Maintenance and Parts Manual ‘Altec Industries, Inc. reserves the right to improve models and change specifications without notice, Maintenance and Parts: 970258290 Maintenance Manual: 970259673 2010 Copyright © 2010/by Altec Industries, Inc. Al rights reserved. No part ofthis publication may be used of reproduced by any means, Of st0red Inia: database or retrieval system, without prior written permission of the publisher. Making copies ot any part of this publication for any purpase ciher than pefsonal use is a viblatioh of United States Copyndht lawsPreface This unit is the result of Altec’s 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 specications contained within this manual are based on the latest product information available atthe time of publication. Itis essential that all personnel involved in the use and/or care of this unit read and understand the Operator's Manual. Given reasonable care and operation, according to the guidelines set forth in the manuals provided, this unit will provide many years of excellent service before requiring major maintenance. The scope of this manual is limited to periodic maintenance. It does not cover methods that, may be required to inspect and repair major damage to the unit. Impacts to and excessive forces on the hydraulic utility equipment, through vehicular accidents, rollovers, excessive loading, and the like, may result in structural damage not obvious during a visual inspection. Ifthe hydraulic utility equipmentis subjected to such impacts or forces, a qualified person may eed to perform additional testing such as acoustic emissions, magnuflux or ultrasonic testing as applicable. If structural damage is suspected or found, contact Altec for additional instructions warning Death or serious injury can result from component failure. Continued use of a mobile unit with hidden damage could lead to component failure. Neveralter 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 possibilty that Unauthorized modification could adversely affect the safe operation of this unit, resulting in personal injury and/or property damage. Aparser Death or serious injury will result from unprotected contact with energized conductors. Non-insulating units have no dielectrie 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 company’s accepted ‘work methods, safety procedures, and protective equipment. Training manuals are available from a vatiety of sources. Set-up requirements, work procedures, and safety precautions for each particular situation are the responsibility of the personnel involved in the use and/or care of this unit.Table of Contents Section 1 — Introduction ‘About This Manual ‘Section 2— Unit Specifications General Specifications... Componentidentitication Section 3— Safety Safety Instructions Disclaimer of Liability Section 4 — Preventive Maintenance and Inspection Equipment Storage Protective Measures Hydraulic System .. Cleanliness Precautions Filtration Oil Specifications OilConditon.... Changing Oil and Flushing the System Lubrication Lubrication Chartand Diagram Structures . Cleaning Welds. Fasteners Rotation Bearing Cap Screw: Rotation Gearbox Mounting Cap Screw: Pins and Pin Retainers .. Pin tntaltion Into Stating Bearings .. Bearings ‘Spherical Bearings Self-Lubricating Bearings .. Slide Pad Bearings Rotation Boar. Cylinders... HydraulicLines . Single Handle Control and Control Handle Covers ‘Atmospheric Vents Fiberglass and Plastic Components Cleaning Plastic. Determining the Degree of Boom Damage Repair... sos Platform Leveling Winch Line nnn Accident Prevention Signs... Accident Prevention Signs Diagram Section 5 — Hydraulic System Hydraulic System OilReservoir Pump. Secondary Stowage DC Pump...Rotary Joint Valves Lower Control Vatve ... Elevator Winch Override Valve . Hydraulic Stop... Upper Control Vaive ... Upper Too Circuit Control Valve Outrigger Control Valves .. Hydraulic ib Extension Valve... Platform Tit and Rotate Control Valve Relief Valve Holding Valves .... Cavitation and Aeration AirBleeding Leakage .... Heat Generation... HydraulicLines Fittings and Valve Cartridges Torqueand Tightening Procedures Valve Cartiidges Cylinders Outrigger Cylinders LowerBoom Cylinder UpperBoom Cylinders. vib Tilt Cylinder Jib Extension Cylinder... Platform Rotator Cylinder Elevator Lower Arm Cylinder Elevator Upper Arm Cylinder... BLERBRISSSSSSSSSTRERREBRSREK Section 6— Mechanical Systems Rotary Joint (L42M, L42P, L45M, L45P)... Rotary Joint (L42M-E48 and L42M-E53) Rotation System 2 Rotation Bearing... Rotation Bearing Gap Screws. Rotation Gearbox Drum Weldment and UpperBoom Lower Boom Leveling System Upper BeomLevaing Syston Lower Boom... Winch Line NNYVSBRRISSY Section 7 — Electrical System Remote Stop/Start Control Box ... Power Distribution Module (PDM) Outrigger Interlock System Slip Ring BRad Seotion B— Troubleshooting, Testing, and Adjustments Troubleshooting Procedure Hydraulic System Cycle Times Main System Pressure. Pump Flow... Outriggers. BANNANRotation Motor Control Valve... Rotary Joint Boom and Elevator Cylinders Upper Too! Circuit Mechanical Systems Rotation Drive Gearbox .. Rotation System Adjustment Leveling System ‘Winch Brake... - Single Handle Conttol..... Electrical System Failure Identification ... 9 Outrigger Interlock System .. Circuit Breakers Section 9 — Dielectric, Structural, and Stability Testing Dielectric - Single Handle Control Structural... Stability Appendix Glossary Service Tools and Supplies Preventive Maintenance and Inspection Checklist Accessory Checkiist Torque Values Basic JIC Symbols Hydraulic System Schematics Basic Electrical Symbols ring Line Diagram ‘Troubleshooting Chart Dielectric Test Forms Stability Test Forms 28 BS88IRSRBBR2 2888Section 1 — Introduction About This Manual. ‘This manual provides instruction to safely inspect, repair, troubleshoot, and test the unit. Charts and figures are provided to support the text. Because options vary from ‘one model to another, some figures may only be a representation of what is actually on the unit. Knowledge of the information nthismanualcombinedwith proper skills and training in hydraulic, electrical, and mechanical systems, provide a basis for safely maintain- ingtheunit. Readand understand the applicable procedure before beginning. Carefully follow each procedure. Contactthe following organizations for additionalinforma- tion. + American National Standards Institute (ANSI) ‘A92.2 for aerial devices; A10.31 for digger derricks + American Public Power Association (Safety Manual for an Electric Utility) + American Society for Testing and Materials (ASTM) + American Welding Society (AWS) + Canadian Standards Association (CSA) + European Committee for Standardization (CEN) + Fluid Power Society (FPS) + Hydraulic Too! Manufacturer's Association (HTMA) + International Electrotechnical Commission (IEC) + International Organization for Standardization (ISO) + Occupational Safety and Health Administration (OSHA) Dealers, installers, owners, users, operators, renters, lessors, and lessees must comply with the appropriate sections of the applicable ANSI standard, The Appendix contains reference items to help maintain the unit. A glossary of industry terms is provided for your convenience. This glossary provides an understanding of the industry terms and phrases used in Altec manuals. ‘Throughout the manual, the term units used to describe the Altec device, subbase, outriggers, andthe associated interface with the vehicle. ‘Additional copies ofthis manual may be ordered through your Altec representative. Supply the model and serial numberfound onthe serial numberplacard and the manual partnumber fromthe front cover to assure thatthe correct, manual willbe supplied. This symbol is used throughout this manual to indicate danger, warning, and caution instruc tions. These instructions must be followed to reduce the likelihood of personal injury andlor property damage. The terms danger, warning, caution, andnotice represent varying degrees of personalinjury and/or property damage that could result if the preventive instructions are not followed. The following paragraphs from ANSI publica- tions explain each term. Danger Indicates a hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. Warning Indicates a hazardous situation which, if not avoided, could result in death or serious injury. Caution Indicates a hazardous situation which, if not avoided, may resultin minor or moderate injury. It may also be used to alert against unsafe prac- tices. Notice Thepreterred signalwordto address practices not related to personal injury. Section 1 — Introduction * 1.2¢ Section 1 — IntroductionSection 2 — Unit Specifications General Speci This insulating unit is an overcenter articulating type. The lowerboomis capable of movementfrom 0 degreesto 125, degrees above horizontal. The upper boom is capable of movement from 0 to 205 degrees. Tumtable rotation is, continuous in either direction. ations This unit is designed for normal instalation infront of the rear axle. The basic structural components of the unit are the upperboom, lower boom, tuntable, pedestalor eleva- tor, and subbase. Carefulconsiderationhas been givento the design and manufacturing process to minimize the possibility of forming fatigue cracks on the structures. This unit is manufactured with nonconductive compo- rents that, when properly used and maintained, will meet the dielectric requirements of ANSI in effect atthe time of manufacture. The ratings of the unit must be known and Understood by its users, This unit shall be used near energized conductors only by qualified operators. Personnel using this equipment must be familiar with the hazards of contact with energized conductors, for the protection of themselves, their cowork- ‘ers/workers and the public. The nature of electrical haz- ards is described in the Operator's Manual. Personnel sing this equipmenton ornear energizedconductors must be familiar with these hazards for their own protection. Section 2— Unit Specifications + 3suonesyjoods wun — 12 21n6i woz (uu 496) 3 1 de8 do 9° 06 81 (wo e9'901 x wo 92 x wo 96°00) .2F x08 x rz 018 SUOISUOMIP WHO}eIA + (wo {'g6).0'91 51 deB voqarnsul woog 01 suoqeouede yun Gumoyo} sues ou OAC 8 SIN (@xozz'e)sa100z's (6x6e0'e) saiooz'9 (64ze1'Z)sqlooz'y (64g92'z)sqI000's (64 280'z)salo0g'y (BxEze'z)sa1006'y un oiseq jo yBIeM (uge).6lyt (wise) 6 tt (Wae'e).6'sst (Wa6e).65S1 (Wo'e),6LyL (Wg) 6 LHL (ujus) de6 uoneinsu woo seddy Wgere wee eo wrest urea wre — wye)at PaMmo1s146I04 OAL Bley wuosre|d Te seuEDIENO (us9),e12 (wo'9) 8°64 (wr9) Foe (wi9) 4'0¢ (wi9) 02 (wy9),;0% __ -woumoogueddn yim yokes WNwIKEA (Ge0iB9p¢21 e wi00q1e%mo})s8qUB0IaN0 (wzonzse (uizonzse (wetove (wet oze (wror).z'se__(WZ'01).2'se __-tuoumiooqueddn ymyovosunuirKeyy z 1uBisy Wiope|d ye s5jueDIENO (us2).2e (woz) .29 (wre)oz (wre) oz (wp2).o2 (wp2)oz wooqieddn yym yores wine) - (see169p 0 1e woog 49Mo}) 19)N0910N0 (usonove wsoove weese Wel) eae (WsoHore _(wso1).9%6 woog seddn uaa yowes winwirceyy (uez)ees (Woo)res wesioos wesi)oos (ws) oz» SP) O2y qyBley BupHOM, Wuyonees wre wreosy wreosr (woer.ozr _(woel).ozr __14Bley UNoAeIdjo Wong or pund1D esa wert era WerT asvT WsbT dev wert well 4 * Section 2 — Unit SpecificationsComponent Identification Ie Parallel Link ‘Compensating Link (Inside Riser) Riser Upper Controls UpperBicom DriveMechanism LowerBoom_ Insulator Upper Boom Cylinders Lower Boom — LowerBoom Cylinder —~ LowerControls (On Other Side of Tumtable) ‘Section 2 — Unit Specifications + 56+ Section 2 — Unit SpecificationsSection 3 — Safety Safety Instruct Itis essential that all personnel involved in the use and/ or care ofthis unitread and understand the Operator's and Maintenance Manual. Safety alerts throughoutthe manu- als highlight situations in which accidents can occur. Pay special attention to all safety alerts. ‘The safety information in this manual applies only to the ‘maintenance of his unit. Although procedureshave been, written to protect the mechanicandother personnel, there is no safety system to account for human error or negli- gence Aparser Death or serious injury will result from electrocution. This unit does not provide protection from contact with or proximity toan electrically charged conductor when youare incontactwith or in proximity toanother conductor or any grounded device, material, or equip- ment. Maintain safe clearances from energized con- ductors. Death or serious injury can result from careless or improper use of the unit. The mechanic bears ultimate responsibility for following all regulations and safety rules of theiremployer and/or any stateor federal law. Notice Maintenance personnel mustbetrainedin safe service procedures. Itisimpossibleto foresee al situations andcombina- tions for the set up and use of the unit while perform- ing maintenance operations. The mechanic bears ultimate responsibility for following all regulations and safety rules of their employer and/or any state or federallaw. Knowledge of the information in this manual, and proper training, provide a basis for safely maintaining the unit Follow the proceduresin his manual while maintaining the unit Work practices may expose maintenance personnel to, hazardous materials. Before using any chemical, readand, understand the manufacturer's label and the material safety data sheet (MSDS). These sheets explain emer- gency and first aid procedures, waste disposal methods andspillorleak procedures. Reporthazardous conditions. General Maintenance Information + Remove the pressure in a hydraulic circuit before disconnecting its components. + Use lifting devices of suitable capacity to support and handle components. + Use a test block to adjust the relief setting on counterbalance holding valves. + Beware of your surroundings. + Fully open all shutoff valves after servicing the unit + Completethe required procedures before returning the unit to operation Disclaimer of Liability Altec Industries, Inc. will not be liable for unauthorized alterations or modifications of the unit. Altec Industries, Ine. will not be liable for improper or abusive operation of the unit. Donot alter or modify this unit in any way that might affect its structural integrity, dielectric integrity, or operational characteristics without specific written approval from Altec Industries, Inc. Unauthorized alterations or modifications will void the warranty. However, of agreater concer isthe possibilty that unauthorized changes could adversely affect the Unit's operation that could endanger personnel andlor damage property. Altec willnotbe responsiblefor unautho- rized alterations or modifications that cause death, seri us injury, and/or property damage. Altec Industries, Inc. assumes no liabilty for any personal injury and/or property damage related to the use of this manual when performing testing, operating, maintenance and/or repair procedures on this Altec unit. Section 3 — Safety *78+ Section 3 — SatetySection 4 — Preventive Maintenance and Inspect Proper unit maintenance will reduce downtime, lower operating and repair costs, and extend equipment life. Safety alone justifies a preventivemaintenance program. This section contains information on properly inspecting the hydraulic system, structures, individual unit compo- nents, and lubrication. Use the Lubrication Chart and Diagram in this section when lubricating the unit ‘A Preventive Maintenance and Inspection Checklist is provided in the Appendix. Use this checklist when per- forming routine maintenance and inspectionstoinsure no areas are overlooked. Components may be installed on ‘your unit that require additional maintenance at different intervals outside the scope of he Preventive Maintenance and Inspection and Accessory Checklists. Referto these ‘component manuals for more information. Keep perma- nent, written, anddatedrecords ofall service performedon the unit Routine maintenance is performed on different compo- nents of the unit at different times (refer to the Preventive Maintenance and Inspection Checklist in the Appendix). More frequent maintenance may be necessary ifthe unit is operated under severe conditions. In addition to the Preventive Maintenance and Inspection Checklistrecom- mendations, follow these recommendations onnew units. + Measure the turntable tit before using a new unit. + Change the return line fiter after the first 15t025 PTO hours. Equipment Storage __ Mobile hydraulic equipment needs maintenance when stored, ornot used, forextensive periods of ime. Depend- ing upon the climate, lack of use may begin to have a negative effect in as little as two weeks. Storage for a period of several months will almost certainly produce some deterioration of the equipment. Rust willform on unprotected ferrous metal surfaces very quickly and water will collect inside unit structures. In dry climates, gaskets will begin to shrink during long periods of non-use, and lubricants will lose their ability to provide lubrication. In cold climates, condensation may occur in fluid reservoirs and other components. Even when protective measures have been taken prior to storage, some degradation of performance must be ex- pected when the equipment is put back into use. One ofthe mostnoticeable effects of prolonged periods of non-use is seal deformation. By its nature, hydraulic ‘equipment generally has a number of heavy, cylindrical actuators. Asthese components are allowedtorestinone position for a period of time, the seals on the piston will tend to flatten along the loaded side. Since the seal material is synthetic, its elasticity is limited and it may not resumeits original shape completely. Atbest, there willbe ‘some failure to seal well for a short period of time after Putting the equipment back nto use. Atworst, the seal will never resume its original shape and will have to be replaced. Protective Measures It itis known that equipment will be stored for a month or more, some steps should be taken to preserve the ‘equipment. 1. The best preservative is to fully cycle (operate) the equipment once weekly if even for a short time. 2. Coat exposed ferrous (iron or steel) bare metal sur- faces with a light grease or heavy oil compatible with system hydraulic oil. This includes cylinder rods, shafts, gears, linkages, and unpainted parts. 8. Top off fluid reservoirs to allow as little air space as possible, tolimitthe effects of condensation. Remove excess oil before operating to limit the chance ot overflow when cylinders are cycled. 4. Coverorwrap exposed rubber orneoprene parts with an ultraviolet resistant covering to shield the parts from sun exposure. 5. Unplug electrical connectors and apply a dielectric grease or an aerosol product designed for protecting electrical connectors. Plug the connector back to- gether. 6. Cover switch panels and control panels to prevent directintrusion of ain ormoisture, while allowing airto circulate over the panel. 7. Cover personnel platforms to prevent the accumula- tion of water in the platform. 8. Shield fiberglass components from the sun andother elements, if stored outside, Hydraulic System Maintaining the hydraulic system is critical to the proper operation ofthe unit. Using the proper type of oil helps to prevent many hydraulicsystem problems. Maintainingthe oll is also important. If the oil is dirty or contaminated, components may be damaged. Awaring Deathor serious injury canresultifthe recommended hydraulic oil is not used. Use of other fluids in the Section 4 — Preventive Maintenance and Inspection + 9hydraulic system canaffectthe insulating capability of the unit. Notice Only use hydraulic oil as recommended. Other fluids added tothe hydraulic system canincrease component wear and affect the lubricating characteristics of the oi Check the oil level in the reservoir with the vehicle level andthe booms and outriggers stowed. Under these condi- tiors, the proper oil level is between the Add and Full marks on the dipstick. Cleanliness Precautions Contamination will ruin any hydraulic eystor. Ite very important that no contamination enter the system. Dit, water and air are types of contaminants. They can enter the hydraulic system in many ways. Contaminants can enter the system when filing the reservoir or changing filters. They can also enter when changing components or performing other service procedures. The following precautions willhelp protectthe cleanliness of tne hydraulic system, + Filter new oilwith a 10 micron fiterasitis addedtothe reservoir. * Clean hydraulic connections before opening them. + Cap or plug ports and lines opened for service. + Keepreplacementhoses, tubes, andother components plugged while stored. + Make sure components are clean before installation. + Cleanthe reservoirand,etumlinefitercovers before openingthem, + Clean the filer breather cap before opening it. + Afterservicing the reservoir, immediately replace the cover. + Make sure quickdisconnect couplers are clean before ‘connecting them + Do not spray water on the reservoir filler breather Filtration ‘The unit is equipped with a complete fitration system. When properly maintained, this system will reduce con- tamination of the hydraulic system. The filtration system must be serviced regulary to be effective. Filler Breather Cap and Strainer Basket Thefillerbreather capislocatedon top of thefillholeof the resarvoir (referto Figure 4.1). Thecap allows arto flowin and out ofthe reservoiras the cil evel changes. Itcontains a 40 micron fiter that cleans. theairas tenters the hydraulic system. The cap also has a strainer basket that keeps large particles from entering thereservoir when oilis poured in 10+ Section 4 — Preventive Maintenance and Inspection — Filler Breather Cap Figure 4.1— Reservoir ‘The filer breather cap on tne 15 gallon (56.781) reservoir has a builtin dipstick with Full and Add marks. Use the marks to determine the oil level of the reservoir as described in this section under Hydraulic Oil Specitica- tions. For reservoirs with no dipstick, the oil level should be above the bottom of the strainer basket. The 40 micron filter in the filler breather cap is not accessible, requiring the replacement of the filler breather caponaroutine basis. Replace thefillerbreathercap once year. Ifthe unitis operatedin a dusty environment, itmay be necessary to replace it more often. Remove and lush out (orreplace) the strainerbasketany timeithas collected dirtor other contaminants. Also, flush the strainer basket when the hydraulic oil is changed. Suction Filter Hydraulic oil leaving the reservoir through the suction|ine,, onits way tothe pump, passes through a suction fier. The suction flteris located inside the reservoirandcontains a 4150 micronwire mesh element. Althoughthe element may be cleaned, itis also available as a service par (see Altec Service Tools and Supplies in the Appendix). Itis important to clean the fiter regularly. Clean it when- ever the hydraulic oilis changed (at least once a year). It the fter becomes cloggec, oil wll nt flow into the pump fast enough. If the pump does not receive sufficient oil flow, pump damage will result The suction fiter is equipped with a bypass valve. This valve opens when there isa pressure drop of 5 psi (0.34 bar) or more across the fiter. When the valve is open, oil flows directly into the pump. This prevents pump cavita- tion during cold oil start-ups. Use the following procedure to remove and clean the suction filter. 1. Drain the reservoir and clean the top of the reservoir cover. Remove the caver.2, Reach down into the reservoir with a crow’s foot wrench or chain wrench. Unscrew the filer by turning the three inch hex bottom counterclockwise. Do not rip the wire mesh screen with the wrench. This will crush the screen. Awarning Death or serious injury can result from improper use of solvents. Followthe manufacturer's labelfor proper use and disposal. A caution Injury can result from airborne particles entering the eyes. Wear appropriate safety equipment. 3. Clean the filter screen by flushing itwith solvent. Use an air hose to dry the filter, blowing the air from the inside of the screen tothe outside. Check other damage. Replace the filter screen. aged. 4, Inspect the inside of the reservoir. necessary, clean, itas described under Changing Oil and Flushing the System. 5. Install the filter by tuning the hex bottom clockwise. Clean the screen no more than four times before replacing it Return Line Filter The retum line filters a 10 micron fier that cleans the oil as it enters the reservoir. It is located in the retur line mounted on the side of the reservoir. The return line iter cartridgeis a spin-ontype which resembles an automotive filter, Particles trappedby the retumlinefiter are collected inthe filter cartridge The retum line fiteris equipped with a bypass valve. The bypass valve opens when theres a pressure drop of [15 psi (1.03bar)](ormore) across thefilter element. When the valve is open, oil lows directly into the reservoir. This prevents the cartridge fromollapsing during cold oilstart- Ups or if it is clogged. Ifthe filter becomes clogged, oil will flow directly into the reservoirthrough the bypass valve. The lack ofoilfitration will eventually cause serious damage to hydraulic compo- nents. During theinitial break-inperiod ofa new unit, the hydraulic. components will deposit break-in wear particles in the retum line filter cartridge. Change the return line cartridge afterthe first 15 to 25 hours of operation. Then change the filter cartridge every 500 PTO hours/6 months. Ifthe unit is operatedin very dusty conditions, replace theretum line filter cartridge more often. Replace the cartridge afternow hydraulic oilhas circulated through the system for the first time. Always replace theretum ine filter cartridge with agenuine Altec replacement part. Other filters may screw into the filter housing, but they may not have the same micron rating. Also, other fiters may allow oil to bypass at a differentrate. Oil Specifications Use high quality oilin the hydraulic system. The oil should contain rust, oxidation, and corrosion inhibitors. It should also contain antifoam and antiwear additives. Hydraulic oils usedin insulating equipment must possess high demulsibilty tallow the oilto separate from the water inthe reservoir. These oils mustpass the ASTM D877 test for dielectric breakdown voltage of insulating oils at 25 kilovolts o higher for new oil. Hydraulic oil is commonly classified by viscosity. The viscosity of hydraulic oil changes with temperature. The higher the viscosity index of an ol, the less the viscosity will change as the temperature changes. A multiviscosity oll contains additives which increase the viscosity index. Multiviscosity oils should have high shear stability to ‘maintain oil performance by avoiding excessive changein viscosity. The ability of hydraulic clo provide adequate fluid at iow temperatures is measured by its pour point. f the pour points not low enough, oil will nt flow into the pump at a fast enough rate when the pump is operated at low temperatures. Thiswill cause cavitation, which can quickly destroy the pump. Qvarnins Death orserious injury can resultif the recommended hydraulic oil is not used. Use of other fluids in the hydraulicsystem canaffectthe insulating capability of the unit. Notice Only use hydraulic oll as recommended. Other fluids added to the hydraulic system can increase compo- nentwearand affect the lubricating characteristics of the oil. Using ahydraulic fluid outside the temperature range itwas prescribed for may cause system damage. is meeting the viscosity rating for military specification MIL-5606 in extremely cold climates. Section 4 — Preventive Maintenance and Inspection + 11These oils havefewer ant not recommended for full Figure 4.2 shows hydraulicoilresommendations or differ- enttemperatures. The requirements are for mineralbased and biodegradable hydraulic fluids. Most companies can supply equivalent oils. The oil selected for the hydraulic system depends onthe temperature during unit operation. When refiling or changing hydraulic fluids it is recom- ‘mendedthe replacement fluid mzetoilcleanliness require- ment 21/17/14 as specified by SO 4406. Oil Condition An important part of hydraulic system preventive mainte- nance includes checking the condition of the hydraulic oil. Periodic laboratory analysisis the most accurate method of determining the condition of hydraulic oil and determin- ing when it should be changed. A visual inspection may also be useful to check oil condition. A hydraulic oil supplier should be able to do testing or recommenda test laboratory. The laboratory should pro- ‘Vide the following information. + Patticle count + Trace element analysis (component wear, outside contaminants, and oil additve concentrations) + Viscosity test + Water content test + Dielectric strength test (when requested) Before taking a sample of oll, operate the unitto circulate the oil. Warmitto operating temperature. Takethe sample from the middle level of the reservoir using a clean hand pump, such asa disposable syringe anda piece of plastic, tubing. f this is not available, the sample can be drained fromthe bottom ofthe reservoir. Allow several quarts of oil to flow out before collecting the sample. This will remove any dirt and water that has collected in the reservoir near the drain. If a sample container has not oeen provided by the laboratory, use a wide mouth, screw top, clear glass container. Clean it with hot waterand detergent. Rinse it thoroughly and let it air dry before puting oil into it. Once the report is received, compare it to previous oil analysis reports for the same unit. This information will provide trends toward oil deterioration. It may give early warnings ofa problem developing within hydraulic system ‘components, Notice Change the oil fthe samplehas any of the characteris- tics listed in Figure 4.3. Ifmaking a visual inspection, compare the sample of oilto a sample of new oil of the same type. Also, compare it io Specification All Weather Oil Cold Weather Warm Weather Oil iSO grade 2 5 2 Ambienttemperaturerange _ -10°to 95° F (-23° to 35° C) -80° to 60" F (-46°to 16°C) 40° F (4° C) and above Viscosity @ 104° F (40° ©) 24 cSt 15 cSt 3208 Viscosity @ 212° F (100° C) 4.6 cSt 4.4 cSt 6.0 cSt Pour point, biodegradable “SP F(-35°O) “58° F (50° O) “31° F (35° O) Pour point, mineral based “48° F (55°C) “76° F (-60° 0) 49° F(-45°C) Flash point (min) 356° F (180° C) 340° F (171°C) 356° F (180°) Dielectric strength (min) 35 KV 35 KV 35K Four-ball wear, scar (max) 0.028 (0.70 mm) 0.028 (0.70 mm) 0.028 (0.70 mm) ‘Oxidation stability, TOST (min) 2,000hours = 2,000hours Oxidation stability, RPVOT (min) 250minutes 17 minutes 250 minutes Water content (max) 63ppm 38 ppm 63ppm Demulsibiliy, minutes to pass 15 10 15 Copperconosion 1A 1A 1A Rust test, pass/fail - Pass Pass Pass Foam test, pass/fail Pass Pass Pass Figure 4.2 — Hydraulic Oil Viscosity Recommendations 12 Section 4 — Preventive Maintenance and InspectionCondition Possible Cause Darkcolor Cloudiness or milky appearance Presence of water or wax - Rancid orbumedodor ‘Oxidation increase in viscosity (Oxidation; addition of improper fluids; presence of water Decrease in viscosity ‘Addition of mproper fluids; additive deterioration ‘Separation of water or other fluids from the oil Presence of water, addition of improper fluids Foreign particles or other visible contamination Contamination; emulsion of water with oil additives Figure 4.3 — Hydraulic Oil Conditions previous samples taken from the same unit Look for the signs of oil deterioration listed in Figure 4. “There are fluid contamination detector kits available which allow for rapid, on-the-spot analysis of the hydraulic system's condition. Contact your Altec representative for furtherinformation. Oxidation produces vamishes that bake onto hot sur- faces. These oxidation products are acidic and tend to attack metal surfaces. This can damage pumps, motors, and valves. High operating temperatures will increase the rate of ‘oxidation ofthe oil. The presence of water orairin hydraulic oil also causes oxidation. ‘The presence of water may cause rust and corrosion. It also reduces the dielectric capability of the oil Hlaboratory analysis or visual inspection indicate that the oilis deteriorating prematurely, determinethe causeot the problem and correct it. Changing Oil and Flushing the System property maintainedfitration system greatly extends the Useful life of the hydraulic oil. However, the oil will eventually need to be replaced due to contaminants that form during normal operation ofthe unit. Itisimpossible torecommendan exacttime interval for oil changes due to varying conditions of unit use. Use the following guidelines to determine when the hydraulic oil should be changed. + Change the oil as recommended by the Preventive Maintenance and Inspection Checklist. + Ifa hydraulic component fails and contaminates the systemwith metallic particles, change the component and the oil immediately + Inclimates where thereis a wide variation in operating temperatures between summer and winter months, change to the appropriate weight oil each spring and fall Replace the retumline fitercartrdge andiler breathercap every time the hydraulic oll is changed. Also, clean or replace the suction filter. A significant quantity of oil remains in the cylinders and lines ofthe hydraulic system when the reservoiris drained Flush the system when the oil is changed. This is ‘especially importantif he systemis heavily contaminated with metal particles, If the oil is contaminated with water, it may not be necessary to change the oil and flush the system. Follow the instructions under Water Removal in this section. The following equipment and supplies are necessary to property flush the hydraulic system. + Approximately 56 gallons (2121) ofproperhydraulicoil fora28gallon (1061) reservoir [30 gallons (113.6!) for 15 gallon (56.78!) reservoir] + Three retum line fiter cartridges + Clean, lint-free rags + Reservoir cover gasket + Filler breather cap and strainer basket (if component has not been replaced within one year) Acaution Spilled hydraulic oil creates slick surfaces and can cause personnel to slip and/or fall. Keep the unit and work areas clean. Use the following procedure toflush the hydraulic system. 1. If the oll is being changed because of contamination dueto hydraulic componentfailure, proceedtostep 2. Section 4 — Preventive Maintenance and Inspection + 13Otherwise, operate the unit to circulate the oil and warmitto operating temperature. This willallowmany of the impurities to drain off in suspension. 2. Drain the oil reservoir completely. 3. Wipe off the top of the reservoir and the fillerbreather cap. 4, Remove and clean the strainer basket. Awarning Death or serious injury can result from improper use of solvents. Follow the manufacturer's labelfor proper use and disposal. 5. Inspect the inside of the reservoir. If sludge or other contamination is found, remove the reservoir and flush it out with a small amount of hydraulic cil 6. Change the retum ine filter and cleanthe suction filter element and the two in-line fiter cartridges. 7. Install the strainer basket. 8, If hydraulic component failure has contaminated the system, change the retum line fiter cartridge. Awarning Death or serious injury can resultif therecommended hydraulic oil is not used. Use of other fluids in the hydraulic system canaffectthe insulating capability of the unit. Notice Oniy use hydraulic oil as recommended. Other fluids added to the hydraulic system can increase compo- nent wear and affect the lubricating characteristics of, the oil. 9. Fill the reservoir with new hydraulic oil of the proper grade to the Full mark on the dipstick. Filter the oil through a 10 micron fiterasitis put into the reservoir. 10. Install the filer breather cap. Ifthe filler breather cap has not been replaced in two years, or is damaged, replace it Notice Damagetothe pumpor return|inefilter canresultif the unitis operated with either or both of the shutoff valves closed. Fully open the shutoff valves before engaging thePTO. 14+ Section 4 — Preventive Maintenance and Inspection 11. Ifthe new oil was not filtered as it was put into the reservoir, connect a service hose to the tool outlet and allow the new oil'o circulate through the tool circuit for 15 minutes. 42. Cycle all the cylinders and the rotation motor to flush the contaminated oil from the lines and components, of the hydraulic system, 13. Change the retum line filter cartridge and clean the suction filter element, 14, Drain the reservoir completely. 15. Fillthe reservoir with new hydraulic oil of the proper grade to the Full mark on the dipstick. Filter the oil through a 10 micron iter as itis putinto the reservoir. 16. If the new oil was not filtered as it was put into tho reservoir, circulate the oll through the tool circuit as described in step 11 17. Change the retum line fiter cartridge after approxi- mately 25 PTO hours. Water Removal If the hydraulic system was heavily contaminated with water, special water removal fitration may be necessary. An oil supplier or a qualitied laboratory can determine whether water has caused excessive oil oxidation or additive deterioration, Ianalysis shows oil deterioration beyond an acceptable level, drain the reservoir and flush the system as de- scribed earlier in this section, Use a water removal filter ‘aartridge during the flushing process to remove any residual water from the system. When the flushing pro- cessis complete, replace the water removalfilter cartridge with a regular cartridge. This fitter cartridge can be found in Service Tools and Supplies in the Appendix. Ifthe condition ofthe oilis zoceptable except forthe water content, allow time for it to separate out of the oil. Then drain the water offthe bottom of the reservoir. Circulate the oilin the reservoir through a separate water removal filter cartridge. While doing this, occasionally start the unit and cycle all the functions. Continue this process until the water content in the oil is reduced to an acceptable level. ‘The preferred method of determining water contentin the oil is laboratory testing. Another testing method is to perform a dielectric test. Do not attempt to use a water removal cartridge in the retum line filter. The flow rate of the pump, even at engine idle, exceeds the flow at which efficient water absorption occurs.Lubrication Proper lubrication willextend the life ofthe equipmentand reduce maintenance problems, The frequency of lubrica- tion required will depend on the amount of use and the conditions the unit is operated in. Operation in extremely dusty, sandy, of rainy environments will require more frequent lubrication. Lubricate the unit as recommended bythe Preventive Maintenance and Inspection Checklist. The Lubrication Chartand Diagram identifies each compo- nent, type of lubricant, and method of application. Any brandoflubricantthat meets or exceeds the specifications of the products listed is acceptable. There are four intervals oflubrication. Select the appropriate intervaland lubricate the components identified by the symbol(s). Components may be installed on your unit that require additional lubrication. Refertothese component manuals for more information. Always wipe grease fitings clean before and after greas- ing to keep contaminants from entering the points of lubrication, Toavoid bearing damage, use manually oper- ated grease guns. Air-driven grease guns may have enough force to cause bearing damage. Ifthe unit is not used, or is stored for any length of time, apply fresh lubricantat all points shown onthe Lubrication Chart and Diagram. This will help prevent corrosion during the idle period. Outriggers Pin connections on the outriggers are made with zinc plated pins coated with anti-seize compound to prevent corrosion. These connections do not require additional lubrication unless they are disassembled, Use the following procedure to lubricate the inner legs of ‘Atrame outriggers. 41. Position the unit on a level surface, apply the parking brake, and chock the wheels. Engage the PTO and extend the outrigger legs. Disengagethe PTOandtum offthe engine. 2. Wipe the exposed inner leg surfaces to remove any dirt, moisture, etc. 3. Wipe on a coating of moly grease. 4, Start the engine and engage the PTO. Retract and extend the outriggerlegs several times to spread the grease evenly on the surface 5. Extend the outrigger legs and wipe off the excess. grease to prevent buildup of dust and other particles. 6. Retract the outrigger legs. Bearings ‘Spherical bearings are used in several places onthe unit. ‘They require periodic lubrication with a chassis lubricant, Itisveryimportantto grease this type ofbearing regularly. if they are not greased properly, the usable life of the bearing will be greatly reduced. These bearings can produce enough twisting force on the mounting pins to break the pin retainers and make removal dificul if they are not properly lubricated. Selt-lubricating bearings require no lubrication. Rotation Bearing The rotation bearing ball path is lubricated through a grease fiting at the front ofthe turntable near the rotation gearbox. Awaring Death or serious injury can result frombeing trapped between moving components. Maintain a safe dis- tance while components are in motion. Rotatethe tumtable slowly through atleast2 complete 360 degree revolutions, stopping periodically to lubricate. Operate the manual grease gunthreetofivetimesineach position, Elbow Grease Fitting Grease is applied to the elbow drum shaft and elbow sprocket mounting shaftthrougha grease fttingonthe end ofthe lower boom. Awamins Death or serious injury can result from being trapped between moving components. Maintain a safe dis- tance while components are in motion. Grease is applied in this area to prevent corrosion on the machined shafts. The bearings do not require lubrication to function properly. Apply grease annually with a manu- ally operated grease gun. Fill the spaces between the shafts with grease. Rotation GearTeeth Apply an open face gear lubricantto the rotation gear and pinion teeth Section 4 — Preventive Maintenance and Inspection * 15Lubrication Chart and Diagram Service items identified by the symbol(s) at the appropriate level. 85 hours/ s500hours/ 1,000hours/ 2,000 hours! ‘Tmonth ‘6 months. ‘year 2years Ifdisassembled Letter Lubricant Application Method A Anti-Soize Compound — Extreme pressure lubricant that prevents seizure, Brush corrosion, rust, and galvanic pitting. © Chassis Grease — Multipurpose lithium base grease with good water Greasegun resistance, rust inhitition, oxidation stability, and extreme pressure properties. G Open Face Gear Lubricant— Spray lubricant that penetrates and adheres with Spray good water resistance, is unatfected by temperature extremes, and has extreme pressure properties, ‘Mobil-LUX EP 0 Grease or Equivalent Hand packed M Moly Grease —Multpurpose lithium base grease with molybdenum disulfide Brush/grease gun additive, good waterresistance, rust inhibition, oxidation stability, and extreme pressure properties. R Chain and Wire Rope Lubricant— Penetrating, cleaning, nongumming protective spray; Spray must minimize friction and eliminate rust. S___ General Purpose Spray Lubricant Spray W _ SAE 140 Worm Gear Oil— AGMA Grade 7 compounded or 7EP, must be Pour noncorrosive to bronze. UprerBearing GreaseFiting [>> Output Shaft A] Input Shaft Splines Check Plug” & Hydraulic Pump Rotation Gearbox Upper and Lower Boom Leveling System 16+ Section 4 — Preventive Maintenance and InspectionWw] Changeoit Bo ontove 4 T 1] Outboard Bearing (Opposite Side of Drum) Winch InnerLeg Outer Surface Cylinderand ‘Shoe Pin. ow Outriggers Control Handle Linkages + UpperControls, + LowerControls, + Outrigger Controls + Stop Valve Elevator Cylinder Pivot Bearing ~f\ (L42M-E4g.and La2M-ESS) LowerBoom Cylinder AN ‘Spherical Bearing wa oT @ [Elbow Area LowerBoom Nj | Cylinder Pin i Lower | Rotation Gearbox, Pivot Pin [ J Eccentric Ring Rotation Pinion and Bearing GearTeeth totation Bearing Ball Race | (Grease Ptng at rontotTumtabe) J Section 4 — Preventive Maintenance and Inspection * 17A caution Injury can result from contactwith pinion and rotation bearing gear teeth. Keep hands clear. Injury can result from being pinched or trapped be- tween moving components. Keep hands clear. Uso caution when access covers have been removed to service the unit. Pinch points and shear points may exist between movingparts. Replacethe access coversimme- diately after servicing. Remove the pinion cover fromthe turntableto lubricate the rotation gearteeth. Replace thecoverafter the lubrication has been completed. Awaming Death or serious injury can result from being trapped between moving components. Maintain a safe dis- ‘tance while components are in motion. ‘Do not lubricate the gear teeth while operating the unit. Stop tumtable movement before lubricating. Rotate the tumtable slowly through a complete 360 degree revolution. Rotation Gearbox The top bearing on the rotation gearbox requires periodic lubrication. Three to five pumpswith a manually operated grease gun will be enough tc adequately grease the gearbox bearing. The rotation gearbox is packed with grease at the time of assembly and should not require further periodic lubrica- tion during the life ofthe unit. The lubricant should only be replaced atthe time ofa major overhaul orif disassembled ‘or service. Check the lubricantbefore operating the unit to get the most accurate lubricant level. Lubricanton the outside of the gearbox orthe needtoadd lubricant regularly tothe rotationgearboxisa sign ofleaks. Determine the cause of the leak and correct it. Ifthe leak, isignored, the intemal components of the gearbox could be damaged by the low lubricantlevel. Ifthe lubricantlevel appears to be increasing, this could bea sign ofan internal hydraulic leak from a defective motor shaft seal. If a ‘gearbox is overheated and the lubricant smells bumed, ‘change the lubricantimmediately. Change the lubricantif itbecomes diluted with hydraulc oil from a leaking seal. Leveling Chain Proper lubrication of roller chain is essential for peak performance and full chain lite. Both the upper and lower ‘boom leveling chains should be lubricated as recom- mended by the Preventive Maintenance and Inspection 18 » Section 4 — Preventive Maintenance and Inspection Checklist. Strictly follow the lubrication schedule and recommendations. Ifthisisnot done, the service life of the chain will be shortened. Lubricants specifically formulated{or use on roller chains mustbe applied. Once applied, thelubricant should notbe wiped off with a cloth or washed with solutions which will remove it or reduce its lubricating properties. Control Handles The connecting link pivot points of the single handle control, outrigger, tools, jib tlt, winch, and platform level- ing, rotate, and titt controls require periodic lubrication. Use a general purpose spray lubricant on the linkage. Valve Spools Use a smallamountot general purpose spraylubricanton the exposed surfaces of valve spools as needed to keep the spools operating smoothly. Operate the valve handle to spread the lubricant on the spool. Wipe off any excess lubricant. Structures The structural components ofthe unit are identiiedin the Component identification in Section 2. The unithas been, designed to meet or exceed the ANSI specifications for vehicle-mounted rotating and elevating aerial devices. Regularinspection ofthe welds and structuresis required to insure that components maintain their strength. Peri- odie cleaning of the structuresisalsorecommended. This llprevent damage that can ocourfrom dirt accumulation. Acartion Injury can result from slipping and falling. Use care and the handles and steps provided. Periodic inspection of the structures is recommended to be certain there is no deformation, abnormal wear or abrasion, interference between movingparts, orcracking of the welds on structural members. Inspectthe structures and welds as recommended by the Preventive Maintenance and Inspection Checklist. Cleaning Accumulated dirt can damage the unit and cause it to malfunction. Dirt buildup also accelerates wear on the components. Caut Spilled hydraulic oll creates slick surfaces and can cause personnel to slip and/or fall. Keep the unit and workareas clean.Keep the platform clean of debris. The weight of the operator and the debris may overload the platform, if pressure washer or steam cleaners used to clean the unit, be careful where the spray is directed, Do not direct, the spray wheretthe cleaning liquid might getinto electrical components, such as electrical connections, switches or lights. Even though all electrical components on the unit are designed for all weather use, itis possible for water pressure from thenozzleto pusha sealoutot position. Do not direct the spray at the filler breather cap of the reservoir. The high pressure can force water andcleaning liquid into the reservoirand contaminate the hydraulic oil. Donotclean the rotary joint or spool ends of any hydraulic, valve with direct pressure from a pressure washer. After washing and cleaning the unit, relubricate as necessary. Refero Fiberglass Care in this section for information on leaning the fiberglass components. Welds Allwelds on the unit are originally appliedin conformance to AWS standards. Every weldonthe unitisimportantand should be periodically inspected. Avarming Death or serious injury can result from improper use of solvents. Follow the manufacturer's label for proper use and disposal. If paint has lifted off the weld, orifrustis found, a closer inspectionisrequired, Remove any loose paint orrust with a wire brush. Clean the area with a solvent such as acetone. Closely inspect the area for cracks in the welds. Dye penetration and magnetic particle testing are simple processes that may be used to verify or disprove a suspected problem, Lower Boom Upper Boom Cylinder ‘Weldments Attachment Bracket \_- Pin Flange Make Sure - Cap Screws < are Tight ~~ Check for ~ Gracks in Welds. Figure 4.8 — Welded Flange When installing a pin into a self-lubricating bearing, only lubricate the area where the pin and the boss make contact. Use the following procedure to properly instal the pin 1. Slide the pin through the first boss and through the bearing until it reaches the second boss. 2. Apply an anti-seize compoundtothe secondpinboss and pin surface that is still exposed. 8. Slide the pin completely into the second pin boss and install the appropriate retaining system. ‘Second Boss First Boss Pin ‘Bearing \ { eC Anti-Seize Compound Figure 4.9— Pin installation into Selt-Lubricating Bearings Bearings ‘The unit is equipped with a variety of bearings. The type of bearing used depends on the particular application, Spherical Bearings ‘Spherical bearings are used in the elevator cylinders, lowerboom cylinder, and base endofthe upperboom drive cylinders. Self-aligning bearings suchas these are usedin, areas where perfect alignmentis difficultto maintain. This type of bearing allows the component to follow the move- ‘ments of the structure without applying a side load to the internal components of the cylinder. Periodiclubrication ofthese bearingsis required. Lubtica- tion prevents the inner rim that maintains the alignment from seizing to the outer rim of the bearing. Lubrication in this section describes how to properly lubricate these bearings. Self-Lubricating Bearings Self-lubricating bearings are used at the mounting points of the following components. + Lowerboompin + Platform mounting shaft + Upper boom drive mechanism link pins Section 4 — Preventive Maintenance and inspection + 23+ Upper boom cylinders (rod end only) + Elbow drum shaft + Elbow sprocket mounting shaft + Jib mounting bracket + Winch shaft support + Platformrotator + Elevator pins + Cylinders for — Platform rotator Platform tit wl tlt vib leveling Self-lubricating bearings are designed forlong life. Under normaluse, this type ofbearing will provide many yearsof service with virtually no maintonance. These bearings resistimpactand shock loads ard abrasive contaminants. Selt-ubricating bearings are made witha braided cordliner containing Tefion fibers. The liner is bonded to the outer, shellof he beating with epoxy resin. The epoxy resin has, a self-lubricating filler added toit. A chrome plated pin is, used with this bearing. “The inside diameter ofa setf-ubrcating bearing contains Teflon fibers. Once apinis installed in the bearing, some of the Teflon transfers to the pin surface and provides lubrication. Applying anti-seize compound to the entire surface of the pinwillpreventthe Teflon fromtransferting. This may shorten bearing Ife. Replace these bearings if the components are disas- sembled for other purposes. Replacement of this type of bearing due to wear is not a no'mal consideration. Iitis, desirable to measure the bearing to determine when itis, ‘worn, several factors must b2 considered. The only accurate way to measure bearing wearis tokeepa record ofthe clearance between the chrome pin and the bearing, Place the magnetic base of a cial indicator in a position ‘that allowsthe clearance between the pin and the bearing tobe measured under load. Take an initial measurement ‘when the unit is new. This will provide a reference point, Monitor the change in bearing clearancewith subsequent, measurements, For sett-lubricating bearings, clearance wearonthe bear- ing of 0.005" (0.13 mm) may suggest that the bearing anti- seize compound needs to be replaced. This figure takes. into account only the wear of the bearing. Through the ‘course of time, there may also be pin and pin boss wear. Anoverallchangein the clearancebetween the pinand the bearing of 0.020” (0.51 mm) or more indicates the pin and bearing both need tobe replaced 24 * Section 4 — Preventive Maintenance and Inspection Replacement Use the following procedure to remove and install selt- lubricatingbearings. 1. Drive out the old bearing. If this is not possible, cut it ‘outwith a cutpoint chisel or hacksawblade. Be careful ‘not to damage the mounting surface of the bearing boss. 2. Use a screwdriver and needle nose pliers to collapse the bearing and pull it out of the bearing boss. 3, Cleanthebearingboss. Donotremove anymetalfrom the boss surface. ifmetalis removed, thenewbearing may not fit properly in the boss. 4, Place the new bearing on a bearing driver. Line it up with the bearing boss and crive the bearing nto placo using a dead blow hammer. 5. Inspect the pin before installing it into the bearing. If itis flaked, cracked or galled, anew pinmustbe used, 6, Place the pinthrough the firstzin boss and through the bearing to the second pin boss. 7. Lubricate the open pin boss and the head of the pin with an anti-seize compound (refer to Figure 4.10), | _] Bearing Driver ~ Removal Install Figure 4.10 — Removal and Installation of Self-Lubricating Bearings 8, Insert the pin through the second pin boss and install the pin retainers. Slide Pad Bearings ‘The outrigger legs are equipped with slide pad bearings. Slide padbearings provide asmooth surface forextension andretraction. The most highly loaded slide pac bearings are made of molybdenum disulfide impregnated nylon. This type of bearing will last indefinitely when run against smooth surfaces.The intemal sliding surfaces are sanded smooth and lubricated with moly grease during factory assembly. The internal surfaces and their mating slide pads require no additional lubrication unless they are disassembled for majormaintenance. Keep the external surface smooth and lightly lubricated. ‘The Lubrication Chart and Diagram in this section speci- fies the proper lubrication interval. If the outside surface becomes rusty or rough, the outrigger maynotextendand retract smoothly. Allowpaintappliedto an outriggerto cure thoroughly. After the painthas cured, ubricate the surface efore retracting or extending the outrigger over the slide pad bearings. The slide pad bearings are mounted with either hex head cap screws or flat countersunk head cap screws. The flat countersunkhead cap screws have anyon insertornylon patch embedded in the threads. Slide pad bearings mounted with the flat countersunkcap screws must have the heads of the mounting screws located below the sliding surface of the bearing. This, prevents the cap screw head from damaging the surface. Siide pad bearings mounted with hex head cap screws have steel nuts embedded into the bearing. The cap serewsare installed with the headlocatedon the opposite side ofthe steel plate from where the bearing is located. When replacing a hex head cap sctew on a slide pad bearing, make sure to replace it with one of the proper length as spectfied in the Parts Manual. Flat Countersunk Cap Screw Leg \ Hex Head Cap Screw Figure 4.11 — Slide Pad Bearing Cap Screws Cap screws that are too short will nt fully engage the nut ‘embeddedin the bearing. Capscrewstthataretoo|ong will protrude beyond the bearing and damage theleg surface. When replacing a slide pad bearing, do not reuse the flat countersunk head cap screws. Once a cap screw is removed, the nylon insert or nylon patch on the threads of the cap screw will be distorted. This distortion may not allow the cap screw to tighten properly fit is reused. Use new flat countersunk screws of the proper length when replacing a slide pad bearing. Do not apply excessive torque when tightening the cap screws. This will prevent the bearings from splting, Rotation Bearing ‘The turntable rotates on a shear ball beating called the rotation bearing. The inner race is mounted to the tum- table. The outer ace of the rotation bearing is mountedto the pedestal. The outer racehas gearteeth thatmeshwith the rotation pinion. The bearing provides for very low torque rotation. Properly maintained, the bearing should provide many years of satisfactory service. Turntable Tilt Measurement ‘The rotation bearing is designed with a tightly controlled internat clearance. The bearing clearance will increase slightly during the initial break-in period. It should then remain essentially constant for many years providing the bearing is properly lubricated and not overloaded. As the bearing raceway begins to wear out, the clearance will increase. Itshould increase steadily at frstand accelerate toward the end of bearing life. Atthis point, operators may notice an increase in the titing or rocking of the turntable. Aninitial turntable tlt measurement should be taken, asa baseline, when the unit is delivered. Future periodic bearing tit measurements willbe comparedto this baseline todetermine howmuch the bearing tithas increasedsince theinitial (new bearing) measurement. Since the greatest portion of the measured tumtabletilt results from structural deflection rather than bearing intemal clearance, it is importantthatthe deflection be held constantby using the same measurement procedure each time. It is recom- mended that a maintenance log be kept to monitor the bearing inspections and turntable tilt measurements dur- ing the life of the unit. Since an increase in bearing clearanceis one of the signs of bearing wear, periodic bearing tit measurements will help determine when bearing replacement is necessary. Perform periodic bearing inspection and turntable tilt measurements annually until the total increase in the tumtable tit measurement reaches 0.050”. After the total increase reaches 0.050”, perform more frequent inspec- tions every 500 PTO hoursié months until the bearing replacement criteria explained below is reached. BearingReplacementCriteria The rotation bearing must be inspected and evaluated. ‘The recommended bearing inspection proceduresinclude the following items. + Monitoring the trend of turntable tit measurements Bearing inspections and turntable tilt measurements, can be used to determine when a bearing should be Section 4 — Preventive Maintenance and Inspection + 25replaced. Generally, an insrease in turntable tit of 0.085" (1.65 mm) above the inital tit measurement indicates that the bearing rray be reaching the end of its useful life. Other factors related to the condition of the bearing must also be considered. Determine ifthe increase in the turntable tit measurements has been steady orifit shows trendof accelerated wear (refer to Figure 4.12). Example 1 shows a steady increase in wear, which is normal Example 2 shows an accelerated increase in wear which would indicate bearing replacement may be necessary. If the tilt measurement has reached 0.065" (1.65 mm) above the initial (new bearing) tit measurement, and periodic measurements show a trend of accelerated wear, replace the bearing 500 Hour/6 Month Inspections Example Example 2 1 112" (2.84inmn)_ 0.110" (2.79mn) 2 0.114"(2.89mm) _0.114"(2.89mm) 3 O416"(2.95mm) _ 0.12"(8. 10mm) Figure 4.12— Turntable Tilt Measurements Because the major portion of the measured turntable tit results from structural deflection, the total tit measurement varies trom model to model. For ex- ample, overalltumtable tt measurementsapproach- ing 0.200” (5.08 mm) are not uncommon on some models, even onbearings which have notreachedthe end oftheir usable lite. Severely wom bearings could haveameasuredtumtabletitasmuch as0.500"(12.7 mm) ormore in addition to other prominent symptoms of wear such as unusual noise and roughness. There~ fore, the total tumtable tit measurementitsetf should notbeusedto gauge abearing’s remaining usablelife. The change in tumtable tit and the trend toward accelerated weer is more important than the total it measurement itself. + Evaluating the “fee!” of the unit ifthereis no trendtoward accelerated wear, consider the “fee!” of the unit during load reversals. Operators may notice an increase in tre tilting or rocking of the tumtable. * Checking for rotation bearing noise and roughness Determine whether there is any presence of rough- ess or noise in the rotation bearing during rotation. Severely worn bearings commonly exhibit grinding, snapping, and popping noises during rotation, These noises may indicate the bearing has broken ball spacers, split ball bearings, or excessive galling, the presence of which would require immediate bearing replacement. Popping or clickingnoises might alsobe 26» Section 4 — Preventive Maintenance and Inspection caused by broken or impropesty torqued bearing fas- teners, a warped mounting surface, or wom teeth. A check of the fastener torque and the rotation bearing grease purged during lubrication willusualy determine if bearing noiseis due tointemal orexteral problems. + Inspecting the condition of thepurged bearing grease Grease from a well worn, poorly maintained, or dam- aged bearing will typically contain fairly large rust or metal particles, instead of metal dust specks which rmightbe foundin any bearing. Fairly large rustormetal particles indicate the bearing has reached anacceler- ated wear condition and immediate bearing replace- ment is required. The presence of rust indicates inadequate lubrication. Rustis commonly indicated by extremely dirty grease. This situation must be corrected to optimize the performance of the new bearing. Always check the purged bearing grease at ceachinspection andtumtable tilt measurement proce- dure even if there isno presence of roughness, noise inthe bearing, orsignificant change inthe turntablettit measurement. ‘One ormore of these evaluation citeria should detect the need for rotation bearing replacementlong beforethereis, any threat of failure. By maintaining proper rotationbearing lubrication and avoiding overload conditions, the replace- ‘ment rotation bearing should provide many years of service, Bearing Inspection and Turntable Tilt Measurement 1. Position the unit on a level surface where the booms canbe elevated and rotated. Apply the parking brake and chock the wheels. Engaga the PTO and property set the outriggers (if so equiped). 2. Position the booms in a position of near maximum side reach. Exact boom position is not ertical. Slowly rotate the turntable 360 degrees using the lower controls while checking for roughness or noise in the rotation bearing. Repeat using the upper controls, since roughness may be feltrrore accurately fromthe platform. Note in the maintenance log whether un- usual noise or roughness was encountered. 3, Rotate the turntable to the position to be used forthe turntable tilt measurement. If the unit is normally operated within a particular zone of rotation, measure the tit with the turntable rotated to this position. For consistent measurement, always use the same rota- tional position with no load in the platform each time the tit measurement is done, Record the rotational position in the maintenance log 4. Position the boomas shown below. For reference, this position is called Position A.LowerBoom Horizontal / Li q Figure 4.13 — Position A 5. Attach the magnetic base of the dial indicator to the pedestal, positioning the pointer at either the front or rear of the turntable. Position the pointer of the dial indicator against the underside of the turntable base plate, as close as possible to the bearing gear cover. Figure 4.14 shows the possible positions for the dial indicator pointer. Any one of these positions may be used, It may be difficult to position the dial indicator and pointerin some zones of rotation without interfer- ence with the tumtable or pedestal. In this case, position the dial indicator and pointer to the area as close as possible to the recommended position. Once acorrectindicator pointer position is chosen, itis very important that the same pointer position is used for each subsequenttilt measurement. Therefore, record the pointer position in the maintenance or service log where the tilt measurements are recorded. Some inspectors prefer to permanently mark the location where the dial indicator pointer contacts the bearing base plate to ensure that subsequent measurements are made in exactly the same spot. 3 Pition Gear Cover ~ Rotation Bearing é Gear Cover Figure 4,14— Dial Indicator Position 6. Setthe dialindicator at zero with the booms in Position A 7. Position the booms to Position B as shown below. Do. not rotate the tumtable, Record the indicator reading, -| —~ LowerBoom | Vertical Figure 4.15 — Position 8 8. Repeat steps 6 and 7 two more times to obtain an accuratereading. 9. Remove the cial indicator to prevent damage. Notice Metal particles may be in the grease. Usea putty knife to collect and wipe the grease. 10. Stowthe booms. Lubricatethe bearing to purge some ‘grease for inspection. Wipe some of the purged bearing grease, which should be visible around the inside ring of the bearing, on a piece of clean white or light-colored paper. Smear the grease on the paper into a very thin layer using a straight edge such as putty knife. Usingaa bright ight, look formetal particles which are larger than normal specks of metal dust. Normally, particles large enough to be concemed about will be felt as @ rough spot when smearing the grease. The smaller, insignificant particles will not normally be felt underthe straight edge. Also, look for signs of rust which would indicate poor lubrication. Record information about the condition of the purged grease in the maintenance log, a, Ifthere are metal particles found in the grease that exceed '/s.” (0.79 mm), the bearing should be replaced at the next maintenance interval. b. Ifthere are any signs ofrustin the grease, lubricate the bearing more frequently to purgethe old grease out. 11. Referto Bearing Replacement Criteriatodetermine if bearing replacomentisrequited Cylinders Inspect all cylinders as recommended by the Preventive Maintenance and Inspection Checklist. Section 4— Preventive Maintenance and inspection * 27Avaring Death or serious injury can result from cylinder fail- ure. Donot operatea cylinderthat hasa dented barrel or a damaged rod. Visually inspect the cylinders for leaks, loose or missing pin retainers, broken bearings, bentrods, and dentsinthe rodor barrel. Check for proper operation ofthe cylinder holding valves, by positioning the boom or outriggerso.aloadis appliedto the cylinder to put pressure against the holding valves. Disengage the PTO. Fully shiff the manual lever for the function being ested. Hold the laver momentarily to allow oil flow trom the holding valve totank. ifthe cylinder does, not move, the extend holding valve is operating properly. Ifthe cylinder retracts slowly, the holding valve may be leaking, Determine the cause of the problem and correct itbefore operating the unit. Hydraulic hoses and tubes transmit hydrat out the hydraulic system. oilthrough- Inspect all hoses and tubes es recommended by the Preventive Maintenance and Inspection Checklist for wear and/or physical damage. Make sure the hoses are properly routed to avoid sharp edges, kinking, and scut- ing, Inspect the tubes for dents or other damage that may restrict oil flow. Make sure all Hoses and tubes are held firmly in their support brackets, Single Handle Control and Control Handle Covers Inspect and perform a confirmation test of the single handle control as recommended by the Preventive Main- tenance and Inspection Checkist. Keep the green single handle control clean, dry, in good ‘condition, and periodically testad to maintain its limited dielectric properties. Wipe any contaminants or moisture ‘from the surface of the control handle assembly and the insulating linkages witha clean cry cloth. Isopropylalcohol may be used to clean these components. Replace any damaged components with repacement parts from your Altec representative and perform a confirmation test on the control. Inspect the rubber control valvehandle covers as recom- mended by the Preventive Maintenance and Inspection ‘Checklist. Keep the rubber contol valve handle covers in pplace andin good condition. Repacedamagedcovers with replacement parts from your Allec representative. 28» Section 4 — Preventive Maintenance and Inspection DOW Figure 4.16 — Upper Control Valve Assembly Atmospheric Vents ‘Atmospheric vents are located a the boom tip/platfor area on Category Bunits, Category Aunits, and units over 50’ (15.24 m). Inspect these vents as recommended by the Preventive Maintenance and Inspection Checklist. On Category A units, these vents must also be tested for proper operation. An atmospheric vent testing kit may be obtained from your local Altec representative (refer to Service Tools and Supplies in the Appendix). |S Figure 4.17 — Atmospheric Vent Fiberglass and Plastic Components ‘The fiberglass components are covered with gelcoat to protect the fiberglass and resin composite. The gelcoat, contains ultraviolet inhibitors to retard the effect of ultra- violet lightonthe fiberglass. With minimal care, the sealing and ultraviolet properties of the fiberglass can be main- tained for many years. The following sections include information on the cleaning and repair of fiberglass and plastic components. Inspect the components for cleanliness and any visible damage such as scratched, cracked, or chipped gelcoat. Surface irregularities may trap dirt and contaminants, which overtimemay reduce the dielectric properties ofthe fiberglass. Of particular concern are irregularities running lengthwise on the boom. Trappedcontaminants, such as dust particles and water, can cause tracking, providing a path to ground or possible dielectric failure. ‘Search for signs of looseness or movement at the bond areas (fiberglass-to-steel connections) at the ends of the fowerboominsulator and the baseend ofthe upperboom. Ifthe fasteners are property tightened and the chemicalbonds are good, itis unlikely damage will be found. if a chemical bondhas failed and the unitis operatedusing the mechanical backup fasteners, cracks or elongation ofthe holes may develop around the fasteners. The fasteners willthen begin to show frictional wear. Other fiberglass and plastic components have a variety of mechanical fasten- ers that require inspection Leveling Rods The generalcondition ofthe leveling rods shouldbenoted. Checkrods for scratches, signs of rubbing, cleanliness, or any other possible damage or wear such asnicks (nonicks are acceptable). Replace the rods that show signs of cracks ornicks. There are no epairprocedures forleveling rods. The allowable wear for leveling rods is explained in the following paragraphs. Inspect the entire length of each leveling rod for wear marks. Wear marks will have a dull appearance. This dull areamay showa flatworm intothe round surface of the rod, ‘Wear Mark Dial Caliper Figure 4.18 — Leveling Rod Wear Mark The causes) of the wear must be determined and cor- rected. Generally, wear marks are caused by the rod contacting a steel edge. Wear marks are not usually caused by the inside diameter ofthe fiberglass boom. A levelingslide hasbeen added tothe lower rodinthe upper boom. This slide keeps the leveling rod from contacting the inside of the upper boom. Be certain all metal edges have the burrs removed. ‘The recommended method for determining an accurate measurement of the wear is to use a dial caliper. Should a significant wear flat area or several wear flat areas be discovered along the length of aleveling rod, contact your Altec representative Use the following procedure to determine an accurate measurement of leveling rod wear. 1, Measure an unworn section of the leveling rod to establish its true diameter. 2, Measure the wear groove. Use the deepest portion of the wear groove in the wear mark for this measure ment. Subtractthe measurementfoundin step 1 from this measurement. This difference is the depth of the weargroove. Normal operation and maintenance should minimize the possibilty of wear orscratches on the leveling rods. Small wearmarksneedtobe documented, theirpossible causo(s) corrected, and rechecked at another inspection to make sure they have not increased in size. Replacement of the leveling rods is explained in Section 6 of this manual. Adjustment of the leveling system is explained in Section 8 of this manual. Cleaning Keep fiberglass andplastic components clean andin good condition to preserve the dielectric properties and appear- ance. Clean all components passing through the boom fiberglass sections. Notice Do not spray water from a high pressure washer directly at hydraulic components. The fiberglass upper boom interior may be cleaned (as necessary) using a pressure washer and directing the stream of soapy water inside the boom. Rinsing with clean water wllthen remove any detergent residue. Elevatethe booms to a vertical position for draining and drying. Allow the booms to dry thoroughly before operating the unit. Ave 9 Death or serious injury can result from improper use of solvents. Follow the manufacturer’s label for proper use and disposal. In.some situations, pressure washing may not remove all of the contaminants from the upper boom interior. A solvent may be used to clean this type of contamination with some type of swab device. Suitable solvents, suchas acetone or MEK (Methyl Ethyl Ketone), may be used to clean these stubbom areas. Please refer to the precau- tions and instructions on the solvent selected for this cleaning procedure. This may require removal of some interior boom components, such as leveling rods and cables,andhoses. Alterthe contaminatedareaisswabbed, se the pressure washer and follow up with a thorough rinsing with clean water. ‘The interior of the lower boom insulator may be washed usingamop orwith iow pressure waterin garden prayer. ‘The lowerboom insulator exterior may be washed with low pressure water. When washing these components, take care not to create any surface scratches. Section 4 — Preventive Maintenance and Inspection * 29‘The exterior of the upper bocm, and other fiberglass ‘components, maybe washed with amild detergent. When ‘washing these components, taxe care not to create any surface scratches, Notice Donotcoata fiberglass surface with any productthat ‘will reduce its dielectric characteristics or cause sur- faceflashover. Do not use petroleum-based products to clean the fiber- glass components. Petroleurn-based products will eave an oily residue that attracts dust. Do not use steel woo! to clear fiberglass components. Retained metallicparticles can provide conductive path. Surface flashover occurs when a substance causes an arcing of electricity between twopoints onthe boom. Ifthis, occurs, the dielectric integrity ofthe boom can be perma- rnently damaged. Notice ‘Whenusinga power buffer to polish fiberglass, donot damage or overheat the gelcoat surface. After the exterior surfaces are clean and dry, polish with Formula Five Clean ‘N Glaze. For best results, polish fiberglass surfaces by hand. Plastic Plastic covers on the unit are covered with an acrylic surface to protectthe plastic from damage from ultraviolet damage. Use a pressure waster and mild detergent to ‘cleanplastic covers. Rinse with clean watertoremove any -detergentresidue. Notice Using solvents (such as acetone, MEK, or lacquer ‘thinner) can damage plastic covers. Use only isopro- pylalcohol (rubbing alcohol) to clean plastic covers. In some situations, pressure washing may not remove all ‘of the contaminants from plastic covers. Use isopropyl (rubbing) alcoho! to clean this type of contamination, After the covers are clean and ry, hand polish using an ‘automotive type wax. Determining the Degree of Boom Damage ‘Minor damage (scratches onthe boom, the boomtip, and, the control covers) is repairable. If no fiberglass cloth fibers are cut or damaged, determine ifthe scratch or nick affects only the gelcoat or ift is through to the resin. To do this, lookat the color at the bottom of the scratch. Ifthe 80 * Section 4 — Preventive Maintenance and Inspection coloris white, the damageison the surface. This damage isminorandcanbe sanded out asdescribed under Minor Surface Damage in this section. Notice If the fiberglass is damaged past the gelcoat and shows up black, and/or the fiberglass cloth fibers are damaged, contact Altec before any repairsare started. Ifthe colorat the bottom ofthe scratch or nickis dark, and thereisno visible damage tothe layers of fiberglass cloth, the damage is through the gelcoat and justinto the resin. This requires a more thorough repair ofthe gelcoat and described under Gelooat inthis section. Any time there is doubt regarding damage to the boom or lower boom insulator, use the following procedure to accurately describe the damage before calling Altec. Upper Boom 1. Identify the quadrant that the damage is in. If the damaged area ison line between quadrants, switch tothe clock method (example — the damages atthe three o'clock position). 2, Identify the exact area along the boom's length (orthe lowerboom insulator) wherethe damageis. Todothis, measure fromthe base endoftheboom tothe damage site [example —46” (116.84 cm) fromthebaseendof the upper boom} 2 —? — auadrantt att . 3 Quadrant Quacrant2 6 Quadrant3, Figure 4.19 — Boom Damage Location 3, Define the type, size and the cause of the damage [example — 2" (50.8 mm) long x 1” (25.4 mm) wide x "Ye" (3.18 mm) deep; gouge caused by a chain saw} 4, When calling Altec to describe the damage in ques- tion, be sureto explain where youarein relation tothe unit (example — curb side of te unit, facing the base end of the upper boom in the stowed po:Lower Boom Insulator 1, Identify the quadrant in which the damage has oc- curred. If the damaged area is on a line between quadrants, switch tothe clock method (example—the damage is at the three o'clock position). Figure 4.20 — Fiberglass Damage Quadrants 2. Identity he area along the lower boominsulatorwhere the damages. Todo this, measure fromthe base end of the boom to the damage site [example — 46” (116.84 cm) from the base end of the boom). 3. Define the type, size, and the cause of the damage [example —2iongx 1” widex Yo" deep (50.8mmiong x 25.4 mm wide x 3.18 mm deep); gouge caused by a chain saw 4, When calling Altec to describe the damage in ques- tion, be sure to explain where youare in elation tothe unit (example —curb side of the unt, facing the base end of the boom in the rest position). Ifthe upperboom orthe lower boom insulator has several damaged or cut inner fiberglass cloth ayers, it may not be repairable. At this point, the boom’s strength may be reduced and repairs will nt restore the boom strength. If such damages discovered, contact your Altec represen- tative. They can evaluate the affect ofthe damage on the structural integrity of the boom and determine if the damage is repairable or ifthe boom must be replaced. If it is determined that the extent and location of the damage will not reduce the safety factor of the boom, it may be acceptable to repair the damaged area with gelcoat to seal it and place the unit back into service. Repair Minor Surtace Damage Minorscratchesin the surface of the gelcoat may be easily repaired. If the bottom of the scratch is the same color as the gelcoat pigment, repair according to the following procedure Acaution Injury can result from airborne particles entering the eyes and lungs. Wear appropriate safety equipment. 1. Use a dual acting sander with 320 grit sandpaper to sand the scratched area. Move the sander to sand around the circumference of the boom. Do not sand lengthwise on the boom, 2, When the scratch has almost disappeared, sand by hand with a 600 grit wet or dry sandpaper until the scratch is no longer visible. 8. Use Formula Five Clean ‘N Glaze to polish the area, Gelcoat Use an Altec gelcoat repair kit (refer to Service Tools and ‘Supplies in the Appendix) with the following procedure. Any scratch that is dark at the bottom is through the gelcoat and into the resin below. In order for gelcoat repairs to cure property, the following special temperature considerations must be understood. The highest quality gelcoat repairs aro accomplished indoors in a heated and well ventilated area. Notice The gelcoat can be burned during the warming pro- cess. Continually move the heat gun or paint stripper during warming. + Ifthe unithas been outside andthe temperatureis less than 70 degrees Fahrenheit (21 degrees Celsius), orit this is a field repair, the boom area must be warmed before proceeding. Warm the fiberglass using a heat gun until itis warm to the touch. It will take approxi- mately 40 minutes to do this. A paint stripper gun will provide a faster method. Do not concentrate the heat of the gun in one specific area for any length of time. ‘+ Ifthe outside temperature is below 60 degrees Fahr- cenheit (16 degrees Celsius), a field gelcoat repairs not suggested. Makeshift tents over the repair area willnot hold sufficient heat, preventing proper curing, Acaution Injury can result from airborne particles entering the eyes and lungs. Wear appropriate safety equipment. Use the following procedure to repair the gelcoat, 1, Useadie grindertowidenthe scratch to ‘/e"(3.18mm), Do not grind into the fiberglass cloth, 2, Inspect the scratch. If the fiberglass cloth is cut, contact your Altec representative. If no fiberglass clothis damaged, bevelthe edgesofthe ' (3.18mm) cut to about 45 degrees. Section 4 — Preventive Maintenance and Inspection + 313, Lightly sand the damaged area by hand to roughen it Up. This will help the resin bond to the surface. Awaning Death or serious injury can result from improper use of solvents. Follow the manufacturer's label for proper use and disposal. 4, Use a solvent such as acetone to clean the area and remove any dust. 5. The Altec gelcoat repair kitcontains a can of resin, a can of fumed silica powder, and a bottle of hardener. Refer to the material safety data sheet included with the kitfor special precautions and recommendations for use with this product. Mix the resin, powder, and. hardener according to the «it instructions. 6. Apply the mixture to the damaged area witha plastic spatula. Work the spatula back and forth to remove any airbubbles. Build up the area soitis slightly above the boom surface. The mixture wll shrink slightly as itcures 7. When the area has cured, sandthe area by handwith 600 arit wot or dry sandpaper. Sand until the patch is, no longer visible. 8. Use Formula Five Clean ‘N Glaze to polish the area, General Fiberglass to Steel Joint Service Overtime the seal between thelower boom insulator and steel boom or the stee! tube t> fiberglass boom at the elbow may require repair or replacement. Damage to the seal or the steel booms in this area can allow rust to start orwaterto seep into the joint. Ifnot repaired, rustandwater will deteriorate the joint integrity. ‘The unitPreventive Maintenance and Inspection checklist calls for a minimum inspection interval of annually. Due to ‘operating conditions this inspection interval may need to beshortened. AQwarning Solvents can be extremely hazardous. Follow the manufacture’s label for proper use and disposal. Acaution Performthis procedure in awell ventilatedarea. Cover, areas of body witha disposable material where adhe- sive could drip on body parts. 92 * Section 4 — Preventive Maintenance and Inspection Repair and Maintenance of Insert Fiberglass To Steel Joint This process should be done where the unit is at a ‘minimum room temperature of 60 degrees Fahrenheit (16 degrees Celsius). When removirg the old seal, look for evidence of rust starting to creep backunderthe steel tube overthe insert. Ifrust has started this should be removed, cleanedanda rustconverting prirrerappliedtoreducethe risk of rust reoccurring. Also, look for signs of water coming out ofthe joint. If water is present, the joint needs todry outand may require rebonding ofthe insert. Oncethe new seal is in place, allow the seal material to dry a minimum of three hours before applying water under pressure or driving in a heavy rain. Refer to the Service Tools and Supplies in the Appendix for part numbers of Resealing and Rebonding kits. Platform and Fiberglass Covers The first step in successful platfcrm repair is to analyze the damage and determine the cause. Cracks in the gelcoator outersurtace of the platform are easily repaired. Damage to the fiberglass structure can be more serious and should be carefully evaluated before attempting to repair the platform. Structural components of the platform include the rim, mounting ribs, platform sides, and the bottom. The plat- form is constructed similar to a basketball hoop and net. The rim supports the sides in the same way a basketball hoop supportsanet. Thestructuralintegrity ofthe platform rimiscritcalin determining whether ornotthe platformean be successfully repaired The platform bottorn and the side with the mounting ribs, are substantially thicker than the other three sides. The ‘mounting ribs are the areas where the platform mounting, bracket fastens to the platform. Consider these factors, when determining whether a successful repair can be made on the platform bottom or mounting rib side. Altec cannot determine ifthe platform is repairable in the field. Evaluate the platform and determine whether ornot itcan be repaired and safely used{or future service. Altec does not recommend that repairs be made to platforms which have the following damage. + Cracks through the fiberglass of the mounting ribs + Cracks through the fiberglass of the rim + Ahole through the floor or mounting rib side of the platform Altec only assumes responsibilty for platform repair performed by Altec personnel.