DB37

Maintenance
and Parts Manual

www.altec.com

Altec Industries, Inc. reserves the right to improve models and change specifications without notice.
749-10061
2013
Copyright  2013 by Altec Industries, Inc.
All rights reserved. No part of this publication may be used or reproduced by any means, or stored in a
database or retrieval system, without prior written permission of the publisher. Making copies of any part
of this publication for any purpose other than personal use is a violation of United States copyright laws.
 Preface
This unit is the result of Altec’s advanced technology and quality awareness in design, engi-
neering, and manufacturing. At the time of delivery from the factory, this unit met or exceeded
all applicable requirements of the American National Standards Institute. All information,
illustrations, and specifications contained within this manual are based on the latest product
information available at the time of publication. It is essential that all personnel involved in
the use and/or care of this unit read and understand the Operator’s Manual.

Given reasonable care and operation, according to the guidelines set forth in the manuals
provided, this unit will provide many years of excellent service before requiring major main-
tenance.

The scope of this manual is limited to periodic maintenance. It does not cover methods that
may be required to inspect and repair major damage to the unit. Impacts to and excessive
forces on the hydraulic utility equipment, through vehicular accidents, rollovers, excessive
loading, and the like, may result in structural damage not obvious during a visual inspection.
If the hydraulic utility equipment is subjected to such impacts or forces, a qualified person
may need to perform additional testing such as acoustic emissions, magnaflux or ultrasonic
testing as applicable. If structural damage is suspected or found, contact Altec for additional
instructions.

Warning
Death or serious injury can result from component failure. Continued use of a mobile
unit with hidden damage could lead to component failure.

Never alter or modify this unit in any way that might affect the structural integrity or operational
characteristics without the specific written approval of Altec Industries, Inc. Unauthorized
alterations or modifications will void the warranty. Of greater concern, is the possibility that
unauthorized modification could adversely affect the safe operation of this unit, resulting in
personal injury and/or property damage.

Danger
Death or serious injury will result from unprotected contact with energized conductors.
Non-insulating units have no dielectric rating. Maintain safe clearances, as defined by
federal, state, and local authorities, and your employer, from energized conductors.

No unit can provide absolute safety when in proximity to energized conductors. No unit is
designed or intended to replace or supersede any protective device or safe work practice
relating to work in proximity to energized conductors. When in proximity to energized con-
ductors, this unit shall only be used by trained personnel using their company’s accepted
work methods, safety procedures, and protective equipment. Training manuals are available
from a variety of sources.

Set-up requirements, work procedures, and safety precautions for each particular situation
are the responsibility of the personnel involved in the use and/or care of this unit.
 Table of Contents

Section 1 — Introduction
About This Manual…..................................................................................................... 1

Section 2 — Unit Specifications

General Specifications................................................................................................... 3
Component Identification............................................................................................... 4

Section 3 — Safety
Safety Instructions......................................................................................................... 7
Disclaimer of Liability..................................................................................................... 7

Section 4 — Preventive Maintenance and Inspection

Equipment Storage........................................................................................................ 9
Protective Measures................................................................................................ 9
Hydraulic System........................................................................................................... 9
Cleanliness Precautions........................................................................................ 10
Filtration................................................................................................................. 10
Oil Specifications................................................................................................... 11
Oil Condition.......................................................................................................... 12
Changing Oil and Flushing the System................................................................. 13
Lubrication................................................................................................................... 14
Lubrication Chart and Diagram.............................................................................. 15
Structures..................................................................................................................... 18
Care of Exterior Surfaces...................................................................................... 18
Welds..................................................................................................................... 19
Fasteners..................................................................................................................... 19
Rotation Bearing Cap Screws............................................................................... 23
Rotation Gearbox Mounting Cap Screws.............................................................. 24
Digger Motor Cap Screws..................................................................................... 24
Slide Pad Bearing Cap Screws............................................................................. 24
Pins and Pin Retainers................................................................................................ 25
Pin Installation Into Self-Lubricating Bearings....................................................... 26
Bearings....................................................................................................................... 26
Self-Lubricating Bearings...................................................................................... 26
Tapered Roller Bearings........................................................................................ 27
Slide Pad Bearings................................................................................................ 27
Rotation Bearing.................................................................................................... 28
Cylinders...................................................................................................................... 30
Hydraulic Lines............................................................................................................ 30
Fiberglass and Plastic Components............................................................................ 30
Cleaning................................................................................................................ 31
Plastic.................................................................................................................... 31
Determining the Degree of Boom Damage........................................................... 31
Repair.................................................................................................................... 32
Winch Line................................................................................................................... 34
Synthetic Winch Line............................................................................................. 34
Auger Windup Sling..................................................................................................... 35
Synthetic Sling....................................................................................................... 35
Auger Stow Bracket Clevis.......................................................................................... 36
Care of Tracks.............................................................................................................. 36
Accident Prevention Signs........................................................................................... 37
Accident Prevention Signs Diagram...................................................................... 38
Section 5 — Hydraulic System
Protection Systems...................................................................................................... 47
Hydraulic Overload Protection (HOP).................................................................... 47
Electronic Side Load Protection System............................................................... 48
Boom Stow Protection........................................................................................... 49
Auger Stow Protection........................................................................................... 50
Oil Reservoir................................................................................................................ 50
Pumps.......................................................................................................................... 50
Valves.......................................................................................................................... 51
Drive/Outrigger/Tools Valve................................................................................... 51
Main System Relief Valve...................................................................................... 51
Boom Functions Valve........................................................................................... 52
Pole Guide/Upper Tools/Auger Release Valve...................................................... 53
Holding Valves....................................................................................................... 53
Cavitation and Aeration................................................................................................ 53
Air Bleeding.................................................................................................................. 54
Relief Valve Cartridge Purging..................................................................................... 54
Leakage....................................................................................................................... 55
Heat Generation........................................................................................................... 55
Hydraulic Lines............................................................................................................ 55
Fittings and Valve Cartridges....................................................................................... 56
Torque and Tightening Procedures........................................................................ 56
Valve Cartridges.................................................................................................... 58
Cylinders...................................................................................................................... 58
Radial Outrigger Cylinder...................................................................................... 59
Lift Cylinder............................................................................................................ 60
Intermediate Boom Cylinder.................................................................................. 60
Upper Boom Cylinder............................................................................................ 62
Auger Latch Cylinder............................................................................................. 63
Pole Guide Cylinder............................................................................................... 63
Pole Guide Tilt Cylinder......................................................................................... 63

Section 6 — Mechanical Systems

Rotary Joint.................................................................................................................. 65
Rotation System........................................................................................................... 66
Rotation Bearing.................................................................................................... 67
Rotation Bearing Cap Screws .............................................................................. 68
Rotation Gearbox.................................................................................................. 69
Upper Boom................................................................................................................. 70
Winch........................................................................................................................... 71
Platform Brake............................................................................................................. 71
Digger Transfer Mechanism......................................................................................... 71

Section 7 — Electrical System

On/Off Circuit............................................................................................................... 73
Proportional Circuit...................................................................................................... 73
Multiplexed Controls.................................................................................................... 74
Below Rotation Valve Driver........................................................................................ 74
Above Rotation Valve Driver........................................................................................ 74
Cable Assemblies........................................................................................................ 75
Multiplex Cable Connectors................................................................................... 75
Calibration and Diagnostic Instrument (CADI)............................................................. 75
Power Distribution Module (PDM)................................................................................ 76
Outrigger Interlock System.......................................................................................... 76
 Lower Control Panel.................................................................................................... 76
Hand Controls........................................................................................................ 76
Slip Ring....................................................................................................................... 77
Tilt Alarm...................................................................................................................... 78

Section 8 — Troubleshooting, Testing, and Adjustments

Troubleshooting Procedure.......................................................................................... 79
Hydraulic System......................................................................................................... 79
Cycle Times........................................................................................................... 79
Main System Relief................................................................................................ 79
Pilot System Pressure........................................................................................... 80
Pump Flow ............................................................................................................ 80
Outriggers.............................................................................................................. 82
Lower Tool Circuit.................................................................................................. 83
Upper Tool Circuit.................................................................................................. 84
Rotary Joint........................................................................................................... 85
Outrigger Interlock System.................................................................................... 86
Pulsar Valves......................................................................................................... 86
Lift Cylinder............................................................................................................ 86
Intermediate and Upper Boom Extension Cylinders.............................................. 87
Holding Valves....................................................................................................... 89
Track Tension........................................................................................................ 91
Mechanical System...................................................................................................... 91
Rotation Gearbox ................................................................................................. 91
Platform Brake....................................................................................................... 92
Electrical System......................................................................................................... 93
Failure Identification.............................................................................................. 93
Circuit Protection................................................................................................... 94
Proximity Switches................................................................................................ 94
Outrigger Interlock System.................................................................................... 95
Programmable Settings......................................................................................... 95
Boom Functions Speeds ...................................................................................... 96
Protection Systems...................................................................................................... 96
Hydraulic Overload Protection (HOP) ................................................................... 96
Load Indicator Gauge............................................................................................ 98
Electronic Side Load Protection............................................................................ 99
Boom Stow Protection......................................................................................... 101
Auger Stow Protection......................................................................................... 101
Lower Boom Pressure Limiter............................................................................. 102
Rotation Pressure Limiter ................................................................................... 102
Extension Pressure Limiter.................................................................................. 103
Tilt Sensor Alarm................................................................................................. 104
Manually Lowering/Stowing the Unit.......................................................................... 105
Rotating the Turntable ........................................................................................ 105
Lowering the Booms ........................................................................................... 106
Manually Raising the Outriggers......................................................................... 106
Auxiliary Power Source.............................................................................................. 107

Section 9 — Dielectric and Stability Testing

Dielectric.................................................................................................................... 109
Stability...................................................................................................................... 109
Appendix
Glossary
Service Tools and Supplies
Preventive Maintenance and Inspection Checklist
Accessory Checklist
Torque Values
Basic JIC Symbols
Hydraulic System Schematics
Basic Electrical Symbols
Wiring Line Diagrams
Troubleshooting Chart
Dielectric Test Forms
Stability Test Forms
 Section 1 — Introduction
the Altec device, subbase, outriggers, and the associated
About This Manual… interface with the vehicle.
This manual provides instruction to safely inspect, re-
pair, troubleshoot, and test the unit. Charts and figures Additional copies of this manual may be ordered through
are provided to support the text. Because options vary your Altec representative. Supply the model and serial
from one model to another, some figures may only be a number found on the serial number placard and the
representation of what is actually on the unit. manual part number from the front cover to assure that
the correct manual will be supplied.
Knowledge of the information in this manual combined
with proper skills and training in hydraulic, electrical, and This symbol is used throughout this manual to
mechanical systems, provide a basis for safely maintaining indicate danger, warning, and caution instruc-
the unit. Read and understand the applicable procedure tions. These instructions must be followed to
before beginning. Carefully follow each procedure. reduce the likelihood of personal injury and/or property
damage.
Contact the following organizations for additional infor-
mation. The terms danger, warning, caution, and notice repre-
sent varying degrees of personal injury and/or property
• American National Standards Institute (ANSI) damage that could result if the preventive instructions
A92.2 for aerial devices; A10.31 for digger derricks are not followed. The following paragraphs from ANSI
• American Public Power Association publications explain each term.
(Safety Manual for an Electric Utility)
• American Society for Testing and Materials (ASTM) Danger
• American Welding Society (AWS) Indicates a hazardous situation which, if not
• Canadian Standards Association (CSA) avoided, will result in death or serious injury. This
• European Committee for Standardization (CEN) signal word is to be limited to the most extreme
• Fluid Power Society (FPS) situations.
• Hydraulic Tool Manufacturer’s Association (HTMA)
• International Electrotechnical Commission (IEC) Warning
• International Organization for Standardization (ISO) Indicates a hazardous situation which, if not
• Occupational Safety and Health Administration avoided, could result in death or serious injury.
(OSHA)
Caution
Dealers, installers, owners, users, operators, renters, Indicates a hazardous situation which, if not
lessors, and lessees must comply with the appropriate avoided, may result in minor or moderate in-
sections of the applicable ANSI standard. jury. It may also be used to alert against unsafe
practices.
The Appendix contains reference items to help maintain
the unit. A glossary of industry terms is provided for your Notice
convenience. This glossary provides an understanding The preferred signal word to address practices
of the industry terms and phrases used in Altec manuals. not related to personal injury.
Throughout the manual, the term unit is used to describe

Section 1 — Introduction • 1
2 • Section 1 — Introduction
 Section 2 — Unit Specifications
compound, providing a smooth surface for moisture to
General Specifications bead. The outer surface has a smooth gelcoat finish to
This unit has a lower boom with telescoping intermediate protect the fiberglass.
and upper booms. The lower and intermediate booms are
steel. The upper boom is fiberglass. Figure 2.1 provides The nonconductive components, when properly main-
general unit specifications. tained, clean, dry, free from tracking, and in good condi-
tion as established by dielectric testing, will meet the
The basic structural components are the outriggers, track dielectric requirements of ANSI in effect at the time of
assembly, subbase, pedestal, turntable, lower boom, in- unit manufacture. The ratings of the unit must be known
termediate boom, and upper boom. The steel structures and understood by its users.
are manufactured in the form of a closed box or tubular
construction. This construction resists torsional loading. This unit shall be used near energized conductors only by
It also resists tension, compression, and bending loads. qualified operators who are fully trained and proficient as
Careful consideration has been given to the design and electrical linemen. Personnel using this equipment must
manufacturing process to minimize the possibility of be familiar with the hazards of contact with energized
fatigue cracks. conductors, for the protection of themselves, their co-
workers, and the public. The nature of electrical hazards
The upper boom is made of filament wound fiberglass. is described in the Operator’s Manual.
The inner fiberglass surface is impregnated with a wax

Item DB37
Maximum sheave height 36.7′ (11.19 m)
Sheave height
Intermediate and upper boom retracted 19.3′ (5.88 m)
Intermediate or upper boom extended 28.0′ (8.53 m)
Intermediate and upper boom extended 36.7′ (11.19 m)
Horizontal reach from centerline of rotation
Intermediate and upper boom retracted 12.2′ (3.72 m)
Intermediate or upper boom extended 21.2′ (6.46 m)
Intermediate and upper boom extended 30.2′ (9.21 m)
Intermediate boom extension 9.1′ (2.77 m)
Upper boom extension 9.0′ (2.74 m)
Boom articulation -6 to 75 degrees
Digger radius (minimum/maximum) 10.5/19.5′ (3.20/5.94 m)
Stowed travel height 8.0′ (2.44 m)
Maximum hydraulic system pressure 2,500 psi (172.4 bar)
Adjustable upper and lower tool circuit pressure 2,000 psi (137.90 bar)
Adjustable upper tool circuit flow 5 gpm (18.92 lpm)
Adjustable lower tool circuit flow 6 gpm (22.7 lpm)
Hydraulic pump output 16.5 gpm (62.5 lpm) at 3,600 rpm
Oil reservoir capacity 16.8 gallons (63.6 l)
Platform capacity 300 pounds (136.08 kg)
Pole carrier weight capacity 2,000 pounds (907.2 kg)
Pole carrier length capacity 50′ (15.2 m) long
Cargo carrier capacity 3,000 pounds (1,360 kg)
Maximum combined payload capacity 3,000 pounds (1,360 kg)
Figure 2.1 — Unit Specifications

Section 2 — Unit Specifications • 3

Component Identification

Pole Guide
Jib Upper
Boom
Tip

Digger Hanger
Bracket Upper Boom

Digger Link

Intermediate Boom
Digger

Auger
Extension
Shaft

Extension
Cylinder
Auger Stow Bracket

Auger
Lower Boom

Boom Angle
Indicator
Auger
Windup Sling
Winch

Slope Lift Cylinder Boom Rest

Capacity Indicator
Chart Turntable Rotation
Gearbox
Lower Diesel Fuel
Controls Tank

Pendant Cargo
Controls Platform
Outrigger Cylinder

Outriggers
Operator’s Battery Pedestal Hydraulic Tracks Carrier
Platform Reservoir Frame

4 • Section 2 — Unit Specifications

 Hydraulic Tilt
Pole Guide

Platform
Brake
Platform
Mounting Bracket

Platform Pin
Platform

Combined
Use Bracket

5′ Personnel Jib

Section 2 — Unit Specifications • 5

6 • Section 2 — Unit Specifications
 Section 3 — Safety
suitable work surfaces clear of obstructions for mainte-
Safety Instructions nance procedures. Do not stand or walk on surfaces that
It is essential that all personnel involved in the care of are not intended as such.
this unit read and understand the Operator’s and Main-
tenance Manuals. Safety alerts throughout the manuals General Maintenance Information
highlight situations in which accidents can occur. Give • Read and understand the complete procedure
special attention to all safety alerts. before beginning.
• Remove the pressure in a hydraulic circuit before
The safety information in this manual applies only to the disconnecting its components.
maintenance of this unit. Although procedures have been • Use lifting devices of suitable capacity to support
written to protect the mechanic and other personnel, and handle components.
there is no safety system to account for human error or • Use a test block to adjust the relief setting on
negligence. counterbalance holding valves.
• Be aware of your surroundings.
• Fully open all shutoff valves after servicing the unit.
Danger • Complete the required procedures before returning
Death or serious injury will result from unprotected the unit to operation.
contact with energized conductors. This unit does • After completing a procedure, check the oil level in
not provide protection from contact with or proximity the hydraulic reservoir and add oil if necessary.
to an electrically charged conductor when you are • Many inspections require the removal of covers.
in contact with or in proximity to another conductor After the inspection is complete, replace the covers
or any grounded device, material, or equipment. before returning the unit to service.
Maintain safe clearances from energized conductors.
Disclaimer of Liability
Warning
Altec Industries, Inc. will not be liable for unauthorized
Death or serious injury can result from careless or alterations or modifications of the unit. Altec Industries,
improper use of the unit. The mechanic bears ultimate Inc. will not be liable for improper or abusive operation
responsibility for following all regulations and safety of the unit.
rules of their employer and/or any state or federal law.
Do not alter or modify this unit in any way that might affect
Notice its structural integrity, dielectric integrity, or operational
characteristics without specific written approval from
Maintenance personnel must be trained in safe ser- Altec Industries, Inc.
vice procedures.
Unauthorized alterations or modifications will void the
Work practices may expose maintenance personnel to warranty. However, of a greater concern is the possibility
hazardous materials. Before using any chemical, read that unauthorized changes could adversely affect the unit’s
and understand the manufacturer’s label and the mate- operation that could endanger personnel and/or damage
rial safety data sheet (MSDS). These sheets explain property. Altec will not be responsible for unauthorized
emergency and first aid procedures and waste disposal alterations or modifications that cause death, serious
methods. Properly dispose of oil and hazardous materials. injury, and/or property damage.

Caution Altec Industries, Inc. assumes no liability for any personal

injury and/or property damage related to the use of this
Injury can result from slipping and falling. Use care
manual when performing testing, operating, maintenance
and suitable work platforms during maintenance.
and/or repair procedures on this Altec unit.
Maintenance procedures may require the use of ladders,
platforms, scaffolding, etc., to access the unit. Provide

Section 3 — Safety • 7
8 • Section 3 — Safety
 Section 4 — Preventive Maintenance and Inspection
Proper unit maintenance will reduce downtime, lower op- One of the most noticeable effects of prolonged periods
erating and repair costs, and extend equipment life. Safety of nonuse is seal deformation. By its nature, hydraulic
alone justifies a preventive maintenance program. This equipment generally has a number of heavy, cylindrical
section contains information on properly inspecting the actuators. As these components are allowed to rest in
hydraulic system, structures, individual unit components one position for a period of time, the seals on the piston
and lubrication. Use the Lubrication Chart and Diagram will tend to flatten along the loaded side. Since the seal
in this section when lubricating the unit. material is synthetic, its elasticity is limited and it may
not resume its original shape completely. At best, there
A Preventive Maintenance and Inspection Checklist is pro- will be some failure to seal well for a short period of time
vided in the Appendix. Use this checklist when performing after putting the equipment back into use. At worst, the
routine maintenance and inspections to insure no areas seal will never resume its original shape and will have
are overlooked. Refer to the engine, trailer, and track to be replaced.
drive manuals for more information on maintenance and
inspections of those components. Components may be Protective Measures
installed on your unit that require additional maintenance If it is known that equipment will be stored for a month
at different intervals outside the scope of the Preventive or more, some steps should be taken to preserve the
Maintenance and Inspection and Accessory Checklists. equipment.
Refer to these component manuals for more information.
Keep permanent, written, and dated records of all service 1. The best preservative is to fully cycle (operate) the
performed on the unit. equipment once weekly if even for a short time.

Routine maintenance is performed on different compo- 2. Coat exposed ferrous (iron or steel) bare metal
nents of the unit at different times (refer to the Preventive surfaces with a light grease or heavy oil compatible
Maintenance and Inspection Checklist in the Appendix with system hydraulic oil. This includes cylinder rods,
and the manuals for the engine, trailer, and track drive). shafts, gears, linkages, and unpainted parts.
More frequent maintenance may be necessary if the unit
is operated under severe conditions. In addition to the 3. Top off fluid reservoirs to allow as little air space as
Preventive Maintenance and Inspection Checklist recom- possible, to limit the effects of condensation. Remove
mendations, follow these recommendations on new units. excess oil before operating to limit the chance of
overflow when cylinders are cycled.
• Check oil level and collect sample for analysis.
• Measure the turntable tilt before using a new unit. 4. Cover or wrap exposed rubber or neoprene parts
• Change the return line filter after the first 15 to 25 with an ultraviolet resistant covering to shield the
engine hours. parts from sun exposure.
• Gearbox manufacturers recommend an initial oil
change after the first 15 to 25 engine hours. 5. Unplug electrical connectors and apply a dielectric
grease or an aerosol product designed for protect-
ing electrical connectors. Plug the connector back
Equipment Storage
together.
Mobile hydraulic equipment needs maintenance when
stored, or not used, for extensive periods of time. De- 6. Cover switch panels and control panels to prevent
pending upon the climate, lack of use may begin to have direct intrusion of rain or moisture, while allowing air
a negative effect in as little as two weeks. Storage for a to circulate over the panel.
period of several months will almost certainly produce
some deterioration of the equipment. 7. Cover personnel platforms to prevent the accumula-
tion of water in the platform.
Rust will form on unprotected ferrous metal surfaces very
quickly and water will collect inside unit structures. In dry 8. Shield fiberglass components from the sun and other
climates, gaskets will begin to shrink during long periods elements, if stored outside.
of nonuse, and lubricants will lose their ability to provide
lubrication. In cold climates, condensation may occur in
fluid reservoirs and other components.
Hydraulic System
Warning
Even when protective measures have been taken prior
to storage, some degradation of performance must be Death or serious injury can result if the recommended
expected when the equipment is put back into use. hydraulic oil is not used. Other fluids added to the

Section 4 — Preventive Maintenance and Inspection • 9

hydraulic system can affect the insulating capability Filler Breather Cap and Strainer Basket
of the unit. The filler breather cap is located on top of the fill hole of
the reservoir (refer to Figure 4.1).
Notice
Filler Breather Cap
Only use hydraulic oil as recommended. Other fluids
added to the hydraulic system can increase compo-
nent wear and affect the lubricating characteristics Strainer
of the oil. Basket

Maintaining the hydraulic system is critical to the proper

operation of the unit. Using the proper type of oil helps
to prevent many hydraulic system problems. Maintaining
the oil is also important. If the oil is dirty or contaminated,
components can be damaged.
Suction
Strainer
Check the oil level in the reservoir with the unit level and
the booms and outriggers stowed. Under these condi-
tions, the proper oil level is between the Add and Full
marks on the dipstick.
Figure 4.1 — Reservoir
Cleanliness Precautions
Contamination will ruin any hydraulic system. It is very The cap allows air to flow in and out of the reservoir as
important that no contaminants enter the system. Dirt, the oil level changes. It contains a filter that cleans the
water, and air are types of contaminants. They can enter air as it enters the hydraulic system. The fill hole strainer
the hydraulic system in many ways. Contaminants can basket keeps large particles from entering the reservoir
enter the system when filling the reservoir or changing when oil is poured into it. The cap has a built-in dipstick
filters. They can also enter when changing components with Full and Add marks. Use the marks to determine the
or performing other service procedures. oil level of the reservoir as described under Hydraulic Oil
Specifications in this section.
The following precautions will help protect the cleanliness
of the hydraulic system. Replace the filler breather cap (refer to Service Tools
and Supplies in the Appendix) as recommended by the
• Filter new oil with a 10 micron filter as it is added to Preventive Maintenance and Inspection Checklist. If the
the reservoir. unit is operated in an extremely dusty environment, the
• Clean hydraulic connections before opening them. cap may need to be changed more often.
• Cap or plug ports and lines opened for service.
• Keep replacement hoses, tubes, and other compo- Remove and flush out (or replace) the strainer basket
nents plugged while stored. any time it has collected dirt or other contaminants. Flush
• Make sure components are clean before installation. the strainer basket when the hydraulic oil is changed.
• Clean the reservoir and return line filter covers before
opening them. Suction Strainer
• Clean the filler breather cap before opening it. A suction strainer is located near the bottom of the res-
• After servicing the reservoir, immediately replace the ervoir at the outlet (refer to Figure 4.1).
cover.
• Make sure quick disconnect couplers are clean before The suction strainer has a pleated wire mesh screen.
connecting them. This screen prevents particles that are 300 micron or
• Do not spray water on the reservoir filler breather larger from entering the pump. One micron is 0.00039.
cap. This could force contaminants into the reservoir.
Clean the strainer whenever the hydraulic oil is changed.
Filtration Oil will not flow into the pump fast enough if the filter be-
The unit is equipped with a complete filtration system. comes clogged. If the pump does not receive sufficient
When properly maintained, this system will reduce con- oil flow, pump damage will result.
tamination of the hydraulic system. The filtration system
must be serviced regularly to be effective. Use the following procedure to remove and clean the filter.

10 • Section 4 — Preventive Maintenance and Inspection

 1. Wipe off the suction hose fittings on the side of the During the break-in period of a new unit, the hydraulic
reservoir. components will deposit break-in wear particles in the
return line filter cartridge. Change the return line filter
2. Remove the plug from the bottom of the reservoir after the first 15 to 25 hours. Then, change the cartridge
and drain the reservoir. as recommended by the Preventive Maintenance and
Inspection Checklist. If the unit is operated in very dusty
3. Remove the suction line, shutoff valve, and fitting conditions, replace the return line filter more often. Also,
from the outside of the reservoir. replace the filter after new oil has circulated through the
system for the first time.
4. Remove the suction strainer. As the strainer is re-
moved from the reservoir, be careful to not damage Always replace the return line filter cartridge with a genuine
the screen. Altec replacement part. Other filters may screw into the
filter housing, but may not have the same micron rating.
Also, other filters may allow oil to bypass at a different rate.
Warning
Death or serious injury can result from improper Oil Specifications
use of solvents. Follow the manufacturer’s label for Use high quality oil in the hydraulic system. The oil should
proper use and disposal. contain rust, oxidation, and corrosion inhibitors. It should
also contain antifoam and antiwear additives.
Caution
Hydraulic oils used in insulated equipment must possess
Injury can result from airborne particles entering the high demulsibility to allow the oil to separate from the
eyes. Wear appropriate safety equipment. water in the reservoir. These oils must pass the ASTM
D877 test for dielectric breakdown voltage of insulating
Eye protection must be worn at all times to prevent par- oils at 35 kilovolts or higher for new oil.
ticles of dirt, metal, or hydraulic oil from entering the eyes.
Hydraulic oil is commonly classified by viscosity. The
5. Clean the screen by flushing it with clean solvent. viscosity of hydraulic oil changes with temperature. The
Blow it dry with an air hose from the inside of the higher the viscosity index of an oil, the less the viscosity
screen to the outside. Check for holes or other dam- will change as the temperature changes. A multiviscosity
age. Replace the strainer if it is damaged. oil contains additives which increase the viscosity index.
Multiviscosity oils should have high shear stability to
6. Install the strainer in the reservoir. Connect the fitting, maintain oil performance by avoiding excessive change
shutoff valve, and suction line. in viscosity.

7. Install the drain plug and fill the reservoir with oil. The ability of hydraulic oil to provide adequate flow at low
temperatures is measured by its pour point. If the pour
Return Line Filter point is not low enough, oil will not flow into the pump
The return line filter is a 10 micron filter that cleans the at a fast enough rate when the pump is operated at low
oil as it enters the reservoir. It is mounted on the side of temperatures. This will cause cavitation, which can very
the reservoir. Particles trapped by the filter are collected quickly destroy the pump.
in the filter cartridge. This cartridge is disposable and is
available from your Altec representative (refer to Service
Tools and Supplies in the Appendix). Warning
Death or serious injury can result if the recommended
The return line filter is equipped with a bypass valve in hydraulic oil is not used. Other fluids added to the
the filter head. The bypass valve opens when there is hydraulic system can affect the insulating capability
a pressure drop of 25 psi (1.72 bar) or more across the of the unit.
filter cartridge. When the valve is open, oil flows directly
into the reservoir. This prevents the cartridge from col-
lapsing during cold weather or if it is clogged. Notice
Using a hydraulic fluid outside the temperature range
If the filter becomes clogged, oil will flow directly into it was prescribed for may cause system damage.
the reservoir through the bypass valve. The lack of oil
filtration will eventually damage hydraulic components. Only use hydraulic oil as recommended. Other fluids
added to the hydraulic system can increase compo-

Section 4 — Preventive Maintenance and Inspection • 11

nent wear and affect the lubricating characteristics • Water content test
of the oil. • Dielectric strength test (when requested)

Figure 4.2 shows hydraulic oil recommendations for differ- Before taking a sample of oil, operate the unit to circu-
ent temperatures. The requirements are for mineral based late the oil. Warm it to operating temperature. Take the
and biodegradable hydraulic fluids. Most companies can sample from the middle level of the reservoir, using a clean
supply equivalent oils. The oil selected for the hydraulic hand pump, such as a disposable syringe and a piece of
system depends on the temperature during unit operation. plastic tubing. If this is not available, the sample can be
drained from the bottom of the reservoir. Allow several
When refilling or changing hydraulic fluids it is recom- quarts of oil to flow out before collecting the sample. This
mended the replacement fluid meet oil cleanliness re- will remove any dirt and water that has collected in the
quirement 21/17/14 as specified by ISO 4406. reservoir near the drain.

Oil Condition If a sample container has not been provided by the labora-
An important part of hydraulic system preventive mainte- tory, use a wide mouth, screw top, clear glass container.
nance includes checking the condition of the hydraulic oil. Clean it with hot water and detergent. Rinse it thoroughly
and let it air dry before putting oil in it.
Periodic laboratory analysis is the most accurate method
of determining the condition of the hydraulic oil and de- Once the report is received, compare it to previous oil
termining when it should be changed. A visual inspection analysis reports for the same unit. This information will
may also be used to check oil condition. provide trends toward oil deterioration. It may give early
warnings of a problem developing within hydraulic system
A hydraulic oil supplier should be able to do testing or components.
recommend a test laboratory. The laboratory should
provide the following information. Notice
• Particle count Change the oil if the sample has any of the charac-
• Trace element analysis (component wear, outside teristics listed in Figure 4.3.
contaminants and oil additive concentrations)
• Viscosity test

Specification All Weather Oil Cold Weather Oil Warm Weather Oil
ISO grade 22 15 32
Ambient temperature range -10° to 95° F (-23° to 35° C) -50° to 60° F (-46° to 16° C) 40° F (4° C) and above
Viscosity @ 104° F (40° C) 24 cSt 15 cSt 32 cSt
Viscosity @ 212° F (100° C) 4.6 cSt 4.4 cSt 6.0 cSt
Pour point, biodegradable -31° F (-35° C) -58° F (-50° C) -31° F (-35° C)
Pour point, mineral based -48° F (-55° C) -76° F (-60° C) -49° F (-45° C)
Flash point (min) 302° F (150° C) 302° F (150° C) 302° F (150° C)
Dielectric strength (min) 35 kV 35 kV 35 kV
Four-ball wear, scar (max) 0.028 (0.70 mm) 0.028 (0.70 mm) 0.028 (0.70 mm)
Oxidation stability, TOST (min) 2,000 hours — 2,000 hours
Oxidation stability, RPVOT (min) 250 minutes 177 minutes 250 minutes
Water content (max) 63 ppm 38 ppm 63 ppm
Demulsibility, minutes to pass 15 10 15
Copper corrosion 1A 1A 1A
Rust test, pass/fail Pass Pass Pass
Foam test, pass/fail Pass Pass Pass
Figure 4.2 — Hydraulic Oil Viscosity Recommendations

12 • Section 4 — Preventive Maintenance and Inspection

 Condition Possible Cause
Dark color Oxidation; contamination
Cloudiness or milky appearance Presence of water or wax
Rancid or burned odor Oxidation
Increase in viscosity Oxidation; addition of improper fluids; presence of water
Decrease in viscosity Addition of improper fluids; additive deterioration
Separation of water or other fluids from the oil Presence of water; addition of improper fluids
Foreign particles or other visible contamination Contamination; emulsion of water with oil additives
Figure 4.3 — Hydraulic Oil Conditions

If making a visual inspection, compare the sample of oil • In climates with a wide variation in operating tempera-
to a sample of new oil of the same type. Also, compare tures between summer and winter months, change
it to previous samples taken from the same unit. Look for to an appropriate weight oil each spring and fall.
the signs of oil deterioration listed in Figure 4.3.
Replace the return line filter cartridge and filler breather
There are fluid contamination level detector kits available cap every time the hydraulic oil is changed. Also, clean
which allow for rapid, on-the-spot analysis of the hydraulic or replace the suction strainer.
system’s condition. Contact your Altec representative for
further information. A significant quantity of oil remains in the cylinders
and lines of the hydraulic system when the reservoir is
Oxidation produces varnishes that bake onto hot sur- drained. Flush the system when the oil is changed. This
faces. These oxidation products are acidic and tend to is especially important if the system is heavily contami-
attack metal surfaces. This can damage pumps, motors, nated with metal particles.
and valves.
If the oil is contaminated with water, it may not be neces-
High operating temperatures will increase the rate of oxi- sary to change the oil and flush the system. Follow the
dation of the oil. The presence of water or air in hydraulic instructions under Water Removal in this section.
oil also causes oxidation.
The following equipment and supplies are necessary to
The presence of water may cause rust and corrosion. It properly flush the hydraulic system.
also reduces the dielectric capability of the oil.
• Approximately 30 gallons (114 l) of proper grade
If laboratory analysis or visual inspection indicate that hydraulic oil
the oil is deteriorating prematurely, determine the cause • Two return line filters
of the problem and correct it. • Clean, lint-free rags
• Filler breather cap (if the component has not been
Changing Oil and Flushing the System replaced within one year)
A properly maintained filtration system greatly extends the
useful life of the hydraulic oil. However, the hydraulic oil Caution
will eventually need to be replaced due to contaminants
that form during the normal operation of the unit. Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
It is impossible to recommend an exact time interval for work areas clean.
oil changes due to varying conditions of unit use. Use
the following guidelines to determine when the hydraulic Use the following procedure to flush the hydraulic system.
oil should be changed.
1. If the oil is being changed because of contamination
• Change the oil as recommended by the Preventive due to a hydraulic component failure, proceed to step
Maintenance and Inspection Checklist. 2. Otherwise, operate the unit to circulate the oil and
warm it to operating temperature. This will allow many
• If a hydraulic component fails and contaminates the of the impurities to drain off in suspension.
system with metallic particles, change the component
and the oil immediately.

Section 4 — Preventive Maintenance and Inspection • 13

 2. Drain the oil reservoir completely. Water Removal
If the hydraulic system was contaminated with water,
3. Wipe off the top of the reservoir, reservoir cover, filler special water removal filtration may be necessary. An oil
breather cap, and return line filter. supplier or a qualified laboratory can determine whether
water has caused excessive oil oxidation or additive
4. Remove the suction strainer. Disassemble and clean deterioration.
it as described under Suction Strainer in this section.
If analysis shows that oil deterioration beyond an accept-
able level, drain the reservoir and flush the system as
Warning
described earlier in this section. Use a water removal filter
Death or serious injury can result from improper cart during the flushing process to remove any residual
use of solvents. Follow the manufacturer’s label for water from the system.
proper use and disposal.
If the condition of the oil is acceptable except for the water
5. Inspect the inside of the reservoir. If sludge or other content, allow time for it to separate from the oil. Then
contamination is found, clean it using solvent and drain the water off the bottom of the reservoir. Circulate
lint-free rags. the oil in the reservoir through a water removal filter cart.
While doing this, occasionally start the unit and cycle
6. Install the clean suction strainer and new filler breather all the functions. This will flush contaminated oil back
cap. to the reservoir. Continue this process until the water
content in the oil is reduced to an acceptable level. The
7. Install the reservoir cover assembly. preferred method of determining the water content in the
oil is laboratory testing. Another method of determining
8. If hydraulic component failure has contaminated the water content in the oil is a dielectric test.
system, change the return line filter.
Do not attempt to use a water removal cartridge in the
9. Add approximately 15 gallons (56 l) of new hydraulic return line filter to remove water from the system. The
oil of the proper grade to the reservoir. If possible, flow rate of the pump, even at engine idle, exceeds the
the new oil should be pumped through a 10 micron flow at which efficient water absorption occurs.
filter as it is put into the reservoir.

10. If the new oil was not filtered as it was put into the Lubrication
reservoir, connect a service hose to the tool outlets Proper lubrication will extend the life of the equipment
and allow the new oil to circulate through the tool and reduce maintenance problems. The frequency of
circuit for about 15 minutes. lubrication will depend on the amount of use and the
conditions the unit is operated in. Operation in extremely
11. Use a slow engine speed, cycle all the cylinders and dusty, sandy, or rainy environments will require more
motors to flush the contaminated oil from the lines frequent lubrication. After washing and cleaning the unit,
and components of the hydraulic system. relubricate as necessary.

12. Change the return line filter. The Lubrication Chart and Diagram identifies each com-
ponent, type of lubricant, and method of application. Any
13. Drain the reservoir completely. brand of lubricant that meets or exceeds the specifica-
tions of the products listed is acceptable. There are five
14. Fill the reservoir with new hydraulic oil of the proper intervals of lubrication. Select the appropriate interval
grade to the Full mark on the dip stick. Filter the oil and lubricate components identified by the symbol(s).
through a 10 micron filter as it is put into the reservoir.
Refer to the engine, trailer, and track drive manuals for
15. If the new oil was not filtered as it was put into the more information on lubrication.
reservoir, circulate the oil through the tool circuit as
described in step 10. Components may be installed on your unit that require
additional lubrication. Refer to these component manuals
16. Change the return line filter after approximately 25 for more information.
hours of operation.
Always wipe grease fittings clean before and after greasing
to keep contamination from entering the points of lubrica-

14 • Section 4 — Preventive Maintenance and Inspection

Lubrication Chart and Diagram
Service items identified by the symbol(s) at the appropriate level.

85 hours/ 500 hours/ 1,000 hours/ 2,000 hours/

1 month 6 months 1 year 2 years If disassembled

Key Lubricant Application Method

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

corrosion, rust, and galvanic pitting.

C Chassis Grease — Multipurpose lithium base grease with good water Grease gun
resistance, rust inhibition, oxidation stability, and extreme pressure properties.

E EP 80W-90 Gear Oil — API Service Designation GL-5. Pour

G Open Face Gear Lubricant — Spray lubricant that penetrates and adheres with Spray
good water resistance, is unaffected by temperature extremes, and has extreme
pressure properties.

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

Y SHC634 Synthetic Gear Oil Pour

P ISO VG 150 Grade Gear Oil Pour

S General Purpose Spray Lubricant Spray

30 SAE 30-CD Oil Pour

P Oil Level

P Change Oil
E Oil Level

E Change Oil

Drain Plug
Winch

Digger

Input Shaft
Splines
Y A

Rotation Gearbox Pump

Section 4 — Preventive Maintenance and Inspection • 15

 Brake Linkage S Pole Guide Tong
G
Gear Teeth
Brake Detent Pin
S Pole Guide Tong
Cylinder Pin A

Pin A

Platform

Pole Guide Tilt

Cylinder Pins
Intermediate Boom
A M
Outer Surface

A
Digger Link
Pivot Pins
Lower Boom M
Inner Surface

Hydraulic
Pole Guide Tilt
Upper and Intermediate
C Auger
Boom Cylinder Pins
Release
A
Trunnion
Pin Heads
Winch Drum A
• Shaft
A
• Keys
• Set screws
• Anchor C
Lift Cylinder Pins

Boom Pin C
Rotation Gearbox
A Eccentric Ring

Rotation Bearing
G and Pinion
Gear Teeth

A Outrigger Pins

Oil Level 30 C
Change Oil 30 Track Extension Tubes

16 • Section 4 — Preventive Maintenance and Inspection

tion. To avoid bearing damage, use manually operated Gearboxes
grease guns. Air-driven grease guns may have enough The need to add oil regularly to any of the gearboxes
force to cause bearing damage. (rotation, digger, or winch) is a sign of a leak. Determine
the cause of the leak and correct it. A low oil level can
If the unit is not used, or is stored for any length of time, damage the internal components of a gearbox.
apply fresh lubricant at all points shown on the Lubrica-
tion Chart and Diagram. This will help prevent corrosion The overall life expectancy of a gearbox may be extended
during the idle period. by regularly draining and refilling the oil. The best time
to drain a gearbox is right after it has been operating.
Outriggers At this time, the oil is warm and the wear particles are
Pin connections on the outrigger have been made with zinc suspended in the oil. Change the oil as recommended
plated pins coated with anti-seize compound to prevent by the Preventive Maintenance and Inspection Checklist.
corrosion. These connections do not require additional If a gearbox is overheated and the oil smells burned,
lubrication unless they are disassembled. change the oil immediately.

Bearings If the oil level of a gearbox appears to be increasing, there

Self-lubricating bearings require no lubrication when they may be an internal hydraulic leak from a defective motor
contact plated shafts. This type of bearing is used at the shaft seal. If this occurs in a rotation gearbox, it may also
boom pin but must be lubricated regularly to protect the be a sign of a defective brake piston seal.
housing from corrosion.
Wipe the gearbox clean before removing the plug from
Rotation Bearing the fill or check hole. Do not overfill the gearbox with oil.
The rotation bearing ball path is lubricated for the life of Overfilling will cause the gearbox to leak. Tighten the
the bearing and requires no further lubrication. plugs securely after checking or filling. Wipe excess oil
off of the gearbox to prevent dirt buildup.
Rotation Gear Teeth
Apply an open face gear lubricant to the rotation gear The winch and rotation gearboxes each have a vent plug
and pinion teeth. that must be kept free of paint and dirt. The vent prevents
excessive pressure buildup inside the gearbox as the oil
expands during operation.
Caution
Injury can result from contact with pinion and rota- The oil level of the single speed digger should be 11/2″
tion bearing gear teeth. Keep hands clear. (3.8 cm) below the top of the fill hole with the digger
hanging vertically.
Injury can result from being pinched or trapped be-
tween moving components. Keep hands clear. Booms
The internal surfaces of the lower boom is lubricated
Use caution when access covers have been removed at the factory. They only need to be lubricated during a
to service the unit. Pinch points and shear points may major overhaul of the unit.
exist between moving parts. Replace the access covers
immediately after servicing. The external surface of the intermediate boom is exposed
to the weather and to cleaning. Lubricate this surface
Remove the pinion cover from the turntable to lubricate as recommended by the Preventive Maintenance and
the rotation gear teeth. Replace the cover after the lu- Inspection Checklist to keep the boom sliding freely on
brication has been completed. the slide pad bearings.

Warning Use the following procedure to lubricate the intermedi-

ate boom.
Death or serious injury can result from being trapped
between moving components. Maintain a safe dis- 1. Position the unit on a level surface and properly set
tance while components are in motion. the outriggers. Extend the intermediate boom and
turn off the engine.
Do not lubricate the gear teeth while operating the unit.
Stop turntable movement before lubricating. Rotate the 2. Wipe the exposed boom surfaces to remove any dirt,
turntable slowly through a complete 360 degree revolution. moisture, etc.

Section 4 — Preventive Maintenance and Inspection • 17

 3. Wipe on a coating of moly grease. resistance to corrosion. While Altec uses components,
designs and coatings that maximize corrosion resistance,
4. Start the engine. Retract and extend the boom several regular cleaning and maintenance is necessary to pre-
times to spread the grease evenly on the surface. serve the finish over the life of the equipment.

5. Extend the boom and wipe off the excess grease to Frequent and regular washing will lengthen the life of your
prevent buildup of dust and other particles. new equipment’s painted finish and components. Wash
your equipment and truck body frequently with warm or
6. Retract the intermediate boom. cold water to remove dirt and preserve the original luster
of the paint. Never wash the equipment in direct sunlight
Chassis Tracks or when the metal surfaces are hot to the touch as it may
cause streaks on the finish. Caution must be used in
Oil Level selecting detergents and degreasers that may damage
Position the unit on a level surface with the gear motor the finish. Use only commercially available automotive
plugs aligned horizontally. Remove the plugs and check grade cleaners. High pressure washing systems should
that the oil level is up to the plug holes. If oil needs to be used with caution, with the tip of the nozzle maintained
be added, fill through one of the holes while checking at a distance of 12” (30.5 cm) or more from the surface.
the other hole for the oil level.
It is particularly important to wash the unit and body during
Replace and tighten the plugs. winter months as salt and other ice melting products are
extremely corrosive and can damage the vehicle. Other
Oil Change corrosive environments that would necessitate additional
Change the oil after the first 200 hours of operation. washing may include coastal areas, farming communi-
Position the unit on a level surface with the gear motor ties where chemicals are sprayed, or mining operations.
plugs aligned vertically. Remove both plugs and drain
out all oil. Move the unit until the holes align horizontally. Waxing of the exterior is typically not required, however
Full the gearbox through one of the holes while checking waxing will provide additional protection and help restore
the other hole for oil level. The oil level should be up to the finish to the original luster. This may not only improve
the plug holes. appearance, but will likely extend the service life of your
truck body and equipment.
Replace and tighten the plugs.
It is important to repair any chips or scratches that occur
to prevent further corrosion. If the paint damage exposes
Structures
primer, then a liquid touch up paint may be used. Dam-
The structural components of the unit are identified in the age that extends to unpainted metal must be primed
Component Identification in Section 2. The unit has been prior to applying a top coat. Touch up paint for standard
designed to meet or exceed the ANSI specifications for Altec colors may be ordered by calling 1-877-GO ALTEC.
vehicle-mounted rotating and elevating derricks. Your local auto body shop can assist you with matching
a custom color.
Regular inspection of the welds and structures is required
to insure that components maintain their strength. Periodic Equipment that is used in harsh environments and off road
cleaning of the structures is also recommended. This will use needs to have more routine washing and maintenance
prevent damage that can occur from dirt accumulation. to the under body area. When the equipment is washed
it should washed on the underside as well and routinely
Periodic inspection of the structures is recommended checked for any damage to the paint/undercoat. Any
to be certain there is no deformation, abnormal wear or damage discovered should be touched up accordingly
abrasion, interference between moving parts, or cracking with a good rust preventative material and/or undercoat.
of the welds on structural members. This will help prevent corrosion that could spread from
these areas that are not easily seen.
Inspect the structures and welds as recommended by
the Preventive Maintenance and Inspection Checklist. Accumulated dirt can damage the unit and cause it to
malfunction. It also accelerates component wear.
Care of Exterior Surfaces
Altec units are manufactured out of structural steel, gal-
vanized steel and/or aluminum components with differing

18 • Section 4 — Preventive Maintenance and Inspection

 Caution Any welds added in the field should be done by qualified
personnel and also conform to AWS standards.
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
After doing repair work on the unit, such as weld repair,
work areas clean.
some testing of the unit may be required.
If a pressure washer or steam cleaner is used to clean
Refer to Section 6 for information on repairing mechani-
the unit, be careful where the spray is directed. Do not
cal components.
direct the spray where the cleaning liquid might get into
electrical components, such as electrical connections,
switches, or lights. Even though all electrical components Fasteners
on the unit are designed for all weather use, it is possible
A variety of fasteners are used on the unit. Different fasten-
for water pressure from the nozzle to push a seal out of
ers have different inspection and installation requirements
position. Do not direct the spray at the filler breather cap
depending on their use and design. This section explains
of the reservoir. The high pressure can force water and
different fasteners used on the unit, torque specifications,
cleaning liquid into the reservoir and contaminate the
and the use of thread locking and anti-seize compounds.
hydraulic oil. Do not clean the spool ends of any hydraulic
valve with direct pressure from a pressure washer. Limit
The standard grade of fastener used on the unit is a zinc
the water pressure to 500 psi (34.47 bar) and keep the
plated, SAE Grade 5, steel cap screw. SAE Grade 8 cap
spray tip at least 18″ (45.72 cm) away from these com-
screws or special high strength cap screws are used in
ponents while washing. After washing and cleaning the
highly loaded areas. A variety of other fasteners such
unit, relubricate as necessary.
as socket head, flat countersunk head, and button head
cap screws are also used on the unit.
Refer to Fiberglass Care in this section for information
on cleaning the fiberglass components.
Check all fasteners for tightness as recommended by
the Preventive Maintenance and Inspection Checklist.
Welds
All welds on the unit are originally applied in conformance
Figure 4.5 represents general locations of fasteners to
to AWS standards. Every weld on the unit is important
inspect. When inspecting fasteners, pay particular atten-
and should be periodically inspected.
tion to the following fasteners.

Warning • Rotation bearing mounting cap screws

Death or serious injury can result from improper • Rotation gearbox mounting cap screws
use of solvents. Follow the manufacturer’s label for • All pin retainer cap screws at pivot pins
proper use and disposal. • Winch mounting cap screws
• Hydraulic motor mounting cap screws on all gear-
If paint has lifted off the weld, or if rust is found, a closer boxes
inspection is required. Remove any loose paint or rust • Digger link pin nuts
with a wire brush. Clean the area with a solvent such • Auger and auger extension shaft cap screws and
as acetone. Closely inspect the area for cracks in the nuts
welds. Dye penetration and magnetic particle testing are • Upper boom extension cylinder trunnion pins
simple processes that may be used to verify or disprove
a suspected problem. A properly installed cap screw applies a clamping force
equal to or greater than the load applied to it. A cap screw
Visual inspections can be very effective if conducted installed at less than the recommended torque value
properly. Clean the area to be inspected. Look for vis- does not provide enough clamping force. The cap screw
ible cracks in the weld and at the weld-to-parent material may fatigue, causing it to loosen or fail. If the cap screw
joint. Use a bright light to provide adequate visibility of is torqued beyond the recommended torque value, the
the inspection area. elastic range of the cap screw may be exceeded. This
may result in premature failure of the cap screw.
Pay close attention to welds that are located where
changes in cross section take place and near the attach- When checking fastener torque value, check at 90 percent
ment points of highly loaded components. To assist in the of the original value. For example, if the torque value for
inspection of the welds on the unit, Figure 4.4 illustrates a cap screw is 100 foot-pounds (136 N•m), check the cap
these areas. If any cracks or unacceptable conditions screw for tightness at 90 foot-pounds (122 N•m).
are discovered, report them to your Altec representative.

Section 4 — Preventive Maintenance and Inspection • 19

 Combined
Use Bracket
Boom Tip
Attachment
Boom Pivot
Pin Bosses
Cylinder Mount,
Rod End and Base End

Cylinder Pin
Bosses

Cylinder
Boom Pivot Gusset to Boom Mount
Pin Bosses

Rotation Bearing Mounting

Plate to Pedestal

Outrigger Mount Pedestal to Outrigger Mount Digger Digger

to Carrier Frame Carrier Frame to Carrier Frame Hanger Link Tube
Bracket

Carrier Frame to Track Frame

Figure 4.4 — Weld Inspections

Some fasteners require torque values that differ from Inspection Marks
common torque charts. Refer to Figure 4.6 for the proper Nuts or cap screws with locking patch element used in
tightening torque for these fasteners on this unit. combination with inspection marks are used at specific
locations on the unit. Many are visible to the operator
Many general application fasteners would not normally during daily inspections.
require an installation torque or lubrication but instead
would be installed using sound mechanical practices. If If any inspection marks are found to be cracked or bro-
it is desired to more closely control the fastener clamp ken during inspection, the original mark must be totally
load it is recommended that a copper based anti-seize removed. The fastener torque must be checked (if no
compound be applied. Refer to Torque Values in the damage is evident) or the fastener replaced and torqued
Appendix as a guide to determine the proper cap screw (if damage is evident), and the inspection mark reapplied.
torque value.
The inspection lacquer (refer to Service Tools and Supplies
Nylon insert locknuts are used for a variety of applica- in the Appendix) should not be used after the expiration
tions on the unit. If a nylock nut is removed it must be date printed on the container.
replaced with a new nut to make sure the nut will maintain
the proper installation torque.

20 • Section 4 — Preventive Maintenance and Inspection

 Boom Tip
Retainers

Extension Cylinder Cap

Screws and Nuts

Digger Link Pin Retainers

Hydraulic Motor
Mounting Cap Screws
Auger and Auger
Extension Shaft
Cap Screws

Upper Boom Cylinder

Trunnion Pins

Winch Mounting
Cap Screws

All Pin
Rotation Gearbox Retainers
Mounting Cap Screws
Hydraulic
Motor Mounting
Cap Screws

All Pin Retainers

Rotation Bearing
Cap Screws

Figure 4.5 — Fasteners

Use the following procedure to apply a new inspection Warning

mark.
Death or serious injury can result from improper
use of solvents. Follow the manufacturer’s label for
1. Remove the majority of the original inspection mark
proper use and disposal.
by chipping it off with a chisel or other cutting method.
Do not damage the surface on the nut, fastener,
2. Be sure the cleaning operation is performed in a well-
washer, and part or structure being attached to.
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.

Section 4 — Preventive Maintenance and Inspection • 21

 Foot-Pounds (N•m)
Rotation bearing cap screws 225 (305)
Rotation gearbox mounting cap screws 115 (156)
Rotation motor mounting cap screws 115 (156)
Upper boom extension cylinder trunnion pin cap screws 50 (68)
Intermediate boom extension cylinder mounting nut 50 (68)
Digger motor mounting cap screws 80 (109)
Winch line guide cap screw nuts 50 (68)
Boom tip mounting cap screws 55 (75)
Platform mounting cap screws 55 (75)
Figure 4.6 — Torque Values

3. Properly torque the fastener. Warning

Death or serious injury can result from improper
4. Clean the area where the inspection stripe is to be
use of solvents. Follow the manufacturer’s label for
applied with a soft clean cloth and acetone.
proper use and disposal.
5. Start at the center of the cap screw and apply a 1/32″ to
1
/16″ (0.8 to 1.6 mm) thick stripe of inspection lacquer Caution
to the head of the cap screw, across the washer, and Injury can result from airborne particles entering the
onto the surface of the parent material. The stripe eyes. Wear appropriate safety equipment.
should extend 1/8″ to 1/4″ (3.2 to 6.4 mm) onto the
parent material. If the threads of the fasteners are not clean and free of
grease and oil, the effectiveness of the thread locking
6. The stripe must be continuous across the surfaces. adhesive will be reduced. Clean the threads of the fasten-
If it is not, remove the stripe with cleaner and reapply ers with solvent and blow dry with compressed air before
the inspection lacquer properly. applying the thread locking adhesive.
Thread Locking Adhesives For optimum thread locking, follow the manufacturer’s
and Anti-Seize Compounds label for proper use and disposal.
Anaerobic thread locking adhesives work in the absence
of air. When a fastener is removed, it must be cleaned Anti-seize compound may be used to prevent rust and
thoroughly and adhesive applied before reinserting. corrosion from forming on the metal-to-metal contact
Properly torque the fastener before the adhesive cures areas between a connecting pin and its boss. It is also
(within 15 minutes of application). When installing trunnion recommended for certain fasteners to reduce friction dur-
pins, apply thread locking adhesive only to the first two ing torquing to increase clamping load. Apply anti-seize
or three threads of the male portion. Refer to Trunnion compound to the following components.
Pins in this section for proper trunnion pin installation.
• Radial outrigger pivot pins
Apply anaerobic thread locking adhesive on the threads • Pump input shaft splines
of the fasteners and connections listed below to provide • Outrigger cylinder/shoe pins
additional security against loosening. • Rotation gearbox eccentric ring
• Winch drum shaft/keys/set screws/line anchor
• Fuel tank mounting bracket — medium strength • Platform mounting pin and boss
• Digger holdback latch cap screws — medium strength • Upper boom extension cylinder trunnion pin heads
• Upper boom extension cylinder trunnion pin cap
screws — medium strength The area on which the anti-seize is applied must be clean
and dry for the anti-seize to be effective.

22 • Section 4 — Preventive Maintenance and Inspection

Chrome pins used with self-lubricating bearings require Visual Inspection Procedure
special attention. Apply anti-seize compound to the sur- Perform this visual inspection procedure as recommended
face of the pin only where the pin and steel bin bosses by the Preventive Maintenance and Inspection Checklist.
make contact. This pin installation procedure is described
under Pins and Pin Retainers in this section. Visually inspect all rotation bearing cap screws, looking for
any evidence that a cap screw is loose. Check for loose
Rotation Bearing Cap Screws washers under the heads of the cap screws by trying to
Special high strength 5/8″ cap screws are used to secure turn each washer by hand. If movement is indicated, all
the rotation bearing to the pedestal and turntable. These the cap screws must be retorqued using the Retorquing
cap screws are coated with a dry film lubricant and have Procedure.
a patch lock material permanently bonded to the threads.
The torque value for the cap screws is 225 foot-pounds Annual Torque Inspection Procedure
(305 N•m). The cap screws require special inspection Check the cap screws to be sure they are torqued to
procedures. 203 foot-pounds (284 N•m), or 90 percent of the normal
installation torque of 225 foot-pounds (305 N•m). Use a
regularly calibrated, accurate torque wrench. If one or
Notice
more of these cap screws turns before the wrench clicks,
Only use Altec supplied cap screws and washers to check the torque on the cap screws as described under
install the rotation bearing. Retorquing Procedure in this section. If the rotation bear-
ing is replaced or removed, the same inspection intervals
When rotation bearing cap screws or washers are re- must be followed.
moved, they must be replaced with new ones. Contact
your Altec representative for replacement fasteners. Retorquing Procedure
Perform this procedure on the entire bearing race (outer,
Insufficient or uneven cap screw tightness can contribute inner, or both) if any cap screws were found loose at the
to reduced life of the bearing. visual or annual inspections.

Caution Some components may need to be removed to make

the rotation bearing cap screws accessible for retorqu-
Injury can result from being pinched or trapped be- ing. It is important that experienced, trained mechanics
tween moving components. Keep hands clear. perform this procedure.

Use caution when access covers have been removed 1. Retorque according to the appropriate pattern shown
to service the unit. Pinch points and shear points may in Figure 4.7 for the inner race and Figure 4.8 for the
exist between moving parts. Replace the access covers outer race.
immediately after servicing.

17 12
Notice
2 5
Use an accurate 1/2″ drive click-type manual torque
wrench for the inspection of these cap screws. Torque 7 15
the cap screws by a smooth pull on the torque wrench
without jerking. Do not overtighten the cap screws.
14 10
If any cap screws are broken or missing, replace all the
fasteners in that race (refer to Section 6 under Rotation X 4 3
Bearing Cap Screws). If a cap screw will not remain
properly torqued between normal inspections, further
9 13
inspection may be required.
Rotation
Impacts to and excessive forces on the unit due to ve- Gearbox 16 8
hicular accidents, rollovers, and excessive loading may
6 1
result in structural damage not obvious during a visual
inspection. A more detailed inspection by a qualified 11 18
individual may be required to determine if replacement
Figure 4.7 —
of the rotation bearing and fasteners is required.
Inner Race Cap Screw Torque Patterns

Section 4 — Preventive Maintenance and Inspection • 23

 exist between moving parts. Replace the access covers
1
11 16 immediately after servicing.

8 6
Notice
Only use Altec supplied cap screws and washers to
13 9 install the rotation gearbox.

Use an accurate 1/2″ drive click-type manual torque

3 4 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.
10 14
Visual Inspection Procedure
Perform this visual inspection procedure as recommended
5 7 by the Preventive Maintenance and Inspection Checklist.
15 12
2 Visually inspect all rotation gearbox cap screws, look-
ing for any evidence that a cap screw is loose. Check
Figure 4.8 — for loose washers under the heads of the cap screws
Outer Race Cap Screw Torque Patterns by trying to turn each washer by hand. If movement is
indicated, retorque all the cap screws.
2. Begin with cap screw number 1 on the outer race and
torque it to 225 foot-pounds (305 N•m). The number Annual Torque Inspection Procedure
one cap screw can be at any location on the bearing Check the cap screws to be sure they are torqued to
with the remainder of the pattern shifted accordingly. 104 foot-pounds (141 N•m), or 90 percent of the normal
installation torque of 115 foot-pounds (156 N•m). Use a
3. Continue around the pattern, torquing each cap screw regularly calibrated, accurate torque wrench. If one or
to 225 foot-pounds (305 N•m). more of these cap screws turns before the wrench clicks,
retorque all the cap screws to 115 foot-pounds (156 N•m).
4. Retorque all cap screws to 225 foot-pounds (305 If the rotation gearbox is replaced or removed, follow the
N•m) again beginning at number 1. Go around in a same inspection intervals.
circular pattern this time instead of the numbered
order. Digger Motor Cap Screws
The digger motor mounting cap screws are 1/2″ -13 UNC.
5. Repeat steps 1 through 4 on the inner race cap Install the cap screws and torque them to 80 foot-pounds
screws, torquing each cap screw to 225 foot-pounds (109 N•m). The upper housing of the digger gearbox is
(305 N•m). made of aluminum. Overtightening the motor mounting
cap screws this may damage the threads in the alumi-
Rotation Gearbox Mounting Cap Screws num housing.
Special 1/2″ cap screws are used to secure the rotation
gearbox to the turntable. The torque value for the cap Slide Pad Bearing Cap Screws
screws is 115 foot-pounds (156 N•m). The cap screws The lower, intermediate, and upper boom are equipped
require special inspection procedures. with slide pad bearings. They are installed with either hex
head cap screws or flat countersunk head, nylon insert
Insufficient or uneven cap screw tightness can contribute or nylon patch cap screws. These fasteners must be
to reduced life of the gearbox. installed using medium strength thread locking adhesive.

Do not reuse the flat countersunk head cap screws if

Caution they are removed. They should be replaced with new
Injury can result from being pinched or trapped be- cap screws and thread locking adhesive to insure a
tween moving components. Keep hands clear. clean and secure fit.

Use caution when access covers have been removed Overtightening the bearing mounting screws can damage
to service the unit. Pinch points and shear points may or split slide pad bearings. Boom Slide Pad Bearings in
this section describes this type of bearing.

24 • Section 4 — Preventive Maintenance and Inspection

 3. Check the trunnion pin cap screws with a torque
Pins and Pin Retainers wrench to be sure they are torqued to 45 foot-pounds
A variety of pins and pin retainers are used on the unit. (61 N•m) or 90 percent of the normal installation
The type of pin or pin retainer used depends upon the torque of foot-pounds (68 N•m).
particular application.
4. If a trunnion pin cap screw is loose, torque it to 50
Chrome plated pins are used in many areas such as the foot-pounds (68 N•m).
lower boom pivot pin. The chrome plating reduces the
likelihood of rust and provides long wear for pins used Warning
with self-lubricating bearings.
Death or serious injury can result from uncontrolled
Use a dead blow hammer to remove or install pins. Use movement. Secure the booms before removing the
of a steel hammer may distort the pin or close the retain- cylinder mounting pins.
ing ring groove. This may make pin installation difficult or
cause the retaining ring to come out of its groove. 5. Replace the trunnion pin access hole covers.

Trunnion Pins 6. Start the engine and stow the unit.

The upper boom extension cylinder is mounted inside
the upper boom with trunnion pins (refer to Figure 4.9). Forged Pin Retainers
Forged pin retainers are used to retain and prevent ro-
tation of the pivot pins. A forged pin retaining system is
shown in Figure 4.10.

Trunnion Pin and Lock Washers

Cap Screw Cylinder Eye

Stem

Lower Boom

Forged Pin
Figure 4.9 — Booms Retainer Retaining
Ring
Retaining
Torque Inspection Ring
Visually check the trunnion pins for looseness as recom-
mended by the Preventive Maintenance and Inspection Figure 4.10 — Forged Pin Retaining System
Checklist
During inspection, look for bent or broken stems. A bent
Use the following procedure to check the trunnion pins. or broken stem may indicate that the bearings within the
joint are worn out. Also, if the pin binds within the joint
1. Position the unit on a level surface and properly set and tries to turn, the stem could bend or break. This may
the outriggers. indicate a lack of lubrication. Make sure the cap screw
through the eye of the retainer is tight.
2. Remove the trunnion pin access hole covers from
the lower boom. If a forged pin retainer is damaged, determine the cause
of damage. Relubricate or take the connection apart and
replace the necessary parts.
Caution
Injury can result from being pinched or trapped be- Retaining Rings
tween moving components. Keep hands clear. Retaining rings are used as a backup retaining system
for some pins and as the only retaining system for others.
Keep hands clear while extending and retracting the
booms. Figure 4.11 illustrates how retaining rings are used as a
backup retainer on the lift cylinder pivot pins. If the forged

Section 4 — Preventive Maintenance and Inspection • 25

pin retainer should fail or fall out, the retaining rings will Use the following procedure to properly install the pin.
hold the pin in place. However, they will not prevent the
pin from rotating. Immediately determine the cause of the 1. Slide the pin through the first boss and through the
problem and replace and/or repair the necessary parts. bearing until it reaches the second boss.

2. Apply an anti-seize compound to the second pin boss

Sharp and pin surface that is still exposed.
Edge
3. Slide the pin completely into the second pin boss
and install the appropriate retaining system.

Bearings
Section A-A The unit is equipped with a variety of bearings. The type
of bearing used depends on the particular application.
Figure 4.11 — Retaining Ring
Self-Lubricating Bearings
When inspecting retaining rings, check that they are Self-lubricating bearings are designed for long life. Under
properly installed and undamaged. normal use, this type of bearing will provide many years
of service with virtually no maintenance. These bearings
Install retaining rings with the sharp edge out (refer to resist impact and shock loads and abrasive contaminants.
Figure 4.11). This makes it more difficult for the retain-
ing ring to come off the pin if the pin is being forced out Self-lubricating bearings are made with a braided cord
the other side. liner containing Teflon fibers. The liner is bonded to the
outer shell of the bearing with epoxy resin. The epoxy
Lower Boom Pin Retaining System resin has a self-lubricating filler added to it. A chrome
The lower boom uses a forged pin retaining system similar plated pin is used with this bearing.
to Figure 4.10. The system uses a pin with a forged pin
in one end, secured by a cap screw. Retaining rings are The inside diameter of a self-lubricating bearing contains
used on both ends as a backup system. Teflon fibers. Once a pin is installed in the bearing, some
of the Teflon transfers to the pin surface and provides
Pin Installation Into lubrication. Applying anti-seize compound to the entire
Self-Lubricating Bearings surface of the pin will prevent the Teflon from transferring.
When installing a pin into a self-lubricating bearing, only This may shorten bearing life.
lubricate the area where the pin and the boss make
contact (refer to Figure 4.12). Replace these bearings if the components are disas-
sembled for other purposes. Replacement of this type
of bearing due to wear is not a normal consideration.
First Boss Second Boss
Pin Bearing If it is desirable to measure the bearing to determine
when it is worn, several factors must be considered. The
only accurate way to measure bearing wear is to keep
a record of the clearance between the chrome pin and
the bearing. Place the magnetic base of a dial indicator
in a position that allows the clearance between the pin
and the bearing to be measured under load. Take an
initial measurement when the unit is new to provide a
reference point. Monitor the change in bearing clearance
with subsequent measurements.

Anti-Seize Compound For self-lubricating bearings, clearance wear on the bear-

ing of 0.005″ (0.13 mm) may suggest the bearing needs
Figure 4.12 — to be replaced. This figure takes into account only the
Pin Installation Into Self-Lubricating Bearings wear of the bearing. Through the course of time, there
may also be pin and pin boss wear. An overall change in

26 • Section 4 — Preventive Maintenance and Inspection

the clearance between the pin and the bearing of 0.020″ Measure Clearance Here
(0.51 mm) or more indicates the pin and bearing both
need to be replaced. Lug

Replacement Pin
Use the following procedure to remove and install self-
lubricating bearings.
Bearing
Machine Bushing
1. Drive out the old bearing. If this is not possible, remove
it with a die grinder, cut point chisel, or hacksaw blade Figure 4.14 — Machine Bushings Clearance
(refer to Figure 4.13). Be careful not to damage the
inside diameter of the bearing boss. Tapered Roller Bearings
Tapered roller bearings are often used in gearboxes. This
bearing type can be used at high speeds and will support
Removal radial and axial loading. Depending on the application,
Tool this bearing may be installed with several thousandths
inch end clearance, no clearance, or with a preload.

A preload is 0.000″ clearance minus a few thousandths.

Bearing
Preload is sometimes checked with a torque wrench (stall
Driver torque) or with a line and scale (rolling torque). Shaft load
Removal Installation and speed of the particular application will determine the
Figure 4.13 — Removal and method of installation. Light loads and high speeds will
Installation of Self-Lubricating Bearings call for a specific amount of end clearance. Heavy loads
and low speeds will call for a specific amount of preload
2. Use a screwdriver and needle nose pliers to collapse on the bearing. Proper installation and lubrication of the
the bearing and pull it out of the bearing boss. tapered roller bearing are very important in determining
the useful life of the bearing.
3. Clean the bearing boss. Do not remove any metal
from the boss surface. If metal is removed, the new Slide Pad Bearings
bearing may not fit properly in the boss. The booms are equipped with slide pad bearings. Slide
pad bearings provide a smooth surface for extension
4. Place the new bearing on a bearing driver. Line it and retraction.
up with the bearing boss and drive the bearing into
place using a dead blow hammer. An old pin may be The most highly loaded slide pad bearings are made of
used as a driver (refer to Figure 4.13). molybdenum disulfide impregnated nylon. Other slide
pad bearings that are not as heavily loaded are made
5. Inspect the pin before installing it into the bearing. of a type of polyethylene. Both types of bearings will last
Use a new pin if the chrome is flaked, cracked, or indefinitely when run against smooth surfaces.
galled.
The internal sliding surfaces of the lower boom are lu-
6. Slide the pin through the first pin boss and through bricated with moly grease during factory assembly. The
the bearing until it reaches the second pin boss. internal surfaces and their mating slide pads require no
additional lubrication unless they are disassembled for
7. Apply an anti-seize compound to the second pin boss major maintenance.
and pin surface that is still exposed (refer to Figure
4.12). The slide pad bearings are mounted with either hex flange
serrated head cap screws or flat countersunk head cap
8. Slide the pin completely into the second pin boss screws. The flat countersunk head cap screws have a
and install the appropriate pin retaining system. nylon patch embedded in the threads.

9. Pins equipped with flange and lug fasteners require Slide pad bearings mounted with the flat countersunk
from 0.010″ to 0.080″ (0.254 to 2.032 mm) pin play cap screws must have the heads of the mounting screws
(end clearance between the bushing and the boss). located below the sliding surface of the bearing (refer
This is accomplished by adding or subtracting ma- to Figure 4.15). This prevents the cap screw head from
chine bushings to obtain the desired dimensions. damaging the boom surface.

Section 4 — Preventive Maintenance and Inspection • 27

 Flat Countersunk Cap Screw and Inspection Checklist. More frequent inspections are
Bearing required when the total increase in turntable tilt measure-
Leg
ment reaches 0.050″ (1.27 mm).

Take an initial turntable tilt measurement when the unit is

Hex Head Cap Screw delivered. This will provide a baseline for future bearing
Leg Bearing tilt measurements. Future bearing tilt measurements will
be compared to this baseline to determine how much the
bearing tilt has increased since the initial (new bearing)
Nut measurement. The greatest portion of the measured
turntable tilt results from structural deflection rather than
Figure 4.15 — Slide Pad Bearing Cap Screws bearing internal clearance. It is important that the deflec-
tion be held constant by using the same measurement
Slide pad bearings mounted with hex head cap screws procedure each time. Keep a maintenance log to monitor
have steel nuts embedded into the bearing itself (refer to the bearing inspections and turntable tilt measurements
Figure 4.15). The cap screws are installed with the head during the life of the unit.
located on the opposite side of the steel plate from where
the bearing is located. When replacing a hex head cap Bearing Replacement Criteria
screw on a slide pad bearing, make sure to replace it The rotation bearing must be inspected and evaluated.
with a cap screw of the proper length as specified in the The recommended bearing inspection procedures include
Parts Manual. Cap screws that are too short will not fully the following items.
engage the nut embedded in the bearing. Cap screws
that are too long will protrude beyond the bearing and • Monitoring the trend of turntable tilt measurements
damage the boom or leg surface. Bearing inspections and turntable tilt measurements
can be used to determine when a bearing should be
When replacing a slide pad bearing, do not reuse the replaced. Generally, an increase in turntable tilt of
flat countersunk head cap screws. Once a cap screw 0.065″ (1.65 mm) above the initial tilt measurement
is removed, the nylon patch on the threads of the cap indicates that the bearing may be reaching the end
screw will be distorted. This distortion may not allow the of its useful life. Other factors related to the condition
cap screw to tighten properly if it is reused. Use new flat of the bearing must also be considered. Determine if
countersunk screws of the proper length when replacing the increase in the turntable tilt measurements has
a slide pad bearing. Do not apply excessive torque when been steady or if it shows a trend of accelerated
tightening the cap screws. This will prevent the bearings wear (refer to Figure 4.16). Example 1 shows a
from splitting. steady increase in wear, which is normal. Example 2
shows an accelerated increase in wear which would
Rotation Bearing indicate bearing replacement may be necessary. If
The turntable rotates on a shear ball bearing called the the tilt measurement has reached 0.065″ (1.65 mm)
rotation bearing. The inner race is mounted to the turn- above the initial (new bearing) tilt measurement, and
table. The outer race is mounted to the pedestal. The periodic measurements show a trend of accelerated
outer race has gear teeth that mesh with the rotation wear, replace the bearing.
pinion. The bearing provides for very low torque rotation.
500 Hour/6 Month
Monitoring Bearing Wear Inspections Example 1 Example 2
The internal bearing clearance will increase slightly
during the break-in period. It should then remain essen- 1 0.112″ (2.84 mm) 0.110″ (2.79 mm)
tially constant for many years if the bearing is properly 2 0.114″ (2.89 mm) 0.114″ (2.89 mm)
lubricated and not overloaded. As the bearing raceway 3 0.116″ (2.95 mm) 0.122″ (3.10 mm)
begins to wear, the clearance will increase. It should
increase steadily at first and accelerate toward the end Figure 4.16 — Turntable Tilt Measurements
of bearing life.
Because the major portion of the measured turntable tilt
An increase in bearing clearance is one sign of bear- results from structural deflection, the total tilt measurement
ing wear. Periodic bearing tilt measurements will help varies from model to model. For example, overall turntable
determine when bearing replacement is necessary. tilt measurements approaching 0.200″ (5.08 mm) are not
Perform bearing inspection and turntable tilt measure- uncommon on some models, even on bearings which
ments as recommended by the Preventive Maintenance have not reached the end of their usable life. Severely

28 • Section 4 — Preventive Maintenance and Inspection

worn bearings could have a measured turntable tilt as 2. Fully extend all boom sections with the booms near
much as 0.500″ (12.7 mm) or more in addition to other horizontal. Exact boom position is not critical. Slowly
prominent symptoms of wear such as unusual noise and rotate the turntable 360 degrees using the lower
roughness. Therefore, the total turntable tilt measurement controls while checking for roughness or noise in
itself should not be used to gauge a bearing’s remain- the rotation bearing. Repeat using the radio controls
ing usable life. The change in turntable tilt and the trend (if so equipped) from the platform since roughness
toward accelerated wear is more important than the total may be felt more accurately from the platform. Note
tilt measurement itself. in the maintenance log whether unusual noise or
roughness was encountered.
• Evaluating the “feel” of the unit
If there is no trend toward accelerated wear, consider 3. Test the system pressure and adjust if necessary as
the “feel” of the unit during load reversals. Operators described in Section 8. Record the system pressure
may notice an increase in the tilting or rocking of the in the maintenance log. The system pressure must
turntable. be correct because changes in the system pressure
will affect the structural deflection and change the
• Checking for rotation bearing noise and roughness turntable tilt measurements.
Determine whether there is any presence of rough-
ness or noise in the rotation bearing during rotation. 4. Rotate the turntable to the position to be used for
Severely worn bearings commonly exhibit grinding, the turntable tilt measurement. If the unit is normally
snapping, and popping noises during rotation. These operated within a particular zone of rotation, mea-
noises may indicate the bearing has broken ball sure the tilt with the turntable rotated to this position.
spacers, split ball bearings, or excessive galling, the For consistent measurement, always use the same
presence of which would require immediate bearing rotational position each time the tilt measurement is
replacement. Popping or clicking noises might also done. Record the rotational position in the mainte-
be caused by broken or improperly torqued bear- nance log.
ing fasteners, a warped mounting surface, or worn
teeth. A check of the fastener torque and the rotation 5. Remove the platform, platform mounting bracket, jib,
bearing grease purged during lubrication will usually jib mounting bracket, and pole guide, if so equipped.
determine if bearing noise is due to internal or external Fully retract the upper boom and fully extend the
problems. intermediate boom. Lower the boom to determine if
the boom tip can be placed on the ground (refer to
One or more of these evaluation criteria should detect the Figure 4.17). If the boom tip cannot be easily placed
need for rotation bearing replacement long before there on the ground, an alternate setup using the auger is
is any threat of failure. By maintaining proper rotation acceptable. Retract the intermediate boom, unstow
bearing lubrication and avoiding overload conditions, the auger, and fully extend the intermediate boom.
the replacement rotation bearing should provide many
years of service. 6. Attach the magnetic base of the dial indicator to the
pedestal, positioning the contact point at the cor-
Bearing Inspection and Turntable Tilt Measurement rect position. The contact point of the dial indicator
1. Position the unit on a level surface where the booms should be positioned against the underside of the
can be elevated and rotated. Properly set the outrig- turntable base plate under the lift cylinder, as close
gers. as possible to the pinion gear cover. Figure 4.18

Intermediate Boom
Fully Extended Upper Boom Fully
Retracted

Boom
Tip
Protective Material
Under Boom Tip

Support

Figure 4.17 — Setup

Section 4 — Preventive Maintenance and Inspection • 29

 shows the position for the dial indicator contact
point. It may be difficult to position the dial indicator Cylinders
and contact point in some zones of rotation without Inspect all cylinders as recommended by the Preventive
interference with the turntable or pedestal. In this Maintenance and Inspection Checklist.
case, position the dial indicator and contact point to
the area as close as possible to the recommended
position. Once a correct indicator contact point po-
Warning
sition is chosen, it is very important that the same Death or serious injury can result from cylinder
contact point position is used for each subsequent failure. Do not operate a cylinder that has a dented
tilt measurement. Therefore, record the contact point barrel or a damaged rod.
position in the maintenance or service log where the
tilt measurements are recorded. Some inspectors Visually inspect the cylinders for leaks, loose or missing
prefer to permanently mark the location where the pin retainers, broken bearings, bent rods, and dents in
dial indicator contact point contacts the bearing base the rod or barrel.
plate to ensure that subsequent measurements are
made in exactly the same spot. Check for proper operation of the cylinder holding valves
by positioning the boom or outrigger so a load is applied

• Dial Indicator Position to the cylinder to put pressure against the holding valves.
Turn off the engine. Fully shift the manual lever for the
function being tested. Hold the lever momentarily to allow
oil flow from the holding valve to tank. If the cylinder does
not move, the extend holding valve is operating properly.
If the cylinder retracts slowly, the holding valve may be
leaking. Determine the cause of the problem and correct
it before operating the unit.

Figure 4.18 — Pointer Position

Hydraulic Lines
7. Position the boom tip or auger tip a few inches above Hydraulic hoses and tubes transmit hydraulic oil through-
a suitable support. Place a thick wooden plank or out the hydraulic system.
similar material under the boom tip to protect it
from damage (refer to Figure 4.17). Operate the Inspect all hoses and tubes as recommended by the
boom lower function until the boom tip contacts the Preventive Maintenance and Inspection Checklist for
protective material on the support or the auger tip wear and/or physical damage. Make sure the hoses
contacts the ground. Continue to operate the boom are properly routed to avoid sharp edges, kinking, and
lower function until the hydraulic system reaches scuffing. Inspect the tubes for dents or other damage
maximum pressure and the lift cylinder stops retract- that may restrict oil flow. Make sure all hoses and tubes
ing. Make sure the lift cylinder does not bottom out are held firmly in their support brackets.
before maximum system pressure is reached. Set
the dial indicator at zero while holding the system at
Fiberglass and Plastic Components
maximum pressure.
The fiberglass components are covered with gelcoat to
8. Slowly raise the boom until the boom tip is raised off protect the fiberglass and resin composite. The gelcoat
the protective material or the auger is raised off the contains ultraviolet inhibitors to retard the effect of ul-
ground. Read and record the indicator reading. traviolet light on the fiberglass. With minimal care, the
sealing and ultraviolet properties of the fiberglass can be
9. Repeat steps 7 and 8 two more times to ensure an maintained for many years. The following sections include
accurate consistent reading. information on the cleaning and repair of fiberglass and
plastic components.
10. Remove the dial indicator to prevent accidental dam-
age. Inspect the fiberglass components for cleanliness and
any visible damage such as scratched, cracked, or
11. Refer to Bearing Replacement Criteria to determine chipped gelcoat. Surface irregularities may trap dirt and
if bearing replacement is required. contaminants, which over time may reduce the dielectric
properties of the fiberglass. Of particular concern are

30 • Section 4 — Preventive Maintenance and Inspection

irregularities running lengthwise on the boom. Trapped washing these components, take care not to create any
contaminants, such as dust particles and water, may surface scratches.
cause tracking, providing a path to ground or possible
dielectric failure.
Notice
Search for signs of looseness or movement at the bond Do not coat a fiberglass surface with any product
areas (fiberglass to steel or fiberglass to fiberglass con- that will reduce its dielectric characteristics or cause
nections) at the boom tip and end of the upper boom. If surface flashover.
the fasteners are properly tightened and the chemical
bond is good, it is unlikely damage will be found. If a Do not use petroleum based products to clean the fiber-
chemical bond has failed and the unit is operated using glass components. Petroleum based products will leave
the mechanical backup fasteners, cracks or elongation an oily residue that attracts dust.
of the holes may develop around the fasteners. The
fasteners will then begin to show frictional wear. Do not use steel wool to clean fiberglass components.
Retained metallic particles can provide a conductive path.
Other fiberglass components have a variety of mechani-
cal fasteners that require inspection. Surface flashover occurs when a substance causes an
arcing of electricity between two points on the boom. If
Cleaning this occurs, the dielectric integrity of the boom can be
Keep fiberglass and plastic components clean and in permanently damaged.
good condition to preserve the dielectric properties and
appearance. Clean all components passing through the Notice
boom fiberglass section.
When using a power buffer to polish fiberglass, do
not damage or overheat the gelcoat surface.
Notice
Do not spray water from a high pressure washer After the exterior surfaces are clean and dry, polish with
directly at hydraulic or electrical components. Formula Five Clean ’N Glaze. For the best results, polish
fiberglass surfaces by hand.
The fiberglass upper boom interior may be cleaned (as
necessary) using a pressure washer and directing the Plastic
stream of soapy water inside the boom. Rinsing with clean Plastic covers on the unit are covered with an acrylic
water will then remove any detergent residue. Elevate surface to protect the plastic from damage from ultraviolet
the booms for draining and drying. Allow the booms to damage. Use a pressure washer and mild detergent to
dry thoroughly before operating the unit. clean plastic covers. Rinse with clean water to remove
any detergent residue.
Warning
Notice
Death or serious injury can result from improper
use of solvents. Follow the manufacturer’s label for Using solvents (such as acetone, MEK, or lacquer
proper use and disposal. 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 the upper boom interior. A In some situations, pressure washing may not remove all
solvent may be used to clean this type of contamination of the contaminants from plastic covers. Use isopropyl
with some type of swab device. Suitable solvents, such (rubbing) alcohol to clean this type of contamination.
as acetone or Methyl Ethyl Ketone (MEK), may be used
to clean these stubborn areas. Refer to the precau- After the covers are clean and dry, hand polish using an
tions and instructions on the solvent selected for this automotive type wax.
cleaning procedure. This may require removal of some
interior boom components. After the contaminated area Determining the Degree of Boom Damage
is swabbed, use the pressure washer and follow up with Minor damage (scratches on the upper boom, the boom
a thorough rinsing with clean water. tip, and fiberglass control covers) is repairable. If no
fiberglass cloth fibers are cut or damaged, determine
The exterior of the upper boom, and other fiberglass if the scratch or nick affects only the gelcoat or if it is
components, may be washed with a mild detergent. When through to the resin. To do this, look at the color at the

Section 4 — Preventive Maintenance and Inspection • 31

bottom of the scratch. If the color is white, the damage is the unit (example — front of the unit, facing the boom
on the surface. This damage is minor and can be sanded tip with the unit in the stowed position).
out as described under Surface Damage in this section.
If the boom has several damaged or cut inner fiberglass
cloth layers, it may not be repairable. At this point, the
Notice
boom’s strength may be reduced and repairs will not
If the fiberglass is damaged past the gelcoat and restore the boom strength. If such damage is discovered,
shows up black, and/or the fiberglass cloth fibers are contact your Altec representative. They can evaluate the
damaged, contact Altec before any repairs are started. affect of the damage on the structural integrity of the
boom and determine if the damage is repairable or if the
If the color at the bottom of the scratch or nick is dark, boom must be replaced.
and there is no visible damage to the layers of fiberglass
cloth, the damage is through the gelcoat and just into the If it is determined that the extent and location of the dam-
resin. This requires a more thorough repair of the gelcoat age will not reduce the safety factor of the boom, it may
and is described under Gelcoat in this section. be acceptable to repair the damaged area with gelcoat
to seal it and place the unit back into service.
Any time there is doubt regarding damage to the boom,
use the following procedure to accurately describe the Repair
damage before calling Altec. Minor Surface Damage
Minor scratches in the surface of the gelcoat may be
1. Identify the quadrant in which the damage has oc- easily repaired. If the bottom of the scratch is the same
curred (refer to Figure 4.19). color as the gelcoat pigment, repair according to the
following procedure.

Caution
Injury can result from airborne particles entering the
eyes and lungs. Wear appropriate safety equipment.

1. Use a dual acting sander with 320 grit sandpaper to

sand the scratched area. Move the sander to sand
around the circumference of the boom. Do not sand
lengthwise on the boom.

2. When the scratch has almost disappeared, sand by

hand with a 600 grit wet or dry sandpaper until the
scratch is no longer visible.

3. Use Formula Five Clean ‘N Glaze to polish the area.

Gelcoat
Use an Altec gelcoat repair kit (refer to Service Tools and
Supplies in the Appendix) with the following procedure.
Figure 4.19 — Boom Damage Location Any scratch that is dark at the bottom is through the
gelcoat and into the resin below.
2. Identify the exact area along the boom’s length where
the damage is. To do this, measure from the boom In order for gelcoat repairs to cure properly, the following
tip to the damage site [example — 46″ (1,168.4 mm) special temperature considerations must be understood.
from the upper boom tip]. The highest quality gelcoat repairs are accomplished
indoors in a heated and well ventilated area.
3. Define the type, size, and the cause of the damage
[example — 2″ long x 1″ wide x 1/8″ deep (50.8 x 25.4 Notice
x 3.18 mm); gouge caused by a chain saw].
The gelcoat can be burned during the warming pro-
4. When calling Altec to describe the damage in ques- cess. Continually move the heat gun or paint stripper
tion, be sure to explain where you are in relation to during warming.

32 • Section 4 — Preventive Maintenance and Inspection

 • If the unit has been outside and the temperature is 7. When the area has cured, sand the area by hand
less than 70 degrees Fahrenheit (21 degrees Cel- with 600 grit wet or dry sandpaper. Sand until the
sius), or if this is a field repair, the boom area must patch is no longer visible.
be warmed before proceeding. Warm the fiberglass
using a heat gun until it is warm to the touch. It will 8. Use Formula Five Clean ‘N Glaze to polish the area.
take approximately 40 minutes to do this. A paint
stripper gun will provide a faster method. Do not Platform and Fiberglass Covers
concentrate the heat of the gun in one specific area The first step in successful repair is to analyze the dam-
for any length of time. age and determine the cause. Cracks in the gelcoat or
outer surface of the platform or cover are easily repaired.
• If the outside temperature is below 60 degrees Fahr- Damage to the fiberglass structure can be more serious
enheit (16 degrees Celsius), a field gelcoat repair is and should be carefully evaluated before attempting to
not suggested. Makeshift tents over the repair area repair the platform.
will not hold sufficient heat, preventing proper curing.
Structural components of the platform include the rim,
Caution mounting ribs, platform sides, and the bottom (refer to
Figure 4.20). The platform is constructed similar to a
Injury can result from airborne particles entering the basketball hoop and net. The rim supports the sides
eyes and lungs. Wear appropriate safety equipment. in the same way that the basketball hoop supports the
net. The structural integrity of the platform rim is critical
Use the following procedure to repair the gelcoat. in determining whether or not the platform can be suc-
cessfully repaired. The platform bottom and the side
1. Use a die grinder to widen the scratch to 1/8″ (3.18 with the mounting ribs are substantially thicker than the
mm). Do not grind into the fiberglass cloth. other three sides. The mounting ribs are the area where
the platform mounting bracket fastens to the platform.
2. Inspect the scratch. If the fiberglass cloth is cut, Consider these factors when determining whether a
contact your Altec representative. If no fiberglass successful repair can be made on the platform bottom
cloth is damaged, bevel the edges of the 1/8″ (3.18 or mounting rib side.
mm) cut to about 45 degrees.

3. Lightly sand the damaged area by hand to roughen

Rim
it up. This will help the resin bond to the surface.

Warning
Mounting
Death or serious injury can result from improper Ribs
use of solvents. Follow the manufacturer’s label for
proper use and disposal.
Sides
4. Use a solvent such as acetone to clean the area and
remove any dust.

5. The Altec gelcoat repair kit contains a can of resin, a

can of fumed silica powder, and a bottle of hardener.
Figure 4.20 — Platform
Refer to the material safety data sheet included with
the kit for special precautions and recommendations
Altec cannot determine if the platform is repairable in the
for use with this product. Mix the resin, powder, and
field. Evaluate the platform and determine whether or not
hardener according to the kit instructions.
it can be repaired and safely used for future service. Altec
does not recommend that repairs be made to platforms
6. Apply the mixture to the damaged area with a plastic
which have the following damage.
spatula. Work the spatula back and forth to remove
any air bubbles. Build up the area so it is slightly
• Cracks through the fiberglass of the mounting ribs
above the boom surface. The mixture will shrink
• Cracks through the fiberglass of the rim
slightly as it cures.
• A hole through the floor or mounting rib side of the
platform

Section 4 — Preventive Maintenance and Inspection • 33

Altec only assumes responsibility for platform repair 7. After the resin has set up completely, grind off any
performed by Altec personnel. rough areas or high spots.

8. Mix an additional cup of resin and catalyst according

Warning
to the directions in the gelcoat repair kit and apply
Death or serious injury can result from contact with smoothly to completely cover the affected area.
energized conductors. Do not operate the unit with
a hole in the platform or liner. 9. Sand the area with the dual acting sander and 320
grit sandpaper.
The following items are required to perform field repair
of the platform or fiberglass covers.
Notice
• Circular grinder with 24 grit sandpaper Do not coat a fiberglass surface with any product
• Dual acting sander with 320 grit sandpaper that will reduce its dielectric characteristics or cause
• Cleaning solvent (acetone) surface flashover.
• Fiberglass cloth or mat
• Gelcoat repair kit 10. Paint the area to match the platform. Do not apply
• Good quality rubber gloves metallic paint to the platform.
• Dust mask
• Safety glasses Damage to the gelcoat layer may be repaired using the
• Nonmetallic spray paint to match the platform instructions that accompany the gelcoat repair kit. This
kit may be ordered from your Altec representative. The
Use the following procedure as a guide in making a gelcoat provides a protective layer of ultraviolet inhibitors.
quality field repair. The gelcoat layer has no inherent strength.

1. Outline the damage with a box that is 1″ (25.4 mm) Before making any repair, the structural integrity of the
wider on all sides of the damaged area. Example — platform and the safety of the operator must be kept in
If the damage is 1″ x 3″ (25.4 x 76.2 mm), the box mind. More specific repair information for a particular situ-
would be 3″ x 5″ (76.2 x 127 mm). ation should be requested from your Altec representative.

Caution Winch Line

Injury can result from airborne particles entering the The winch drum is designed to accommodate synthetic
eyes and lungs. Wear appropriate safety equipment. winch line. Inspect the winch line as recommended by
the Preventive Maintenance and Inspection Checklist.
2. While wearing safety glasses and a dust mask for
breathing protection, grind the area within the box Synthetic Winch Line
to a depth of approximately 1/8″ (3 mm).
Warning
3. Cut strips of fiberglass cloth to fit the box area. Death or serious injury can result when the synthetic
winch line contacts an energized conductor and the
ground. Do not allow the winch line to contact an
Warning
energized conductor.
Death or serious injury can result from improper
use of solvents. Follow the manufacturer’s label for The synthetic winch line is not to be considered an in-
proper use and disposal. sulator. Contact between an energized conductor and
the ground may result when the winch line is extended
4. Clean the area thoroughly with solvent. to the ground.

5. While wearing rubber gloves, mix the approximate Normal use will gradually reduce the strength of synthetic
amount of polyester resin and catalyst according to winch line. The entire length of the line must be inspected
the directions in the gelcoat repair kit. as recommended by the Preventive Maintenance and
Inspection Checklist.
6. While wearing rubber gloves, saturate the fiberglass
cloth with the mixed resin and apply it to the damaged Keep a permanent, written, and dated report of the line’s
area. Work the area to squeeze out any air bubbles. condition and any corrective action taken during the
inspection on file.

34 • Section 4 — Preventive Maintenance and Inspection

Follow the instructions of the line manufacturer when diameter of the drum and d is the diameter of the rope)
splicing a synthetic winch line. A properly made splice is for turntable winches. For boom tip winch replacement
a strong and efficient means of attachment. line consult your Altec representative. The replacement
winch line must be long enough to provide at least five
When inspecting the synthetic winch line, use the fol- full wraps of the line on the winch drum. This is with the
lowing guidelines to determine the condition of the line. load hook on the ground and the booms and any jib at
full extension and elevation.
• A few damaged strands spaced out along the length
of the line are acceptable. List the location of the Warning
damaged strands in the report. Check these strands
carefully in future inspections. Death or serious injury can result from loss of load
control. Install the winch line in the proper direction
• To determine wear, compare an individual strand in of the drum rotation.
an area where it is exposed and subjected to wear
with an area of the same strand where it has been The winch line must be installed in the proper direction
protected from wear. If individual cover strands have of drum rotation for the holding valve to be effective.
worn to within 50 percent of their original bulk over
an extended area of the line, replace the line. When spooling new line on the drum, make sure the first
wrap that exits the anchor pocket is flush with the drum
• If half of the cover strands are cut at a given point, flange. This will help you achieve even spooling of the
replace the line or cut out the damaged section and winch line.
splice the line back together.
Put the first layer of line close and tight around the winch
• Replace a spliced line if it does not meet the length drum. The line should be under a tension of at least 50
requirements under Replacement in this section. pounds (22.68 kg). This will help prevent subsequent
wraps from slipping down between the first layer of wraps
• If a damaged section is removed near the eye of the when a load is applied to the winch.
line, put in a new eye splice. Use a standard end-
for-end splice to rejoin the line in other areas. Auger Windup Sling
Knots can reduce rope strength. A winch line should The unit is equipped with a synthetic auger windup sling.
never have a knot tied in it.
Warning
Wash the line with a mild detergent and warm water.
Strong cleaning agents or bleaches may be harmful to Death or serious injury can result if the auger sling
the line and must not be used. breaks. Replace a worn or damaged auger sling.

Rinse the line thoroughly after washing it. Squeeze out If any of the conditions given in this section are found,
the water by placing the line under tension. Allow the replace the sling with an Altec replacement part to insure
line to air dry. that the proper rope is used.

Rotate the winch line end-for-end on a periodic basis. Synthetic Sling

This will vary the high stress and wear points, extending When inspecting a synthetic auger windup sling, check
the useful life of the line. This is not possible if a closed the following items.
thimble is spliced into the lifting eye.
• A few damaged strands that are spaced out along
Replacement the length of the line are acceptable. Check these
When replacing a synthetic winch line, the replacement strands carefully in future inspections.
synthetic winch line must be of the same size and at
least the same rated working load as the rope originally • If individual cover strands have worn to within 50
furnished with the unit. The winch line rated working load percent of their original bulk over an extended area
of the originally furnished line is shown on the capacity of the line, replace the line. This can be determined
placard at the lower controls. ANSI requires that the de- by comparing an individual strand in an area where it
sign factor of synthetic-type ropes shall not be less than is exposed and subjected to wear to the same strand
5:1 and that the winch drum diameter be in a ratio of no where it crosses under other strands and has been
less than 8:1 to the rope diameter (d < D/8, where D is the protected from wear.

Section 4 — Preventive Maintenance and Inspection • 35

 • If half of the cover strands are cut at a given point, The following may cause the sling to overload while
the line must be replaced or the damaged section stowing the auger.
must be cut out and the line spliced back together.
• Excessive digger speed
• Check the welded lug (refer to Figure 4.21) that • A bent auger or auger extension shaft
secures the sling during auger stowage. If the lug • Improper adjustment or malfunctioning of the auger
appears to be cutting strands on the sling, repair or stow switch
replace the lug and the sling.
When inspecting the shear pin, make sure it is intact. If
• Knots can reduce line strength. A sling should never the shear pin is broken, replace it with a new one. De-
have a knot tied in it. termine the cause of the shear pin failure and correct it.

Auger Stow Bracket Clevis Care of Tracks

The auger stow bracket is equipped with a pivoting clevis The following tips for storage and use of rubber tracks
attached to the auger windup sling (refer to Figure 4.21). will help lengthen lifespan.
The clevis is held in its normal position by a shear pin.
• Avoid sharp objects such as rocks, broken concrete,
If the windup sling is overloaded while stowing the auger, and steel that can cut rubber.
the shear pin will fail before the sling is damaged. When
the shear pin fails, the clevis tilts to a vertical position. • Keep debris from becoming entangled in track which
This drops the auger slightly with a jolt to alert the op- can lead to cuts or stretching of the track. Debris that
erator that too much tension is being put on the auger does accumulate should be washed between jobs to
windup sling. If the shear pin fails, promptly replace it minimize wear on tracks, rollers, and drive sprocket.
with a genuine Altec replacement part.

Auger Stow Bracket

Shear Pin
Clevis

Auger Windup Sling

Auger Auger Stow Auger
Extension Bracket Tube Auger
Digger Bail Cable Guide Shaft Lug Cap Screw
Dish
Digger
Hanger
Link

Figure 4.21 — Auger Mechanism

36 • Section 4 — Preventive Maintenance and Inspection

• Avoid unnecessary sharp turns which, in addition to • During storage, whether the track is installed on
the extra wear due to increased scrubbing, will also equipment or loose, rotate the track monthly to keep
make sharp objects more likely to dig into rubber the sections at each end which are under greater
and debris more likely to pack in between track and bending stress from establishing cracks.
rollers.
• As cracks develop in the rubber, the track will con-
• Avoid unnecessary turns while transversing hills or tinue to function; however, it will become increasingly
driving with track edges against or on curbs, slopes, important to minimize exposure to corrosive environ-
etc., both of which will accelerate wear and can ments during storage and use once the crack has
stretch the metal cable core of the track and/or tear penetrated the thickness of the rubber to the steel
the rubber exterior. core of the track.

• Maintain proper track tension to avoid detracking. A

Accident Prevention Signs
track that becomes loose on the drive sprocket teeth
can be stretched while detracking. This unit was equipped with accident prevention signs
at the time of manufacture. If any of these are lost or
• Rubber will crack due to UV and ozone degradation become illegible, obtain replacements from your Altec
with age. To minimize this, store tracks or tracked representative.
equipment indoors or cover the tracks to avoid sun-
light exposure. Grey “non-marking” tread compounds The location, part numbers, and descriptions of all plac-
are more severely affected by sunlight exposure ards are listed in the Parts Manual. Refer to the Accident
and ozone gas due to not being compounded with Prevention Signs Diagram for examples of the placards
the same anti-aging additives; therefore, the proper and their locations.
storage of these tracks will be very important to avoid
shortened useful life.

Section 4 — Preventive Maintenance and Inspection • 37

Accident Prevention Signs Diagram

A
21 31

6*
23
38
17*
6*
1

17*
37
Item Information
A * Both sides
16 Installed on platform of dual platform units 36
33 and 34 Installed at boom tip of combined use units All Outrigger
Legs 19

31 21

23

25
3 1

Auger Stow Bracket

24 35

15 2 13 18
Radio Controls Material Handling Jib

38 • Section 4 — Preventive Maintenance and Inspection

 1 23
4 9 10 38 3
11 28
24 20 31
5 20 5
22
9 11 14 8

20 29 28 29 32 27
8 30
12 35
7
10 30
26
4

Section A-A

3
2

Section 4 — Preventive Maintenance and Inspection • 39

 5

4
6

40 • Section 4 — Preventive Maintenance and Inspection

9
10

12

11

13

Section 4 — Preventive Maintenance and Inspection • 41

 14

15

16

17 18

42 • Section 4 — Preventive Maintenance and Inspection

19
20

22

21

24
23

Section 4 — Preventive Maintenance and Inspection • 43

 26

25

28

27




29 30

44 • Section 4 — Preventive Maintenance and Inspection

 32
31

33

Section 4 — Preventive Maintenance and Inspection • 45

 35

34
NOTICE

37
36

NOTICE
38

46 • Section 4 — Preventive Maintenance and Inspection

 Section 5 — Hydraulic System
The unit uses a closed center hydraulic system. The
proportional control valve has a load sense circuit with
a bypass inlet. A fixed displacement, tandem section,
50% 75% 10
gear pump supplies a maximum total flow of 16.5 gpm 25% 0%
HO
0%
(62.46 lpm). Operation of the pump is explained under P

Pumps in this section. LOAD INDICATOR

When a function is operated, the function’s speed is

proportional to the distance the hand control is shifted.
If the boom hand control is shifted in the Raise posi-
tion at maximum hand control travel, the boom rises at
maximum speed. Figure 5.1 — Load Indicator Gauge
Hydraulic schematic drawings are an important tool in
understanding the operation of a hydraulic system. The Warning
symbols identify the flow paths and operation of the Death or serious injury can result from overloading
components in the system. A thorough understanding of the unit. Do not exceed the rated capacity values.
these symbols can reduce downtime and increase the
accuracy of diagnosing malfunctions. Basic hydraulic
schematic symbols are identified in the Appendix. Notice
The load indicator gauge only measures the load as
This section includes a description of the hydraulic a percentage of the unit’s rated hydraulic capacity.
components and an illustration of the components. Hy- It does not reflect stability of the unit, which can
draulic schematics of the components can be found in cause the load capacity to be less than the hydraulic
the Appendix. capacity.

Operation
Protection Systems
The derrick is designed so that at rated hydraulic capacity,
The unit is equipped with protection systems that are regardless of boom angle or extension, the pressure in the
intended to protect it from being overloaded due to opera- base end of the lift cylinder will be 2,350 psi (162.03 bar)
tor error. However, even with these protection systems, for non-dual platforms. When the derrick is overloaded,
the unit can be damaged if the operator disregards the a higher pressure will be induced in the base end of the
recommended methods and procedures described in the cylinder. A pressure switch in the valve block on the base
Operator’s Manual. end of the cylinder (refer to Figure 5.2) senses pressure.
When the pressure reaches 10 percent over the pressure
Hydraulic Overload Protection (HOP) allowed in the lower boom circuit, HOP engages. HOP
The HOP system prevents excessive overloading of the electrically interrupts the following functions.
derrick. The system consists of hydraulic and electrical
components. • Winch raise
• Digger dig
Load Indicator Gauge • Boom lower
The load indicator gauge is located at the lower control • Intermediate boom extend
station. It shows the percentage of the derrick’s rated • Upper boom extend
hydraulic capacity that is being used when lifting a load.
The gauge has two zones. At 100 percent, rated hydraulic
capacity. The area to the right of the 100 percent mark
represents loads that are over rated hydraulic capacity. At Pressure Transducer
the point marked HOP, the hydraulic overload protection
system will activate. By noting the reading on the gauge,
the operator is aware of the percentage of the unit’s rated
hydraulic capacity used when lifting a load. The gauge
in Figure 5.1 illustrates a load that is 75 percent of the
unit’s rated hydraulic capacity. Lift Cylinder

Figure 5.2 — HOP Pressure Switch Connection

Section 5 — Hydraulic System • 47

The following functions remain operational so the operator Rotation/Side Load
can relieve the overload when the HOP system is engaged. Gearbox Motor
Protection Valve

• Winch lower
• Digger clean
• Boom raise
• Intermediate boom retract
• Upper boom retract

When the overload is eliminated, the system automatically

restores operation to the functions that were temporarily
shut off.
Figure 5.3 — Rotation/Side Load Protection Valve
The electrical connection runs from the pressure trans-
ducer in the valve block on the base end of the lift cylinder The housing of the rotation/side load protection valve
to the above rotation driver board. (refer to Figure 5.4) contains two counterbalance valve
cartridges, two pressure transducers and a shuttle valve.
Electronic Side Load Protection System Each counterbalance valve cartridge controls one direc-
The side load protection system prevents damage to the tion of rotation.
unit structures when an excessive side load is developed
on the booms. Units with a side load gauge on the lower Normal Rotation Operation
control panel have electronic side load protection. Side Dual counterbalance valves, located on the rotation
loads are commonly caused by winching a load in from motor, prevent rotation of the booms when all controls
the side or corkscrewing an auger into the ground. Side are in neutral.
loads are also caused by failing to follow the movement
of a screw anchor or auger with the boom, rotation, and Side Load Protection Operation
intermediate boom controls or applying excessive down If a side load is created on the booms during digger or
force when setting a screw anchor or digging. winch operation, the rotation system attempts to back
drive. This causes the rotation motor to act as a pump,
When properly adjusted, the side load protection system building hydraulic pressure in the side load protection
engages the HOP system when excessive side loading system. This pressure is measured by the transducers
occurs due to operator error during digging and winching in the rotation/side load protection valve which sends a
operations. HOP shuts down the functions that could be signal to a circuit board in the above rotation valve driver.
creating the side load. The circuit board is connected to the side load indicator
light at the lower control panel.
Notice
The side load indicator light indicates different operations
Repeatedly engaging the side load protection system of the system. The light will stay off until a preset pressure
can damage the unit. value in the system is reached by side loading. While
winching and digging, with no rotation of the turntable,
Operate the unit in a manner that avoids developing a the light will come on when the pressure in the side load
side load on the booms. Do not rely on the side load pressure system reaches the preset pressure value and
protection system to prevent side loads from developing HOP will be engaged. The light will stay on until the pres-
on the booms. The system is intended to protect the unit sure drops below the preset and the system resets itself.
from excessive side loading due to operator error. Each
time the side load protection system operates, the unit During normal rotation of the turntable or when the op-
is subjected to an overload. Repeated overloads could erator is operating the rotation function and the dig or
cause fatigue failure of unit components. winch function, the protection system monitors side load
pressure. If the pressure exceeds the preset value, the
The rotation/side load protection valve has two purposes. indicator light will illuminate. There will be no side load
It controls hydraulic oil flow to the rotation motor and protection while the rotation function is being operated.
senses rotation system hydraulic pressures for the side HOP will not be engaged. As the operator stops rotating
load protection (refer to Figure 5.3) system. The rotation/ and continues to operate the dig or winch function, the
side load protection valve is mounted on the rotation system will not measure the side load pressure until the
gearbox motor. pressure in the system drops below the preset value or

48 • Section 5 — Hydraulic System

 Figure 5.4 — Rotation Hydraulic Circuit

until two seconds after stopping rotation. The system will

then function as previously described.

The preset values for clockwise and counterclockwise

directions are adjusted with the CADI (refer to Section
8 under Protection Systems).

Notice
Overriding the side load protection system with the
Boom
rotation hand control can damage the unit. Stow Bracket
Never attempt to counteract the side load protection sys-
tem by shifting the rotation hand control in the opposite Boom Stow Switch (Inside)
direction of the sideslip. Figure 5.5 — Boom Stow Bracket

Test the side load protection system for proper operation The boom stow switch is actuated when the boom is
as recommended by the Preventive Maintenance and stowed in the boom rest. The switch engages the HOP
Inspection Checklist. Also, check the side load protection system. One of the functions the HOP system shuts off
system any time excessive side load protection actuation is the boom lower function. With the boom lower func-
occurs during normal digging or winching operation. Refer tion shut off, damage to the chassis is prevented if the
to Section 8 for procedures to properly test and adjust boom control is not immediately released once the boom
the side load protection system. is stowed.

Boom Stow Protection The boom stow switch may be used to test the operation
The derrick has a proximity switch in the boom stow bracket of the electrical portion of the HOP system. With the boom
on the underside of the lower boom (refer to Figure 5.5). in the boom rest, all of the functions which are disabled
by actuation of the HOP system should be inoperable,
as described under Hydraulic Overload Protection (HOP)
in this section.

The actuation point of the boom stow switch is adjustable.

Section 5 — Hydraulic System • 49

Test the boom stow switch (refer to Section 8 under Boom Filler Breather Cap
Stow) as recommended by the Preventive Maintenance
and Inspection Checklist.
Strainer
Basket
Auger Stow Protection
The derrick has a proximity switch in the auger stow
bracket on the side of the lower boom (refer to Figure 5.6).

Lower Boom

Suction
Strainer

Figure 5.7 — Hydraulic Oil Reservoir

Pumps
Auger Stow Switch (Inside) The unit uses a fixed displacement, tandem section,
gear pump.
Figure 5.6 — Auger Stow Bracket
In case of catastrophic pump failure, the hydraulic system
The auger stow switch is actuated when the auger reaches must be flushed. This procedure is described in Section
the top of its travel during stowing, shutting off the digger 4 under Changing Oil and Flushing the System. Flushing
dig function. With the digger dig function shut off, damage the system will remove most of the metallic contamina-
to the unit is prevented if the digger hand control is not tion from the system.
immediately released once the auger is stowed.
Before servicing the pump, close the shutoff valve and
The actuation point of the auger stow switch is adjustable. remove the top cover on the head of the return line filter.
Closing the shutoff valve allows the pump to be serviced
Test the auger stow switch (refer to Section 8 under Auger or removed without draining the reservoir. The shutoff
Stow) as recommended by the Preventive Maintenance valve is located below the hydraulic reservoir in the suc-
and Inspection Checklist. tion line between the reservoir and the pump. Removing
the top cover on the return line filter head prevents oil
Oil Reservoir from siphoning out of the reservoir and back through the
hydraulic system when the pump is opened or hoses
The 16.8 gallon (63.6 l) reservoir is vented. A 300 micron are removed.
magnetic suction strainer is located at the outlet. A filler
breather cap is also located on top of the fill hole of the
reservoir. The cap contains a 40 micron filter that cleans Notice
the air as it enters the hydraulic system. The cap also Damage to the pump or return line filter can result if
has a strainer basket that keeps large particles from the unit is operated with either or both of the shutoff
entering the reservoir when oil is poured into it. Refer to valves closed. Fully open the shutoff valves before
Section 4 under Filtration for information on the filters in engaging the hydraulic system.
the reservoir.

Figure 5.8 — Hydraulic Pump

When service is completed, open the shutoff valve before

operating the unit.

50 • Section 5 — Hydraulic System

Valves
When describing hydraulic valves, “position” identifies
the number of operating positions of the valve spool. A
two-position blocking valve has two operating positions,
open and closed.

The word “way” identifies the number of ports in a valve

section. A four-way control valve has four ports. One port
is for a pressure connection, one is for a return line con-
nection, and the other two ports are the working ports.

Refer to Figure 5.9 for the general locations of the hy-

draulic system valves. Figure 5.10 — Drive/Outrigger/Tools Valve

Drive/Outrigger/Tools Valve Main System Relief Valve

The drive/outrigger/tools valve (refer to Figure 5.10) is The system utilizes a relief valve cartridge located in
located on the track frame near the fuel tank. The spools the inlet end of the drive/outrigger/tools valve. This relief
in this valve operate the cylinders to lower and raise the should be set at 2,500 psi (172.37 bar) at 16 gpm (60.57
outriggers, extend and retract the tracks, turn the lower lpm), combined pump flow. Adjustment of this valve is
tool circuit on and off, and operate the track drive motors. described in Section 8 under Main System Relief.
This valve also has pressure reliefs for the tool circuits,
an adjustable flow control for the tools, and a blocking
valve that will block flow to derrick unit for outrigger and
track operation and will block flow to the outriggers and
tracks for operation of derrick.

Pole Guide/Upper Tools/

Auger Release

Boom Functions

Drive/Outrigger/Tools

Figure 5.9 — Valve Locations

Section 5 — Hydraulic System • 51

 The spool valve for the boom raise and lower functions
is a closed work port spool. This means that in neutral,
no hydraulic flow can enter or leave the work ports.

The spool valves for the rotation, intermediate, and up-

per boom functions are float center spools. In neutral,
Relief the two working ports are connected to tank. This allows
the intermediate and upper boom extension cylinders to
creep down if they are overloaded. The rotation, lower,
intermediate, and upper boom spools have pressure
limiter cartridges. Adjustment of these pressure limiters
is described in Section 8 under Protection Systems.
Figure 5.11 — System Relief Valve
Two spool valves are used to direct hydraulic oil flow for
Boom Functions Valve the operation of the winch and digger functions. These
The boom functions valve is an electrohydraulic propor- valves are three-position, four-way valves. The winch and
tional control valve located at the turntable. When the digger spool valves are float center spools. In neutral,
lower controls or radio controls are used to operate the the work ports are connected to tank.
unit, it uses electrically controlled pulsars (solenoid pilot
valves) to control valve spools operating the turntable Bypass Spool
rotation motor, lift cylinder, intermediate and upper boom A bypass spool is located in the inlet section of the boom
extension cylinders, and digger/winch functions. functions valve. This spool is a two-position, two-way valve.

The boom function valve is equipped with manual controls When the unloader valve is energized, the bypass spool
that can be used to operate the unit. The manual controls will connect the pump flow to tank at a differential pres-
have had the handles removed but are accessible for sure of 215 psi (15 bar). As the pressure for a function
operation if the required. is applied to the bypass spring cavity, the spool meters
the oil from the tank output into the boom functions valve
bank. The sense pressure will read 215 psi (15 bar) less
than system pressure due to the bypass spring tension.

Load Sense Shuttles

Shuttles are located between each spool in the load
sense circuit. Load sense pressure is applied to the
bypass spring cavity. The spool meters inlet flow to tank
to maintain system pressure at 215 psi (15 bar) higher
than load sense pressure. When more than one function
is operated at the same time, shuttles send the highest
pressure requirement to the bypass spool.

Individual Pressure Compensators

The boom functions valve has pressure compensators for
the rotation, lower boom, intermediate boom, and upper
boom spool valves. This maintains constant flow to the work
ports, independent of supply or load pressure variances.

Relief Cartridge
Figure 5.12 — Boom Functions Valve A relief cartridge is located in the inlet section of the
boom functions valve. This valve limits the pressure in
Spool Valves the system to a factory preset 2,800 psi (193 bar).
The valve has four spool valves used for the boom func-
tions. These valves are three-position, four-way valves. Pilot Pressure Reducing Cartridge
The spool valves direct hydraulic flow to the actuators The pilot pressure reducing cartridge in the inlet section
that operate the boom functions. Maximum travel of the is set at 150 psi (10.34 bar). This valve supplies the pul-
spools may be adjusted to control the speeds of the sars with the reduced pilot pressure. Adjustment of this
boom functions. cartridge is described in Section 8 under Pilot System
Pressure.

52 • Section 5 — Hydraulic System

Pulsars (Solenoid Pilot Valves) Pilot Operated Check Valves
Pulsars are driven by a pulse width modulation (PWM) Pilot operated check valves are used to block flow out
signal to vary the modulation ratio. This digital signal of the pole guide tong cylinder and the base end of the
varies the on time versus the off time to provide smooth outrigger cylinders.
valve operation. The solenoid controls the pilot pressure
applied to work section spools. Thus the valve spool posi- A pilot operated check valve allows free flow into the
tion and corresponding function speed are proportional actuator and blocks return flow. It is equipped with an
to the handle position of the electrical control. internal pilot piston that allows the valve to be hydrauli-
cally piloted open to allow flow out of the actuator.
Pole Guide/Upper Tools/
Auger Release Valve Counterbalance Valves
The auxiliary functions valve (refer to Figure 5.13) is Counterbalance valves are used to block flow out of the
located on the side of the turntable, next to the boom following actuators.
functions valve. It contains solenoid-operated valves for
the auger release, pole guide tilt, and pole guide open- • Lift cylinder
close/boom-tip tools functions. • Rotation motor
• Upper boom extension cylinder
• Intermediate boom extension cylinder
• Winch motor
• Outrigger cylinders (rod end)
• Pole guide tilt cylinder

A counterbalance valve is a combination of a check valve

and a relief valve. The check valve allows free flow into
the function and blocks the flow from coming back out.

The relief valve function can be piloted open to allow

flow out of the function. It also allows the valve to relieve
excess pressure and prevents damage from thermal
expansion of the oil.

The counterbalance valves used with the rotation motor

and intermediate and upper boom extension cylinders
are installed in pairs and are cross-ported. Oil sent to one
Figure 5.13 — side of the actuator is used to pilot open the counterbal-
Pole Guide/Upper Tools/Auger Release Valve ance valve on the other side of the actuator.

Spool Valves
Cavitation and Aeration
The spool valves are solenoid operated. The spool valve
that operates the pole guide tilt and pole guide open/ Cavitation and aeration are two problems that can cause
close/boom-tip tools function is a three-position, four- pump damage. Pump cavitation occurs when inlet oil does
way valve. The auger release valve is a two position, not entirely fill the cavities that open during the intake
three-way valve. part of the pumping cycle and the pump tries to draw a
vacuum. The characteristic sound of cavitation is a high
Holding Valves pitched scream. This sound increases with the degree
The unit uses holding valves to insure that various of cavitation and increased flow. The following items are
actuators maintain their position under load or if there possible causes of cavitation.
is hydraulic line failure. These holding valves block the
hydraulic oil in the actuators to prevent movement. Pilot • Excessive pump operating speed
operated check valves and counterbalance valves are • Clogged suction filter
types of holding valves. • Excessive oil viscosity (thickness)
• Restrictions or sharp bends in hose
Testing of pilot operated check valves and counterbalance • Excessive inlet hose length
valves is described in Section 8 under Hydraulic System. • Pump inlet too high above reservoir level
• Shutoff valve in suction line not fully open

Section 5 — Hydraulic System • 53

 Notice • A leak in the plumbing between the reservoir and
Cavitation can quickly destroy the pump. If signs of the pump can suck air in and not leak out when the
pump cavitation are noticed, determine the cause system is shut down.
and promptly repair the problem.
• Loose connections in the pressure system will nor-
If pump cavitation is due to excessive oil viscosity caused mally leak externally during unit operation, but can
by cold temperatures, allow the oil to warm up before suck air into the system after the unit is shut down
operating the unit. as the oil tries to find its way to the low points of the
system.
Aeration occurs when air bubbles are introduced into the
hydraulic oil and carried along as the oil flows through the • Hydraulic lines taken loose during maintenance
pump. Aeration can be caused by the following conditions. operations.

• Low oil level in the reservoir. This can cause a whirl- Notice
pool at the suction line opening, which sucks air into
the system along with the oil. Air circulating through the pump can cause unit
malfunctions or pump damage. Determine the cause
• Leaking connections in the suction line between the and repair the problem.
reservoir and the pump.
Air entering the system due to low oil levels or leaks in
• Return line outlet is located above the oil level in the the suction line will cause the most problems and should
reservoir. This causes turbulence as the return oil be corrected immediately. Most of the lines in the system
stream discharges above the surface of the oil. will purge the air from the circuit during normal use.

Notice Relief Valve Cartridge Purging

Air circulating through the pump can cause unit Contamination in the boom functions/digger/winch system
malfunctions or pump damage. Determine the cause relief can cause inconsistent readings while checking or
and repair the problem. adjusting the relief. Use the following procedure to purge
the system relief.
An air leak in the suction line can occur even if there
is no oil leak when the system is shut down. A leak in 1. Position the unit on a level surface and properly set
the suction line can often be located by slowly squirting the outriggers. Turn off the engine. Remove the car-
clean hydraulic oil around each connection in the suction rier cover from the front, right side of the carrier (as
line. Do this with the pump running at normal operating viewed from the boom tip to the carrier).
speed. Be sure to check for leaking around the O-ring
where the four bolt flange attaches to the pump. A suc- 2. Remove the cap on the cartridge and turn the adjusting
tion leak will suck oil in. The pump may temporarily run screw counterclockwise to decrease the pressure.
quietly as the air leak is sealed by the oil. The leak can
then be eliminated. 3. Start the engine and move the drive outriggers tools/
lower/radio control to the Lower position. With the
When aeration occurs, the oil in the reservoir is likely boom stowed, move the intermediate boom control
to become foamy. The pump may also become noisy. to the Retract position. Note the pressure indicated
on the system pressure gauge at the lower controls.
Turn off the engine.
Air Bleeding
The presence of air in any hydraulic system will cause Notice
abnormal operation, noise, and damage to the pump.
The presence of air in the hydraulic system can usually Do not turn the adjusting screw completely out of
be traced to one of the following. the cartridge.

• If the oil level in the reservoir gets too low, the pump 4. Repeat the steps 2 and 3 until the gauge indicates
suction can cause a whirlpool to form in the reservoir no change is made in the pressure by turning the
which will allow air to be sucked into the system. adjusting screw. Turn the adjusting screw counter-
clockwise one full turn more.

54 • Section 5 — Hydraulic System

 5. Start the engine and move the drive outriggers tools/ a rotary joint will cause functions to slow down and/or
lower/radio control to the Lower position. With the fail to build pressure. Replacing the seals in the leaking
boom stowed, move the intermediate boom control component will usually stop an internal leak.
to the Retract position and hold the control in this
position for at least 30 seconds to allow the oil to go A leaking holding valve in a cylinder can cause drifting
over relief and purge the relief of any contamination. or malfunction of the cylinder. It may be stopped by re-
placing the holding valves in the component. However,
6. Adjust the pressure to 2,500 psi (172.37 bar) (refer some types of damage, such as scoring of the inside of
to Section 8 under Boom Functions/Digger/Winch a cylinder barrel, require more extensive repair.
System Relief).
Heat Generation
Leakage Heat is the result of pressurized fluid escaping to the
If components and connections are installed properly, reservoir. Most hydraulic components have a small in-
leakage can be kept to a minimum. Small external leaks ternal leak due to machine tolerances. This type of leak
are usually easy to find because dust will collect on the generates a very small amount of heat that is taken into
hydraulic oil film. account when the component is designed. The amount
of heat in the system has a direct relationship to the
Improperly tightened fittings are a primary cause of ex- pressure and volume of leakage.
ternal leakage. Follow the torque and tightening specifi-
cations explained under Fittings and Valve Cartridges in Internal leaks in the system may be caused by internal
this section to properly tighten hydraulic fittings. housing cracks, bad relief valves, or leaking seals. This
type of leak allows a large volume of pressurized oil to
return to the reservoir, creating excessive heat in the
Warning
hydraulic system. Continuous operation with excessive
Death or serious injury can result from hydraulic heat will damage the hydraulic oil, seals, and O-rings
oil being injected into the flesh. Do not use hands throughout the system.
or other body parts to check hydraulic lines and fit-
tings for leaks. The following conditions cause heat generation.

Seek immediate medical attention if injured by escap- • Excessive pump speed during high flow operations
ing hydraulic oil. Serious infection or reaction can (such as digging)
result if medical treatment is not given immediately. • Worn or defective pump
• Defective pulsar valve
Spilled hydraulic oil creates slick surfaces and can • Low hydraulic oil level
cause personnel to slip and/or fall. Keep the unit and • Improper hydraulic oil
work areas clean. • Defective relief valve cartridge in boom functions
valve or drive/outrigger/tools valve
If a connection is properly tightened but continues to • Using boom lower function to hold downward boom
leak, disassemble the connection. Seal the necessary force continuously during prolonged periods of dig-
parts and/or replace the defective part. ging
• Leakage past power beyond seal in outrigger valve
Worn or damaged parts such as scratched cylinder rods
can cause leaks. A worn or scratched output shaft on a Refer to Section 8 under Hydraulic System for information
hydraulic motor can also cause a leak. Such conditions about troubleshooting specific components for internal
must be repaired or replaced. A new seal should also leaks.
be installed.

Internal leaks allow pressurized hydraulic oil to escape Hydraulic Lines

to tank or another hydraulic circuit. Most hydraulic com- Hydraulic lines provide a passageway for fluid flow
ponents have a small internal leak due to machining between components in the hydraulic system. Fluid is
tolerances. transmitted through the lines from the pump to the ac-
tuator to operate the unit. A variety of lines may be used
An internal leak can cause a variety of problems in a on the unit depending on the specific application. The
hydraulic system. An internal leak in a cylinder can cause lines may be conductive or nonconductive rubber hoses,
drifting or malfunction of a cylinder. Internal leakage in flexible plastic, or rigid steel tube.

Section 5 — Hydraulic System • 55

Most hoses and have a lay line on them. The lay line from the cylinder after the hydraulic lines are reinstalled.
contains the following information. The presence of air in the cylinder can cause inadvertent
retraction or extension of the cylinder, resulting in death
• Manufacturer’s name or serious injury.
• Manufacturer’s part number
• SAE rating Caution
• Burst pressure (sometimes)
• “Nonconductive” appears on nonconductive hoses Injury can result from airborne particles entering the
eyes and lungs. Wear appropriate safety equipment.
The hoses connected to the pole guide are non-pin
perforated, nonconductive, thermoplastic hoses. These Injury can result from being pinched or trapped be-
hoses are located in the hose carriers. The hose carriers tween moving components. Keep hands clear.
are on the right side of the boom (when standing at the
boom tip looking toward the turntable). 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
Danger immediately after servicing.
Death or serious injury can result from unprotected
contact with energized conductors. Never replace a Remove all fluid pressure from a hydraulic circuit before
nonconductive hose with a conductive hose. disconnecting lines or fittings.

Replace the hoses in the hose carriers with hoses of Mark all hydraulic line fittings before disconnecting them
the same type. Do not use wire braid hoses in the hose to ease installation later. Place a container under the
carriers. hoses to catch the hydraulic oil. Cap or plug all open
ports, hoses, and fittings to prevent contamination.
When servicing a hose carrier, do not pull the hoses tight.
It may cause a hose to kink. Warranty will be denied on components returned to Altec if
ports are not plugged and cylinder rods are not retracted.
When replacing a hose, use one the same size, length,
and pressure rating. If hose size is doubled, four times Properly torque all connections. Refer to the Torque and
the amount of oil will flow at the same pressure. If hose Tightening Procedures in this section.
size is decreased, the flow in the circuit will decrease and
back pressure will increase. The increase in back pres- After completing a procedure, check the oil level in the
sure will cause heat to build up and system malfunction. hydraulic oil reservoir and add oil if necessary.

Warning Fittings and Valve Cartridges

Death or serious injury can result from uncontrolled Most hydraulic ports and fittings are SAE straight thread
movement. Purge the air from the actuator before O-ring or 37 degree flared JIC straight thread. These
operating the unit. types of fittings provide a good seal and resist vibration.

Death or serious injury can result from hydraulic Use the proper torque and tightening specifications when
oil being injected into the flesh when loosening or installing a hydraulic fitting to reduce the likelihood of leaks
disconnecting hydraulic components. Remove the in the system. Use caps and plugs during the handling
pressure before loosening or disconnecting hydraulic and storage of hydraulic components to prevent damage
components. to sealing surfaces and fitting threads.

Seek immediate medical attention if injured by escap- When installing a valve cartridge into a valve body,
ing hydraulic oil. Serious infection or reaction can properly torque the cartridge. Tightening the cartridge
result if medical treatment is not given immediately. less than the specified torque value may cause a leak.
Overtorquing a cartridge can damage the valve, valve
Spilled hydraulic oil creates slick surfaces and can body, or bind internal parts.
cause personnel to slip and/or fall. Keep the unit and
work areas clean. Torque and Tightening Procedures
Overtorquing a component can distort the part and cause
After removing a hydraulic line from a cylinder, do not op- a leak. When a leaking fitting is found, check to see if
erate the unit from the radio controls until all air is purged

56 • Section 5 — Hydraulic System

it is tight. If it is not tight, torque it to the proper value. SAE O-Ring Fittings Without Locknuts
Replace the fitting if it will not stay tight. 1. Lubricate the O-ring and threads with hydraulic oil
or light grease, such as petroleum jelly.
If the fitting is tight, stop the unit, determine the cause
of the leak and take corrective action. When making a 2. Turn the fitting in full length until finger tight.
connection that uses a swivel nut, use one wrench to hold
the hose, tube, or fitting and another wrench to turn the 3. Use a wrench to tighten the fitting to the proper value.
nut. This is necessary to prevent damage to the sealing
surface of the JIC connections. Tube and JIC Fittings
1. Clean the male threads of the fitting with a cleaning
The following procedure describes proper torque and solvent.
tightening procedures for various types of hydraulic
fittings. Refer to Torque Values in the Appendix for the 2. Tighten the nut until first wrench resistance [approxi-
appropriate torque chart. mately 30 inch-pounds (3.4 N•m)].

3. Using a felt tip pen or marker, mark a line lengthwise

Warning
on the nut and extend it onto the adapter body (refer
Death or serious injury can result from improper to Torque Values in the Appendix).
use of solvents. Follow the manufacturer’s label for
proper use and disposal. 4. Determine the proper number of hex flats the nut
must be turned with a wrench. Using a wrench to
Tapered Pipe Thread Fittings hold the adapter body, rotate the nut with another
1. Clean the male threads of the fitting with a cleaning wrench the proper number of hex flats from wrench
solvent. resistance (F.F.W.R.).

2. Apply pipe sealant to the male threads of the fitting, 5. Use the marks to count the proper number of hex
being careful not to get sealant on the first two male flats to turn the nut. The marks also serve as a visual
threads. Apply enough sealant to form a ring of sealant indicator that the fitting has been properly tightened.
on the outside of the connection when the threads
are tightened into the mating body. Compression Fittings
1. Cut the tubing to length, allowing for bend, equipment
3. Screw the fitting into the mating part and finger tighten. movement, etc.

4. Turn the fitting with a wrench the appropriate turns 2. Fit the brass insert into the nylon pilot tubing with the
from finger tight (T.F.F.T.), taking the final position of flanged end out. The insert should fit snug in the pilot
the tube end into consideration. tubing. The color coded 5/16″ (7.9 mm) outer diameter
tubing requires the use of an insert.
5. Follow the sealant manufacturer’s directions for cure
time. The ring of sealant described in step 2 will not 3. With the threaded end of the compression nut facing
completely harden due to its exposure to air. the fitting body, slide the nut onto the nylon tubing,
followed by the compression sleeve.
SAE O-Ring Fittings With Locknuts
1. Lubricate the O-ring and threads with hydraulic oil
or light grease, such as petroleum jelly. Notice
To prevent damaging the nut and threads, do not
2. Screw the fitting into the SAE straight thread boss overtighten compression fittings.
until the backup washer bottoms out on the boss
face with the O-ring squeezed into the boss cavity. 4. Insert the tubing into the fitting body. Making sure the
tubing rests firmly on the shoulder of the fitting, hand
3. Unscrew the fitting (maximum of one full turn) to align tighten the compression nut. Tighten the compression
the fitting with the mating part. nut the proper number of turns.

4. Tighten the locknut with a wrench and torque to the Four-Bolt Split Flange Assembly —
proper value for the size and material (stainless steel SAE Code 61 [3,000 psi (206.84 bar)]
or steel) so the backup washer contacts the boss 1. Clean the sealing surface of any burrs, scratches,
face. or foreign particles.

Section 5 — Hydraulic System • 57

 2. Lubricate the O-ring with hydraulic oil. Holding valves are often used to maintain cylinder posi-
tion if there is hydraulic line failure. The boom cylinders
3. Position the flange and clamp halves. Put the bolts use counterbalance holding valves. The outrigger and
with the lock washers in place (refer to Figure 5.14) pole guide cylinders use pilot operated check valves.
and hand tighten the bolts.
The holding valves may be installed in cavities machined
Flange Clamping Bolt directly into the cylinders. They may also be installed
Lock in a valve block in the hydraulic lines connected to the
Washer cylinder or directly mounted on the cylinder.

All cylinder rods are chrome plated to prevent rust and

Split corrosion. The chrome plating also provides a smooth
Clamp
Half surface for the end gland bearing and seal.

Warning
Death or serious injury can result from uncontrolled
O-Ring movement. Use a sling and hoist of adequate capacity.
Figure 5.14 — Four-Bolt Flange Assembly
Death or serious injury can result from cylinder
4. Follow the pattern in Figure 5.15 to torque the bolts failure. Do not operate a cylinder that has a dented
in place. barrel or a damaged rod.

Death or serious injury can result from cylinder

failure. Never reuse a self-locking piston nut or re-
tention device.

Death or serious injury can result from cylinder fail-

ure. Properly install and torque a piston nut or gland
retention device.

Death or serious injury can result from hydraulic oil

Figure 5.15 — Four-Bolt Flange Torque Pattern being injected into the flesh. Properly cap or connect
hydraulic lines before operating the unit.
5. Use small increments to torque the bolts.
Death or serious injury can result from hydraulic
Valve Cartridges oil being injected into the flesh when loosening or
1. Clean the male threads of the cartridge with a clean- disconnecting hydraulic components. Remove the
ing solvent. pressure before loosening or disconnecting hydraulic
components.
2. Lubricate the threads and O-ring with hydraulic oil.
Seek immediate medical attention if injured by escap-
3. Turn the cartridge in until it is finger tight. ing hydraulic oil. Serious infection or reaction can
result if medical treatment is not given immediately.
4. Use a wrench to tighten the cartridge to the proper
value. Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
work areas clean.
Cylinders
Hydraulic cylinders operate the outriggers, booms, and Death or serious injury can result from uncontrolled
pole guide. movement. Purge the air from the actuator before
operating the unit.
The cylinders used to operate the pole guide, booms,
and outriggers are double-acting cylinders. This means Caution
the cylinder produces force in both the extend and retract
directions. Injury can result from airborne particles entering the
eyes and lungs. Wear appropriate safety equipment.

58 • Section 5 — Hydraulic System

Injury can result from being pinched or trapped be- 2. Start the engine and lower the outrigger until it just
tween moving components. Keep hands clear. makes contact with the ground.

Pinch points exist at both ends of the cylinder. Be ex- 3. Remove the forged pin retainer from the pin con-
tremely careful when removing or installing cylinders. necting the rod end of the cylinder to the outrigger
leg and the folding shoe (refer to Figure 5.16).
Use caution when access covers have been removed
to service the unit. Pinch points and shear points may
exist between moving parts. Replace the access covers
immediately after servicing.
Outrigger
Never install a cylinder with side pressure on the rod. Do Cylinder
not operate a cylinder if the cylinder barrel is dented or
if the rod is damaged.
Forged Pin
Altec does not recommend repairing cylinders in the field. Retainer With Bolt
Most repairs require cylinder disassembly which should
be done in a clean, properly equipped shop. The Parts
Manual contains a drawing of each cylinder. The drawing
lists the Altec part numbers for the seal kits and provides
torque specifications for piston nuts and end glands.
Retaining Ring
Hydraulic cylinder piston nuts and end glands must be Forged Pin Retainer
torqued to the proper values at assembly. Many piston Shoe
nuts and end glands have retention devices, such as
cotter pins and set screws. These retention devices must Figure 5.16 — Radial Outrigger Cylinder Fasteners
be installed properly.
4. Secure the cylinder with a sling and hoist. Carefully
If the internal size tolerance of the cylinder barrel is ex- retract the cylinder to avoid scratching the rod. With
ceeded, the piston seal could be pushed out when the the cylinder fully retracted, turn off the engine.
cylinder is put under a load. This will cause cylinder failure.
5. Release any pressure in the hoses connected to
After reconnecting a hydraulic line from any cylinder, the cylinder by shifting the outrigger control for the
extend and retract the cylinder five to six times to purge cylinder in both directions several times with the
the air out of the cylinder and to check for hydraulic leaks. ignition switch on, without the engine running.

Mark all hydraulic line fittings before disconnecting them 6. Remove the hoses from the fittings on the pilot
to ease installation later. Place a container under the operated check valve block on the base end of the
hoses to catch the hydraulic oil. Cap or plug all open cylinder.
ports, hoses, and fittings to prevent contamination.
7. Remove the two cap screws that secure the pin at
Warranty will be denied on components returned to Altec if the base end of the cylinder (refer to Figure 5.16).
ports are not plugged and cylinder rods are not retracted.
8. With the hoist, carefully lift the cylinder out of the
Properly torque all connections and cap screws. Refer to outrigger weldment.
Torque and Tightening Procedures in this section.
Installation
After completing a procedure, check the oil level in the 1. Secure the cylinder to the hoist. Lift the cylinder
hydraulic oil reservoir and add oil if necessary. above the outrigger leg weldment. Carefully guide the
cylinder as it slides into the outrigger leg weldment.
Radial Outrigger Cylinder
A sling and hoist are needed to perform the following 2. Install the pin that secures the base end of the cylinder
procedures. in the weldment. Install the cap screws or forged pin
retainer that secures the pin.
Removal
1. Position the unit on a level surface.

Section 5 — Hydraulic System • 59

 3. Reconnect the hoses to the pilot operated check 8. Making sure the cylinder is supported, carefully re-
valve housing. move the pin from the base end of the cylinder and
the cylinder attachment bracket on the turntable.
4. Start the engine. With the cylinder properly secured,
extend the cylinder. Be careful not to scratch the rod. 9. Immediately lower the cylinder to the ground.
Line up the pin hole in the rod end with the boss
in the outrigger leg. Make sure the bearing for the Installation
outrigger leg is in place. 1. Remove the fittings from the old lift cylinder and install
the components on the new lift cylinder.
5. Install the pin connecting the cylinder and leg. Install
the cap screws that secure the pin. 2. Secure the sling around the cylinder barrel.

6. Extend and retract the outrigger leg five to six times 3. Lift the cylinder with the hoist and align the base end
to purge any air in the cylinder while checking for of the cylinder with the cylinder attachment bracket
hydraulic leaks and proper operation. on the turntable. Install the cylinder pin through the
first hole of the attachment bracket, the bearing in
Lift Cylinder the base end of the cylinder and the second pin hole
Removal in the cylinder attachment bracket.
1. Position the unit on a level surface. Start the engine
and properly set the outriggers. Position the boom 4. Connect the two hydraulic hoses and pressure trans-
in the rest. ducer to the cylinder.

2. Turn off the engine. Release any pressure in the hoses 5. Align the rod end of the cylinder with the cylinder at-
connected to the lift cylinder by shifting the boom tachment bracket on the lower boom. If necessary,
control on the main control valve on the turntable in start the engine and operate the lower controls to
both directions several times. extend the rod to help in alignment. Install the rod
end cylinder pin through the first hole in the cylinder
3. Use a sling and hoist to support the rod end of the attachment bracket, the bearing in the rod end of the
cylinder. cylinder and the second hole in the cylinder attach-
ment bracket.
4. Remove the two hoses and pressure transducer
that are connected to the lift cylinder. Mark the hose 6. Insert the forged pin retainer through the cylinder pin.
connections to ease installation later. Cap or plug the Install the cap screw through the forged pin retainer
open ports. and torque it to the proper value. Repeat this step
on the pin at the base end of the cylinder.
5. Figure 5.17 shows the fasteners securing the pin at
each end of the cylinder. Unscrew the cap screw and 7. Make sure the outriggers are properly set. Start
remove the forged pin retainer from the cylinder pin. the engine and using the lower controls, raise and
lower the boom several times to remove air from the
cylinder. While operating the lift cylinder, check the
cylinder for leaks and proper operation.

Intermediate Boom Cylinder

Removal
1. Position the unit on a level surface and properly set
the outriggers.
Forged Pin
Retainer 2. Rotate the boom to the side of the unit. Unstow the
digger as described in the Operator’s Manual.
Figure 5.17 — Lift Cylinder Mounting Pin
3. Extend the intermediate boom 2′ to 3′ (60.96 to 91.44
6. Remove the pin from the rod end of the cylinder and cm). Turn off the engine.
the cylinder attachment bracket on the lower boom.
4. The intermediate boom cylinder is shown in Figure
7. As described in step 5, remove the cap screw and 5.18. Wrap a sling around the base end of the cylin-
forged pin retainer from the base end of the cylinder.

60 • Section 5 — Hydraulic System

 Cap Screw Intermediate Cap Screw
and Nut Boom Cylinder Cylinder Guide and Nut

Figure 5.18 — Booms

der. Use a hoist or other lifting device to support the 12. Slowly lower the base end of the cylinder to the
cylinder. ground.

13. Position the sling and hoist or other lifting device to

Warning
support the rod end of the cylinder.
Death or serious injury can result from uncontrolled
movement. Secure the booms before removing the 14. The rod end of the extension cylinder is mounted to
cylinder mounting pins. the lower boom by cap screw and nut. Remove the
nut and cap screw. The nylon insert locknut is not
Failure to secure the intermediate boom hood to the reusable. If the nut is removed, it must be replace
lower boom can result in uncontrolled extension of the with a new nut.
intermediate boom when the cylinder anchor cap screw
is removed from the intermediate boom. 15. Use the sling and hoist or other lifting device to lower
the rod end of the cylinder to the ground.
5. Use rope or chains to secure the hood of the inter-
mediate boom to the lower boom. Installation
1. Before installing the cylinder on the unit, test operate
6. The base end of the cylinder is mounted to the in- the cylinder and check for leaks. This may be done
termediate boom by a cap screw and nut (refer to by connecting the extend and retract ports on the
Figure 5.18). Remove the nut. Use a brass drift and counterbalance valve block to a lower tool circuit.
a dead blow hammer to remove the cap screw. Be careful not to damage the cylinder rod.

7. Start the engine. Make sure the intermediate boom 2. Make sure the cylinder is completely retracted. Re-
cylinder is supported. Carefully retract the cylinder move the cylinder guide from the old cylinder and
out of the digger hanger bracket. position it on the new cylinder. Position the sling
around the rod end of the cylinder. Lift the cylinder
8. Turn off the engine. Release any pressure in the with the hoist or other lifting device. Align the mounting
hoses connected to the cylinder by operating the hole in the rod end of the cylinder with the mounting
intermediate boom control handle for both directions. holes in the lower boom weldment.

9. The intermediate boom cylinder is supported by a 3. Install the cap screw and nut that secures the rod end
cylinder guide. Adjust the hoist or other lifting device of the cylinder to the lower boom weldment (refer to
so that the cylinder is not touching the cylinder guide. Figure 5.18). Torque the nut to 50 foot-pounds (68
Remove the cap screws securing the cylinder guide N•m).
to the lower boom.
4. Reconnect the hoses to the counterbalance valve
10. Disconnect wires from the boom stow bracket weld- block at the rod end of the cylinder.
ment and remove it from the under side of the lower
boom. 5. Position the sling around the midsection of the cylin-
der. Lift the cylinder into its position under the boom.
11. There is a counterbalance valve block mounted to Install the cylinder guide to the lower boom.
the rod end of the cylinder. Remove the two hydraulic
hoses that are connected to this valve block. Remove 6. Position the sling around the base end of the cylinder.
the fittings from the ports in the block. Cap or plug Start the engine and extend the intermediate boom
all open ports and hose ends. cylinder through the digger hanger bracket. Extend

Section 5 — Hydraulic System • 61

 the cylinder until the mounting hole in the base end 4. Remove the lower boom cover and access hole
of the cylinder lines up with the cylinder mounting covers from the base end of the lower boom.
holes in the intermediate boom.
5. There are access holes on each side of the lower
7. Install the cap screw and nut that mount the base end boom near the turntable. Reach through the access
of the cylinder to the intermediate boom hood (refer hole closest to the turntable on each side of the
to Figure 5.18). Torque the nut to 50 foot-pounds (68 boom. Remove the two retaining rings and the pin
N•m). that secure the rod end of the upper boom cylinder
to the lower end of the intermediate boom (refer to
8. Install the boom stow bracket weldment and con- Figure 5.19).
nect the wires to the boom stow switch if they were
removed. 6. Disconnect the two upper boom extension cylinder
hydraulic lines connected at the hose carrier. Cap
9. Make sure the outriggers are properly set and start the or plug all open ports and hose ends.
engine, engage. Using the lower controls, extend and
retract the intermediate boom several times. While 7. At the base end of the upper boom, remove the two
operating the intermediate boom cylinder, check for trunnion pin cap screws and trunnion pins securing
leaks and proper operation. the upper boom cylinder to the upper boom (refer to
Figure 5.19).
Upper Boom Cylinder
Removal 8. Remove the winch cover from the end of the lower
1. Position the unit on a level surface and properly set boom.
the outriggers.
9. Pull the cylinder out of the upper boom.
2. Rotate the boom to the side of the unit. Use chains
or rope to secure the upper boom tip to the lower or Installation
intermediate boom. 1. Before installing the cylinder, operate the cylinder
and check for leaks. This may be done by connect-
Warning ing the extend and retract ports on the cylinder to a
lower tool circuit. Be careful not to damage the rod.
Death or serious injury can result from uncontrolled
movement. Secure the booms before removing the 2. Remove the upper boom cylinder support plates
cylinder mounting pins. and hydraulic lines from the old cylinder. Install all
the components on the new cylinder as they were
Failure to secure the upper boom tip to the lower or installed on the old cylinder.
intermediate boom can result in uncontrolled extension
of the upper boom when the cylinder mounting pin is 3. Use a sling and hoist or other lifting device to posi-
removed from the intermediate boom. tion the cylinder inside the upper boom. Guide the
hydraulic lines out the access hole in the bottom of
3. Turn off the engine. Release any pressure in the the upper boom as the cylinder is inserted into the
hoses connected to the cylinder by operating the boom.
upper boom control handle for both directions.

Trunnion Pin
End Cap Screw

Upper Boom
Cylinder Rod End Pin
Figure 5.19 — Booms

62 • Section 5 — Hydraulic System

 4. Install the two trunnion pins through the base end of When the auger release switch is operated, hydraulic
the upper boom and into the cylinder (refer to Figure flow and pressure are sent to the auger latch cylinder.
5.19). Torque the trunnion pin cap screws to 50 foot- The latch cylinder then extends. When the auger release
pounds (68 N•m). switch is released, an internal spring in the latch closes
the latch and retracts the latch cylinder.
5. Install the pin and two retaining rings to secure the
rod end of the cylinder to the base end of the inter- Warning
mediate boom (refer to Figure 5.19). The retaining
rings should be installed with the sharp edge toward Injury can result from uncontrolled movement. Care-
the end of the pin. fully install or remove the auger latch.

6. Connect the two upper boom cylinder hydraulic lines Injury can result from uncontrolled movement. Do
to the fittings at the hose carrier. not pressurize the auger latch cylinder when it is
removed from the latch.
7. Make sure the outriggers are properly set. Start the
engine and extend and retract the upper boom several The internal spring in the auger latch contains a great
times. This will purge any air that is in the hoses or amount of stored energy. Use caution when removing
cylinder. While operating the cylinder, check it for or installing the auger latch. Failure to do so may cause
leaks and proper operation. serious injury. Removal or installation of the auger latch
should be performed only by personnel who are familiar
8. Install the boom access covers and winch cover. with this procedure. The auger latch cylinder does not
contain a piston or other means of retaining the rod in the
Auger Latch Cylinder cylinder when it is fully extended. The cylinder is limited
The cylinder used to operate the auger latch is a single by the latch mechanism when it is installed on the auger
acting cylinder (refer to Figure 5.20). This type of cylinder stow bracket. Do not pressurize the cylinder when it is
only produces force in the extend direction. It is retracted removed from the latch. When the cylinder is removed,
by an internal spring in the auger latch weldment. pressure will eject the rod from the cylinder.

Pole Guide Cylinder

Removal and installation of the pole guide cylinder is a
simple procedure. To remove or install this cylinder only
involves removing and installing the mounting pins and
hose connections. Make sure to remove the hydraulic
load from the pilot operated check valves. This can be
done by moving the pole guide switch back and forth in
both positions until the cylinder can be rocked by hand.

Pole Guide Tilt Cylinder

Removal and installation of the pole guide tilt cylinder is
Cylinder a simple procedure. To remove or install this cylinder only
involves removing and installing the mounting pins and
Spring hose connections. Make sure to remove the hydraulic
load from the counterbalance valves. This can be done
by moving the pole guide tilt control back and forth in
both positions until the cylinder can be rocked by hand.
Figure 5.20 — Auger Latch

Section 5 — Hydraulic System • 63

64 • Section 5 — Hydraulic System
 Section 6 — Mechanical Systems
A mechanical system consists of unit components ar- 6. After reconnecting a hydraulic line, operate the con-
ranged so the motion of one mechanically moves the trols in the system five to six times to purge the air
other. Examples of mechanical components are the out of the system and to check for hydraulic leaks.
rotation bearing, rotation gearbox, and the booms. Me-
chanical components may be moved by each other or 7. Properly torque all connections and cap screws.
by hydraulic or electrical actuators. Refer to Section 5 under Torque and Tightening
Procedures.
When welding on the unit, a welding ground clamp must
be attached to the same structure on which the welding is 8. Perform a dielectric test as described in Section 9
being performed. This is necessary to prevent electrical after any component is installed that could affect the
current from being sent through components. dielectric integrity of the unit.

Components such as the rotation bearing, wire braid Caution

hoses, and hydraulic cylinders can be damaged by
electrical current. Electrical current flowing through a Injury can result from being pinched or trapped be-
component can be very intense, causing serious internal tween moving components. Keep hands clear.
damage to the component.
Use caution when access covers have been removed
Follow this list of safety procedures when servicing the unit. to service the unit. Pinch points and shear points may
exist between moving parts. Replace the access covers
1. Select a work site large enough to operate the re- immediately after servicing.
quired functions.
Rotary Joint
2. Position the unit on a level surface and turn off the
engine. Check the hydraulic oil level. Start the engine The rotary joint permits continuous rotation of the turntable
and properly set the outriggers. without twisting the hydraulic hoses and electrical cables
that pass between the pedestal and turntable.
Warning The outer housing of the rotary joint is fastened to the
Death or serious injury can result from uncontrolled pedestal. The inner core is attached to the turntable with
movement. Use a sling and hoist of adequate capacity. a drive bar. As the turntable rotates the inner core rotates
with the turntable. As the turntable is rotated, the outer
3. Use a hoist to safely support heavy components housing rotates with the turntable.
before loosening the fasteners on that component.
Two cap screws secure the drive bar on the top of the
inner core of the rotary joint. The drive bar fits in a slotted
Warning
bracket that is welded to the turntable. As the turntable
Death or serious injury can result from hydraulic rotates, the outer housing is held in place by the pedestal
oil being injected into the flesh when loosening or while the inner core rotates with the turntable.
disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic Figure 6.1 illustrates the location of the hydraulic ports
components. of the rotary joint.

Seek immediate medical attention if injured by escap-

Pressure Line Port Pressure
ing hydraulic oil. Serious infection or reaction can Line Port
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.

4. Never loosen or remove a pressurized hose or fitting.

5. Mark all hydraulic line fittings before disconnecting Return Line Port Return Line Port
them to ease installation later. Place a container Figure 6.1 — Rotary Joint
under the hoses to catch the hydraulic oil. Cap or
plug all open ports immediately.

Section 6 — Mechanical Systems • 65

Various electrical circuits also pass through the centerline 8. Follow the rotation bearing installation procedure
of rotation by way of the slip ring. The slip ring is mounted and install the turntable.
to the bottom of the rotary joint. It is mounted by three
cap screws. The cap screws are inserted through metal 9. Install any other components and covers removed
spacer tubes for support. while removing the turntable.

Removal 10. Start the engine and properly set outriggers. Operate
1. Turn off the engine. the unit while checking for leaks at the rotary joint
and turntable.
2. Follow the rotation bearing removal procedure to
remove the turntable from the pedestal.
Rotation System
3. Inside the pedestal, disconnect the hydraulic hoses The turntable rotates on a large shear ball bearing, re-
that are connected to the rotary joint. Cap or plug all ferred to as the rotation bearing. The inner race of the
open ports. bearing is fastened to the turntable. The outer race of
the bearing is fastened to the pedestal. It has gear teeth
4. Disconnect the electrical connections from the slip cut on the outside surface of the outer race.
ring to below rotation.
Rotation is accomplished by a gearbox mounted on the
5. Remove the four cap screws that connect the rotary turntable (refer to Figure 6.2). The gearbox is driven by
joint to the pedestal. a hydraulic motor. The rotation pinion meshes with the
teeth on the rotation bearing.
6. Lift the rotary joint and slip ring out of the pedestal.

7. Remove the three cap screws and spacers that con-

nect the slip ring to the rotary joint. Remove slip ring
and set it out of the way.

Installation
1. Remove the hydraulic fittings, hoses, and drive bar
from the old rotary joint and install them on the new Rotation
rotary joint in corresponding locations. Properly torque Gearbox
the drive bar cap screws.

2. Coat the cap screws that mount the slip ring to the Rotation
rotary joint with pipe sealant. Insert a cap screw Pinion
through a tab in the rotary joint and spacer into High Tooth Rotation
the slip ring. Repeat this step for the other two cap Location Bearing
screws and spacers that mount the slip ring to the
rotary joint. Figure 6.2 — Rotation System

3. Lower the slip ring and rotary joint back into the When the rotation control is in neutral, the counterbal-
pedestal guiding the electrical connection through ance valves in the rotation/side load protection valve are
the hole in the side of the pedestal. closed. The closed valves trap oil in the rotation motor,
locking the rotation gearbox in place.
4. Line up the holes in the outer housing of the rotary
joint with the mounting holes in the pedestal. When the rotation function is operated, the counterbal-
ance valve for the direction of operation (clockwise or
5. Install and properly torque the four cap screws through counterclockwise) opens. The open valve allows hydraulic
the rotary joint outer housing and into the pedestal. oil to flow through the rotation motor. The motor powers
the rotation pinion. As the rotation pinion drives the rota-
6. Connect all electrical connectors in the pedestal to tion bearing, the turntable rotates.
the below rotation driver board.
When a side load is created on the booms during opera-
7. Connect all the hydraulic hoses in the pedestal to tion, the side load protection system operates. Section
the rotary joint. 5 under Protection Systems describes the side load
protection systems.

66 • Section 6 — Mechanical Systems

Rotation Bearing Warning
The rotation bearing provides for very low torque rota-
Death or serious injury can result from improper
tion. The bearing should provide many years of service
use of solvents. Follow the manufacturer’s label for
if properly maintained.
proper use and disposal.
The unit is equipped with a rotation bearing lubricated
1. Clean the rotation bearing mounting surfaces on
for the life of the bearing. It does not require lubrication
the pedestal, turntable, and the bearing with a cloth
except at the time of a major overhaul of the unit.
and solvent to remove any dirt or grease. Allow the
surfaces to completely dry.
Procedures for measuring turntable tilt and inspecting
the rotation bearing cap screws are found in Section 4
2. Remove the grease fitting from the old rotation bear-
under Rotation Bearing.
ing and install it in the new bearing.
Removal
3. Agitate the adhesive compound by shaking the bottle.
Components may need to be removed to access the
Apply the adhesive to the pedestal bearing surface in
rotation bearing cap screws for removal.
the pattern shown in Figure 6.3. Apply a 3/16” to ¼”
(0.48 to 0.64 cm) bead of adhesive. Keep the bead
1. Position the unit on a level surface, properly set the
far enough away from the holes so that adhesive will
outriggers, and turn off the engine.
not get in the holes when the bearing is installed.
The bearing must be completely installed within 30
2. Disconnect the hydraulic and electrical lines that are
minutes of applying the adhesive.
routed through the rotation bearing.

3. Adjust the rotation drive gearbox backlash to move

the rotation pinion away from the rotation bearing gear
teeth. Refer to the backlash adjustment procedure
in Section 8 under Rotation Gearbox.

Warning
Death or serious injury can result from uncontrolled
movement. Properly support the component before
loosening fasteners and removing hydraulic com-
ponents.
Figure 6.3 — Outer Race
4. Support the turntable (and booms, if still attached) to
prevent it from accidentally coming off the pedestal 4. Position the new rotation bearing on the pedestal
after the cap screws are removed. Remove the cap weldment. Locate the high tooth, marked by yellow or
screws and washers from the inner race. blue paint, where it will align with the rotation gearbox
pinion (refer to Figure 6.2). Align the mounting holes
5. Use a hoist or other lifting device to lift the turntable with the mating cap screw holes in the bearing.
from the rotation bearing. The boom may or may not
be still attached to the turntable. Notice
Only use Altec supplied cap screws and washers to
6. Remove the cap screws and washers from the outer
install the rotation bearing.
race of the rotation bearing.
If a rotation bearing cap screw is removed, it must be
7. Lift the bearing off the pedestal weldment.
replaced with a new cap screw. Contact your Altec rep-
resentative for replacement rotation bearing cap screws.
Installation
New rotation bearings shipped from Altec include new
5. Install the cap screws with washers in the outer race
cap screws, hardened washers, cleaner, and installation
of the bearing. Notice that the washer has a more
instructions.
rounded edge on one side. Install the washer with
the rounded edge toward the cap screw head. Do
not torque the cap screws until all of them have been
installed on the outer race.

Section 6 — Mechanical Systems • 67

 6. Torque the cap screws in three phases. 8. Use a sling and hoist to position the turntable on top
of the rotation bearing. Align the turntable mounting
a. Torque the cap screws to 110 foot-pounds (149 holes with the mating cap screw holes in the bearing.
N•m) using the alternating star pattern shown in
Figure 6.4. 9. Install the cap screws in the inner race of the bearing
in the same manner as the outer race cap screws.
1
11 16 10. Torque the cap screws in three phases with the same
procedure used on the outer race in step 5. Follow
8 6 the alternating star pattern shown in Figure 6.5.

11. Install all components that were removed to access

13 9 the cap screws. Reconnect all hydraulic lines and
the electrical lines.

3 4 12. Adjust the backlash between the rotation pinion and

the rotation bearing gear teeth as described in Sec-
tion 8 under Rotation Gearbox.
10 14
13. Lubricate the rotation gear teeth as described in
7 Section 4 under Lubrication.
5

15 12 14. From the lower controls, operate each function five

2 or six times to purge any air that may have entered
the system.
Figure 6.4 —
Outer Race Cap Screw Torque Pattern 15. Perform a stability test as described in Section 9.
Rotate the turntable through three complete revolu-
b. Set the torque to 225 foot-pounds (305 N•m). tions.
Follow the same alternating star pattern.
16. Torque the rotation bearing cap screws to 225 foot-
c. Keep the torque wrench set for 225 foot-pounds pounds (305 N•m) (both inner and outer race) again,
(305 N•m). Torque each cap screw a third time using the star pattern as shown in Figures 6.4 and
using a circular pattern starting with cap screw 6.5.
number one.
17. Inspect the rotation bearing cap screws as recom-
7. Rotate the inner race as shown in Figure 6.5. mended by the Preventive Maintenance and In-
spection Checklist as described in Section 4 under
Rotation Bearing Cap Screws.
17 12
2 5 Rotation Bearing Cap Screws
15 Use this procedure when only the rotation bearing cap
7 screws are being replaced.

14 10
Notice

X 4 3
Only use Altec supplied cap screws and washers.

When rotation bearing cap screws or washers are re-

9 13 moved, they must be replaced with new ones. Contact
your Altec representative for replacement fasteners.
Rotation
Gearbox 16 8
1. Position the unit on a level surface, properly set the
6 1 outriggers, and turn off the engine.
11 18

Figure 6.5 — Inner Race Cap Screw Torque Pattern

68 • Section 6 — Mechanical Systems

 Warning 3. Remove any wiring, control lines, hoses, or tubes
that are in the way of the gearbox removal. Cap or
Death or serious injury can result from uncontrolled plug all open connections to prevent contamination
movement. Replace only one cap screw at a time. from entering the system.
2. Loosen and replace only one cap screw at a time. 4. Remove the pinion cover. Loosen the eccentric ring
lock and the four cap screws securing the gearbox.
3. Install the new cap screw and washer. Notice the
washer has a more rounded edge on one side. Install 5. Engage a suitable bar or drift pin, preferably of a soft
the washer with the rounded edge toward the cap material such as brass, in a drive slot of the eccen-
screw head. tric ring. Rotate the eccentric ring using light blows
from a hammer against a bar or drift pin. Rotate the
4. Torque the cap screw to 100 percent of the normal eccentric ring to position the gearbox the maximum
installation torque value. distance from the rotation bearing gear teeth.
5. Repeat steps 2 through 4 for each cap screw in the 6. Operate the rotation control to relieve the pressure
race, going around in a circular pattern. from the rotation function lines.
6. Perform a stability test as described in Section 9. 7. Remove the rotation motor hydraulic hoses. Plug
Rotate the turntable through three complete revolu- and cap the openings.
tions.
8. Place a nylon sling around the gearbox.
7. Torque the rotation bearing cap screws to 100 per-
cent of the normal installation torque value using a 9. Connect the sling to a hoist. Remove the eccentric
circular pattern. ring lock and the four gearbox mounting cap screws.
Lift the gearbox out of the turntable and lower it to
Resume regular inspection of the rotation bearing cap the ground.
screws as recommended by the Preventive Maintenance
and Inspection Checklist. Use the inspection procedures Installation
as described in Section 4 under Rotation Bearing Cap 1. Clean the mounting surface and eccentric ring. Ap-
Screws. ply anti-seize compound to the inside and outside
surface of the eccentric ring and boss. Install the
Rotation Gearbox eccentric ring in a position so that adjusting 1/4 turn
Removal one way will produce full adjustment and 1/4 turn the
1. Position the unit on a level surface, properly set the other way will completely loosen the gearbox.
outriggers, and turn off the engine.
2. Position the nylon sling on the gearbox as before
Warning and connect it to the hoist. Position the gearbox on
the turntable.
Death or serious injury can result from uncontrolled
movement. Secure the booms before removing the
3. Install the gearbox mounting cap screws loosely.
rotation gearbox.
4. Reconnect the rotation motor hoses. Reconnect any
2. Secure the boom with a strap so the turntable cannot
other wiring, hoses, tubes, and control lines that may
rotate when the gearbox is removed.
have been removed for this procedure. Remove the
strap(s) used to secure the boom.
Caution
Injury can result from contact with pinion and rota- 5. Adjust the rotation pinion to the rotation bearing
tion bearing gear teeth. Keep hands clear. following the procedure in Section 8 under Rotation
Gearbox.
Injury can result from airborne particles entering the
eyes. Wear appropriate safety equipment. 6. Position the unit on a level surface with sufficient
clearance for full boom movement. Properly set the
Wear eye protection while adjusting the eccentric ring to outriggers.
prevent particles of metal or dirt from entering the eyes.

Section 6 — Mechanical Systems • 69

 7. Operate the unit through all boom angles and rotation 6. There are two access holes on each side of the
from the lower controls while checking for leaks and lower boom near the turntable. Reach through the
proper operation. access hole closest to the turntable on each side of
the boom. Remove the two retaining rings and the pin
8. Inspect the rotation gearbox mounting cap screws that secure the rod end of the upper boom cylinder
as recommended by the Preventive Maintenance to the lower end of the intermediate boom (refer to
and Inspection Checklist. Figure 6.6).

7. Disconnect the two upper boom extension cylinder

Upper Boom
hydraulic lines connected at the hose carrier. Cap
Removal or plug all open ports and hose ends.
1. Position the unit on a level surface and properly set
the outriggers. 8. Remove the cap screws securing the slide pad blocks
and bearings from the upper end of the intermediate
Warning boom.

Death or serious injury can result from uncontrolled 9. Use another derrick, forklift, or a hoist, to support the
movement. Secure the booms before removing the upper boom. Protect the fiberglass boom from nicks
cylinder mounting pins. or scratches from the lifting device. Unhook the rope
or chain securing the boom tip to the lower boom.
Failure to secure the upper boom tip to the lower or
intermediate boom can result in uncontrolled extension 10. With the aid and support of another vehicle (derrick,
of the upper boom when the cylinder mounting pin is forklift, etc.), carefully pull the upper boom assembly
removed from the intermediate boom. out of the intermediate boom. Set the boom on the
ground.
2. Rotate the boom to the side of the unit. Use chains
or rope to secure the upper boom tip to the lower or 11. At the base end of the upper boom, remove the two
intermediate boom. trunnion pins fastened to the upper boom cylinder.

3. Turn off the engine. Release any pressure in the 12. Pull the cylinder out of the upper boom.
hoses connected to the cylinder by operating the
upper boom control handle for both directions. Installation
1. Use a sling and hoist or other lifting device to position
4. Remove any components on the unit attached to the the cylinder inside the upper boom.
upper boom assembly such as the platform or jib,
that may interfere with upper boom removal. Remove 2. Install the two trunnion pins through the base end of
anything on the unit, such as a winch line, that makes the upper boom and into the cylinder (refer to Figure
a connection between the upper and intermediate 6.6). Torque the trunnion pin cap screws to 50 foot-
boom when the upper boom is removed. pounds (68 N•m).

5. Remove the lower boom cover and access hole 3. Use another derrick, forklift, or other heavy equipment
covers closest to the turntable. to slide the upper boom into the intermediate boom.

Trunnion Pin and Slide Pad Bearing

Cap Screw Cap Screws

Upper Boom Cylinder

Rod End Pin
Figure 6.6 — Booms

70 • Section 6 — Mechanical Systems

 Take care not to damage the fiberglass boom and When the brake is unlocked, the platform is free to pivot
boom tip. on its mounting shaft to provide gravity leveling as the
boom angle changes. Figure 6.7 illustrates the brake in
4. Install the slide pad blocks and bearings. the locked and unlocked positions.

5. Install the pin and two retaining rings to secure the Unlocked Locked
rod end of the cylinder to the base end of the inter-
mediate boom. Install the retaining rings with the
sharp edge toward the end of the pin.

6. Connect the two upper boom cylinder hydraulic lines

to the fittings at the hose carrier.

7. Be sure the outriggers are properly set and start the

engine. Extend and retract the upper boom several
times. This will purge any air that is in the hoses or
cylinder. While operating the cylinder, check it for
leaks and proper operation.
Figure 6.7 — Platform Brake
8. Install the lower boom cover and access covers.
The brake can be locked at any boom angle to keep the
9. Install other components, such as the winch line, that platform from swinging while working from the platform.
were removed. The brake should also be locked after the platform is re-
turned to its stowed position before road travel. The brake
is locked by rotating the brake lever downward toward
Winch
the rim of the platform. An overcenter mechanism locks
The unit is equipped with a winch mounted at the base the brake in the fully applied position when the handle
end of the lower boom. reaches the bottom of its travel.

The winch is a planetary winch driven by a hydraulic motor.

Operation of the winch valve directs hydraulic system oil
Digger Transfer Mechanism
to the winch motor. The winch motor powers the planetary The digger hanger bracket is equipped with a digger trans-
gear set. The gear set drives the winch drum. fer mechanism (refer to Figure 6.8). The digger transfer
mechanism consists of a detent lug on the digger hanger
When installing the winch, check whether there is a gap link and a digger holdback latch on the lower boom. When
between any of the mounting feet and the winch mounting the digger is stowed, the digger transfer mechanism locks
surface. If there is a gap of 0.060″ (1.524 mm) or more the digger hanger bracket to the lower boom. When the
beneath one or more mounting feet with the remain- digger is unstowed, the mechanism automatically trans-
ing feet tight against the mounting surface, use shims fers the bracket from the lower boom to the intermediate
(washers or machinery bushings) to take up the gap. If boom. In order for the digger transfer mechanism to work
this is not done, the winch may be put into a bind when properly, the intermediate boom must be fully retracted
the mounting cap screws are tightened. during stowing and unstowing of the digger.

Hydraulic pressure acts on a piston in the brake chamber. If the intermediate boom is not fully retracted when the
The piston moves against the springs, which releases digger is unstowed, the digger hanger bracket will not
the brake discs. This causes the winch brake to be hy- attach itself to the intermediate boom. When the opera-
draulically released. tor extends the intermediate boom to position the auger
for digging, the auger will be left behind. If this happens,
the intermediate boom may be retracted without first
Platform Brake
stowing the auger.
The personnel platform is equipped with a caliper-type
disc brake in the platform mounting bracket.

Section 6 — Mechanical Systems • 71

 When the digger is stowed, the digger holdback latch
holds the hanger bracket against the lower boom as the
Digger Bail intermediate boom is extended. Any binding or other
problem that could cause enough force to make the
hanger bracket jump past the holdback latch must be
Digger Hanger Link corrected immediately. If the digger hanger bracket jumps
past the digger holdback latch, it could cause damage
Digger Hanger
Intermediate to the digger link and other components. This condition
Boom Latch could be caused by the hanger bracket slide bearings
binding against the intermediate boom or the hanger
bracket slide bearings shimmed too tightly against the
intermediate boom.

Digger
Latch Pin

Digger
Holdback Latch
Figure 6.8 —
Digger Hanger Link in Stowed Position

72 • Section 6 — Mechanical Systems

 Section 7 — Electrical System
Electrical power is used on the unit to operate the so-
lenoids that shift the hydraulic valve spools to operate
On/Off Circuit
the unit from the ground drive controls, radio controls, The on/off circuit supplies constant 12 volts power to a
and some functions of the lower controls. The electrical solenoid or other component when a switch or relay is
power is supplied from the battery. Figure 7.1 shows a closed. When the circuit is opened, the power is removed.
comparison between electrical and hydraulic components.
On/off circuits are used to control solenoid valves that
Caution operate the following functions.

Injury can result from electric shock. Severe arc- • Pole guide open/close
ing can occur even when working with low voltage • Outrigger extend/retract
electrical systems. Use caution when working with • HOP
any electrical device. • Digger speed high/low
• Tools on/off
Voltage levels of this system are based on a constant • Track speed low/high
power source. Voltage may vary from 11 to 14 volts and • Track extend/retract
still be considered normal in a 12 VDC system.

The major electrical components and their operation Proportional Circuit

are described in this section. Wiring Line Diagrams in Certain functions of the derrick require variable speeds
the Appendix illustrate the component wiring. Refer to of operation with slow starts and stops. They cannot be
Section 8 for troubleshooting information. operated with on-off solenoid valves, but must be oper-
ated by a proportional control system. Each function uses
The electrical system uses two basic types of circuits — a different control and operates a different pulsar valve.
an on/off circuit and a proportional circuit.

Electrical Component Hydraulic Component Function Performed

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

Figure 7.1 — Electrical/Hydraulic Comparison

Section 7 — Electrical System • 73

A proportional control system allows the function’s speed
to be proportional to the distance the control is shifted. Below Rotation Valve Driver
For example, if the boom control is shifted in the Raise The below rotation valve driver (refer to Figure 7.2) is
position at maximum hand control travel, the boom rises located next to the pedestal. It is the connection between
at maximum speed. The boom will continue to rise until the selector/unloader valve, below rotation controls, and
the handle is shifted to neutral or the boom reaches its the electrical functions of the unit. Multiplexing for the
maximum travel for the boom raise function. unit begins with the below rotation valve driver. An LED
indicates the condition of the processors.
The following radio control functions use proportional
circuits.
Above Rotation Valve Driver
• Drive The above rotation valve driver (refer to Figure 7.3) is
• Boom raise/lower located on the turntable. It is the connection between the
• Rotation left/right following control system components.
• Intermediate boom extend/retract
• Upper boom extend/retract • Boom, digger and winch functions, auxiliary func-
• Winch raise/lower tions, and above rotation control panels
• Digger dig/clean • Upper controls or radio controls and the boom,
digger/winch, and auxiliary functions
Multiplexed Controls • HOP, system pressure transducers, and electronic
side load transducers and the control panels
Multiplexing is used on the unit to combine and transmit • Electrical circuits running through the slip ring to
multiple signals over a single channel (or pair of wires), the below rotation valve driver
eliminating the need for individual channels for each signal.

CON1 CON2 CON3 CONTROL STATION A CON4 CONTROL STATION B CON5 SLIP RING CON6 INPUT CONTROL
1 NOT USED 1 LEFT REAR O/R UP 1 COMMUNICATION B 1 COMMUNICATION B 1 COMMUNICATION B 1-2 +12V
2 NOT USED 2 LEFT FRONT O/R UP 2 COMMUNICATION A 2 COMMUNICATION A 2 COMMUNICATION A 3-13 NOT USED
3 RIGHT TRACK REV 3 LEFT FRONT O/R DOWN 3 +12V LOWER CONTROLS 3 +12V LOWER CONTROLS 3 INTERLOCK 14-15 GROUND
4 NOT USED 4 LEFT REAR O/R DOWN 4 GROUND 4 GROUND 4 GROUND 16-21 NOT USED
5 LEFT TRACK FWD 5 UNLOADING 5 INTERLOCK 5 INTERLOCK 5 22 SYSTEM PRESSURE TRANSDUCER
6 LEFT TRACK REV 6 COMBINER 6 +12V UPPER CONTROLS 6 +12V UPPER CONTROLS 6 EMERGENCY STOP 23 NOT USED
7 RIGHT TRACK FWD 7 O/R INTERLOCK 7 EMERGENCY STOP IN 7 EMERGENCY STOP IN 7 +12V INPUT
8 NOT USED 8 NOT USED 8 EMERGENCY STOP OUT 8 EMERGENCY STOP OUT 8 +12V INPUT
9 NOT USED 9 TRACK EXTEND
970162705 REV A

10 TRACK 2 SPEED 10 TRACK RETRACT

11 RIGHT FRONT O/R DOWN 11 POLEPULLER RETRACT
12 RIGHT FRONT O/R UP 12 TOOLS
13 RIGHT REAR O/R DOWN 13 POLEPULLER EXTEND
14 RIGHT REAR O/R UP 14 BOOM ENABLE
DERRICK MULTIPLEXED CONTROL SYSTEM
BELOW ROTATION VALVE DRIVER

+5V +12V INTERLOCK MO-1 MO-8 MO-3 MI-2 BOOM

ENABLE

Figure 7.2 — Below Rotation Valve Driver

Figure 7.3 — Above Rotation Valve Driver

74 • Section 7 — Electrical System

 The CADI also uses a permanently attached, multiplex
Cable Assemblies cable. The CADI can be connected to a receptacle pro-
Cable assemblies made up of electrical conductors vided on the lower control panel.
are used to send and receive all the multiplexed com-
munication signals (and some analog signals) between Multiplex Cable Connectors
the various control system components. All multiplexed There are 8, 14, 23, and 35 pin weatherproof quick con-
communication is accomplished with two wires that serve nectors used to connect the multiplex cable assemblies
as the communications channel. to the control system components.

Ten cable assemblies are used on the unit. Each of these When connecting a multi-pin connector, make sure it is
cable assemblies establishes a common ground between properly aligned before pushing the plug fully into the
the various control system components. receptacle. Make sure the rubber insulating ring between
the connector and receptacle is in place and is in good
• A 14 wire cable assembly connects the circuit wiring condition.
between the proportional valve pulsars and the above
rotation valve driver. Immediately after disconnecting one of these connec-
tors, cap the plug or wrap it in a plastic bag to prevent
• A 14 wire cable assembly connects the circuit wiring contamination.
between the auxiliary functions valve and the above
rotation valve driver.
Calibration and Diagnostic
Instrument (CADI)
• A 14 wire cable assembly connects the circuit wiring
between the control panel and the right hand switches. The CADI (refer to Figure 7.4) is a separate, self-contained
component of the control system. The CADI does not
• A 14 wire cable assembly connects the circuit wiring come with the unit, but is available from your service
between the control panel and the left hand switches. representative (refer to Service Tools and Supplies in the
Appendix). The CADI is used to set the various adjust-
• A 35 wire cable assembly connects the circuit wiring able parameters for the derrick control system. A Quick
between the control panel and the boom and digger/ Reference Guide is included with the CADI containing
winch function hand controls. full instructions for its operation.

• A 14 wire cable assembly connects the circuit wiring

between the terminal strip on the below rotation valve
driver and the below rotation valve driver.

• An eight-wire multiplex cable assembly connects

the below rotation valve driver to the above rotation
valve driver via the slip ring.

• An eight-wire multiplex cable assembly connects the LCD

upper control panel or radio controls to the above
rotation valve driver.

• An eight-wire multiplex cable assembly connects the

lower control panel to the above or below rotation Push Button
valve driver depending on the location of the lower Key Pad
control panel.

• A 23 wire cable assembly connects the HOP, platform,

auger and boom stow, and load indicator and system
pressure gauge transducers, and electronic side load
protection transducers to the above rotation valve Figure 7.4 — CADI
driver.

Section 7 — Electrical System • 75

 When the outriggers are raised, the outrigger interlock
Power Distribution Module (PDM) switches are open. Therefore, the solenoid for the un-
The PDM is the central connection point between the loader valve will not be energized when a function on the
unit electrical system and the vehicle electrical system. control panel is operated. This prohibits oil from flowing
The PDM is used when electronic circuits are required to the lower control valve to allow for boom operation.
to operate the unit and additional accessories or when
electronic engine controls are used. Refer to the PDM If one switch is defective or out of alignment, the system
Information Manual for introduction, familiarization, and will not operate. Adjustment of these switches is described
onboard diagnostic system information. in section 8 under Electrical System.

Switch Removal From Radial Outriggers

Outrigger Interlock System Remove the cap screws that hold the switch to the out-
The outrigger interlock system is a combination of electric rigger frame. At the end of the switch wiring, disconnect
and hydraulic components designed to prevent boom the connector. Remove the switch and wiring.
operation until all outriggers are lowered.
Switch Installation on Radial Outriggers
There is one outrigger interlock electrical switch for Connect the electrical connector of the new switch. At-
each outrigger leg extension. They are mounted on the tach the new switch to the outrigger frame with one cap
stationary parts of the outrigger. Figure 7.5 shows the screw. The wired end of the switch must be located toward
switch. When the outriggers are lowered, the switches the outrigger shoe. Use the other cap screw to lock the
close. The interlock switches are connected to the outrig- switch in place after it has been adjusted.
ger interlock control module. When all the switches are
closed, electrical power will be sent to the solenoid of Lower Control Panel
the unloader valve when a function on the control panel
is operated. The lower control panel is used to operate all the unit
functions except the outriggers and lower tool circuit. As
shown in Figure 7.6, hand controls, switches, gauges,
and panel lights are mounted in the top cover of the
control panel.

Hand Controls
The control panel is equipped with hand controls (refer
to Figure 7.7) for each proportional function.
Figure 7.5 — Proximity Switch

On Units With Tilting Pole Guide

Figure 7.6 — Lower Control Panel

76 • Section 7 — Electrical System

 Fasteners

Interlock

Microswitch

Figure 7.8 — Slip Ring Identification

2. Remove any turntable or pedestal covers required

to access the slip ring assembly. Disconnect any
plumbing necessary to allow removal of the cover
Figure 7.7 — Hand Control from the slip ring assembly.

When operated, the hand controls send electrical signals 3. Remove the cover from the slip ring assembly. Re-
to the pulsar valves. The electrical signals vary in propor- connect any plumbing which was disconnected in
tion to the distance the hand control is moved. step 2.

When the interlock on a hand control knob is lifted and the

hand control is moved just out of neutral, a microswitch Caution
is activated. The microswitch sends electrical power to Injury can result from being pinched or trapped be-
close the interlock relays. tween moving components. Keep hands clear.

Slip Ring 4. Spray the slip ring surfaces with DeoxIT cleaner/
protectant (refer to Service Tools and Supplies in
This unit uses an electrical slip ring assembly to transmit the Appendix). Normally one to two bursts of spray
electrical signals between the pedestal and the turntable. is sufficient. If access to the slip ring is limited, rotate
It protects the electrical wiring that passes through the the turntable to access all areas. Use care when
centerline of rotation. Failure to properly maintain the slip rotating the unit, as removed covers may expose
ring may result in corrosion or degradation of contacting pinch points or other hazards.
surfaces, which may lead to malfunction and eventual
need for replacement of the slip ring. 5. Following treatment of all contact surfaces, start the
engine, engage the PTO, and rotate the turntable a
This unit may be equipped with a serviceable slip ring. minimum of three full revolutions in both directions.
The procedure outlined in this section should only be If contact surfaces appear clean and discoloration
performed on a serviceable slip ring. Attempting to from oxidation is greatly reduced, or no oxidation
perform this procedure on any other slip ring may void residue is noted when the slip ring contact surfaces
the manufacturer’s warranty. A serviceable slip ring is are wiped with a clean white rag, proceed to step 8.
identified by the presence of fasteners which hold the
metal cover over the slip ring circuit assembly (refer to 6. If the slip ring is heavily oxidized (discoloration of the
Figure 7.8). contact surfaces), spray the slip ring contact surfaces
again and allow it to sit overnight.
1. Position the unit on a level surface where the booms
can be elevated and rotated 360 degrees without 7. After sitting overnight, rotate the turntable three full
contact with fixed objects. Apply the parking brake turns, then wipe all contact surfaces with a clean white
and chock the wheels. Engage the PTO and properly rag or blow off contact surfaces with compressed air
set the outriggers. Disengage the PTO and turn off until dry.
the engine.

Section 7 — Electrical System • 77

 8. Spray all contact surfaces again (one to two bursts) 2. Coat the threads of the cap screws that mount the
with DeoxIT. slip ring to the rotary joint with pipe sealant. Insert
a cap screw through a tab on the rotary joint and
9. Reinstall the slip ring cover and turntable or pedestal through a spacer tube into the slip ring. Repeat this
covers that were removed. step for the other two cap screws and spacers that
mount the slip ring to the rotary joint.
10. Test all functions that use the slip ring to conduct
electrical power between the turntable and pedestal. 3. Connect the electrical connectors in the pedestal to
the below rotation valve driver.
11. Following a successful test, return unit to service.
4. Connect the electrical connectors to the above rotation
Removal valve driver. Connect the ground wire to the ground
1. Remove the turntable covers. block.

2. Disconnect the electrical connections from the slip 5. Install the turntable covers.
ring that are routed to the above rotation valve driver.
Disconnect the electrical connections from the below
Tilt Alarm
rotation valve driver that are routed through the rotary
joint. Disconnect the ground wire from the ground The tilt alarm is an electronic audible alarm that sounds
block. when the unit nears an unstable condition while driving.
The alarm is not intended to be the only indication of
3. Remove the three cap screws that connect the slip the driving instability, but acts as an early warning of a
ring to the rotary joint. Remove the slip ring. possible unstable situation.

Installation The tilt alarm is mounted at the base of the boom on

1. Position the slip ring inside the turntable and route the winch cover. When the unit reaches 10 degrees
the cable through the rotary joint. Position the slip side-to-side angle the tilt sensor will activate an audible
ring on bottom of the rotary joint. alarm. If the sensor is not set properly, the alarm will not
activate at the correct angle. Adjustment of the sensor
is described in Section 8 under Tilt Alarm.

78 • Section 7 — Electrical System

 Section 8 — Troubleshooting, Testing, and Adjustments
move. Movement occurs when sufficient pressure is
Troubleshooting Procedure applied to the movable component of an actuator. If an
Establish a troubleshooting procedure to be followed actuator does not move, the cause may be insufficient
any time there is a malfunction. This procedure will pro- pressure.
vide a starting point for determining the root cause of
the malfunction and increase troubleshooting accuracy. Flow is a measure of the amount of fluid displaced dur-
Consider using the following procedure. ing a specified amount of time. The flow rate determines
the speed of actuator movement. The more fluid that is
1. Position the unit on a level surface. Check the oil displaced, the faster the actuator will move. If an actuator
level in the reservoir. moves slowly, the cause may be low flow.

2. Warm the hydraulic oil to operating temperature, and Cycle Times

properly set the outriggers. Figure 8.1 shows average cycle times in seconds (refer
to Boom Functions Speeds in this section for the testing
3. Before testing each function through its full travel procedure).
capabilities, try small movements to be certain the
function is operating properly. Test each function for Function Seconds
full travel capabilities.
Boom raise 12 to 17
Boom lower 9 to 13
Warning
Intermediate boom extend 9 to 14
Death or serious injury can result from falling from
the platform. All platform occupants must properly Intermediate boom retract 9 to 14
use an appropriate OSHA approved personal fall Upper boom extend 9 to 14
protection system. Upper boom retract 12 to 16
4. Operate the unit from the lower controls and then Rotation 44 to 51
the radio controls (if so equipped) to identify the Figure 8.1 — Average Cycle Times
malfunction.
The Hydraulic System Schematic (refer to the Appendix)
5. Use the Hydraulic System Schematic and Wiring Line identifies the paths of oil flow in the system. It also identi-
Diagrams in the Appendix to determine the flow path fies the operation of every hydraulic component. A thor-
required to operate the failed function. Make a list of ough understanding of JIC symbols and their meanings
the components used to operate the failed function. is helpful in troubleshooting (refer to Basic JIC Symbols
Cross off components used to operate other functions in the Appendix).
that are operating properly. This should minimize the
number of items to check. Use an accurately calibrated gauge to test the pressure
of a particular circuit. A calibrated gauge will provide an
6. Check the easiest component first. Verify the proper accurate reading, which is essential for proper hydraulic
operation of each component remaining on the list adjustments.
until the bad component is found.
Before testing or adjusting unit functions, position the
7. Use accurate test equipment to verify flow, pressure, unit on a level surface.
voltage, and current.
Main System Relief
Once the symptom has been positively identified, use The system utilizes a relief valve cartridge in the inlet
the Troubleshooting Chart in the Appendix for suggested end of the drive/outrigger/tools valve located near the
causes and corrective actions. diesel fuel tank. This relief in the port marked RV1 should
be set at 2,500 psi (172.37 bar) at 16 gpm (60.57 lpm).
Hydraulic System
Testing
Hydraulic fluid pressure and flow are required to operate 1. Position the unit on a level surface and turn off the
the hydraulic system functions. engine. Connect a 3,000 psi (206.34 bar) minimum
pressure gauge to the quick disconnect on the drive/
Pressure is the force applied on a given area. The amount outrigger/tools valve.
of pressure determines whether or not the actuator will

Section 8 — Troubleshooting, Testing, and Adjustments • 79

 2. Start the engine and move the drive outrigger/lower
tools/radio control to the Drive/Outrigger position. Pilot
Reducing
Cartridge
3. With the outriggers fully stowed, move the outrigger
control to the Retract position while operating the Pilot
engine at a speed to produce full pump flow. Pressure
Gauge
Port
4. Read the pressure on the gauge.

Adjustment
1. Locate the relief valve cartridge in the port marked
RV1 on the drive/outrigger/tools valve (refer to Figure
8.2).

Tools System Tank

Pressure Tools Flow Pressure Pressure
Reducing Regulator Gauge
Cartridge Port

Figure 8.3 — Boom Functions Valve

2. Remove the cover surrounding the lower control

functions valve. Install an accurate 0 to 600 psi (0 to
41 bar) pressure gauge to the pilot pressure gauge
port on the boom functions valve (refer to Figure 8.3)
and a 0 to 200 psi (0 to 14 bar) pressure gauge on
the tank gauge port.

Figure 8.2 — Drive/Outrigger/Tools Valve 3. Start the engine and move the drive outrigger/lower
tools/radio control to the Lower position. With the
2. Loosen the jam nut, and turn the adjusting screw engine running at a speed that produces full pump
clockwise to increase the setting or counterclockwise flow, move the hand control of a function out of neutral
to decrease the setting until the proper pressure is to energize the pilot system.
obtained. Hold the adjusting screw to keep it from
turning, tighten the jam nut, and retest the setting. 4. The difference between pilot pressure and tank pres-
sure should be between 150 and 175 psi (10.7 and
3. Turn off the engine and remove the gauge. 11.03 bar).

Pilot System Pressure Adjustment

When the unloader spool is closed, a constant, controlled 1. Turn off the engine.
flow of oil is sent to the pilot system. Pilot pressure is
maintained in the system by an adjustable reducing valve 2. Remove the cap on the pilot pressure relief cartridge.
cartridge in the boom functions valve (refer to Figure 8.3). Turn the adjusting screw clockwise to increase the
pressure or counterclockwise to decrease pressure.
The pilot pressure should be between 155 and 160 psi
(10.7 and 11.03 bar). If the pilot pressure is too low, the 3. Test the pressure.
spools may not reach full stroke. If the pilot pressure is
too high, all functions may exhibit a loss of metering. Pilot 4. Repeat the adjustment until the pressure differential
pressure should not need to be adjusted. If it is adjusted, is between 155 and 160 psi (10.7 and 11.03 bar).
control of flow from all functions could be affected.
5. Remove the gauge, replace the cap on the pilot
Testing pressure relief cartridge, and install the cover.
1. Position the unit on a level surface and properly set
the outriggers. Turn off the engine. Pump Flow
A slow down in unit movement may indicate a worn or
defective pump. If a worn or defective pump is suspected,

80 • Section 8 — Troubleshooting, Testing, and Adjustments

perform the following procedure to determine if full flow Danger
can be generated.
Death or serious injury will result from contact with
rotating components in the pump driveline. Keep
Warning hands and clothing clear of the pump driveline.
Death or serious injury can result from hydraulic
oil being injected into the flesh when loosening or 4. Connect the inlet of the flowmeter (refer to Figure 8.4)
disconnecting hydraulic components. Remove the to the pump using a long section of hydraulic hose.
hydraulic pressure before loosening or disconnect- The hose diameter must be the same size or larger
ing hydraulic components. than the hose used on the unit and long enough to
allow reading the flowmeter without possible contact
Seek immediate medical attention if injured by escap- with the pump driveline.
ing hydraulic oil. Serious infection or reaction can
result if medical treatment is not given immediately. 5. If the pump is equipped with a compensator, con-
nect the pump sense line to the pump pressure line
Spilled hydraulic oil creates slick surfaces and may entering the flowmeter (refer to variable displacement
cause personnel to slip and/or fall. Keep the unit and pump in Figure 8.4).
work areas clean.
6. Connect the outlet of the flowmeter to a reservoir
Testing return line. Fully open any shutoff valves on the
1. Position the unit on a level surface, apply the parking flowmeter.
brake, and chock the wheels.
Warning
2. Disengage the hydraulic system and turn off the
Death or serious injury can result from pump or hy-
engine.
draulic system failure. Do not perform this procedure
without a pressure relief installed.
3. Disconnect the pump pressure line from the pump. If
multiple section pumps are used, test only one pump
7. Install a pressure relief to bypass the pump flow
section at a time.
around the flowmeter and shutoff valve. Refer to

Fixed Displacement Pump Variable Displacement Pump

Figure 8.4 — Pump Flow Test Connections

Section 8 — Troubleshooting, Testing, and Adjustments • 81

 Figure 8.4 for relief placement. The relief should Use the appropriate test to determine the cause of out-
be set no more than 200 psi (13.8 bar) above the rigger drift.
required unit system pressure. System pressure is
stamped on the unit serial number placard. Cap and Drift Up
plug any open connections. If an outrigger drifts up several inches when it is loaded,
the holding valve in the extend circuit may be leaking. If
8. Start the vehicle engine and engage the hydraulic the outrigger drifts up a little and stops, there may be an
system. internal leak in the piston seal.

Testing — Internal Cylinder Leakage

Notice
A liquid container is required to perform this test.
If the pump is equipped with a compensator, test full
flow at 500 psi (34.5 bar) below the pressure listed 1. Position the unit on a level surface.
in the following step.
2. Retract the cylinder completely and turn off the engine.
9. The flowmeter will indicate the flow from the pump.
Increase the load on the pump by slowly closing the 3. Shift the outrigger control in both directions several
load inducing shutoff valve. Do not exceed the unit times to relieve any pressure in the hoses.
system pressure as indicated on the unit serial number
placard. Each pump section may have different flow 4. Disconnect the outrigger cylinder hose from the extend
and pressure requirements. The large side of the port of the drive/outrigger/tools valve. Allow the oil
pump should indicate approximately 10.5 gpm (39.75 remaining in the hose to drain into a container. Cap
lpm) at 2,500 psi (172.37 bar). The small side of the the fitting at the valve.
pump should indicate approximately 6 gpm (22.71
lpm) at 2,500 psi (172.37 bar). If the pump flow is 5. Hold the open end of the hose over a container and
less than required for unit operation, the pump may start the engine. Shift the outrigger control to the
be defective or worn. Retract position.

10. If the pump flow is correct, disengage the hydraulic 6. If a heavy stream of oil drains from the hose with the
system and turn off the engine. control in the Retract position, the cylinder is leaking
internally. Reconnect the hose to the drive/outrigger/
11. Open the load inducing shutoff valve. Remove the tools valve. Repair or replace the cylinder.
flowmeter, temporary lines, and fittings. Reconnect
the unit lines to their original positions. Testing — Piston Seal and Check Valve
A vehicle jack, a liquid container, and the ability to let the
Outriggers unit sit overnight is required to perform this test.
Outrigger cylinders and holding valves must operate
properly to assure unit stability. Any leak must be cor- 1. Position the unit on a level surface.
rected before placing the unit in service.
2. Extend the outrigger cylinder completely and turn off
Warning the engine.

Death or serious injury can result from hydraulic 3. Raise the unit with a jack so the outrigger does not
oil being injected into the flesh when loosening or carry its own weight.
disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic 4. Shift the outrigger control in both directions several
components. times to relieve any pressure in the hoses.

Seek immediate medical attention if injured by escap- 5. Disconnect the retract hose from the control valve
ing hydraulic oil. Serious infection or reaction can and place the hose in a liquid container. Disconnect
result if medical treatment is not given immediately. the extend hose from the valve and place the hose
in another liquid container.
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and 6. Let the jack down so the outrigger carries its own
work areas clean. weight. Let the unit sit overnight.

82 • Section 8 — Troubleshooting, Testing, and Adjustments

 a. If the extend hose container has oil in it, the hold- Place a jack under the outrigger shoe to support
ing valve is defective. the outrigger. Replace the holding valve in the V2
port of the valve housing (refer to Holding Valves
b. If the cylinder moved a few inches and stopped, in this section).
the cylinder piston seal is leaking.
b. If the outrigger extended but there is no liquid in
c. If the cylinder retracts all the way in and there is the container, the cylinder is leaking internally.
oil in the retract hose container, the cylinder piston Replace or repair the cylinder.
seal is leaking and the holding valve is defective.
Lower Tool Circuit
7. The holding valve port marked V1 controls cylinder Flow
extension and the port marked V2 controls cylinder The flow of the lower tool circuit, factory set at 6 gpm
retraction. Both ports are located in the valve hous- (22.71 lpm), is controlled by an adjustable flow regulator
ing. This housing is on the base end of the outrigger in the drive/outrigger/tools valve.
cylinder (refer to Figure 8.5). Replace the appropriate
valve cartridge as described under Holding Valves Testing
in this section and repeat the test. 1. Turn off the engine. Connect a flowmeter to the lower
tool circuit.

2. Start the engine and move the drive outrigger/lower

Valve tools/radio control to the Lower/Tools position. Move
Housing the tool control to the On position.

3. The flowmeter should indicate 6 gpm (22.71 lpm).

Adjustment
1. Locate the drive/outrigger/tools valve near the hy-
draulic reservoir.

2. The flow regulator controls the flow of the tool circuit

(refer to Figure 8.6).

Figure 8.5 — Outriggers

Unloader Valve Cartridge
Tools and Solenoid Valve
Drift Down Pressure
If the outrigger drifts down from the raised position over- Reducing Tools Flow
night or over the weekend, the cylinder may be leaking Cartridge Regulator
internally or the holding valve in the retract circuit may
be leaking.

Testing — Internal Cylinder Leakage and Check Valve

A vehicle jack, a liquid container, and the ability to let the
unit sit overnight are required to perform this test.

1. Place a jack under the outrigger shoe to support the

outrigger and turn off the engine.

2. Shift the outrigger control handle in both directions

several times to relieve any pressure in the hoses. Figure 8.6 — Drive/Outrigger/Tools Valve

3. Disconnect the retract hose from the control valve 3. Loosen the jam nut. Turn the adjusting screw clock-
and place the hose in a liquid container. Remove the wise to increase the output flow of the tools circuit.
jack and let the unit sit overnight. Turn the adjusting screw counterclockwise to de-
crease the output flow of the tools circuit. Make the
a. If the outrigger extended and there is liquid in proper adjustment.
the container, the retract holding valve is leaking.

Section 8 — Troubleshooting, Testing, and Adjustments • 83

 4. After making the proper adjustment, tighten the jam Seek immediate medical attention if injured by escap-
nut. Test the flow again. ing hydraulic oil. Serious infection or reaction can
result if medical treatment is not given immediately.
Warning
Spilled hydraulic oil creates slick surfaces and can
Death or serious injury can result from hydraulic cause personnel to slip and/or fall. Keep the unit and
oil being injected into the flesh when loosening or work areas clean.
disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic 3. Loosen the jam nut. Turn the adjusting screw clock-
components. wise to increase the output pressure of the tools
circuit. Turn the adjusting screw counterclockwise
Seek immediate medical attention if injured by escap- to decrease the output pressure of the tools circuit.
ing hydraulic oil. Serious infection or reaction can Make the proper adjustment.
result if medical treatment is not given immediately.
4. After making the proper adjustment, tighten the jam
Spilled hydraulic oil creates slick surfaces and can nut. Test the pressure again.
cause personnel to slip and/or fall. Keep the unit and
work areas clean. Upper Tool Circuit
Flow
Pressure The flow of the upper tool circuit, factory set at 3 to 5 gpm
The output pressure of the tool circuit is adjustable to (11.36 to 18.93 lpm), is controlled by an adjustable flow
accommodate hydraulic tools with various pressure regulator in the auger release/pole guide/upper tool valve.
requirements. Pressure is adjustable from 500 to 2,000
psi (34.47 to 137.90 bar). The tools circuit pressure is Testing
factory set at 2,000 psi (137.90 bar). 1. Position the unit on a level surface and properly set
the outriggers. Disconnect the pole guide hoses
Testing at the boom tip. Connect a flowmeter to the quick
1. Position the unit on a level surface and properly set disconnects.
the outriggers. Move the drive outrigger/lower tools/
radio control to the Lower/Tools position. 2. Start the engine and activate the upper tool circuit
from the radio remote control. The radio remote must
2. Connect a 3,000 psi (206.84 bar) minimum pressure be in the docking station to activate the upper tools.
gauge to the tools quick disconnect coupler pressure
connection. 3. The flowmeter should indicate 3 to 5 gpm (11.36 to
18.93 lpm).
3. Turn on the tools. The pressure gauge should indicate
2,000 psi (137.90 bar). Adjustment
1. Locate the auger release/pole guide/upper tool valve
4. If necessary, adjust the tool circuit pressure to oper- on the turntable side plate (near the above rotation
ate tools that require a pressure setting below 2,000 boom function valve).
psi (137.90 bar).
2. The flow regulator controls the flow of the tool circuit
Adjustment (refer to Figure 8.7).
1. Locate the drive/outrigger/tools valve near the diesel
fuel tank. 3. Loosen the jam nut. Turn the adjusting screw clock-
wise to increase the output flow to the tools circuit.
2. The pressure reducing valve cartridge controls the Turn the adjusting screw counterclockwise to de-
pressure of the tool circuit (refer to Figure 8.6). crease the output flow of the tools circuit. Make the
proper adjustment.
Warning
4. After making the proper adjustment, tighten the jam
Death or serious injury can result from hydraulic oil nut. Test the flow again.
being injected into the flesh if the tool hoses burst
or the tool ruptures. Do not adjust the pressure of
the tool circuit above the hydraulic power tools
manufacturer’s rating for the tool.

84 • Section 8 — Troubleshooting, Testing, and Adjustments

 4. After making the proper adjustment, tighten the jam
nut. Test the pressure again.

Rotary Joint
A leaking seal in the rotary joint can cause oil flowing to
any hydraulic circuit above rotation to be diverted directly
to the return line. This will cause functions to slow down
and/or fail to build pressure.

Testing
To test the rotary joint, a few simple hydraulic connections
must be made.

Pressure Reducing 1. Position the unit on a level surface and properly set
Valve Cartridge Flow Regulator the outriggers.

Figure 8.7 — 2. Turn off the engine.

Auger Release/Pole Guide/Upper Tool Valve
3. Remove the below rotation covers to allow access
Pressure to the pedestal.
The output pressure of the upper tool circuit is adjustable
to accommodate hydraulic tools with various pressure 4. Disconnect the pressure line and the load sense line
requirements. Pressure is adjustable from 500 to 2,000 from the top of the rotary joint (refer to Figure 8.8).
psi (34.47 to 137.90 bar). The tools circuit pressure is Cap the open ports on the rotary joint and the open
factory set at 2,000 psi (137.90 bar). hose ends.

Testing
1. Position the unit on a level surface and properly set Sense Line
Ports
the outriggers. Disconnect the pole guide hoses at
the boom tip. Connect a flowmeter with a needle
valve to the quick disconnects.

2. Start the engine and activate the upper tool circuit

from the radio remote control. The radio remote must
be in the docking station in order to activate the upper
tools. Pressure
Line Ports
3. Deadhead the flow in the circuit with the needle valve
to reach maximum pressure.

4. The pressure gauge should indicate 2,000 psi (137.90

bar).

Adjustment Tank
1. Locate the auger release/pole guide/upper tool valve Line Ports
on the turntable side plate (near the above rotation
boom function valve). Figure 8.8 — Rotary Joint

2. The pressure reducing valve cartridge controls the 5. Disconnect the return line from the top of the rotary
pressure of the tool circuit (refer to Figure 8.7). joint and cap the open port and hose end.

3. Loosen the jam nut. Turn the adjusting screw clock- 6. Connect a flowmeter in the pressure line between
wise to increase the output pressure to the tools the boom function port on the outrigger/drive/tools
circuit. Turn the adjusting screw counterclockwise valve and the pressure port on the outside of the
to decrease the output pressure of the tools circuit. rotary joint.
Make the proper adjustment.

Section 8 — Troubleshooting, Testing, and Adjustments • 85

 7. Make a temporary connection between the sense except for the pulsar. However, it may also be an
signal line and the pressure line before the flowmeter. electrical system problem.

8. Disconnect the return line from the side of the rotary If the function does not operate, the problem is in
joint. Allow the rotary joint to drain into a liquid con- the hydraulic system other than the pulsar. Continue
tainer until no oil remains. troubleshooting the hydraulic system.

9. Start the engine. Move the function selector switch 4. Switch the connector for the disabled function with
to Lower Controls. Operate the boom raise function. one that operates properly. The control for the work-
This will pressurize the pressure circuit in the rotary ing function will become the alternate control for the
joint. disabled function. Move the drive outrigger/lower
tools/radio control to the Radio Control position.
10. If oil starts to drain from the return line into the liquid
container, the seals in the rotary joint are leaking. 5. Attempt to operate the disabled function with the
Turn off the engine. Reseal or replace the rotary joint. alternate control from the radio controls. If the
After the rotary joint has been resealed or replaced, disabled direction of the function will now operate,
return the hydraulic connections back to normal and the problem is likely in the electrical portion of the
reinstall the covers. function. Proceed to step 6. If the function will not
operate, proceed to step 7.
11. If no oil drains into the liquid container, turn off the
engine. Return the hydraulic connections back to 6. Return the pulsar connector to the proper connector.
normal and reinstall the covers. Continue to troubleshoot the electrical portion of the
function.
12 Start the engine. Operate the unit from lower controls
to ensure proper operation and check for leaks. Notice
Outrigger Interlock System Properly seat the O-ring when installing a new pulsar.
If no functions above rotation will operate and the outrig-
gers are properly set, the problem may be that the out- There is an O-ring in the bottom of the pulsar cavity that
rigger interlock switches are not closing. If the outrigger has to be replaced with the new O-ring that comes with
interlock switches are properly adjusted (refer to Electrical each new pulsar. Torque the new pulsar at 60 to 78 inch-
System in this section), then it is possible that one of the pounds (6.8 to 8.8 N•m).
switches is not closing. They can be individually checked
for continuity in the closed position. 7. If the disabled function will not operate with an alter-
nate control, then it is likely the pulsar is defective.
Pulsar Valves Replace the pulsar. A new pulsar may be ordered
If one direction of a major function stops working from from your Altec representative.
the radio controls, the problem may be in the hydraulic or
electrical portion of the electrohydraulic control system. Lift Cylinder
The boom, rotation, intermediate and upper boom, dig- If the boom drifts down under load or under its own
ger and winch functions are considered major functions. weight, first rule out external causes such as pulsar valve
malfunction or electrical slip ring cross talk.
The following procedure will isolate the cause of the
problem by attempting to operate the disabled function If the components controlling the cylinder are working
with an alternate control. properly, the problem may be caused by leakage past the
counterbalance valve. It may also be caused by internal
1. Position the unit on a level surface and properly set leakage in the cylinder. Use the following test procedure
the outriggers. to isolate the cause.

2. Move the drive outrigger/lower tools/radio control to Testing

the Lower/Tools position. This will close the unloader 1. With the unit positioned on a level surface, properly
spool. set the outriggers.

3. Attempt to operate the disabled function from the 2. Raise the boom several inches out of the stowed
boom functions valve. If the function operates, all position. Turn off the engine. The boom functions
other hydraulic system problems may be ruled out, valve is equipped with manual handles. Locate the

86 • Section 8 — Troubleshooting, Testing, and Adjustments

 handle for the boom function. Make sure no other 4. Reconnect the hoses to the proper elbows. Repair
function is operating and that the digger speed switch or replace the cylinder.
is in the Low position. Shift the manual handle for
the boom in the lower direction. Watch for a change The lift cylinder does not have a holding valve in the retract
in speed of the boom as it drifts down. side. It is held in position under tensile load by the blocked
cylinder port in the boom functions valve. Normal leakage
a. If the speed of the boom changes from a slow past the blocked cylinder port will allow slow outward drift
drift to a more rapid descent as the handle is of the cylinder rod with the boom hand control in neutral
shifted, the counterbalance valve is leaking or its during operations that put the cylinder in tension. Such
relief pressure is set too low. Return the manual leakage will occur when applying downward force with
handle to neutral. Discontinue testing. Replace the the boom against the auger while digging.
counterbalance valve or adjust its relief setting.
Refer to Section 5 under Counterbalance Valves. Intermediate and Upper
Boom Extension Cylinders
b. If the speed of the boom changes as the handle If an extension cylinder creeps in or out or does not
is shifted in the Raise position, this indicates the respond properly to the hand control, first check the
cylinder piston seal is leaking. Return the manual components associated with controlling the cylinder for
handle to neutral. Repair or replace the cylinder. proper operation.
Refer to Section 5 under Lift Cylinder.
If no external cause is found, the problem is most likely
c. If there is no change in the speed of the drift with due to leakage past a counterbalance valve or internal
the handle shifted, return to neutral. Proceed to leakage in the cylinder.
step 3.
Testing
3. Start the engine and raise the boom several inches 1. With the unit positioned on a level surface properly
above the boom rest. Turn off the engine. Shift the set the outriggers. Make sure the boom is stowed.
valve spool with the manual handle to release any Completely retract (if drifting in) or extend (if drifting
trapped pressure in the circuit. out) the malfunctioning cylinder. Turn off the engine.

2. Locate the spool valve section on the boom functions

Warning
valve that controls the cylinder that is being tested.
Death or serious injury can result from hydraulic Disconnect the cylinder extend hose (if drifting in) or
oil being injected into the flesh when loosening or retract hose (if drifting out) from the 90 degree elbow
disconnecting hydraulic components. Remove the on the spool valve. Cap the elbow at the valve. Allow
pressure before loosening or disconnecting hydraulic the oil remaining in the hose to drain into a container.
components.
3. Hold the open hose end over the container. Start the
Seek immediate medical attention if injured by escap- engine.
ing hydraulic oil. Serious infection or reaction can
result if medical treatment is not given immediately. 4. Shift the hand control for the cylinder in the Retract
(if drifting in) or Extend (if drifting out) position. There
Spilled hydraulic oil creates slick surfaces and can may be an initial surge of oil out of the open hose
cause personnel to slip and/or fall. Keep the unit and end as pressure is first applied to the cylinder. Watch
work areas clean. whether oil continues to flow while holding the sys-
tem at maximum pressure [1,650 psi (206.84 bar)
Disconnect the extend and retract hoses at the base end for the intermediate boom or 1,700 psi (117 bar) for
of the lift cylinder. Plug the open ends of the hoses. Let the upper boom].
the oil initially remaining in the elbows drain out. Watch
both open elbows for continuous dripping of oil as the a. If a heavy stream of oil continues to flow from the
boom drifts down. hose, this indicates internal leakage in the cylinder.
Reconnect the hose to the boom functions valve.
a. If oil flows from the open extend port elbow, the Discontinue testing. Repair or replace the cylinder.
counterbalance valve is leaking.
b. If no oil continues to flow from the hose, there is
b. If oil flows from the open retract port, the cylinder no internal leakage in the cylinder. The extend (if
piston seal is allowing oil to leak past it.

Section 8 — Troubleshooting, Testing, and Adjustments • 87

 drifting in) or the retract (if drifting out) counterbal- 9. Disconnect the cylinder retract hose (if drifting in)
ance valve needs to be replaced. or extend hose (if drifting out) from the 90 degree
elbow on the spool valve. Cap the elbow at the boom
c. If oil continues to drip steadily or flows in a small functions valve. Allow the oil remaining in the hose
stream (pencil lead size or less), this test cannot to drain into a container.
determine the cause of the problem. The oil flow
may be due to internal cylinder leakage or normal 10. Hold the open hose end over the container. Watch for
oil flow through the pilot section of the counter- oil flow from the open hose end as the boom drifts.
balance valve. Reconnect the hose to the boom If the boom does not drift under its own weight, lift
functions valve. Proceed to step 5 to confirm or a load with the winch line of sufficient weight (within
rule out internal leakage. load capacity) to initiate the drift.

With boom raised to maximum boom angle

Warning
a. If oil does not continue to drain from the hose as
Death or serious injury can result from uncontrolled the boom drifts in, the drift is due to leakage past
movement. Fully unload the actuator or position it the extend counterbalance valve.
so it cannot move, before removing a holding valve.
b. If oil continues to drain steadily from the hose as
Death or serious injury can result from hydraulic the cylinder drifts, this indicates internal leakage
oil being injected into the flesh when loosening or in the cylinder.
disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic With boom lowered to minimum boom angle
components. a. If oil does not continue to drain from the hose
as the boom drifts out, the drift is due to internal
Seek immediate medical attention if injured by escap- leakage in the cylinder.
ing hydraulic oil. Serious infection or reaction can
result if medical treatment is not given immediately. b. If oil continues to drain steadily from the hose as
the cylinder drifts, this indicates leakage past the
Spilled hydraulic oil creates slick surfaces and can retract counterbalance valve.
cause personnel to slip and/or fall. Keep the unit and
work areas clean. 11. Reconnect the hose to the boom functions valve.
Fully retract the cylinder. Take the necessary cor-
5. Remove the trapped pressure in the circuit. This rective action to correct the leakage problem.
can be done by shifting the manual control for both
directions.
Warning
Death or serious injury can result from uncontrolled
Warning
movement. Fully unload the actuator or position it
Death or serious injury can result from unexpected so it cannot move, before removing a holding valve.
movement. Counterbalance valves that have had the
relief setting changed must be replaced or reset to Death or serious injury can result from hydraulic
the proper setting using an Altec test block before oil being injected into the flesh when loosening or
the unit is operated. disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic
6. Turn the adjusting screw on the retract (if drifting in) components.
or extend (if drifting out) counterbalance valve all the
way in (clockwise) to hold the valve open. Seek immediate medical attention if injured by escap-
ing hydraulic oil. Serious infection or reaction can
7. Start the engine. Extend the cylinder about 12″ (30 result if medical treatment is not given immediately.
cm). Mark the extended boom stage with chalk or a
felt tip marker. This will provide a reference point to Spilled hydraulic oil creates slick surfaces and can
check for drift. cause personnel to slip and/or fall. Keep the unit and
work areas clean.
8. Raise the boom to the maximum boom angle (if
drifting in) or lower the boom to the minimum boom 12. If the counterbalance is not the problem, remove it
angle (if drifting out). Turn off the engine. and adjust it to the correct pressure setting with a

88 • Section 8 — Troubleshooting, Testing, and Adjustments

 test block. Using a test block and pressure gauge is Pilot operated check valves assure the cylinder will main-
the only accurate way to determine that the proper tain its position if there is hydraulic line failure.
setting has been obtained. A test block and instruction
sheet for 11/8″ hex cartridges and 7/8″ hex cartridges Notice
are available from your Altec representative (refer to
Service Tools and Supplies in the Appendix. Pilot operated check valves are not adjustable and
must be replaced if defective.
Holding Valves
The unit uses holding valves to insure that various Loading the Function
actuators maintain their position under load or if there 1. Load the function protected by the pilot operated
is hydraulic line failure. These holding valves block the check valve.
hydraulic oil in the actuators to prevent movement. The
types of holding valves used are pilot operated check 2. Turn off the engine.
valves and counterbalance valves.
3. Move the control handle for the function to connect
If the valve stops holding the load, or malfunctions in the function to tank. If the function moves, the pilot
some other way, it is most likely contaminated. Do not operated check valve is leaking and must be replaced.
disassemble a holding valve in the field. Holding valves
should only be disassembled by the manufacturer. Counterbalance Valves
A counterbalance valve provides a positive lock against
When removing a holding valve cartridge, do not allow hydraulic flow or leakage until it is opened by pressure
dirt, water, or other contaminants to enter the holding from a control valve.
valve cavity when the cartridge is removed.
Counterbalance valves are used to block flow out of the
following actuators.
Warning
Death or serious injury can result from uncontrolled • Rotation motor
movement. Fully unload the actuator or position it • Lift cylinder (extend port only)
so it cannot move, before removing a holding valve. • Upper boom extension cylinder
• Intermediate boom extension cylinder
Death or serious injury can result from hydraulic • Winch motor
oil being injected into the flesh when loosening or • Outrigger (retract port only)
disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic Counterbalance valves assure the cylinder or motor will
components. maintain its position if there is hydraulic line failure.

Seek immediate medical attention if injured by escap- Testing

ing hydraulic oil. Serious infection or reaction can There are two methods for testing counterbalance valves.
result if medical treatment is not given immediately.
Switching Valve Cartridges
Spilled hydraulic oil creates slick surfaces and can 1. Position the unit on a level surface and properly set
cause personnel to slip and/or fall. Keep the unit and the outriggers. Stow the booms.
work areas clean.
2. Move the control selector to the Lower position. Re-
move the hydraulic load from the valves by shifting
Caution
the manual control handle in both directions until the
Injury can result from airborne particles entering the cylinder can be rocked by hand. Turn off the engine.
eyes. Wear appropriate safety equipment.
3. Locate the plugs in the extend and retract test ports
Pilot Operated Check Valves at the base end of the cylinder. Use an Allen wrench
A pilot operated check valve provides a positive lock to slowly unscrew the test plugs. Allow the pressure
against hydraulic flow or leakage until it is opened by to bleed off before completely removing the plugs.
pressure from a control valve. The pole guide tong cyl- If the cylinder is under pressure and the plugs are
inder uses a pilot operated check valve in the extend unscrewed quickly, hydraulic oil may spray out of the
port. The outrigger cylinders use a pilot operated check test ports. Replace the test plugs.
in the extend ports.
4. Switch the position of the two valve cartridges.

Section 8 — Troubleshooting, Testing, and Adjustments • 89

 5. If the problem moves to the other location, replace 2. Shift the lower control handle for the function until the
the valve. If the problem does not move, the coun- cylinder can be rocked by hand. Turn off the engine.
terbalance valve is not the cause of the malfunction.
3. Locate the plugs in the extend and retract test ports
Loading the Function at the base end of the cylinder or counterbalance
1. Load the function protected by the counterbalance valve block. Use an Allen wrench to slowly unscrew
valve. the test plugs. If the cylinder is under pressure and
the plugs are unscrewed quickly, hydraulic oil may
2. Turn off the engine. spray out of the test ports. If the test ports are not
available, slowly screw the counterbalance valve
3. Move the control selector to the Lower position. cartridge from its housing.

4. Move the manual control handle for the function to 4. Carefully unscrew the cartridge from its housing to
connect the function to tank. If the function moves, allow the pressure to bleed off before the cartridge
the counterbalance valve is leaking and must be is fully unscrewed from the cavity.
replaced.
Testing
Relief Pressure 1. Lubricate the O-rings on the counterbalance valve
Counterbalance valves are set to relieve pressure at cartridge and install the cartridge in the test block.
different settings. The counterbalance valve used in the
lower boom cylinder is set to relieve pressure at 3,250 2. Connect a hydraulic pressure source and an accurate
psi (224.08 bar). The counterbalance valves used in the pressure gauge to port 1 (refer to Figure 8.9). The
intermediate and upper boom cylinders are set to relieve pressure source and gauge must be adequate for
pressure at 3,000 psi (206.84 bar). The counterbalance a pressure greater than the desired counterbalance
valve used with the winch motor is set to relieve pressure valve relief setting.
at 2,550 psi (175.82 bar). The counterbalance valves used
with the outriggers are set to relieve pressure at 3,000 psi Adjusting Screw Jam Nut
(206.84 bar). Do not adjust counterbalance valves in the Counterbalance
field. If the setting on a counterbalance valve has been Valve Cartridge
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 Port 2
the proper setting using an Altec test block before
the unit is operated. Port 1
Figure 8.9 — Counterbalance Valve Test Block
Do not adjust a counterbalance valve without a test
block. Using a test block and pressure gauge is the only 3. Install a straight adapter in port 2 to aid in observing
accurate way to determine that the proper setting has the oil flow from this port during the procedure.
been obtained.
4. Gradually increase the pressure at port 1 with the
A test block and instruction sheet for 11/8″ hex cartridges pressure source. The counterbalance valve relief
and 7/8″ hex cartridges are available from your Altec setting is the pressure at which a fine stream of oil
representative (refer to Service Tools and Supplies in begins to flow from port 2. Note this pressure reading
the Appendix). and then remove the pressure from port 1.

Removal 5. If the relief setting is correct, relieve the pressure

Before removing a counterbalance valve, the cylinder of the pressure source by turning off the pressure
must be unloaded. Use the following procedure to remove source and moving the control several times in both
a counterbalance valve. directions.

1. Position the unit on a level surface and properly set

the outriggers. Stow the booms.

90 • Section 8 — Troubleshooting, Testing, and Adjustments

 6. Disconnect the pressure source from port 1 and To loosen the track, turn hex shaped valve counterclock-
remove the counterbalance valve cartridge. wise until grease comes out. When the correct track
tension is obtained, turn the valve clockwise and tighten
7. If the relief setting is incorrect, adjust the relief setting it. Clean off any expelled grease.
as described in the following procedure.
Replace access cover and tighten the screws.
Adjustment
1. Loosen the jam nut and turn the adjusting screw
Mechanical System
clockwise to decrease the setting or counterclockwise
to increase the setting. Rotation Gearbox
Adjustment
2. Hold the adjusting screw from turning and tighten The rotation pinion can be adjustable to mesh properly
the jam nut. with the rotation bearing. Proper adjustment minimizes
backlash in the mesh between the pinion and rotation
3. Repeat the test procedure until the proper relief set- bearing gear teeth. Adjustment is accomplished with the
ting is obtained. eccentric ring and eccentric ring lock.

4. Repeat the test procedure at least three more times Excessive backlash will appear as excessive side-to-side
to confirm the proper setting. boom movement when the rotation function is stopped. It
can also appear as excessive side-to-side boom move-
5. Relieve the pressure of the pressure source by turn- ment when a load suspended from the winch line is
ing off the pressure source and moving the control swinging from side to side. Adjustment of the backlash
several times in both directions. may be necessary to compensate for wear after extended
operation. It is also necessary if a new rotation gearbox
6. Disconnect the pressure source from port 1 and and/or rotation bearing is installed.
remove the counterbalance valve cartridge.
Use the following procedure to check and adjust the mesh
Track Tension points between the rotation pinion and the rotation bearing.
Testing
Position the unit on a level surface. Lift the machine off 1. Position the unit on a level surface and properly set
the ground using the outriggers. Place adequate supports the outriggers.
under the frame after lifting.
Caution
Measure the deflection between the bottom center roller
and the inside surface of the rubber track. Track tension Injury can result from contact with pinion and rota-
is normal when this distance is 1/2″. If the deflection is tion bearing gear teeth. Keep hands clear.
more or less than this, the tension needs to be adjusted.
Injury can result from being pinched or trapped be-
Adjustment tween moving components. Keep hands clear.
Warning Use caution when access covers have been removed
Death or serious injury can result from pressurized to service the unit. Pinch points and shear points may
grease escaping from the track hydraulics. Do not exist between moving parts. Replace the access covers
loosen the grease valve more than necessary to allow immediately after servicing.
grease to come out. Do not loosen the grease fitting
used to tension the tracks. 2. Remove the pinion cover from under the turntable
bottom plate.
Remove the screws and cover to access the adjustment
system. 3. Rotate the boom to the position that seems to have
the least amount of movement between the rotation
To tighten the track, connect a grease gun to the nipple pinion and the rotation bearing. This is normally where
and add grease to the system. When the track stretches the pinion meshes with the high tooth of the rotation
to the correct tension, stop adding grease. Clean off any bearing gear teeth. The high tooth is the point on the
excess grease. bearing where the rotation pinion meshes with the
rotation bearing when the booms are stowed.

Section 8 — Troubleshooting, Testing, and Adjustments • 91

 The high tooth of a new rotation bearing is painted 8. The eccentric ring is located on top of the turntable
yellow or blue. However, the high tooth may not al- base plate, under the gearbox. Since the bore of
ways be the area with the least amount of movement the eccentric ring is 1/16″ (1.59 mm) off center from
between the rotation pinion and the rotation bearing. the outside diameter of the ring, rotating the ring will
In some situations, there has been a greater amount move the gearbox and pinion toward or away from
of concentrated wear in this area than on other areas the rotation bearing. The gearbox mounting holes
of the bearing. If this is the case, rotate the booms to are 1/8″ (3.18 mm) oversize to accommodate this
the area that does have the least amount of move- movement.
ment between the pinion and the bearing teeth.
Engage a suitable bar or drift pin, preferably of a soft
4. With another person rocking the boom tip back and material such as brass, in a drive slot of the ring.
forth, observe the movement of the pinion. If side-to- Rotate the eccentric ring using light blows from a
side movement between the pinion and rotation gear hammer against the bar or drift pin. Should the gear
teeth is seen at the point of gear mesh, the mesh mesh become looser, the ring must be turned in the
between the pinion and rotation bearing is loose. Do opposite direction. Rotate the eccentric ring until the
not confuse backlash with slight lost motion within pinion bottoms out in the rotation gear teeth. At this
the rotation gearbox. Internal gearbox backlash will point, the ring will stop rotating. Do not use excessive
cause the pinion to rotate back and forth slightly. force to drive the eccentric ring past this point.
This cannot be reduced externally. If adjustment is
necessary to bring the pinion into closer mesh with 9. Rotate the booms back to the position where the
the rotation bearing, continue with the following steps. keeper was removed. Align the keeper to the ec-
centric ring so one of the holes lines up with the hole
in the turntable plate. It may be necessary to rotate
Caution
the eccentric ring slightly to loosen the adjustment
Injury can result from airborne particles entering the to install the keeper. Install the cap screw through
eyes. Wear appropriate safety equipment. the eccentric ring keeper, lock washer, and turntable
plate. Install the nut and torque it to the proper value.
Wear eye protection at all times to prevent particles of
dirt, metal, or hydraulic oil from entering the eyes. 10. Tighten the gearbox cap screws firmly. Rotate the
turntable slowly through at least two revolutions.
5. Rotate the booms to a position where the eccentric
ring keeper can be easily removed. The keeper is a. If the unit rotates smoothly, proceed to step 11.
located on the turntable bottom plate next to the
rotation pinion, as shown in Figure 8.10. Remove b. If rotation binds or hesitates in any position, the
the keeper. backlash may have been set too tight. Loosen the
mounting cap screws. Rotate the eccentric ring to
Keeper Eccentric Ring loosen the adjustment by one locking increment
(refer to step 8). Repeat step 9.

11. Torque each gearbox mounting cap screw to 115

foot-pounds (155.94 N•m).

12. If a new gearbox was installed, or if the rotation gear

teeth are dry, apply an open face gear lubricant as
recommended in Section 4 under Lubrication.

13. Install the pinion cover.

Figure 8.10 — Eccentric Ring Adjustment
Platform Brake
6. Rotate the booms back to the minimum backlash When properly adjusted, the brake will support 300 pounds
position determined in step 3. (136 kg) at the platform lip and should not slip when the
operator leans over the side of the platform. If slippage
7. Loosen, but do not remove, the four cap screws that occurs under this condition, the brake should be checked
mount the rotation gearbox to the turntable base and adjusted according to the following procedure.
plate.

92 • Section 8 — Troubleshooting, Testing, and Adjustments

 Notice If the self-locking nuts on the brake mounting cap
Do not overtighten the platform brake. screws are tightened completely and the brake pads
are new, the brake may not release completely with
Overtightening will make the brake difficult to operate the brake handle unlocked. If this occurs, the nuts
and can cause failure of the cam lever. should be unscrewed just to the point that the brake
does not drag in the unlocked position. As the pads
Adjustment become worn, the nuts can be tightened completely
1. Remove the cover from the platform mounting bracket to obtain full use of the adjustable range of the brake.
assembly.
5. Tighten the jam nut against the yoke once the proper
2. Measure the thickness of the friction pad material adjustment is attained.
on each caliper plate. The pads are 1/4″ (6.35 mm)
thick when new. If there is more than 1/8″ (3.18 mm) 6. Install the cover on the platform mounting bracket.
of pad material remaining, proceed with step 4. If
the pads are 1/8″ (3.18 mm) thick or less, they may
be worn down to the rivet heads. Proceed to step 3
Electrical System
to determine if the pads are worn to the rivets. A basic understanding of electrical components and
system failure will aid in troubleshooting the unit’s elec-
3. Disassemble and remove the caliper assembly from trical system.
the bracket and inspect the pad surfaces. If there is
sufficient material remaining above the rivet heads, Failure Identification
reassemble the brake and proceed to step 4. If the The following types of failures in the electrical system
pads are worn down to the rivet heads, they must be will cause the system to operate improperly or not at all.
replaced. Inspect the actuating surfaces of the cam
lever (refer to Figure 8.11). If there is substantial wear, • Short circuit
the entire brake caliper assembly must be replaced. • Open circuit
If the cam is in good condition, only the caliper plates • Defective component
on which the pads are mounted need to be replaced.
Refer to the Parts Manual for the necessary part This section describes how to identify these electrical
numbers. Reassemble the brake with the required system problems.
new parts and proceed with step 4.
Short Circuit
4. Back the jam nut on the adjusting cap screw away A short circuit occurs when a contact of low resistance
from the yoke. To tighten the brake, screw the adjust- between a power conductor and a ground diverts electric-
ing cap screw clockwise farther into the yoke. If new ity from a component of greater resistance. Resistance
pads were installed, screw the adjusting cap screw refers to how well the component conducts electricity.
farther out of the yoke (counterclockwise) to loosen Electricity always flows in the path of least resistance.
the brake and allow for the increased thickness of
the new pads. A short circuit will usually trip one or more circuit break-
ers. A short circuit can be caused by the following items.

Cam Lever Yoke Jam Nut Adjusting

Bolt

Inside Caliper Plate

Brake Disc
Outside Caliper Plate
Figure 8.11 — Platform Brake Components

Section 8 — Troubleshooting, Testing, and Adjustments • 93

 • Pinched wires can be located, and the proper voltage is being applied
• Worn insulation to the components, the problem may be hydraulic or
• Defective component mechanical rather than electrical.
• Loose connection touching a ground
If one direction of a major function stops working, the
To find the location of a short circuit, first analyze the problem may be in the hydraulic or electrical portion of
location of the circuit breaker that is opening and what the system. The boom, rotation, intermediate and up-
is being operated when it opens. per boom, digger, and winch functions are considered
major functions. The troubleshooting procedures in this
It may be necessary to progressively isolate the loca- section can help pin point whether it is an electrical or
tion of a short by disconnecting circuits until the short hydraulic problem.
disappears. A short can also be detected by turning off
power to the unit and using an ohmmeter to check the Make every effort to locate the problem component before
resistance to ground at connections and terminals that installing new components. When parts are replaced by
would have a voltage applied during normal operation. trial and error, many good parts are needlessly replaced.
Zero resistance between ground and one of these loca-
tions indicates a short circuit. This checking procedure Circuit Protection
should begin closest to the power source. Circuit breakers protect certain wiring and components
from electrical overload during a short circuit or other
Open Circuit electrical fault. When an electrical circuit is overloaded,
An open circuit prevents the normal flow of current through the breaker for that circuit will trip. If a circuit breaker trips
component(s) of the electrical system. This interrupts repeatedly, determine the cause of the problem promptly
the operation of the components. An open circuit may and correct it.
be caused by the following items.
Notice
• Broken wire
• Corrosion Damage to the electrical system can result if a circuit
• Wire pulled from a connection breaker trips repeatedly.
• Poor contact where an electrical component is
grounded to the unit structure Thermal Self-Resetting Circuit Breakers
The unit has several thermal self-resetting type break-
Begin the search for an open circuit at the point closest ers. This type of circuit breaker will normally reset within
to the component that is not operating. Trace the wiring a few minutes when the electrical overload is removed.
from the component. Look for a broken connection or cor-
rosion. Also, look for other visible damage to the cable or There is a thermal circuit breaker in the main power sup-
wires. If the component is grounded to the unit structure, ply running from the battery to the lower control panel.
make sure the ground connection is good.
If the circuit breaker for the main power supply trips open,
If the wiring looks good and the ground contact is good, all functions above rotation will stop working. Also, the
disconnect the leads to the component. Check the resis- lower control panel light will be dead. The breaker will
tance reading through the component with an ohmmeter. normally reset within a few minutes if the cause of the
electrical overload is removed.
If the component is a switch, an infinite resistance reading
on the ohmmeter indicates an open circuit. Proximity Switches
Normally closed proximity switches are used in the boom
Component Failure stow protection, auger stow protection, and outrigger
A component malfunction is sometimes the most difficult interlock systems (refer to Figure 8.12). A square sens-
problem to locate. It may appear as an open or a short ing face on one side of the proximity switch actuates the
circuit, or the component may not perform to its design switch when this surface is within a certain distance of
capacity. a metal surface. Each switch is equipped with two LED
lights on the side opposite from the sensing face. The
To accurately determine that a component is defective, green light indicates there is power to the switch. The
decide what functions are affected and what components yellow light is on when metal is not sensed, and turns
could be causing the problem. If no open or short circuits off when metal is sensed.

94 • Section 8 — Troubleshooting, Testing, and Adjustments

 Sensing Face there is power to the switch. The yellow light is off when
Yellow LED
Green LED the leg is raised above a certain point, and on when the
leg is lowered below this point. The switches can be
tested for proper operation using the procedure under
Proximity Switches in this section.

The switch must be set to close when the outrigger shoe

lowers into a range of 10″ to 14″ (25 to 36 cm) of the
ground. This distance is needed when setting the outrig-
gers on a sloping surface. Tilt the switch to obtain the
Figure 8.12 — Proximity Switch proper range above the ground. The switch may then be
locked in place with the second cap screw.
Testing
In addition to the testing and adjustment procedures Programmable Settings
provided in this section for each system that contains a All of the unit’s programmable function parameters are
proximity switch, use the following procedure to test a set at the factory. The parameters are adjusting using
proximity switch for proper operation. a CADI, (refer to Figure 8.13 and to the CADI Quick
Reference Guide). The parameters are adjusted to the
1. Check that the green light on the switch is on. individual unit for optimum performance. For example,
if a function does not start or stop smoothly, or does not
2. Each proximity switch is located to sense the presence operate at the proper speed, the function’s threshold
or absence of a metal component in the associated and/or max out parameters may require adjustment.
system. The yellow light should be on when no metal The CADI allows each function direction to be adjusted
is present within a sensing range of about 0.75″ (1.9 independent of the opposite function direction. Thus,
cm) from the switch sensing face, and should turn changing the threshold or max out for boom up has no
off when metal is present within the sensing range. effect on boom down.
Test the switch using one of the following methods.

a. Operate the appropriate derrick function to move

the sensed component within and beyond the
sensing range of the switch.

b. Move a metal object, such as a screwdriver or

wrench, within and beyond the sensing range of
the switch.
LCD
c. Remove the switch from the structure, and move
the sensing face toward and away from a flat metal
surface within and beyond the sensing range.

3. If the green and yellow lights do not operate as de- Push Button
scribed, the switch may be defective or there may be Key Pad
a fault in the electrical cable leading to the switch.

Outrigger Interlock System

The outrigger interlock electrical switches are connected
to a control module. If one switch is defective or out of
alignment, the outrigger interlock will not operate. If all
the switches are functioning properly and if adjustment Figure 8.13 — CADI
does not correct the problem, there may be an electrical
wiring problem. The control system settings are stored in the above rota-
tion valve driver. If the above rotation valve driver needs
Adjustment on Radial Outriggers to be replaced, use the CADI to determine the current
The switches are normally closed proximity switches. settings for each parameter and write these down before
Each switch is equipped with two LED lights on the side removing the original valve driver from the unit. After
opposite from the sensing face. The green light indicates installing the new valve driver, use the CADI to adjust
the settings to the values recorded from the original

Section 8 — Troubleshooting, Testing, and Adjustments • 95

valve driver. If the original values could not be obtained, Checking Speeds of Intermediate Boom Extend and
all the settings must be properly calibrated for optimum Retract Functions: Position the boom 10 degrees
performance (refer to the CADI Quick Reference Guide). above horizontal. On units equipped with a turntable
winch, pay out enough winch line to accommodate
Boom Functions Speeds the full length of the intermediate boom when it is
Changing the speed of the boom functions is done with extended. Starting with the intermediate boom fully
the CADI. This adjustment changes the valve spool travel. retracted, time the seconds it takes to fully extend
The valve spool travel controls the flow of hydraulic oil the boom. Write this time down. Starting with the
to a function. This determines the maximum speed of intermediate boom fully extended, time the seconds it
the function. takes to fully retract the boom. Write this time down.

Testing Checking Speeds of the Upper Boom Extend and

1. Testing of the boom functions requires an open area Retract Functions: Pay out enough winch line to ac-
with sufficient clearance to fully extend and raise the commodate the length of the upper boom when it is
booms. fully extended. Repeat the process in the previous
paragraph using the upper boom extend and retract
2. Position the unit on a level surface and properly set functions. Write these times down.
the outriggers.
7. Compare the speed that was recorded for each func-
3. Warm the oil in the hydraulic system to 120 to 130 tion to the average cycle times in seconds shown in
degrees Fahrenheit (49 to 54 degrees Celsius). Figure 8.14. If the speed that was recorded is within
the range, the function’s speed is properly set and
4. Check the pilot system pressure, standby pressure, does not need adjustment. If the speed that was
and system/compensator pressure as described in recorded is above or below the range, the speed of
this section, and make any necessary adjustments. the function may be adjusted.

5. Verify that the pump is delivering the proper amount Function Seconds
of hydraulic oil flow as described under Pump Flow
in this section. Boom raise 12 to 17
Boom lower 9 to 13
6. The following paragraphs describe how to properly Intermediate boom extend 9 to 14
check the cycle times for each function. A stop watch
is needed to do this. The lower controls should be Intermediate boom retract 9 to 14
used to test all boom function cycle times. Hold each Upper boom extend 9 to 14
hand control in the full stroke position during the Upper boom retract 12 to 16
entire timing. Maintain maximum pump speed when
performing the test. Run only one function at a time. Rotation 44 to 51
Figure 8.14 — Average Cycle Times
Checking the Speeds of the Rotation Functions:
Raise the boom until the lift cylinder is fully extended. Adjustment
Using a stop watch, time the seconds it takes for the Adjustments are made using the CADI. Refer to the CADI
unit to rotate 360 degrees clockwise. Write this time Quick Reference Guide.
down. With the lift cylinder still extended, time the
seconds it takes to rotate the turntable 360 degrees
counterclockwise. Write this time down. Protection Systems
Hydraulic Overload Protection (HOP)
Checking the Speeds of the Boom Raise and Lower The functions that are temporarily shut off by the HOP
Functions: Starting with the lift cylinder fully extended, system are the boom lower, intermediate and upper boom
time the seconds it takes to lower the boom until the extend, winch raise, and digger dig functions. If these
lift cylinder is fully retracted. Write this time down. functions stop working, but the opposite direction of each
Starting with the lift cylinder fully retracted, determine function operates, the HOP system is engaged. If the unit
the seconds it takes to raise the boom until the lift is not overloaded, there are several possible causes for
cylinder is fully extended. Write this time down. this. Use the following procedure to isolate the problem.

96 • Section 8 — Troubleshooting, Testing, and Adjustments

 1. The HOP pressure transducer engages HOP if it is when the HOP system engages. Perform this step
defective. If the transducer is working properly, the several times for a consistent result.
electrical cable leading to the HOP pressure trans-
ducer may be disconnected or faulty. 5. If the HOP system engages at loads higher or lower
than the ANSI A10.31 stability test weight ±15 pounds,
2. The boom stow proximity switch engages HOP when adjust as necessary with CADI.
it is actuated or if it is malfunctioning. If the boom stow
switch is not actuated, the switch may be defective, 6. If the HOP system continues to engage at loads
or the electrical cable leading to the switch may be higher or lower than the ANSI A10.31 stability test
disconnected or faulty. weight ±15 pounds, an electrical problem may exist.
Troubleshoot the electrical system to find and correct
3. On units with electronic side load protection, this the problem.
system engages HOP when actuated. Check for
proper operation of the electronic side load protec- Alternative HOP Test Procedure
tion system. If the system is not being actuated by To test the operation of the system, a test load is neces-
side loading, a side load pressure transducer may sary. The test load must be within the load capacity of
be defective, or the electrical cable leading to a side the derrick at a given boom angle with the booms fully
load pressure transducer may be disconnected or retracted. The load must create a sufficient overload to
faulty. induce 2,585 psi (178.23 bar) in the lift cylinder as the
intermediate and upper booms are extended.
4. Once the component causing the malfunction has
been isolated, check the component and the electrical 1. Position the unit on a level surface and properly set
wiring connected to it. Determine the cause of the the outriggers.
problem and correct it.
2. Verify the system pressure is properly adjusted (refer
For the HOP system to operate properly, HOP must en- to Main System Relief in this section).
gage when the pressure in the base end of the lift cylinder
reaches 2,585 psi (178.23 bar) for single platform units. If 3. Verify the load indicator gauge is properly calibrated
HOP does not engage, the functions that are inoperative (refer to Load Indicator Gauge is this section).
when the HOP system is operating will be operational.
This allows overloading to continue. Test the operation Warning
of the HOP system as recommended by the Preventive
Maintenance and Inspection Checklist. Use the follow- Death or serious injury can result from hydraulic
ing procedure to test the system. Do not use any other oil being injected into the flesh when loosening or
method to test the pressure switch. disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic
Testing components.
A dynamometer is needed to test the operation of the
system. Refer to the ANSI A10.31 stability test weight Seek immediate medical attention if injured by escap-
that is given on the capacity chart at the lower controls ing hydraulic oil. Serious infection or reaction can
for the test weight. result if medical treatment is not given immediately.

1. Position the unit on a level surface and properly set Spilled hydraulic oil creates slick surfaces and can
the outriggers. cause personnel to slip and/or fall. Keep the unit and
work areas clean.
2. Position the booms over the front of the carrier and
raise them to a 15 degree angle. Fully extend the 4. Install a pressure gauge [4,000 psi (275.8 bar)
intermediate and upper booms. minimum] to the quick disconnect on top of the lift
cylinder valve block (may require additional fittings
3. Attach a calibrated dynamometer to the winch line. to connect QD). If residual pressure in the cylinder
Attach the other end of the dynamometer to a fixed causes difficulty in connecting the gauge, shift the
anchor or significant weight. boom hand control to the Lower position while con-
necting the gauge.
4. Slowly attempt to raise the load with the winch line.
The dynamometer should indicate a load equivalent 5. Start the engine and rotate the boom to the load.
to the ANSI A10.31 stability test weight ±15 pounds

Section 8 — Troubleshooting, Testing, and Adjustments • 97

 6. Make sure the intermediate and upper booms are 12. If the HOP system continues to engage at loads
fully retracted. Determine the boom angle that will higher or lower than 2,585 psi (178.23 bar), an elec-
keep the test load within the load capacity by using trical problem may exist. Troubleshoot the electrical
the derrick capacity placard by the lower control system to find and correct the problem.
station. Raise the booms to this angle.
13. Remove the load from the booms. Position the booms
7. Attach the test load to the winch line. Pick up the so the lift cylinder can be fully retracted. Lower the
load with the winch line. booms until the lift cylinder is fully retracted or lower
the boom into the stow.
8. Slowly extend the boom while observing the load
indicator gauge. Pay out the winch line while extend- 14. Remove the pressure gauge from the quick discon-
ing the boom. This will keep the load from coming nect on the lift cylinder valve block. If residual pres-
up against the boom tip. The reading on the gauge sure in the cylinder causes difficult in disconnecting
should rise slowly as the boom is extended. the gauge, shift the boom hand control to the Lower
position while disconnecting the gauge.
9. When the pressure reaches 2,585 psi (178.23 bar),
the extend function should automatically stop. The Warning
load indicator gauge needle should be in the area
marked HOP. Death or serious injury can result from hydraulic
oil being injected into the flesh when loosening or
disconnecting hydraulic components. Remove the
Notice pressure before loosening or disconnecting hydraulic
Property damage can result from overloading the components.
unit. Stop extending the boom if pressure exceeds
the area marked HOP on the load indicator gauge. Seek immediate medical attention if injured by escap-
ing hydraulic oil. Serious infection or reaction can
10. If the extend function stops when the pressure reaches result if medical treatment is not given immediately.
2,585 psi (178.23 bar), the pressure setting is cor-
rect. No adjustment is needed. Make a note of how Spilled hydraulic oil creates slick surfaces and can
far the boom was extended before the HOP system cause personnel to slip and/or fall. Keep the unit and
engaged. work areas clean.

Warning Load Indicator Gauge

Check the load indicator gauge to ensure that the gauge
Death or serious injury can result from hydraulic gives a proper indication of the load being applied to the
oil being injected into the flesh when loosening or base end of the lift cylinder.
disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic Testing
components. 1. Position the unit on a level surface, apply the park-
ing brake, and chock the wheels. Properly set the
Seek immediate medical attention if injured by escap- outriggers.
ing hydraulic oil. Serious infection or reaction can
result if medical treatment is not given immediately. 2. Use the lower controls to raise the lower boom to full
extension of the lift cylinder.
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and 3. The pressure in the base end of the lift cylinder should
work areas clean. be maximum system pressure and the load indicator
gauge needle should be at 100 percent.
11. If the extend function shuts off before the pressure
reaches 2,585 psi (178.23 bar), the setting must be 4. If the needle is not at 100 percent, adjust the gauge.
increased. If the extend function continued to operate
after the pressure gauge indicated 2,585 psi (178.23 Adjustment
bar), the setting must be lowered, adjust as neces- 1. Connect the CADI to the lower control panel.
sary with CADI.

98 • Section 8 — Troubleshooting, Testing, and Adjustments

 2. Use the mode button on the CADI to select the Cali- Testing
bration Mode. Use the menu button to select HOP To test the side load protection and rotation motor, the
Meter. Use the select button to scroll across to MX. following tools will be needed. They are available from
Use the value buttons to adjust the gauge. Make the your Altec representative (refer to Service Tools and
adjustments until the gauge indicates 100 percent Supplies in the Appendix).
when the pressure on the base end of the lift cylinder
is maximum system pressure. • A 500 pound dynamometer or one with less than or
equal to 10 pound increments is recommended
3. Repeat the test procedure to ensure a proper reading • Side load test bracket
on the load indicator gauge. Disconnect the CADI. • CADI

Electronic Side Load Protection 1. To have an accurate test of the side load protection,
The side load protection system is connected to the digger the backlash between the rotation pinion and rotation
and winch hydraulic circuit. If an excessive side load is bearing gear teeth must be properly set. Check the
then developed on the booms, the side load protection backlash between the rotation pinion and rotation
system engages the HOP system, shutting off the boom bearing gear teeth as described under Rotation
lower, boom extend, winch up, and digger dig functions. Gearbox in this section. Adjust if necessary.
The system resets when the side load is removed. Figure
8.15 illustrates the rotation/side load protection valve. 2. Position the unit on a level surface. Properly set the
outriggers.
Gearbox Motor Electronic Rotation/Side
Load Protection Valve 3. Operate the unit to warm the oil in the hydraulic
system.

4. Fully extend the intermediate boom and fully retract

the upper boom.

5. Lower the boom tip until it can be reached from the

ground.

6. Attach the side load test bracket to the boom tip (refer
Pressure Transducers
to Figure 8.16).
Figure 8.15 — Rotation/Side Load Protection Valve

Pole Guide
Mounting Pins

Winch Line
Boom Tip
Test bracket sheave
pinned in hole closest to
direction of winch line pull

Clockwise Sideslip Counterclockwise Sideslip

Figure 8.16 — Side Load Test Bracket

Section 8 — Troubleshooting, Testing, and Adjustments • 99

 7. Adjust the boom angle to position the bottom of the tripped, read the dynamometer as the value settles
test bracket 3″ to 6″ (8 to 15 cm) above the ground on a steady level (the load stops bouncing back and
(approximately -10 degrees). forth). The Max value seen by the dynamometer is
created by the dynamic motion of the boom and dy-
8. Run the winch line through the side load test bracket namometer and is not used to set the electronic side
as shown in Figure 8.16. load protection trip point. If the side load protection
system engages HOP within the range, no adjust-
9. Figure 8.16 shows the proper holes used for pinning ment is needed. If the side load protection system
the test bracket sheave. Pin the test bracket sheave engages HOP before the lower limit is reached, or
according to the direction being tested. Make certain does not engage HOP by the time the upper limit is
the winch line clears the side of the boom tip. Make reached, adjust the system pressure values for the
sure the winch line runs properly over the sheaves appropriate direction with the CADI.
of the boom tip and side load test bracket. Pay out
the winch line to at least 10′ (3 m) beyond the test Adjustment
bracket. 1. Remove any side load on the booms.

10. Attach the winch line to the dynamometer. 2. Connect the CADI to the lower control panel.

11. Attach the other end of the dynamometer to a solid 3. Use the mode button on the CADI to select the Cali-
structure. The solid structure must be located so bration Mode. Use the menu button to select ESLP
that the winch line is horizontal between the side CW or ESLP CCW depending on which direction
load test bracket and dynamometer and makes a the booms are being pulled. Use the select button
90 degree angle to the side of the booms (refer to to select LMX. Use the value buttons to adjust the
Figure 8.16). It may be necessary to rotate the booms side load setting for the particular model as shown
and adjust the length of the winch line to obtain this in the test procedure.
winch line arrangement. There must be at least 10′
(3 m) between the boom tip and the dynamometer. 4. Repeat the test procedure until the proper value is
obtained at least three consecutive times. This will
insure the consistency of the system. If it is difficult
Notice
to obtain the proper value, refer to the notes at the
Side loading will result if the winch line becomes end of this procedure.
tight at a side angle while raising the booms, which
can damage the unit. 5. Repeat the side load protection testing and adjusting
procedures on the opposite direction of rotation.
If it is necessary to raise the boom with the winch line
attached to the dynamometer, pay out the winch line 6. Disconnect the CADI from the lower control panel.
so that no side load is applied to the boom. The side
load protection system does not protect against side If the side load protection setting in one direction is unaf-
loading developed by operation of the boom function. fected by adjusting the side load protection calibration,
either the valve cartridge for that direction of rotation or a
Notice pressure transducer may be defective. A valve cartridge
that is leaking will cause an abnormally low value on the
Do not exceed the limit range. dynamometer.

12. The side load limit range is 220 to 260 pounds (978 As described at the beginning of this section, the side
to 1156 N). From the radio remote or lower controls, load protection relies on the rotation motor to act like a
with the engine running at maximum operating rpm, pump when the rotation gearbox back drives. A motor
shift the winch hand control to the Raise position. To that has internal leakage could affect the adjustability
minimize the bouncing of the dynamometer during of the system. A defective motor may cause a low or
testing, slowly tighten the winch line until the slack is inconsistent side pull value in both directions.
taken up. It may also help to prop the dynamometer
up on a surface in line with the winch rope. After the
slack has been taken up, operate the winch control Warning
at full stroke until the side load protection system Death or serious injury can result from hydraulic
engages HOP and the winch function is disabled or oil being injected into the flesh when loosening or
until the upper limit reading is reached. After HOP has disconnecting hydraulic components. Remove the

100 • Section 8 — Troubleshooting, Testing, and Adjustments

pressure before loosening or disconnecting hydraulic Adjustment
components. 1. Loosen the two cap screws that attach the switch
mounting bracket to the side plate of the boom stow
Seek immediate medical attention if injured by escap- bracket.
ing hydraulic oil. Serious infection or reaction can
result if medical treatment is not given immediately. 2. If the boom lower function shuts off before the boom
is seated, raise the position of the switch. If the boom
Spilled hydraulic oil creates slick surfaces and can lower function does not shut off once the boom is
cause personnel to slip and/or fall. Keep the unit and seated, lower the position of the switch. Do not move
work areas clean. the bottom switch below the bottom of the stow
bracket, as the switch can be damaged by contact
Use the following procedure to test for a defective motor. with the boom rest. Tighten the cap screws.

1. Follow the previous steps 2 through 11 in this pro- 3. Repeat the test procedure and adjust as necessary
cedure under Testing. until the boom lower function shuts off as the boom
is seated in the boom rest.
2. Turn off the engine. Disconnect both hoses from the
motor, plug the hoses, and cap the motor port fittings.
Notice
3. Start the engine. Operate the winch raise function Properly adjust the boom stow switch to prevent
as in step 12 while watching the dynamometer. If the boom damage.
boom sideslips at the same abnormally low reading
on the dynamometer as was seen when attempt- Auger Stow Protection
ing to adjust side load protection, this confirms the Test the actuation point of the auger stow switch as
presence of excessive internal leakage in the motor. recommended by the Preventive Maintenance and In-
Replace or repair the motor. spection Checklist.

Boom Stow Protection The auger stow switch is a normally closed proximity
Test the actuation point of the boom stow switch as switch. It is equipped with two LED lights which are vis-
recommended by the Preventive Maintenance and In- ible through holes in the side of the auger stow bracket.
spection Checklist. The green light indicates there is power to the switch.
The yellow light is on when the auger tube is more than
The boom stow switch is a normally closed proximity a certain distance from the switch, and turns off when the
switch. It is equipped with two LED lights which are visible switch senses the auger tube during stowing.
through holes in the boom stow bracket. The green light
indicates there is power to the switch. The yellow light Testing
is on when the boom is unstowed, and turns off when 1. Position the unit on a level surface and properly set
the boom is stowed. the outriggers.

Testing 2. Raise the boom out of the boom rest. Make sure the
1. Position the unit on a level surface and properly set digger is in low speed.
the outriggers.
3. Shift the digger hand control slightly in the dig direc-
2. Raise the lower boom several inches above the boom tion. If the dig function shuts off just before the auger
rest bracket on the chassis. tube contacts the top of the arch in the stow bracket,
the system is operating properly. If the dig function
3. Shift the boom hand control to the Lower position. is shut off before the auger tube rises to just below
The boom lower function should shut off as the boom the top of the arch, test the switch operation as de-
is seated in the boom rest. If the boom lower func- scribed under Proximity Switches in this section. If
tion is shut off before the boom is seated or fails to the switch operates properly, the actuation point of
shut off once the boom is seated, test the boom stow the auger stow switch needs to be adjusted.
switch as described under Proximity Switches in this
section. If the switch operates properly, the actuation Adjustment
point of the boom stow switch needs to be adjusted. 1. Rotate and lower the boom until the auger stow
bracket can be reached from the ground. Unstow
the auger, allowing it to rest on the ground.

Section 8 — Troubleshooting, Testing, and Adjustments • 101

 2. Loosen the two cap screws that attach the switch 2. Operate the unit to warm the oil in the hydraulic sys-
mounting bracket to the side plate of the auger stow tem. Cold oil can result in a pressure limiter setting
bracket. that is too low for normal operation.

3. If the dig function shuts off too early when stowing 3. Turn off the engine.
the auger, raise the position of the switch. If the dig
function does not shut off before the auger tube con- 4. Remove the lower control cover. Connect a 0 to
tacts the top of the arch in the stow bracket, lower the 4,000 psi (0 to 275.80 bar) pressure gauge to the
position of the switch. Do not move the bottom of the load sense port on the boom functions valve (refer
switch below the top of the arch, as the switch can to Figure 8.17).
be damaged by contact with the auger tube. Tighten
the cap screws. 5. Start the engine. From the lower controls, with the
engine speed at maximum operating speed, fully raise
4. Repeat the test procedure and adjust as necessary the booms. While holding the lower boom control
until the switch shuts off the digger dig function just at full stroke, and the booms fully raised, read the
before the auger tube contacts the top of the arch pressure indicated on the gauge.
in the auger stow bracket.
6. The pressure gauge should indicate a maximum
Lower Boom Pressure Limiter pressure of 2,350 psi (162.03 bar) for single platform
The lower boom spool valve in the boom functions valve units. The pressure limiter should be limiting any
contains a pressure limiter (refer to Figure 8.17). The excess pressure.
pressure limiter limits pressure when the lower boom
circuit pressure reaches a specific value. If the gauge indicates a value lower than the given
value, the pressure limiter is set too low. If the gauge
indicates a value above the given value, the pressure
limiter is set too high. In both cases, adjustment is
necessary.

Adjustment
Use the following procedure to adjust the rotation pres-
sure limiter.
Lower Rotation Intermediate Upper
Boom Boom Boom 1. Turn off the engine.

2. Remove the plug on the pressure limiter cartridge

(refer to Figure 8.17).

3. Turn the adjusting screw clockwise to increase the

pressure. Turn the adjusting screw counterclockwise
to decrease the pressure. Make the appropriate
adjustment. Install the plug.

4. Repeat the test procedure. If necessary, make adjust-

ments until the pressure limiter relieves pressure at
Load Sense Port
the proper value.
Figure 8.17 —
Boom Functions Valve Pressure Limiters 5. Repeat the test procedure until the proper limit is
obtained at least three consecutive times. This will
Testing insure the consistency of the pressure limiter.
To test the lower boom pressure limiter, a 0 to 4,000 psi
(0 to 275.80 bar) pressure gauge is needed. 6. Remove the pressure gauge and replace the cover.

1. Position the unit on a level surface with sufficient Rotation Pressure Limiter
clearance to fully raise the booms and properly set The rotation spool valve in the lower control valve contains
the outriggers. a pressure limiter (refer to Figure 8.17). The pressure

102 • Section 8 — Troubleshooting, Testing, and Adjustments

limiter limits pressure when the rotation system pressure 12. Shift the rotation hand control in the direction of
reaches a specific value. rotation to place the winch line in tension. Slowly
rotate the boom while watching the reading on the
Testing pressure gauge. The pressure gauge should indicate
To test the rotation pressure limiter, a 0 to 4,000 psi (0 to a maximum pressure of 1,750 psi (120.70 bar). The
275.80 bar) pressure gauge and a side load test bracket pressure limiter should be limiting any excess pres-
(refer to Figure 8.16) are needed. These items are avail- sure. If the gauge indicates a value lower than the
able from your Altec representative (refer to Service Tools given value, the pressure limiter is set too low. If
and Supplies in the Appendix). the gauge indicates a value above the given value,
the pressure limiter is set too high. In both cases,
1. Position the unit on a level surface with sufficient adjustment is necessary.
clearance to rotate the turntable all the way to the
rotation stop and properly set the outriggers. 13. Repeat the test procedure in the other direction of
rotation.
2. Operate the unit to warm the oil in the hydraulic sys-
tem. Cold oil can result in a pressure limiter setting Adjustment
that is too low for normal operation. The single pressure limiter affects both directions of rota-
tion. Use the following procedure to adjust the rotation
3. Turn off the engine. pressure limiter.

4. Remove the turntable cover on the right side of the 1. Turn off the engine.
turntable as viewed from the boom tip. Connect a
0 to 4,000 psi (0 to 275.80 bar) pressure gauge to 2. Remove the plug on the pressure limiter cartridge
the load sense pressure test port quick disconnect (refer to Figure 8.17).
on the lower control valve mounting bracket (refer
to Figure 8.17). 3. Turn the adjusting screw clockwise to increase the
pressure. Turn the adjusting screw counterclockwise
5. Start the engine. From the lower controls, fully extend to decrease the pressure. Make the appropriate
the intermediate boom and fully retract the upper adjustment. Install the plug.
boom.
4. Repeat the test procedure. If necessary, make adjust-
6. Lower the boom tip until it can be reached from the ments until the pressure limiter relieves pressure at
ground. the proper value.

7. Attach the side load test bracket to the boom tip. 5. Repeat the test procedure until the proper limit is
obtained at least three consecutive times. This will
8. Adjust the boom angle to position the bottom of the insure the consistency of the pressure limiter.
test bracket 3″ to 6″ (7.62 to 15.24 cm) above the
ground. 6. If necessary, repeat the adjustment procedure in the
other direction of rotation.
9. Run the winch line through the side load test bracket.
7. Remove the pressure gauge and replace the cover.
10. Figure 8.16 illustrates the appropriate hole used for
pinning the test bracket sheave. Pin the test bracket Extension Pressure Limiter
sheave in the hole closest to the direction of winch The intermediate and upper boom spool valves in the
line pull. Make sure the winch line clears the side of boom functions valve contain pressure limiters for the
the boom tip and runs properly over the sheaves of extend functions (refer to Figure 8.17). The pressure
the boom tip and side load test bracket. Pay out the limiters are set to limit extension pressure to 1,650 psi
winch line to at least 10′ (3 m) beyond the test bracket. (113.76 bar) for the intermediate boom and 1,700 psi
(117.21 bar) for the upper boom. The hydraulic pressure
11. Attach the winch line to a solid structure. The solid in the retract circuit is not limited.
structure must be located so the winch line between
the test bracket and the structure is horizontal. The Testing
winch line must make a 90 degree angle to the side A 0 to 4,000 psi (0 to 275.80 bar) pressure gauge is
of the booms with at least 10′ (3 m) between the necessary to test the extension pressure limiters. The
boom tip and the structure.

Section 8 — Troubleshooting, Testing, and Adjustments • 103

procedure is the same for either the intermediate or Tilt Sensor Alarm
upper boom. This unit can be equipped with an audible alarm that
sounds when the unit nears an unstable condition while
1. Position the unit on a level surface and properly set driving. The alarm is not intended to be the only indica-
the outriggers. tion of driving instability, but acts as an early warning of
a possible unstable situation.
2. Operate the unit to warm the oil in the hydraulic sys-
tem. Cold oil can result in a pressure limiter setting The alarm must be properly set to accurately sense con-
that is too low for normal operation. ditions that might cause unit instability. Use the following
procedure to set the tilt sensor alarm. Outrigger pads (or
3. Turn off the engine. other material suitable to provide a stable platform) and
a digital level or protractor are required to perform the
4. Remove the lower control cover. Connect a 0 to procedure. Read and understand the procedure before
4,000 psi (0 to 275.80 bar) pressure gauge to the beginning the procedure.
load sense port on the boom functions valve. When
the boom is operated to the full extended position, 1. Position the unit on a level surface. Position the level
with the engine at maximum operating speed, the on the turntable plate and check to see if the plate
gauge will indicate the extension pressure limiter is near level. Reposition the unit, if needed, to be as
pressure. close to level as possible. Zero the level.

5. Start the engine. From the lower controls, fully extend 2. Place a stack of pancakes or blocking approximately
the boom. The pressure gauge should indicate a 12” high under the outriggers on one side of the unit.
maximum pressure of 1,650 psi (113.76 bar) for the
intermediate boom and 1,700 psi (117.21 bar) for the 3. Engage the unit’s hydraulic system. Lower both sets
upper boom when the boom reaches full extension. of outriggers until the side opposite the pads is about
The pressure limiter should be relieving any excess 6” off the ground and the other side is just on the
pressure. stack of pancakes.

If the gauge indicates a value lower than the given 4. Lower the outriggers on the side of the unit contact-
value, the pressure limiter is set too low. If the gauge ing the outrigger pads until the tilt sensor alarm is
indicates a value above the given value, the pressure activated. There will be a steady alarm tone. Adjust
limiter is set too high. In both cases, adjustment is the outriggers on either side of the unit until the tilt
necessary. sensor is just at the activation point of the steady
tone.
6. Repeat the test procedure for the other boom.
5. Check the angle of the turntable plate with the level.
Adjustment The angle should be between 9 and 11 degrees. If
1. Turn off the engine. the angle is outside the range, proceed to step 6 to
adjust the sensor angle setting. If the angle is correct,
2. Remove the plug on the pressure limiter cartridge proceed to step 12.
(refer to Figure 8.17).
6. Disconnect the tilt sensor from the electrical harness.
3. Turn the adjusting screw clockwise to increase the Remove the winch cover and tilt sensor from the base
pressure. Turn the adjusting screw counterclockwise end of the boom.
to decrease the pressure. Make the appropriate
adjustment. Install the plug. 7. Loosen the fasteners that hold the tilt sensor to the
winch cover. Place the base of the winch cover and
4. Repeat the test procedure. If necessary, make adjust- the tilt sensor on a level surface.
ments until the pressure limiter relieves pressure at
the proper value. 8. Hold the cover in a vertical position. Position the
bottom surface of the tilt sensor to level using the
5. Repeat the test procedure until the proper value is protractor or level and tighten the fasteners.
obtained at least three consecutive times. This will
insure the consistency of the pressure limiter. 9. Test the sensor setting by connecting the wiring
harness for the sensor to the unit. Turn the ignition
6. Remove the pressure gauge and replace the cover. switch to the On position. The tilt sensor should have

104 • Section 8 — Troubleshooting, Testing, and Adjustments

 one LED light illuminated indicating 12 volts to the If the unit has a load on the winch line, determine if
sensor. the load is heavy enough to cause the unit to become
overloaded or unstable when the booms are manually
10. Hold the cover so the sensor is level (0 degrees). rotated and lowered. If the load will cause the unit to
Both LED lights on the sensor should illuminate. Tilt be unstable or overloaded, remove the load with other
the cover until the audible alarm sounds and check heavy equipment.
the angle with the level. The alarm should sound
when the level shows the tilt sensor is between 9
Caution
and 11 degrees (refer to Figure 6). If the level shows
the angle of sensor activation is out of that range, Injury and property damage can result from contact of
use steps 6 through 10 to adjust the sensor until the the booms or platform with fixed objects. Made sure
angle is correct. there is sufficient clearance before operating the unit.

11. Install the tilt sensor and winch cover onto the boom. Rotating the Turntable
Perform a final test using steps 4 and 5. Make any To rotate the turntable manually, another piece of heavy
corrections necessary. equipment, such as a crane or derrick, is needed to as-
sist in rotation. Use the following procedure to manually
12. Stow the outriggers and return the unit to service. rotate the turntable.

Manually Lowering/Stowing the Unit Warning

The following text explains how to manually rotate the Death or serious injury can result from uncontrolled
turntable and to lower the lower boom and outrigger unit movement. Maintain control of the booms when
cylinders. using another piece of equipment to rotate the turn-
table.

Danger If the disabled unit is not level, the booms must be

Death or serious injury will result from improper use positively restrained. This may be done by hooking the
of the unit. Do not manually operate the unit without booms to an operable unit that is positioned uphill from
proper training. the disabled unit. Proceed with caution when using an-
other piece of equipment to rotate or restrain the booms.
It is not possible to manually retract the booms, stow the If the booms are not restrained, uncontrolled rotation of
digger, or raise and lower the winch line. Internal holding the booms could result.
valves in the extension cylinders prevent the booms from
being manually retracted. The digger cannot be manu- Caution
ally stowed. If the booms are extended or the auger is
unstowed and the unit does not have a major hydraulic Death or serious injury can result from hydraulic
leak, an auxiliary power source could be used to stow oil being injected into the flesh when loosening or
the unit. The winch cannot be raised or lowered without disconnecting hydraulic components. Remove the
hydraulic power. pressure before loosening or disconnecting hydraulic
components.

Warning Seek immediate medical attention if injured by escap-

Death or serious injury can result from being trapped ing hydraulic oil. Serious infection or reaction can
between moving components while adjusting the result if medical treatment is not given immediately.
holding valve. Allow an exit path from the area.
Spilled hydraulic oil creates slick surfaces and can
Death or serious injury can result if the unit becomes cause personnel to slip and/or fall. Keep the unit and
unstable. If the unit looses hydraulic power, remove work areas clean.
the load on the winch line before manually stowing
the unit. 1. Secure the booms to prevent uncontrolled movement.

Death or serious injury can result if the unit becomes 2. Disconnect the hydraulic lines from the rotation motor.
unstable. Properly stow the booms before raising
the outriggers. 3. Using a socket wrench, rotate the 1/2″ hex shaft (refer
to Figure 8.18) clockwise or counterclockwise, as

Section 8 — Troubleshooting, Testing, and Adjustments • 105

 required, to manually rotate the turntable until the the proper setting using an Altec test block before
booms are positioned above the boom rest. the unit operated.

4. When the boom has been lowered to the rest, re-

turn the adjusting screw to its original position and
tighten the jam nut. Replace or properly adjust the
counterbalance valve to its original setting. Return
the lower control handle to neutral.

Manually Raising the Outriggers

Use the following procedure to manually raise the out-
Hex Shaft riggers.

Notice
Follow the stowing procedure to prevent damage
to the unit.

Figure 8.18 — Rotation Gearbox 1. Stow the booms.

4. Remove the restraints used to control movement of 2. If the equipment is available, raise the unit to remove
the booms. the load from the outrigger leg.

Lowering the Booms 3. Locate the two holding valves installed near the base
1. At the lower control station, move the lower boom end of the cylinder (refer to Figure 8.19). One of the
control handle to the Boom Lower position. valves has a screw in the top of the cartridge. Turn
the screw in (clockwise) until the cylinder begins to
retract. Control the speed of cylinder retraction using
Warning the hex screw.
Death or serious injury can result from being trapped
between moving components. Maintain a safe dis-
tance while components are in motion. Holding
Valve
Take care when turning the counterbalance valve adjust-
ing screw. As the adjusting screw is turned, the boom
will begin to lower. The rate of movement will increase
as the boom is lowered.

The rate of movement can be adjusted by how far the

counterbalance valve adjusting screw is turned after
movement of the boom starts.

2. Loosen the jam nut on the holding valve cartridge

located in the cavity in the base end of the lift cylinder.

3. Using an Allen wrench, turn the holding valve adjust- Figure 8.19 — Outrigger Cylinder
ing screw clockwise until the boom begins to lower.
Speed of descent should be controlled with the 4. When there is no weight on the outrigger, lift the
adjusting screw. Make note of the number of turns outrigger leg with a come-along or a pry bar. Block
the adjusting screw is turned in. up the outrigger shoe at intervals if lifting in succes-
sive steps with a pry bar. Use the come-along to
Warning completely retract the extended outrigger leg.

Death or serious injury can result from unexpected 5. Secure the outrigger legs in the stowed position until
movement. Counterbalance valves that have had the the hydraulic system is again operational.
relief setting changed must be replaced or reset to

106 • Section 8 — Troubleshooting, Testing, and Adjustments

 6. Stow the outriggers. unit is equipped with a power tools hose reel, use
the pressure hose on the reel for this purpose. If a
7. Turn the screw out (counterclockwise) to close the tools reel is not available, use another pressure hose
valve before again using the outrigger. from the operable unit of sufficient length. Appropriate
fittings will need to be added to the pressure hose
on the disabled unit to do this.
Auxiliary Power Source
Another hydraulically powered unit may be used as an 4. Locate the return hose that runs from the drive/
auxiliary power source to stow a unit that has lost its hy- outrigger/tools valve to the return line filter (refer to
draulic power. The alternate power source must contain Figure 8.20). Disconnect this hose at one end, and
compatible hydraulic oil and should produce a flow no cap or plug the reservoir side of this connection.
greater than 16.5 gpm (62.46 lpm).
5. Connect a return inlet from the operative unit to the
Only use the alternate power source to stow the unit for return line disconnected from the disabled unit in step
road travel. It should not be used to operate the unit for 4. If available, use the return hose on the tools reel
an extended period of time. on the operable unit for this purpose. Otherwise, use
another hose of sufficient length from a return inlet
Before beginning the following procedure, turn off the on the operable unit. Add appropriate fittings to the
engine on both the disabled unit and operable unit. return hose of the disabled unit to do this.

The following procedure refers to the disabled unit, except If a return inlet is not available, connect a hose to the
where specified. return line disconnected in step 4. Insert the free end
of the hose in the fill opening on top of the reservoir
1. Close the shutoff valve below the oil reservoir in the of the operable unit.
suction line of the pump.
6. Start the engine and engage the PTO on the oper-
2. Locate the pressure hose that runs from the pump able unit. If the electrical system on the unit is still
to the drive/outrigger/tools valve inlet (refer to Figure operable, use the lower controls to stow the unit. Use
8.20). Disconnect this line from the pump and plug the outrigger control handles to raise the outriggers.
the pump outlet.
7. Once the unit is stowed, disengage the PTO and turn
3. Connect a pressure outlet from the operable unit to off the engine on the operable unit. Return all the
the pressure hose or the valve inlet that was discon- hydraulic hoses to their original connections on both
nected from the disabled unit in step 2. If the operable units. Open the shutoff valve on the disabled unit.

Pressure DV3

Line
PV1 PV2 SV2 SV6 SV9
SV7 SV8 SV10
SV1

G2
FC1

CV1
G

SV5

RV1
2500 PSI
SV4 RV2
2000 PSI

Return Line

Figure 8.20 — Auxiliary Power Source Plumbing

Section 8 — Troubleshooting, Testing, and Adjustments • 107

108 • Section 8 — Troubleshooting, Testing, and Adjustments
 Section 9 — Dielectric and Stability Testing
This unit has been factory tested and, at the time of In addition to regular tests, conduct tests any time the
delivery, all applicable ANSI requirements were met or dielectric strength of the insulating components is in doubt.
exceeded. Any time an alteration is made that may affect
the unit’s stability or dielectric insulation, testing must be If it is necessary to change or replace any component
performed to confirm that the unit operates safely and in which is part of the unit’s insulation, including booms, tool
compliance with all governing organizations. lines, control lines, etc., a dielectric test must be performed.
If there is any doubt about the dielectric strength of the
hydraulic oil, perform a dielectric test.
Dielectric
ANSI requires that manufacturers conduct an AC dielec- The leakage monitor system is a tool used to measure
tric qualification test on each device before it is sold to the leakage of electrical current through the components
a customer. Once the unit is in the hands of the owner, it is attached to and for dielectric tests of all voltages.
ANSI permits the use of a less stringent periodic dielectric This system consists of wires connected to components
test. This test is to be done at least annually, but typically internal to the upper boom and to a test electrode that
in 1 to 12 month intervals. Since the AC periodic test as extends through the bottom of the fiberglass upper boom.
defined by ANSI uses the very same procedure but with A test electrode may also be located on the turntable.
less voltage, Altec suggests using the qualification test
to avoid confusion. However, some owners prefer to use Dielectric test forms can be found in the Appendix. Choose
DC to do periodic dielectric testing. the appropriate form, thoroughly document all tests, and
maintain records in a permanent file.
This unit is tested to a rating listed on the serial num-
ber placard at the time of delivery. The platform liner,
if furnished, will carry the certification test of the liner
Stability
manufacturer. Due to the possible affect on stability, this unit should
never be altered or modified without the specific written
Danger approval from Altec Industries, Inc. Component replace-
ment with original equipment parts will not affect the
Death or serious injury will result from contact with stability of this unit.
or proximity to an energized conductor. Maintain the
dielectric characteristics of the fiberglass boom(s). ANSI A10.31 requires tests when the unit is complete.
These stability tests are not required to be performed
Surface irregularities such as scratched, cracked, or again unless significant changes are made.
chipped gelcoat can trap dirt and contaminants, which
over time may reduce the dielectric properties of the
fiberglass. Of particular concern are irregularities running Warning
lengthwise on the boom. Trapped contaminants, such Death or serious injury can result from uncontrolled
as dust particles and water, can cause tracking, provid- movement. Do not permit anyone to occupy the
ing a path to ground. Surface flashover occurs when a platform until the unit has passed applicable tests.
substance causes an arcing of electricity between two
points on the boom. If this occurs, the dielectric integrity Death or serious injury can result if the mobile unit
of the boom may be permanently damaged. becomes unstable. Provide a suitable restraint while
the stability tests are performed.
Dielectric tests that can be performed only after instal-
lation are the responsibility of the installer, whether the
Notice
installer is a dealer, owner, or user. After the completed
unit is in the possession of the owner or user, subsequent Carefully load the test weight to prevent damage to
testing becomes the responsibility of the owner or user. the platform or liner.

The importance of dielectric testing cannot be overem- Test Forms

phasized. Understand the dielectric test procedures in Stability test forms are provided in the Appendix. The
ANSI publications. Provide for periodic inspection and forms designate the proper boom positions and the
dielectric testing of insulated components at intervals of proper test loads to be used. They show the unit loading
1 to 12 months. This recommendation is not intended to configuration(s) that would most likely cause overturning.
alter more frequent inspection or testing of other com- Completed forms should be dated and signed by the test
ponents as defined in ANSI publications. technician after conducting the stability tests and should
be retained as part of the original unit documentation.

Section 9 — Dielectric and Stability Testing • 109

Two test forms are provided. Both tests must be con- 7. If the initial test shows that the mobile unit is unstable,
ducted. adjust the outriggers to determine any effect on
stability. Rotate the turntable again in a full rotation
Digger Derrick Use cycle watching for any evidence of instability.
General Test Conditions
• Remove all tools and material including removable 8. If it is determined that the mobile unit will not pass
boom supports, extra platforms (not attached to the the test as originally built, permanent counterweight,
unit), and all removable cargo. unit capacity reduction, zone capacity rating, or other
similar solutions must be evaluated to ensure that
• Restrict the amount of total fuel in the tank to 2 gal- the finished unit will pass the test. Use temporary
lons (9.09 l) or less. counterweight to determine how much permanent
counterweight is needed and where the counterweight
• Do not use outrigger pads. should be added. Rotate the turntable in a full rota-
tion cycle watching for any evidence of instability
• Perform the test only while operating from the lower after adding the temporary counterweight. If the unit
controls. passes the test with the temporary counterweight,
remove the temporary weight and add the permanent
• Provide a suitable restraint during all stability tests counterweight. Perform the test again.
to prevent the mobile unit from overturning in the
event a condition of instability is reached. A typical 9. After the test has been completed, torque all acces-
restraint method is to position the chassis between sible rotation bearing cap screws to 225 foot-pounds
tie downs and with the tracks fully retracted. Loosely (305 N•m) using a circular pattern (only required
loop a chain over the cargo deck near the center of following initial stability test at the time of initial instal-
the unit (allows the outrigger to raise off the test sur- lation of unit on chassis).
face at least 6″ to 8″ (15 to 20 cm) before tightening
the chain). Increase the length of the chain to allow 10. After the test has been completed, torque the rotation
further movement if there is any doubt about whether gearbox mounting cap screws to 115 foot-pounds
the mobile unit has reached a condition of instability. (156 N•m) (only required following initial stability test
Raising of outriggers does not necessarily indicate at the time of initial installation of unit on chassis).
a condition of instability.
Combined Digger Derrick and Platform Use
• The unit must pass the Level Surface Test before General Test Conditions
conducting the Five Degree Slope Test. • Remove all tools and material including removable
boom supports, extra platforms (not attached to the
Testing unit), and all removable cargo.
1. Position the unit on a level, hard surface.
• Restrict the amount of total fuel in all tanks to 2 gal-
2. Properly set the outriggers. Fully extend the outrig- lons (9.09 l) or less.
gers. Level the unit side to side and front to back
with the outriggers. • Do not use outrigger pads.

3. Remove all boom tip options. • Perform the test only while operating from the lower
controls.
4. Position the booms for the test as described on the
capacity chart. • Provide a suitable restraint during all stability tests
to prevent the mobile unit from overturning in the
5. Apply the proper stability test load to the winch line event a condition of instability is reached. A typical
(refer to the capacity chart). restraint method is to position the chassis between
tie downs and with the tracks fully retracted. Loosely
6. Rotate the turntable a full rotation cycle, watching for loop a chain over the cargo deck near the center of
any evidence of instability. Outriggers may lift off the the unit (allows the outrigger to raise off the test sur-
surface during the test without indicating a condition face at least 6″ to 8″ (15 to 20 cm) before tightening
of instability as long as the mobile unit does not tend the chain). Increase the length of the chain to allow
to overturn. further movement if there is any doubt about whether
the mobile unit has reached a condition of instability.

110 • Section 9 — Dielectric and Stability Testing

 Raising of outriggers does not necessarily indicate showed the mobile unit has a greater tendency to
a condition of instability. overturn about one side than another, position the
least stable side on the low side of the slope.
• The unit must pass the Level Surface Test before
conducting the Five Degree Slope Test. 2. Properly set the outriggers. Extend all outriggers
fully.
Level Surface Test
1. Position the unit on a level, hard surface. 3. Remove all boom tip options.

2. Properly set the outriggers. Fully extend the outrig- 4. Position the booms for the test as described on the
gers. Level the unit side to side and front to back test form.
with the outriggers.
5. Apply the load shown on the test form to the winch
3. Remove all boom tip options. line.

4. Position the booms for the test as described on the 6. Rotate the turntable a full 360 degree rotation cycle,
test form. watching for any evidence of instability. Outriggers
may lift off the surface during the test without indicat-
5. Apply the load shown on the test form to the winch ing a condition of instability as long as the mobile
line. unit does not tend to overturn.

6. Rotate the turntable a full rotation cycle, watching for 7. If the initial test shows that the mobile unit is unstable,
any evidence of instability. Outriggers may lift off the adjust the outriggers to determine any effect on
surface during the test without indicating a condition stability. Rotate the turntable again in a full rotation
of instability as long as the mobile unit does not tend cycle watching for any evidence of instability.
to overturn.
8. If it is determined that the mobile unit will not pass
7. If the initial test shows that the mobile unit is unstable, the test as originally built, permanent counterweight,
adjust the outriggers to determine any effect on unit capacity reduction, zone capacity rating, or other
stability. Rotate the turntable again in a full rotation similar solutions must be evaluated to ensure that
cycle watching for any evidence of instability. the finished unit will pass the test. Use temporary
counterweight to determine how much permanent
8. If it is determined that the mobile unit will not pass counterweight is needed and where the counterweight
the test as originally built, permanent counterweight, should be added. Rotate the turntable in a full rota-
unit capacity reduction, zone capacity rating, or other tion cycle watching for any evidence of instability
similar solutions must be evaluated to ensure that after adding the temporary counterweight. If the unit
the finished unit will pass the test. Use temporary passes the test with the temporary counterweight,
counterweight to determine how much permanent remove the temporary weight and add the permanent
counterweight is needed and where the counterweight counterweight. Perform the test again.
should be added. Rotate the turntable in a full rota-
tion cycle watching for any evidence of instability 9. After the test has been completed, torque all acces-
after adding the temporary counterweight. If the unit sible rotation bearing cap screws to 225 foot-pounds
passes the test with the temporary counterweight, (305 N•m) using a circular pattern (only required
remove the temporary weight and add the permanent following initial stability test at the time of initial instal-
counterweight. Perform the test again. lation of unit on chassis).

Five Degree Slope Test 10. After the test has been completed, torque the rotation
1. Position the unit on a level, hard surface with the gearbox mounting cap screws to 115 foot-pounds
centerline positioned approximately perpendicular to (156 N•m) (only required following initial stability test
the direction of the slope. If the Level Surface Test at the time of initial installation of unit on chassis).

Section 9 — Dielectric and Stability Testing • 111

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

1 Appendix — Glossary
closest to the turntable. 3: the end of an articulating boom that remains from the winch to the load. 2: the lower sheave in a digger derrick up-
positioned closest to the turntable when the boom is fully unfolded. per boom tip containing two sheaves, which carries the winch line as it
basket — see platform. travels from the upper sheave (boom tip idler sheave) to the load.
battery charger — a device used to restore the electrical charge in boom tip tools — see upper tool circuit.
a battery. boom tip winch — a winch located at the tip of a boom.
bearing — a machine part that is installed between two adjacent machine bore — the inside diameter of a pipe, tube, cylinder barrel, or cylindrical
parts to allow those parts to rotate or slide with respect to each other. hole in any of various other components.
Commonly used to decrease friction or wear on components. boss — protruding material on a part which adds strength, facilitates
behind cab mount — a pedestal mounting position located immediately assembly, provides for fastenings, etc.
behind the vehicle cab on the longitudinal centerline of the chassis. brake — a device used to slow or stop the rotation or movement of a
below rotation — in reference to a position on or about a unit that is component such as a rotation gearbox, winch, gravity leveled platform,
vertically below the rotation bearing. or arbor bar.
below rotation controls — controls that are located on the chassis, brake caliper — mechanical assembly that houses the brake pads
used for operating some or all of the functions of the unit. and piston used to apply stopping force on the brake rotor.
bleed-off — to reduce the trapped pressure in a hydraulic system, brake controller — interface between tow vehicle and electric trailer
line, or component, to a zero state by allowing fluid to escape under brakes. Can be inertia activated or based on time delay from activation
controlled conditions through a valve or outlet. of vehicle brakes. Typically in the tow vehicle’s driving compartment
blocking valve — a two-position, two-way valve that blocks pump flow with electrical line running to the trailer wiring connector. Most require
to a hydraulic circuit or system when it is not actuated, and opens to the user to adjust brake gain to compensate for varying trailer load.
allow fluid when actuated. Necessary for the use of electric trailer brakes.
body — a structure containing compartments for storage of tools, brake rotor — rotating disk attached to a shaft that transfers the force
materials, and/or other payload which is installed on a vehicle frame from the brake caliper to the shaft.
or subbase. break-away switch — a device which automatically activates the
body belt — a component in a personal fall protection system consisting breaking system of a towed unit when unintentionally separated from
of a strap which is secured about the waist of a person, with a means the towing vehicle.
for attaching it to a lanyard. (As of January 1, 1998, the use of a body breather — a device that permits air to move in and out of a container
belt for personal fall protection is prohibited by OSHA.) or component to maintain atmospheric pressure.
body harness — a component in a personal fall protection system bridge mount — a unit mounting configuration in which the turntable
consisting of an assembly of straps which are secured about the waist, is mounted on a pedestal structure which forms a bridge over the
chest, shoulders, and legs of a person, with a means for attaching the cargo area.
assembly to a lanyard. broadband — a high speed telecommunication system utilizing fiber
bolt — a cylindrical fastener with external screw threads at one end optic and/or coaxial cable.
and a head configuration such hexagonal, square, or round at the other bucket — see platform.
end, which conforms to the dimensional and material specifications
published for bolts. (These specifications are different from those for buckeye — see forged pin retainer.
cap screws.) bullwheel assembly — an assembly of steel rollers used as a portion
boom — a movable, mechanical structure that is used to support a of a cable stringing system.
platform, material handling components and/or other attachments on burst pressure — the minimum internal pressure that will cause a
a unit. hose, tube, cylinder, or other hydraulic or pneumatic component to
boom angle indicator — a device which indicates the angle between rupture or split open.
the boom centerline and a horizontal plane. button head — a type of cap screw with a rounded head containing a
boom flares — steel structures mounted on the boom tip of a digger socket into which a tool can be inserted to turn the cap screw.
derrick which are used to protect the boom tip from loads and support bypass — a secondary passage for fluid flow.
poles carried on the winch line.
bypass valve — a hydraulic valve that allows for an alternate pas-
boom functions valve — the control valve on a digger derrick that sage for fluid flow.
directs hydraulic pressure and flow to the boom functions (boom, rota-
tion, intermediate boom, upper boom) hydraulic circuits. cable — 1: a wire or wire rope by which force is exerted to control or
operate a mechanism. 2: an assembly of two or more electrical conduc-
boom limiting system — the system of hydraulic cylinders or a tors or optical fibers laid up together, usually by being twisted around a
combination of switches that prevent the platform from moving into a central axis and/or by being enclosed within an outer covering.
non-working position.
cable chute — a device used to guide cable into strand for lashing
boom pin — the horizontal pin that connects the lower boom to the the cable to the strand when placing cable. A trolley allows the device
turntable or riser. to ride on the strand as cable is fed through the chute.
boom rest — the structural member attached to the chassis or body cable drive system — an upper boom drive mechanism which utilizes
to support the lower boom in the travel or rest position. cables to produce upper boom movement.
boom stow switch — a limit switch which is actuated to shut off the cable guide — a bracket which is mounted on a boom to guide the
boom lower function when the boom reaches its stowed position in winch line.
the boom rest.
cable keeper — 1: a mechanical device attached to a cable that is used
boom stow valve — a mechanically actuated hydraulic valve that limits to maintain the position of the cable on a sheave. 2: a component used
the downward pressure of a boom as it is placed in its rest. to prevent a cable or winch line from coming off a sheave.
boom tip — the area at the end of an extendible or articulating upper cable lasher — a mechanical device which wraps lashing wire in a
boom that is farthest from the turntable when the boom assembly is spiral configuration around a length of suspension strand and adjacent
extended or unfolded. This area includes all components at the end communication cable.
of the boom above the band of arrows.
cable lug — a mechanical device attached to a cable that is used to
boom tip idler sheave — the upper sheave in a digger derrick upper maintain the position of the cable on a sheave.
boom tip containing two sheaves, which carries the winch line as it
travels from the winch to the lower sheave (boom tip sheave). cable placer — a type of aerial device which contains a cable string-
ing system and associated components for use in erecting overhead
boom tip pin — a horizontal pin at the upper boom tip. Platform mounting communication cable.
bracket(s) and material handling devices are fastened to this pin.
cable slug — the steel end fitting at each end of the drive cable in an
boom tip sheave — 1: the sheave in a digger derrick upper boom tip upper boom drive system. One end is attached to the cylinder rod and
containing only one sheave, which carries the winch line as it travels the other is secured in a pocket on the elbow sheave.

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

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

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

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

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

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

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

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

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

11 Appendix — Glossary
rotary joint — a multiple port manifold that has a rotating portion and sequence — 1: the order of a series of operations or movements. 2:
a stationary portion, used to provide a continuous hydraulic connection to divert flow to accomplish a subsequent operation or movement.
between rotating and stationary hydraulic lines. Commonly used at the sequence valve — a pressure operated valve that diverts flow to a
centerline of rotation of units equipped with continuous rotation. secondary actuator while holding pressure on the primary actuator at
rotate frame — the structure located above the stationary frame on a a predetermined minimum value after the primary actuator completes
pressure digger that is used to support and rotate the slide frame. its travel.
rotating platform — a platform which can be rotated about a vertical sequential extension — the operation by which one boom section
axis to change its position in relationship to the boom tip. in an extendible boom assembly reaches full extension or retraction
rotation bearing — the rotating member, usually a shear ball bear- before the next boom section begins movement.
ing, located between the pedestal and the turntable which allows the set screw — a short screw, typically with an Allen type head, that is
turntable to rotate and which contains gear teeth that mesh with the used as a clamp to bind parts together.
rotation pinion. shackle — see clevis.
rotation chain — a chain attached to the stationary frame of a pressure shear — an action or stress resulting from opposing applied forces that
digger that is used by the rotation gearbox to rotate the rotate frame. attempt to separate a part into two pieces that would then slide along
rotation gearbox — the gearbox which drives the rotational motion each other in opposite directions along the plane of separation.
of the turntable. shear ball bearing — an antifriction bearing with rolling ball contact
rotation pinion — the gear on the output shaft of the rotation gearbox in which the direction of load transmitted through the balls is parallel
which meshes with the rotation bearing gear teeth and drives the to the axial centerline of the bearing, producing shear loading on the
turntable rotational motion. balls. The bearing can support axial, radial, and tilt loading. Commonly
rotation resistant wire rope — wire rope which is constructed to resist used as a rotation bearing.
the tendency to untwist or rotate when carrying a suspended load. This shear pin — a replaceable pin which prevents motion between two
is accomplished by laying the outer strands in the opposite direction adjacent parts by the production of shear loading in the pin, and which
to the lay of the inner strands or core. may be designed to fail under overload to protect other parts.
rotation system — the system which drives the rotation of the turntable shear stability — resistance of a hydraulic fluid viscosity index improver
about the centerline of rotation. It typically consists of a rotation bearing, additive to shearing.
rotation gearbox, hydraulic motor, and load holding valve. shearing — molecular damage or breakdown of the viscosity index
rpm — revolutions per minute. improver additive in hydraulic fluid. Shearing can occur when the fluid
running torque — the torque produced by a rotating device such as flows through fine clearances at high velocity. Shearing can cause
a motor or gearbox at a specified rotational speed. permanent loss in fluid viscosity.
SAE — Society of Automotive Engineers. 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
safety belt — see body belt. line or cable.
safety chains — the chains that are attached to the trailer tongue with sheave height — the vertical distance from ground level to the centerline
hooks on their free ends. These chains keep the trailer connected to of the boom tip sheave in a digger derrick upper boom tip.
the tow vehicle should the coupler or hitch ball detach from the tow
vehicle. Safety chains must be secured every time you tow. short circuit — an inadvertent path of low resistance established
between two points of an electrical circuit. A short circuit will result in
saybolt universal viscosity — A measure of viscosity equal to the time excessive current flow.
it takes in seconds for 60 milliliters of fluid to flow through a capillary
tube in a Saybolt universal viscosimeter at a given temperature. shutoff valve — a device which is used to stop hydraulic fluid flow.
scissor link — the mechanical linkage on a reel lifter used to connect shuttle valve — a three-port valve that accepts hydraulic fluid pres-
the lifter cylinder to the arm. sure 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
screw anchor — a rod with an eye on one end and auger flighting on from one another.
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. side gun — a hand held water nozzle and hose that can be used from
the ground for washing or fire fighting.
seating in — an initial microscopic surface deformation of components
that are clamped together with threaded fasteners. This causes a slight side load — an external horizontal load placed on a boom from one
reduction in the dimension of the components, reducing the clamping side.
force applied by the fasteners. side load protection system — the system on a digger derrick that
secondary stowage DC pump — a low flow hydraulic pump driven by a helps prevent damage to the digger derrick structure when excessive
direct current electric motor. This pump is used to provide hydraulic flow side loads are applied to the booms.
to stow the unit when the system for normal operation has failed. side-mounted platform — a platform which is attached to a mount-
secondary stowage system — those components used to stow the ing bracket that extends from one side of the boom tip, positioning
unit when the system for normal operation has failed. the platform (and platform rotation pivot, if so equipped) beside the
boom tip.
selector switch — a switch which is used to direct electrical current
to one of two or more electrical circuits. sideslip — sideways motion of a component caused by an externally
applied sideways force which overcomes resistive forces from hy-
selector valve — a valve which is used to direct hydraulic fluid to one draulics, friction, etc. Commonly used to describe rotation of a digger
of two or more hydraulic circuits. derrick boom caused by side loading which exceeds the side load
self feed — a wood-chipper with no control of the infeed rate to the protection setting.
cutting mechanism. signal — a command or indication of a desired position, velocity, flow
self-locking nut — a nut which contains a built-in device or shape to or pressure.
increase thread friction so as to resist loosening due to vibration or signal line — see sense line.
repeated loading.
single-acting cylinder — a cylinder in which fluid pressure can be ap-
self-lubricating bearing — an antifriction bearing in which lubricating plied to move the rod in only one direction. Return motion is produced
material is incorporated in the bearing. by an external force such as a spring or gravity.
sense line — a line that carries a hydraulic pressure signal from a single elevator — an elevator lift with one load carrying arm. The
valve or actuator to the compensator control on a variable displace- single elevator system includes a lower pedestal, arm, arm cylinder(s),
ment pump. parallel links, and upper pedestal.
sense selector valve — a valve which prevents hydraulic fluid in single handle control — a control, with an interlock trigger incorpo-
the sense line from reaching the pump until a certain function(s) is rated in the handle, which allows the operator to simultaneously control
operated. multiple functions of the booms and turntable from the platform.

Appendix — Glossary 12
single-pole, double-throw (SPDT) switch — a three-terminal electri- stall torque — the torque produced by a rotating device such as a
cal switch or relay that connects one terminal to either of two other motor or gearbox at zero rotational speed.
terminals. standard option — an option which can be ordered from a standard
single-pole, single-throw (SPST) switch — a two-terminal electrical order form and can be supplied without additional engineering work.
switch or relay that opens or closes one circuit. start/stop control module — an electrical device that relays sig-
slave control panel — a secondary derrick lower control panel that nals from the unit’s remote start/stop system to the component(s) or
is configured as a remote terminal of the master panel. The slave system(s) being controlled, such as the secondary stowage DC pump
panel is used in conjunction with a master panel to provide dual sta- and/or vehicle ignition system.
tion lower controls. static mixer — a tube with no moving parts used to combine two or
slave cylinder — a cylinder in which motion of the piston is produced more fluids.
by the transfer of hydraulic fluid from a master cylinder, resulting in stationary frame — the structure attached to the subbase of a pressure
corresponding motion. digger that supports the outriggers and rotate frame.
slide frame — the structure on a pressure digger used to support the stationary hood — normally non-removable part of the disc housing
auxiliary engine, hydraulic reservoir, control station, and pivot weldment. in which the discharge chute attaches.
The slide frame can be extended horizontally from its stowed position
to adjust the distance of the kelly bar from the 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.
slide pad — a rectangular block used as a bearing between extend-
ible boom or outrigger sections, usually composed of a non-metallic stow — to place a component such as a boom or digger derrick auger
material. in its rest position.
slip ring — an assembly of one or more conductive, rotating rings and strainer — a coarse filter.
stationary brushes used to provide a continuous electrical connection strainer basket — a coarse, basket shaped filter which is mounted in
between rotating and stationary conductors. Commonly used at the the fill hole of a reservoir and projects into the reservoir.
centerline of rotation of units equipped with continuous rotation.
strand — 1: one of the groups of individual fibers or wires within a
slug face — the extreme end of the cable slug which is secured to the synthetic winch line or wire rope. 2: see suspension strand.
cylinder rod or adjusting stud.
strand carrier — a device used to support and transport strand reels
SMA connector — metal connector used for connecting fiber optic on a vehicle.
components.
strand reel — a reel or spool used for carrying suspension stand.
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 street side — the side of a vehicle toward oncoming traffic when the
around an internal sheave. vehicle is traveling forward in the normal direction in a lane of traffic.
snubber valve — a two-port valve with a manually adjustable orifice stroke — 1: total linear movement in either direction of a piston or
that restricts the flow of fluid through the valve. plunger. 2: to change the displacement of a variable displacement
pump or motor.
socket head — a cylindrical cap screw head design containing a
hexagonal (six-sided) female socket into which an Allen wrench can subbase — a structural mounting interface between the pedestal and
be inserted to turn the cap screw. the vehicle frame. It provides torsional stiffness and strength in addition
to that which would be provided from the vehicle frame alone.
solenoid — a coil of insulated wire that produces a magnetic field within
the coil when electrically energized. When attached to a hydraulic valve, subweldment — a smaller welded subassembly used within a more
the magnetic field acts upon the valve to move internal valve parts. complex welded structure.
solenoid valve — a valve which is actuated by a solenoid to controlling suction filter — a filter located in a hydraulic system suction line or at
the flow of hydraulic fluid. the outlet of a hydraulic reservoir which cleans fluid flowing from the
reservoir to the pump inlet.
speed reducer — see gearbox.
suction line — the hydraulic line connecting the pump inlet port to
spherical bearing — a bearing with a spherically shaped inner race the reservoir outlet.
that is allowed to move freely inside a stationary outer race to accom-
modate misalignment. surge — a momentary rise of pressure in a circuit.
splicer platform — a fiberglass platform equipped with a door and surge brake system — a surge brake system is entirely self-contained
latch. on the trailer and is activated when the tow vehicle decelerates. The
momentum of the trailer pushes the surge brake housing forward. This
spline — one of a number of equally spaced, load carrying teeth that drives the push rod that is connected to the coupler into the master
have been cut on the outside diameter of a shaft or inside diameter of cylinder. Brake fluid is then forced out of the master cylinder into the
a bore, parallel to the shaft or bore centerline. wheel cylinders or pistons that apply the trailer brakes. The entire
spool — a moving, cylindrically shaped part of a hydraulic valve that activation process is completed in less than one second.
moves to direct flow through the valve. suspension strand — a type of wire rope which is used to support
spring lockouts — a mechanical system which is engaged to keep the weight of an attached communication cable suspended between
a vehicle’s suspension system from flexing during operation of the poles or other overhead support structures.
unit. swage — to taper or reduce the diameter of a rod, tube or fastener by
sprocket — a wheel with teeth along the circumference which are forging, squeezing or hammering.
shaped so as to engage with a chain, used to support and guide the synthetic winch line — a winch line made from nonmetallic synthetic
chain at a point of change in the direction of motion of the chain. fibers which are formed into strands that are then braided together to
SSU (Saybolt Second Universal) — the unit of measure for Saybolt make a complete rope.
universal viscosity. T-stand — a “T” shaped weldment for mounting lower controls to the
stability — a condition of a mobile unit in which the sum of the mo- vehicle.
ments which tend to overturn the mobile unit is less than the sum of tachometer — an instrument used for displaying the speed of rotation
the moments tending to resist overturning; the mobile unit’s ability to of an engine output shaft.
resist tipping.
tailshelf — the rear portion of the mobile unit above and behind the
stabilize — to provide adequate stability for a mobile unit to allow rear axle.
operation of the vehicle-mounted device(s).
tailshelf tools — see lower tool circuit.
stabilizer — a device used to assist in stabilizing a mobile unit, such
as an outrigger, torsion bar or spring lockout. tank — the hydraulic reservoir.
stake — to slightly deform the threads of a fastener or material at the telescopic — having sections that slide within or over one another to
joint between two components by placing the blade of punch or chisel change overall length.
on the threads or joint and tapping on the handle with a hammer. The tension spring — springs controlling downward force of the upper
deformed material serves to prevent loosening of the components. feed roll.

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

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

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

Product Purpose/Use Part Number

Lubrication

Gear Shield Lubricate rotation gears and pinions. 099-00017

Chain and Cable Fluid Lubricate cables such as wire rope winch line, auger windup 099-00018
sling, and leveling cables or chains.

Moly grease Component lubrication. 099-00025

Anti-seize compound (16 oz can) Component lubrication. 099-00033

Anti-seize compound (1/4 lb tube) Component lubrication. 099-00050

Fasteners

Thread locking adhesive Low strength thread locking and sealing agent for small diam- 099-00019
(purple 50 ml) eter screws.

Thread locking adhesive Medium strength thread locking and sealing agent for bolts 099-00020
(blue 50 ml) and nuts.

Thread locking adhesive High strength thread locking and sealing agent for large diam- 099-00037
(red 50 ml) eter bolts and cap screws.

Thread locking adhesive Medium/high strength thread locking agent. 099-00069

(red 50 ml)

Inspection lacquer, blue (1/2 oz) Visual inspection stripe. 099-00123

Cleaner for inspection lacquer (1/2 oz) Visual inspection stripe removal. 099-00124

Stainless steel safety wire Lockwiring fasteners. 099-00021

(5 lb roll)

Cleaning solvent (12 oz) Quick drying, nonflammable solvent used for cleaning parts 099-00039
prior to bonding. Leaves no residue.

Primer (Grade N — 6 oz) Anaerobic solvent reduces cure time on thread locking adhe- 099-00040
sive.

Primer (Grade T — 6 oz) Anaerobic solvent reduces cure time on thread locking adhe- 099-00041
sive.

Wire twisting pliers Lockwiring fasteners. 099-60007

Appendix — Service Tools and Supplies

 Product Purpose/Use Part Number
Fiberglass Care

Gelcoat kit Repair fiberglass platforms and booms. 041-90001

Formula Five Clean ’N Glaze Cleaning and polishing fiberglass. 041-90002

Plastic Kleen #2 Polish Nontoxic plastic cleaner. 099-00062

Bonding kit Rebond fiberglass booms. 703-50039

White paint Nonmetallic spray paint. 099-00008

Hydraulic System Care

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

Flowmeter Testing hydraulic system. 099-00034

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

Test block — large bore (11/8″) Testing counterbalance valve. 352-79008

Return line filter cartridge Filters hydraulic oil before it is returned to the reservoir. 353-10002

Water removal filter cartridge Removes water from the hydraulic system. 353-30016

Diagnostic test kit Testing hydraulic systems. 356-90002

Oil warming kit Warm hydraulic oil to operating temperature in cold weather. 750-40039

Corrosion suppressant Chrome cylinder rod protection. 099-00051

Electrical System Care

Conformal coating (14 oz) Silicon based electrical component protection. 099-00042

FD Electrical Contact Cleaner Clean and degrease electrical systems. 970176850

DeoxIT Cleaner/protectant. 099-00185

Miscellaneous

Side load text fixture Test side load protection system. 970184379

CADI Calibration instrument. 970222172

CADI extension cable Use CADI farther from connection socket. 970432863

Slip ring bypass harness Diagnose slip ring. 970238905

Appendix — Service Tools and Supplies

 DB37

Preventive Maintenance and Inspection Checklist

Vehicle No. ________________________ Location __________________________ Date _________________

Service Request # ____________________ Model # ____________________ Serial # ______________________

Odometer ________________ Hours Meter ________________ Inspector ______________________________

Perform all inspections, adjustments, repairs, and lubrication according to Altec specifications in the Maintenance
Manual. Refer to any MABs, CSNs, or other applicable documents provided by Altec for servicing the unit.

If 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
/O = Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable

Prior to Placing Unit in Service

Perform the Daily Preoperational Inspection Turntable tilt measurement2: ___________
(refer to the Operator’s Manual)
Hydraulic Reservoir and System
Check oil and collect oil sample for analysis1
Rotation Bearing 85 Engine Hours/1 Month
Perform the Daily Preoperational Inspection Auger windup sling clevis shear pin intact
(refer to the Operator’s Manual) Upper Boom
Covers/Placards Fiberglass cleanliness
Condition, in place Track
Hydraulic Reservoir Tension
Oil level Lubrication
Auger Stow Bracket Rotation pinion and bearing gear teeth
Auger windup sling (condition) Track oil level
500 Engine Hours/6 Months
Perform the 85 hour/1 month inspection Track frame mounting (welds intact, no cracks)
Chassis Underside Track structure (welds intact, no cracks)
Hoses (routing, condition) Boom rest (welds intact, no deformation or cracks)
Exhaust shields (in place, secure, condition) Pedestal mounting (welds intact, no cracks)
Electrical components and wiring (no cracks or Hydraulic Reservoir
split insulation) Mounting (cap screws secure, welds intact, no cracks)
Electrical connections (secure, no corrosion) No leaks
Pump Shutoff valve fully open
Mounting bolts secure Drain water from bottom
4-bolt flange bolts secure Filters
Drive line Change return line filter cartridge
Noise level Outriggers
No leaks Mounting (welds intact, no deformation or cracks)
Unit Mounting Interlock system operation
Chassis frame (welds intact, no cracks) Electrical connections (secure, no corrosion)
jun 13 Appendix — Preventive Maintenance and Inspection Checklist
 Electrical components and wiring (no cracks or Turntable
split insulation) Structure (welds intact, no deformation or cracks)
Hydraulic valve spools (return to neutral, no sticking Boom pin and retainers secure
or leaks) Lift cylinder pivot pin and retainers secure
Hydraulic valve housings (no cracks or leaks) Hoses and tubes (routing, condition), no leaks
Motion alarm operation Electrical components and wiring (no cracks or
Operation (holding without drift, no leaks) split insulation)
Pins and retainers secure Electrical connections (secure, no corrosion)
Hoses and tubes (routing, condition) Rotation Bearing and Gearbox
Cylinder rods (no scores, nicks, or dents) Gearbox mounting cap screws visual inspection
Cylinder barrels (no dents) Motor mounting cap screws secure
Lower Tools Circuit Eccentric ring lock in place and secure
Operation, no leaks No leaks
Hoses (routing, condition) Rotation bearing/pinion gear teeth (no distortion, cracks,
Tool couplers (condition, operation, dust caps) or significant wear)
Hydraulic System Pressure Pinion to rotation bearing gear backlash
Outrigger system (2,500 psi) Gearbox internal lost motion
Upper boom (1,700 psi) Operation (smoothness and noise level)
Intermediate boom (1,650 psi) Rotation bearing inspection and measurement (after
Rotation (1,500 psi) 0.050″ increased wear from initial measurement)2
Lift (2,350 psi) Rotation bearing cap screws visual inspection
Digger/winch pressure (2,500 psi) Lift Cylinder
Pilot system (155-160 psi) Pivot bearings secure within cylinder eyes
Lower Control Station Operation, no leaks
Electrical components and wiring (no cracks or Holding valves (operation, no leaks)
split insulation) Rod (no scores, nicks, or dents)
Electrical connections (secure, no corrosion) Barrel (no dents)
Hydraulic valve spools (return to neutral, no sticking Extension Cylinders
or leaks) Upper boom extension cylinder trunnion pins secure
Hydraulic valve housings (no cracks or leaks) Upper and intermediate boom cylinder pins and
Panel night light operation retaining rings secure
Engine ignition switch operation Intermediate boom cylinder cap screw and jam nut
Drive outrigger/lower tools/radio control switch secure
operation Intermediate boom cylinder rod (no scores, nicks, or
Controls (operation) dents)
Switches (safety covers and seals intact) Intermediate boom cylinder barrel (no dents)
Digger speed switch Hoses and tubes (routing, condition)
Pressure gauge Operation, no leaks
Pedestal Lower Boom
Structure (welds intact, no deformation or cracks) Structure (welds intact, no deformation or cracks)
Hoses and tubes (routing, condition, no leaks) Lift cylinder pivot pin and retainers secure
Electrical components and wiring (no cracks or Slide bearing nuts and cap screws secure
split insulation) Slide bearings (no cracks or excessive wear)
Electrical connections (secure, no corrosion) Fasteners secure
Electrical connections (secure, no corrosion)

Appendix — Preventive Maintenance and Inspection Checklist

 Electrical components and wiring (no cracks or Jib
split insulation) Fiberglass condition (clean, undamaged)
Boom stow switch operation Bracket and mounting pins
Boom angle indicators Sheave (turns freely)
Intermediate Boom Sheave pin and retainer secure
Structure (welds intact, no deformation or cracks) Winch
Surface condition Gearbox mounting cap screws secure
Winch rope rollers turn freely Motor mounting cap screws secure
Pins and retainers secure Drum (welds intact, no deformation or cracks)
Fasteners secure Operation, no leaks
Slide bearing nuts and cap screws secure Winch line (condition, anchor point secure)
Slide bearings (no cracks or excessive wear) Auger Stow Bracket
Two-part load line attachment secure Structure (welds intact, no deformation or cracks)
Upper Boom Fasteners secure
Fiberglass fasteners secure Auger stow switch operation
Slide bearing nuts and cap screws secure Auger release mechanism operation
Slide bearings (no cracks or excessive wear) No leaks
Fiberglass condition (clean, undamaged) Digger
Boom Flares Operation, no leaks
Structure (welds intact, no deformation or cracks) Noise level
Fasteners secure Hoses (routing, condition)
Upper Boom Tip Bail pivot pin nuts secure
Structure (welds intact, no deformation or cracks) Digger Link and Hanger Bracket
Mounting to upper boom secure Structures (welds, slide bearing, no deformation, cracks)
Sheaves (condition, turn freely) Link pivot pin or retainers secure
Sheave pins and retainers secure Fasteners secure
Rope retaining pin above upper sheave in place Latch and latch keeper (alignment, operation)
Pole Guide Latch weldment lug operation
Structure (welds intact, no deformation or cracks) Auger and Extension Shaft
Tongs (no deformation or cracks) Flighting condition
Cap screws secure Teeth and pilot bit condition
Hoses and tubes (routing, condition) Windup sling lug, weld intact
Operation, no leaks Extension shaft, auger retaining cap screws secure
Couplers (condition, operation, dust caps) Extension shaft and auger straight
Boom Tip Power Package Hydraulic Overload Protection (HOP)
Hose carrier track (links pivot freely) Winch raise, digger dig, boom lower, intermediate
Fiberglass tube condition and upper boom extend disabled by HOP
Hoses and tubes (routing, condition), no leaks Side Load Protection
Digger couplers (condition, operation, dust caps) Counterclockwise sideslip: ________ lbs
Platform Clockwise sideslip: ________ lbs
Mounting fasteners and pins secure Lubrication
Storage lock detent pin operation Boom pin
Brake (adjustment, pad and rotor condition) Lift cylinder pins
Platform (condition, cleanliness) Auger stow bracket latch
Fall protection system condition Platform brake detent pin

Appendix — Preventive Maintenance and Inspection Checklist

 Digger hanger bracket latch pivot point Platform mounting pin and socket
Pole guide tong gear teeth Intermediate boom outer surface
Platform brake linkage Digger gearbox oil level
Auger windup sling (wire rope) Rotation gearbox oil level
Winch line (wire rope) Winch gearbox oil level
Required Maintenance (Regardless of Hours)
Annual Testing Dielectric test platform liner(s)
Dielectric test unit
1,000 Engine Hours/1 Year
Perform the 500 hour/6 month inspection Chassis
Rotation Bearing and Gearbox Engine (condition, operation)
Rotation bearing cap screws annual torque inspection Exhaust (condition, no leaks)
Rotation gearbox mounting cap screws annual Steering (operation)
torque inspection Fasteners and Pins
Lubrication All fasteners included on 500 hour/6 month checklist
Pump input shaft splines (no significant corrosion)
Change winch gearbox oil All pins and retainers included on 500 hour/6 month
Track oil change checklist (no significant corrosion)
Hydraulic Reservoir Structures
Collect oil sample for analysis1 All structures and welds included on 500 hour/6 month
Operator’s Station checklist (no significant corrosion)
Standup platform (secure, condition)
2,000 Engine Hours/2 Years
Perform the 1,000 hour/1 year inspection Clean or change filler hole strainer
Rotation Bearing and Gearbox Change filler/breather cap filter
Rotation bearing inspection and measurement (before Reservoir cover gasket condition
0.050″ increased wear from initial measurement)2 Change hydraulic oil
Hydraulic Reservoir Lubrication
Flush hydraulic system Change digger gearbox oil
Clean inside of reservoir Change rotation gearbox oil
Clean suction strainer
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.

Comments __________________________________________________________________________________

___________________________________________________________________________________________

Appendix — Preventive Maintenance and Inspection Checklist

 Accessory Checklist
Vehicle No. ________________________ Location __________________________ Date _________________

Model Number _________________ Serial Number ___________________ Inspector ____________________

Symbols
/O = Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable

1,000 PTO Hours or as Recommended by the Manufacturer

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

Appendix — Accessory Checklist

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

Pipe Thread T.F.F.T. Valve Cartridges (Standard SAE Cavity)

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

Compression Fittings Split Flanges

Tube Size Fitting Size T.F.F.T. Flange Size Thread Torque in-lbs (N•m)
1
/8″ thru /4″ 1
2 thru 4 1 /4
1 3
/4″ 3
/8″-16 250 to 350 (28 to 40)
5
/16″ 5 1 /4
3
1″ 3
/8″-16 325 to 425 (37 to 48)
3
/8″ thru 1″ 6 thru 16 2 /4
1
1 /4″
1 7
/16″-14 425 to 550 (48 to 62)
1 /2″
1 1
/2″-13 550 to 700 (62 to 79)

SUN Counterbalance Valves 2″ 1

/2″-13 650 to 800 (73 to 90)

Wrench Size Torque ft-lbs (N•m)

7
/8″ 30 to 35 (41 to 47)
11/8″ 45 to 50 (61 to 68)
11/4″ 150 to 160 (203 to 217)

Appendix — Torque Values

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

Tube and JIC Fittings

Misalignment of
marks show how much
nut was tightened

Tube Connection Swivel Nut or Hose

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

Appendix — Torque Values

 Basic JIC Symbols
Lines Methods of Operation

Line, pressure or tank Spring

Line, sense (for control) Manual

Component enclosure Manual, rotary )

Hydraulic
Flow, direction of Push button
Pneumatic

Lines crossing or Push/pull lever

Lines joining Pedal or treadle

Line with fixed restriction Mechanical

Flow control — adjustable, non-compensated Detent

Flow control — adjustable

Pressure compensated
(temperature and pressure compensated)

Station, testing, measurement,

Solenoid, single winding
power take-off or plugged port

Servo motor

Remote supply
Pilot pressure
Internal supply

Appendix — Basic JIC Symbols

Valves Cylinders

Check Double-acting

Counterbalance Single-acting, internal spring

On - off (manual shut-off) Single-acting, external spring

Pressure relief Fluid Storage

Vented
Reservoir
Pressurized
Pressure reducing

Above fluid level

Line, to reservoir
Two-position, two connection Below fluid level

)
Vented manifold
Two-position, three connection

Motors
Two-position, four connection
Hydraulic oscillator

Three-position, four connection

Fixed displacement

Hydraulic motor Variable displacement

Two-position, in transition

Bidirectional
Valves capable of infinite
positioning (horizontal bars
indicate infinite positioning ability) Pumps

Shuttle valve Fixed displacement

Hydraulic pump
Variable displacement
Typical closed center spool

Typical open center spool

Logic element, poppet type

Appendix — Basic JIC Symbols

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

Pressure compensated units

Accumulator, spring loaded
(arrow parallel to short side of symbol)

(
(
Accumulator, gas charged

Direction of shaft rotation

Weighted
(assume arrow on near side of shaft)

Filter, strainer Flowmeter

Filter with adjustable bypass Pressure switch

Heater Pressure gauge

Cooler Pressure sensor

Temperature controller Temperature gauge

Temperature cause or effect Quick disconnect

Appendix — Basic JIC Symbols

Appendix — Basic JIC Symbols
 Hydraulic System Schematics

SV1

AUG
RELEASE

SH2 LS

SH1

SV2

SH3

DV3

SV3

PV1 PV2 SV2 SV6 SV9

SV7 SV8 SV10
SV1

G2
FC1

CV1
G

SV5

RV1
2500 PSI
SV4 RV2
2000 PSI

Appendix — Hydraulic System Schematics

 DV3

PV1 PV2 SV2 SV6 SV9

SV7 SV8 SV10
SV1

G2
FC1

CV1
G

SV5

RV1
2500 PSI
SV4 RV2
2000 PSI

Drive/Outrigger/Tools Valve

Boom Functions Valve

SV3

AUG
RELEASE

SH2 LS

SH1

SV1

Pole Guide/Upper Cross-Ported Pilot Counterbalance Pump

Tools/Auger Release Operated Check Valve Valve

Reservoir

Appendix — Hydraulic System Schematics

 Basic Electrical Symbols

Relays
Circuit breaker
Simple

Fuse

Bistable
Capacitor

Air-core Latching
Coil
Iron-core

Logic
Connection

Switches
No connection
Single-pole, single-throw (SPST)

Battery
Single-pole, double-throw (SPDT)

Chassis or common return connected Double-pole, single throw (DPST)

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

Motor M

Appendix — Basic Electrical Symbols

Appendix — Basic Electrical Symbols
Wiring Line Diagrams

Above Rotation

Appendix — Wiring Line Diagrams

 Below Rotation

Appendix — Wiring Line Diagrams

Control Panel 1

Appendix — Wiring Line Diagrams

 Control Panel 2

Appendix — Wiring Line Diagrams

Control Panel 3

Appendix — Wiring Line Diagrams

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

Boom lower, intermedi- A short or loss of continuity. Check electric circuit of boom stow, auger stow, HOP.
ate and upper boom
extend, digger dig, and Boom stow switch is acti- Check boom stow switch.
winch raise functions will vated.
not operate.
Defective HOP pressure Test HOP system. Replace pressure switch if necessary.
switch.

Pole guide close/open Spool valve controlling Check solenoid resistance.

function will not operate pole guide tong function is
in one direction. inoperative.

Pole guide open function Pilot operated check valve Remove the pilot operated check valve from the pole guide tong
will not operate. is inoperative. cylinder. Replace pilot operated check valve.

Excessive heat genera- There are many possible Check possible causes. Repair source of the heat generation as
tion. causes of heat generation. necessary.

Rotation function will not Rotation gearbox motor Install a flowmeter in the rotation pressure line. If there is flow but no
operate. worn out or failed. movement, the rotation gearbox motor has failed. Repair or replace
rotation motor as necessary.

No drive/outrigger and Electrical system failure. Troubleshoot and repair electrical system.
no boom functions from
radio operate.

All boom functions oper- Low large side pump flow. Check pump with flowmeter. Repair or replace pump as necessary.
ate slowly from lower
controls and radio. Restriction in pressure line. Check for hot spots in lines. Restricted area will feel warmer than rest
of system. Remove restriction.

Cylinder drifts. Internal leakage in cylinder. Test cylinder. If internal leakage is confirmed, repair seals in cylinder
or replace cylinder.

Leakage past holding valve. Test cylinder. If leakage past a holding valve is confirmed and it is a
counterbalance valve, replace the valve or adjust the valve using an
Altec test block. If the holding valve is a pilot operated check valve,
replace the valve cartridge.

Cylinder extends instead Severe internal leakage in Test cylinder. If internal leakage is confirmed, repair seals in cylinder or
of retracting when the cylinder. replace cylinder. If leakage past a holding valve is confirmed, replace
hand control is operated the valve or adjust the valve using an Altec test block.
to retract the cylinder.

Winch and digger oper- Combiner valve in drive/ Check for 12 volts at valve solenoid.
ate slowly from lower outrigger/tools valve not
controls and radio. shifting.

Unloader valve in drive/ Check for 12 volts at valve solenoid.

outrigger/tools valve not
shifting.

Defective pump. Install flowmeter in pressure line for digger/winch and check vane
section pump flow.

Restriction in pressure line. Check for hot spots in lines. Restricted area will feel warmer than rest
of system. Remove restriction.

All boom, winch and Low pilot pressure setting. Replace pilot pressure reducing valve.
digger functions operate
slowly from radio only. Incorrect threshold Reprogram threshold parameter setting(s) with radio.
setting(s).

Appendix — Troubleshooting Chart

Symptom Possible Cause Test Procedure/Corrective Action

Difficulty starting boom Relief valve cartridge con- Purge the relief valve cartridge.
operation smoothly. tamination.

Boom function(s) will not Incorrect threshold setting(s). Reprogram threshold parameter setting(s) with radio.
operate slowly from radio.

Shut off response delayed Unloader valve staying open Check electrical operation of the unloader valve.
when a control is returned when control is returned to
to neutral. neutral.

Appendix — Troubleshooting Chart

 Dielectric Test Form for DB37
Without Personnel Jib (46 kV and Below)

Bonding
Jumper
Minimum Extension
Placard

Ground/Return High Voltage

Lead Test Lead

Controls High Voltage

Transformer Ground
Polyethylene Pad

Procedure

1. Read and understand the dielectric test information in the Maintenance Manual and ANSI requirements.
2. Insulate the unit from ground by placing polyethylene pads beneath each outrigger leg.
3. If the unit is so equipped, install the platform(s) on the boom tip.
4. Fully retract the intermediate boom.
5. Extend the upper boom so the minimum extension placard is beyond the farthest extent of all metal compo-
nents on or attached to the intermediate boom tip.
6. The winch line must not bridge extended upper boom.
7. Electrically bond all metal at the boom tip to ensure all possible current paths are considered. Include all con-
ductive brackets, air plunger switches, hydraulic valves, controls, cylinders, jib brackets, etc.
8. Attach the ground/return lead to the intermediate boom.
9. Attach the high voltage test lead (insulated from ground) to the boom tip.
10. Position the boom at the same angle as recorded on previous test report(s) for this unit. Record the boom
angle used during the test.
11. Do not use cancel (null) circuit if the tester is so equipped.
12. Gradually increase the voltage to 100 kV (60 hertz).
13. 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 below.

General Information

Model number ________________________________ Serial number _________________________________

Test device number ____________________________ Boom angle (degrees) ___________________________

Appendix — Dielectric Test Forms

Conclusion

Leakage reading (microamp) ___________________________________________________________________

Pass _____ Fail (reason) _____________________________________________________________________

Comments _________________________________________________________________________________

__________________________________________________________________________________________

Signature of technician ______________________________________ Date of test ______________________

Appendix — Dielectric Test Forms

 DC Periodic Dielectric Test For All Category A, B, and C
Insulating Telescopic Aerials and Insulating Digger Derricks
(For DC Test Device With Output Current Metering Only)
Upper Boom Extension
Upper Boom Test ­– ­– ­– ­– ­– 35″ Minimum 40″ Minimum
AT30-G D2/3/4A
AT30-GV D2/3/4B
LS40/45 DB
DC
Minimum DL/DM
Bonding Jumper for Extension
Intermediate Boom DLB/DMB

High Voltage
Test Lead
2′ Minimum

Ground Post Control Box

Drawing not intended to represent a specific model

Discharge Stick

Procedure

1. Read and understand the dielectric test information in the Maintenance Manual, ANSI requirements, and the
manual for the test device being used.
2. This procedure is for a DC test device with output current metering only. Do not use this procedure when using a
DC test device that measures the return current instead of the output current. If equipped with a selector switch,
set the switch to Ground Return.
3. The test area should be dry and appropriately roped off to prevent bystanders from entering the test area.
4. Ground chassis, test device or control box, and discharge stick as shown.
5. No isolation pads are required under the vehicle tires or outriggers.
6. Set up booms to maintain at least 2′ (61 cm) of clearance between conductive components as shown.
7. Electrically bond all metal at the boom tip to ensure all possible current paths are considered. Include all conduc-
tive brackets, air plunger switches, hydraulic valves, controls, cylinders, jib brackets, etc.
8. Extend upper boom to minimum extension length for dielectric test. If possible, fully retract all intermediate
booms extending only the insulating upper boom. Attach a bonding jumper between intermediate boom tip, if so
equipped, and lower base boom.
9. Attach the high voltage test lead and bonding jumpers as shown for the upper boom test.
10. It is not necessary to use the meter receptacle on the upper boom of Category A and B machines for the upper
boom test. However, whether the meter receptacle is used or not, all internal connections to this receptacle must
be checked to verify that all current paths through the boom are properly connected to ensure proper function.
11. Voltage and maximum allowable leakage for the upper boom test are as follows.
a. Derricks and Category C – 46 kV and below – 56 microamps at 56 kV after 3 minutes
b. Category A/B – 46 kV and below – 28 microamps at 56 kV after 3 minutes
c. Category A/B – 69 kV – 42 microamps at 84 kV after 3 minutes
d. Category A/B – 138 kV – 84 microamps at 168 kV after 3 minutes
12. To test the upper boom, it may be helpful, though not required, to increase the angle of the boom to help keep
the high voltage lead from contacting the ground or other conductive components. Gradually increase the volt-
age to the proper level. Hold for 3 minutes. If flashover occurs or the leakage rate exceeds the maximum value,
the unit has failed the test. Record leakage reading.

Appendix — Dielectric Test Forms

13. If the derrick is equipped with a personnel jib, perform a second test with the jib in place, platform mounted and
pull-out controls connected. Attach high voltage lead to the new platform position at the end of the jib with all
conductive components properly bonded. Repeat the upper boom test procedure and record leakage reading.

General Information

Model number ________________________________ Serial number _________________________________

Test device number ____________________________ Category/voltage rating _________________________

Conclusion

Upper boom leakage reading (microamp) _______________________________________________________

Pass _____ Fail (reason) _____________________________________________________________________

Comments _________________________________________________________________________________

__________________________________________________________________________________________

Signature of technician _____________________________________ Date of test _______________________

Appendix — Dielectric Test Forms

 Periodic Dielectric Test Form for Platform Liners
Either method may be used.

Wet Method Setup

1. Connect a ground lead to the steel tank. High Voltage Lead 6″ (15.24 cm) Maximum

2. Immerse the liner in the tank and fill with conductive fluid
Liner
until the level around both the inner and outer surfaces of the
liner is within 6″ (15.24 cm) of the top of the liner. Conductive
Fluid
3. Suspend the high voltage lead in the fluid within the liner.
Ground Tank
Dry Method Setup

1. Refer to TRS-0001 to apply conductive foil to the liner and High Voltage Lead 6″ (15.24 cm) Maximum
conduct the test. Liner
2. Connect a ground to the outer conductive foil.

3. Connect the high voltage lead to the inner conductive foil. Conductive
Foil
Testing (Wet or Dry) Ground

1. Apply the test voltage to the conductive fluid or foil. Voltage may be either 35 kV (60 hertz) for 1 minute or 100
kV DC for 3 minutes.

2. If flashover occurs, or the liner wall punctures, the liner has failed the test.

3. Turn off the test voltage (be sure the voltage meter indicates zero voltage). Remove the high voltage lead.
Remove the liner from the tank or remove the foil covering.

4. The test for more than one liner may be recorded on the same form providing the same setup is used to elimi-
nate external variables.

Conclusion

Unit Serial No. Liner Part No. Liner Serial No. Pass (Initials) Fail (Reason)
_____________ _____________ _____________ ___________ __________________________________

_____________ _____________ _____________ ___________ __________________________________

_____________ _____________ _____________ ___________ __________________________________

_____________ _____________ _____________ ___________ __________________________________

_____________ _____________ _____________ ___________ __________________________________

_____________ _____________ _____________ ___________ __________________________________

_____________ _____________ _____________ ___________ __________________________________

Wet/dry __________ Test voltage _________ Test device number ____________________________________

Date _____________________ Test performed by _________________________________________________

Comments _________________________________________________________________________________

__________________________________________________________________________________________

Appendix — Dielectric Test Forms

Appendix — Dielectric Test Forms
 Stability Test Form for DB37 Digger Derrick Use

Test
Weight

Procedure

1. Perform the stability test in accordance with applicable ANSI or CSA requirements.
2. Fill out all information on this form as a record of a completed stability test.
3. Remove all platforms, pole guides, and material handling jibs before conducting this stability test.
4. Position the unit on a level surface with the outriggers properly extended and the booms fully extended. Test
weight and boom angle are shown on the capacity chart for digger derrick use located at the lower controls.
5. After the test has been completed, torque all accessible rotation bearing cap screws to 225 foot-pounds using
a circular pattern (only required following initial stability test at the time of initial installation of unit on chassis).
6. After the test has been completed, torque the rotation gearbox mounting cap screws to 115 foot-pounds (only
required following initial stability test at the time of initial installation of unit on chassis).

General Information

Model number ________________________________ Serial number _________________________________

Winch line test weight (lbs) ___________ Thickness of outrigger pads (inches — N/A if not used) ____________

Boom angle (degrees) ________________________________________________________________________

Conclusion

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

Pass _____ Fail (reason) _____________________________________________________________________

Comments _________________________________________________________________________________

__________________________________________________________________________________________

Signature of technician _____________________________________ Date of test _______________________

Appendix — Stability Test Form
Appendix — Stability Test Form
 Stability Test Form for DB37 Platform Use

Test
Weight

Test Weight
Platform Level Five Degree Slope
The test weight indicated considers the weight and center of
gravity of the platform, platform mounting bracket, and test load Single, 1-man 670 620

Procedure

1. Perform the stability test in accordance with applicable ANSI or CSA requirements.
2. Fill out all information on this form as a record of a completed stability test.
3. Remove all boom tip options.
4. Position the unit on a level surface with the outriggers fully extended.
5. Raise the booms out of the rest enough to allow rotation.
6. Fully extend the intermediate and upper booms.
7. Apply the test weight from the chart above to the winch line. Make sure the booms and auger will still clear the
rest during rotation.
8. Rotate the turntable 360 degrees.
9. Position the unit on a five degree slope with the outriggers fully extended and the curb side downhill.
10. Raise the booms out of the rest enough to allow rotation.
11. Fully extend the intermediate and upper booms.
12. Apply the test weight from the chart above to the winch line. With the booms off the front of the carrier, make
sure the booms and auger will still clear the rest during rotation.
13. Rotate the turntable 360 degrees.
14. After the test has been completed, torque all accessible rotation bearing cap screws to 225 foot-pounds using
a circular pattern (only required following initial stability test at the time of initial installation of unit on chassis).
15. After the test has been completed, torque the rotation gearbox mounting cap screws to 115 foot-pounds (only
required following initial stability test at the time of initial installation of unit on chassis).

General Information

Model number ________________________________ Serial number _________________________________

Boom angle (degrees) _____________ Thickness of outrigger pads (inches — N/A if not used) ______________

Rated platform capacity (pounds) ________________________________________________________________

Level Surface Test

Test weight on winch line = 1.5 x rated capacity + platform + platform bracket = _____________________ pounds

Five Degree Slope Test

Test weight on winch line = 1.33 x rated capacity + platform + platform bracket = _____________________ pounds

Appendix — Stability Test Form

Conclusion

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

Load moment limiter trip value (if so equipped) _____________________________________________________

Pass _____ Fail (reason) _____________________________________________________________________

Comments _________________________________________________________________________________

__________________________________________________________________________________________

Signature of technician _____________________________________ Date of test _______________________

Appendix — Stability Test Form

 Stability Test Form for DB37 Combined Platform Use

Test
Weight

Test Weight
Platform Level Five Degree Slope
1-man, combined use 800 725

Procedure

1. Perform the stability test in accordance with applicable ANSI or CSA requirements.
2. Fill out all information on this form as a record of a completed stability test.
3. Position the unit on a level surface with the outriggers fully extended.
4. Fully extend the boom.
5. Install 8′ material handling jib (fully retracted, tilt position 3).
6. Raise the boom to 35 degrees.
7. Apply the level test weight from the chart above to the winch line.
8. Complete a 360 degree rotation test.
9. Position the unit on a five degree slope with the outriggers extended.
10. Fully extend the boom.
11. Install 8′ material handling jib (fully retracted, tilt position 3).
12. Raise the boom to 35 degrees.
13. Apply the five degree slope test weight from the chart above to the winch line.
14. Complete a 360 degree rotation test.
15. This test may be conducted without a platform or jib by adding 125 pounds for the platform and 150 pounds
for the jib.
16. After the test has been completed, torque all accessible rotation bearing cap screws to 225 foot-pounds using
a circular pattern (only required following initial stability test at the time of initial installation of unit on chassis).
17. After the test has been completed, torque the rotation gearbox mounting cap screws to 115 foot-pounds (only
required following initial stability test at the time of initial installation of unit on chassis).

General Information

Model number ________________________________ Serial number _________________________________

Boom angle (degrees) _____________ Thickness of outrigger pads (inches — N/A if not used) ______________

Rated platform capacity (pounds) ________________________________________________________________

Appendix — Stability Test Form

Level Surface Test

Test weight on winch line = 1.5 x rated capacity + platform + platform bracket = ______________________ pounds

Five Degree Slope Test

Test weight on winch line = 1.33 x rated capacity + platform + platform bracket = _____________________ pounds

Conclusion

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

Load moment limiter trip value (if so equipped) _____________________________________________________

Pass _____ Fail (reason) _____________________________________________________________________

Comments _________________________________________________________________________________

__________________________________________________________________________________________

Signature of technician _____________________________________ Date of test _______________________

Appendix — Stability Test Form

 Stability Test Form for DB37 Dual Platform Use

Test
Weight

Test Weight
Platform Equivalent Platform Capacity Level Five Degree Slope
Dual, 1-man 925 1,245 1,140

Procedure

1. Perform the stability test in accordance with applicable ANSI or CSA requirements.
2. Fill out all information on this form as a record of a completed stability test.
3. Remove all boom tip options.
4. Position the unit on a level surface with the outriggers extended.
5. Fully extend the boom and raise the boom to position the winch line at a 15′ load radius (59 degrees) over the
curb side of the unit.
6. Apply the equivalent platform capacity from the chart above to the winch line.
7. Boom down to engage HOP.
8. If the unit is stable per definition, disable HOP and apply the level test weight from the chart above to the
winch line. Do not raise or reposition the boom when adding weight.
9. Slowly lift the weight high enough to provide adequate clearance for full rotation and rotate boom 360 de-
grees.
10. Reactivate HOP and verify that it is operational.
11. Repeat steps 4 to 7 on a five degree slope with the unit positioned with the curb side down hill, applying the
equivalent platform capacity from the chart above to the winch line.
12. If the unit is stable per definition, disable HOP and apply the five degree test weight from the chart above to
the winch line. Do not raise or reposition the boom when adding weight.
13. Slowly lift the weight high enough to provide adequate clearance for full rotation and rotate boom 360 de-
grees.
14. Reactivate HOP.
15. Position the unit on a level surface with the outriggers extended.
16. Fully extend the boom and raise the boom to position the winch line at a 15′ load radius (59 degrees) off of
the side of the unit.
17. Apply the equivalent platform capacity from the chart above to the winch line.
18. Boom down to verify HOP is active.
19. After the test has been completed, torque all accessible rotation bearing cap screws to 225 foot-pounds using
a circular pattern (only required following initial stability test at the time of initial installation of unit on chassis).
20. After the test has been completed, torque the rotation gearbox mounting cap screws to 115 foot-pounds (only
required following initial stability test at the time of initial installation of unit on chassis).
Appendix — Stability Test Form
General Information

Model number ________________________________ Serial number _________________________________

Boom angle (degrees) _____________ Thickness of outrigger pads (inches — N/A if not used) ______________

Rated platform capacity (pounds) ________________________________________________________________

Level Surface Test

Test weight on winch line = 1.5 x rated capacity + platform + platform bracket = ______________________ pounds

Five Degree Slope Test

Test weight on winch line = 1.33 x rated capacity + platform + platform bracket = _____________________ pounds

Conclusion

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

Load moment limiter trip value (if so equipped) _____________________________________________________

Pass _____ Fail (reason) _____________________________________________________________________

Comments _________________________________________________________________________________

__________________________________________________________________________________________

Signature of technician _____________________________________ Date of test _______________________

Appendix — Stability Test Form