntable and
pedestal that are accessible with a torque wrench without
removing major components. Select cap screws that are
evenly spaced around the pattern. Remove and discard
any protective caps from these cap screws. Check the
selected cap screws to be sure they are torqued to 295
foot-pounds or 90 percent of the normal installation torque
6
14
10
12
1
13
5
11
4
9
16
2
7
15
3
8
of 325 foot-pounds. Use an accurate torque wrench,
calibrated on a regular basis. If one or more of these cap
screws are loose, check the torque on all the cap screws
in the pattern as described in the Retorquing Procedure. If
the rotation bearing is replaced or removed, follow the
same inspection intervals.
Retorquing Procedure
Attention
Use a
3
/4 drive click-type manual torque wrench,
accurately calibrated, for the inspection of these cap
screws. Torque the cap screws by applying a smooth
pull on the torque wrench without jerking. Do not
overtighten the cap screws.
Depending on the particular unit this procedure is being
performed on, various components will need to be re-
moved to make the rotation bearing cap screws acces-
sible for retorquing. It is important that experienced,
trained mechanics will perform this procedure and that
they are aware of the process needed to properly torque
rotation bearing cap screws.
1. Remove and discard any remaining protective plastic
caps from the cap screw heads on the turntable.
2. Begin with cap screw number 1 and torque it to 325
foot-pounds. Watch to see if the cap screw rotates
before reaching this torque. If any of the cap screws
rotate, replace it with a new one. New cap screws have
a patch lock material permanently bonded to the
threads and have a dry film lubricant preapplied to the
entire surface of the part. Anti-seize compound is no
longer needed for installation.
Figure 6 Pedestal
3. Look at the hole in the washer. Notice that it has a
more rounded edge on one side of the washer. Install
the washer with the rounded edge of the washer toward
the cap screw head. Reinstall it into the bearing and
torque it to 325 foot-pounds.
4. Torque cap screw number 2 to 325 foot-pounds
watching it for any rotation.
5. Continue around the pattern shown in the figure,
torquing each cap screw and watching it for rotation
until the entire pattern is complete.
6. If any of the cap screws rotated when being torqued in
steps 3 through 5, retorque all cap screws again
beginning at number 1. Go around in a circular pattern
this time instead of in the numbered order.
7. Do steps 1 through 6 on the pedestal side of the
rotation bearing.
The same pattern applies to all unit types and mounting
arrangements. Number one cap screw can be at any
location on the bearing with the remainder of the pattern
shifted accordingly. Components will need to be removed
for access to all cap screws.
Figure 7 Turntable
Rotation Gearbox Mounting Cap Screws
Special
5
/8 cap screws are used to secure the rotation
gearbox to the turntable. The torque value for the cap
screws is 225 foot-pounds. The cap screws require special
inspection procedures.
Insufficient 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.
3
4
6
12
10
14 11
15
2 1
13
5
17
8
18
9
7
16
6
5
8
11
1
12
9
14
3 4
10
7
15
2
16
13
Use caution when access covers have been removed to
service the unit. Pinch points and shear points may exist
between moving parts. Replace the access covers imme-
diately after servicing.
Attention
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.
Perform this visual inspection procedure as recommended
by the Preventive Maintenance and Inspection Checklist.
Visually inspect all rotation gearbox cap screws, looking
for any evidence that a cap screw is loose. Check for loose
washers under the heads of the cap screws by trying to
turn each washer by hand. If movement is indicated,
retorque all the cap screws.
Annual Torque Inspection Procedure
Check the cap screws to be sure they are torqued to 203
foot-pounds or 90 percent of the normal installation torque
of 225 foot-pounds. Use a regularly calibrated, accurate
torque wrench. If one or more of these cap screws turns
before the wrench clicks, retorque all the cap screws to
225 foot-pounds. If the rotation gearbox is replaced or
removed, follow the same inspection intervals.
Lubrication
Proper lubrication on a regular basis will extend the life of
the equipment and help to avoid maintenance problems in
the future. The frequency of lubrication coincides with an
inspection interval. The PTO hours should be used or
estimated for the inspection and lubrication intervals. If a
unit is seldom used, monthly intervals should be followed.
Particular areas of inspection and lubrication points is
provided in the Lubrication Chart and Diagram. This
information should be recorded and kept up to date. Any
notes on repairs or dielectric testing should also be
recorded and filed.
Lubricate the unit as recommended by the Preventive
Maintenance and Inspection Checklist.
As mentioned in the bearings section of this manual, the
self-lubricating and oil impregnated bronze bushings are
self-lubricating, and require no lubrication. The self lubri-
cating bearings are used at both boom pivots, the large
leveling sheaves, the upper boom linkage pivots, and the
platform rotators. Oil impregnated bronze bushings are
used on the rest of the idler sheaves and the upper control
linkage.
There are bearings that require lubrication with a chassis
lubricant. The spherical bearings in the ends of the lower
boom cylinder require periodic lubrication. The rotation
gear has a fitting located on the front of the turntable.
Rotate the unit through two full revolutions while lubricating
the bearings. The top bearing on the rotation gearbox
requires periodic lubrication. The elbow rotation bearing
has a fitting located on the outside of the outer race.
Lubricate the bearing in several positions of the upper
boom. After lubrication, fold/unfold the upper boom through
two full cycles.
Lubricate the inner outrigger legs with a molygrease.
Excessive lubricant on or around the legs will attract dust
and form an abrasive substance.
The rotation gearbox requires SAE 140 Worm Gear Oil. It
should be checked and maintained at a level approxi-
mately half full.
The cables for the leveling system require lubrication with
a wire rope Lubricant. It is extremely important that the
leveling cables not be allowed to run dry. The upper
controls should be periodically lubricated with a light
Iubricant. The wire rope lubricant could be used as a
substitute for the upper controls linkage.
Apply an open face gear lubricant to the rotation gear and
pinion teeth. Remove the pinion cover from the turntable
and lubricate the rotation gear teeth.
Use a small amount of general purpose spray lubricant on
the single handle control linkage pivot points. Wipe off the
isolating links and any excess lubricant. Isolating links
must be clean and dry.
Lubrication Chart and Diagram
Service items identified by the symbol(s) at the appropriate level.
85 hours/1 month 500 hours/6 months 1,000 hours/1 year 2,000 hours/2 year If disassembled
Letter Lubricant Application Method
A Anti-Seize Compound Extreme pressure lubricant that prevents seizure, Brush
corrosion, rust, and galvanic pitting.
C Chassis Grease Multipurpose lithium base grease with good water Grease gun
resistance, rust inhibition, oxidation stability, and extreme pressure properties.
G Open Face Gear Lubricant Spray lubricant that penetrates and adheres with Spray
good water resistance, is unaffected by temperature extremes, and has extreme
pressure properties.
M Moly Grease Multipurpose lithium base grease with molybdenum disulfide Brush/grease gun
additive, good water resistance, rust inhibition, oxidation stability, and extreme
pressure properties.
R Wire Rope Lubricant Penetrating, cleaning, nongumming protective spray; Spray
must minimize friction and eliminate rust.
S General Purpose Spray Lubricant Spray
W SAE 140 Worm Gear Oil AGMA Grade 7 compounded or 7EP, must be Pour
noncorrosive to bronze.
W
Drain Plug
Change Oil Oil Level
Rotation Gearbox
Output Shaft
Upper Bearing
Drain Plug
on Bottom
W
A
Input Shaft
Splines
Hydraulic Pump Winch Gearbox
C
Change Oil
Oil Level
W
W
M
A
Lower Boom Leveling Cables
Upper Boom
Leveling Cables
G
C
C
A
C
Rotation Pinion and
Bearing Gear Teeth
Rotation Bearing
Ball Race
Rotation Gearbox
Eccentric Ring
Lower Boom Cylinder
Spherical Bearings
Elbow Bearing
Ball Race
Turntable/Booms
A-Frame Outriggers
Inner Leg
Outer Surface
Cylinder and
Shoe Pins
Control Handle Linkage
Single handle control
All control handle linkages at platform
Lower control valve
Outrigger control valve
Valve Spools
Outrigger
Tool
Jib/winch
Platform rotate
Leveling System
S
S
R
R
Adjustment of Rotation
Pinion to the Rotation Bearing
At the time of unit shipment, the mesh or backlash
between the rotation pinion and the rotation bearing gear
teeth was properly adjusted. Readjustment may be neces-
sary after an extended period of operation or a gearbox
change. An eccentric ring provides
1
/8" of adjustment. Use
of the eccentric ring is explained later in this section.
Excessive backlash in the gear set may appear as boom
movement. To visually inspect the gear set, remove the
pinion cover. With another person rocking the boom elbow
back and forth, the rotation pinion should be observed. If
movement between the pinion and the rotation gear teeth
is noted, the backlash is excessive. Be careful not to
confuse backlash in the gear set with slight lost motion
within the gearbox. If the pinion does not move in relation-
ship to the rotation bearing, but tries to rotate, the backlash
probably cannot be further reduced.
If adjustment is necessary to bring the pinion into closer
mesh with the rotation bearing, perform the following
procedure.
Caution
Eye protection must be worn at all times to prevent
particles of dirt or metal from entering the eyes.
Hands and fingers must be kept off the pinion and
rotation bearing gear teeth to avoid serious injury.
1. Lower the outriggers as for normal operation.
2. The gear lash must be set on the high tooth of the
rotation bearing. The high tooth is located over the
front side of the pedestal.
3. Remove the pinion cover and the lock bar. Loosen the
four cap screws which clamp the rotation gearbox in
place on the turntable socket head bolts plate.
4. Using a soft punch, preferably brass, and a hammer,
the eccentric ring can be rotated. This ring is located
on top of the turntable plate under the gearbox. Since
the eccentric ring can be rotated in either direction, it
must be determined that the pinion is being tightened.
Should the gear mesh become Iooser, the ring must
be turned in the opposite direction.
5. The pinion will bottom out in the rotation bearing as the
eccentric ring is turned.
6. Install the lock bar. The bar can be installed two
different ways (refer to Figure 8). This gives twice as
many locking increments as there are holes. If the
Iocking bar does not line up with any holes, the
eccentric ring may have to be backed off slightly.
Figure 8 Eccentric Ring
7. After installing the locking bar, torque the gearbox
mounting bolts to 225 foot-pounds.
8. Install the pinion cover and rotate the unit through at
least two rotations to determine that the backlash has
been properly adjusted. It should not bind or hesitate
in any position. If a new gearbox was installed or the
teeth on the rotation bearing are dry, apply an open
face gear lubricant.
Hydraulic Plumbing,
Hoses, and Fittings
The unit is manufactured with hydraulic components,
hoses, lines, and fittings which meet ANSI requirements.
Certain hoses used on insulated units must be of the
nonconductive type. The hoses will be found in use
through the insulated upper boom, the fiberglass insert in
the lower boom and generally on hydraulic tools which may
be used with the unit. Insulated hoses in the applications
mentioned above, as well as in other possible applica-
tions, are orange in color. The small lines which connect
the platform controls to the lower part of the unit are also
nonconductive lines. These lines are color coded for the
convenience of maintenance and repair.
The Parts Manual identifies all nonconductive hoses. It
also identifies fittings and other plumbing hardware.
It is extremely important that nonconductive hoses be
replaced only with hoses of the same type and size.
Replacement fittings, lines, tubes, etc. should be the
same type and size that were furnished with the unit. Never
use wire braid hoses or any hose that is not fully insulated
in an insulated location. If there is ever any doubt concern-
ing the proper hose to be used for replacement, contact an
Altec representative.
Lock Bar
Drive Slots
Eccentric
Ring
Caution
Never substitute a conductive type hose for any insu-
lated or nonconductive hose. Death or serious injury
may result from the bridging of an insulated gap with
a conductive hose. Nonconductive hoses must be
non-pin perforated.
Single Handle Control
and Control Handle Covers
Inspect and dielectric test the insulated single handle
control, if so equipped, as recommended by the Preven-
tive Maintenance and Inspection Checklist.
Keep the green insulated single handle control clean, dry,
in good condition, and periodically tested to maintain its
limited dielectric properties. Wipe any contaminants or
moisture from the surface of the control handle assembly
and the insulating linkages with a clean dry cloth. Isopropyl
alcohol may be used to clean these components. Replace
any damaged components with replacement parts from
your Altec representative and perform a dielectric test on
the control.
Inspect the rubber control valve handle covers as recom-
mended by the Preventive Maintenance and Inspection
Checklist. Keep the rubber control valve handle covers in
place and in good condition. Replace damaged covers with
replacement parts from your Altec representative.
Atmospheric Vents
Atmospheric vents are located at the boom tip/platform
area. Inspect these vents as recommended by the Pre-
ventive Maintenance and Inspection Checklist. On Cat-
egory A units these vents must also be tested for proper
operation. An atmospheric vent testing kit may be ob-
tained from your local Altec representative.
Oil Filtration
The unit is equipped with a complete filtration system.
Filtration starts when the oil reservoir is filled. The reser-
voir has a 30 mesh strainer basket to prevent large
particles from entering the reservoir during filling. The
reservoir breather cap has a 40 micron element to filter the
air which enters and leaves the reservoir as the oil level
changes.
Oil leaving the reservoir on its way to the pump passes
through a 150 micron strainer. The strainer prevents large
particles from getting into the pump. Oil returning to the
reservoir from all parts of the system passes through a 10
micron return line filter. The return line filter has the
replaceable, spin-on type cartridge. While the spin-on
replacement cartridge resembles an automotive filter, do
not use an automotive filter because of differences in the
bypass characteristics.
Frequency of servicing of filters will vary with the condi-
tions under which the unit is being used. Shorter intervals
between filter servicing may be necessary in unusually
dirty or dusty conditions.
A new unit should have the return line filter cartridge
changed, and the 150 micron strainer cleaned after the first
15 to 25 hours of operation. During this initial run-in period,
the pump, motor, and cylinders may deposit wear particles
in the oil. Subsequent return line filter cartridge changes
should be as recommended by the Preventive Mainte-
nance and Inspection Checklist.
Caution
After filter servicing, the shutoff valve in the suction
line must be fully open before starting the pump.
Failure to do so will result in serious damage to the
pump or other components.
Oil Selection
The hydraulic oil selected should contain rust and oxida-
tion inhibitors, antifoam, and antiwear additives. Oils used
in insulated equipment must also pass ASTM D877-67,
the dielectric breakdown voltage of insulating liquids, at 25
KV or better, and possess high demulsibility. Do not use
detergent oils because of their ability to retain water. All
major oil companies have an oil to comply with these
specifications.
Specification Cold Weather Oil All Weather Oil Warm Weather Oil
Ambient temperature range -50 to 60F (-46 to 16C) -10 to 90F (-23 to 32C) 40F (4C) and above
Viscosity @ 100F (38C) 85 SSU (17 cSt) 90 SSU (20.2 cSt) 150 SSU (30 cSt)
Viscosity @ 210F (99C) 35 SSU (4.5 cSt) 43 SSU (5.0 cSt) 46 SSU (5.5 cSt)
Pour point -80F (-62C) -55F (-48C) -30F (-34C)
Maximum oil temperature 160F (71C)
Minimum pump start-up temperature -15F (-26C)
Figure 9 Hydraulic Oil Viscosity Recommendations
Warning
Death or serious injury can result if the recommended
hydraulic oil is not used. Use of other fluids in the
hydraulic system can affect the insulating capability of
the unit.
Attention
Only use hydraulic oil as recommended. Other fluids
added to the hydraulic system can increase compo-
nent wear and affect the lubricating characteristics of
the oil.
Only use oils meeting the viscosity rating for military
specification MIL-5606 in extremely cold climates.
These oils have fewer antiwear characteristics and are
not recommended for full time use.
Changing the Oil
Check the oil level in the reservoir weekly. Booms must be
stored and outriggers retracted. In this condition, the oil
level should be within two inches of the top of the reservoir.
Overfilling or filling with the cylinders other than as
instructed may result in the reservoir overflowing.
It is extremely important that hydraulic oil be clean and free
of moisture. Moisture or impurities can reduce the insulat-
ing capability of the oil or shorten the life of the hydraulic
components.
Visual Inspection of Hydraulic Oil
In addition to the regular checking of the quantity of
hydraulic oil, it is strongly recommended that samples of
the oil be inspected at maintenance intervals. This can be
done conveniently by draining a quart of oil from the
petcock at the drain pipe in the reservoir. Use a glass
container to permit visual examination of the oil (refer to
Figure 10). Water content in the oil may give it a cloudy
appearance or it may separate from the oil. A rancid or
burned odor emanating from the oil may indicate the need
for change. If visible foreign particles are noted, the oil
should be changed. If desirable, oil samples may be
dielectrically tested in an ASTM test cup by a qualified test
laboratory.
Flushing the Hydraulic System
If there is ever any doubt about the insulating or lubricating
quality of the oil, it should be changed. If the oil is changed
for other than seasonal or routine maintenance, the sys-
tem should be flushed using the following steps.
1. Drain the reservoir completely. This will leave approxi-
mately one-third of the system capacity in cylinders
and lines.
2. Using a short fill of five to six gallons of new oil, from
the lower controls operate the cylinders, rotation,
purge the control system, and operate the power tool
system through a few cycles.
3. Drain the reservoir again.
4. Clean the screens in the suction strainer. Replace the
cartridge in the return line.
5. Fill the reservoir.
6. Operate the unit as instructed above and recheck the
oil level in reservoir. Add oil if necessary.
7. After 20-30 hours of operating service, clean the
suction strainer and replace return filter cartridge
again.
If there is a major component failure, such as a pump,
cylinder, or motor, which has dumped contamination into
the system, thoroughly clean the hydraulic system. Change
the defective component and drain the oil. Remove the
cover to the reservoir and clean out completely. Clean the
suction strainer. Replace the return line filter and run a
short fill. The new return line filter should catch any
contaminants left in the cylinders or hoses. Drain the five
gallons of oil and replace with new oil. Replace the return
line filter again and a third time after 20 or 30 hours of
operation.
Figure 10 Hydraulic Oil Conditions
Condition Possible Cause
Dark color Oxidation; contamination
Cloudiness or milky appearance Presence of water or wax
Rancid or burned odor Oxidation
Increase in viscosity Oxidation; addition of improper fluids; presence of water
Decrease in viscosity Addition of improper fluids; additive deterioration
Separation of water or other fluids from the oil Presence of water; addition of improper fluids
Foreign particles or other visible contamination Contamination; emulsion of water with oil additives
Air Bleeding
The presence of air in any hydraulic system will cause
abnormal operation, noises, and damage to the pump. The
presence of air in a hydraulic system can usually be traced
to one of the following.
1. If the oil level in the reservoir is allowed to get too low,
the pump suction can cause a vortex to form in the
reservoir which will allow air to be sucked into the
system along with the oil.
2. A leak in the plumbing between the reservoir and the
pump can suck air even though it will not leak out when
the system is shut down. These leaks may be found
by filling a pump type oil can with clean hydraulic oil
and squirting oil slowly at each connection in the
suction line with the pump operating at normal operat-
ing speed. A suction leak will suck the oil in. Be sure
to check the connection at the attachment to the
pump.
3. Loose connections in the pressure system normally
will leak externally during unit operation, but can suck
air into the system after the unit is shut down as the
oil tries to find its way to the low points of the system.
4. Hydraulic lines taken loose during maintenance op-
erations will contain air until it is purged out. Some of
these lines will purge during normal use but others will
require specific bleeding operations.
Air entering the system due to low oil levels or leaks in the
suction line will cause the most problems and should be
corrected immediately.
Warning
Serious pump damage and unit malfunctions are
likely to occur if conditions allowing air to enter the
suction side of the pump are present.
Troubleshooting Procedure
Establish a troubleshooting procedure to be followed any
time there is a malfunction. This procedure will provide a
starting point for determining the root cause of the mal-
function and increase troubleshooting accuracy. Consider
using the following procedure.
1. Position the unit on a level surface. Apply the parking
brake and chock the wheels. Check the oil level in the
reservoir.
2. Engage the PTO, warm the hydraulic oil to operating
temperature, and properly set the outriggers.
3. Before testing each function through its full travel
capabilities, try small movements to be certain the
function is operating properly. Test each function for
full travel capabilities.
Warning
Death or serious injury can result from falling from the
platform. All platform occupants must properly use an
appropriate OSHA approved personal fall protection
system.
4. Operate the unit from the lower controls and then the
upper controls to identify the malfunction.
5. Use the Hydraulic System Schematic in the Appendix
to determine the flow path required to operate the
failed function. Make a list of the components used to
operate the failed function. Cross off components
used to operate other functions that are operating
properly. This should minimize the number of items to
check.
6. Check the easiest component first. Verify the proper
operation of each component remaining on the list
until the bad component is found.
7. Use accurate test equipment to verify flow, pressure,
voltage, and current.
Once the symptom has been positively identified, use the
Troubleshooting Chart in the Appendix for suggested
causes and corrective actions.
Engine Throttle Control
The oil pressure in the signal line to the pump actuates the
engine throttle cylinder. When the signal pressure ex-
ceeds 200-300 psi, the throttle cylinder begins to extend
until it reaches its full stroke at about 450 psi.
The piston rod actuates the throttle linkage which causes
the engine to accelerate to the adjusted rpm. The adjusted
rpm should provide a pump shaft speed of 1,800 rpm at
high pressure standby. The correct pump speed when
operating all boom functions simultaneously is 1,450 rpm.
The difference between the high pressure standby setting
of 1,800 rpm and the full load setting of 1,450 rpm allows
the engine to reach the top of its torque curve.
The mechanism of the engine throttle linkage is easy to
adjust and can be set to give the desired engine rpm to
match the desired pump rpm. A set screw on the end of the
throttle cylinder piston rod can be adjusted in or out and
locked into place with the jam nut on the screw.
Removing the Rotary Joint
The rotary joint permits continuous rotation of the turntable
without imposing torsional or twisting loads on the hydrau-
lic hoses.
The inner core of the rotary joint is bolted to the stationary
pedestal. The outer housing rotates with the turntable,
driven by a drive bar on the side of the housing. Hydraulic
fittings used in the rotary joint are the SAE straight thread
type. Pipe fittings will not fit these threads and should
never be used.
Removal of the rotary joint should begin with the booms
stored and the hydraulic pump disengaged. As the hydrau-
lic connections are removed, they should be capped to
prevent loss of oil or foreign material from entering the
rotary joint. The rotary joint can be removed by the
following method.
1. Disconnect all hydraulic fittings on the bottom of the
rotary joint in the pedestal.
2. Disconnect the hydraulic lines from the main control
valve to the lower boom cylinder and to the upper
boom cylinders. Move the lines to the rear of the
turntable out of the way of the rotary joint.
3. Disconnect all hydraulic connections to the rotary joint
inside the turntable.
4. Remove the four
3
/8 x
3
/4 bolts which fasten the rotary
joint mounting plate to the pedestal on the top of the
pedestal.
5. Remove the rotary joint through the access cutaway
on the side of the turntable below the main control
valve.
Replace the rotary joint by reversing this sequence.
On units equipped with an air plunger type remote start/
stop system, an electric slip ring will be mounted on top of
the rotary joint. This must be removed before the rotary
joint can be removed from the turntable.
Removal of Upper Boom Lift
Cylinders
The hydraulic cylinders which articulate the upper boom
are mounted between the Iower and upper boom structures
at the upper portion of the lower boom. The base end of
each cylinder is connected directly to the lower boom by
a pin and self-Iubricating bearing. The rod end of each
cylinder is connected to one of the elbow links of the
articulation mechanism. This walking link arrangement
allows the elbow link to wrap around the elbow pivot as the
boom is unfolded or folded. When the upper boom is in the
folded position for transport, the top upper boom cylinder
is completely retracted and the bottom upper boom cylin-
der is completely extended.
If it should become necessary to remove one or both of the
upper boom cylinders, it is very important to use a safe and
reliable means of lifting the upper boom away from the
lower boom. It will be necessary to be able to lift the upper
boom at least five feet above the lower boom and at a point
above the boom rest saddle. Care should be used in
handling the upper boom to avoid the possibility of damag-
ing the fiberglass surface.
Caution
When removing and installing the upper boom cylin-
der or linkage, safeguards must be used to prevent the
fall of the upper boom for any reason because it will be
necessary for personnel to be under the suspended
upper boom during at least part of the work.
The upper boom cylinders elevate the boom hydraulically.
Lowering the boom at the end of its travel is done by
gravity. Because of this, it is necessary to have a hoist or
lifting device with a capacity of at least one ton. The hoist
should be connected to the fiberglass boom near the outer
end. Lifting the fiberglass should be done with a nylon strap
connected as a choker. It is important that the choker be
restrained from sliding up the boom as the boom is lifted.
It is also important to protect the fiberglass from damage
while lifting.
To remove the bottom upper boom cylinder, the unit should
be in the stored booms position. The lower booms should
be rotated to the side of the unit. Be sure to lower the
outriggers before rotating the booms. With the hoist, raise
the upper boom approximately two feet out of the boom
rest. With the hoist supporting the load, remove the pin
from the rod end of the bottom upper boom cylinder.
Support the cylinder from falling with a fork truck or other
hoist mechanism. After the rod end of the cylinder is
disconnected, disconnect and cap the hydraulic line to the
base end of the cylinder to prevent oil loss or system
contamination. Remove the pin from the base end of the
cylinder. The cylinder must be supported. Lower the
cylinder safely to the ground with a fork truck or hoist.
To remove the top upper boom cylinder, position the
booms in the stored booms position. Position the unit so
the top upper boom cylinder is under a hoist. With the unit
hydraulic system, raise the upper boom about five feet out
of the upper boom rest. Disconnect the hose to the middle
port on the top upper boom cylinder. Cap the hose and the
fitting on the cylinder. Lower the upper boom to about two
feet out of the rest - just high enough to allow access to the
top upper boom cylinder base end pin.
Support the cylinder with a hoist and choker strap. Discon-
nect and cap the other two hoses on the top upper boom
cylinder. Remove the base end cylinder pin. Lift the
cylinder with the hoist to allow access to the rod end pin
and remove the pin. Remove the cylinder with the hoist.
If the cylinders are going to be left off the unit for an
extended period of time, the upper boom should be lowered
by the hoist into the boom rest and the unit stored. To
reinstall the cylinders, reverse the procedure.
It may be necessary during installation or removal to
extend the individual upper boom cylinders. It will be
necessary to attach an auxiliary hydraulic power source to
the base end ports of the cylinder being actuated. To
actuate the cylinder, one hydraulic line should be attached
to the R port on the cylinder. Attach the second line to the
E port on the cylinder base. It will also be necessary to
connect the E and P ports on the base end of the cylinder
in order to open the counterbalance holding valve to allow
the cylinder to extend. Once the cylinder has been
plumbed in this manner, use the auxiliary power source to
extend or retract the individual cylinder as desired. When
reinstalling the bottom upper boom cylinder, completely
extend the cylinder. When reinstalling the top upper boom
cylinder, extend it approximately three inches from its fully
retracted position.
Warning
Do not articulate the upper boom overcenter until you
are certain there is oil in the rod end of both upper
boom cylinders.
To be sure both cylinders are full of oil, use the lower
controls to articulate the upper boom up and down about
60 degrees from the boom rest for 5 or 6 cycles.
Upon completion of this job, structurally test the boom in
accordance with the section under Testing, and dielectri-
cally test the unit.
Leveling Cable Inspection,
Replacement, and Adjustment
The Ieveling system functions to maintain the floor of the
platform parallel to the turntable. This is a positive,
mechanical system operated through cables, insulated
rods, sheaves, etc. The two principle parts of the Ieveling
system are identified as the Ieveling cables and Ieveling
rods. Each of the cables is anchored at the turntable and
at the platform sheave. Because of the geometric arrange-
ment, movement of the booms results in platform move-
ment.
The Ieveling cables are an IWRC type cable
1
/2 in size with
a minimum strength of 20,600 pounds when new. In the
insulated section of the upper and lower booms, the
Ieveling cable is connected to a fiberglass insulator rod
3
/
4 in diameter to preserve the dielectric integrity of the
insulated components. Threaded end terminals on the
Ieveling cables are mechanically swaged onto the wire
rope. Turnbuckles are provided in the upper boom and in
the lower boom for proper adjustment for the entire Ieveling
system. Leveling cables and insulator rods are thoroughly
tested before they are installed in the unit.
Movement of the booms and the resultant movement of
the Ieveling cable system is transmitted to the platform
through the keyed shaft at the elbow and through the keyed
platform shaft. Persons who perform inspections, make
adjustments, etc., should be familiar with the entire
leveling system before beginning disassembly.
Inspection of Leveling
and Holdback Cables
A cable is a mechanism within itself, consisting of moving
parts which are called strands and wires. Cable wires
move in relationship to other wires under operating condi-
tions. Two of the operating conditions with which the cable
inspector must be concerned are as follows.
The movement of wires against each other as the
cable is loaded and unloaded.
The flexibility and bending of the cable, strands, and
wires as the cable passes over.
Inspection is an important part of satisfactory cable life, as
well as the safety and reliability of the cable. Lubrication
plays a very important part in extending cable life by
reducing internal wear as the wires move in relationship to
each other. While the platform Ieveling system is designed
with a safety factor several times greater than the rated
loads applied to the platform, periodic inspection and
lubrication must be performed.
Adjustment of the cables may be required after extended
periods of operation. This method of adjustment is ex-
plained in a later section. Specific inspection of Ieveling
cables must be performed as recommended by the Pre-
ventive Maintenance and Inspection Checklist. This is the
same interval recommended for other inspections and
lubrication of the completed unit.
Cable wear will be greatest where the cables are contact-
ing sheaves. To perform a thorough inspection, all covers
must be removed from the booms. It will also be necessary
to inspect the cables with the unit in three different
positions. During the inspection, it would be advisable to
also lubricate the cables.
Look for broken wires. Feeling by hand or by wiping with a
soft cloth will expose broken wires. If four or more broken
wires are found, replace that cable. If it is determined that
there are broken wires, but not enough to cause replace-
ment, perform more frequent inspections. Any time there
is doubt in the mind of the inspector concerning the safety
of a cable, it should be changed.
While operating the unit, observe the sheaves for freedom
of movement. It is extremely important that all idler
sheaves turn as the cable moves. Evidence of a frozen or
slipping sheave would be a very shiny groove. As the cable
slips, it wipes the lubrication off.
Position 1
The booms stored. Inspect the cables at the turntable.
Also inspect the sheave grooves for evidence of scuffing.
Inspect the cables and sheaves at the elbow. The cables
or rods should not touch anything. Make sure the cable
keepers are in place. Reach inside the upper boom at the
platform through the side access holes at the boom tip.
Pay particular attention to the cable that comes off the top
of the 12 sheave. Reach into the boom past the idler
sheaves for inspection.
Position 2
Raise the lower boom vertical and the upper boom fully
down. This exposes a new length of cable. Inspect the
cables at the turntable and boom tip. With another aerial
platform, inspect the cables at the elbow. Have someone
raise the upper boom and make sure no cables are riding
on each other. If they do, they can be pried in place on the
cast sheaves with a screwdriver.
Position 3
Place the lower boom horizontal and the upper boom
overcenter. Reach inside the upper boom and inspect as
in Position 2.
Note the general condition of the leveling system compo-
nents including leveling rods, boom interiors, control lines,
hydraulic hoses, leakage monitor wires, etc. Check boom
interiors for hydraulic leaks and the accumulation of debris
or other foreign material, particularly units used in tree
trimming activity. Check cables for rust even if they are
galvanized. Tree sap, etc., may act as an acid which may
produce rust.
Caution
If the unit is washed with a high pressure washer or
chemical degreasers are used the leveling cables
must be lubricated within a 24 hour period or before
the unit is operated.
Replacement of Leveling Cables
One type of leveling cable must be replaced at least every
5 years or 5,000 hours, whichever comes first. The other,
newer type, of leveling cable must be replaced at least
every 8 years or 8,000 hours, whichever comes first. The
newer type is recognized by yellow paint on the end
coupling of the cable. This requirement is based on normal
use, proper care, regular inspection, and lubrication. If the
unit is operated under severe conditions, or not properly
serviced, replace cables, leveling rods, or sheaves more
frequently. This emphasizes the need to perform regular
inspections as instructed in this manual.
Before any attempt is made to remove or replace leveling
cables or rods, study Figure 3 in the Parts Manual. It is
very important that the correct procedures be followed to
assure proper routing of cables for the safety of operation.
Several inspections will be required during the replace-
ment of cables. Use only genuine Altec replacement parts.
Substitution of inferior parts can lead to dangerous condi-
tions.
Procedure for Removing
Leveling Cables and Rods
1. Remove all access covers from the booms. This will
permit access to the leveling system which is mostly
housed within the booms.
2. Remove the platform(s) for access to the boom tip.
This can be done by detaching the fiberglass platform(s)
from the mounting shaft. If the platform can be
supported while it is removed, it may not be necessary
to remove the control head.
3. Disconnect the current leakage monitoring bonding
wires from the leveling rods inside the upper boom at
the elbow.
4. Remove the cable keepers (retainers) from all sheaves.
5. Release the lower boom Ieveling rods from the cables
by unscrewing the turnbuckles in the lower boom.
Push the lower boom Ieveling rods through the lower
boom to extend outside at the elbow.
6. Remove the idler sheave at the elbow end of the lower
boom.
7. Release the upper boom Ieveling rods from the cables
by unscrewing the turnbuckles at the lower end of the
upper boom.
8. Make note of the Ieveling rods to become familiar with
the right hand and left hand threads at the ends of the
rods.
9. Release the upper boom Ieveling rods from the elbow
cables by unscrewing the turnbuckles in the upper
boom.
10. Remove the platform mounting shaft from the upper
boom tip. Note the orientation of the 12 sheaves at
the tip and at the elbow.
11. Remove the pins from the 8 idler sheaves at the boom
tip and the lower 8 idler sheave at the elbow end of the
upper boom.
12. Slide the 8 idler sheaves at the boom tip, the 12
boom tip sheave, the boom tip cable, and the Ieveling
rods out of the boom tip.
13. Remove the cables at the boom tip from the Ieveling
rods.
14. By removing the anchor pin from the mounting bracket
inside the turntable, the lower end cables can be
removed.
Inspection
1. Thoroughly inspect all Ieveling rods to determine if
they are suitable for reuse. Check rods for severe
scratches, signs of rubbing, cleanliness, or any other
possible damage or wear. Inspect the terminals at the
ends of the rods for secure attachment and condition.
Replace the rods if there are any signs of cracks,
damage, or wear.
2. Inspect all idler sheaves. Sheaves must not be reused
if they show signs of scuffing on the surface which
contacts the cable. All sheaves must turn freely
without excessive looseness in the bearing.
3. Inspect the large sheaves at the elbow. If there are any
broken flanges or excessive wear, replace the sheave.
If excessive wear is noted in the shaft bearings, they
must be replaced.
4. New sheaves, bearings, and pins are furnished with
the cable kit. It is recommended that these parts be
replaced at cable replacement.
5. Inspect all cable keepers for wear, damage, or defor-
mation. Never use a cable keeper which is not in good
condition.
6. If the Ieveling rods have been determined to be
reusable, clean the surface of the rods to avoid
degrading their dielectric strength.
Installation of Cables and Rods
Before installing or reassembling the leveling system,
carefully study the boom assembly. Becoming familiar
with these two diagrams and using them for reference will
greatly assist the assembly and eliminate confusion.
1. Spray the new Ieveling cables with wire rope lubricant.
Wipe them with a clean cloth to remove excessive
lubricant. Do not allow lubricant to dry on fiberglass
surfaces because dirt can collect and reduce the
dielectric strength of the fiberglass. Avoid getting dirt
or grit on the cable.
2. Install the long end of the elbow upper boom Ieveling
cable to the top upper boom Ieveling rod lower end
using jam nuts and 1
1
/2 outside hex turnbuckle.
Screw the turnbuckle onto the Ieveling rod and the
cable end fitting at least 1
1
/4. Slide the top upper boom
rod toward the tip until the upper end of the rod
protrudes out of the boom tip weldment. Slide the
bottom rod so that its upper end protrudes from the
boom tip weldment. Attach the boom tip Ieveling cable
assembly to the top upper boom leveling rod. Engage
the cable end fitting threads at least 1
1
/4, tighten the
jam nuts securely against the Ieveling rod end fittings,
and lockwire the assembly according to Figure 11.
Attach the long end of the boom tip Ieveling cable to
the bottom upper boom Ieveling rod. Lockwire the
assembly according to Figure 11.
3. Orient the boom tip leveling sheaves according to
Figure 6, wrap the cable as shown and engage the
drive lug on the cable assembly into the recess on the
Ieveling sheave. Be sure to wrap the cables correctly
as shown.
4. Install the 8 Nylatron idler sheaves at the boom tip.
Use the appropriate thrust washers, retaining pin,
buckeye pin retainer, and drilled head fasteners.
Lockwire the fasteners as shown in the Iockwiring
section.
5. Install the platform mounting shaft and drive key
through the boom tip assembly and the platform
Ieveling sheave. Use an appropriate rust preventive
lubricant such as Never Seize on the keyways, keys,
and the inside bore of the platform Ieveling sheaves.
Install the idler sheave cable keepers.
6. Orient the elbow upper boom leveling sheave. Install
the 8 Nylatron idler sheaves spacer, thrust washers,
pins, retainers, and retaining bolts. The pivot pins for
the idler sheaves will retain the cables in their sheave
grooves and eliminate the need for additional cable
keepers. Attach the bottom upper boom Ieveling rod
to the short end of the elbow upper boom Ieveling
cable using the 1
1
/2 hex turnbuckle and jam nuts. The
drive lug on the elbow upper boom Ieveling cable must
be secured into the recess on the elbow Ieveling
sheave. Tighten the lower turnbuckle hand tight and
then an additional five turns. This will provide the
proper pretension on the Ieveling system for the initial
run-in of the new cables. Tighten the jam nuts se-
curely. Do not lockwire at this time.
7. Install the Iower cables to the turntable anchor point
and wrap them around the main boom pivot pin
sheave. Install the 8" Nylatron sheaves, pins, bush-
ings, thrust washers, pin retainers, and retaining bolts
at the Iower boom. Install the lower boom elbow
Ieveling cable with the long end on the upper side of
the lower boom elbow sheave. Engage the drive lug
into the recess on the Ieveling sheave securely.
Attach the end fittings of the lower boom elbow
assembly to the lower boom Ieveling rods, engaging
the end fittings at least 1
1
/4. Tighten the jam nuts and
lockwire as shown in Figure 11. Install the 6 idler
sheave, thrust washers, pivot pin, pin retainer, and
retaining bolts at the elbow end of the lower boom.
Lockwire the pin retainer bolt according to the lockwir-
ing section.
8. Slide the lower boom Ieveling rods toward the lower
end of the lower boom being sure to keep them
separate as to which is the top one and which is the
bottom one.
9. Connect the lower end of the Ieveling rod to the cable
at the lower boom main pivot with the turnbuckle in the
lower boom. Tighten the turnbuckle sufficiently to
permit operation of the Ieveling system but do not
adjust the platform at this time. It is very important that
all cables and rods be held with wrenches while the
turnbuckle is tightened. Otherwise, severe twist can
damage the cable and Ieveling rods.
10. Inspect the entire Ieveling system throughout to make
certain cables are not crossed and they will operate
freely without rubbing. The cable wrap at the main
boom pivot sheave, the elbow sheave, and the boom
tip sheave can be pushed into alignment for good
tracking without rubbing.
11. Install the platforms onto the platform mounting shaft.
12. Using the lower controls, with outriggers set, operate
the boom throughout all positions with rated load in the
platform
Caution
Do not permit anyone to occupy the platform until after
the operations have been tested and structural tests
have been passed.
Inspect cables, rods, pins, etc. at the turntable, elbow,
and boom tip to determine that there is no rubbing
between the moving parts. This inspection can be
made from another unit
13. Perform a structural test as explained in Testing. Final
adjustment of the cables as explained in the section
of Adjustment of Leveling Cable Tension will give the
proper cable tension and level the platform properly.
14. Connect all current leakage monitoring wires at the
elbow end of the upper boom. Install all covers.
15. The unit be given a dielectric test anytime work has
been performed which might affect the insulating
properties of the fiberglass. Records of dielectric test
should be retained and filed for future reference.
Figure 11 Leveling Rod/Cable
L.H. Thread R.H. Thread
Section C-C Section D-D
Figure 12 Adjusting Turnbuckles
Section A-A
Turnbuckle
Section B-B
R.H. Thread L.H. Thread
Adjustment of Leveling Cable Tension
The adjustment of platform Ieveling cables is a simple,
very important operation. It is necessary to have the
proper tension in order that the platform will be carried in
a position parallel to the turntable so that unnecessary
platform movement will be eliminated. However, between
the adjustments on the Ieveling cable system in the upper
and lower booms, the system can be greatly overtensioned.
This serves no purpose but does shorten the life of cables,
sheaves, bearings, etc.
Cable adjustment will most likely not be required until after
extended periods of operation. Loose cables can be
readily noticed when the platforms are loaded. Without
proper tension, the platforms will lean away from the boom
and the operators will find it uncomfortable to perform work
from the platforms. In addition, loose cables will allow the
Ieveling rods, cables, and platforms to bounce while the
vehicle is being driven.
To properly tension the Ieveling cables, raise both booms
until they clear the boom rests. By removing the cover
plate from the side of the lower boom and upper boom, the
turn buckles will be visible through the access hole. The
turnbuckles in the lower boom adjust the level of the
platforms and the upper boom turnbuckles adjust the
upper boom cable tension. The back turnbuckle inside the
lower boom at the access hole adjusts the platform tilt
while the front turnbuckle adjusts the tension in the lower
boom cables. As in any turnbuckle, one thread is right
hand pitch and one thread is left hand pitch. In the lower
boom, the left hand threads are on the turntable cables. In
the upper boom, the left hand threads are on the upper
boom Ieveling rods. Anytime the turnbuckle is being
turned, the end of the Ieveling rods and the end of the cable
must be held with wrenches to avoid twisting. To adjust the
upper boom system, loosen the turnbuckle and jam nuts
on the bottom upper boom Ieveling rods. Tighten the
turnbuckle hand tight and then an additional five turns
using a wrench. This will provide a proper tension in the
upper boom Ieveling system. Tighten the jam nuts on the
turnbuckle and secure the turnbuckle with lockwire as
shown in Figure 12. Unfold the upper boom overcenter until
the other turnbuckle is accessible at the upper boom elbow
access hole. Tighten the jam nuts securely and lockwire
this turnbuckle also.
Rotating Platforms
With rotating type platforms, the platforms must be loaded
to rated capacity and swung to a position 45 degrees from
beside the boom position. The platforms may be loaded by
placing the load in the platforms, or by suspending the load
under the platform at the transverse center line. Care must
be used to avoid damaging the fiberglass. If the platforms
have liners, the suspended load should be 250 pounds to
each platform. Without platform liner, the load should be
300 pounds per platform. The boom or the vehicle should
not be moved while the load is suspended.
The upper boom should be positioned slightly out of the
upper boom rest and the lower boom should be positioned
slightly out of the lower boom rest.
Lubricate both the upper and lower turnbuckle at the lower
boom side access hole with a light lubricant. Loosen the
jam nuts on both turnbuckles, until the upper turnbuckle is
handtight. Level the platform with the turntable or vehicle
bed by tightening or loosening the lower turnbuckle.
Tighten the jam nuts on the Ieveling cable.
Tighten the upper cable turnbuckle hand tight or until the
slack is out. Continue to tighten three more full turns.
Tighten the jam nuts and lockwire both Ieveling cables as
in Figure 12.
Remove the test load from the platform. You will notice
that the platforms have tipped very slightly toward the
boom as the weight is removed. This is normal as the
platforms are loaded for use, they will return to the parallel
position.
Caution
Care must be taken not to overload the platforms and
Ieveling cables while applying test loads.
Non-Rotating Platforms
To adjust the Ieveling cable tension on non-rotating
platforms, loosen both lower boom Ieveling cable turn-
buckles. Lubricate the threads of the cables and rods with
a light lubricant. When tightening the turnbuckles, tighten
the Ieveling and holdback turnbuckles alternately, keeping
the top of the platform parallel to the vehicle body. A slight
tilt so the bottom of the platform is away from the pedestal
will compensate for boom deflection when the booms are
loaded.
With the upper boom out of its rest, tighten the turnbuckles
until hand tight or until all the slack is out of the cables.
Continue to alternately tighten the two turnbuckles three
complete turns total. Do not tighten each turnbuckle three
turns, but three turns between the two turnbuckles. Lock-
wire the turnbuckles as in Figure 12.
Non-Overcenter Cam
Valve Adjustment
The unit is equipped with a hydraulic mechanism to
prevent the upper boom from articulating past an angle of
72 degrees with respect to the ground. A cam operated
manual valve located inside the elbow end of the upper
boom is actuated when the upper boom angle reaches 72
degrees. This valve then pilots open two valves. The first
valve dumps the pilot line pressure in the lower boom down
and upper boom unfold control lines inside the upper boom.
The second valve is located at the rear of the turntable and
blocks the flow of oil from the main control valve to the
lower boom cylinder retract port and the bottom upper
boom cylinder retract port. Consequently, all boom motion
is stopped which might cause the upper boom to go
overcenter.
The non-overcenter stop cam orientation must be adjusted
after leveling the platforms since the cam is attached to
the leveling system (refer to Figure 13).
Figure 13 Non-Overcenter Cam
Warning
Death or serious injury can result from improper
adjustment of the non-overcenter cam valve. Make
sure that the non-overcenter cam valve is properly
adjusted before operating and using the unit.
Non-Overcenter Stop Cam
and Cam Valve Adjustment
To adjust the cam and cam valve, the leveling system
must be properly adjusted. Stow both booms for transport.
Remove the cover on the side of the upper boom lower end
weldment. The cam and cam valve will be readily visible.
The cam is secured to the elbow leveling shaft by the hub
mounting. The hub mounting clamps the cam to the shaft
when the four
3
/8 cap screws are tightened on the end of
the shaft. A gear puller may be necessary to loosen the
cam.
Remove the
3
/8 clamp bolts and end cap. If the hub has
not loosened, tap the cam towards the elbow leveling
sheave with a hammer. If the cam does not loosen easily,
pull the cam off the shaft with a gear puller. After loosening,
reorient the cam so that the O indicator is aligned with the
cam valve roller cam. The cam surface should be centered
under the cam roller. About
1
/8 -
1
/4 of the hub mounting
should extend beyond the elbow leveling shaft. Reinstall
the end cap and clamp bolts to the end of the shaft.
Gradually tighten the bolts until all are tightened to the
proper torque (35 foot-pounds).
Check the clearance of the cam roller on the cam. The
roller should clear the cam by the thickness of a business
card or about 0.015. This clearance is adjusted by
loosening the
3
/8 cap screws securing the cam valve
mounting bracket to the boom top and bottom surfaces.
After adjustment, tighten the cap screws to proper torque
(35 foot-pounds).
Cam Lobe
Cam Valve
Cam Valve
Mounting Bracket
Roller Cam
Always operate the unit to be sure the non-overcenter
mechanism is working properly. With the booms stowed,
raise the lower boom about six inches out of the boom rest
and raise the upper boom slowly until the cam valve is
actuated. The upper boom unfold function should stop
completely. If the mechanism fails to stop the upper boom
after the cam valve is fully actuated, it will be necessary
to troubleshoot the cause of the malfunction. Recheck the
cam orientation and clearance before replacing the boom
cover.
Main System Pressure/
Standby Pressure Adjustment
The axial piston pump controls both the main system
pressure and the pump standby pressure. These two
pressures are adjusted and controlled by two cartridges on
the pump housing (refer to Figure 14).
To check these pressures, install a 0-3,000 psi pressure
gauge into the test port located on the bottom of the
combination valve on the side of the turntable.
Position the control selector in the Upper Controls posi-
tion. Turn off upper and lower power tools if so equipped.
Standby Pressure
The pressure gauge should read 350 psi. If this pressure
is not correct, adjust the standby pressure.
Parker PAVC38 Pump
Loosen the lock nut on standby pressure cartridge using
an
11
/16 open end wrench. Adjust the standby pressure by
screwing the adjustment knob in to increase pressure or
out to decrease pressure. Hold the adjustment knob from
turning while retightening the lock nut.
Vickers PVE 19 Pump
The standby pressure is adjusted by means of an Allen
screw and normally does not require adjustment if the
standby pressure is 350 psi +/-50 psi. Screw the Allen
wrench in to increase standby pressure and out to de-
crease pressure to the proper adjustment. On earlier model
pumps, the standby pressure is shim adjusted. The shim
kit is available if adjustment is required on this type of
pump. Increasing pressure requires the addition of shims.
Decreasing standby pressure requires removal of shims
from the standby pressure adjustment.
Main System Pressure
To check the main system pressure, place the control
selector valve in the Lower Controls position. The pump
will then be in the high pressure standby mode. Read the
pressure on the pressure gauge and return the control
selector valve to the Upper Control position. The maximum
pressure should be as listed in Figure 15.
Model Without Material Handling With Material
Number 1 Platform 2 Platforms Handling
AM450 2,500 psi 2,500 psi 2,500 psi
AM550 2,500 psi 2,500 psi 2,500 psi
AM600 2,500 psi 2,500 psi 2,500 psi
AM450H N/A N/A 2,750 psi
AM755H 2,750 psi 2,750 psi 2,750 psi
AM800 2,750 psi 2,750 psi 2,750 psi
AM900 2,750 psi 2,750 psi 2,750 psi
Figure 15
Hydraulic System Operating Pressures
Figure 14 Pump Adjustments
Vickers PVE19 Pump Parker PAVC38 Pump
9
/16 Flats
Hex Jam Nut
11
/16 Flats
Hex Jam Nut
Standby Pressure
Adjustment Knob
Main System Pressure
Adjustment Knob
Compensator
Adjustment Plug
Standby Pressure
Adjustment
Plug Lockwire
Adjust the pressure setting as necessary by loosening the
9
/16 flats - hex jam nut and turning the adjustment knob in
to increase pressure or out to decrease pressure. After
adjustment is complete, be sure to retighten the jam nut.
Pilot System Pressure Adjustment
The pilot system pressure is controlled by the pilot
pressure reducing valve cartridge located in the combina-
tion valve on the turntable (refer to Figure 16).
Figure 16 Combination Valve
To check this pressure, install a 0-500 or 0-1,000 psi
pressure gauge into the UCD port located on the left front
face of the combination valve. With the unit engaged for
operation and the control selector valve in the Upper
Controls position, the gauge should read 350 psi. If it
varies from this reading, adjustment is necessary.
To adjust the pilot pressure, disengage the pump or shut
off the unit. With a
3
/8 Allen wrench, remove the plug from
the end of the pressure reducing valve cartridge. Insert a
5
/16 Allen wrench into the pressure adjusting screw located
inside the end of the cartridge. Start the unit and adjust the
screw in to increase or out to decrease the pilot system
pressure as required. When the pressure has been set,
replace the plug on the end of the cartridge.
Tool System Pressure Adjustment
The tool system pressure is controlled by a tool pressure
reducing valve cartridge located on the upper right hand
corner of the combination valve on the turntable.
To check the tool system pressure, install a 0-3,000 psi
pressure gauge in the TD port on the right hand side of the
combination valve.
Start the unit, place the control selector in Upper Controls
position, disconnect any power tool attachments, and turn
the tools valve to the On position. The pressure gauge
should read 2,000 psi. If the tool pressure is incorrect,
adjustment is necessary.
To adjust the tool system pressure, disengage the pump
or shut off the unit. With a
3
/8 Allen wrench, remove the
plug from the end of the tool system pressure reducing
cartridge. Insert a
5
/16 Allen wrench into the pressure
adjusting screw located inside the end of the cartridge.
Start the unit and check the tool system pressure as
described above. Adjust the screw clockwise to increase
pressure or counterclockwise to decrease pressure. When
the pressure is correctly adjusted, be sure to replace and
tighten the plug on the end of the cartridge.
Setting Main Control Valve Flow
Controls/Boom Function Speed
If the main control valve is replaced or if boom function
speed is not correct, it may be necessary to check and
adjust the speed of the individual boom functions.
The main control valve is equipped with adjustable flow
controls to precisely and consistently control the speed of
each boom function. The adjusting stems are found on the
right hand side of the main control valve sections just to
the left of the handle boots.
The proper speed for each function is shown below
adjacent to the valve section which controls that function.
To Adjust the Speed of Specific Functions:
1. The correct spool stop to adjust is on the same section
on the opposite end of the section from the direction
of handle travel.
2. It is extremely important not to turn the Fine Tune
metering adjusting screws when adjusting the spool
stops. To avoid turning the metering adjusting screws
loosen jam nut B (refer to Figure 17) while holding the
metering screw stationary with an Allen wrench.
3. Loosen jam nut A.
4. While holding the metering screw as described in step
2, adjust the spool stop as required. Turning the spool
stop clockwise (into the end cap) will slow down the
function. Turning the spool stop counterclockwise will
speed up the function. Never adjust the spool stop
more than one turn at a time before rechecking
function speed.
5. When the adjustment is complete, retighten jam nuts
A and B but do not turn the spool stop or the metering
adjusting screw while tightening.
Attention
Although the spool stops provide some leeway for
operator selection of boom speeds, the pump flow,
engine speed, and boom cylinders are matched to
provide the best operation at the speeds shown in
Figure 17.
Tool System Pressure
Reducing Valve
Pilot Pressure
Reducing Valve
Upper Boom Stow
The upper boom is gravity lowered into the boom rest, so
it requires no boom stow protection. To avoid damage to
the fiberglass boom, lower the boom gently into its rest. It
is very important to strap the upper boom in place while
transporting the unit.
Holding Valves
All cylinders on the unit, including the outrigger cylinders,
are equipped with load holding valves to ensure that the
cylinders will maintain their position in the event of a
hydraulic line failure.
The basic types of load holding valves are used.
Pilot operated check valves which provides a positive
lock against leakage until a positive pressure is
applied to the pilot by operation of a control valve.
Counterbalance holding valves which may be opened
by a positive pilot pressure from a control valve or may
be opened internally when the pressure it is holding
reaches a preset level.
Counterbalance valves are used in the lower boom and
upper boom cylinders. Pilot operated check valves are
used in the outrigger cylinders, rotation motor, and jib tilt
cylinder.
Attention
Pilot operated check valves are not adjustable and
must be replaced if defective.
Counterbalance valves are factory set to relieve at 3,000
psi when no pilot pressure is applied. If a counterbalance
holding valve ceases to hold the load properly, it has most
likely become contaminated. In such case, remove the
cartridge and replace it with a new one.
Do not adjust counterbalance valves in the field. The only
exception is adjusting the counterbalance valves for
manually stowing as described in the Operators Manual.
If the setting on a counterbalance valve has been changed,
the cartridge must be removed and adjusted with a test
block or replaced.
Warning
Death or serious injury can result from unexpected
movement. Counterbalance valves that have had the
relief setting changed must be replaced or reset to the
proper setting using an Altec test block before the unit
is operated.
Do not adjust a counterbalance valve without a test block.
A test block and pressure gauge is the only accurate way to
determine that the proper setting has been obtained.
A test block and instruction sheet for 1
1
/8 and
7
/8 hex
cartridges are available from your Altec representative
(refer to Service Tools and Supplies in the Appendix).
Removal
Before removing a counterbalance valve, the cylinder
must be unloaded. The following steps describe how to
remove a counterbalance valve.
1. Stow the unit.
2. Disengage the PTO and turn off the engine.
3. Shift the lower control handle for the function until the
cylinder can be rocked by hand.
Figure 17 Main Control Valve
Jam Nut A
Jam Nut B
Flow Control
Adjustment
64 Seconds
50 Seconds
(from stowed to
190 degrees)
45 Seconds Up
35 Seconds Down
Speed Function
4. Locate the plugs in the extend and retract test ports at
the base end of the cylinder or counterbalance valve
block. Use an Allen wrench to slowly unscrew the test
plugs. If the cylinder is under pressure and the plugs
are unscrewed quickly, hydraulic oil may spray out of
the test ports. If the test ports are not available, slowly
screw the counterbalance valve cartridge from its
housing.
5. Carefully unscrew the cartridge from its housing to
allow the pressure to bleed off before the cartridge is
fully unscrewed from the cavity.
Testing
1. Lubricate the O-rings on the counterbalance valve
cartridge and install the cartridge in the test block.
2. Connect a hydraulic pressure source and an accurate
pressure gauge to port 1 (refer to Figure 18). The
pressure source and gauge must be adequate for a
pressure greater than the desired counterbalance
valve relief setting.
Figure 18 Counterbalance Valve Test Block
3. Install a straight adapter in port 2 to aid in observing
the oil flow from this port during the procedure.
4. Gradually increase the pressure at port 1 with the
pressure source. The counterbalance valve relief
setting is the pressure at which a fine stream of oil
begins to flow from port 2. Note this pressure reading
and then remove the pressure from port 1.
5. If the relief setting is correct, relieve the pressure of
the pressure source by turning off the pressure source
and moving the control several times in both direc-
tions.
6. Disconnect the pressure source from port 1 and
remove the counterbalance valve cartridge.
7. If the relief setting is incorrect, adjust the relief setting
as described in the following procedure.
Adjustment
1. Loosen the jam nut and turn the adjusting screw
clockwise to decrease the setting or counterclock-
wise to increase the setting.
2. Hold the adjusting screw from turning and tighten the
jam nut.
3. Repeat the test procedure until the correct relief
setting is obtained.
4. Repeat the test procedure at least three more times to
confirm the correct setting.
5. Relieve the pressure of the pressure source by turning
off the pressure source and moving the control several
times in both directions.
6. Disconnect the pressure source from port 1 and
remove the counterbalance valve cartridge.
Winch Brake
The winch is a worm gear driven by the hydraulic motor.
The winch valve directs hydraulic oil to the winch motor.
The winch motor powers the worm gear set. The worm gear
set drives an output shaft keyed to the winch drum.
The winch is equipped with a brake, located at the end of
the worm shaft opposite the winch motor (refer to Figure
19). The brake is an overrunning clutch that runs freely in
the winch Raise position, but applies continuous braking
action in the winch Lower position. The brake assists the
self-locking worm gear set in stopping a load that is being
lowered when the control handle is returned to neutral.
Figure 19 Winch
Adjustment
If the winch brake is not holding or stopping the load
properly, adjust the brake using the following procedure.
1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the PTO and
properly set the outriggers.
Adjusting
Screw
Motor Brake
Adjusting Screw
Jam Nut
Counterbalance
Valve Cartridge
Port 1
Port 2
11. Tighten the jam nut.
12. Install the hydraulic winch motor and shaft adapter on
the input shaft of the winch gearbox.
13. Install the hydraulic connections and winch covers.
14. Start the vehicle engine, engage the PTO, and raise
the upper boom enough to clear any obstacles as the
lower boom is raised. Raise the lower boom to nearly
vertical. Position the upper boom with the platform
just past the tailshelf of the vehicle.
15. Position the jib pointing down so that the load line is
hanging nearly straight off of the winch drum.
16. Attach a 2,000 pound load to the winch line.
17. From the lower controls, lift the load three to four feet
off the ground with the winch.
18. Start lowering the load with the lower winch control
handle shifted fully to the winch pay out position. At
the same time, move the upper control/lower control
selector to the upper controls position. The load
should stop.
19. Repeat this test three times.
20. If the load stops every time, return the unit to service.
If the load does not stop, follow the steps below.
21. Remove the winch covers and hydraulic connections
to allow access to the winch brake.
22. Remove the brake cover and inspect for any worn or
damaged components.
23. If any broken or worn parts are found, replace with new
parts and reassemble. Test as previously described.
24. If the brake components are not damaged and do not
look worn, but will not hold the load in the test
described above, replace the gearbox.
Upper Control Linkage
The boot over the upper controls should be removed
periodically and the entire linkage lubricated with a spray
lubricant. Make sure all the nuts, bolts, and screws are
tight. Adjust the actuator buttons that push on the spring
packs by loosening the jam nuts. The buttons can be
moved up or down to take out any free play. Be sure that
none of the buttons are pushing on spring packs in the
neutral position. Rock the function back and forth to make
sure there is a 0.010 to 0.030 free play.
2. Position the booms to allow access to the winch.
Disengage the PTO and turn off the engine.
Warning
Death or serious injury can result from hydraulic oil
being injected into the flesh when loosening or dis-
connecting hydraulic components. Remove the pres-
sure before loosening or disconnecting hydraulic
components.
Seek medical attention if injured by escaping hydrau-
lic oil. Serious infection or reaction can result if
medical treatment is not given immediately.
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
work areas clean.
3. Release any pressure in the hoses connected to the
motor by moving the winch control on the upper con-
trols to the Pay In and Pay Out positions several times.
4. Remove the winch covers to allow access to the winch
and hydraulic winch motor.
5. Place a container under the hoses connected to the
winch to catch the hydraulic oil. Mark the hose
connections and disconnect the hoses from the winch
motor. Cap the ports in the motor and plug the hoses.
6. Remove the two cap screws that attach the hydraulic
motor to the winch gearbox. Remove the hydraulic
motor from the input of the winch.
7. If the shaft adapter remains on the winch input shaft,
remove the shaft adapter to expose the input shaft.
8. Place the brake torque adapter (refer to Service Tools
and Supplies in the Appendix) on the input shaft of the
winch gearbox, lining up the slot in the socket with the
key on the input shaft. Connect a torque wrench on the
adapter socket.
9. Loosen the jam nut on the brake adjusting screw.
10. Turn the torque wrench so that the drum turns in the
pay out direction one full turn before taking a torque
measurement. Refer to the parts page for the torque
setting for the winch used on the unit. If the torque is
below the setting indicated on the parts page, turn the
adjusting screw clockwise
1
/4 turn and check the
torque again. Repeat until the torque is correct. If the
torque is above the setting indicated on the parts
page, turn the adjusting screw counterclockwise
1
/4
turn and check the torque again. Repeat until the
torque is correct.
7-06
Upper Controls Interlock Trigger
The single handle control uses an interlock linkage to
prevent unintentional boom movement resulting from
accidental contact with the control.
When the interlock trigger on the bottom of the control
handle is engaged, the single handle control can be
operated. Squeezing the trigger causes a linkage inside
the single handle control assembly to manually shift the
blocking section of the upper control valve. When the
blocking section is shifted, hydraulic oil flows to the boom
function spools of the upper control valve.
When the control is not operated, the blocking section of
the upper control valve is spring offset to the closed
position.
The trigger on the single handle control should show
slightly when it is fully engaged into the handle. The trigger
should not bottom out or completely disappear into the
handle, rather the spool should bottom out, stopping
trigger movement.
Adjust the interlock connecting linkage to insure that the
interlock spool fully shifts when the trigger is actuated. If
the spool is not being fully shifted, adjust the interlock
linkage using the following procedure.
Adjustment
1. Locate the self-locking nut near the top of the interlock
cable (refer to Figure 20).
Figure 20 Upper Control Assembly
2. Make the necessary adjustment.
a. Turn the nut clockwise to shorten the cable so the
spool will move to the fully open position before the
trigger disappears into the handle.
b. Turn the nut counterclockwise to lengthen the
cable so the spool will move to the fully closed
position when the trigger is released.
3. After the adjustment is made, move the single handle
control without engaging the interlock trigger to check
that movement does not open the interlock valve.
Readjust if necessary.
Outrigger Interlock Switches
The outrigger interlock electrical switches are connected
to the outrigger interlock control module. If one switch is
defective or out of alignment, the outrigger interlock will not
operate.
Adjustment
Caution
Injury can result from electric shock. Severe arcing
can occur even when working with low voltage vehicle
electrical systems. Use caution when working with
any electrical device.
Place the truck/machine switch in the Truck position. This
will remove the electrical current from the vehicle to the
unit while working on the electrical switch.
A-Frame Outriggers
The interlock switches are not adjustable. The proximity
switches are equipped with two LED lights. The green light
indicates there is power to the switch and the yellow light
indicates the leg is extended. Depending upon the unit, the
lights may be visible through the hole in the cover or the
cover and switch may have to be removed to access the
lights. If the assembly is removed to access the lights, the
yellow light will be out. Move the assembly to within 0.75
inches of a flat metal object. If the yellow light comes on,
the switch is working properly.
Radial Outriggers
1. Loosen the switch fasteners.
2. Adjust the switch so it closes when the outrigger shoe
is within 10 to 14 inches from the ground.
3. Lock the switch in place by properly tightening the
fasteners. If adjustment does not correct the problem,
replace the switch.
Interlock Trigger
Interlock Valve
Self-Locking Nut
Testing
This unit has been factory tested and, at the time of
delivery, all applicable ANSI requirements were met or
exceeded. Any time an alteration is made that may affect
the units stability or dielectric insulation, testing must be
performed to confirm that the unit operates safely and in
compliance with all governing organizations.
Dielectric
This unit is tested to a rating listed on the serial number
placard at the time of delivery. The platform liner, if
furnished, will carry the certification test of the liner
manufacturer. Periodic dielectric testing is required by
ANSI.
Danger
Death or serious injury will result from contact with or
proximity to an energized conductor. Maintain the
dielectric characteristics of the fiberglass boom(s).
Surface irregularities such as scratched, cracked, or
chipped gelcoat can trap dirt and contaminants, which
over time may reduce the dielectric properties of the
fiberglass. Of particular concern are irregularities running
lengthwise on the boom. Trapped contaminants, such as
dust particles and water, can cause tracking, providing a
path to ground. Surface flashover occurs when a sub-
stance causes an arcing of electricity between two points
on the boom. If this occurs, the dielectric integrity of the
boom may be permanently damaged.
Dielectric tests that can be performed only after installa-
tion are the responsibility of the installer, whether the
installer is a dealer, owner, or user. After the completed
unit is in the possession of the owner or user, subsequent
testing becomes the responsibility of the owner or user.
The importance of dielectric testing cannot be overempha-
sized. Understand the dielectric test procedures in ANSI
publications. Provide for periodic inspection and dielectric
testing of insulated components at intervals of 1 to 12
months. This recommendation is not intended to alter
more frequent inspection or testing of other components
as defined in ANSI publications.
In addition to regular tests, conduct tests any time the
dielectric strength of the insulating components is in
doubt.
If it is necessary to change or replace any component
which is part of the units insulation, including booms, tool
lines, control lines, etc., a dielectric test must be per-
formed. If there is any doubt about the dielectric strength
of the hydraulic oil, perform a dielectric test.
The leakage monitor system is a tool used to measure the
leakage of electrical current through the components it is
attached to and for dielectric tests of all voltages. This
system consists of wires connected to components inter-
nal to the upper boom and to a test electrode that extends
through the bottom of the fiberglass upper boom. A test
electrode may also be located on the turntable.
Dielectric test forms can be found in the Appendix. Choose
the appropriate form, thoroughly document all tests, and
maintain records in a permanent file.
Insulated Single Handle Control
This unit may be equipped with an insulated single handle
control(s). This control, which is green in color, may offer
limited secondary dielectric protection. To maintain this
limited secondary protection it must be kept clean, dry,
and in good condition with periodic tests of its dielectric
properties. Never rely on the insulating feature of the single
handle control as a substitute for your primary protection
from electrical contact.
In addition to regular tests, conduct a test any time any
component which is part of the controls insulation has
been replaced. A dielectric test form can be found in the
Appendix. Complete the test, document the results, and
maintain the test in a permanent file.
Structural
After replacing any major component, perform a 1.5 to 1
structural test to verify structural soundness before put-
ting the unit back into service.
Warning
Death or serious injury can result if the unit becomes
unstable. Maintain stability of the unit while perform-
ing a structural test by following proper procedures.
Use the following procedure to perform a structural test.
1. The area where the test is performed should be level
and free from any overhead obstructions. Position the
unit in the test area so the platform may be accessed
by a forklift (or other lifting device) to place the test
weight.
2. Apply the parking brake and chock the wheels. En-
gage the PTO and properly set the outriggers.
3. The position of the booms for the test is somewhat
dependent upon the component(s) which has been
replaced. If a component of the leveling system has
been replaced, the booms can be raised approxi-
mately one foot out of each rest. Replacement of other
components requires the test be performed with the
lower boom vertical and the upper boom horizontal.
4. Position the platform(s) in the end-mounted position.
Allow enough space to permit jib/winch operation.
5. Calculate the test weight for the platform by multiply-
ing 1.5 times the platform capacity shown on the serial
number placard.
If the unit is equipped with a platform liner, deduct the
weight of the liner from the test weight figure.
Attention
Carefully load the test weight to prevent damage to the
platform or liner.
6. Place a sling around the platform to suspend the
weight directly under its centerline. Use a forklift (or
other lifting device) to slowly apply the weight. If the
test is being performed with the lower boom below
horizontal, the test weight can be placed in the
platform without the use of a lifting device.
7. Pay out the winch line so a weight of 1.5 times the
rated load may be applied to the winch line at less than
2 feet from the ground.
8. Apply the test weight for five minutes. During that
time, do not operate any function of the unit. This is a
static test only.
9. Remove the weight from the platform and the winch
line. Inspect the unit for structural soundness if any
cracking or popping was heard during the test.
10. Operate the unit through its full range of movement
before returning it to service.
Stability
Due to the possible affect on stability, this unit and/or
vehicle should never be altered or modified without the
specific written approval from Altec Industries, Inc. Com-
ponent replacement with original equipment parts will not
affect the stability of this unit.
ANSI A92.2 requires a level surface test and a five degree
slope test when the unit mounting is complete on the
vehicle. These stability tests are not required to be
performed again unless significant changes are made in
the original vehicle and body mounting or the unit is
remounted on another vehicle.
Warning
Death or serious injury can result from uncontrolled
movement. Do not permit anyone to occupy the plat-
form until the unit has passed applicable tests.
Death or serious injury can result if the mobile unit
becomes unstable. Provide a suitable restraint while
the stability tests are performed.
Attention
Carefully load the test weight to prevent damage to the
platform or liner.
Test Forms
Stability test forms are provided in the Appendix. The
forms designate the proper boom and jib positions and the
proper test loads to be used. They show the unit loading
configuration(s) that would most likely cause overturning.
Completed forms should be dated and signed by the test
technician after conducting the stability tests and should
be retained as part of the original unit documentation.
Additional test forms may be needed to show appropriate
stability tests for units equipped with special lifting fea-
tures such as a lower boom lifting eye or a gin pole socket.
If Altec Engineering determines that these special lifting
features will always produce less tendency toward over-
turning than would normal platform and jib stability test
loads, stability tests using these special lifting features
are not required.
General Test Conditions
Remove all tools and material including removable
boom supports, extra platforms (not attached to the
unit), and all removable cargo.
Restrict the amount of total fuel in all tanks to 20
gallons or less.
Only the test technician can be on the unit during the
test.
Do not use outrigger pads.
Perform the test only while operating from the lower
controls.
Provide a suitable restraint during all stability tests to
prevent the mobile unit from overturning in the event
a condition of instability is reached. A typical restraint
method is a loose loop of chain around each side of the
rear axle (allows the axle to raise off the test surface
at least 8 to 10 inches before tightening the chain),
near the wheel, which is securely anchored to the
ground. Increase the length of the chain to allow
further movement if there is any doubt about whether
the mobile unit has reached a condition of instability.
Raising of outriggers or tires does not necessarily
indicate a condition of instability.
Choose Test A or Test B depending on the location of
the weight for the test. Test B can only be used if the
jib can structurally carry both the jib load and the
platform load.
The unit must pass the Level Surface Test before
conducting the Five Degree Slope Test.
Level Surface Test
1. Position the unit on a level, hard surface, apply the
parking brake and chock the wheels. Engage the
hydraulic system.
2. Properly set the outriggers. Extend the outriggers to
remove the bulge from the tires while still maintaining
at least some tire-to-surface contact at each tire.
Level the mobile unit side-to-side with the outriggers.
If equipped with two sets of outriggers, use the
outriggers to level in the front to back direction.
3. Move the booms and jib into a position to most likely
cause overturning (refer to the test form).
4. Apply a load at the center of the platform(s) equal to
1.5 times the rated platforms load. The load can be
applied either into the platform(s) or suspended by a
load line from the center of the platform(s). The
platform test load may be suspended on the jib line, in
addition to the jib test load, if the unit is equipped with
a material handling jib structurally capable of carrying
the added load.
5. Apply a load to the material handling jib, if equipped,
equal to 1.5 times its rated load.
6. Rotate the turntable in a full rotation cycle, watching
for any evidence of instability. Outriggers and tires
may lift off the surface during the test without indicat-
ing a condition of instability as long as the mobile unit
does not tend to overturn.
7. If the initial test shows that the mobile unit is unstable,
adjust the outriggers to determine any effect on
stability. Rotate the turntable again in a full rotation
cycle watching for any evidence of instability.
8. Add permanent counterweight if it is determined that
the mobile unit will not pass the test as originally built.
Use temporary counterweight to determine how much
permanent counterweight is needed and where the
counterweight should be added. Rotate the unit in a full
rotation cycle watching for any evidence of instability
after adding the temporary counterweight. If the unit
passes the test with the temporary counterweight,
remove the temporary weight and add the permanent
counterweight. Perform the test again. The unit must
pass this test before moving on to the Five Degree
Slope Test.
Five Degree Slope Test
1. Position the unit on a level, hard surface with the
centerline of the vehicle positioned approximately
perpendicular to the direction of the slope. If the Level
Surface Test showed the mobile unit has a greater
tendency to overturn about one side than another,
position the least stable side on the low side of the
slope. Apply the parking brake and chock the wheels.
Engage the hydraulic system.
2. Properly set the outriggers. Extend the outriggers fully
on the low side of the slope. The mobile unit does not
have to be level or maintain tire contact on the low side
for this test. (The mobile unit is usually the most stable
when the low side outriggers are at maximum penetra-
tion and the high side outriggers are at minimum
penetration.) Extend the outriggers on the high side of
the slope, enough to complete a full cycle of rotation
without any intermediate readjustment of any of the
outriggers. Do not extend the high side outriggers
enough to cause the front tire or outside dual rear tires
on the high side of the slope to lose surface contact.
3. Move the booms and jib into a position to most likely
cause overturning (refer to the test form).
4. Apply a load at the center of the platform(s) equal to
1.33 times the rated platform load. The load can be
applied either into the platform(s) or suspended by a
load line from the center of the platform(s). The
platform test load may be suspended on the jib line, in
addition to the jib test load, if the unit is equipped with
a material handling jib structurally capable of carrying
the added load.
5. Apply a load to the material handling jib, if equipped,
equal to 1.33 times its rated load.
6. Rotate the turntable in a full rotation cycle, watching
for any evidence of instability. Outriggers and tires
may lift off the surface during the stability test without
indicating a condition of instability as long as the
mobile unit does not tend to overturn.
7. If the initial Five Degree Slope Test shows that the
mobile unit is unstable, adjust the outriggers to deter-
mine any effect on stability. Rotate the turntable again
in a full rotation cycle watching for any evidence of
instability.
8. Add permanent counterweight if it is determined that
the mobile unit will not pass the test as originally built.
Use temporary counterweight to determine how much
permanent counterweight is needed and where the
counterweight should be added. Rotate the unit in a full
rotation cycle watching for any evidence of instability
after adding the temporary counterweight. If the unit
passes the test with the temporary counterweight,
remove the temporary weight and add the permanent
counterweight. Perform the test again. The mobile unit
must pass this test.
9. After the test has been completed, torque all acces-
sible rotation bearing cap screws to 325 foot-pounds
using a circular pattern (only required at the time of
initial installation of unit on chassis).
10. After the test has been completed, torque the rotation
gearbox mounting cap screws to 225 foot-pounds
(only required at the time of initial installation of unit on
chassis).
Appendix
1 Appendix Glossary
Glossary
2nd stage boom see intermediate boom.
3rd stage boom see upper boom.
A-frame outrigger an extendible outrigger having two diagonal
members which are connected at the top and joined near the midsec-
tion by a horizontal cross piece. Resembles a broad based A.
above rotation in reference to a position on or about a unit that is
vertically above the rotation bearing.
absolute a measure having as its zero point or base the complete
absence of the item being measured.
absolute pressure a pressure scale with the zero point at a perfect
vacuum.
accumulator a container used to store fluid under pressure as a
source of hydraulic power or as a means of dampening pressure
surges.
actuator a device for converting hydraulic energy into mechanical
energy, such as a motor or cylinder.
adapter a device used to connect two parts of different type or
diameter.
adjusting stud a component of a cable drive system that is threaded
on both ends and has a hex adjusting flat in the center. It secures the
drive cable to the cylinder rod and can be used to adjust the tension of
the drive cable.
aeration the entrapment of air in hydraulic fluid. Excessive aeration
may cause the fluid to appear milky and components to operate
erratically because of the compressibility of the air trapped in the fluid.
aerial control valve the control valve on the turntable of an elevator
unit which operates the movement functions of the aerial device.
aerial device a vehicle-mounted device with a boom assembly
which is extendible, articulating, or both, which is designed and used to
position personnel. The device may also be used to handle material, if
designed and equipped for that purpose.
Allen wrench a six-sided wrench that fits into the hex socket of a cap
screw or set screw.
American National Standards Institute (ANSI) a self-governing
body of professionals whose primary objective is to prevent accidents
by establishing requirements for design, manufacture, maintenance,
performance, use and training for manufactured goods including aerial
devices and digger derricks.
anaerobic adhesive a bonding agent or adhesive that cures in the
absence of air.
analog signal an electrical signal that communicates information by
the continuous variation of voltage or current level within a defined
range, in proportion to an input parameter such as pressure or control
lever position.
annular area a ring shaped area. Usually refers to the piston area
minus the cross-sectional area of the rod of a hydraulic cylinder.
ANSI see American National Standards Institute.
antirotation fork a two-pronged retainer which is fastened to the
inside of the turntable and used to prevent movement of the rotary joint
outer housing.
antifoam additive an agent added to hydraulic fluid to inhibit air
bubbles from forming and collecting together on the surface of the fluid.
antiwear additive an agent added to hydraulic fluid to improve the
ability of the fluid to prevent wear on internal moving parts in the
hydraulic system.
arbor bar the shaft or spindle that is used to support a cable reel.
arbor bar collar a cylindrical device that is used to secure a cable
reel on an arbor bar.
arm 1: the primary load-carrying structure of an articulating arm. 2:
the primary load-carrying structure of a single elevator. 3: the articulat-
ing structure which supports the arbor bar for reel lifting.
arm cylinder the hydraulic cylinder that moves the arm of a single
elevator up and down.
articulating arm a system located between the turntable and lower
boom of an aerial device which is used for lifting the boom assembly to
increase the platform working height. This system includes the arm,
link(s), riser and articulating arm cylinder.
articulating arm cylinder the hydraulic cylinder that moves an
articulating arm up and down.
articulating-boom aerial device an aerial device with two or more
boom sections that are connected at joint(s) which allow one boom to
pivot with respect to the adjacent boom.
ASTM American Society for Testing and Materials.
atmosphere (one) a pressure measure equal to 14.7 psi.
atmospheric pressure pressure on all objects in the atmosphere
because of the weight of the surrounding air. At sea level, about 14.7
psi absolute.
atmospheric vents a vacuum prevention device designed to allow
air to enter a hydraulic line that has encountered an internal pressure
below that of the atmosphere (vacuum).
attention information that must be followed to reduce the likelihood
of property damage. Property damage could include structural damage
to the unit, component failure, or damage to nearby property.
auger the hole boring tool of the digger, consisting of a hollow tube
with hardened teeth attached at one end to dig into and break up soil
and/or rock as the auger is rotated. Several turns of flighting are welded
to the tube to carry the loose material away from the teeth.
auger extension shaft a shaft which fits into the auger tube to
connect the digger output shaft to the auger.
auger rotation hydraulic system the hydrostatic system on a
pressure digger which operates the auger transmission gearbox.
auger stow bracket the bracket on a digger derrick lower boom
which stores the digger and auger assembly when it is not in use.
auger stow switch a limit switch which is actuated by the auger to
shut off digger operation in the stowing direction when the auger
reaches its fully stowed position in the auger stow bracket.
auger transmission gearbox the gearbox mounted on the mast
weldment of a pressure digger that is used to rotate the kelly bar.
auger tube the hollow tube at the centerline of an auger to which the
auger flighting is welded.
auger windup sling the cable or strap attached to the auger stow
bracket which is used to store the digger and auger.
auxiliary engine a separately mounted engine that is used to
provide power for the units hydraulic system.
auxiliary hydraulic system the secondary hydraulic system of a
pressure digger that operates all the hydraulic functions except auger
rotation.
AWS American Welding Society.
back pressure pressure existing in the discharge flow from an
actuator or hydraulic system. It adds to the pressure required to operate
an actuator under a given load.
backlash the clearance at the tooth contact point between the
adjacent gear teeth of two or more meshing gears.
baffle a device, usually a plate, installed in a reservoir to separate
the return line inlet from the suction line outlet.
band of arrows decals used on extendible and articulating upper
booms to define the boom tip area and the insulated portions of the
upper boom and lower boom insert.
bare-hand work a technique of performing live line maintenance on
energized conductors and equipment whereby one or more authorized
persons work directly on an energized part after having been raised and
bonded to the energized conductors or equipment.
barrel the hollow body of a hydraulic cylinder into which the piston
and rod are assembled.
base boom see lower boom.
base end 1: the closed end of a hydraulic cylinder, opposite from the
end that the rod extends from. 2: the end of an extendible boom that is
closest to the turntable. 3: the end of an articulating boom that remains
positioned closest to the turntable when the boom is fully unfolded.
basket see platform.
battery charger a device used to restore the electrical charge in a
battery.
bearing a machine part that is installed between two adjacent
machine parts to allow those parts to rotate or slide with respect to each
other. Commonly used to decrease friction or wear on components.
behind cab mount a pedestal mounting position located immedi-
ately behind the vehicle cab on the longitudinal centerline of the
chassis.
3-05
2 Appendix Glossary
below rotation in reference to a position on or about a unit that is
vertically below the rotation bearing.
below rotation controls controls that are located on the chassis,
used for operating some or all of the functions of the unit.
bleed-off to reduce the trapped pressure in a hydraulic system, line,
or component, to a zero state by allowing fluid to escape under
controlled conditions through a valve or outlet.
blocking valve a two-position, two-way valve that blocks pump flow
to a hydraulic circuit or system when it is not actuated, and opens to
allow fluid when actuated.
body a structure containing compartments for storage of tools,
materials, and/or other payload which is installed on a vehicle frame or
subbase.
body belt a component in a personal fall protection system consist-
ing of a strap which is secured about the waist of a person, with a means
for attaching it to a lanyard. (As of January 1, 1998, the use of a body
belt for personal fall protection is prohibited by OSHA.)
body harness a component in a personal fall protection system
consisting of an assembly of straps which are secured about the waist,
chest, shoulders, and legs of a person, with a means for attaching the
assembly to a lanyard.
bolt a cylindrical fastener with external screw threads at one end and
a head configuration such hexagonal, square, or round at the other end,
which conforms to the dimensional and material specifications pub-
lished for bolts. (These specifications are different from those for cap
screws.)
boom a movable, mechanical structure that is used to support a
platform, material handling components and/or other attachments on a
unit.
boom angle indicator a device which indicates the angle between
the boom centerline and a horizontal plane.
boom flares steel structures mounted on the boom tip of a digger
derrick which are used to protect the boom tip from loads and support
poles carried on the winch line.
boom functions valve the control valve on a digger derrick that
directs hydraulic pressure and flow to the boom functions (boom,
rotation, intermediate boom, upper boom) hydraulic circuits.
boom pin the horizontal pin that connects the lower boom to the
turntable or riser.
boom rest the structural member attached to the chassis or body to
support the lower boom in the travel or rest position.
boom stow switch a limit switch which is actuated to shut off the
boom lower function when the boom reaches its stowed position in the
boom rest.
boom stow valve a mechanically actuated hydraulic valve that limits
the downward pressure of a boom as it is placed in its rest.
boom tip the area at the end of an extendible or articulating upper
boom that is farthest from the turntable when the boom assembly is
extended or unfolded. This area includes all components at the end of
the boom above the band of arrows.
boom tip idler sheave the upper sheave in a digger derrick upper
boom tip containing two sheaves, which carries the winch line as it
travels from the winch to the lower sheave (boom tip sheave).
boom tip pin a horizontal pin at the upper boom tip. Platform
mounting bracket(s) and material handling devices are fastened to this
pin.
boom tip sheave 1: the sheave in a digger derrick upper boom tip
containing only one sheave, which carries the winch line as it travels
from the winch to the load. 2: the lower sheave in a digger derrick upper
boom tip containing two sheaves, which carries the winch line as it
travels from the upper sheave (boom tip idler sheave) to the load.
boom tip tools see upper tool circuit.
boom tip winch a winch located at the tip of a boom.
bore the inside diameter of a pipe, tube, cylinder barrel, or cylindrical
hole in any of various other components.
boss protruding material on a part which adds strength, facilitates
assembly, provides for fastenings, etc.
brake a device used to slow or stop the rotation or movement of a
component such as a rotation gearbox, winch, gravity leveled platform,
or arbor bar.
breather a device that permits air to move in and out of a container
or component to maintain atmospheric pressure.
bridge mount a unit mounting configuration in which the turntable
is mounted on a pedestal structure which forms a bridge over the cargo
area.
broadband a high speed telecommunication system utilizing fiber
optic and/or coaxial cable.
bucket see platform.
buckeye see forged pin retainer.
bullwheel assembly an assembly of steel rollers used as a portion
of a cable stringing system.
burst pressure the minimum internal pressure that will cause a
hose, tube, cylinder, or other hydraulic or pneumatic component to
rupture or split open.
button head a type of cap screw with a rounded head containing a
socket into which a tool can be inserted to turn the cap screw.
bypass a secondary passage for fluid flow.
bypass valve a hydraulic valve that allows for an alternate passage
for fluid flow.
cable 1: a wire or wire rope by which force is exerted to control or
operate a mechanism. 2: an assembly of two or more electrical
conductors or optical fibers laid up together, usually by being twisted
around a central axis and/or by being enclosed within an outer covering.
cable chute a device used to guide cable into strand for lashing the
cable to the strand when placing cable. A trolley allows the device to ride
on the strand as cable is fed through the chute.
cable drive system an upper boom drive mechanism which utilizes
cables to produce upper boom movement.
cable guide a bracket which is mounted on a boom to guide the
winch line.
cable keeper 1: a mechanical device attached to a cable that is used
to maintain the position of the cable on a sheave. 2: a component used
to prevent a cable or winch line from coming off a sheave.
cable lasher a mechanical device which wraps lashing wire in a
spiral configuration around a length of suspension strand and adjacent
communication cable.
cable lug a mechanical device attached to a cable that is used to
maintain the position of the cable on a sheave.
cable placer a type of aerial device which contains a cable stringing
system and associated components for use in erecting overhead
communication cable.
cable slug the steel end fitting at each end of the drive cable in an
upper boom drive system. One end is attached to the cylinder rod and
the other is secured in a pocket on the elbow sheave.
cable stringing system the group of steel rollers, bullwheel assem-
blies, strand sheave assemblies and fairlead which directs communi-
cation cable or suspension strand from the reel it is stored on to the
working position of the operator.
calibrate to check, adjust, or determine by measurement in compari-
son with a standard, the proper value of each scale reading or setting
on a meter or other device.
caliper a measuring instrument with two legs or jaws that can be
adjusted to determine the distance between two surfaces.
cam a rotating or sliding piece that imparts motion to a roller moving
against its edge or to a pin free to move in a groove on its face or that
receives motion from such a roller or pin.
candling a method of inspecting filament wound fiberglass booms
by slowly passing a light through the inside of the boom in a darkened
area. Cracks, crazing, and other damage show up as dark spots or
shadows.
cap a device located on the hand of a reel lifter that is used to retain
the arbor bar.
cap end see base end.
cap screw a cylindrical fastener with external screw threads at one
end and a head configuration such as hexagonal, hex socket, flat
countersunk, round, or slotted at the other end, which conforms to the
dimensional and material specifications published for cap screws.
capacitive coupling the transfer of electrical energy from one circuit
to another through a dielectric gap.
3-05
3 Appendix Glossary
capacity chart a table or graph showing the load capacity, rated
capacity, or rated load capacity figures for a unit or accessory.
captive air system a closed circuit, low pressure pneumatic system
used to actuate a pressure switch by means of a manually operated air
plunger.
cartridge 1: the replaceable element of a fluid filter. 2: the
replaceable pumping unit of a vane pump, composed of the rotor, ring,
vanes and side plates. 3: A removeable hydraulic valve that is screwed
into place in a cavity in a hydraulic manifold or cylinder.
catrac see hose carrier.
caution information that indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury. It may also
be used to alert against unsafe practices.
cavitation the formation of gaseous voids in hydraulic fluid caused
by a low pressure condition which typically occurs when inlet starvation
prevents the pump from filling completely with fluid. The characteristic
sound of cavitation is a high pitched scream.
center mount see behind cab mount.
center of gravity the point in a component or assembly around
which its weight is evenly balanced.
centerline of rotation the vertical axis about which the turntable of
a unit rotates.
centrifugal pump a pump in which motion and force are applied to
fluid by a rotating impeller within a housing.
chain a series of identical rigid segments connected to each other
at joints which allow each segment to pivot with respect to adjacent
segments, used to transmit mechanical force.
chain extension system a mechanical system consisting of a
motor, gearbox, chains, and sprockets that is used to extend and retract
an extendible upper boom.
chain sling an inverted Y-shaped length of chain used for lifting a
strand reel with an aerial device and placing it in a strand carrier.
chamber a compartment within a hydraulic component that may
contain elements to aid in operation or control, such as a spring
chamber or drain chamber.
channel a fluid passage that has a large length dimension compared
to the dimension of the cross-section.
charge to fill an accumulator with fluid under pressure.
charge pressure the pressure, above atmospheric pressure, at
which replenishing fluid is forced into the hydraulic system.
charge pump the hydrostatic hydraulic system pump that provides
fluid at low pressure to make up for internal leakage, provides cooling
fluid flow, and tilts the hydrostatic pump swash plate.
chassis a vehicle on which a unit is mounted, such as a truck, trailer,
or all-terrain vehicle.
check valve a valve that permits flow of fluid in one direction, but not
in the reverse direction.
circuit the complete path of flow in a hydraulic or electrical system.
circuit breaker a form of electrical switch which opens (trips) to
interrupt a circuit when it senses excessive current flow that may be
caused by a short circuit, to protect wiring and components from
damage. Some types of circuit breakers reset automatically when the
excessive current discontinues and others must be reset manually.
clevis a U-shaped fastening device secured by a pin or bolt through
holes in the ends of two arms.
closed center a directional valve design in which pump output is
blocked by the valve spool(s) when the valve spool(s) is in the center
or neutral operating condition.
clutch the device on a reel lifter which allows the connection and
disconnection of the arbor bar and the driver.
coaxial cable a type of shielded cable used for conducting telecom-
munication signals, in which the signal carrier is a single wire at the core,
surrounded by a layer of insulating material, which is in turn surrounded
by a metallic, conductive layer which serves as a shield, with an overall
outer layer of insulation.
combined digger derrick and platform use the stability criteria for
a digger derrick mobile unit which indicates that the load capacity chart
and stability requirements apply to the use of the derrick for lifting of
loads with the winch line at the upper boom tip or material handling jib
tip, with the platform occupied.
come-along a device for gripping and putting tension into a length
of cable, wire, rope, or chain by means of two jaws or attaching devices
which move closer together when the operator pulls on a lever.
communication cable a copper wire, coaxial, or fiber optic cable
used for conducting telecommunication signals.
compensating link a mechanical linkage that serves as a connector
between the turntable and the upper boom drive mechanism. As the
lower boom is raised or lowered, this linkage causes the upper boom to
maintain its relative angle in relationship to the ground.
compensator a valve spool that is used to maintain a constant
pressure drop regardless of supply or load pressure.
compensator control a control for a variable displacement pump
that alters displacement in response to pressure changes in the system
as related to its adjusted pressure setting.
component a single part or self-contained assembly.
compressibility the change in volume of a unit volume of a fluid
when it is subjected to a unit change in pressure.
conductive having the ability to act as a transmitter of electricity.
Electricity will flow through metal, therefore metal is conductive.
conductive shield a device used to shield the lower test electrode
system from capacitive coupling.
conductor a wire, cable, or other body or medium that is suitable for
carrying electric current.
constant resistivity monitor device used to continuously measure
the electrical resistance of the wash water in the tank of an insulator
washer.
contaminate to render unfit or to soil by introduction of foreign or
unwanted material.
continuous rotation a rotation system in which the turntable is able
to rotate an unlimited number of revolutions about the centerline of
rotation without restriction.
control a device, such as a lever or handle, which is actuated by the
operator to regulate the direction and speed of one or more functions
of a unit.
control station a position where controls for unit operation are
located. These positions may include the platform, upper boom tip,
turntable, pedestal or vehicle tailshelf.
control valve a directional valve controlled by an operator, used to
control the motion or function of an actuator or system.
cooler a heat exchanger used to remove heat from the hydraulic
fluid.
corner mount a pedestal mounting position located behind the rear
axle(s) with the centerline of rotation located to one side of the chassis.
corona ring see gradient control device.
counterbalance valve a load holding valve that can be opened to
allow flow in the normally blocked direction by applying hydraulic
pressure to a pilot port, and which contains a relief capability to allow
flow from the blocked direction if the blocked pressure exceeds a
certain value.
cracking pressure the pressure at which a pressure actuated valve,
such as a relief valve, begins to pass fluid.
crazing a network of fine cracks on or below the fiberglass surface.
Crazing often occurs when the fiberglass is struck with a blunt object,
sometimes causing deformation and breakdown of the fiberglass resin.
crosstalk a form of interference in which one circuit or channel
receives some unintentional signal from another.
cross-ported a hydraulic path connected between the two opposite
flow paths of a hydraulic circuit that allows a route for flow between the
two paths in lieu of flow thru an actuator. To allow sensing of the
pressure in one path by a component installed in the other path.
cSt (centistoke) a metric unit of kinematic viscosity. In customary
use, equal to the kinematic viscosity of a fluid having dynamic viscosity
of one centipose and a density of one gram per cubic centimeter.
curb side the side of a vehicle which is opposite from oncoming
traffic when the vehicle is traveling forward in the normal direction in a
lane of traffic.
cushion a device built into a hydraulic cylinder that restricts the flow
of fluid at the outlet port to slow the motion of the rod as it reaches the
end of its stroke.
3-05
4 Appendix Glossary
custom option an option which is not shown on a standard order
form and which requires additional engineering work to supply.
cylinder a device that converts fluid power into linear mechanical
force and motion. It usually consists of a moveable piston and rod, or
plunger, operating within a cylindrical bore.
danger information that indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury. This signal
word is to be used in the most extreme situations.
DC pump a pump which is powered by a direct current electric motor.
dead band the area or range near the center rest position of a hand
control where the function does not respond to movement of the lever
or handle.
decal a thin sheet of flexible material which is attached to another
surface by adhesive, and is used to convey instructions, information
and warnings.
deenergize to remove electrical power from a device, as from the coil
of a solenoid valve.
delivery the volume of fluid discharged by a pump in a given time,
usually expressed in gallons per minute (gpm).
demulsibility the ability of a liquid to expel another type of liquid.
Commonly used to describe a fluids ability to cause water to separate
out rather than being held in suspension.
design voltage the maximum rated line voltage for which an aerial
device has been designed, and for which it can be qualified.
detent a device for positioning and holding one mechanical part in
relation to another so that the device can be released by force applied
to one of the parts.
diagnostic relating to the practice of investigation or analysis of the
cause or nature of a condition, situation, or problem.
diagonal brace the structural member attached near the top of a
corner mount pedestal and extending downward and forward to a point
of attachment on the subbase or vehicle frame between the pedestal
and the vehicle cab.
dial indicator a meter or gauge with a calibrated circular face and
a spring-loaded plunger, used as a measuring device.
diegrinder a small, hand held, rotary grinding tool.
dielectric nonconductive to electrical current.
differential cylinder any cylinder that has two opposed piston areas
that are not equal.
digger the mechanism which drives the auger.
digger bail a tubular housing attached to the gearbox portion of a
digger, which surrounds the motor and provides an attachment point to
the digger link.
digger derrick a multipurpose, vehicle-mounted device with an
extendible boom which may accommodate components that dig cylin-
drical holes, set utility poles, and position materials, apparatus, and/or
personnel.
digger derrick use the stability criteria for a digger derrick mobile
unit which indicates that the load capacity chart and stability require-
ments apply to the use of the derrick for lifting of loads with the winch
line at the upper boom tip or material handling jib tip, with the platform
stowed or removed, if so equipped.
digger hanger bracket the structural member on a digger derrick
which supports the digger link on the extendible boom.
digger latch mechanism a mechanism which secures the digger to
the lower boom when it is stowed and to the extendible boom when it
is unstowed.
digger link the structural member which attaches the digger to the
digger hanger bracket.
digger/winch valve the control valve on a digger derrick that directs
hydraulic pressure and flow to the digger and winch hydraulic circuits.
digital signal an electrical signal that communicates information by
the use of two distinct levels of voltage or current, a high on level and
a low off level, which are sent in a series of pulses. The timing of the
pulses is used to indicate the level of an input parameter such as control
lever position, or information such as the address setting of a radio
control transmitter linking it to its receiver.
diode an electrical component that allows current flow in one
direction but not in the reverse direction.
directional valve a valve that selectively directs or prevents fluid
flow through desired passages.
displacement the quantity of fluid that can pass through a pump,
motor or cylinder in a single revolution or stroke.
docking station a device used to mount a remote control transmitter
on a platform.
dog clutch see drum clutch.
double-acting cylinder a cylinder in which fluid pressure can be
applied to either side of the piston to move the rod in either direction.
double elevator an elevator lift with two load carrying arms. The
double elevator system includes a lower pedestal, lower arm, lower arm
cylinder(s), riser, upper arm, upper arm cylinder(s), and upper pedestal,
plus parallel links in both the lower and upper sections.
double-pole, double-throw (DPDT) switch a six-terminal electrical
switch or relay that connects, at the same time, one pair of terminals to
either of two other pairs of terminals.
double-pole, single-throw (DPST) switch a four-terminal electrical
switch or relay that, at the same time, opens or closes two separate
circuits or both sides of the same circuit.
down load the downward force created when an external force is
exerted on the boom, such as a winch pulling cable on a cable placer.
drain a passage or a line from a hydraulic component that returns
leakage fluid to the reservoir.
drift 1: a gradual, uncontrolled change from a set position of an
actuator or component. 2: a tool for ramming or driving something.
driver the gearbox and motor assembly on a reel lifter which is
connected to and disconnected from the arbor bar through the clutch
assembly.
drop pocket an open top tool storage area on the chassis of a unit.
drum clutch a clutch consisting of two or more drive lugs that engage
similar driven lugs to transmit torque. Commonly used between the
gearbox and cable drum on front or bed mounted winches.
dump valve a normally open, two-position, two-way valve that sends
pump flow through a path going directly to the reservoir or bypassing
hydraulic circuit when it is not actuated, preventing operation of the
hydraulic system or circuit. When it is actuated, it closes off this path,
redirecting flow to the hydraulic system or circuit to allow operation.
dynamometer an instrument for measuring mechanical force or
power.
earth anchor see screw anchor.
eccentric ring a ring with the center hole located in a position off the
geometric center, commonly used to adjust the position of the rotation
pinion with respect to the rotation bearing gear teeth.
eccentric ring lock a device which engages a hole or notch in an
eccentric ring to prevent the ring from rotating.
efficiency the ratio of output to input. Volumetric efficiency of a pump
is the actual output in gpm divided by the theoretical or design output.
The overall efficiency of a hydraulic system is the output power divided
by the input power. Efficiency is usually expressed as a percent.
elbow the structure on an articulating-boom aerial device that
connects the upper boom to the lower boom. The elbow allows the
upper boom to pivot relative to the lower boom.
elbow bearing the rotating member that allows the upper boom to
rotate around the end of the lower boom. Used on aerial devices with
the upper and lower booms mounted side by side.
elbow pin the horizontal pin that attaches the upper boom to the
lower boom on an articulating-boom aerial device. Used on aerial
devices with the upper boom mounted over the lower boom.
electrical harness an assembly of electrical wires that is used to
deliver electrical current between components.
electrocution receiving an electrical shock resulting in death.
electrohydraulic a combination of electric and hydraulic control
mechanisms in which an electrically controlled actuator is used to shift
the spool in a hydraulic control valve.
electrohydraulic control system a control system in which the
function control handles are connected to electric controls. The electric
controls actuate electrohydraulic valves to operate the functions of the
unit.
3-05
5 Appendix Glossary
flange on a flange and lug pin retaining system, an end plate that is
welded to one end of the pin. The purpose of the flange is to position the
pin in the connection.
flange and lug pin retaining system a connecting pin retention
system in which an end plate is welded to one end of the pin and a
retaining plate is attached with cap screws to the other end to hold the
pin in position.
flashover a disruptive electrical discharge at the surface of electrical
insulation or in the surrounding medium, which may or may not cause
permanent damage to the insulation.
flats from finger tight (F.F.F.T.) a method of counting the number
of wrench flats when tightening a hydraulic adapter to establish a torque
value.
flat-shoe outrigger an outrigger which has a shoe that is fixed in a
horizontal position.
flighting a curved plate or series of curved plates welded together,
spiraling along the axis of an auger tube or screw anchor rod.
flow the movement of fluid generated by pressure differences.
flow control valve a valve that regulates the rate of fluid flow.
flow rate the volume, mass or weight of a fluid passing through any
conductor per unit of time.
flow straightener a component part of a nozzle used to straighten
or remove any swirling motion of fluid going through the nozzle.
flowmeter an instrument used to measure the flow rate of fluid in a
hydraulic tube or hose.
fluid a liquid that is specially compounded for use as a power
transmitting medium in a hydraulic system.
fold to move a pivoting structure such an articulating upper boom
toward its stowed position.
fold-up shoe outrigger an outrigger which has a shoe that pivots
into a vertical position when the outrigger is fully retracted.
force any push or pull measured in units of weight.
forged pin retainer a pin retainer made from forged steel, consisting
of a slender, cylindrical body with a flattened, circular head at one end,
with a mounting hole through the head perpendicular to the body. The
body is inserted through a hole in the pin to be retained, and the head
is fastened to the adjacent structure with a cap screw.
four-way valve a valve having four ports for direction of fluid flow.
FPS Fluid Power Society.
frequency the number of times an action occurs in a unit of time.
gasket a packing made of a deformable material, usually in the form
of a sheet or ring, used to make a pressure tight fit between stationary
parts.
gate valve see shutoff valve.
gauge pressure a pressure scale that ignores atmospheric pres-
sure by establishing atmospheric pressure as its zero point. Its zero
point is 14.7 psi absolute.
gauge snubber see snubber valve.
gearbox an assembly with internal speed changing gears; a trans-
mission. Gearboxes are commonly used to transmit power from a
hydraulic motor to operate a function through an output shaft.
gelcoat a protective coating used on fiberglass components to
prevent the wicking of moisture into the fiberglass strands and to retard
the degrading effect of ultraviolet light on the fiberglass.
GFI ground fault interrupter.
gin pole a vertical phase-holding apparatus which is attached to a
platform or upper boom tip.
gpm gallons per minute.
gradient control device a device at the upper end of an insulating
boom that reduces electrical stress level(s) below that considered to be
disruptive.
gravity leveling system a system which uses the force of gravity to
keep the bottom of a platform parallel to level ground as the boom is
raised or lowered. One means of accomplishing this is by allowing the
platform to pivot freely about a horizontal shaft attached above the
platforms center of gravity.
grease fitting a small fitting that acts as the connection between a
grease gun and the component to be lubricated.
electrohydraulic valve a directional valve that receives a variable
or controlled electrical signal which is used to control or meter hydraulic
flow.
elevator lift a system located between the turntable and subbase of
an aerial device which is used for lifting the aerial device to increase the
platform working height. This system may be configured as a single
elevator or a double elevator.
elevator unit the overall device including the subbase, elevator lift
and the aerial device.
emergency operating DC pump see secondary stowage DC pump.
emergency operating system see secondary stowage system.
end gland a hollow, cylindrical part that screws into or is retained in
the open end of a hydraulic cylinder barrel, through which the rod
protrudes.
end-mounted platform a platform which is attached to a mounting
bracket that extends beyond the boom tip, positioning the platform (and
platform rotation pivot, if so equipped) beyond the end of the upper
boom.
energize to send electrical power to a device, as to the coil of a
solenoid valve.
energized conductor an apparatus that is transmitting electric
current.
energy the ability or capacity to do work, measured in units of work.
engine protection system a system which detects when the
auxiliary engine oil pressure or temperature is out of the proper range
and shuts the engine off.
extendible capable of linear movement of one or more portions of
an assembly to increase the overall length or reach of the assembly.
extendible-boom aerial device an aerial device with a telescopic
or extendible boom assembly.
extension cylinder a hydraulic cylinder which extends and retracts
an extendible boom(s).
fairlead the group of steel rollers at the platform of a cable placer
which guide the cable or suspension strand during the placing process.
fall protection system a system consisting of a body harness or
body belt, a decelerating lanyard, connectors, and an anchor point at
the boom tip, used to catch and hold a person who falls from a platform.
(As of January 1, 1998, the use of a body belt for personal fall protection
is prohibited by OSHA.)
feedback (feedback signal) the return of part of an output signal to
the input for the purpose of modification and control of the output.
feeder tube a telescopic hydraulic tube assembly mounted on an
extendible boom which carries pump flow to a device mounted on the
extendible portion of the boom such as a digger or boom tip winch.
fiber optic cable a type of cable used for conducting control or
telecommunication signals, in which the signal carrier(s) is one or more
optical fibers, enclosed within an outer covering.
fiber optics the use of transparent fibers of glass or plastic which
transmit light signals throughout the length of the fiber. Commonly used
to transmit signals from a remote control.
fiberglass glass in fibrous form added as a reinforcement to a plastic
for use in making various products.
filler breather cap the component on the top of a reservoir that
allows air to enter and exit the reservoir as the fluid level changes, and
which can be removed to access a fill hole when adding hydraulic fluid
to the reservoir.
filter a device through which fluid is passed to remove and retain
insoluble contaminants from a fluid.
filter cart a portable device which can be connected to a units
hydraulic system to filter water and/or other contaminants out of the
hydraulic system fluid.
filter cartridge a component containing filtration material which is
installed within a filter housing or attached to a filter receptacle for use,
and can be removed and replaced as a self-contained unit.
firm footing outrigger placement and extension in accordance with
the instructions in a units operators manual to ensure proper leveling
of the vehicle and adequate stability when operating the unit.
fixed displacement pump a pump in which displacement is con-
stant, so that the output flow can be changed only by varying the drive
speed.
3-05
6 Appendix Glossary
hydraulically extendible jib a jib boom that may be extended or
retracted by hydraulic power.
hydraulics an engineering science pertaining to liquid pressure and
flow.
hydrostatic hydraulic system any hydraulic drive in which a
positive displacement pump and motor transfer rotary power by means
of fluid under pressure.
individual address setting the code that identifies a specific
transmitter as the one emitting the signal corresponding to a specific
receivers reception address.
in-line the installation of a component in series between two portions
of a hydraulic line or electrical conductor so that flow in the line or
conductor toward the component passes through the component and
continues on in the line or conductor on the other side.
instability a condition of a mobile unit where the sum of the moments
tending to overturn the mobile unit is equal to or exceeds the sum of the
moments tending to resist overturning.
insulated aerial device an aerial device with dielectric components
designed and tested to meet the specific electrical insulating rating
consistent with the manufacturers name plate.
insulated digger derrick a digger derrick designed for and manu-
factured with a fiberglass boom(s) for use around energized conductors
at a maximum of 46 kV phase to phase.
insulated liner see platform liner.
insulated portions those sections which are designed, maintained,
and tested in accordance with the electrical requirements of ANSI
A92.2.
insulator a device that isolates the energized conductor of a power
line from the support structure.
intercom system a transmitter and receiver system that allows two-
way verbal communication between a platform operator and a person
at ground level.
interference any energy that inhibits the transmission or reception
of electrical or radio signals.
intermediate boom (INT BOOM) an extendible boom section which
is located between the upper boom and the lower boom in an extendible
boom assembly.
ISO International Standards Organization.
jam nut a nut that is screwed down firmly against another nut to
prevent loosening.
jaw clutch see drum clutch.
jib an auxiliary boom which attaches to the upper boom tip to extend
the reach of the boom.
JIC Joint Industry Conference.
joystick a two or three axis control lever which allows the operator
to simultaneously control multiple functions.
junction box an enclosed central connecting point for electrical
wiring.
kelly bar 1: for derricks see auger extension shaft. 2: the auger drive
shaft of a pressure digger which is extendible from the ram cylinder.
key a parallel-sided piece that fits into grooves in two adjacent parts
to prevent movement between the parts. Often used as the driving
member between a shaft and a sheave or winch drum.
keyway a groove that is cut in a shaft or bore for a key to fit into.
kilovolts (kV) a unit of potential difference equal to 1,000 volts.
knuckle see elbow.
L-bracket an L-shaped weldment that is used to connect a splicer
platform to the upper boom tip.
lanyard a component in a personal fall protection system consisting
of a flexible, nonmetallic strap or rope with a connector at each end for
connecting a body harness or body belt to a specified anchor point
provided at the boom tip, used to catch and decelerate a person in a fall
from the platform. (As of January 1, 1998, the use of a body belt for
personal fall protection is prohibited by OSHA.)
lashing wire a thin, solid wire which is wrapped in a helix configu-
ration around a length of suspension strand and adjacent communica-
tion cable so that the suspension strand carries the weight of the cable.
lay the length of wire rope in which one strand makes one complete
spiral around the rope.
gripper tool a component used for grasping an object or electrical
lines through the use of an articulated mechanism.
ground 1: a large conducting body with a potential of zero volts used
as a common current return for an electric circuit. 2: an object that
makes an electrical connection with a ground or with the earth.
ground fault interrupter (GFI) a fast acting form of circuit breaker
that opens to interrupt an electrical circuit if it senses a very small
current leakage to ground, to protect personnel against a potential
shock hazard from defective electrical tools or wiring. It does this by
monitoring for any difference in current flow between the hot and neutral
wires in the circuit. An imbalance exceeding a very small preset value
indicates that current is finding an improper path to ground, and causes
the breaker to trip.
guard ring see conductive shield.
hand an extension of the reel lifter arm that allows for loading the
arbor bar.
hand control a hand operated control lever or handle located at a
control station used to regulate a function of a unit, where the speed of
the function is proportional to the distance the control is moved.
heat the form of energy that has the capacity to create warmth or to
increase the temperature of a substance. Any energy that is wasted or
used to overcome friction is converted to heat. Heat is measured in
calories or British thermal units (Btu). One Btu is the amount of heat
required to raise the temperature of one pound of water one degree
Fahrenheit.
heat exchanger a device that transfers heat through a conducting
wall from one fluid to another or into the atmosphere.
hertz (Hz) a unit of frequency equal to one cycle per second.
high tooth the individual tooth out of all the gear teeth on a rotation
bearing at which the minimum backlash occurs with the rotation pinion.
This is because of a slight difference between the actual and theoretical
tooth pitch lines due to manufacturing tolerances.
HLIW hot line insulator washer.
holding valve see load holding valve.
HOP see hydraulic overload protection system.
horsepower (HP) the power required to lift 550 pounds one foot in
one second or 33,000 pounds 1 foot in one minute. One horsepower is
equal to 746 watts or to 42.4 British thermal units per minute.
hose carrier a flexible component which contains hydraulic, electri-
cal, and/or air lines, usually mounted inside or along the side of an
extendible boom. As the boom is extended, the hose carrier unfolds in
a rolling motion to allow the lines to extend with the boom.
hose carrier tube a rigid, enclosed tube which contains hydraulic,
electrical, and/or air lines, and may contain components for upper
controls. It is usually attached to a hose carrier on the side of an
extendible boom.
hot line insulator washer (HLIW) a vehicle-mounted device which
is designed and used for cleaning pole and structure mounted transmis-
sion and distribution insulators.
HTMA Hydraulic Tool Manufacturers Association.
Huck bolt a bolt-like fastener that is placed in position and then
stretched while an end fitting is swaged on. Commonly used to attach
a pedestal, subbase, and/or outriggers to a vehicle frame.
hydrant a discharge pipe with a valve and spout at which water may
be drawn from a water main.
hydraulic control a control that is actuated by hydraulically induced
forces.
hydraulic leveling system an automatic hydraulic control system
which keeps the bottom of a platform parallel to or at a fixed angle to the
turntable base plate as the boom is raised or lowered. One means of
accomplishing this is by transferring hydraulic fluid between a master
cylinder actuated by movement of the lower boom and a slave cylinder
mounted between the platform and the upper boom.
hydraulic overload protection (HOP) system the system on a
digger derrick that shuts off certain functions to help prevent damage
to the digger derrick structure when an overload is applied to the boom
in the downward direction.
hydraulic schematic a drawing that uses common hydraulic
symbols to represent the hydraulic system of the unit.
hydraulic swivel a fluid conducting fitting having two joined parts
that are capable of pivoting freely about each other to accommodate
motion of an attached hydraulic line.
3-05
7 Appendix Glossary
layer all wraps of winch line on a winch drum which are on the same
level between drum flanges.
leakage monitor system a means by which current leakage is
measured through the insulated section(s) of a boom to confirm of
dielectric integrity.
leveling cable the wire rope portion of a mechanical leveling system
that passes over the sheaves.
leveling chain the chain portion of a mechanical leveling system that
passes over the sprockets.
leveling cylinder 1: a cylinder that is used in a master/slave
arrangement in a hydraulic leveling system to hydraulically level the
platform. 2: the hydraulic cylinder that is used to tilt the pivot and mast
weldments of a pressure digger to either side of the vertical position.
leveling rod a slender, round, fiberglass rod used in a mechanical
leveling system that passes through a units boom to connect the
leveling chains or cables at each end of the boom.
leveling system see platform leveling system.
leverage a gain in output force over input force; mechanical
advantage or force multiplication.
lift cylinder the hydraulic cylinder that moves the lower boom up and
down on a digger derrick or extendible-boom aerial device.
lifter cylinder the hydraulic cylinder that moves the reel lifter arms.
lifting eye a shackle or weldment used for attaching chain, cable,
rope, etc. to a boom for material handling.
light emitting diode (LED) a semiconductor diode that emits light
when subjected to an applied voltage. LEDs are used for electronic
display.
line a tube, pipe or hose used as a passageway to move hydraulic
fluid.
linear in a straight line.
linear actuator a device for converting hydraulic energy into linear
motion such as a cylinder or ram.
linear position transducer an extendible length measuring device
which produces a variable electrical signal that is proportional to the
length to which the device is extended.
liner see platform liner.
link the secondary load-carrying structure of an articulating arm.
load capacity (as defined by ANSI for digger derricks) the maximum
load, specified by the manufacturer, that can be lifted by the mobile unit
at regular intervals of load radius or boom angle, through the specified
ranges of boom elevation, extension and rotation, with options installed
and inclusive of stability requirements.
load holding valve a hydraulic valve which blocks fluid flow from a
hydraulic actuator, such as a cylinder or motor, to prevent motion when
the control valve is not being operated or in case of a hydraulic line
failure.
load radius the horizontal distance from the centerline of rotation to
the winch line load attachment point.
lock washer a solid or split washer that is placed underneath a nut
or cap screw to help prevent loosening by exerting pressure against the
fastener.
locknut see self-locking nut.
lockwire a wire that is installed to prevent loosening of fasteners or
components.
lower arm the primary load-carrying structure of a double elevator
which is located between the lower pedestal and the riser.
lower arm cylinder the hydraulic cylinder that moves the lower arm
of a double elevator up and down.
lower boom (LWR BOOM) the boom section in a boom assembly
which is attached to the turntable or riser, and which supports the upper
boom or intermediate boom.
lower boom cylinder the hydraulic cylinder that moves the lower
boom about its pivot point on an articulating-boom aerial device.
lower boom insulator the part of the lower boom made of high
dielectric strength material (usually fiberglass reinforced plastic or
equivalent) to interrupt the conductive path for electricity through the
lower boom.
lower boom winch a winch that is located on the lower boom.
lower control valve the hydraulic valve on the vehicle, turntable, or
pedestal of an aerial device used for operating some or all of the
functions of the aerial device.
lower controls the controls on the vehicle, turntable, or pedestal,
used for operating some or all of the functions of the unit.
lower pedestal the structure within an elevator lift that connects the
elevator lift to the subbase.
lower test electrode system a system on an insulated aerial device
utilizing conductive bands installed permanently on the inside and
outside surfaces of the insulated portion of the upper boom and
conductive connections to components inside that portion of the boom
such as leveling rods and hydraulic lines. All the bands and component
connections are connected to a common pickup point for use in
measuring current leakage to confirm of dielectric integrity.
lower tool circuit a hydraulic tool circuit with quick disconnect
couplings located on the pedestal or on the vehicle.
lug a metal part which serves as a cap, handle, support, or fitting
connection.
magnetic suction separator filter see magnetic suction strainer.
magnetic suction strainer a suction filter consisting of a strainer
which contains one or more magnets to trap ferrous metallic contami-
nants that are small enough to pass through the strainer.
mainframe see pedestal.
man-and-a-half platform an oversized one-man platform.
manifold a fluid conductor that provides multiple connection ports.
manual lowering valve a manually operated hydraulic valve used
to lower the boom in the event of power failure.
manual override a means of manually actuating an automatically or
remotely controlled device.
manually extendible jib a jib that is capable of being extended and
retracted by human force.
mast the structure on a pressure digger which supports the auger
transmission gearbox, ram cylinder, kelly bar, and pole setter.
master control panel the primary derrick lower control panel which
contains the electrical connections between the derrick control system
and components such as the power module and the dump or blocking
valve. The master control panel is used in conjunction with a slave panel
to provide dual station lower controls.
master cylinder a cylinder in which motion of the piston under an
external force transfers hydraulic fluid to a slave cylinder to produce
corresponding motion.
material handling having the ability to use the boom or attachments
on the boom to lift and position materials.
material handling system the system on an aerial device that
consists of a jib and winch used to lift material to the upper boom tip.
mechanical leveling system a mechanical system which keeps the
bottom of a platform parallel to or at a fixed angle to the turntable base
plate as the boom is raised or lowered. One means of accomplishing
this is by utilizing a parallelogram arrangement of leveling rods attached
to cables or chains operating around sheaves or sprockets at boom
pivot points.
mercury switch a switch that is closed or opened when an internal
globule of mercury moves to or away from the contacts when the switch
is tilted.
meter to regulate the amount of fluid flow.
meter-in to regulate the amount of fluid flow into an actuator or
system.
meter-out to regulate the flow of the discharge fluid from an actuator
or system.
micron (micrometer) one-millionth of a meter or about 0.00004.
micron rating the minimum size of the particles that a filter is
designed to remove.
microswitch a small electrical device that is used to turn an electrical
current on or off, or to change the connections in a circuit.
minimum approach distance the three dimensional area surround-
ing a conductor into which a person may not enter nor bring any
conductive object unless they are: qualified electrical workers, wearing
insulating gloves (and sleeves when required), protected against
contact with any other objects at a different electrical potential.
3-05
8 Appendix Glossary
NPT National Pipe Thread.
NPTF National Pipe Thread Fluid, a pipe thread form which is
modified from the NPT form to improve the resistance to fluid leakage
through the threads in a connection.
O-ring a ring of material with a circular cross section that is used as
a gasket, usually made of synthetic rubber.
ohmmeter an instrument used to measure the resistance in ohms
between two points in an electrical component or circuit.
on/off circuit circuit that supplies constant electrical power to a
solenoid or other component when a relay or switch is closed and
removes the power when the relay or switch is opened.
one-man platform a platform designed to carry one person. It is
usually 24 wide x 30 wide or 24 wide x 24 wide.
open center a directional valve design in which pump output returns
freely to the reservoir when the valve spool(s) is in the center or neutral
position.
open circuit an electric circuit that has infinitely high resistance,
resulting in no current flow. An open circuit may be caused by a loose
connection, broken wire, corrosion or poor contact where an electrical
component is grounded to the unit structure.
operator a person trained, authorized and engaged in the operation
of the unit.
optical fiber a thin strand of transparent glass or plastic used to
transmit signals using light throughout the length of the strand.
orifice a restriction in a hydraulic or pneumatic circuit, the length of
which is small in respect to its diameter.
OSHA Occupational Safety and Health Administration.
out and down outrigger an outrigger that has independently-
controlled horizontal and vertical extendible outrigger legs.
outboard bearing a bearing which supports the end of a gearbox
output shaft farthest from the gearbox.
output signal a radio wave intended to pass communication from a
source to a destination.
outrigger a structural member, which when properly extended or
deployed on firm ground or outrigger pads, assists in stabilizing the
mobile unit.
outrigger controls the controls for operating the outriggers.
outrigger cylinder the hydraulic cylinder which extends and retracts
or unfolds and folds an outrigger leg.
outrigger interlock system a system which requires all outriggers
to be extended to a specified position before other unit functions are
allowed to operate.
outrigger interlock valve a valve which prevents above rotation
sense line signals from reaching the pump until the outriggers have
been lowered.
outrigger leg 1: the moveable structural component of an outrigger
which extends or unfolds to position the outrigger shoe on the ground,
and which retracts or folds to return the outrigger shoe to the stored
position. 2: the stationary structural component of an extendible outrig-
ger from which the moveable outrigger leg extends.
outrigger motion alarm an audible warning system to alert person-
nel that outriggers are being lowered or moved.
outrigger pad a portable piece of rigid material which is placed
under an outrigger shoe to increase the contact area with the ground
surface when the ground surface is not firm enough to support direct
contact from the outrigger shoe.
outrigger shoe the component of an outrigger that is attached to the
moveable leg and that contacts the ground or outrigger pad to stabilize
the mobile unit.
outrigger signal valve a valve used to provide a signal to the pump
when the outriggers are being operated and to allow a separate signal
system to control the aerial device operation.
outrigger spread the distance between the outer edges on fixed
shoes, or between pin centerlines on pivoting shoes, of opposite
outriggers which have been extended or deployed to a given position.
over travel movement of a mechanism beyond its normal stopping
point.
overcenter aerial device a type of articulating-boom aerial device
on which the upper boom can unfold from the stored position to beyond
a vertical position.
mobile operation the use of the aerial device or digger derrick while
the mobile unit is traveling.
mobile unit the combination of a unit, its chassis and related
permanently attached equipment.
modified A-frame outrigger an extendible outrigger that is config-
ured like a large broad based A with an open top.
modulation ratio the on time vs. the off time of a pulse width
modulated digital signal. This ratio is determined by dividing the on time
during one cycle by the total cycle time.
moly see molybdenum disulfide.
molybdenum disulfide a black inorganic chemical that is used as
a dry lubricant and as an additive for grease and oils. Molybdenum
disulfide has a very high melting point and is insoluble in water.
molydisulfide see molybdenum disulfide.
moment a force multiplied by the perpendicular distance from the
line of action of the force to an axis or point. The force may be the weight
of an item, with the vertical line of action located at the items center of
gravity. Moment is measured in units of force times distance; for
example, pound-feet or foot-pounds.
monitor head remotely controlled articulated assembly with a
nozzle, mounted at the upper end of an HLIW.
motor a device that converts hydraulic or electrical energy into
continuous rotary motion and torque.
multiple-part line the arrangement of the winch line on a digger
derrick in which the winch line is routed between the boom tip and the
load two or more times. A snatch block is used at the load and a snatch
block or additional boom tip sheave(s) is used on the boom to reverse
the direction of the winch line. The end of the winch line is connected
to a stationary attachment point on the boom or lower snatch block. A
multiple-part line is used to reduce the tension in the winch line to a
value below the winch line rated working load when a lifting load that
exceeds the winch line rated working load.
multiplexing a process by which signals from multiple inputs are
combined and transmitted simultaneously over a single channel.
multiviscosity the viscosity characteristic of a fluid which contains
additives that increase the viscosity index. The fluid does not become
as thin at high temperatures or as thick at low temperatures as a fluid
without these additives. This allows the fluid to be used over a wider
temperature range.
nonconductive the characteristic of a substance that allows it to
transmit electricity only in a very small degree when it is clean, dry and
properly maintained.
noncontinuous rotation a rotation system in which the turntable is
prevented from rotating more than approximately one revolution about
the centerline of rotation.
non-insulated aerial device or digger derrick an aerial device or
digger derrick which is not designed, manufactured, or tested to meet
any dielectric rating.
nonmetallic formed of materials which are not any type of metal.
non-overcenter aerial device a type of articulating-boom aerial
device on which the upper boom will not unfold from the stored position
to beyond a vertical position regardless of the position of the lower
boom.
nontransferable boom flares boom flares that are permanently
attached to the boom tip of a digger derrick.
nontransferable upper controls an upper control panel on a digger
derrick that is permanently attached to the upper boom tip.
normally closed switch a switch which is closed to allow current to
flow through it when it is not actuated, and opens to interrupt current flow
when actuated.
normally closed valve a two-way valve which is closed to block fluid
from flowing through it when it is not actuated, and opens to allow flow
when actuated.
normally open switch a switch which is open to prevent current from
flowing through it when it is not actuated, and closes to allow current
flow when actuated.
normally open valve a two-way valve which is open to allow fluid to
flow through it when it is not actuated, and closes to block flow when
actuated.
nozzle a tube-like device for accelerating and directing the dis-
charge flow of fluid.
3-05
9 Appendix Glossary
overframe an outrigger weldment mounting position located above
the vehicle chassis frame.
overload the condition existing when a load greater than the rated
capacity or design lead is applied to a unit or component.
override the takeover of boom movement control functions from the
platform controls by the activation of the lower control station controls.
overtighten to torque a threaded fastener beyond the recom-
mended torque value.
oxidation the reaction of a substance with oxygen.
parallel link the secondary load-carrying structure of an elevator lift.
particle count a visual count of the numbers of particulate contami-
nants in a quantity of a hydraulic fluid.
passage a machined or cored fluid conducting path that lies within
or passes through a component.
payload any tools, materials, fuel and occupants carried by the
mobile unit that are not permanently attached.
pedestal the stationary base of a unit that supports the turntable and
is attached to the subbase or vehicle frame.
pedestal mount a mounting configuration for an aerial device in
which the turntable is mounted on a pedestal consisting of a box-like
structure.
penetration the distance the vehicle frame is lifted after the outrig-
gers contact the ground surface.
phase a conductive wire or cable used for transmitting high voltage
electrical current. The phrase phase to phase can be referenced as
any two conductors of a three-phase electrical power line system.
pilot operated condition in which a valve is actuated by hydraulic
fluid pressure.
pilot operated check valve a check valve that can be opened to
allow flow in the normally blocked direction by applying hydraulic
pressure to a pilot port.
pilot pressure auxiliary pressure used to actuate or control hydrau-
lic components.
pilot valve an auxiliary valve used to control the operation of another
valve.
pin a cylindrical structural device used to allow a pivoting joint or to
connect mating parts.
pin retainer a device which is used to hold a pin in place in an
assembly.
pinch point a particular location in which a human body or a part of
the body may become pinched or pinned between moving mechanical
parts.
pinion a gear with a small number of teeth that has been designed
to mesh with a larger gear.
piston a cylindrically shaped part that fits within a cylinder or
cylindrical bore and transmits or receives linear motion by means of a
connecting rod or other component.
piston pump a pump in which motion and force are applied to fluid
by a reciprocating piston(s) in cylindrical bore(s).
pivot weldment the structure located above the slide frame on a
pressure digger which supports the mast.
placard 1: a thin sheet of rigid material which is attached to another
surface by adhesive and/or mechanical fasteners, and is used to
convey instructions, information and warnings. 2: May also refer to a
decal.
planetary gear set an assembly of meshed gears consisting of a
central gear (sun gear), a coaxial internal tooth ring gear and several
intermediate pinions (planet gears) supported on a revolving carrier.
planetary gearbox a gearbox containing one or more planetary gear
sets.
platform the personnel-carrying component of a unit, mounted at the
upper boom tip.
platform heater an electrically powered device mounted in a splicer
platform which is used to warm the occupant.
platform leveling system a system which keeps the bottom of a
platform parallel to or at a fixed angle to the base plate of the turntable,
or parallel to level ground, as the boom is raised or lowered. The system
may be mechanically, hydraulically, or gravity operated.
platform liner a component made of material having a high dielectric
strength which is designed to be inserted into a platform to cover the
walls and bottom of the platform.
platform pin the horizontal pin that is used to fasten a platform
mounting bracket to the upper boom tip. The mounting bracket pivots
about this pin for platform leveling or positioning.
platform rest the structural member attached to the chassis or body
to support and cushion the platform in the travel or rest position.
platform ring a metal band around the lip of a splicer platform which
supports and guides the platform as it is rotated about its vertical
centerline.
platform rotation override system a system which allows the zone
of platform rotation to extend beyond a predetermined limit when
actuated by the operator.
platform rotator a system which allows the operator to rotate the
platform about a vertical axis. This permits the position of the platform
to be changed with respect to the boom tip.
platform tilt system a system which allows the operator to adjust the
orientation of the platform about a horizontal axis. Some systems allow
the operator to adjust the working position of the platform floor and tilt
the platform for cleaning. Other systems allow tilting of the platform for
cleaning but do not provide for operator adjustment of the working
position.
platform use the stability criteria for a digger derrick mobile unit
which indicates that the load capacity chart and stability requirements
apply to the use of the derrick with the platform occupied, with no lifting
of loads with the winch line.
plunger a cylindrically shaped part that is used to transmit thrust; a
ram.
pole a long cylindrical piece of material such as wood, metal, or
concrete which is installed in a vertical position for use as a support
structure for power and communication lines.
pole guide a mechanism at the tip of a boom used for guiding and
stabilizing a utility pole while using the winch line to raise or lower the
pole.
pole guide tilt cylinder the hydraulic cylinder which is used to tilt
(raise or lower) the pole guide.
pole guide tong cylinder the hydraulic cylinder which opens and
closes the pole guide tongs.
pole guide tongs moveable arms on a pole guide used to stabilize
and guide a utility pole as it is being raised or lowered with the winch line.
pole puller an apparatus consisting of a hydraulic cylinder, chain
and other components used to loosen a utility pole from the ground.
pole setter an assembly attached to the mast of a pressure digger
that is used to pick up, position, and set a pole.
polyethylene a moisture proof plastic.
poppet that part of certain valves that prevents flow when it closes
against a seat and allows flow when it moves away from the seat.
port an internal or external opening for intake or exhaust of fluid in
a component.
portable resistivity tester a device used for testing the electrical
resistance of water. Commonly used for testing the wash water for
insulator washers.
position a term which describes the number of possible positions a
valve spool or mechanism can be shifted to.
post mount a mounting configuration for an aerial device in which
the turntable is mounted on a pedestal which utilizes a round vertical
tube as its primary load-carrying structure.
potentiometer a variable resistor that is connected to act as an
electrical voltage divider.
pour point the lowest temperature at which a fluid will flow or pour
under specific conditions.
power work per unit of time, measured in horsepower (HP) or watts.
power module the central connection point between the chassis
and unit electrical systems. This device is used to provide battery power
to the unit when the truck/machine selector is in the machine position.
power take-off (PTO) a supplementary mechanism enabling ve-
hicle engine power to be used to operate non-automotive apparatus
such as a pump.
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10 Appendix Glossary
ram cylinder the hydraulic cylinder that is used to retract and extend
the kelly bar on a pressure digger.
range diagram a diagram which shows the load radius and sheave
height of a digger derrick at all the configurations of boom extension and
boom angle covered by the corresponding load capacity chart
.
rated capacity (as defined by ANSI for digger derricks) the maxi-
mum load, specified by the manufacturer, that can be lifted by the digger
derrick at regular intervals of load radius or boom angle, through the
specified ranges of boom elevation and extension, with specified
options installed, and exclusive of stability requirements.
rated line voltage the nominal voltage, phase to phase, at which
electrical systems are rated.
rated load capacity (as defined by ANSI for aerial devices) the
maximum loads, specified by the manufacturer, which can be lifted by
the aerial device through the specified range of boom elevation and
extension with specified options installed and in consideration of
stability requirements.
reach diagram a drawing that shows the horizontal and vertical
limits of travel of the platform, upper boom tip, and/or jib tip throughout
all possible configurations of lower boom angle, boom extension, upper
boom angle, articulating arm travel, and/or elevator lift travel.
rear mount a pedestal mounting position located over or near the
rear axle(s) on the longitudinal centerline of the chassis.
receiver a device that converts radio waves into electrical signals for
communication and/or control purposes.
reel brake a component of the reel driver which prevents the
overrunning of cable reels carried by a strand carrier and reel lifter. The
brake is used to maintain tension in the cable or suspension strand
when used with the reel driver.
reel driver a component of a strand carrier and reel lifter used for
paying in or paying out cable or suspension strand.
reel lifter a device used to support and move cable reels from the
ground to the vehicle.
reel lifter arms the structure on a reel lifter used to lift and store reels
of cable or suspension strand on the chassis.
reengage to repeat the activation of a function after it has been
momentarily halted.
relay an automatic switch with contacts that can be closed or opened
by electrical current in a coil.
relief valve a pressure operated valve that bypasses pump delivery
to the reservoir to limit system pressure to a predetermined maximum
value.
remote arm a remotely operated jib used to handle equipment or
electrical lines.
remote assist a vehicle-mounted device with a boom assembly
which is extendible, articulating, or both, which is designed and used to
accommodate attachments for performing operations such as support-
ing or cutting electrical conductors, lifting or holding objects, or cutting
tree branches. It is operated by remote control from the ground or from
the platform of an adjacent personnel lifting device. It may be mounted
on the vehicle by itself or in addition to a personnel lifting device.
remote control system a system used for operating some or all of
the functions of a unit from a portable control station. The control station
may be a transmitter which sends signals by radio waves to a receiver
on the unit, or a control module which sends signals through a fiber optic
or electrical cable to the unit.
remote operated auxiliary control system (ROACS) a radio
controlled system for starting and stopping certain functions of the
mobile unit.
remote start/stop system the components used to actuate a
function of the unit from a location other than for normal operation. The
most common functions controlled are engine start/stop and the sec-
ondary stowage DC pump.
reservoir a container for storage of liquid in a fluid power system.
resistance the opposition to the flow of electricity or hydraulic fluid.
restriction a reduced cross-sectional area in a line or passage that
produces a pressure drop.
retaining ring a hardened, washer-like ring that may be spread apart
or compressed and installed into a groove or recess to serve as a
retaining device.
precharge pressure the pressure of compressed gas in an accumu-
lator before any fluid is added.
pressure the force applied in a given area. It can be expressed in
pounds per square inch (psi).
pressure compensator a device on a variable displacement pump
that adjusts pump output flow to develop and maintain a preset
maximum pressure.
pressure differential the difference in pressure between two points
in a system or component.
pressure drop the reduction in pressure between two points in a line
or passage due to the energy required to maintain flow.
pressure gauge an instrument which displays the hydraulic or
pneumatic pressure sensed at a port on the device.
pressure line the line carrying fluid from a pump outlet to the
pressurized port of a valve or actuator.
pressure override the difference between the cracking pressure of
a valve and the pressure reached when the valve is passing full flow.
pressure reducing valve a pressure control valve whose primary
function is to limit its outlet pressure.
pressure switch an electric switch which is actuated when the
hydraulic or pneumatic pressure applied to a port on the switch reaches
a specified value.
pressure transducer a pressure measuring device which produces
a variable electrical signal that is proportional to the hydraulic pressure
applied to a port on the device.
proportional circuit a circuit that supplies a varying voltage to a coil
in a pilot valve as electrical current applied to the circuit is varied by a
hand control.
proximity alarm a system which measures the distance from a
detector to another object, and sounds an alarm when this distance is
less than a specified value. Commonly used to inform the operator of
an HLIW of the distance between the boom tip nozzle and a power line
insulator or support structure.
psi pounds per square inch.
PTO see power take-off.
pullout upper controls an upper control panel on a digger derrick
which is mounted on a housing that can be extended from inside an
outer housing when additional length is needed, such as to attach the
control panel to a personnel jib with the outer housing attached to the
upper boom tip, or to attach the upper control panel to the upper boom
tip with the outer housing attached to the transferable boom flares.
pulse width modulation (PWM) a means of transmitting a digital
signal in continuous cycles of pulses where the total length of time for
a cycle of one on pulse and the following off period is constant, and
the length of time (width) of the on pulse within each cycle is varied
(modulated) in proportion to the level of an input parameter such as
control lever position.
pump a device that converts mechanical force and motion into
hydraulic flow and pressure.
purge system a system of check valves that allows hydraulic fluid
flow in a reverse manner through the hydraulic system, usually from the
lower control valve to the upper controls. This actions frees or purges
the control system of any trapped air and restores a solid column of fluid
for precise control. The purge system may also be used to warm up the
control system in cold weather conditions if the fluid in the reservoir is
warm.
purge/upper/lower controls selector valve a valve which is used
to direct hydraulic fluid to the purge system, the upper control valve, or
the lower control valve.
PWM pulse width modulation.
quick disconnect couplings hydraulic fittings designed for fast and
easy attachment and separation.
radial ball bearing an antifriction bearing with rolling ball contact in
which the direction of action of the load transmitted is perpendicular to
the axial centerline of the bearing.
radial outrigger an outrigger in which the moveable outrigger leg
pivots in an arc around a pin connection between the leg and a
supporting structure as the leg is lowered and raised.
radio communication communication by means of radio waves.
ram 1: a single-acting cylinder with a single diameter plunger rather
than a piston and rod. 2: the plunger in a ram-type cylinder.
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return line a hydraulic line used to carry discharge flow from a
hydraulic system or actuator back to the reservoir at low pressure.
return line filter a filter located in a hydraulic system return line or
at the inlet of a hydraulic reservoir which cleans fluid flowing from the
hydraulic system to the reservoir.
reversing valve a four-way directional valve used to change the
direction of movement of a double-acting cylinder or reversible motor.
ribbon hose a group of hoses that are attached side by side to
produce a flat bundle. Commonly used to carry hydraulic fluid, air and/
or electrical cable(s) to the boom tip or upper controls.
riding seat an operators control station attached to the side of the
turntable, with a seat on which the operator rides with the rotation of the
unit.
riser 1: the structure on a double elevator that connects the lower
elevator arm to the upper elevator arm. 2: the structure within an
articulating arm to which the lower boom is connected.
ROACS see remote operated auxiliary control system.
rod the cylindrically shaped part of a cylinder which extends and
retracts from the barrel to actuate or move a component.
rod end the end of a cylinder that the extending component or rod
is on.
roller a cylindrical device which spins freely about a pin or shaft, used
to guide the motion of another component.
rollpin a pin that has been formed by rolling up a thin, flat strip of
metal to form a cylinder. Commonly used by being driven into a hole to
serve as a retaining device.
rope a stout, flexible cord, which consists of many strands of wire
or fibers that are twisted or braided together.
rotary actuator a device for converting hydraulic energy into rotary
motion and torque in which the rotary motion is restricted to within
certain angular limits.
rotary joint a multiple port manifold that has a rotating portion and
a stationary portion, used to provide a continuous hydraulic connection
between rotating and stationary hydraulic lines. Commonly used at the
centerline of rotation of units equipped with continuous rotation.
rotate frame the structure located above the stationary frame on a
pressure digger that is used to support and rotate the slide frame.
rotating platform a platform which can be rotated about a vertical
axis to change its position in relationship to the boom tip.
rotation bearing the rotating member, usually a shear ball bearing,
located between the pedestal and the turntable which allows the
turntable to rotate and which contains gear teeth that mesh with the
rotation pinion.
rotation chain a chain attached to the stationary frame of a pressure
digger that is used by the rotation gearbox to rotate the rotate frame.
rotation gearbox the gearbox which drives the rotational motion of
the turntable.
rotation pinion the gear on the output shaft of the rotation gearbox
which meshes with the rotation bearing gear teeth and drives the
turntable rotational motion.
rotation resistant wire rope wire rope which is constructed to resist
the tendency to untwist or rotate when carrying a suspended load. This
is accomplished by laying the outer strands in the opposite direction to
the lay of the inner strands or core.
rotation system the system which drives the rotation of the turntable
about the centerline of rotation. It typically consists of a rotation bearing,
rotation gearbox, hydraulic motor, and load holding valve.
rpm revolutions per minute.
running torque the torque produced by a rotating device such as a
motor or gearbox at a specified rotational speed.
SAE Society of Automotive Engineers.
safety belt see body belt.
saybolt universal viscosity A measure of viscosity equal to the time
it takes in seconds for 60 milliliters of fluid to flow through a capillary tube
in a Saybolt universal viscosimeter at a given temperature.
scissor link the mechanical linkage on a reel lifter used to connect
the lifter cylinder to the arm.
screw anchor a rod with an eye on one end and auger flighting on
the opposite end. It is designed to screw into the ground and serve as
an anchor to hold an attached cable such as a guy wire.
seating in an initial microscopic surface deformation of components
that are clamped together with threaded fasteners. This causes a slight
reduction in the dimension of the components, reducing the clamping
force applied by the fasteners.
secondary stowage DC pump a low flow hydraulic pump driven by
a direct current electric motor. This pump is used to provide hydraulic
flow to stow the unit when the system for normal operation has failed.
secondary stowage system those components used to stow the
unit when the system for normal operation has failed.
selector switch a switch which is used to direct electrical current to
one of two or more electrical circuits.
selector valve a valve which is used to direct hydraulic fluid to one
of two or more hydraulic circuits.
self-locking nut a nut which contains a built-in device or shape to
increase thread friction so as to resist loosening due to vibration or
repeated loading.
self-lubricating bearing an antifriction bearing in which lubricating
material is incorporated in the bearing.
sense line a line that carries a hydraulic pressure signal from a valve
or actuator to the compensator control on a variable displacement
pump.
sense selector valve a valve which prevents hydraulic fluid in the
sense line from reaching the pump until a certain function(s) is oper-
ated.
sequence 1: the order of a series of operations or movements. 2: to
divert flow to accomplish a subsequent operation or movement.
sequence valve a pressure operated valve that diverts flow to a
secondary actuator while holding pressure on the primary actuator at a
predetermined minimum value after the primary actuator completes its
travel.
sequential extension the operation by which one boom section in
an extendible boom assembly reaches full extension or retraction
before the next boom section begins movement.
set screw a short screw, typically with an Allen type head, that is
used as a clamp to bind parts together.
shackle see clevis.
shear an action or stress resulting from opposing applied forces that
attempt to separate a part into two pieces that would then slide along
each other in opposite directions along the plane of separation.
shear ball bearing an antifriction bearing with rolling ball contact in
which the direction of load transmitted through the balls is parallel to the
axial centerline of the bearing, producing shear loading on the balls.
The bearing can support axial, radial, and tilt loading. Commonly used
as a rotation bearing.
shear pin a replaceable pin which prevents motion between two
adjacent parts by the production of shear loading in the pin, and which
may be designed to fail under overload to protect other parts.
shear stability resistance of a hydraulic fluid viscosity index im-
prover additive to shearing.
shearing molecular damage or breakdown of the viscosity index
improver additive in hydraulic fluid. Shearing can occur when the fluid
flows through fine clearances at high velocity. Shearing can cause
permanent loss in fluid viscosity.
sheave a grooved wheel used to support and guide a winch line or
leveling cable at a point of change in the direction of motion of the line
or cable.
sheave height the vertical distance from ground level to the
centerline of the boom tip sheave in a digger derrick upper boom tip.
short circuit an inadvertent path of low resistance established
between two points of an electrical circuit. A short circuit will result in
excessive current flow.
shutoff valve a device which is used to stop hydraulic fluid flow.
shuttle valve a three-port valve that accepts hydraulic fluid pressure
from two inlets and allows only the highest pressure fluid to pass
through it to a single outlet while keeping the inlet fluid pressure isolated
from one another.
side gun a hand held water nozzle and hose that can be used from
the ground for washing or fire fighting.
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side load an external horizontal load placed on a boom from one
side.
side load protection system the system on a digger derrick that
helps prevent damage to the digger derrick structure when excessive
side loads are applied to the booms.
side-mounted platform a platform which is attached to a mounting
bracket that extends from one side of the boom tip, positioning the
platform (and platform rotation pivot, if so equipped) beside the boom
tip.
sideslip sideways motion of a component caused by an externally
applied sideways force which overcomes resistive forces from hydrau-
lics, friction, etc. Commonly used to describe rotation of a digger derrick
boom caused by side loading which exceeds the side load protection
setting.
signal a command or indication of a desired position, velocity, flow
or pressure.
signal line see sense line.
single-acting cylinder a cylinder in which fluid pressure can be
applied to move the rod in only one direction. Return motion is produced
by an external force such as a spring or gravity.
single elevator an elevator lift with one load carrying arm. The
single elevator system includes a lower pedestal, arm, arm cylinder(s),
parallel links, and upper pedestal.
single handle control a control, with an interlock trigger incorpo-
rated in the handle, which allows the operator to simultaneously control
multiple functions of the booms and turntable from the platform.
single-pole, double-throw (SPDT) switch a three-terminal electri-
cal switch or relay that connects one terminal to either of two other
terminals.
single-pole, single-throw (SPST) switch a two-terminal electrical
switch or relay that opens or closes one circuit.
slave control panel a secondary derrick lower control panel that is
configured as a remote terminal of the master panel. The slave panel
is used in conjunction with a master panel to provide dual station lower
controls.
slave cylinder a cylinder in which motion of the piston is produced
by the transfer of hydraulic fluid from a master cylinder, resulting in
corresponding motion.
slide frame the structure on a pressure digger used to support the
auxiliary engine, hydraulic reservoir, control station, and pivot weld-
ment. The slide frame can be extended horizontally from its stowed
position to adjust the distance of the kelly bar from the rotate frame.
slide pad a rectangular block used as a bearing between extendible
boom or outrigger sections, usually composed of a non-metallic mate-
rial.
slip ring an assembly of one or more conductive, rotating rings and
stationary brushes used to provide a continuous electrical connection
between rotating and stationary conductors. Commonly used at the
centerline of rotation of units equipped with continuous rotation.
slug face the extreme end of the cable slug which is secured to the
cylinder rod or adjusting stud.
snatch block a device which has a means of attachment to connect
it to a boom or load, and which can be opened to receive a winch line
around an internal sheave.
snubber valve a two-port valve with a manually adjustable orifice
that restricts the flow of fluid through the valve.
socket head a cylindrical cap screw head design containing a
hexagonal (six-sided) female socket into which an Allen wrench can be
inserted to turn the cap screw.
solenoid a coil of insulated wire that produces a magnetic field within
the coil when electrically energized. When attached to a hydraulic
valve, the magnetic field acts upon the valve to move internal valve
parts.
solenoid valve a valve which is actuated by a solenoid to controlling
the flow of hydraulic fluid.
speed reducer see gearbox.
spherical bearing a bearing with a spherically shaped inner race
that is allowed to move freely inside a stationary outer race to accom-
modate misalignment.
splicer platform a fiberglass platform equipped with a door and
latch.
spline one of a number of equally spaced, load carrying teeth that
have been cut on the outside diameter of a shaft or inside diameter of
a bore, parallel to the shaft or bore centerline.
spool a moving, cylindrically shaped part of a hydraulic valve that
moves to direct flow through the valve.
spring lockouts a mechanical system which is engaged to keep a
vehicles suspension system from flexing during operation of the unit.
sprocket a wheel with teeth along the circumference which are
shaped so as to engage with a chain, used to support and guide the
chain at a point of change in the direction of motion of the chain.
SSU (Saybolt Second Universal) the unit of measure for Saybolt
universal viscosity.
stability a condition of a mobile unit in which the sum of the moments
which tend to overturn the mobile unit is less than the sum of the
moments tending to resist overturning; the mobile units ability to resist
tipping.
stabilize to provide adequate stability for a mobile unit to allow
operation of the vehicle-mounted device(s).
stabilizer a device used to assist in stabilizing a mobile unit, such as
an outrigger, torsion bar or spring lockout.
stake to slightly deform the threads of a fastener or material at the
joint between two components by placing the blade of punch or chisel
on the threads or joint and tapping on the handle with a hammer. The
deformed material serves to prevent loosening of the components.
stall torque the torque produced by a rotating device such as a motor
or gearbox at zero rotational speed.
standard option an option which can be ordered from a standard
order form and can be supplied without additional engineering work.
start/stop control module an electrical device that relays signals
from the units remote start/stop system to the component(s) or system(s)
being controlled, such as the secondary stowage DC pump and/or
vehicle ignition system.
stationary frame the structure attached to the subbase of a pressure
digger that supports the outriggers and rotate frame.
stationary platform a platform which can not be rotated about a
vertical axis to change its position in relationship to the boom tip.
stow to place a component such as a boom or digger derrick auger
in its rest position.
strainer a coarse filter.
strainer basket a coarse, basket shaped filter which is mounted in
the fill hole of a reservoir and projects into the reservoir.
strand 1: one of the groups of individual fibers or wires within a
synthetic winch line or wire rope. 2: see suspension strand.
strand carrier a device used to support and transport strand reels
on a vehicle.
strand reel a reel or spool used for carrying suspension stand.
street side the side of a vehicle toward oncoming traffic when the
vehicle is traveling forward in the normal direction in a lane of traffic.
stroke 1: total linear movement in either direction of a piston or
plunger. 2: to change the displacement of a variable displacement
pump or motor.
subbase a structural mounting interface between the pedestal and
the vehicle frame. It provides torsional stiffness and strength in addition
to that which would be provided from the vehicle frame alone.
subweldment a smaller welded subassembly used within a more
complex welded structure.
suction filter a filter located in a hydraulic system suction line or at
the outlet of a hydraulic reservoir which cleans fluid flowing from the
reservoir to the pump inlet.
suction line the hydraulic line connecting the pump inlet port to the
reservoir outlet.
surge a momentary rise of pressure in a circuit.
suspension strand a type of wire rope which is used to support the
weight of an attached communication cable suspended between poles
or other overhead support structures.
swage to taper or reduce the diameter of a rod, tube or fastener by
forging, squeezing or hammering.
synthetic winch line a winch line made from nonmetallic synthetic
fibers which are formed into strands that are then braided together to
make a complete rope.
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T-stand a T shaped weldment for mounting lower controls to the
vehicle.
tachometer an instrument used for displaying the speed of rotation
of an engine output shaft.
tailshelf the rear portion of the mobile unit above and behind the rear
axle.
tailshelf tools see lower tool circuit.
tank the hydraulic reservoir.
telescopic having sections that slide within or over one another to
change overall length.
terminal block an insulating mounting used for making electrical
terminal connections.
test block a manifold with ports for connecting a hydraulic pressure
source, pressure gauge and a cartridge valve such as a counterbalance
valve or relief valve used for testing and adjusting the relief setting of the
valve.
thimble a metal ring around which a rope is passed and spliced to
make a loop or eye.
thread locking adhesive an anaerobic adhesive that is applied to
fastener threads to prevent loosening due to vibration or repeated
loading.
three-phase a system for transmitting high voltage, alternating
current, electrical power along three separate conductors, with 120
degrees between the voltage waveform cycles of any two conductors.
three-position valve a valve having three positions for direction of
fluid flow, such as neutral, flow in one direction, and flow in the opposite
direction.
three-way valve a valve having three ports for direction of fluid flow.
throttle control a manual, hydraulic, or electrical device used to
regulate vehicle or auxiliary engine speed.
toggle switch an electrical switch operated by a short projecting
lever combined with a spring to quickly open or close a circuit when the
lever is pushed through a small arc.
topping cylinder see lift cylinder.
torque 1: a rotational twisting force. 2: to preload a threaded fastener
by application of a rotational twisting force.
torque converter a rotary device for transmitting and amplifying
torque, especially by hydraulic means.
torsion bar a rod-like spring which is flexed by being twisted about
its axis, used to assist in stabilizing a mobile unit.
tow line winch a winch located on a cable placer which is used for
tensioning suspension strand or self-supporting cable or towing a cable
lasher.
trace element analysis analysis of a small sample of hydraulic fluid
to determine contamination level and condition of additives.
tracking a current leakage path created across the surface of
insulating material when a high-voltage current forms a carbonized
path within a foreign material on the surface.
transducer a device that converts input energy of one form into
output energy of another, such as hydraulic pressure into an electrical
signal.
transferable boom flares boom flares, on which a pole guide may
be mounted, that can be pinned to either the intermediate boom tip or
the upper boom tip of a digger derrick.
transferable upper controls an upper control panel on a digger
derrick that can be attached to either the upper boom tip or the
transferable boom flares by the use of a detent pin.
transmitter a device used to generate and emit a radio frequency
carrier signal. The signal is sent to a receiver which translates the signal
into usable information.
trim pot a potentiometer which is used to make fine adjustments in
a circuit during manufacture or calibration, typically by turning a slotted
adjusting screw.
troubleshoot to locate and diagnose problems in a system or a
component.
trunnion a mounting device consisting of a pair of opposite,
projecting cylindrical pivots on which something can be rotated or tilted.
trunnion bearing a bearing that a trunnion pin pivots in.
trunnion pin a cylindrical pivot pin that is a part of a trunnion.
turnbuckle a link with screw threads at both ends that is turned to
bring the ends closer together for tightening purposes.
turns from finger tight (T.F.F.T.) a method of counting the number
of turns of a hydraulic adapter to establish a torque value.
turntable the structure located above the rotation bearing which
supports the lower boom or articulating arm, and rotates about the
centerline of rotation.
turntable winch a winch located on the turntable.
turret see turntable.
two-man platform a platform designed to carry two people. It is
usually 24 wide x 48 wide.
two-part line a multiple-part line on a digger derrick in which the
winch line is routed from the boom tip sheave down to a snatch block
at the load and then back up to a stationary attachment point on the
boom.
two-position valve a valve having two positions for direction of fluid
flow, such as open and closed.
two-speed motor a motor which has two operating speed and
torque modes (a low-speed, high-torque mode, and a high-speed, low-
torque mode) that can be selected by the operator.
two-way valve a valve having two ports for direction of fluid flow, with
one internal flow path which can be open or blocked.
UNC Unified National Coarse, a thread description.
underframe an outrigger weldment mounting position located
beneath the unit subbase or vehicle chassis frame.
undertighten to torque a threaded fastener below the recom-
mended value.
UNF Unified National Fine, a thread description.
unfold to move a pivoting structure such as an articulating upper
boom away from its stowed position.
unit the Altec device(s), subbase, outriggers, body and associated
interface items mounted on a chassis, but not including the chassis
itself.
unload to release hydraulic flow, usually directly to the reservoir, to
prevent pressure buildup.
unloaded vehicle weight the total weight of the completed mobile
unit without payload.
unloading valve a valve that bypasses flow to the reservoir when a
set pressure is maintained on its pilot port.
upper arm the primary load-carrying structure of a double elevator
which is located between the riser and the upper pedestal.
upper arm cylinder the hydraulic cylinder that moves the upper arm
of a double elevator up and down.
upper boom (UPR BOOM) the boom section in a boom assembly
which is farthest from the turntable when the boom assembly is fully
extended or unfolded, and which supports the boom tip sheave and/or
platform(s).
upper boom cylinder the hydraulic cylinder that moves the upper
boom about its pivot point on an articulating-boom aerial device.
upper boom drive mechanism the components used to produce
upper boom movement on an articulating boom-aerial device, such as
linkage, cables, sheaves and/or gears.
upper boom rest the structural member that supports the upper
boom in the rest or travel position.
upper boom tip the boom tip of an upper boom.
upper control valve the hydraulic valve on or beside the platform
of an aerial device used for operating some or all of the functions of the
aerial device.
upper controls the controls located on or beside the platform used
for operating some or all of the functions of the unit.
upper pedestal the structure within an elevator lift that connects the
elevator lift to the aerial device rotation bearing.
upper tool circuit a tool hydraulic circuit with quick disconnect
couplings located at the upper boom tip.
vacuum the absence of pressure. A perfect vacuum is the total
absence of pressure; a partial vacuum is some condition less than
atmospheric pressure. Vacuum is measured in inches of mercury (in.
Hg.).
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valve a device that controls fluid flow direction, pressure or flow rate.
vane pump a type of pump with a rotor and several sliding vanes in
an elliptical chamber. Hydraulic fluid enters the expanding area and is
forced out as the fluid is moved to the decreasing chamber area.
variable displacement pump a pump in which the size of the
pumping chamber(s) can be changed, so that the output flow can be
changed by moving the displacement control or varying the drive speed
or both.
vehicle a carrier for a unit.
velocity the speed of linear motion in a given direction.
velocity fuse a hydraulic valve that is used to stop fluid flow through
it when the flow rate reaches a predetermined cut-off value.
vent an air breathing device on a fluid reservoir or hydraulic line.
VI see viscosity index.
viscosity a measure of the internal friction or resistance to flow of a
fluid.
viscosity index (VI) a measure of the resistance to change in
viscosity of a fluid with change in temperature. The higher the number,
the less the viscosity will change as the temperature changes.
voltmeter an instrument used to measure the potential difference in
volts between two points in an electrical circuit.
volume 1: the size of a space or chamber in cubic units. 2: loosely
applied to the output flow of a pump in gallons per minute (gpm).
vortex a whirlpool of liquid.
waist harness a belt device worn by the operator of a radio remote
control system to which the transmitter is attached.
walking beam outrigger an extendible outrigger which has a pivot
point at the top of the nonextending leg and a linkage attached to the
extending leg, so that the leg assembly rotates about the pivot point to
increase the outrigger spread as it is extended.
warning an instruction that indicates a potentially hazardous situa-
tion which, if not avoided, could result in death or serious injury.
water monitor an articulating mechanism that is used to direct the
flow of a high pressure water stream.
water removal filter cartridge a special filter cartridge designed to
absorb and remove water from hydraulic fluid. It is not intended for use
during normal operation, but is for use when water removal is required.
way a term which describes how many ports are in a valve or valve
section.
weldment a structural unit formed by welding together an assembly
of pieces.
wheel chock a wedge or block placed on the ground in front of or
behind the wheel of a vehicle to block the movement of the wheel.
winch a mechanism consisting of a gearbox with a cylindrical
rotating drum on which to coil a line for load hoisting or line tensioning.
winch capacity the maximum load, specified by the manufacturer,
that can be pulled on the first layer of line on the winch drum at rated
system pressure.
winch line a load hoisting line consisting of a synthetic or wire rope.
winch line rated working load the average breaking strength of a
winch line (as specified by the line manufacturer) divided by the
appropriate design factor as specified by ANSI.
wire rope a rope made from steel wires which are formed into
strands that are then twisted about each other in a spiral configuration.
work the exertion of a force moving through a definite distance. Work
is measured in units of force multiplied by distance; for example, pound-
feet.
worm gearbox a gearbox that utilizes a gear which has a continuous
helix tooth or teeth similar to a large screw thread along shaft (worm),
that drives a gear which has teeth cut at an angle along a its outside
diameter (worm gear). The rotational axis of the worm is perpendicular
to the rotational axis of the worm gear.
wrap a single coil of winch line on a winch drum.
Y-cable an electrical cable assembly which contains three branches
joined at a common point, similar to a Y.
zerk see grease fitting.
3-05
Appendix Service Tools and Supplies
Service Tools and Supplies
Most routine maintenance and service of the unit can be
performed with common hand tools and shop supplies
available from a tool supply company. Some special tools
and supplies are available from your Altec representative
that may be useful or required to perform certain mainte-
nance procedures. These items are categorized with their
corresponding Altec part number. The list contains items
for both aerial devices and derricks. An Accessory and
Replacement Parts Catalog is also available for ordering
other items that may not be shown in the Parts Manual.
This catalog can be obtained through your Altec represen-
tative.
Part Number
099-00017
099-00018
099-00025
099-00033
099-00050
099-00019
099-00020
099-00037
099-00069
099-00123
099-00124
099-00021
099-00039
099-00040
099-00041
099-60007
Product
Lubrication
Gear Shield
Chain and Cable Fluid
Moly grease
Anti-seize compound (16 oz can)
Anti-seize compound (
1
/4 lb tube)
Fasteners
Thread locking adhesive
(Purple 50 ml)
(Blue 50 ml)
(Red 50 ml)
(Red 50 ml)
Inspection lacquer, blue (
1
/2 oz)
Cleaner for inspection lacquer (
1
/2 oz)
Stainless steel safety wire
(5 lb roll)
Cleaning solvent (12 oz)
Primer (Grade N 6 oz)
Primer (Grade T 6 oz)
Wire twisting pliers
Purpose/Use
Lubricate rotation gears and pinions.
Lubricate cables such as wire rope winch line, auger windup
sling, and leveling cables or chains.
Component lubrication.
Low strength thread locking and sealing agent for small
diameter screws.
Medium strength thread locking and sealing agent for bolts
and nuts.
High strength thread locking and sealing agent for large
diameter bolts and cap screws.
Medium/high strength thread locking agent.
Visual inspection stripe.
Visual inspection stripe removal.
Lockwiring fasteners.
Quick drying, nonflammable solvent used for cleaning parts
prior to bonding. Leaves no residue.
Anaerobic solvent reduces cure time on thread locking
adhesive.
Anaerobic solvent reduces cure time on thread locking
adhesive.
Lockwiring fasteners.
Appendix Service Tools and Supplies
Part Number
041-90001
041-90002
099-00062
703-50039
099-00008
099-00038
099-00034
352-79006
352-79008
353-30007
353-30016
356-90002
750-40039
099-00051
099-00042
099-00061
750-40013
415-08042
356-90042
Product
Fiberglass Care
Gelcoat kit
Formula Five Clean N Glaze
Plastic Kleen #2 Polish
Bonding kit
White paint
Hydraulic System Care
Pipe sealant (50 ml)
Flowmeter
Test block small bore (
7
/8 hex)
Test block large bore (1
1
/8)
Return line filter cartridge
Water removal filter cartridge
Diagnostic test kit
Oil warming kit
Corrosion suppressant
Electrical System Care
Conformal coating (14 oz)
Lectra-Motive Electric
Parts Cleaner (19 oz)
Miscellaneous
Leveling cable kit
Brake torque adapter
Atmospheric vent valve tester
Purpose/Use
Repair fiberglass platforms and booms.
Cleaning and polishing fiberglass.
Nontoxic plastic cleaner.
Rebond fiberglass booms.
Nonmetallic spray paint.
General purpose pipe sealant for use on pipes to two inches.
Testing hydraulic system.
Testing counterbalance valve.
Testing counterbalance valve.
Filters hydraulic oil before it is returned to the reservoir.
Removes water from the hydraulic system.
Testing hydraulic systems.
Warm hydraulic oil to operating temperature in cold weather.
Chrome cylinder rod protection.
Silicon based electrical component protection.
Clean and degrease electrical systems.
Parts for the five year mandatory leveling cable change.
Winch brake adjustment.
Test atmospheric vents for proper operation.
Preventive Maintenance and Inspection Checklist
Appendix Preventive Maintenance and Inspection Checklist
Vehicle No. __________________________ Location ___________________________ Date ___________________
Model Number _________________________________ Serial Number _____________________________________
Odometer _________________ Hours Meter __________________ Inspector _______________________________
Perform all inspections, adjustments, repairs, and lubrication according to Altec specifications in the Maintenance
Manual. Refer to any MABs, CSNs, or other applicable documents provided by Altec for servicing the unit.
If you are tracking PTO hours utilizing an approved method or device, follow the recommended hourly maintenance
intervals, or if you are performing maintenance based upon a calendar-based schedule, follow the recommended monthly
intervals. The required items apply to both interval-tracking systems.
Intervals
Prior to placing unit in service 85 PTO hours/1 month 500 PTO hours/6 months
1,000 PTO hours/1 year 2,000 PTO hours/2 years Required maintenance
Symbols
= Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
Perform the Daily Preoperational Inspection
(refer to the Operators Manual)
Hydraulic Reservoir and System
Check oil and collect oil sample for analysis
1
Rotation Bearing
Turntable tilt measurement
2
: ___________
Prior to Placing Unit in Service
Perform the 85 hour/1 month inspection
PTO
Operation, noise level, no leaks
Mounting cap screws secure
Supplemental Brake Lock
Operation (holding, no bleed-off)
Chassis Underside
Hoses (routing, condition)
Exhaust shields
Pump
Mounting cap screws secure
4-bolt flange cap screws secure
Perform the Daily Preoperational Inspection
(refer to the Operators Manual)
General Condition
Clean debris from turntable, cylinders, boom tip
Hydraulic Reservoir
Oil level
Hydraulic System
Pedestal (no leaks)
Turntable (no leaks)
Elbow (no leaks)
Boom tip (no leaks)
Fiberglass Boom(s)
Upper boom (condition, clean)
Lower boom (condition, clean)
Lubrication
Rotation bearing ball race
Lower boom lift cylinder pivot bearings
Upper boom lift cylinder pivot bearings
Rotation pinion and bearing gear teeth
Outrigger inner leg outer surfaces
Elbow bearing ball race
85 PTO Hours/1 Month
Drive line
Noise level
No leaks
Unit Mounting
Subbase mounting (fasteners secure, welds intact,
no cracks)
Subbase structure (welds intact, no cracks)
Pedestal mounting (fasteners secure, welds intact,
no cracks)
Boom rest (welds intact, no deformation or cracks)
Utility body mounting (cap screws secure, welds intact,
no cracks)
500 PTO Hours/6 Months
Hydraulic Reservoir
Mounting (cap screws secure, welds intact, no cracks)
No leaks
Shutoff valves fully open
Drain water from bottom
Filters
Change return line filter
Change pilot line filter
Outriggers
Mounting (welds intact, no deformation or cracks)
Machine/ground level functions selector valve
(operation, no leaks)
Two-speed throttle switch operation
Interlock system operation
Operation (holding without drift, no leaks)
Structures (welds intact, no deformation or cracks)
Pins and retainers secure, retaining cap screws secure
Motion alarm
Hoses and tubes (routing, condition)
Placards (condition, readable)
Control valves (operation, leaks)
Lower Tools Circuit
Operation, no leaks
Hoses (routing, condition)
Quick disconnect couplers (condition, operation,
dust caps)
Hydraulic System Pressure
Pump compensator (_________psi)
Standby pressure (________psi)
Tool system pressure (_______psi)
Pilot system (_______ psi)
Lower Controls
Engine start/stop switch (operation)
Secondary stowage DC pump switch (operation)
Lower/emergency stop/upper control (operation)
Lower control valve (operation, no leaks)
Pedestal
Structure (welds intact, no deformation or cracks)
No leaks
Rotary joint mounting cap screws secure
Rotary joint drive bracket (condition, in place)
Slip ring mounting cap screws secure
Turntable
Boom pin and retainers secure
Lift cylinder pivot pin and retainers secure
No leaks
Boom stow valve (operation, condition, no leaks)
Rotation Bearing and Gearbox
Gearbox mounting cap screw visual inspection
Motor mounting cap screws secure
Eccentric ring lock (in place, secure)
No leaks
Pinion gear teeth
Rotation bearing gear teeth condition
Pinion to rotation bearing gear backlash
Gearbox internal lost motion
Operation (smoothness, noise level)
Rotation bearing cap screw visual inspection
Rotation bearing inspection and measurement (after
0.050 increased wear from initial measurement)
2
Lower Boom Lift Cylinder
Pivot bearings secure within cylinder eyes
Pin retainers secure
Operation, no leaks
Holding valves (operation, no leaks)
Chromed rod condition
Lower Boom
Lift cylinder pivot pin and retainers secure
Fasteners secure
Boom stow switch operation
Boom angle indicators
Insulator fasteners secure
Insulator (condition, clean, undamaged)
Leveling rods/cables
Jam nuts on leveling turnbuckles (in place, secure)
Remove any debris from inside lower boom
Lifting eye (welds, hardware)
Upper Boom
Fiberglass fasteners secure
Fiberglass (condition, clean)
Jam nuts on leveling turnbuckles (in place, secure)
Leveling rods/cables
Upper Controls
Operation (metering, proper direction, no leaks)
Emergency stop operation
Mechanical linkage (operation, adjustment)
Rubber boot (condition, in place)
Interlock linkage (condition, adjustment)
Blocking section of upper control valve (operation,
no leaks)
Engine start/stop control
Tools at Platform
Quick disconnects (condition, operation, no leaks)
Quick disconnect dust caps (condition, in place)
Hoses (routing, condition, no leaks)
Material Handling Package
Fiberglass condition
Bracket and mounting pins (condition)
Sheave (condition, turns freely)
Sheave pin and retainer secure
Jib operation (tilt and extension)
Jib cylinders (condition, no leaks, chromed rod)
Winch mounting (cap screws secure, welds intact,
no deformation or cracks)
Winch motor mounting cap screws
Winch brake operation
Gearbox outboard bearing secure
Winch rope (condition, anchor point secure)
Control valve (condition, operation, no leaks)
Winch cover (condition, in place)
Winch line/hook (condition)
Platform Tilt System
Tilt valve (condition, no leaks)
Operation
Platform tilt cylinder (operation, fasteners secure,
no leaks)
Lubrication
Leveling cables
Interlock linkage
Platform rotator pivot bearings
Platform rotator rotate stop pin
Upper control mechanical linkage
Winch gearbox outboard bearing
Boom angle indicator
Outrigger valve handle linkage
Hose assembly (no leaks, secure to tension rod)
Non-overcenter cam and valve (operation, no leaks)
Tension rod (securely attached, tightened)
No leaks
Covers in place
Upper boom restraint (condition, operation)
Upper boom stow pad (condition, in place)
Boom tip weldment (welds intact, no deformation
or cracks)
Boom tip fasteners secure
Remove any debris from inside upper boom
Upper Boom Cylinders
Cylinder attachment pins (condition, cap screws
secure and lockwired, retaining rings in place)
Pivot bearings secure within cylinder eyes
Operation, no leaks
Holding valves (operation, no leaks)
Chromed rod condition
Elbow
Leveling shaft retainers
Elbow bearing cap screw visual inspection
Elbow bearing cap screw initial inspection
Upper boom drive mechanism (condition, cap
screws secure and lockwired, rollpin in place)
Cover (in place, condition)
Leakage monitor system test receptacle (condition,
not corroded)
Platform
Mounting secure (bracket, pins and fasteners)
Platform mounting cap screws secure
Storage lock detent pin operation
Brake (adjustment, pad and rotor condition)
Platform (condition, clean)
Platform angle (leveling system tension)
Liner (condition, clean, fasteners secure)
Hoses (routing, not pinched or pulled, no leaks)
Lanyard attachment secure
Covers in place
Platform Rotator
Operation
Pivot pin or cap screw (looseness, nut secure)
Rotary actuator (condition, no leaks)
Pivot bearings
Rotate stop pin (operation)
Perform the 500 hour/6 month inspection
Clean suction filter
Change filler breather cap
Clean or change filler hole strainer
Reservoir cover gasket condition
Collect oil sample for analysis
1
Lubrication
Pump input shaft splines
Elbow Bearing
Annual torque inspection
Rotation Bearing and Rotation Gearbox
Annual torque inspection
Atmospheric vents (visually inspect all, verify operation
on Category A units)
Leveling Cables
Replace leveling system cables
3
Annual Testing
Dielectric test unit
Dielectric test platform liner(s)
Dielectric test insulated single handle control(s),
if so equipped
Platform mounting pin and boss
Outrigger inner leg outer surface
Top bearing on rotation bearing gearbox
1
Periodic laboratory analysis is the most accurate method of determining the condition of the hydraulic oil and when it should be changed.
If laboratory analysis is used, take baseline sample. Compare future lab tests on subsequent samples to the original to establish a trend.
2
Initially measure turntable tilt as a baseline. Check rotation bearing wear every 2 years until it measures 0.050 increased wear from initial
measurements. After reaching 0.050 increased wear, measure every 6 months. Refer to the Maintenance Manual for the proper procedure.
3
Refer to the Maintenance Manual for inspection and replacement criteria.
Lubrication
Change winch gearbox oil
Change rotation gearbox oil
Rotation Bearing
Rotation bearing inspection and measurement (before
0.050 increased wear from initial measurement)
2
Perform the 1,000 hour/1 year inspection
Flush hydraulic system
Clean inside of reservoir
Clean magnetic suction separator filter
Change hydraulic oil
Rotation gearbox oil level
Winch gearbox oil level
2,000 PTO Hours/2 Years
1,000 PTO Hours/1 Year
Required Maintenance (Regardless of Hours)
Appendix Accessory Checklist
Accessory Checklist
Vehicle No. __________________________ Location ___________________________ Date ___________________
Model Number ___________________ Serial Number ___________________ Inspector _______________________
Symbols
= Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
1,000 PTO Hours or as Recommended by the Manufacturer
* DOT items
Unit Accessories
Platform liners
Platform covers
Tool holders (mounting and condition)
Scabbard (mounting and condition)
Spare augers
Screw anchor wrench
Lifting slings and chains
Hydraulic cooler (mounting, condition and fan operation)
Hydraulic oil heater (operation and condition)
ROACS system (operation)
Radio controls
Auxiliary power unit (mounting, pump to bellhousing
bolts, exhaust system, cooling system, fuel system)
Body Accessories
Body (structure, mounting)
Outrigger pads and holders
Pole rack mounting
Access steps (condition and mounting)
Cargo area retention (mounting and condition)
Dump bed operation (dump hoist and body prop)
Spotlights and work lights
Beacons
Wheel chocks and holders
Mud flaps
Cones and holders
Inverters (operation and mounting)
Generators (operation and mounting)
Platform rest (condition and mounting)
Fire extinguishers*
First aid kit
Flare kit/warning triangles (3)*
Grounding reel
Power cord reel
Hotstick tube or box
Ladder rack
Spare fuse pack*
Chassis Accessories
Front winch (mounting and operation)
PTO and driveline
Bed winch
Capstan
Collapsible reel
Secondary brake system
Pintle hitch (condition and mounting)
Safety chain eyebolts
Trailer plug
Tow hooks
Cab guard
Brake controller (mounting and operation)
Back up alarm (mounting and operation)
Torsion bar
Hydraulic Tools and Hoses
Hose reel and hoses
Pole puller, chain and base
Impact
Chain saw
Tamp
Quick disconnects
Appendix Accessory Checklist
Appendix Torque Values
Fitting Size T.F.F.T. Fitting Size T.F.F.T.
1
/8 2 to 2
1
/2
3
/4 1
1
/2 to 2
3
/16 2 to 2
1
/2
7
/8 1
1
/2 to 2
1
/4 2 to 2
1
/2 1 1
1
/2 to 2
5
/16 2 to 2
1
/2 1
1
/8 1
1
/2 to 2
3
/8 1
1
/2 to 2 1
1
/2 1
1
/2 to 2
1
/2 2 to 2
1
/2 2 1
1
/2 to 2
5
/8 2 to 2
1
/2
Pipe Thread T.F.F.T. Valve Cartridges
Wrench Size Fitting Size Torque ft-lbs (Nm)
7
/8 -8 20 (27)
1 -10 25 (34)
1
1
/8 -10 25 (34)
1
1
/4 -12 35 (48)
1
1
/2 -16 50 (68)
2 -20 65 (88)
Compression Fittings
Tube Size Fitting Size T.F.F.T.
1
/8 thru
1
/4 2 thru 4 1
1
/4
5
/16 5 1
3
/4
3
/8 thru 1 6 thru 16 2
1
/4
Split Flanges
Flange Size Thread Torque in-lbs (Nm)
3
/4
3
/8-16 250 to 350 (28 to 40)
1
3
/8-16 325 to 425 (37 to 48)
1
1
/4
7
/16-14 425 to 550 (48 to 62)
1
1
/2
1
/2-13 550 to 700 (62 to 79)
2
1
/2-13 650 to 800 (73 to 90)
Torque Values
Size
SAE Grade 5
ft-lbs (Nm)
SAE Grade 8
Hex and Socket Head
ft-lbs (Nm)
Button and Flat Head
ft-lbs (Nm)
1
/4 0.2500 8 (11) 6 (8) 11 (15) 9 (12) 9 (12) 8 (11)
5
/16 0.3125 16 (22) 13 (18) 22 (30) 18 (24) 19 (26) 15 (20)
3
/8 0.3750 28 (38) 23 (31) 39 (53) 33 (45) 33 (45) 28 (38)
7
/16 0.4375 44 (60) 37 (50) 63 (85) 52 (71) 54 (73) 45 (61)
1
/2 0.5000 68 (92) 57 (77) 96 (130) 80 (108) 82 (111) 68 (92)
9
/16 0.5625 98 (133) 82 (111) 138 (187) 115 (156) 118 (160) 98 (133)
5
/8 0.6250 135 (183) 113 (153) 191 (259) 159 (216) 164 (222) 136 (184)
3
/4 0.7500 240 (325) 200 (271) 339 (460) 282 (382) 290 (393) 241 (327)
7
/8 0.8750 386 (523) 322 (437) 545 (739) 455 (617) 467 (633) 390 (529)
1 1.0000 579 (785) 483 (655) 818 (1,109) 681 (923) 701 (951) 583 (791)
Cap Screws
Torque values shown are for turning the nut while holding the head of the bolt with a wrench. If the application demands tightening by the bolt head,
increase the torque slightly (by 5-20 percent depending on the bolt length) to allow for the normal twist of the bolt shank.
Dry Lubed Dry Lubed Dry Lubed
Appendix Torque Values
Torque With Self-Locking Nuts Torque Without Self-Locking Nuts
Fitting Size in-lbs (Nm) in-lbs (Nm)
-2 60 to 70 (7 to 8) 85 to 95 (10 to 11)
-3 120 to 140 (14 to 16) 160 to 180 (18 to 20)
-4 180 to 200 (20 to 23) 205 to 235 (23 to 27)
-5 245 to 275 (28 to 31) 245 to 275 (28 to 31)
-6 300 to 340 (34 to 38) 300 to 340 (34 to 38)
-8 545 to 595 (62 to 67) 545 to 595 (62 to 67)
-10 690 to 750 (78 to 85) 1,010 to 1,110 (114 to 125)
-12 910 to 1,010 (103 to 114) 1,250 to 1,350 (141 to 153)
-14 1,675 to 1,825 (189 to 206) 1,675 to 1,825 (189 to 206)
-16 1,845 to 1,995 (208 to 225) 1,895 to 1,945 (214 to 220)
-20 2,550 to 2,850 (288 to 322) 2,550 to 2,850 (288 to 322)
-24 2,850 to 3,150 (322 to 356) 2,850 to 3,150 (322 to 356)
-32 3,700 to 4,100 (418 to 463) 3,700 to 4,100 (418 to 463)
Upper values are for stainless steel.
SAE O-Ring Fittings
Misalignment
of marks show
how much nut
was tightened
Tube and JIC Fittings
Rotate Number
Tube Size Fitting Size of Hex Flats
1
/4 -4 2
5
/16 -5 2
3
/8 -6 1
1
/2
1
/2 -8 1
1
/2
5
/8 -10 1
1
/2
3
/4 -12 1
1
/4
1 -16 1
1
1
/4 -20 1
1
1
/2 -24 1
Basic JIC Symbols
Appendix Basic JIC Symbols
Methods of Operation
Spring
Manual
Manual, rotary
Push button
Push/pull lever
Pedal or treadle
Mechanical
Detent
Pressure compensated
Solenoid, single winding
Servo motor
Pilot pressure
Lines
Remote supply
Internal supply
Line, pressure or tank
Line, sense (for control)
Component enclosure
Flow, direction of
Lines crossing
Lines joining
Line with fixed restriction
Flow control adjustable, non-compensated
Flow control adjustable
(temperature and pressure compensated)
Station, testing, measurement,
power take-off or plugged port
or
)
Hydraulic
Pneumatic
Double-acting
Single-acting, internal spring
Single-acting, external spring
Check
Counterbalance
On - off (manual shut-off)
Pressure relief
Pressure reducing
Two-position, two connection
Two-position, three connection
Two-position, four connection
Three-position, four connection
Two-position, in transition
Valves capable of infinite
positioning (horizontal bars
indicate infinite positioning ability)
Shuttle valve
Typical closed center spool
Typical open center spool
Cylinders Valves
Reservoir
Line, to reservoir
Vented manifold
Vented
Pressurized
Above fluid level
Below fluid level
Fluid Storage
Hydraulic oscillator
Hydraulic motor
Fixed displacement
Variable displacement
Bidirectional
Motors
Pumps
Hydraulic pump
Fixed displacement
Variable displacement
)
Variable component
(run arrow through symbol at 45 degrees)
Pressure compensated units
(arrow parallel to short side of symbol)
Direction of shaft rotation
(assume arrow on near side of shaft)
Flowmeter
Pressure switch
Pressure gauge
Pressure sensor
Temperature gauge
Quick disconnect
Internal combustion engine
Accumulator, spring loaded
Accumulator, gas charged
Weighted
Filter, strainer
Filter with adjustable bypass
Heater
Cooler
Temperature controller
Temperature cause or effect
Miscellaneous
(
(
Hydraulic System Schematics
Appendix Hydraulic System Schematics
n
n
358-00040A
3-04
AM800/900
Appendix Troubleshooting Chart
Troubleshooting Chart
Symptom
Pump is noisy.
Excessive heat
buildup (180+).
Boom functions
operate slowly.
One boom function
operates slowly.
Test Procedure/Corrective Action
Fill the reservoir to the proper level.
Fully open the suction line shutoff valve.
Check for kinked or plugged suction hose. Remove restriction.
Make sure suction hose is 1
1
/4 minimum.
Tighten loose hydraulic fittings.
Correct misalignment.
Remove restriction or replace line.
Use hydraulic oil of proper viscosity.
Reduce pump speed.
Adjust the throttle cylinder.
Check the outrigger power beyond plug seals for leaks.
Make sure the relief valve settings are properly set.
Check the boom tip tool valve for leakage. Replace if necessary.
Change power tools or adjust the tool flow control.
Lubricate or replace as necessary.
Adjust the pilot pressure to 350 psi.
Adjust the forced opening on the upper control valve to the proper
value.
Make sure the lower control valve handles are not hitting the
turntable cover, hoses, etc.
Adjust the engine rpm.
Properly adjust the valve spool stops.
Check the pump with a flowmeter. Replace if defective.
Adjust the standby pressure to 350 psi.
The restricted area will be warmer to the touch than the rest of the
system. Remove the restriction.
Test by connecting a flowmeter at valve input and back to reservoir.
Replace the blocking valve if necessary.
Operate the lower control handle to verify that function operates
properly from that control.
Clean or replace the check valve.
Possible Cause
The reservoir oil level is too low.
Restriction in pump suction line.
Air entering suction line.
PTO/pump connection misaligned.
Cavitation.
The reservoir oil level is too low.
The engine speed is set too high.
Excessive internal system
leakage.
Power tools improperly sized for
gpm flow of tool circuit.
Lower control valve spools do not
fully shift.
Engine rpm is set too low or the
throttle does not increase engine
speed.
Improperly adjusted lower control
valve spool stop(s).
Low pump flow.
Low pump standby pressure.
Restriction in the pressure line.
Blocking valve is not fully open.
Purge check not seating.
Possible Cause
Tool signal not working.
Tool pressure is set too low.
Power tools improperly sized
for gpm flow of tool circuit.
Engine throttle does not work.
Pump standby pressure is
too low.
Tool valve is on.
Tool blocking valve is defective.
The pump signal is not bleeding
off.
The control selector valve is in
the Lower Controls position.
The control selector valve is
not fully shifted.
Air in the hydraulic line.
Low or no pilot pressure.
Improper upper control interlock
valve cable adjustment.
Blocking valve of the upper
control valve is not fully shifted.
Outriggers are not properly set.
Improper pilot pressure.
Low system pressure.
Malfunctioning lower control
blocking valve.
No signal at the lower control
valve.
No signal to the pump control
manifold.
Symptom
Tools, jib, winch
operate slowly or
will not work under
load.
Pump pressure
oscillates during
operation.
The engine and
pump remain
loaded all the time.
No functions from
the upper controls.
Only the outriggers
and power tools
operate.
Replace the tool signal pressure reducing valve.
Adjust the tool pressure reducing valve.
Change power tools or adjust the tool flow control.
Adjust or replace the engine throttle control.
Adjust to 350 psi.
Turn the lower or upper tool circuit valve off.
Replace the tool blocking valve cartridge.
Open the signal drain line needle valve (in turntable or pedestal).
Readjust 1
1
/2 turns open.
Place the control in the Upper Controls position.
Check the operation of the upper/lower control selector valve.
Replace if defective.
Purge all air out of the lines.
Test and/or adjust standby pressure to 350 psi.
Test and/or adjust pilot pressure to 350 psi.
Adjust the cable.
Check the operation of the blocking section of the upper control
valve. If defective, replace the spool for the blocking section.
Properly set the outriggers. All interlock switches must be activated
for unit functions to operate.
Test and/or adjust the pilot pressure to 350 psi.
Test and/or adjust the system pressure to 3,000 psi.
Clean or replace the blocking valve.
Check the relief valve in the lower control housing.
Replace if necessary.
Check the blocking valve in the inlet manifold housing.
Replace if necessary.
Check the pilot pressure reducing valve at the test port
quick disconnect. Replace the valve if necessary.
The seals may be leaking in the rotary joint if the signal is reaching
the rotary joint but not the pump control manifold.
Check for blocked, plugged, or cut hydraulic lines. If necessary,
repair or replace.
Turn the lower or upper tool circuit valve on.
Release the interlock trigger on the single handle control.
Remove and cap the pilot port line of the tool control valve to
determine if the blocking valve is malfunctioning.
Remove and cap TP port line of the tool control valve to determine
if the system is receiving an external signal.
Check for pressure at the signal port of the tool control valve.
Lubricate or replace as necessary.
Remove the restriction or replace the line.
Clean the valve in solvent and blow it dry with compressed air.
Replace the valve.
Replace the seals in the cylinder.
Replace the counterbalance valve.
Remove the valve and adjust using a test block.
Replace the counterbalance valve.
Replace the seals in the cylinder.
Check the PTO. If it is not engaged, properly engage it.
Open the shutoff valve in the suction line.
Check for a blocked, plugged, or cut suction line. If necessary, repair
or replace.
Check the Hydraulic Schematic. The signal port is port B, the drain
port is A. Check pump installation for proper shaft alignment. Side
loads on the pump drive shaft will cause complete loss of pressure.
If there is no pressure at the system pressure test port on the tool
control valve, check for loss of prime to pump. May be caused by a
leak in the pump suction line. Repair if necessary.
Connect a flowmeter to the pump and check flow.
Disassemble the pump compensator housing at the back of the
pump and check for excessive friction on the compensator spool or
contamination. Pump malfunction is usually caused by improper
installation, contamination, or lack of oil in the pump.
If the pump generates pressure when the signal line is connected
to the pump, the pump is not the problem.
Rebuild or replace the pump.
Replace the defective component.
Possible Cause
Tools are turned off.
The upper control interlock is
engaged.
The blocking valve is shifting
off or malfunctioning.
The tool system is receiving an
external signal.
The pump is not receiving a
signal from the tool control valve.
Sticky outrigger valve spools.
Blocked or plugged hydraulic line.
Pilot operated check valve
contamination.
Pilot operated check valve
malfunction.
Internal cylinder leakage.
Counterbalance valve
contamination.
Counterbalance valve
malfunction out of adjustment.
Internal cylinder leakage.
PTO is not engaged.
Hydraulic oil is not reaching the
pump.
Improperly plumbed pump.
No system pressure.
Pump is not operating properly.
Hose, tube, fitting, seal failure,
etc.
Symptom
All functions
operate except
power tools.
All functions
operate except
outriggers.
The outrigger leg
does not hold under
load.
The lower boom
cylinder does not
hold under load.
Nothing operates.
Severe hydraulic
leak.
Appendix Dielectric Test Forms
Dielectric Test Form for AM Series
Category C 46 kV and Below
Polyethylene Pad
Ground/Return
Leads
Position A
Controls
High Voltage
Test Leads
Ground
Position B
Upper Boom Test
Lower Boom Test
Procedure
1. Read and understand the dielectric test information in the Maintenance Manual and ANSI requirements.
2. Insulate the vehicle from ground by placing polyethylene pads beneath each tire and outrigger leg.
3. The preferred test is with the unit in Position A. Position B may be used for an inside facility with limited test
space. When using Position B place the bottom of the platform 15 feet from the ground. Electrical connections
are the same for both positions.
4. Electrically bond all metal at the boom tip and the booms.
5. Attach the ground/return leads to the vehicle.
6. Attach the high voltage test lead (insulated from ground) to the lower boom for the lower boom test and to the
upper boom for the upper boom test as shown.
7. Do not use cancel (null) circuit if the tester is so equipped.
8. To test the upper boom, gradually increase the voltage to 100 kV. Hold at 100 kV (60 hertz) for 3 minutes
continuously. If flashover occurs or the leakage rate exceeds 1,000 microamps, the unit has failed the test.
Record leakage reading.
9. To test the lower boom, gradually increase the voltage to 50 kV. Hold at 50 kV (60 hertz) for 3 minutes continu-
ously. If flashover occurs or the leakage rate exceeds 3,000 microamps, the unit has failed the test. Record
leakage reading.
General Information
Model number __________________________________ Serial number ____________________________________
Test device number _____________________________ Test position _____________________________________
Conclusion
Date _________________________ Test performed by __________________________________________________
Upper boom leakage reading (microamp) ____________ Lower boom leakage reading (microamp) ______________
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
Bonding
Jumper
Bonding
Jumper
Control Leads High Voltage
Transformer

Category B 46 kV and Below
Polyethylene Pad
Ground/
Return
Leads
Position A
Controls
High Voltage
Leads
Ground
Position B
Control Leads
Test Band
Meter Receptacle
Ground
(for upper boom test)
Procedure
5. Attach the ground and test leads for the upper boom test as shown.
7. Gradually increase the voltage to 27 kV. Hold at 27 kV (60 hertz) for 1 minute continuously. If flashover occurs
or the leakage rate exceeds 27 microamps, the unit has failed the test. Record leakage reading.
8. Gradually increase the voltage to 54 kV. Record leakage when 54 kV (60 hertz) is reached. If flashover occurs
9. Hold the voltage at 54 kV (60 hertz) for 1 minute continuously. If flashover occurs or the leakage rate exceeds
54 microamps, the unit has failed the test. Record leakage reading.
10. Gradually increase the voltage to 80 kV. Hold at 80 kV (60 hertz) for 10 seconds. If flashover occurs or the
leakage rate exceeds 80 microamps, the unit has failed the test. Record leakage reading.
11. Remove the ground and test leads from the upper boom. Attach the test leads for the lower boom test as
shown.
12. Gradually increase the voltage to 50 kV. Hold at 50 kV (60 hertz) for 3 minutes continuously. If flashover occurs
or the leakage rate exceeds 3,000 microamps, the unit has failed the test. Record leakage reading.
General Information
Model number _________________________________ Serial number ____________________________________
Upper Boom Test
Leakage reading (microamp) at: 27 kV _______ 54 kV _______ 54 kV after 1 minute _______ 80 kV _______
Upper Boom Test
Lower Boom Test

Bonding
Jumper
High Voltage
Transformer
Lower Boom Test
Leakage reading (microamp) _____________________
Conclusion
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
Category B 69 kV
Procedure
5. Attach the ground and test leads for the upper boom test as shown.
7. Gradually increase the voltage to 40 kV. Hold at 40 kV (60 hertz) for 1 minute continuously. If flashover occurs
8. Gradually increase the voltage to 80 kV. Record leakage when 80 kV (60 hertz) is reached. If flashover occurs
9. Hold the voltage at 80 kV (60 hertz) for 1 minute continuously. If flashover occurs or the leakage rate exceeds
80 microamps, the unit has failed the test. Record leakage reading.
10. Gradually increase the voltage to 120 kV. Hold at 120 kV (60 hertz) for 10 seconds. If flashover occurs or the
leakage rate exceeds 120 microamps, the unit has failed the test. Record leakage reading.
11. Remove the ground and test leads from the upper boom. Attach the test leads for the lower boom test as
shown.
12. Gradually increase the voltage to 50 kV. Hold at 50 kV (60 hertz) for 3 minutes continuously. If flashover occurs
or the leakage rate exceeds 3,000 microamps, the unit has failed the test. Record leakage reading.
General Information
Upper Boom Test
Leakage reading (microamp) at: 40 kV _______ 80 kV _______ 80 kV after 1 minute _______ 120 kV _______
Polyethylene Pad
Ground/
Return
Leads
Position A
Controls
High Voltage
Leads
Ground
Position B
Control Leads
Test Band
Meter Receptacle
Ground
(for upper boom test)
Upper Boom Test
Lower Boom Test

Bonding
Jumper
High Voltage
Transformer
Lower Boom Test
Leakage reading (microamp) ______________________
Conclusion
Date __________________________ Test performed by _________________________________________________
Pass ______ Fail (reason) __________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
Procedure
3. Wrap a 0.375 to 1.000 inch diameter spring around the control handle as shown. Conductive aluminum foil may
be used in lieu of a spring.
4. Attach the ground/return leads to the spring on the control handle as shown.
5. Attach the high voltage test lead (insulated from ground) to the control base or platform mounting bracket. This
lead must contact a bare metal surface. (The bellows must be in place for this test.)
6. Use the lower controls to raise or extend the upper boom the minimum distance as required on the unit dielec-
tric test form.
8. To test the control, gradually increase the voltage (refer to the chart). Hold at the appropriate voltage for 3
minutes continuously. If flashover occurs or the leakage rate exceeds the appropriate microamps from the
chart, the control has failed the test. Record leakage reading.
General Information
Test device number _______________________________________________________________________________
Conclusion
Test conducted AC ____________________________________ DC _____________________________________
Curb side control leakage reading (microamp) _________ Street side control leakage reading (microamp) ________
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
Signature of Technician _______________________________________ Date of Test ________________________
Dielectric Test Form for Insulated Single Handle Control
Ground/Return Lead Attached to
Spring Wrapped Around Handle
High Voltage Lead
Control Lead
Tester
Test Voltage Leakage
AC 40 kV 400
DC 56 kV 28
Maximum
Test Microamp
Bellows
Either method may be used.
Wet Method Setup
1. Connect a ground lead to the steel tank.
2. Immerse the liner in the tank and fill with conductive fluid until
the level around both the inner and outer surfaces of the liner
is within six inches of the top of the liner.
3. Suspend the high voltage lead in the fluid within the liner.
Dry Method Setup
1. Refer to TRS-0001 to apply conductive foil to the liner and
conduct the test.
2. Connect a ground to the outer conductive foil.
3. Connect the high voltage lead to the inner conductive foil.
Testing (Wet or Dry)
1. Apply the test voltage to the conductive fluid or foil. Voltage may be either 35 kV (60 hertz) for 1 minute or 100
kV DC for 3 minutes.
2. If flashover occurs, or the liner wall punctures, the liner has failed the test.
3. Turn off the test voltage (be sure the voltage meter indicates zero voltage). Remove the high voltage lead.
Remove the liner from the tank or remove the foil covering.
4. The test for more than one liner may be recorded on the same form providing the same setup is used to
eliminate external variables.
Conclusion
Unit Serial No. Liner Part No. Liner Serial No. Pass (Initials) Fail (Reason)
_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________
Wet/dry ___________ Test voltage __________ Test device number ______________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
Periodic Dielectric Test Form for Platform Liners
Ground
Liner
Ground
Liner
Tank
Conductive
Foil
High Voltage Lead
Conductive
Fluid
High Voltage Lead
Six Inch Maximum
Six Inch Maximum
11-06
Appendix Stability Test Forms
ANSI Stability Test Form, AM800/900 Series (Without Jib)
Procedure
1. Perform the stability test on a level surface and on a five degree slope in accordance with applicable ANSI
requirements.
2. Fill out all information on this form as a record of a completed stability test.
3. Position the lower boom at a five degree angle above horizontal and place the upper boom vertical.
4. Calculate the platform test weight by multiplying 1.5 for the Level Surface Stability Test and 1.33 for the Five
Degree Slope Stability Test times the platform capacity shown on the serial number placard.
5. Subtract the weight of liners, tools, etc., from the test weight.
6. Load the platform with the proper weight.
7. After the test has been completed, torque all accessible rotation bearing cap screws to 325 foot-pounds using a
circular pattern (only required at time of initial installation of unit on chassis).
8. After the test has been completed, torque the rotation gearbox mounting cap screws to 225 foot-pounds (only
required at time of initial installation of unit on chassis).
General Information
Model number ___________________________ Serial number ___________________________________________
Platform type ___________________________ Platform capacity (lbs) ____________________________________
Counterweight added to unit (lbs) _____________________________________________________________________
Location of counterweight relative to rear axle __________________________________________________________
Level Surface Test
Platform test weight (lbs) _________________ Thickness of outrigger pads (0 if not used) ___________________
Side of vehicle on low side of slope __________________________________________________________________
Conclusion
Rotation bearing cap screws torqued ____________ Rotation gearbox mounting cap screws torqued ____________
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
Signature of Technician _______________________________________ Date of test ________________________
CSA Stability Test Form, AM800/900 Series (Without Jib)
Procedure
1. Perform the stability test on a level surface and on a five degree slope in accordance with applicable CSA
requirements.
3. Fully raise the lower boom and place the upper boom horizontal.
4. Calculate the platform test weight by multiplying two times the platform capacity shown on the serial number
placard.
5. Subtract the weight of liners, tools, etc., from the test weight.
6. Load the platform with the proper weight.
General Information
Platform type ____________________________ Platform capacity (lbs) ____________________________________
Counterweight added to unit (lbs) ____________________________________________________________________
Level Surface Test
Platform test weight (lbs) __________________ Thickness of outrigger pads (0 if not used) ___________________
Side of vehicle on low side of slope __________________________________________________________________
Conclusion
Pass _____ Fail (reason) _______________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
Signature of Technician _______________________________________ Date of test _________________________
ANSI Stability Test Form, AM800/900 Series (With Jib)
Five Degree Slope Stability Test Chart
Single Side Hung 350 lbs. 525 lbs. 750 lbs. - 4 0 1,300 lbs. - 2
Double Side Hung 300 lbs. 900 lbs. 250 lbs. - 4 0 1,150 lbs. - 2
Single Side Hung 350 lbs. 525 lbs. 420 lbs. - 4 0 950 lbs. - 2
Double Side Hung 300 lbs. 900 lbs. 00000 0 900 lbs. - 2
Platform Jib Test Platform Jib Test
Test Weight Weight at D Test Weight Weight at D
Capacity
Model Platform Options Per Platform
Standard Test A
Level Surface Stability Test Chart
Alternate Test B
AM800
AM900
Double Side Hung 300 lbs. 800 lbs. 220 lbs. - 4 0 1,000 lbs. - 2
Single Side Hung 350 lbs. 465 lbs. 375 lbs. - 4 0 850 lbs. - 2
Double Side Hung 300 lbs. 800 lbs. 00000 0 800 lbs. - 2
Capacity
Standard Test A Alternate Test B
AM800
AM900
Procedure
1. Perform the stability test on a level surface and on a five degree slope in accordance with applicable ANSI
requirements.
4. Find the model being tested in the chart for the test being performed.
5. Position the jib so the distance (D) from the center of the load line to the center of the jib pivot equals either two
or four feet, as designated in the stability charts.
6. If the unit is equipped with platform rotators, the platforms must be rotated to the position furthest from the
7. Alternate Test B is a more conservative test that may be used instead of Standard Test A to reduce weight
handling time. On units which require counterweight, Standard Test A may be preferred to minimize counter-
weight.
8. Subtract the weight of liners, tools, etc., from the test weight shown in the stability charts. For platform capaci-
ties not shown, use a test weight of 1.5 times rated load for the Level Surface Stability Test and 1.33 times
rated load for the Five Degree Slope Stability Test.
9. Load the jib and the platform with the proper weight.
General Information
Level Surface Test
Test conducted A ______ B ______ Platform test weight (lbs) ___________ Jib test weight (lbs) ____________
Thickness of outrigger pads (0 if not used) _____________________________________________________________
Side of vehicle on low side of slope __________ Thickness of outrigger pads (0 if not used) ____________________
Conclusion
Rotation bearing cap screws torqued ___________ Rotation gearbox mounting cap screws torqued ____________
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
CSA Stability Test Form, AM800/900 Series (With Jib)
Single Side Hung 350 lbs. 700 lbs. 1,000 lbs. - 4 0 1,750 lbs. - 2
Double Side Hung 300 lbs. 1,200 lbs. 330 lbs. - 4 0 1,500 lbs. - 2
Double Side Hung 300 lbs. 1,200 lbs. 000000 0 1,200 lbs. - 2
Capacity
Standard Test A
Level Surface and Five Degree Slope Stability Test Chart
Alternate Test B
AM800
AM900
Procedure
1. Perform the stability test on a level surface and on a five degree slope in accordance with applicable CSA
requirements.
4. Find the model being tested in the chart for the test being performed.
5. Position the jib so the distance (D) from the center of the load line to the center of the jib pivot equals either two
or four feet, as designated in the stability chart.
6. If the unit is equipped with platform rotators, the platforms must be rotated to the position furthest from the
7. Alternate Test B is a more conservative test that may be used instead of Standard Test A to reduce weight
handling time. On units which require counterweight, Standard Test A may be preferred to minimize counter-
weight.
8. Subtract the weight of liners, tools, etc., from the test weight shown in the stability chart. For platform capaci-
ties which are not shown, use a test weight of two times rated load for the Level Surface Stability Test and the
Five Degree Slope Stability Test.
9. Load the jib and the platform with the proper weight.
General Information
Level Surface Test
Thickness of outrigger pads (0 if not used) __________________________________________________________
Side of vehicle on low side of slope __________ Thickness of outrigger pads (0 if not used) ____________________
Conclusion
Pass ______ Fail (reason) _________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________

Am800-900 M

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