Professional Documents
Culture Documents
This unit is the result of Altecs advanced technology and quality awareness in design,
engineering, and manufacturing. At the time of delivery from the factory, this unit met or
exceeded all applicable requirements of the American National Standards Institute. All
information, illustrations, and specifications contained within this manual are based on the
latest product information available at the time of publication. It is essential that all personnel
involved in the use and/or care of this unit read and understand the Operators Manual.
Given reasonable care and operation, according to the guidelines set forth in the manuals
provided, this unit will provide many years of excellent service before requiring major
maintenance.
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 conduc-
tors. Non-insulated units have no dielectric rating. Maintain safe clearances, as
defined by federal, state, and local authorities, and your employer, from energized
conductors.
No unit can provide absolute safety when in proximity to energized conductors. No unit is
designed or intended to replace or supersede any protective device or safe work practice
relating to work in proximity to energized conductors. When in proximity to energized
conductors, this unit shall only be used by trained personnel using their companys accepted
work methods, safety procedures, and protective equipment. Training manuals are available
from a variety of sources.
Set-up requirements, work procedures, and safety precautions for each particular situation
are the responsibility of the personnel involved in the use and/or care of this unit.
3-02
The terms danger, warning, and caution represent vary-
About This Manual
ing degrees of personal injury and/or property damage
This manual provides instruction to safely inspect, repair, that could result if the preventive instructions are not
and troubleshoot the unit. Charts and figures are pro- followed. The following paragraphs from ANSI publica-
vided to support the text. Because options vary from one tions explain each term.
model to another, some figures may only be a represen-
tation of what is actually on the unit. Danger
Indicates an imminently hazardous situation
Knowledge of the information in this manual combined which, if not avoided, will result in death or
with proper skills and training in hydraulic, electrical, and serious injury. This signal word is to be limited to
mechanical systems, provide a basis for safely maintain- the most extreme situations.
ing the unit. Read and understand the applicable proce-
dure before beginning. Warning
Indicates a potentially hazardous situation which,
Contact the following organizations for additional infor- if not avoided, could result in death or serious
mation. injury.
Maintenance Manual 1
3. Even new hydraulic oil from a barrel or other con-
Structures
tainer from the petroleum company is highly con-
taminated compared to the filtered oil of the hydraulic The basic structural components are the pedestal, turn-
system. All oil being added to the reservoir must be table, lower boom, upper boom, and the outriggers. The
filtered before using it to power the unit. This is most steel structures are made in the form of a closed box
effectively done by running the oil through a micron structure in order to resist torsional loading as well as
filter as it is put into the reservoir. If this is not tension, compression and bending loads to which the
possible, allow the oil to circulate through the system unit may be subjected. Careful consideration has been
for approximately 15 minutes before operating the given to the elimination of stress risers caused by sharp
unit. Change the filter cartridges soon after using cornered openings and abrupt changes in section, to
them to filter any substantial quantity of new hydrau- minimize the possibility of fatigue cracks forming.
lic oil. A new barrel of oil is moisture free, however,
this may not be true of barrels which have not been Periodic inspection of the structures is recommended to
stored properly. be certain that there has been no deformation, abnormal
wear or abrasion, interference between moving parts, or
4. Always be certain that the shutoff valve between the cracking of the welds on structural members. Any such
reservoir and the pump inlet and the shutoff valve at problem found should be brought to the attention of an
the return line filter are completely open before Altec representative so that the cause can be determined
operating the pump. and steps taken to prevent a recurrence.
Unauthorized alterations or modifications will void the Even when protective measures have been taken prior to
warranty. However, of a greater concern is the possibility storage, some degradation of performance must be
that unauthorized changes could adversely affect the expected when the equipment is put back into use.
units operation that could endanger personnel and/or
damage property. Altec will not be responsible for unau- One of the most noticeable effects of prolonged periods
thorized alterations or modifications that cause death, of non-use is seal deformation. By its nature, hydraulic
serious injury, and/or property damage. equipment generally has a number of heavy, cylindrical
actuators. As these components are allowed to rest in
Altec Industries, Inc. assumes no liability for any per- one position for a period of time, the seals on the piston
sonal injury and/or property damage related to the use of will tend to flatten along the loaded side. Since the seal
this manual when performing testing, operating, mainte- material is synthetic, its elasticity is limited and it may not
nance and/or repair procedures on this Altec unit. resume its original shape completely. At best, there will
be some failure to seal well for a short period of time after
putting the equipment back into use. At worst, the seal
will never resume its original shape and will have to be
replaced.
2 Maintenance Manual
Protective Measures Operators and maintenance personnel should make
If it is known that equipment will be stored for a month or sure there is no build-up of tree branches, etc. in the area
more, some steps should be taken to preserve the of the leveling cable sheave at the platform and the area
equipment. of the lower boom near the turntable. This is most likely
to occur on units used in tree-trimming work.
1. The best preservative is to fully cycle (operate) the
equipment once weekly if even for a short time. The interior and exterior of the fiberglass boom and lower
boom insert must be kept in good condition to preserve
2. Coat exposed ferrous (iron or steel) bare metal the dielectric integrity of the insulating components.
surfaces with a light grease or heavy oil compatible Clean the interior as necessary using a pressure washer
with system hydraulic oil. This includes cylinder rods, and mild detergent. After pressure washing, throroughly
shafts, gears, linkages, and unpainted parts. rinse the interior to remove detergent and elevate the
booms to the vertical position for draining and drying.
3. Top off fluid reservoirs to allow as little air space as Wash the exterior of the upper boom, lower boom insert,
possible, to limit the effects of condensation. Re- and the fiberglass platform with a mild detergent, using
move excess oil before operating to limit the chance care not to make surface scratches. After the exterior
of overflow when cylinders are cycled. surfaces are clean and dry, polish them with Formula 5
Clean N Glaze Compound or an equivalent. The booms
4. Cover or wrap exposed rubber or neoprene parts should be polished by hand, not with a buffer. Nothing
with an ultraviolet resistant covering to shield the should be used for coating a fiberglass component which
parts from sun exposure. will reduce the dielectric strength or cause surface flash-
over.
5. Unplug electrical connectors and apply a dielectric
grease or an aerosol product designed for protecting In the event that cuts or deep scratches are discovered
electrical connectors. Plug the connector back to- in the fiberglass components, it is recommended that an
gether. Altec representative be contacted to evaluate the effect
of the damage on structural integrity and to determine if
6. Cover switch panels and control panels to prevent the damage is repairable. Surface nicks that only effect
direct intrusion of rain or moisture, while allowing air the gelcoat can be filled with a gelcoat kit. Fill the nick and
to circulate over the panel. sand smooth with a 600 grit wet or dry sandpaper. Clean
afterwards with Formula Five Clean n Glaze compound.
7. Cover personnel platforms to prevent the accumula-
tion of water in the platform.
Tightening of Fasteners
8. Shield fiberglass components from the sun and other The standard quality fastener used on the unit is a zinc
elements, if stored outside. plated, SAE Grade 5, steel cap screw. SAE Grade 8 cap
screws are used where the higher strength is required in
the design. Special cap screws are used at the elbow
Cleaning the Unit and Fiberglass bearing and the rotation bearing to handle the loads on
Any piece of equipment which is kept clean and neat these components. A variety of other fasteners such as
looking is the reflection of a maintenance department flat head screws, socket head screws, and button head
which has pride in its work. It will also have a positive screws are also used on the unit. It is good maintenance
effect on the operators. They are more likely to treat the practice to check all of the fasteners occasionally to
unit with reasonable care if they see that the mainte- make certain they are tight. Use the Torque Values in the
nance crew cares enough to keep it looking good. Appendix as a guide to determine how tight the various
bolts should be tightened.
When washing inside the pedestal with the cover off, do
not spray water on or around the fill cap of the oil The following is a list of fasteners to which particular
reservoir. This could spray water inside the oil cap. attention should be given.
It is common for debris to accumulate in the bottom of the Pedestal mounting bolts
platforms or liners. Regularly clean out all such material Rotation gearbox mounting bolts
because of the abuse to the platform or liner bottom All pin retainer bolts
aggravated by the weight of the lineman standing on it. Outrigger attachment bolts
Boom end attachment bolts
Maintenance Manual 3
Boom insert attachment bolts Inspection Marks
Elbow bearing attachment bolts
Attachment bolts for upper boom to elbow weldment Nuts or cap screws with locking patch element used in
Platform mounting bolts combination with inspection marks are used at specific
locations on the unit that are visible to the operator during
daily inspections.
Lockwiring
All critical fasteners on the unit must be Iockwired. This If any inspection marks are found to be cracked or broken
includes bolts through forged pin retainers in pins, all during inspection, the original mark must be totally re-
turnbuckles on leveling cables and insulator rods, and moved. The fastener torque must be checked (if no
certain other mounting or retaining bolts. Lockwires must damage is evident) or the fastener replaced and torqued
be installed in a way that tends to pull the fastener in the (if damage is evident), and the inspection mark reap-
direction which would tighten it. An aircraft type wire plied.
should be used. It should be relatively soft. This wire is
easy to work with and will produce neat and effective The inspection lacquer (refer to Service Tools and Sup-
Iockwires. plies in the Appendix) should not be used after the
expiration date printed on the container.
Twist lockwires between the fastener and the anchor
point. At least three full twists should remain on the Use the following procedure to apply a new inspection
standing end of the Iockwire when it is trimmed off. mark.
Overtwisting a Iockwire will tend to work harden the wire
which may cause it to break. 1. Remove the majority of the original inspection mark
by chipping it off with a chisel or other cutting method.
Pliers used in Iockwiring should have smooth, flat sur- Do not damage the surface on the nut, fastener,
faces to minimize working or cutting the wire, thus washer, and part or structure being attached to.
weakening it. With a small amount of practice, a me-
chanic can become skilled at installing neat and effective
Iockwires. Warning
Death or serious injury can result from improper use
of solvents. Follow the manufacturers label for proper
use and disposal.
4 Maintenance Manual
Other welds to inspect are anywhere a change in cross
Pins
section takes place on the booms, turntable, or pedestal.
All pins on the unit have been plated to prevent rusting Pay particular attention to where the lower boom cylinder
and to provide long wear for those pins mating with self- meets the turntable and lower boom.
lubricating bearings.
Maintenance Manual 5
A Preventive Maintenance and Inspection Checklist is Upper Boom Side Inspection
provided in the Appendix. Use this checklist when per- 1. Remove and discard the protective plastic caps from
forming routine maintenance and inspections to insure the cap screw heads.
no areas are overlooked. Keep permanent, written, and
dated records of all service performed on the unit. 2. Inspection should be done in a star or crisscross
pattern as shown in Figure 4.
Routine maintenance is performed on different compo-
nents of the unit at different times (refer to the Preventive
Maintenance and Inspection Checklist in the Appendix).
1 8
More frequent maintenance may be necessary if the unit 15 13
is operated under severe conditions. In addition to the 10
6
Preventive Maintenance and Inspection Checklist rec-
ommendations, follow these recommendations on new 3
11
units. 17
18
Measure the turntable tilt before using a new unit. 12
Change the return line filter after the first 15 to 25 4
PTO hours. 5
9
Gearbox manufacturers recommend an initial oil 14
7 16
change after the first 15 to 25 PTO hours. 2
6 Maintenance Manual
Lower Boom Side Inspection Rotation Bearing Cap Screw
1. Remove the cover from the elbow area to gain Inspection Procedure
access to the elbow bearing cap screws inside the Special high-strength 3/4″ cap screws are used to secure
lower boom. If the plastic caps are on the cap screw the rotation bearing to the pedestal and the turntable.
heads, remove and discard them. The rotation bearing cap screws are torqued at the
factory to 325 foot-pounds. Rotation bearing cap screw
2. On the lower boom side, only inspect one cap screw heads may be colored and/or plastic caps are installed
per quadrant (refer to Figure 5). over the heads to help identify the new fasteners.
Attention
11 1 Use a 3/4″ drive click-type manual torque wrench,
13
accurately calibrated, for the installation of the rota-
8 6 tion bearing cap screws. Torque the cap screws by
15 applying a smooth pull on the torque wrench without
jerking. Do not overtighten the cap screws.
3 9
Depending on the particular unit this procedure is being
16 performed on, components will need to be removed to
10 make the rotation bearing cap screws accessible for
4
removal. It is important that experienced. Trained me-
chanics perform this procedure and are aware of the
14
5 process needed to make the rotation bearing accessible
7 for removal.
2
12
Caution
Failure to keep the rotation bearing cap screws
Figure 5 Lower Boom properly tightened may lead to fatigue failure of the
cap screws and consequent damage to the unit.
3. Check the torque on a cap screw at 200 foot-pounds. Insufficient or uneven cap screw tightness may also
contribute to reduced life of the rotation bearing.
4. If any of the cap screws that are checked move, they
should be marked and all the remaining cap screws Visual Inspection Procedure
checked in the pattern shown in Figure 5. To check Visually inspect both sets of rotation bearing cap screws
the torque on all the cap screws, it may be necessary looking for any evidence that a cap screw is loose. Check
to remove the leveling cable sheave at the elbow. for loose washers under the heads of the cap screws by
trying to turn each washer by hand. If movement is
5. The retorquing procedure, steps 4-6, on the upper shown, all the cap screws must be retorqued using the
boom side, should be followed when loose cap Retorquing Procedure.
screws require all cap screws to be inspected on the
lower boom side. Annual Torque Inspection Procedure
Some seating in of the cap screw threads and mounting
Visual Inspection Procedure surfaces may occur in any bolted joint during the initial
Visually inspect both sets of cap screws retaining the break-in period, causing a partial loss of cap screw
elbow bearing. Check for loose washers under the heads tightness without any cap screw rotation. Randomly
of the cap screws. Also check for evidence of movement select four to five cap screws each on both the turntable
between the bearing and boom weldment. Movement and pedestal that are accessible with a torque wrench
can be checked by raising the upper boom a few feet out without removing major components. Select cap screws
of the boom rest and rocking the upper boom side to side. that are evenly spaced around the pattern. Remove and
If there is any indication or movement or a loose washer, discard any protective caps from these cap screws.
retorque the cap screws as described in the Annual Check the selected cap screws to be sure they are
Inspection Procedure. torqued to 295 foot-pounds or 90 percent of the normal
Maintenance Manual 7
installation torque of 325 foot-pounds. Use an accurate 4. Torque cap screw number 2 to 325 foot-pounds
torque wrench, calibrated on a regular basis. If one or watching it for any rotation.
more of these cap screws are loose, check the torque on
all the cap screws in the pattern as described in the 5. Continue around the pattern shown in the figure,
Retorquing Procedure. If the rotation bearing is replaced torquing each cap screw and watching it for rotation
or removed, follow the same inspection intervals. until the entire pattern is complete.
Retorquing Procedure 6. If any of the cap screws rotated when being torqued
Attention in steps 3 through 5, retorque all cap screws again
Use a 3/4″ drive click-type manual torque wrench, beginning at number 1. Go around in a circular
accurately calibrated, for the inspection of these cap pattern this time instead of in the numbered order.
screws. Torque the cap screws by applying a smooth
pull on the torque wrench without jerking. Do not 7. Do steps 1 through 6 on the pedestal side of the
overtighten the cap screws. rotation bearing.
Depending on the particular unit this procedure is being The same pattern applies to all unit types and mounting
performed on, various components will need to be re- arrangements. Number one cap screw can be at any
moved to make the rotation bearing cap screws acces- location on the bearing with the remainder of the pattern
sible for retorquing. It is important that experienced, shifted accordingly. Components will need to be re-
trained mechanics will perform this procedure and that moved for access to all cap screws.
they are aware of the process needed to properly torque
rotation bearing cap screws.
3. Look at the hole in the washer. Notice that it has a Figure 7 Turntable
more rounded edge on one side of the washer. Install
the washer with the rounded edge of the washer The same torque pattern applies to all unit types. Com-
toward the cap screw head. Reinstall it into the ponents will need to be removed for access to all cap
bearing and torque it to 325 foot-pounds. screws.
Figure 6 Pedestal
8 Maintenance Manual
Use caution when access covers have been removed to This information should be recorded and kept up to date.
service the unit. Pinch points and shear points may exist Any notes on repairs or dielectric testing should also be
between moving parts. Replace the access covers im- recorded and filed.
mediately after servicing.
Lubricate the unit as recommended by the Preventive
Attention Maintenance and Inspection Checklist.
Only use Altec supplied cap screws and washers to
install the rotation gearbox. As mentioned in the bearings section of this manual, the
self-lubricating and oil impregnated bronze bushings are
Use an accurate 3/4″ drive click-type manual torque self-lubricating, and require no lubrication. The self lubri-
wrench for the inspection of these cap screws. Torque cating bearings are used at both boom pivots, the large
the cap screws by a smooth pull on the torque leveling sheaves, the upper boom linkage pivots, and the
wrench without jerking. Do not overtighten the cap platform rotators. Oil impregnated bronze bushings are
screws. used on the rest of the idler sheaves and the upper
control linkage.
Visual Inspection Procedure
Perform this visual inspection procedure as recommended There are bearings that require lubrication with a chassis
by the Preventive Maintenance and Inspection Check- lubricant. The spherical bearings in the ends of the lower
list. boom cylinder require periodic lubrication. The rotation
gear has a fitting located on the front of the turntable.
Visually inspect all rotation gearbox cap screws, looking Rotate the unit through two full revolutions while lubricat-
for any evidence that a cap screw is loose. Check for ing the bearings. The top bearing on the rotation gearbox
loose washers under the heads of the cap screws by requires periodic lubrication. The elbow rotation bearing
trying to turn each washer by hand. If movement is has a fitting located on the outside of the outer race.
indicated, retorque all the cap screws. Lubricate the bearing in several positions of the upper
boom. After lubrication, fold/unfold the upper boom
Annual Torque Inspection Procedure through two full cycles.
Check the cap screws to be sure they are torqued to 203
foot-pounds (284 Nm) or 90 percent of the normal Lubricate the inner outrigger legs with a molygrease.
installation torque of 225 foot-pounds (305 Nm). Use a Excessive lubricant on or around the legs will attract dust
regularly calibrated, accurate torque wrench. If one or and form an abrasive substance.
more of these cap screws turns before the wrench clicks,
retorque all the cap screws to 225 foot-pounds (305 The rotation gearbox requires SAE 140 Worm Gear Oil.
Nm). If the rotation gearbox is replaced or removed, It should be checked and maintained at a level approxi-
follow the same inspection intervals. mately half full.
Maintenance Manual 9
Lubrication Chart and Diagram
Service items identified by the symbol(s) at the appropriate level.
85 hours/1 month 500 hours/6 months 1,000 hours/1 year 2,000 hours/2 year If disassembled
¿
Letter Lubricant Application Method
C Chassis Grease Multipurpose lithium base grease with good water Grease gun
resistance, rust inhibition, oxidation stability, and extreme pressure properties.
G Open Face Gear Lubricant Spray lubricant that penetrates and adheres with Spray
good water resistance, is unaffected by temperature extremes, and has extreme
pressure properties.
M Moly Grease Multipurpose lithium base grease with molybdenum disulfide Brush/grease gun
additive, good water resistance, rust inhibition, oxidation stability, and extreme
pressure properties.
W SAE 140 Worm Gear Oil AGMA Grade 7 compounded or 7EP, must be Pour
noncorrosive to bronze.
Output Shaft
C
Upper Bearing
¿
W Change Oil
Change Oil W
¿ W Oil Level Drain Plug
10 Maintenance Manual
S
S Inner Leg
Valve Spools Outer Surface
Outrigger
Tool M
Jib/winch
Platform rotate Cylinder and
Shoe Pins A
Upper Boom
R
Leveling Cables
R
Lower Boom Leveling Cables
Leveling System
Elbow Bearing
C Ball Race Rotation Bearing
C Ball Race
Maintenance Manual 11
6. Install the lock bar. The bar can be installed two
Adjustment of Rotation different ways (refer to Figure 8). This gives twice as
Pinion to the Rotation Bearing many locking increments as there are holes. If the
At the time of unit shipment, the mesh or backlash Iocking bar does not line up with any holes, the
between the rotation pinion and the rotation bearing gear eccentric ring may have to be backed off slightly.
teeth was properly adjusted. However, after an extended
period of operation, or a gearbox change, readjustment
may be necessary. An eccentric adjusting ring provides Eccentric
1
/8" of adjustment. Use of the eccentric ring is explained Ring Drive Slots
later in this section.
12 Maintenance Manual
It is extremely important that nonconductive hoses be Frequency of servicing of filters will vary with the condi-
replaced only with hoses of the same type and size. tions under which the unit is being used. Shorter intervals
Replacement fittings, lines, tubes, etc. should be the between filter servicing may be necessary in unusually
same type and size that were furnished with the unit. dirty or dusty conditions.
Never use wire braid hoses or any hose that is not fully
insulated in an insulated location. If there is ever any A new unit should have the return line filter cartridge
doubt concerning the proper hose to be used for replace- changed, and the 150 micron strainer cleaned after the
ment, contact an Altec representative. first 15 to 25 hours of operation. During this initial run-in
period, the pump, motor, and cylinders may deposit wear
particles in the oil. Subsequent return line filter cartridge
Caution changes should be as recommended by the Preventive
Never substitute a conductive type hose for any Maintenance and Inspection Checklist.
insulated or nonconductive hose. Death or serious
injury may result from the bridging of an insulated
gap with a conductive hose. Nonconductive hoses Caution
must be non-pin perforated. After filter servicing, the shutoff valve in the suction
line must be fully open before starting the pump.
Failure to do so will result in serious damage to the
Atmospheric Vents pump or other components.
Atmospheric vents are located at the boom tip/platform
area. Inspect these vents as recommended by the Pre-
Oil Selection
ventive Maintenance and Inspection Checklist. On Cat-
egory A units these vents must also be tested for proper The hydraulic oil selected should contain rust and oxida-
operation. An atmospheric vent testing kit may be ob- tion inhibitors, antifoam, and antiwear additives. Oils
tained from your local Altec representative. used in insulated equipment must also pass ASTM
D877-67, the dielectric breakdown voltage of insulating
liquids, at 25 KV or better, and possess high demulsi-
Oil Filtration bility. Do not use detergent oils because of their ability to
The unit is equipped with a complete filtration system. retain water. All major oil companies have an oil to
Filtration starts when the oil reservoir is filled. The reser- comply with these specifications.
voir has a 30 mesh strainer basket to prevent large
particles from entering the reservoir during filling. The
reservoir breather cap has a 40 micron element to filter Caution
the air which enters and leaves the reservoir as the oil Brake fluid should never be put into a hydraulic
level changes. system because it can be conductive, thus destroy-
ing the insulating capability of the hydraulic oil. Oils
Oil leaving the reservoir on its way to the pump passes meeting military specification MIL-5606 may be used
through a 150 micron strainer. The strainer prevents in extremely cold climates. Since these oils have less
large particles from getting into the pump. Oil returning to antiwear characteristics, they are not recommended
the reservoir from all parts of the system passes through for full time use. If MIL-5606 oil is used, it should be
a 10 micron return line filter. The return line filter has the changed as the weather permits to one of the oils
replaceable, spin-on type cartridge. While the spin-on recommended under Warm Weather Oils or All
replacement cartridge resembles an automotive filter, do Weather Oils.
not use an automotive filter because of differences in the
bypass characteristics.
Specification Cold Weather Oil All Weather Oil Warm Weather Oil
Ambient temperature range -50° to 60°F (-46° to 16°C) -10° to 90°F (-23° to 32°C) 40°F (4°C) and above
Viscosity @ 100°F (38°C) 85 SSU (17 cSt) 90 SSU (20.2 cSt) 150 SSU (30 cSt)
Viscosity @ 210°F (99°C) 35 SSU (4.5 cSt) 43 SSU (5.0 cSt) 46 SSU (5.5 cSt)
Pour point -80°F (-62°C) -55°F (-48°C) -30°F (-34°C)
Maximum oil temperature 160°F (71°C)
Minimum pump start-up temperature -15°F (-26°C)
Figure 9 Hydraulic Oil Viscosity Recommendations
Maintenance Manual 13
1. Drain the reservoir completely. This will leave ap-
Caution proximately one-third of the system capacity in cylin-
Do not add kerosene or other thinners to hydraulic ders and lines.
oil. These fluids will cause swelling an rapid deterio-
ration of O-rings and other seals in any hydraulic 2. Using a short fill of five to six gallons of new oil, from
system. the lower controls operate the cylinders, rotation,
purge the control system, and operate the power tool
system through a few cycles.
Changing the Oil
Check the oil level in the reservoir weekly. Booms must 3. Drain the reservoir again.
be stored and outriggers retracted. In this condition, the
oil level should be within two inches of the top of the 4. Clean the screens in the suction strainer. Replace
reservoir. Overfilling or filling with the cylinders other than the cartridge in the return line.
as instructed may result in the reservoir overflowing.
5. Fill the reservoir.
It is extremely important that hydraulic oil be clean and
free of moisture. Moisture or impurities can reduce the 6. Operate the unit as instructed above and recheck the
insulating capability of the oil or shorten the life of the oil level in reservoir. Add oil if necessary.
hydraulic components.
7. After 20-30 hours of operating service, clean the
suction strainer and replace return filter cartridge
Visual Inspection of Hydraulic Oil again.
In addition to the regular checking of the quantity of
hydraulic oil, it is strongly recommended that samples of If there is a major component failure, such as a pump,
the oil be inspected at maintenance intervals. This can be cylinder, or motor, which has dumped contamination into
done conveniently by draining a quart of oil from the the system, thoroughly clean the hydraulic system.
petcock at the drain pipe in the reservoir. Use a glass Change the defective component and drain the oil.
container to permit visual examination of the oil (refer to Remove the cover to the reservoir and clean out com-
Figure 10). Water content in the oil may give it a cloudy pletely. Clean the suction strainer. Replace the return
appearance or it may separate from the oil. A rancid or line filter and run a short fill. The new return line filter
burned odor emanating from the oil may indicate the should catch any contaminants left in the cylinders or
need for change. If visible foreign particles are noted, the hoses. Drain the five gallons of oil and replace with new
oil should be changed. If desirable, oil samples may be oil. Replace the return line filter again and a third time
dielectrically tested in an ASTM test cup by a qualified after 20 or 30 hours of operation.
test laboratory.
Air Bleeding
Flushing the Hydraulic System The presence of air in any hydraulic system will cause
If there is ever any doubt about the insulating or lubricat- abnormal operation, noises, and damage to the pump.
ing quality of the oil, it should be changed. If the oil is The presence of air in a hydraulic system can usually be
changed for other than seasonal or routine maintenance, traced to one of the following.
the system should be flushed using the following steps.
14 Maintenance Manual
1. If the oil level in the reservoir is allowed to get too low,
the pump suction can cause a vortex to form in the Warning
reservoir which will allow air to be sucked into the Death or serious injury can result from falling from
system along with the oil. the platform. All platform occupants must properly
use an appropriate OSHA approved personal fall
2. A leak in the plumbing between the reservoir and the protection system.
pump can suck air even though it will not leak out
when the system is shut down. These leaks may be 4. Operate the unit from the lower controls and then the
found by filling a pump type oil can with clean upper controls to identify the malfunction.
hydraulic oil and squirting oil slowly at each connec-
tion in the suction line with the pump operating at 5. Use the Hydraulic System Schematic in the Appen-
normal operating speed. A suction leak will suck the dix to determine the flow path required to operate the
oil in. Be sure to check the connection at the attach- failed function. Make a list of the components used
ment to the pump. to operate the failed function. Cross off components
used to operate other functions that are operating
3. Loose connections in the pressure system normally properly. This should minimize the number of items
will leak externally during unit operation, but can to check.
suck air into the system after the unit is shut down as
the oil tries to find its way to the low points of the 6. Check the easiest component first. Verify the proper
system. operation of each component remaining on the list
until the bad component is found.
4. Hydraulic lines taken loose during maintenance op-
erations will contain air until it is purged out. Some of 7. Use accurate test equipment to verify flow, pressure,
these lines will purge during normal use but others voltage, and current.
will require specific bleeding operations.
Once the symptom has been positively identified, use the
Air entering the system due to low oil levels or leaks in the Troubleshooting Chart in the Appendix for suggested
suction line will cause the most problems and should be causes and corrective actions.
corrected immediately.
Engine Throttle Control
Warning The oil pressure in the signal line to the pump actuates
Serious pump damage and unit malfunctions are the engine throttle cylinder. When the signal pressure
likely to occur if conditions allowing air to enter the exceeds 200-300 psi, the throttle cylinder begins to
suction side of the pump are present. extend until it reaches its full stroke at about 450 psi.
Maintenance Manual 15
The inner core of the rotary joint is bolted to the stationary If it should become necessary to remove one or both of
pedestal. The outer housing rotates with the turntable, the upper boom cylinders, it is very important to use a
driven by a drive bar on the side of the housing. Hydraulic safe and reliable means of lifting the upper boom away
fittings used in the rotary joint are the SAE straight thread from the lower boom. It will be necessary to be able to lift
type. Pipe fittings will not fit these threads and should the upper boom at least five feet above the lower boom
never be used. and at a point above the boom rest saddle. Care should
be used in handling the upper boom to avoid the possi-
Removal of the rotary joint should begin with the booms bility of damaging the fiberglass surface.
stored and the hydraulic pump disengaged. As the
hydraulic connections are removed, they should be
capped to prevent loss of oil or foreign material from Caution
entering the rotary joint. The rotary joint can be removed When removing and installing the upper boom cylin-
by the following method. der or linkage, safeguards must be used to prevent
the fall of the upper boom for any reason because it
1. Disconnect all hydraulic fittings on the bottom of the will be necessary for personnel to be under the
rotary joint in the pedestal. suspended upper boom during at least part of the
work.
2. Disconnect the hydraulic lines from the main control
valve to the lower boom cylinder and to the upper The upper boom cylinders elevate the boom hydrauli-
boom cylinders. Move the lines to the rear of the cally. Lowering the boom at the end of its travel is done
turntable out of the way of the rotary joint. by gravity. Because of this, it is necessary to have a hoist
or lifting device with a capacity of at least one ton. The
3. Disconnect all hydraulic connections to the rotary hoist should be connected to the fiberglass boom near
joint inside the turntable. the outer end. Lifting the fiberglass should be done with
a nylon strap connected as a choker. It is important that
4. Remove the four 3/8″ x 3/4″ bolts which fasten the the choker be restrained from sliding up the boom as the
rotary joint mounting plate to the pedestal on the top boom is lifted. It is also important to protect the fiberglass
of the pedestal. from damage while lifting.
5. Remove the rotary joint through the access cutaway To remove the bottom upper boom cylinder, the unit
on the side of the turntable below the main control should be in the stored booms position. The lower booms
valve. should be rotated to the side of the unit. Be sure to lower
the outriggers before rotating the booms. With the hoist,
Replace the rotary joint by reversing this sequence. raise the upper boom approximately two feet out of the
boom rest. With the hoist supporting the load, remove the
On units equipped with an air plunger type remote start/ pin from the rod end of the bottom upper boom cylinder.
stop system, an electric slip ring will be mounted on top Support the cylinder from falling with a fork truck or other
of the rotary joint. This must be removed before the rotary hoist mechanism. After the rod end of the cylinder is
joint can be removed from the turntable. disconnected, disconnect and cap the hydraulic line to
the base end of the cylinder to prevent oil loss or system
contamination. Remove the pin from the base end of the
Removal of Upper Boom Lift Cylinders
cylinder. The cylinder must be supported. Lower the
The hydraulic cylinders which articulate the upper boom cylinder safely to the ground with a fork truck or hoist.
are mounted between the Iower and upper boom struc-
tures at the upper portion of the lower boom. The base To remove the top upper boom cylinder, position the
end of each cylinder is connected directly to the lower booms in the stored booms position. Position the unit so
boom by a pin and self-Iubricating bearing. The rod end the top upper boom cylinder is under a hoist. With the unit
of each cylinder is connected to one of the elbow links of hydraulic system, raise the upper boom about five feet
the articulation mechanism. This walking link arrange- out of the upper boom rest. Disconnect the hose to the
ment allows the elbow link to wrap around the elbow pivot middle port on the top upper boom cylinder. Cap the hose
as the boom is unfolded or folded. When the upper boom and the fitting on the cylinder. Lower the upper boom to
is in the folded position for transport, the top upper boom about two feet out of the rest - just high enough to allow
cylinder is completely retracted and the bottom upper access to the top upper boom cylinder base end pin.
boom cylinder is completely extended.
16 Maintenance Manual
Support the cylinder with a hoist and choker strap. The Ieveling cables are an IWRC type cable 1/2″ in size
Disconnect and cap the other two hoses on the top upper with a minimum strength of 20,600 pounds when new. In
boom cylinder. Remove the base end cylinder pin. Lift the the insulated section of the upper and lower booms, the
cylinder with the hoist to allow access to the rod end pin Ieveling cable is connected to a fiberglass insulator rod
and remove the pin. Remove the cylinder with the hoist. 3
/4″ in diameter to preserve the dielectric integrity of the
insulated components. Threaded end terminals on the
If the cylinders are going to be left off the unit for an Ieveling cables are mechanically swaged onto the wire
extended period of time, the upper boom should be rope. Turnbuckles are provided in the upper boom and in
lowered by the hoist into the boom rest and the unit the lower boom for proper adjustment for the entire
stored. To reinstall the cylinders, reverse the procedure. Ieveling system. Leveling cables and insulator rods are
thoroughly tested before they are installed in the unit.
It may be necessary during installation or removal to
extend the individual upper boom cylinders. It will be Movement of the booms and the resultant movement of
necessary to attach an auxiliary hydraulic power source the Ieveling cable system is transmitted to the platform
to the base end ports of the cylinder being actuated. To through the keyed shaft at the elbow and through the
actuate the cylinder, one hydraulic line should be at- keyed platform shaft. Persons who perform inspections,
tached to the R port on the cylinder. Attach the second make adjustments, etc., should be familiar with the entire
line to the E port on the cylinder base. It will also be leveling system before beginning disassembly.
necessary to connect the E and P ports on the base end
of the cylinder in order to open the counterbalance Inspection of Leveling
holding valve to allow the cylinder to extend. Once the and Holdback Cables
cylinder has been plumbed in this manner, use the A cable is a mechanism within itself, consisting of moving
auxiliary power source to extend or retract the individual parts which are called strands and wires. Cable wires
cylinder as desired. When reinstalling the bottom upper move in relationship to other wires under operating
boom cylinder, completely extend the cylinder. When conditions. Two of the operating conditions with which
reinstalling the top upper boom cylinder, extend it ap- the cable inspector must be concerned are as follows.
proximately three inches from its fully retracted position.
The movement of wires against each other as the
cable is loaded and unloaded.
Warning
Do not articulate the upper boom overcenter until The flexibility and bending of the cable, strands, and
you are certain there is oil in the rod end of both upper wires as the cable passes over.
boom cylinders.
Inspection is an important part of satisfactory cable life,
To be sure both cylinders are full of oil, use the lower as well as the safety and reliability of the cable. Lubrica-
controls to articulate the upper boom up and down about tion plays a very important part in extending cable life by
60 degrees from the boom rest for 5 or 6 cycles. reducing internal wear as the wires move in relationship
to each other. While the platform Ieveling system is
Upon completion of this job, structurally test the boom in designed with a safety factor several times greater than
accordance with the section under Testing, and dielectri- the rated loads applied to the platform, periodic inspec-
cally test the unit. tion and lubrication must be performed.
Maintenance Manual 17
Look for broken wires. Feeling by hand or by wiping with Replacement of Leveling Cables
a soft cloth will expose broken wires. If four or more One type of leveling cable must be replaced at least
broken wires are found, replace that cable. If it is deter- every 5 years or 5,000 hours, whichever comes first. The
mined that there are broken wires, but not enough to other, newer type, of leveling cable must be replaced at
cause replacement, perform more frequent inspections. least every 8 years or 8,000 hours, whichever comes
Any time there is doubt in the mind of the inspector first. The newer type is recognized by yellow paint on the
concerning the safety of a cable, it should be changed. end coupling of the cable. This requirement is based on
normal use, proper care, regular inspection, and lubrica-
While operating the unit, observe the sheaves for free- tion. If the unit is operated under severe conditions, or not
dom of movement. It is extremely important that all idler properly serviced, replace cables, leveling rods, or
sheaves turn as the cable moves. Evidence of a frozen sheaves more frequently. This emphasizes the need to
or slipping sheave would be a very shiny groove. As the perform regular inspections as instructed in this manual.
cable slips, it wipes the lubrication off.
Before any attempt is made to remove or replace leveling
Position 1 cables or rods, study Figure 3 in the Parts Manual. It is
The booms stored. Inspect the cables at the turntable. very important that the correct procedures be followed to
Also inspect the sheave grooves for evidence of scuffing. assure proper routing of cables for the safety of opera-
Inspect the cables and sheaves at the elbow. The cables tion. Several inspections will be required during the
or rods should not touch anything. Make sure the cable replacement of cables. Use only genuine Altec replace-
keepers are in place. Reach inside the upper boom at the ment parts. Substitution of inferior parts can lead to
platform through the side access holes at the boom tip. dangerous conditions.
Pay particular attention to the cable that comes off the top
of the 12″ sheave. Reach into the boom past the idler Procedure for Removing
sheaves for inspection. Leveling Cables and Rods
1. Remove all access covers from the booms. This will
Position 2 permit access to the leveling system which is mostly
Raise the lower boom vertical and the upper boom fully housed within the booms.
down. This exposes a new length of cable. Inspect the
cables at the turntable and boom tip. With another aerial 2. Remove the platform(s) for access to the boom tip.
platform, inspect the cables at the elbow. Have someone This can be done by detaching the fiberglass
raise the upper boom and make sure no cables are riding platform(s) from the mounting shaft. If the platform
on each other. If they do, they can be pried in place on the can be supported while it is removed, it may not be
cast sheaves with a screwdriver. necessary to remove the control head.
18 Maintenance Manual
9. Release the upper boom Ieveling rods from the Installation of Cables and Rods
elbow cables by unscrewing the turnbuckles in the Before installing or reassembling the leveling system,
upper boom. carefully study the boom assembly. Becoming familiar
with these two diagrams and using them for reference will
10. Remove the platform mounting shaft from the upper greatly assist the assembly and eliminate confusion.
boom tip. Note the orientation of the 12″ sheaves at
the tip and at the elbow. 1. Spray the new Ieveling cables with wire rope lubri-
cant. Wipe them with a clean cloth to remove exces-
11. Remove the pins from the 8″ idler sheaves at the sive lubricant. Do not allow lubricant to dry on
boom tip and the lower 8″ idler sheave at the elbow fiberglass surfaces because dirt can collect and
end of the upper boom. reduce the dielectric strength of the fiberglass. Avoid
getting dirt or grit on the cable.
12. Slide the 8″ idler sheaves at the boom tip, the 12″ boom
tip sheave, the boom tip cable, and the Ieveling rods 2. Install the long end of the elbow upper boom Ieveling
out of the boom tip. cable to the top upper boom Ieveling rod lower end
using jam nuts and 11/2″ outside hex turnbuckle.
13. Remove the cables at the boom tip from the Ieveling Screw the turnbuckle onto the Ieveling rod and the
rods. cable end fitting at least 11/4″. Slide the top upper
boom rod toward the tip until the upper end of the rod
14. By removing the anchor pin from the mounting bracket protrudes out of the boom tip weldment. Slide the
inside the turntable, the lower end cables can be bottom rod so that its upper end protrudes from the
removed. boom tip weldment. Attach the boom tip Ieveling
cable assembly to the top upper boom leveling rod.
Inspection Engage the cable end fitting threads at least 11/4″,
1. Thoroughly inspect all Ieveling rods to determine if tighten the jam nuts securely against the Ieveling rod
they are suitable for reuse. Check rods for severe end fittings, and lockwire the assembly according to
scratches, signs of rubbing, cleanliness, or any other Figure 11. Attach the long end of the boom tip
possible damage or wear. Inspect the terminals at Ieveling cable to the bottom upper boom Ieveling
the ends of the rods for secure attachment and rod. Lockwire the assembly according to Figure 11.
condition. Replace the rods if there are any signs of
cracks, damage, or wear. 3. Orient the boom tip leveling sheaves according to
Figure 6, wrap the cable as shown and engage the
2. Inspect all idler sheaves. Sheaves must not be drive lug on the cable assembly into the recess on
reused if they show signs of scuffing on the surface the Ieveling sheave. Be sure to wrap the cables
which contacts the cable. All sheaves must turn correctly as shown.
freely without excessive looseness in the bearing.
4. Install the 8″ Nylatron idler sheaves at the boom tip.
3. Inspect the large sheaves at the elbow. If there are Use the appropriate thrust washers, retaining pin,
any broken flanges or excessive wear, replace the buckeye pin retainer, and drilled head fasteners.
sheave. If excessive wear is noted in the shaft Lockwire the fasteners as shown in the Iockwiring
bearings, they must be replaced. section.
4. New sheaves, bearings, and pins are furnished with 5. Install the platform mounting shaft and drive key
the cable kit. It is recommended that these parts be through the boom tip assembly and the platform
replaced at cable replacement. Ieveling sheave. Use an appropriate rust preventive
lubricant such as Never Seize on the keyways, keys,
5. Inspect all cable keepers for wear, damage, or defor- and the inside bore of the platform Ieveling sheaves.
mation. Never use a cable keeper which is not in Install the idler sheave cable keepers.
good condition.
6. Orient the elbow upper boom leveling sheave. Install
6. If the Ieveling rods have been determined to be the 8″ Nylatron idler sheaves spacer, thrust wash-
reusable, clean the surface of the rods to avoid ers, pins, retainers, and retaining bolts. The pivot
degrading their dielectric strength. pins for the idler sheaves will retain the cables in their
sheave grooves and eliminate the need for addi-
Maintenance Manual 19
L.H. Thread R.H. Thread
tional cable keepers. Attach the bottom upper boom that all cables and rods be held with wrenches while
Ieveling rod to the short end of the elbow upper boom the turnbuckle is tightened. Otherwise, severe twist
Ieveling cable using the 11/2″ hex turnbuckle and jam can damage the cable and Ieveling rods.
nuts. The drive lug on the elbow upper boom Ieveling
cable must be secured into the recess on the elbow 10. Inspect the entire Ieveling system throughout to
Ieveling sheave. Tighten the lower turnbuckle hand make certain cables are not crossed and they will
tight and then an additional five turns. This will operate freely without rubbing. The cable wrap at the
provide the proper pretension on the Ieveling system main boom pivot sheave, the elbow sheave, and the
for the initial run-in of the new cables. Tighten the jam boom tip sheave can be pushed into alignment for
nuts securely. Do not lockwire at this time. good tracking without rubbing.
7. Install the Iower cables to the turntable anchor point 11. Install the platforms onto the platform mounting
and wrap them around the main boom pivot pin shaft.
sheave. Install the 8" Nylatron sheaves, pins, bush-
ings, thrust washers, pin retainers, and retaining 12. Using the lower controls, with outriggers set, operate
bolts at the Iower boom. Install the lower boom elbow the boom throughout all positions with rated load in
Ieveling cable with the long end on the upper side of the platform
the lower boom elbow sheave. Engage the drive lug
into the recess on the Ieveling sheave securely.
Attach the end fittings of the lower boom elbow Caution
assembly to the lower boom Ieveling rods, engaging Do not permit anyone to occupy the platform until
the end fittings at least 11/4″. Tighten the jam nuts and after the operations have been tested and structural
lockwire as shown in Figure 11. Install the 6″ idler tests have been passed.
sheave, thrust washers, pivot pin, pin retainer, and
retaining bolts at the elbow end of the lower boom. Inspect cables, rods, pins, etc. at the turntable,
Lockwire the pin retainer bolt according to the lock- elbow, and boom tip to determine that there is no
wiring section. rubbing between the moving parts. This inspection
can be made from another unit
8. Slide the lower boom Ieveling rods toward the lower
end of the lower boom being sure to keep them 13. Perform a structural test as explained in Testing.
separate as to which is the top one and which is the Final adjustment of the cables as explained in the
bottom one. section of Adjustment of Leveling Cable Tension will
give the proper cable tension and level the platform
9. Connect the lower end of the Ieveling rod to the cable properly.
at the lower boom main pivot with the turnbuckle in
the lower boom. Tighten the turnbuckle sufficiently to 14. Connect all current leakage monitoring wires at the
permit operation of the Ieveling system but do not elbow end of the upper boom. Install all covers.
adjust the platform at this time. It is very important
20 Maintenance Manual
15. The unit be given a dielectric test anytime work has boom Ieveling rods. Anytime the turnbuckle is being
been performed which might affect the insulating turned, the end of the Ieveling rods and the end of the
properties of the fiberglass. Records of dielectric test cable must be held with wrenches to avoid twisting. To
should be retained and filed for future reference. adjust the upper boom system, loosen the turnbuckle
and jam nuts on the bottom upper boom Ieveling rods.
Adjustment of Leveling Cable Tension Tighten the turnbuckle hand tight and then an additional
The adjustment of platform Ieveling cables is a simple, five turns using a wrench. This will provide a proper
very important operation. It is necessary to have the tension in the upper boom Ieveling system. Tighten the
proper tension in order that the platform will be carried in jam nuts on the turnbuckle and secure the turnbuckle
a position parallel to the turntable so that unnecessary with lockwire as shown in Figure 12. Unfold the upper
platform movement will be eliminated. However, be- boom overcenter until the other turnbuckle is accessible
tween the adjustments on the Ieveling cable system in at the upper boom elbow access hole. Tighten the jam
the upper and lower booms, the system can be greatly nuts securely and lockwire this turnbuckle also.
overtensioned. This serves no purpose but does shorten
the life of cables, sheaves, bearings, etc. Rotating Platforms
With rotating type platforms, the platforms must be
Cable adjustment will most likely not be required until loaded to rated capacity and swung to a position 45
after extended periods of operation. Loose cables can be degrees from beside the boom position. The platforms
readily noticed when the platforms are loaded. Without may be loaded by placing the load in the platforms, or by
proper tension, the platforms will lean away from the suspending the load under the platform at the transverse
boom and the operators will find it uncomfortable to center line. Care must be used to avoid damaging the
perform work from the platforms. In addition, loose cables fiberglass. If the platforms have liners, the suspended
will allow the Ieveling rods, cables, and platforms to load should be 250 pounds to each platform. Without
bounce while the vehicle is being driven. platform liner, the load should be 300 pounds per plat-
form. The boom or the vehicle should not be moved while
To properly tension the Ieveling cables, raise both booms the load is suspended.
until they clear the boom rests. By removing the cover
plate from the side of the lower boom and upper boom, The upper boom should be positioned slightly out of the
the turn buckles will be visible through the access hole. upper boom rest and the lower boom should be posi-
The turnbuckles in the lower boom adjust the level of the tioned slightly out of the lower boom rest.
platforms and the upper boom turnbuckles adjust the
upper boom cable tension. The back turnbuckle inside Lubricate both the upper and lower turnbuckle at the
the lower boom at the access hole adjusts the platform tilt lower boom side access hole with a light lubricant.
while the front turnbuckle adjusts the tension in the lower Loosen the jam nuts on both turnbuckles, until the upper
boom cables. As in any turnbuckle, one thread is right turnbuckle is handtight. Level the platform with the turn-
hand pitch and one thread is left hand pitch. In the lower table or vehicle bed by tightening or loosening the lower
boom, the left hand threads are on the turntable cables. turnbuckle. Tighten the jam nuts on the Ieveling cable.
In the upper boom, the left hand threads are on the upper
Turnbuckle
Maintenance Manual 21
Tighten the upper cable turnbuckle hand tight or until the
Main System Pressure/
slack is out. Continue to tighten three more full turns.
Standby Pressure Adjustment
Tighten the jam nuts and lockwire both Ieveling cables as
in Figure 12. The axial piston pump controls both the main system
pressure and the pump standby pressure. These two
Remove the test load from the platform. You will notice pressures are adjusted and controlled by two cartridges
that the platforms have tipped very slightly toward the on the pump housing (refer to Figure 13).
boom as the weight is removed. This is normal as the
platforms are loaded for use, they will return to the To check these pressures, install a 0-3,000 psi pressure
parallel position. gauge into the test port located on the bottom of the
combination valve on the side of the turntable.
Caution Position the control selector in the Upper Controls posi-
Care must be taken not to overload the platforms and tion. Turn off upper and lower power tools if so equipped.
Ieveling cables while applying test loads.
Standby Pressure
Non-Rotating Platforms The pressure gauge should read 350 psi. If this pressure
To adjust the Ieveling cable tension on non-rotating is not correct, adjust the standby pressure.
platforms, loosen both lower boom Ieveling cable turn-
buckles. Lubricate the threads of the cables and rods Parker PAVC38 Pump
with a light lubricant. When tightening the turnbuckles, Loosen the lock nut on standby pressure cartridge using
tighten the Ieveling and holdback turnbuckles alternately, an 11/16 ″ open end wrench. Adjust the standby pressure
keeping the top of the platform parallel to the vehicle by screwing the adjustment knob in to increase pressure
body. A slight tilt so the bottom of the platform is away or out to decrease pressure. Hold the adjustment knob
from the pedestal will compensate for boom deflection from turning while retightening the lock nut.
when the booms are loaded.
Vickers PVE 19 Pump
With the upper boom out of its rest, tighten the turnbuck- The standby pressure is adjusted by means of an Allen
les until hand tight or until all the slack is out of the cables. screw and normally does not require adjustment if the
Continue to alternately tighten the two turnbuckles three standby pressure is 350 psi +/-50 psi. Screw the Allen
complete turns total. Do not tighten each turnbuckle wrench in to increase standby pressure and out to
three turns, but three turns between the two turnbuckles. decrease pressure to the proper adjustment. On earlier
Lockwire the turnbuckles as in Figure 12. model pumps, the standby pressure is shim adjusted.
Compensator
Adjustment Plug
Standby Pressure
Adjustment
11
/16 Flats 9
/16 Flats
Hex Jam Nut Hex Jam Nut
Parker PAVC38 Pump Vickers PVE19 Pump
22 Maintenance Manual
The shim kit is available if adjustment is required on this
type of pump. Increasing pressure requires the addition Pilot Pressure Tool System Pressure
Reducing Valve Reducing Valve
of shims. Decreasing standby pressure requires removal
of shims from the standby pressure adjustment.
Adjust the pressure setting as necessary by loosening To check the tool system pressure, install a 0-3,000 psi
the9/16″ flats - hex jam nut and turning the adjustment knob pressure gauge in the TD port on the right hand side of the
in to increase pressure or out to decrease pressure. After combination valve.
adjustment is complete, be sure to retighten the jam nut.
Start the unit, place the control selector in Upper Controls
Pilot System Pressure Adjustment position, disconnect any power tool attachments, and
The pilot system pressure is controlled by the pilot turn the tools valve to the On position. The pressure
pressure reducing valve cartridge located in the combi- gauge should read 2,000 psi. If the tool pressure is
nation valve on the turntable (refer to Figure 15). incorrect, adjustment is necessary.
To check this pressure, install a 0-500 or 0-1,000 psi To adjust the tool system pressure, disengage the pump
pressure gauge into the UCD port located on the left front or shut off the unit. With a 3/8″ Allen wrench, remove the
face of the combination valve. With the unit engaged for plug from the end of the tool system pressure reducing
operation and the control selector valve in the Upper cartridge. Insert a 5/16″ Allen wrench into the pressure
Controls position, the gauge should read 350 psi. If it adjusting screw located inside the end of the cartridge.
varies from this reading, adjustment is necessary. Start the unit and check the tool system pressure as
described above. Adjust the screw clockwise to increase
To adjust the pilot pressure, disengage the pump or shut pressure or counterclockwise to decrease pressure. When
off the unit. With a3/8″ Allen wrench, remove the plug from the pressure is correctly adjusted, be sure to replace and
the end of the pressure reducing valve cartridge. Insert a tighten the plug on the end of the cartridge.
5
/16″ Allen wrench into the pressure adjusting screw
located inside the end of the cartridge. Start the unit and Setting Main Control Valve Flow
adjust the screw in to increase or out to decrease the pilot Controls/Boom Function Speed
system pressure as required. When the pressure has If the main control valve is replaced or if boom function
been set, replace the plug on the end of the cartridge. speed is not correct, it may be necessary to check and
adjust the speed of the individual boom functions.
Maintenance Manual 23
The main control valve is equipped with adjustable flow
controls to precisely and consistently control the speed
Upper Boom Stow
of each boom function. The adjusting stems are found on The upper boom is gravity lowered into the boom rest, so
the right hand side of the main control valve sections it requires no boom stow protection. To avoid damage to
just to the left of the handle boots. the fiberglass boom, lower the boom gently into its rest.
It is very important to strap the upper boom in place while
The proper speed for each function is shown below transporting the unit.
adjacent to the valve section which controls that function.
64 Seconds
50 Seconds
(from stowed to
190 degrees)
Jam Nut B
24 Maintenance Manual
Do not adjust counterbalance valves in the field. The only Jam Nut
Adjusting Screw
exception is adjusting the counterbalance valves for
manually stowing as described in the Operators Manual. Counterbalance
If the setting on a counterbalance valve has been changed, Port 2 Valve Cartridge
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 Port 1
relief setting changed must be replaced or reset to
the proper setting using an Altec test block before Figure 17 Counterbalance Valve Test Block
the unit is operated.
3. Install a straight adapter in port 2 to aid in observing
Do not adjust a counterbalance valve without a test block. the oil flow from this port during the procedure.
A test block and pressure gauge is the only accurate way
to determine that the proper setting has been obtained. 4. Gradually increase the pressure at port 1 with the
pressure source. The counterbalance valve relief
A test block and instruction sheet for 11/8″ and 7/8″ hex setting is the pressure at which a fine stream of oil
cartridges are available from your Altec representative begins to flow from port 2. Note this pressure reading
(refer to Service Tools and Supplies in the Appendix). and then remove the pressure from port 1.
1. Stow the unit. 6. Disconnect the pressure source from port 1 and
remove the counterbalance valve cartridge.
2. Disengage the PTO and turn off the engine.
7. If the relief setting is incorrect, adjust the relief setting
3. Shift the lower control handle for the function until the as described in the following procedure.
cylinder can be rocked by hand.
Adjustment
4. Locate the plugs in the extend and retract test ports 1. Loosen the jam nut and turn the adjusting screw
at the base end of the cylinder or counterbalance clockwise to decrease the setting or counterclock-
valve block. Use an Allen wrench to slowly unscrew wise to increase the setting.
the test plugs. If the cylinder is under pressure and
the plugs are unscrewed quickly, hydraulic oil may 2. Hold the adjusting screw from turning and tighten the
spray out of the test ports. If the test ports are not jam nut.
available, slowly screw the counterbalance valve
cartridge from its housing. 3. Repeat the test procedure until the correct relief
setting is obtained.
5. Carefully unscrew the cartridge from its housing to
allow the pressure to bleed off before the cartridge is 4. Repeat the test procedure at least three more times
fully unscrewed from the cavity. to confirm the correct setting.
2. Connect a hydraulic pressure source and an accu- 6. Disconnect the pressure source from port 1 and
rate pressure gauge to port 1 (refer to Figure 17). The remove the counterbalance valve cartridge.
pressure source and gauge must be adequate for a
pressure greater than the desired counterbalance
valve relief setting.
Maintenance Manual 25
3. Release any pressure in the hoses connected to the
Winch Brake winch motor by moving the winch control on the
The winch is a worm gear driven by the hydraulic motor. upper controls to the Pay In and Pay Out positions
The winch valve directs hydraulic oil to the winch motor. several times.
The winch motor powers the worm gear set. The worm
gear set drives an output shaft keyed to the winch drum. 4. Remove the winch covers to allow access to the
winch and hydraulic winch motor.
The winch is equipped with a brake, located at the end of
the worm shaft opposite from the winch motor (refer to 5. Place a container under the hoses connected to the
Figure 18). The brake is an overrunning clutch that runs winch to catch the hydraulic oil. Mark the hose
freely in the winch Raise position, but applies continuous connections and disconnect the hoses from the
braking action in the winch Lower position. The brake winch motor. Cap the ports in the motor and plug the
assists the self-locking worm gear set in stopping a load hoses.
that is being lowered when the control handle is returned
to neutral. 6. Remove the two cap screws that attach the hydraulic
motor to the winch gearbox. Remove the hydraulic
Motor Brake motor from the input of the winch.
Spilled hydraulic oil creates slick surfaces and can 15. Position the jib pointing down so that the load line is
cause personnel to slip and/or fall. Keep the unit and hanging nearly straight off of the winch drum.
work areas clean.
16. Attach a 2,000 pound load to the winch line.
26 Maintenance Manual
17. From the lower controls, lift the load three to four feet The trigger on the single handle control should show
off the ground with the winch. slightly when it is fully engaged into the handle. The
trigger should not bottom out or completely disappear
18. Start lowering the load with the lower winch control into the handle, rather the spool should bottom out,
handle shifted fully to the winch pay out position. At stopping trigger movement.
the same time, move the upper control/lower control
selector to the upper controls position. The load Adjust the interlock connecting linkage to insure that the
should stop. interlock spool fully shifts when the trigger is actuated. If
the spool is not being fully shifted, adjust the interlock
19. Repeat this test three times. linkage using the following procedure.
20. If the load stops every time, return the unit to service. Adjustment
If the load does not stop, follow the steps below. 1. Remove the cover over the upper control assembly.
Locate the jam nut on top of the interlock cable (refer
21. Remove the winch covers and hydraulic connec- to Figure 19).
tions to allow access to the winch brake.
22. Remove the brake cover and inspect for any worn or
damaged components.
23. If any broken or worn parts are found, replace with Mechanical
new parts and reassemble. Test as previously de- Linkage
scribed.
Interlock
24. If the brake components are not damaged and do not Jam Nut Trigger
look worn, but will not hold the load in the test
described above, replace the gearbox.
Maintenance Manual 27
The leakage monitor system is a tool used to measure
Testing
the leakage of electrical current through the components
This unit has been factory tested and, at the time of it is attached to and for dielectric tests of all voltages. This
delivery, all applicable ANSI requirements were met or system consists of wires connected to components inter-
exceeded. Any time an alteration is made that may affect nal to the upper boom and to a test electrode that extends
the units stability or dielectric insulation, testing must be through the bottom of the fiberglass upper boom. A test
performed to confirm that the unit operates safely and in electrode may also be located on the turntable.
compliance with all governing organizations.
Dielectric test forms can be found in the Appendix.
Dielectric Choose the appropriate form, thoroughly document all
This unit is tested to a rating listed on the serial number tests, and maintain records in a permanent file.
placard at the time of delivery. The platform liner, if
furnished, will carry the certification test of the liner Structural
manufacturer. Periodic dielectric testing is required by After replacing any major component, perform a 1.5 to 1
ANSI. structural test to verify structural soundness before put-
ting the unit back into service.
Danger
Death or serious injury will result from contact with Warning
or proximity to an energized conductor. Maintain the Death or serious injury can result if the unit becomes
dielectric characteristics of the fiberglass boom(s). unstable. Maintain stability of the unit while perform-
ing a structural test by following proper procedures.
Surface irregularities such as scratched, cracked, or
chipped gelcoat can trap dirt and contaminants, which Use the following procedure to perform a structural test.
over time may reduce the dielectric properties of the
fiberglass. Of particular concern are irregularities run- 1. The area where the test is performed should be level
ning lengthwise on the boom. Trapped contaminants, and free from any overhead obstructions. Position
such as dust particles and water, can cause tracking, the unit in the test area so the platform may be
providing a path to ground. Surface flashover occurs accessed by a forklift (or other lifting device) to place
when a substance causes an arcing of electricity be- the test weight.
tween two points on the boom. If this occurs, the dielectric
integrity of the boom may be permanently damaged. 2. Apply the parking brake and chock the wheels.
Engage the PTO and properly set the outriggers.
Dielectric tests that can be performed only after installa-
tion are the responsibility of the installer, whether the 3. The position of the booms for the test is somewhat
installer is a dealer, owner, or user. After the completed dependent upon the component(s) which has been
unit is in the possession of the owner or user, subsequent replaced. If a component of the leveling system has
testing becomes the responsibility of the owner or user. been replaced, the booms can be raised approxi-
mately one foot out of each rest. Replacement of
The importance of dielectric testing cannot be overem- other components requires the test be performed
phasized. Understand the dielectric test procedures in with the lower boom vertical and the upper boom
ANSI publications. Provide for periodic inspection and horizontal.
dielectric testing of insulated components at intervals of
1 to 12 months. This recommendation is not intended to 4. Position the platform(s) in the end-mounted position.
alter more frequent inspection or testing of other compo- Allow enough space to permit jib/winch operation.
nents as defined in ANSI publications.
5. Calculate the test weight for the platform by multiply-
In addition to regular tests, conduct tests any time the ing 1.5 times the platform capacity shown on the
dielectric strength of the insulating components is in serial number placard.
doubt.
If the unit is equipped with a platform liner, deduct the
If it is necessary to change or replace any component weight of the liner from the test weight figure.
which is part of the units insulation, including booms, tool
lines, control lines, etc., a dielectric test must be per- Attention
formed. If there is any doubt about the dielectric strength Carefully load the test weight to prevent damage to
of the hydraulic oil, perform a dielectric test. the platform or liner.
28 Maintenance Manual
6. Place a sling around the platform to suspend the and should be retained as part of the original unit docu-
weight directly under its centerline. Use a forklift (or mentation.
other lifting device) to slowly apply the weight. If the
test is being performed with the lower boom below Additional test forms may be needed to show appropriate
horizontal, the test weight can be placed in the stability tests for units equipped with special lifting fea-
platform without the use of a lifting device. tures such as a lower boom lifting eye or a gin pole
socket. If Altec Engineering determines that these spe-
7. Pay out the winch line so a weight of 1.5 times the cial lifting features will always produce less tendency
rated load may be applied to the winch line at less toward overturning than would normal platform and jib
than 2 feet from the ground. stability test loads, stability tests using these special
lifting features are not required.
8. Apply the test weight for five minutes. During that
time, do not operate any function of the unit. This is General Test Conditions
a static test only. Remove all tools and material including removable
boom supports, extra platforms (not attached to the
9. Remove the weight from the platform and the winch unit), and all removable cargo.
line. Inspect the unit for structural soundness if any
cracking or popping was heard during the test. Restrict the amount of total fuel in all tanks to 20
gallons or less.
10. Operate the unit through its full range of movement
before returning it to service. Only the test technician can be on the unit during the
test.
Stability
Due to the possible affect on stability, this unit and/or Do not use outrigger pads.
vehicle should never be altered or modified without the
specific written approval from Altec Industries, Inc. Com- Perform the test only while operating from the lower
ponent replacement with original equipment parts will not controls.
affect the stability of this unit.
Provide a suitable restraint during all stability tests to
ANSI A92.2 requires a level surface test and a five prevent the mobile unit from overturning in the event
degree slope test when the unit mounting is complete on a condition of instability is reached. A typical restraint
the vehicle. These stability tests are not required to be method is a loose loop of chain around each side of
performed again unless significant changes are made in the rear axle (allows the axle to raise off the test
the original vehicle and body mounting or the unit is surface at least 8 to 10 inches before tightening the
remounted on another vehicle. chain), near the wheel, which is securely anchored to
the ground. Increase the length of the chain to allow
further movement if there is any doubt about whether
Warning the mobile unit has reached a condition of instability.
Death or serious injury can result from uncontrolled Raising of outriggers or tires does not necessarily
movement. Do not permit anyone to occupy the indicate a condition of instability.
platform until the unit has passed applicable tests.
Choose Test A or Test B depending on the location
Death or serious injury can result if the mobile unit of the weight for the test. Test B can only be used if
becomes unstable. Provide a suitable restraint while the jib can structurally carry both the jib load and the
the stability tests are performed. platform load.
Attention The unit must pass the Level Surface Test before
Carefully load the test weight to prevent damage to conducting the Five Degree Slope Test.
the platform or liner.
Level Surface Test
Test Forms 1. Position the unit on a level, hard surface, apply the
Stability test forms are provided in the Appendix. The parking brake and chock the wheels. Engage the
forms designate the proper boom and jib positions and hydraulic system.
the proper test loads to be used. They show the unit
loading configuration(s) that would most likely cause 2. Properly set the outriggers. Extend the outriggers to
overturning. Completed forms should be dated and signed remove the bulge from the tires while still maintaining
by the test technician after conducting the stability tests at least some tire-to-surface contact at each tire.
Maintenance Manual 29
Level the mobile unit side-to-side with the outriggers. the low side for this test. (The mobile unit is usually
If equipped with two sets of outriggers, use the the most stable when the low side outriggers are at
outriggers to level in the front to back direction. maximum penetration and the high side outriggers
are at minimum penetration.) Extend the outriggers
3. Move the booms and jib into a position to most likely on the high side of the slope, enough to complete a
cause overturning (refer to the test form). full cycle of rotation without any intermediate read-
justment of any of the outriggers. Do not extend the
4. Apply a load at the center of the platform(s) equal to high side outriggers enough to cause the front tire or
1.5 times the rated platforms load. The load can be outside dual rear tires on the high side of the slope to
applied either into the platform(s) or suspended by a lose surface contact.
load line from the center of the platform(s). The
platform test load may be suspended on the jib line, 3. Move the booms and jib into a position to most likely
in addition to the jib test load, if the unit is equipped cause overturning (refer to the test form).
with a material handling jib structurally capable of
carrying the added load. 4. Apply a load at the center of the platform(s) equal to
1.33 times the rated platform load. The load can be
5. Apply a load to the material handling jib, if equipped, applied either into the platform(s) or suspended by a
equal to 1.5 times its rated load. load line from the center of the platform(s). The
platform test load may be suspended on the jib line,
6. Rotate the turntable in a full rotation cycle, watching in addition to the jib test load, if the unit is equipped
for any evidence of instability. Outriggers and tires with a material handling jib structurally capable of
may lift off the surface during the test without indicat- carrying the added load.
ing a condition of instability as long as the mobile unit
does not tend to overturn. 5. Apply a load to the material handling jib, if equipped,
equal to 1.33 times its rated load.
7. If the initial test shows that the mobile unit is unstable,
adjust the outriggers to determine any effect on 6. Rotate the turntable in a full rotation cycle, watching
stability. Rotate the turntable again in a full rotation for any evidence of instability. Outriggers and tires
cycle watching for any evidence of instability. may lift off the surface during the stability test without
indicating a condition of instability as long as the
8. Add permanent counterweight if it is determined that mobile unit does not tend to overturn.
the mobile unit will not pass the test as originally built.
Use temporary counterweight to determine how much 7. If the initial Five Degree Slope Test shows that the
permanent counterweight is needed and where the mobile unit is unstable, adjust the outriggers to
counterweight should be added. Rotate the unit in a determine any effect on stability. Repeat step 6.
full rotation cycle watching for any evidence of insta-
bility after adding the temporary counterweight. If the 8. Add permanent counterweight if it is determined that
unit passes the test with the temporary counter- the mobile unit will not pass the test as originally built.
weight, remove the temporary weight and add the Use temporary counterweight to determine how much
permanent counterweight. Perform the test again. permanent counterweight is needed and where the
The unit must pass this test before moving on to the counterweight should be added. Rotate the unit in a
Five Degree Slope Test. full rotation cycle watching for any evidence of insta-
bility after adding the temporary counterweight. If the
Five Degree Slope Test unit passes the test with the temporary counter-
1. Position the unit on a level, hard surface with the weight, remove the temporary weight and add the
centerline of the vehicle positioned approximately permanent counterweight. Perform the test again.
perpendicular to the direction of the slope. If the The mobile unit must pass this test.
Level Surface Test showed the mobile unit has a
greater tendency to overturn about one side than 9. After the test has been completed, torque all acces-
another, position the least stable side on the low side sible rotation bearing cap screws to 325 foot-pounds
of the slope. Apply the parking brake and chock the using a circular pattern (only required at the time of
wheels. Engage the hydraulic system. initial installation of unit on chassis).
2. Properly set the outriggers. Extend the outriggers 10. After the test has been completed, torque the rota-
fully on the low side of the slope. The mobile unit tion gearbox mounting cap screws to 225 foot-
does not have to be level or maintain tire contact on pounds (only required at the time of initial installation
of unit on chassis).
30 Maintenance Manual
Appendix
Glossary
2nd stage boom see intermediate boom. articulating-boom aerial device an aerial device with two or more
3rd stage boom see upper boom. boom sections that are connected at joint(s) which allow one boom to
pivot with respect to the adjacent boom.
A-frame outrigger an extendible outrigger having two diagonal
members which are connected at the top and joined near the midsection ASTM American Society for Testing and Materials.
by a horizontal cross piece. Resembles a broad based A. atmosphere (one) a pressure measure equal to 14.7 psi.
above rotation in reference to a position on or about a unit that is atmospheric pressure pressure on all objects in the atmosphere
vertically above the rotation bearing. because of the weight of the surrounding air. At sea level, about 14.7 psi
absolute a measure having as its zero point or base the complete absolute.
absence of the item being measured. attention information that must be followed to reduce the likelihood
absolute pressure a pressure scale with the zero point at a perfect of property damage. Property damage could include structural damage
vacuum. to the unit, component failure, or damage to nearby property.
accumulator a container used to store fluid under pressure as a auger the hole boring tool of the digger, consisting of a hollow tube
source of hydraulic power or as a means of dampening pressure with hardened teeth attached at one end to dig into and break up soil
surges. and/or rock as the auger is rotated. Several turns of flighting are welded
to the tube to carry the loose material away from the teeth.
actuator a device for converting hydraulic energy into mechanical
energy, such as a motor or cylinder. auger extension shaft a shaft which fits into the auger tube to
connect the digger output shaft to the auger.
adapter a device used to connect two parts of different type or
diameter. auger rotation hydraulic system the hydrostatic system on a
pressure digger which operates the auger transmission gearbox.
adjusting stud a component of a cable drive system that is threaded
on both ends and has a hex adjusting flat in the center. It secures the auger stow bracket the bracket on a digger derrick lower boom
drive cable to the cylinder rod and can be used to adjust the tension of which stores the digger and auger assembly when it is not in use.
the drive cable. auger stow switch a limit switch which is actuated by the auger to
aeration the entrapment of air in hydraulic fluid. Excessive aeration shut off digger operation in the stowing direction when the auger
may cause the fluid to appear milky and components to operate reaches its fully stowed position in the auger stow bracket.
erratically because of the compressibility of the air trapped in the fluid. auger transmission gearbox the gearbox mounted on the mast
aerial control valve the control valve on the turntable of an elevator weldment of a pressure digger that is used to rotate the kelly bar.
unit which operates the movement functions of the aerial device. auger tube the hollow tube at the centerline of an auger to which the
aerial device a vehicle-mounted device with a boom assembly auger flighting is welded.
which is extendible, articulating, or both, which is designed and used to auger windup sling the cable or strap attached to the auger stow
position personnel. The device may also be used to handle material, if bracket which is used to store the digger and auger.
designed and equipped for that purpose. auxiliary engine a separately mounted engine that is used to
Allen wrench a six-sided wrench that fits into the hex socket of a cap provide power for the units hydraulic system.
screw or set screw. auxiliary hydraulic system the secondary hydraulic system of a
American National Standards Institute (ANSI) a self-governing pressure digger that operates all the hydraulic functions except auger
body of professionals whose primary objective is to prevent accidents rotation.
by establishing requirements for design, manufacture, maintenance, AWS American Welding Society.
performance, use and training for manufactured goods including aerial
devices and digger derricks. back pressure pressure existing in the discharge flow from an
actuator or hydraulic system. It adds to the pressure required to operate
anaerobic adhesive a bonding agent or adhesive that cures in the an actuator under a given load.
absence of air.
backlash the clearance at the tooth contact point between the
analog signal an electrical signal that communicates information by adjacent gear teeth of two or more meshing gears.
the continuous variation of voltage or current level within a defined
range, in proportion to an input parameter such as pressure or control baffle a device, usually a plate, installed in a reservoir to separate the
lever position. return line inlet from the suction line outlet.
annular area a ring shaped area. Usually refers to the piston area bare-hand work a technique of performing live line maintenance on
minus the cross-sectional area of the rod of a hydraulic cylinder. energized conductors and equipment whereby one or more authorized
persons work directly on an energized part after having been raised and
ANSI see American National Standards Institute. bonded to the energized conductors or equipment.
antirotation fork a two-pronged retainer which is fastened to the barrel the hollow body of a hydraulic cylinder into which the piston
inside of the turntable and used to prevent movement of the rotary joint and rod are assembled.
outer housing.
base boom see lower boom.
antifoam additive an agent added to hydraulic fluid to inhibit air
bubbles from forming and collecting together on the surface of the fluid. 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
antiwear additive an agent added to hydraulic fluid to improve the closest to the turntable. 3: the end of an articulating boom that remains
ability of the fluid to prevent wear on internal moving parts in the positioned closest to the turntable when the boom is fully unfolded.
hydraulic system.
basket see platform.
arbor bar the shaft or spindle that is used to support a cable reel.
battery charger a device used to restore the electrical charge in a
arbor bar collar a cylindrical device that is used to secure a cable battery.
reel on an arbor bar.
bearing a machine part that is installed between two adjacent
arm 1: the primary load-carrying structure of an articulating arm. 2: machine parts to allow those parts to rotate or slide with respect to each
the primary load-carrying structure of a single elevator. 3: the articulat- other. Commonly used to decrease friction or wear on components.
ing structure which supports the arbor bar for reel lifting.
behind cab mount a pedestal mounting position located immedi-
arm cylinder the hydraulic cylinder that moves the arm of a single ately behind the vehicle cab on the longitudinal centerline of the
elevator up and down. chassis.
articulating arm a system located between the turntable and lower below rotation in reference to a position on or about a unit that is
boom of an aerial device which is used for lifting the boom assembly to vertically below the rotation bearing.
increase the platform working height. This system includes the arm,
link(s), riser and articulating arm cylinder. below rotation controls controls that are located on the chassis,
used for operating some or all of the functions of the unit.
articulating arm cylinder the hydraulic cylinder that moves an
articulating arm up and down. bleed-off to reduce the trapped pressure in a hydraulic system, line,
or component, to a zero state by allowing fluid to escape under con-
trolled conditions through a valve or outlet.
Most routine maintenance and service of the unit can be egorized with their corresponding Altec part number. The
performed with common hand tools and shop supplies list contains items for both aerial devices and derricks. An
available from a tool supply company. Some special Accessory and Replacement Parts Catalog is also avail-
tools and supplies are available from your Altec repre- able for ordering other items that may not be shown in the
sentative that may be useful or required to perform Parts Manual. This catalog can be obtained through your
certain maintenance procedures. These items are cat- Altec representative.
Chain and Cable Fluid Lubricate cables such as wire rope winch line, auger windup 099-00018
sling, and leveling cables or chains.
Fasteners
Thread locking adhesive Low strength thread locking and sealing agent for small 099-00019
(Purple 50 ml) diameter 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 099-00037
(Red 50 ml) diameter bolts and cap screws.
Cleaner for inspection lacquer (1/2 oz) Visual inspection stripe removal. 099-00124
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 099-00040
adhesive.
Primer (Grade T 6 oz) Anaerobic solvent reduces cure time on thread locking 099-00041
adhesive.
Pipe sealant (50 ml) General purpose pipe sealant for use on pipes to two inches. 099-00038
Test block small bore (7/8″ hex) Testing counterbalance valve. 352-79006
Return line filter cartridge Filters hydraulic oil before it is returned to the reservoir. 353-30007
Water removal filter cartridge Removes water from the hydraulic system. 353-30016
Oil warming kit Warm hydraulic oil to operating temperature in cold weather. 750-40039
Conformal coating (14 oz) Silicon based electrical component protection. 099-00042
Miscellaneous
Leveling cable kit Parts for the five year mandatory leveling cable change. 750-40013
Atmospheric vent valve tester Test atmospheric vents for proper operation. 356-90042
0 3
0-
Model Number _________________________________ Serial Number _________________________________
r 1
Odometer _________________ Hours Meter _________________ Inspector _____________________________
f te
Perform all inspections, adjustments, repairs, and lubrication according to Altec specifications in the Maintenance
a
Manual. Refer to any MABs, CSNs, or other applicable documents provided by Altec for servicing the unit.
ilt
If you are tracking PTO hours utilizing an approved method or device, follow the recommended hourly maintenance
u
intervals, or if you are performing maintenance based upon a calendar-based schedule, follow the recommended
b
monthly intervals. The required items apply to both interval-tracking systems.
Intervals
i t s
n
❏ Prior to placing unit in service ❏ 85 PTO hours/1 month ❏ 500 PTO hours/6 months
u
❏ 1,000 PTO hours/1 year ❏ 2,000 PTO hours/2 years ❏ Required maintenance
Symbols
o r
F
✓ = Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
Symbols
✓ = Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
SAE Grade 8
SAE Grade 5 Hex and Socket Head Button and Flat Head
Size ft-lbs (Nm) ft-lbs (Nm) ft-lbs (Nm)
Dry Lubed Dry Lubed Dry Lubed
1
/4″ 0.2500″ 8 (11) 6 (8) 11 (15) 9 (12) 9 (12) 8 (11)
/16″
5
0.3125″ 16 (22) 13 (18) 22 (30) 18 (24) 19 (26) 15 (20)
3
/8″ 0.3750″ 28 (38) 23 (31) 39 (53) 33 (45) 33 (45) 28 (38)
/16″
7
0.4375″ 44 (60) 37 (50) 63 (85) 52 (71) 54 (73) 45 (61)
1
/2″ 0.5000″ 68 (92) 57 (77) 96 (130) 80 (108) 82 (111) 68 (92)
/16″
9
0.5625″ 98 (133) 82 (111) 138 (187) 115 (156) 118 (160) 98 (133)
5
/8″ 0.6250″ 135 (183) 113 (153) 191 (259) 159 (216) 164 (222) 136 (184)
3
/4″ 0.7500″ 240 (325) 200 (271) 339 (460) 282 (382) 290 (393) 241 (327)
7
/8″ 0.8750″ 386 (523) 322 (437) 545 (739) 455 (617) 467 (633) 390 (529)
1″ 1.0000″ 579 (785) 483 (655) 818 (1,109) 681 (923) 701 (951) 583 (791)
Torque values shown are for turning the nut while holding the head of the bolt with a wrench. If the application demands tightening by the bolt head,
increase the torque slightly (by 5-20 percent depending on the bolt length) to allow for the normal twist of the bolt shank.
Misalignment
of marks show
how much nut
was tightened
Rotate Number
Tube Size Fitting Size of Hex Flats
1
/4″ -4 2
5
/16 ″ -5 2
3
/8″ -6 11/2
1
/2″ -8 11/2
5
/8″ -10 11/2
3
/4″ -12 11/4
1″ -16 1
1 /4″1
-20 1
1 /2″1
-24 1
Push button
Pneumatic
Pedal or treadle
Lines crossing
Mechanical
or
Detent
Pressure compensated
Lines joining
Servo motor
Flow control —
adjustable, non-compensated
Pilot pressure Remote supply
Flow control —
adjustable (temperature and Internal supply
pressure compensated)
Pressurized
Pressure reducing
Line, to reservoir Above fluid level
Vented manifold
Two position, three connection
Hydraulic oscillator
Three position, four connection
Hydraulic motor
Fixed displacement
Two position, in transition
Variable displacement
Valves capable of infinite
positioning (horizontal bars Bidirectional
indicate infinite positioning ability)
Hydraulic pump
Fixed displacement
Variable displacement
Weighted
Pressure switch
Heater
Pressure gauge
Temperature gauge
Temperature controller
Quick disconnect
Pump is noisy. The reservoir oil level is too low. Fill the reservoir to the proper level.
Restriction in pump suction line. Fully open the suction line shutoff valve.
Air entering suction line. Fill the reservoir to the proper level.
Excessive heat The reservoir oil level is too low. Fill the reservoir to the proper level.
buildup (180°+).
The engine speed is set too high. Adjust the throttle cylinder.
Excessive internal system Check the outrigger power beyond plug seals for leaks.
leakage.
Make sure the relief valve settings are properly set.
Check the boom tip tool valve for leakage. Replace if necessary.
Power tools improperly sized for Change power tools or adjust the tool flow control.
gpm flow of tool circuit.
Boom functions Lower control valve spools do not Lubricate or replace as necessary.
operate slowly. fully shift.
Adjust the pilot pressure to 350 psi.
Adjust the forced opening on the upper control valve to the proper
value.
Make sure the lower control valve handles are not hitting the
turntable cover, hoses, etc.
Engine rpm is set too low or the Adjust the engine rpm.
throttle does not increase engine
speed.
Improperly adjusted lower control Properly adjust the valve spool stops.
valve spool stop(s).
Low pump flow. Check the pump with a flowmeter. Replace if defective.
Low pump standby pressure. Adjust the standby pressure to 350 psi.
Restriction in the pressure line. The restricted area will be warmer to the touch than the rest of the
system. Remove the restriction.
Blocking valve is not fully open. Test by connecting a flowmeter at valve input and back to reservoir.
Replace the blocking valve if necessary.
One boom function Purge check not seating. Operate the lower control handle to verify that function operates
operates slowly. properly from that control.
Tools, jib, winch Tool signal not working. Replace the tool signal pressure reducing valve.
operate slowly or
will not work under Tool pressure is set too low. Adjust the tool pressure reducing valve.
load.
Power tools improperly sized Change power tools or adjust the tool flow control.
for gpm flow of tool circuit.
Engine throttle does not work. Adjust or replace the engine throttle control.
The engine and Tool valve is on. Turn the lower or upper tool circuit valve off.
pump remain
loaded all the time. Tool blocking valve is defective. Replace the tool blocking valve cartridge.
The pump signal is not bleeding Open the signal drain line needle valve (in turntable or pedestal).
off. Readjust 11/2 turns open.
No functions from The control selector valve is in Place the control in the Upper Controls position.
the upper controls. the Lower Controls position.
The control selector valve is Check the operation of the upper/lower control selector valve.
not fully shifted. Replace if defective.
Air in the hydraulic line. Purge all air out of the lines.
Low or no pilot pressure. Test and/or adjust standby pressure to 350 psi.
Blocking valve of the upper Check the operation of the blocking section of the upper control
control valve is not fully shifted. valve. If defective, replace the spool for the blocking section.
Only the outriggers Outriggers are not properly set. Properly set the outriggers. All interlock switches must be activated
and power tools for unit functions to operate.
operate.
Improper pilot pressure. Test and/or adjust the pilot pressure to 350 psi.
Low system pressure. Test and/or adjust the system pressure to 3,000 psi.
No signal at the lower control Check the relief valve in the lower control housing.
valve. Replace if necessary.
No signal to the pump control The seals may be leaking in the rotary joint if the signal is reaching
manifold. the rotary joint but not the pump control manifold.
All functions Tools are turned off. Turn the lower or upper tool circuit valve on.
operate except
power tools. The upper control interlock is Release the interlock trigger on the single handle control.
engaged.
The blocking valve is shifting Remove and cap the pilot port line of the tool control valve to
off or malfunctioning. determine if the blocking valve is malfunctioning.
The tool system is receiving an Remove and cap TP port line of the tool control valve to determine
external signal. if the system is receiving an external signal.
The pump is not receiving a Check for pressure at the signal port of the tool control valve.
signal from the tool control valve.
The outrigger leg Pilot operated check valve Clean the valve in solvent and blow it dry with compressed air.
does not hold under contamination.
load.
Pilot operated check valve Replace the valve.
malfunction.
Nothing operates. PTO is not engaged. Check the PTO. If it is not engaged, properly engage it.
Hydraulic oil is not reaching the Open the shutoff valve in the suction line.
pump.
Fill the reservoir to the proper level.
Improperly plumbed pump. Check the Hydraulic Schematic. The signal port is port B, the drain
port is A. Check pump installation for proper shaft alignment. Side
loads on the pump drive shaft will cause complete loss of pressure.
No system pressure. If there is no pressure at the system pressure test port on the tool
control valve, check for loss of prime to pump. May be caused by a
leak in the pump suction line. Repair if necessary.
Pump is not operating properly. Connect a flowmeter to the pump and check flow.
Severe hydraulic Hose, tube, fitting, seal failure, Replace the defective component.
leak. etc.
Bonding
Jumper
High Voltage
Test Leads
1. Read and understand the dielectric test information in the Maintenance Manual and ANSI requirements.
2. Insulate the vehicle from ground by placing polyethylene pads beneath each tire and outrigger leg.
3. The preferred test is with the unit in Position A. Position B may be used for an inside facility with limited test
space. When using Position B place the bottom of the platform 15 feet from the ground. Electrical connections
are the same for both positions.
4. Electrically bond all metal at the boom tip and the booms.
5. Attach the ground/return leads to the vehicle.
6. Attach the high voltage test lead (insulated from ground) to the lower boom for the lower boom test and to the
upper boom for the upper boom test as shown.
7. Do not use cancel (null) circuit if the tester is so equipped.
8. To test the upper boom, gradually increase the voltage to 100 kV. Hold at 100 kV (60 hertz) for 3 minutes
continuously. If flashover occurs or the leakage rate exceeds 1,000 microamps, the unit has failed the test.
Record leakage reading.
9. To test the lower boom, gradually increase the voltage to 50 kV. Hold at 50 kV (60 hertz) for 3 minutes con-
tinuously. If flashover occurs or the leakage rate exceeds 3,000 microamps, the unit has failed the test.
Record leakage reading.
General Information
Conclusion
Upper boom leakage reading (microamp) ___________ Lower boom leakage reading (microamp) _____________
Comments ___________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
Test Band
Bonding
Jumper
High Voltage
Ground/ Leads
Return
Leads
Control Leads High Voltage
Transformer
Procedure
1. Read and understand the dielectric test information in the Maintenance Manual and ANSI requirements.
2. Insulate the vehicle from ground by placing polyethylene pads beneath each tire and outrigger leg.
3. The preferred test is with the unit in Position A. Position B may be used for an inside facility with limited test
space. When using Position B place the bottom of the platform 15 feet from the ground. Electrical connections
are the same for both positions.
4. Electrically bond all metal at the boom tip and the booms.
5. Attach the ground and test leads for the upper boom test as shown.
6. Do not use cancel (null) circuit if the tester is so equipped.
7. Gradually increase the voltage to 27 kV. Hold at 27 kV (60 hertz) for 1 minute continuously. If flashover occurs
or the leakage rate exceeds 27 microamps, the unit has failed the test. Record leakage reading.
8. Gradually increase the voltage to 54 kV. Record leakage when 54 kV (60 hertz) is reached. If flashover occurs
or the leakage rate exceeds 54 microamps, the unit has failed the test. Record leakage reading.
9. Hold the voltage at 54 kV (60 hertz) for 1 minute continuously. If flashover occurs or the leakage rate exceeds
54 microamps, the unit has failed the test. Record leakage reading.
10. Gradually increase the voltage to 80 kV. Hold at 80 kV (60 hertz) for 10 seconds. If flashover occurs or the
leakage rate exceeds 80 microamps, the unit has failed the test. Record leakage reading.
11. Remove the ground and test leads from the upper boom. Attach the test leads for the lower boom test as
shown.
12. Gradually increase the voltage to 50 kV. Hold at 50 kV (60 hertz) for 3 minutes continuously. If flashover
occurs or the leakage rate exceeds 3,000 microamps, the unit has failed the test. Record leakage reading.
General Information
Leakage reading (microamp) at: 27 kV _______ 54 kV _______ 54 kV after 1 minute _______ 80 kV _______
Conclusion
Comments ___________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
Test Band
Bonding
Jumper
High Voltage
Ground/ Leads
Return
Leads
Control Leads High Voltage
Transformer
Procedure
1. Read and understand the dielectric test information in the Maintenance Manual and ANSI requirements.
2. Insulate the vehicle from ground by placing polyethylene pads beneath each tire and outrigger leg.
3. The preferred test is with the unit in Position A. Position B may be used for an inside facility with limited test
space. When using Position B place the bottom of the platform 15 feet from the ground. Electrical connections
are the same for both positions.
4. Electrically bond all metal at the boom tip and the booms.
5. Attach the ground and test leads for the upper boom test as shown.
6. Do not use cancel (null) circuit if the tester is so equipped.
7. Gradually increase the voltage to 40 kV. Hold at 40 kV (60 hertz) for 1 minute continuously. If flashover occurs
or the leakage rate exceeds 40 microamps, the unit has failed the test. Record leakage reading.
8. Gradually increase the voltage to 80 kV. Record leakage when 80 kV (60 hertz) is reached. If flashover occurs
or the leakage rate exceeds 80 microamps, the unit has failed the test. Record leakage reading.
9. Hold the voltage at 80 kV (60 hertz) for 1 minute continuously. If flashover occurs or the leakage rate exceeds
80 microamps, the unit has failed the test. Record leakage reading.
10. Gradually increase the voltage to 120 kV. Hold at 120 kV (60 hertz) for 10 seconds. If flashover occurs or the
leakage rate exceeds 120 microamps, the unit has failed the test. Record leakage reading.
11. Remove the ground and test leads from the upper boom. Attach the test leads for the lower boom test as
shown.
12. Gradually increase the voltage to 50 kV. Hold at 50 kV (60 hertz) for 3 minutes continuously. If flashover
occurs or the leakage rate exceeds 3,000 microamps, the unit has failed the test. Record leakage reading.
General Information
Leakage reading (microamp) at: 40 kV _______ 80 kV _______ 80 kV after 1 minute _______ 120 kV _______
Conclusion
Comments ___________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________
Procedure
5. If flashover occurs, or the liner wall punctures, the liner has failed Ground
the test.
6. Turn off the test voltage, remove the high voltage lead and remove the liner from the tank.
7. The test for more than one liner may be recorded on the same form providing the same setup is used to
eliminate external variables.
Conclusion
Liner Part No. Liner Serial No. Pass (Initials) Fail (Reason)
Comments _________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
1. Perform the stability test on a level surface and on a five degree slope in accordance with applicable ANSI
requirements.
2. Fill out all information on this form as a record of a completed stability test.
3. Find the model being tested in the chart for the test being performed.
4. Position the lower boom at the angle (A) indicated in the chart and place the upper boom horizontal.
5. Position the jib so the distance (D) from the center of the load line to the center of the jib pivot equals either
one or two feet, as designated in the stability charts.
6. If the unit is equipped with platform rotators, the platforms must be rotated to the position furthest from the
centerline of rotation.
7. Alternate Test B is a more conservative test that may be used instead of Standard Test A to reduce weight
handling time. On units which require counterweight, Standard Test A may be preferred to minimize counter-
weight.
8. Subtract the weight of liners, tools, etc., from the test weight shown in the stability charts. For platform capaci-
ties not shown, use a test weight of 1.5 times rated load for the Level Surface Stability Test and 1.33 times
rated load for the Five Degree Slope Stability Test.
9. Load the jib and the platform with the proper weight.
10. After the test has been completed, torque all accessible rotation bearing cap screws to 325 foot-pounds using
a circular pattern (only required at time of initial installation of unit on chassis).
11. After the test has been completed, torque the rotation gearbox mounting cap screws to 225 foot-pounds (only
required at time of initial installation of unit on chassis).
General Information
Test conducted A _____ B _____ Platform test weight (lbs) ___________ Jib test weight (lbs) ____________
Test conducted A _____ B _____ Platform test weight (lbs) ___________ Jib test weight (lbs) ____________
Side of vehicle on low side of slope _________ Thickness of outrigger pads (0 if not used) __________________
Conclusion
Rotation bearing cap screws torqued ___________ Rotation gearbox mounting cap screws torqued ___________
Comments ___________________________________________________________________________________
_____________________________________________________________________________________________
Procedure
1. Perform the stability test on a level surface and on a five degree slope in accordance with applicable CSA
requirements.
2. Fill out all information on this form as a record of a completed stability test.
3. Find the model being tested in the chart for the test being performed.
4. Position the lower boom at the angle (A) indicated in the chart and place the upper boom horizontal.
5. Position the jib so the distance (D) from the center of the load line to the center of the jib pivot equals either
one or two feet, as designated in the stability chart.
6. If the unit is equipped with platform rotators, the platforms must be rotated to the position furthest from the
centerline of rotation.
7. Alternate Test B is a more conservative test that may be used instead of Standard Test A to reduce weight
handling time. On units which require counterweight, Standard Test A may be preferred to minimize counter-
weight.
8. Subtract the weight of liners, tools, etc., from the test weight shown in the stability chart. For platform capaci-
ties not shown, use a test weight of two times rated load for the Level Surface and the Five Degree Slope
Stability Test.
9. Load the jib and the platform with the proper weight.
10. After the test has been completed, torque all accessible rotation bearing cap screws to 325 foot-pounds using
a circular pattern (only required at time of initial installation of unit on chassis).
11. After the test has been completed, torque the rotation gearbox mounting cap screws to 225 foot-pounds (only
required at time of initial installation of unit on chassis).
Test conducted A _____ B _____ Platform test weight (lbs) ___________ Jib test weight (lbs) ____________
Test conducted A _____ B _____ Platform test weight (lbs) ___________ Jib test weight (lbs) ____________
Side of vehicle on low side of slope _________ Thickness of outrigger pads (0 if not used) __________________
Conclusion
Rotation bearing cap screws torqued ___________ Rotation gearbox mounting cap screws torqued ___________
Comments ___________________________________________________________________________________
_____________________________________________________________________________________________
_____________________________________________________________________________________________