D2-3B Maint 749-10067

Copyright 2013 by Altec Industries, Inc.
All rights reserved. No part of this publication may be used or reproduced by any means, or stored in a
database or retrieval system, without prior written permission of the publisher. Making copies of any part
of this publication for any purpose other than personal use is a violation of United States copyright laws.
Altec Industries, Inc. reserves the right to improve models and change specifcations without notice.
2013
www.altec.com
749-10067
D2000B/3000B
Maintenance
and Parts Manual
Preface
This unit is the result of Altecs advanced technology and quality awareness in design, engi-
neering, and manufacturing. At the time of delivery from the factory, this unit met or exceeded
all applicable requirements of the American National Standards Institute. All information,
illustrations, and specifcations contained within this manual are based on the latest product
information available at the time of publication. It is essential that all personnel involved in
the use and/or care of this unit read and understand the Operators Manual.
Given reasonable care and operation, according to the guidelines set forth in the manuals
provided, this unit will provide many years of excellent service before requiring major main-
tenance.
The scope of this manual is limited to periodic maintenance. It does not cover methods that
may be required to inspect and repair major damage to the unit. Impacts to and excessive
forces on the hydraulic utility equipment, through vehicular accidents, rollovers, excessive
loading, and the like, may result in structural damage not obvious during a visual inspection.
If the hydraulic utility equipment is subjected to such impacts or forces, a qualifed person
may need to perform additional testing such as acoustic emissions, magnafux or ultrasonic
testing as applicable. If structural damage is suspected or found, contact Altec for additional
instructions.
Warning
Death or serious injury can result from component failure. Continued use of a mobile
unit with hidden damage could lead to component failure.
Never alter or modify this unit in any way that might affect the structural integrity or operational
characteristics without the specifc written approval of Altec Industries, Inc. Unauthorized
alterations or modifcations will void the warranty. Of greater concern, is the possibility that
unauthorized modifcation could adversely affect the safe operation of this unit, resulting in
personal injury and/or property damage.
Danger
Death or serious injury will result from unprotected contact with energized conductors.
Non-insulating units have no dielectric rating. Maintain safe clearances, as defned by
federal, state, and local authorities, and your employer, from energized conductors.
No unit can provide absolute safety when in proximity to energized conductors. No unit is
designed or intended to replace or supersede any protective device or safe work practice
relating to work in proximity to energized conductors. When in proximity to energized con-
ductors, this unit shall only be used by trained personnel using their companys accepted
work methods, safety procedures, and protective equipment. Training manuals are available
from a variety of sources.
Set-up requirements, work procedures, and safety precautions for each particular situation
are the responsibility of the personnel involved in the use and/or care of this unit.
Table of Contents
Section 1 Introduction
About This Manual..................................................................................................... 1
Section 2 Unit Specifcations
General Specifcations .................................................................................................. 3
Component Identifcation .............................................................................................. 5
Section 3 Safety
Safety Instructions ........................................................................................................ 7
Disclaimer of Liability .................................................................................................... 7
Section 4 Preventive Maintenance and Inspection
Equipment Storage ....................................................................................................... 9
Protective Measures ............................................................................................... 9
Hydraulic System .......................................................................................................... 9
Cleanliness Precautions ....................................................................................... 10
Filtration ................................................................................................................ 10
Oil Specifcations .................................................................................................. 12
Oil Condition ......................................................................................................... 13
Changing Oil and Flushing the System ................................................................ 14
Electrical System ........................................................................................................ 16
Slip Ring ............................................................................................................... 16
Lubrication .................................................................................................................. 16
Lubrication Chart and Diagram ............................................................................. 18
Structures .................................................................................................................... 23
Care of Exterior Surfaces ..................................................................................... 23
Welds .................................................................................................................... 24
Fasteners .................................................................................................................... 24
Rotation Bearing Cap Screws .............................................................................. 28
Rotation Gearbox Mounting Cap Screws ............................................................. 30
Digger Motor Cap Screws .................................................................................... 31
Auger and Auger Extension Shaft Cap Screws and Nuts ..................................... 31
Slide Pad Bearing Cap Screws ............................................................................ 31
Pins and Pin Retainers ............................................................................................... 31
Pin Installation Into Self-Lubricating Bearings ...................................................... 33
Pin Installation Into Lubricated Joints ................................................................... 34
Bearings ...................................................................................................................... 34
Spherical Bearings ............................................................................................... 34
Pressure Cast Cylindrical Bearings ...................................................................... 34
Self-Lubricating Bearings ..................................................................................... 34
Tapered Roller Bearings ....................................................................................... 35
Slide Pad Bearings ............................................................................................... 35
Rotation Bearing ................................................................................................... 36
Cylinders ..................................................................................................................... 39
Hydraulic Lines ........................................................................................................... 39
Atmospheric Vents ...................................................................................................... 39
Fiberglass and Plastic Components ........................................................................... 39
Cleaning ............................................................................................................... 39
Plastic ................................................................................................................... 40
Determining the Degree of Boom Damage........................................................... 40
Repair ................................................................................................................... 41
Winch Line .................................................................................................................. 43
Synthetic Winch Line ............................................................................................ 43
Wire Rope Winch Line .......................................................................................... 44
Auger Windup Sling .................................................................................................... 45
Wire Rope Sling .................................................................................................... 46
Synthetic Sling ...................................................................................................... 46
Auger Stow Bracket Clevis ................................................................................... 46
Accident Prevention Signs .......................................................................................... 46
Accident Prevention Signs Diagram ..................................................................... 47
Section 5 Hydraulic System
Protection Systems ..................................................................................................... 57
Hydraulic Overload Protection (HOP) ................................................................... 57
Hydraulic Side Load Protection (HSLP) System .................................................. 58
Electronic Side Load Protection (ESLP) System .................................................. 59
Boom Stow Protection .......................................................................................... 61
Auger Stow Protection .......................................................................................... 61
Load Moment Limiter .................................................................................................. 62
Anti-Two-Block (ATB) .................................................................................................. 62
Oil Reservoir ............................................................................................................... 63
Pump ........................................................................................................................... 64
Hydraulic Shock Absorber ........................................................................................... 64
Rotary Joint ................................................................................................................. 64
Valves.......................................................................................................................... 65
Outrigger Control Valve and Outrigger/Tools Control Valve ................................. 65
Lower Tool Circuit Flow Control Valve .................................................................. 66
Selector Valve ....................................................................................................... 66
Lower Control Valve ............................................................................................. 67
Auxiliary Functions Valve ...................................................................................... 68
Rotation Float Valve ............................................................................................. 69
Rotation Float Brake Release Valve ..................................................................... 69
Holding Valves ...................................................................................................... 70
Cavitation and Aeration ............................................................................................... 70
Air Bleeding ................................................................................................................. 71
Leakage ...................................................................................................................... 71
Heat Generation .......................................................................................................... 72
Hydraulic Lines ........................................................................................................... 72
Fittings and Valve Cartridges ...................................................................................... 73
Torque and Tightening Procedures ....................................................................... 73
Cylinders ..................................................................................................................... 74
Radial Outrigger Cylinder ..................................................................................... 76
A-Frame, X-Frame, and Modifed A-Frame Outrigger Cylinder ........................... 76
Out and Down Outrigger Vertical Leg Cylinder ..................................................... 78
Out and Down Outrigger Horizontal Leg Cylinder ................................................ 79
Lift Cylinder ........................................................................................................... 80
Intermediate Boom Cylinder ................................................................................. 80
Upper Boom Cylinder ........................................................................................... 82
Auger Latch Cylinder ............................................................................................ 84
Digger Shift Cylinder ............................................................................................. 84
Pole Guide Cylinders ............................................................................................ 85
Thermal Compensation Cylinder .......................................................................... 85
Section 6 Mechanical Systems
Rotary Joint ................................................................................................................. 87
Rotation System .......................................................................................................... 88
Rotation Bearing ................................................................................................... 89
Rotation Bearing Cap Screws ............................................................................. 91
Rotation Gearbox ................................................................................................. 92
Upper Boom ................................................................................................................ 94
Winch .......................................................................................................................... 95
Drum ..................................................................................................................... 95
Platform Brake ............................................................................................................ 96
Digger Transfer Mechanism ........................................................................................ 96
Section 7 Electrical System
On/Off Circuit .............................................................................................................. 99
Proportional Circuit ..................................................................................................... 99
Multiplexed Controls ................................................................................................. 100
Below Rotation Valve Driver...................................................................................... 100
Above Rotation Valve Driver ..................................................................................... 100
Cable Assemblies ..................................................................................................... 100
Multiplex Cable Connectors ...................................................................................... 100
Calibration and Calibration Diagnostic Instrument (CADI) ........................................ 104
Power Distribution Module (PDM) ............................................................................. 105
Outrigger Interlock System ....................................................................................... 105
A-Frame, X-Frame, Modifed A-Frame, Out and Down, or
Corner Mount Street Side Outriggers .......................................................... 105
Radial or Corner Mount Curb Side Outriggers ................................................... 105
Lower Control Panel ................................................................................................. 106
Dual Lower Control Panels ................................................................................. 106
Hand Controls ..................................................................................................... 106
Joysticks ............................................................................................................. 107
Slip Ring .................................................................................................................... 107
Upper Controls .......................................................................................................... 108
Operation ............................................................................................................ 108
Pole Guide Interlock System ..................................................................................... 109
Section 8 Troubleshooting, Testing, and Adjustments
Troubleshooting Procedure ........................................................................................111
Hydraulic System .......................................................................................................111
Cycle Times .........................................................................................................111
Pilot System Pressure ........................................................................................ 112
Standby Pressure ............................................................................................... 113
System/Compensator Pressure .......................................................................... 113
Secondary System Relief Pressure .................................................................... 114
Outrigger System Pressure ................................................................................ 115
Lower Tools System Pressure ............................................................................ 115
Pump Flow .......................................................................................................... 116
Outriggers ........................................................................................................... 117
Lower Tool Circuit ............................................................................................... 118
Upper Tool Circuit ............................................................................................... 120
Derrick Blocking Valve (DS1) ............................................................................. 121
Outrigger/Tool Blocking Valve (DS2) .................................................................. 122
Outrigger/Tool Sense Dump Valve (DS4) ........................................................... 123
Selector Valve Orifce ......................................................................................... 124
Outrigger/Tool Pressure Selector Valve (DS3) ................................................... 124
Sense Lines and Sense Shuttle Valves ............................................................. 125
Outrigger Interlock System ................................................................................. 128
Rotary Joint ........................................................................................................ 128
Pulsar Valves and Hand Controls ....................................................................... 129
Lift Cylinder ......................................................................................................... 131
Intermediate and Upper Boom Extension Cylinders ........................................... 132
Holding Valves .................................................................................................... 134
Mechanical System ................................................................................................... 136
Rotation Gearbox ............................................................................................... 136
Rotation Brake With Hydraulic Side Load Protection ......................................... 139
Rotation Brake With Electronic Side Load Protection ........................................ 139
Platform Brake .................................................................................................... 139
Digger Shift Cylinder ........................................................................................... 140
Electrical System ...................................................................................................... 140
Failure Identifcation ........................................................................................... 140
Short Circuit ........................................................................................................ 141
Pin and Circuit Identifcation ............................................................................... 142
Circuit Protection ................................................................................................ 142
Proximity Switches ............................................................................................. 142
Tilt Switches........................................................................................................ 143
Outrigger Interlock System ................................................................................. 144
Programmable Settings ...................................................................................... 144
Boom Functions Speeds .................................................................................... 146
Upper Control Sequential Boom Extension ........................................................ 147
Pole Guide Interlock System .............................................................................. 148
Protection Systems ................................................................................................... 150
Hydraulic Overload Protection (HOP) ................................................................. 150
Load Indicator Gauge ......................................................................................... 151
Hydraulic Side Load Protection (HSLP) ............................................................. 152
Electronic Side Load Protection (ESLP) ............................................................. 156
Boom Stow Protection ........................................................................................ 159
Auger Stow Protection ........................................................................................ 159
Rotation Pressure Limiter ................................................................................... 160
Lower Boom Pressure Limiter ........................................................................... 161
Extension Pressure Limiter ................................................................................. 162
Load Moment Limiter .......................................................................................... 163
Anti-Two-Block (ATB) ........................................................................................ 163
Manually Lowering/Stowing the Unit ......................................................................... 164
Rotating the Turntable ........................................................................................ 165
Lowering the Booms ........................................................................................... 165
Manually Raising the Outriggers ........................................................................ 166
Auxiliary Power Source ............................................................................................. 166
Bypassing the Derrick Blocking Valve ....................................................................... 169
Bypassing the Outrigger/Tool Blocking Valve............................................................ 169
Section 9 Dielectric and Stability Testing
Dielectric ................................................................................................................... 173
Stability ..................................................................................................................... 173
Load Moment Limiter ................................................................................................ 176
Appendix
Glossary
Service Tools and Supplies
Preventive Maintenance and Inspection Checklist
Accessory Checklist
Torque Values
Basic JIC Symbols
Hydraulic System Schematics
Basic Electrical Symbols
Wiring Line Diagrams
Dielectric Test Forms
Stability Test Forms
Section 1 Introduction 1
Section 1 Introduction
Throughout the manual, the term unit is used to describe
the Altec device, subbase, outriggers, and the associated
interface with the vehicle.
Additional copies of this manual may be ordered through
your Altec representative. Supply the model and serial
number found on the serial number placard and the
manual part number from the front cover to assure that
the correct manual will be supplied.
This symbol is used throughout this manual to
indicate danger, warning, and caution instruc-
tions. These instructions must be followed to
reduce the likelihood of personal injury and/or property
damage.
The terms danger, warning, caution, and notice repre-
sent varying degrees of personal injury and/or property
damage that could result if the preventive instructions
are not followed. The following paragraphs from ANSI
publications explain each term.
Danger
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury. This
signal word is to be limited to the most extreme
situations.
Warning
avoided, could result in death or serious injury.
Caution
avoided, may result in minor or moderate in-
jury. It may also be used to alert against unsafe
practices.
Notice
The preferred signal word to address practices
not related to personal injury.
About This Manual
This manual provides instruction to safely inspect, re-
pair, troubleshoot, and test the unit. Charts and fgures
are provided to support the text. Because options vary
from one model to another, some fgures may only be a
representation of what is actually on the unit.
Knowledge of the information in this manual combined
with proper skills and training in hydraulic, electrical, and
mechanical systems, provide a basis for safely maintaining
the unit. Read and understand the applicable procedure
before beginning. Carefully follow each procedure.
Contact the following organizations for additional infor-
mation.
American National Standards Institute (ANSI)
A92.2 for aerial devices; A10.31 for digger derricks
American Public Power Association
(Safety Manual for an Electric Utility)
American Society for Testing and Materials
(ASTM)
American Welding Society (AWS)
Canadian Standards Association (CSA)
European Committee for Standardization (CEN)
Fluid Power Society (FPS)
Hydraulic Tool Manufacturers Association (HTMA)
International Electrotechnical Commission (IEC)
International Organization for Standardization
(ISO)
Occupational Safety and Health Administration
(OSHA)
Dealers, installers, owners, users, operators, renters,
lessors, and lessees must comply with the appropriate
sections of the applicable ANSI standard.
The Appendix contains reference items to help maintain
the unit. A glossary of industry terms is provided for your
convenience. This glossary provides an understanding
of the industry terms and phrases used in Altec manuals.
2 Section 1 Introduction
Section 2 Unit Specifcations 3
Section 2 Unit Specifcations
General Specifcations
This unit has a lower boom with telescoping intermediate
and upper booms. The lower and intermediate booms are
steel. The upper boom is fberglass. Figure 2.1 provides
general unit specifcations.
The basic structural components are the outriggers, sub-
base, pedestal, turntable, lower boom, intermediate boom,
and upper boom. The steel structures are manufactured in
the form of a closed box or tubular construction. This con-
struction resists torsional loading. It also resists tension,
compression, and bending loads. Careful consideration
has been given to the design and manufacturing process
to minimize the possibility of fatigue cracks.
The round upper boom is made of centrifugally cast
fberglass. The inner fberglass surface is impregnated
with a wax compound, providing a smooth surface for
moisture to bead. The outer surface has a smooth gelcoat
fnish to protect the fberglass.
The nonconductive components, when properly main-
tained, clean, dry, free from tracking, and in good condi-
tion as established by dielectric testing, will meet the
dielectric requirements of ANSI in effect at the time of
unit manufacture. The ratings of the unit must be known
and understood by its users.
This unit shall be used near energized conductors only by
qualifed operators who are fully trained and profcient as
electrical linemen. Personnel using this equipment must
be familiar with the hazards of contact with energized
conductors, for the protection of themselves, their co-
workers, and the public. The nature of electrical hazards
is described in the Operators Manual.
4 Section 2 Unit Specifcations
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Section 2 Unit Specifcations 5
Component Identifcation
Lower Boom
Lift Cylinder
Outrigger
Cylinder
Outrigger Controls
Pedestal
Rotation Bearing
Boom Pin
Boom Angle Indicator
Auger Stow
Bracket
Extension
Cylinder
Auger
Auger
Extension Shaft
Digger
Digger Link
Boom Tip Winch
Upper Boom
Platform
Jib
Upper
Boom Tip
Platform Pin
Capacity
Chart
Turntable
Rotation
Gearbox
Turntable
Winch
Lower
Controls
Intermediate Boom
Digger Hanger
Bracket
Pole Guide Tong
Cylinder
Pole Guide
Outriggers
Anti-
Two-Block
Switch
6 Section 2 Unit Specifcations
Section 3 Safety 7
Section 3 Safety
Maintenance procedures may require the use of ladders,
platforms, scaffolding, etc., to access the unit. Provide
suitable work surfaces clear of obstructions for mainte-
nance procedures. Do not stand or walk on surfaces that
are not intended as such.
General Maintenance Information
Read and understand the complete procedure
before beginning.
Remove the pressure in a hydraulic circuit before
disconnecting its components.
Use lifting devices of suitable capacity to support
and handle components.
Use a test block to adjust the relief setting on
counterbalance holding valves.
Be aware of your surroundings.
Fully open all shutoff valves after servicing the
unit.
Complete the required procedures before returning
the unit to operation.
After completing a procedure, check the oil level in
the hydraulic reservoir and add oil if necessary.
Many inspections require the removal of covers.
After the inspection is complete, replace the covers
before returning the unit to service.
Disclaimer of Liability
Altec Industries, Inc. will not be liable for unauthorized
alterations or modifcations of the unit. Altec Industries,
Inc. will not be liable for improper or abusive operation
of the unit.
Do not alter or modify this unit in any way that might affect
its structural integrity, dielectric integrity, or operational
characteristics without specifc written approval from
Altec Industries, Inc.
Unauthorized alterations or modifcations will void the
warranty. However, of a greater concern is the possibility
that unauthorized changes could adversely affect the units
operation that could endanger personnel and/or damage
property. Altec will not be responsible for unauthorized
alterations or modifcations that cause death, serious
injury, and/or property damage.
Altec Industries, Inc. assumes no liability for any personal
injury and/or property damage related to the use of this
manual when performing testing, operating, maintenance
and/or repair procedures on this Altec unit.
Safety Instructions
It is essential that all personnel involved in the care of
this unit read and understand the Operators and Main-
tenance Manuals. Safety alerts throughout the manuals
highlight situations in which accidents can occur. Give
special attention to all safety alerts.
The safety information in this manual applies only to
the maintenance of this unit. Although procedures have
been written to protect the mechanic and other person-
nel, there is no safety system to account for human error
or negligence.
Danger
Death or serious injury will result from unprotected
contact with energized conductors. This unit does
not provide protection from contact with or proximity
to an electrically charged conductor when you are in
contact with or in proximity to another conductor or
any grounded device, material, or equipment. Maintain
safe clearances from energized conductors.
Warning
Death or serious injury can result from careless
or improper use of the unit. The mechanic bears
ultimate responsibility for following all regulations
and safety rules of their employer and/or any state
or federal law.
Notice
Maintenance personnel must be trained in safe ser-
vice procedures.
Work practices may expose maintenance personnel to
hazardous materials. Before using any chemical, read
and understand the manufacturers label and the mate-
rial safety data sheet (MSDS). These sheets explain
emergency and frst aid procedures and waste disposal
methods. Properly dispose of oil and hazardous materi-
als.
Caution
Injury can result from slipping and falling. Use care
and suitable work platforms during maintenance.
8 Section 3 Safety
Section 4 Preventive Maintenance and Inspection 9
Section 4 Preventive Maintenance and Inspection
Proper unit maintenance will reduce downtime, lower op-
erating and repair costs, and extend equipment life. Safety
alone justifes a preventive maintenance program. This
section contains information on properly inspecting the
hydraulic system, structures, individual unit components
and lubrication. Use the Lubrication Chart and Diagram
in this section when lubricating the unit.
A Preventive Maintenance and Inspection Checklist is
provided in the Appendix. Use this checklist when per-
forming routine maintenance and inspections to insure
no areas are overlooked. Components may be installed
on your unit that require additional maintenance at
different intervals outside the scope of the Preventive
Maintenance and Inspection and Accessory Checklists.
Refer to these component manuals for more information.
Keep permanent, written, and dated records of all service
performed on the unit.
Routine maintenance is performed on different com-
ponents of the unit at different times (refer to the Pre-
ventive Maintenance and Inspection Checklist in the
Appendix).
More frequent maintenance may be necessary if the
unit is operated under severe conditions. In addition to
the Preventive Maintenance and Inspection Checklist
recommendations, follow these recommendations on
new units.
Check oil level and collect sample for analysis.
Measure the turntable tilt before using a new unit.
Change the return line flter cartridge after the frst
15 to 25 PTO hours
Gearbox manufacturers recommend an initial oil
change after the frst 15 to 25 PTO hours.
Equipment Storage
Mobile hydraulic equipment needs maintenance when
stored, or not used, for extensive periods of time. De-
pending upon the climate, lack of use may begin to have
a negative effect in as little as two weeks. Storage for a
period of several months will almost certainly produce
some deterioration of the equipment.
Rust will form on unprotected ferrous metal surfaces very
quickly and water will collect inside unit structures. In dry
climates, gaskets will begin to shrink during long periods
of nonuse, and lubricants will lose their ability to provide
lubrication. In cold climates, condensation may occur in
fuid reservoirs and other components.
Even when protective measures have been taken prior
to storage, some degradation of performance must be
expected when the equipment is put back into use.
One of the most noticeable effects of prolonged periods
of nonuse is seal deformation. By its nature, hydraulic
equipment generally has a number of heavy, cylindrical
actuators. As these components are allowed to rest in
one position for a period of time, the seals on the piston
will tend to fatten along the loaded side. Since the seal
material is synthetic, its elasticity is limited and it may
not resume its original shape completely. At best, there
will be some failure to seal well for a short period of time
after putting the equipment back into use. At worst, the
seal will never resume its original shape and will have
to be replaced.
Protective Measures
If it is known that equipment will be stored for a month
or more, some steps should be taken to preserve the
equipment.
1. The best preservative is to fully cycle (operate) the
equipment once weekly if even for a short time.
2. Coat exposed ferrous (iron or steel) bare metal
surfaces with a light grease or heavy oil compatible
with system hydraulic oil. This includes cylinder rods,
shafts, gears, linkages, and unpainted parts.
3. Top off fuid reservoirs to allow as little air space as
possible, to limit the effects of condensation. Remove
excess oil before operating to limit the chance of
overfow when cylinders are cycled.
4. Cover or wrap exposed rubber or neoprene parts
with an ultraviolet resistant covering to shield the
parts from sun exposure.
5. Unplug electrical connectors and apply a dielectric
grease or an aerosol product designed for protect-
ing electrical connectors. Plug the connector back
together.
6. Cover switch panels and control panels to prevent
direct intrusion of rain or moisture, while allowing air
to circulate over the panel.
7. Cover personnel platforms to prevent the accumula-
tion of water in the platform.
8. Shield fberglass components from the sun and other
elements, if stored outside.
Hydraulic System
Warning
Death or serious injury can result if the recommended
hydraulic oil is not used. Other fuids added to the
10 Section 4 Preventive Maintenance and Inspection
hydraulic system can affect the insulating capability
of the unit.
Notice
Only use hydraulic oil as recommended. Other fuids
added to the hydraulic system can increase compo-
nent wear and affect the lubricating characteristics
of the oil.
Maintaining the hydraulic system is critical to the proper
operation of the unit. Using the proper type of oil helps
to prevent many hydraulic system problems. Maintaining
the oil is also important. If the oil is dirty or contaminated,
components can be damaged.
Check the oil level in the reservoir with the vehicle level
and the booms and outriggers stowed. Under these
conditions, the proper oil level is between the Add and
Full marks on the dipstick.
Cleanliness Precautions
Contamination will ruin any hydraulic system. It is very
important that no contaminants enter the system. Dirt,
water, and air are types of contaminants. They can enter
the hydraulic system in many ways. Contaminants can
enter the system when flling the reservoir or changing
flters. They can also enter when changing components
or performing other service procedures.
The following precautions will help protect the cleanliness
of the hydraulic system.
Filter new oil with a 10 micron flter as it is added
to the reservoir.
Clean hydraulic connections before opening them.
Cap or plug ports and lines opened for service.
Keep replacement hoses, tubes, and other compo-
nents plugged while stored.
Make sure components are clean before installa-
tion.
Clean the reservoir and return line flter covers
before opening them.
Clean the fller breather cap before opening it.
After servicing the reservoir, immediately replace
the cover.
Make sure quick disconnect couplers are clean
before connecting them.
Do not spray water on the reservoir fller breather cap.
This could force contaminants into the reservoir.
Filtration
The unit is equipped with a complete fltration system.
When properly maintained, this system will reduce con-
tamination of the hydraulic system. The fltration system
must be serviced regularly to be effective.
Filler Breather Cap and Strainer Basket
The fller breather cap is located on top of the fll hole of
the reservoir (refer to Figure 4.1).
Figure 4.1 Reservoir
The cap allows air to fow in and out of the reservoir as
the oil level changes. It contains a flter that cleans the
air as it enters the hydraulic system. The fll hole strainer
basket keeps large particles from entering the reservoir
when oil is poured into it. The cap has a built-in dipstick
with Full and Add marks. Use the marks to determine the
oil level of the reservoir as described under Hydraulic Oil
Specifcations in this section.
Replace the fller breather cap flter (refer to Service Tools
and Supplies in the Appendix) as recommended by the
Preventive Maintenance and Inspection Checklist. If the
unit is operated in an extremely dusty environment, the
flter may need to be changed more often.
Remove and fush out (or replace) the strainer basket any
time it has collected dirt or other contaminants. Flush the
strainer basket when the hydraulic oil is changed.
Suction Filter
A magnetic suction separator flter is located in the bottom
of the reservoir at the outlet (refer to Figure 4.1).
The magnetic suction separator flter has a pleated wire
mesh screen. This screen prevents particles that are 250
Filler Breather
Cover
Assembly
Suction
Filter
Return Line Filter
Outlet
Pipe
micron or larger from entering the pump. One micron is
0.00039. Magnets located inside the flter attract and
collect iron and steel particles in the hydraulic oil.
Clean the flter whenever the hydraulic oil is changed. Oil
will not fow into the pump fast enough if the flter becomes
clogged. If the pump does not receive suffcient oil fow,
pump damage will result.
Use the following procedure to remove and clean the
flter.
1. Drain the reservoir and wipe the top of the reservoir
cover. Loosen the cap screw in the center of the
cover two to three turns. Slide the cover assembly
to one side. Lift up on the other side and slide the
assembly back to remove it from the reservoir.
2. Reach down into the reservoir with a wrench which
will ft the 3.15 (80 mm) hex at the bottom of the
flter. Unscrew the flter by using the wrench to turn
the flter counterclockwise. Do not grip the wire mesh
screen by hand or with the wrench. This will crush
the screen.
3. Disassemble the flter and remove the magnet as-
sembly out of the suction flter.
Warning
Death or serious injury can result from improper
use of solvents. Follow the manufacturers label for
proper use and disposal.
Caution
Injury can result from airborne particles entering the
eyes. Wear appropriate safety equipment.
Eye protection must be worn at all times to prevent particles
of dirt, metal, or hydraulic oil from entering the eyes.
4. Clean the flter screen by fushing it with clean sol-
vent. Blow it dry with an air hose from the inside of
the screen to the outside. Check for holes or other
damage. Replace the suction flter if the screen is
damaged.
5. Clean the magnets by fushing them with solvent.
Blow them off with an air hose and wipe them dry
with a lint-free rag.
6. Assemble the flter screen and magnet assembly.
7. Inspect the inside of the reservoir. If necessary, clean
it as described under Changing Oil and Flushing the
System in this section.
8. Install the suction flter in the reservoir by turning the
hex at the bottom clockwise with a wrench. Clean the
flter no more than four times before replacing it.
9. Install the cover assembly.
Return Line Filter
The return line flter is a 10 micron flter that cleans the oil
as it enters the reservoir. It is mounted in the reservoir.
Particles trapped by the flter are collected in the flter
cartridge. This cartridge is disposable and is available
from your Altec representative (refer to Service Tools and
Supplies in the Appendix).
The return line flter is equipped with a bypass valve in
the flter head. The bypass valve opens when there is
a pressure drop of 25 psi (1.72 bar) or more across the
flter cartridge. When the valve is open, oil fows directly
into the reservoir. This prevents the cartridge from col-
lapsing during cold weather or if it is clogged.
If the flter becomes clogged, oil will fow directly into the
reservoir through the bypass valve. The lack of oil fltration
will eventually damage hydraulic components.
During the break-in period of a new unit, the hydraulic com-
ponents will deposit break-in wear particles in the return
line flter cartridge. Change the return line flter cartridge
after the frst 15 to 25 hours. Then, change the cartridge
as recommended by the Preventive Maintenance and
Inspection Checklist. If the unit is operated in very dusty
conditions, replace the return line flter cartridge more
often. Also, replace the flter cartridge after new oil has
circulated through the system for the frst time.
Use the following procedure to change the return line
flter cartridge.
1. Wipe off the cover on the flter head (refer to Figure
4.1). Remove the cover and bypass valve.
2. Lift the cartridge out of the flter housing.
3. Inspect the inside of the flter housing for dirt buildup.
Wipe the housing out if necessary. Do not drop any
dirt through the outlet hole at the bottom of the flter
housing.
4. Insert the new cartridge in the housing. Do not clean
and reuse the old cartridge.
5. At the bottom end of the cartridge there is a sealing
grommet. Fit the raised portion of the outlet tube
through the grommet. Push the cartridge down until
it sits against the bottom of the housing.
6. Install the bypass valve and flter cover. Tighten the
cover cap screws. Do not overtighten the cover cap
screws. Excessive torque will strip the threads in the
aluminum flter housing.
Cold Oil/Change Filter Light
A cold oil/change flter light is located on the lower control
panel (refer to Figure 4.2). This light alerts the operator
when the return line flter needs changing or when the
hydraulic oil is cold. The cold oil/change flter light is
operated by the flter switch on the rotary joint.
When the return line flter becomes contaminated, a pres-
sure drop is created across the return line flter cartridge.
When the pressure drop reaches 25 psi (1.72 bar), oil
begins to fow through the bypass valve in the return line
flter instead of through the flter cartridge. When the pres-
sure at the rotary joint is 38 psi (2.62 bar), the cold oil/
change flter light will turn on to warn of the condition.
The cold oil/change flter light will also be on when the
hydraulic oil is cold. Cold oil increases back pressure in
the return line. Excessive pump speed also increases
back pressure. Even if the flter cartridge is in good con-
dition, the light will turn on if the back pressure exceeds
the pressure switch setting of 38 psi (2.62 bar).
Use the cold oil/change flter light as an indicator of flter
condition only when the oil is warm and the pump is run-
ning at no more than maximum rated fow.
Oil Specifcations
Use high quality oil in the hydraulic system. The oil should
contain rust, oxidation, and corrosion inhibitors. It should
also contain antifoam and antiwear additives.
Hydraulic oils used in insulated equipment must possess
high demulsibility to allow the oil to separate from the
water in the reservoir. These oils must pass the ASTM
D877 test for dielectric breakdown voltage of insulating
oils at 35 kilovolts or higher for new oil.
Hydraulic oil is commonly classifed by viscosity. The
viscosity of hydraulic oil changes with temperature. The
higher the viscosity index of an oil, the less the viscosity
will change as the temperature changes. A multiviscosity
oil contains additives which increase the viscosity index.
Multiviscosity oils should have high shear stability to
maintain oil performance by avoiding excessive change
in viscosity.
The ability of hydraulic oil to provide adequate fow at low
temperatures is measured by its pour point. If the pour
point is not low enough, oil will not fow into the pump
at a fast enough rate when the pump is operated at low
temperatures. This will cause cavitation, which can very
quickly destroy the pump.
Warning
Death or serious injury can result if the recommended
hydraulic oil is not used. Other fuids added to the
hydraulic system can affect the insulating capability
of the unit.
Figure 4.2 Lower Control Panel
Cold Oil/Change Filter Light
Notice
Only use hydraulic oil as recommended. Other fuids
added to the hydraulic system can increase compo-
nent wear and affect the lubricating characteristics
of the oil.
Using a hydraulic fuid outside the temperature range
it was prescribed for may cause system damage.
Only use oils meeting the viscosity rating for military
specifcation MIL-5606 in extremely cold climates.
These oils have fewer antiwear characteristics and
are not recommended for full time use.
Figure 4.3 shows hydraulic oil recommendations for dif-
ferent temperatures. The requirements are for mineral
based and biodegradable hydraulic fuids. Most compa-
nies can supply equivalent oils. The oil selected for the
hydraulic system depends on the temperature during
unit operation.
When reflling or changing hydraulic fuids it is recom-
mended the replacement fuid meet oil cleanliness re-
quirement 21/17/14 as specifed by ISO 4406.
Oil Condition
An important part of hydraulic system preventive main-
tenance includes checking the condition of the hydraulic
oil.
Periodic laboratory analysis is the most accurate method
of determining the condition of the hydraulic oil and de-
termining when it should be changed. A visual inspection
may also be used to check oil condition.
A hydraulic oil supplier should be able to do testing or
recommend a test laboratory. The laboratory should
provide the following information.
Particle count
Trace element analysis (component wear, outside
contaminants and oil additive concentrations)
Viscosity test
Water content test
Dielectric strength test (when requested)
Before taking a sample of oil, operate the unit to circu-
late the oil. Warm it to operating temperature. Take the
sample from the middle level of the reservoir, using a clean
hand pump, such as a disposable syringe and a piece of
plastic tubing. If this is not available, the sample can be
drained from the bottom of the reservoir. Allow several
quarts of oil to fow out before collecting the sample. This
will remove any dirt and water that has collected in the
reservoir near the drain.
If a sample container has not been provided by the labora-
tory, use a wide mouth, screw top, clear glass container.
Clean it with hot water and detergent. Rinse it thoroughly
and let it air dry before putting oil in it.
Specifcation All Weather Oil Cold Weather Oil Warm Weather Oil
ISO grade 22 15 32
Ambient temperature range -10 to 95 F (-23 to 35 C) -50 to 60 F (-46 to 16 C) 40 F (4 C) and above
Viscosity @ 104 F (40 C) 24 cSt 15 cSt 32 cSt
Viscosity @ 212 F (100 C) 4.6 cSt 4.4 cSt 6.0 cSt
Pour point, biodegradable -31 F (-35 C) -58 F (-50 C) -31 F (-35 C)
Pour point, mineral based -48 F (-55 C) -76 F (-60 C) -49 F (-45 C)
Flash point (min) 302 F (150 C) 302 F (150 C) 302 F (150 C)
Dielectric strength (min) 35 kV 35 kV 35 kV
Four-ball wear, scar (max) 0.028 (0.70 mm) 0.028 (0.70 mm) 0.028 (0.70 mm)
Oxidation stability, TOST (min) 2,000 hours 2,000 hours
Oxidation stability, RPVOT (min) 250 minutes 177 minutes 250 minutes
Water content (max) 63 ppm 38 ppm 63 ppm
Demulsibility, minutes to pass 15 10 15
Copper corrosion 1A 1A 1A
Rust test, pass/fail Pass Pass Pass
Foam test, pass/fail Pass Pass Pass
Figure 4.3 Hydraulic Oil Viscosity Recommendations
Once the report is received, compare it to previous oil
analysis reports for the same unit. This information will
provide trends toward oil deterioration. It may give early
warnings of a problem developing within hydraulic system
components.
Notice
Change the oil if the sample has any of the charac-
teristics listed in Figure 4.4.
If making a visual inspection, compare the sample of oil
to a sample of new oil of the same type. Also, compare
it to previous samples taken from the same unit. Look for
the signs of oil deterioration listed in Figure 4.4.
There are fuid contamination level detector kits available
which allow for rapid, on-the-spot analysis of the hydraulic
systems condition. Contact your Altec representative for
further information.
Oxidation produces varnishes that bake onto hot sur-
faces. These oxidation products are acidic and tend to
attack metal surfaces. This can damage pumps, motors,
and valves.
High operating temperatures will increase the rate of oxi-
dation of the oil. The presence of water or air in hydraulic
oil also causes oxidation.
The presence of water may cause rust and corrosion. It
also reduces the dielectric capability of the oil.
If laboratory analysis or visual inspection indicate that
the oil is deteriorating prematurely, determine the cause
of the problem and correct it.
Changing Oil and Flushing the System
A properly maintained fltration system greatly extends the
useful life of the hydraulic oil. However, the hydraulic oil
will eventually need to be replaced due to contaminants
that form during the normal operation of the unit.
It is impossible to recommend an exact time interval for
oil changes due to varying conditions of unit use. Use
the following guidelines to determine when the hydraulic
oil should be changed.
Change the oil as recommended by the Preventive
Maintenance and Inspection Checklist.
If a hydraulic component fails and contaminates the
system with metallic particles, change the component
and the oil immediately.
In climates with a wide variation in operating tempera-
tures between summer and winter months, change
to an appropriate weight oil each spring and fall.
Replace the return line flter cartridge and fller breather
cap flter every time the hydraulic oil is changed. Also,
clean or replace the magnetic suction separator flter.
A signifcant quantity of oil remains in the cylinders
and lines of the hydraulic system when the reservoir is
drained. Flush the system when the oil is changed. This
is especially important if the system is heavily contami-
nated with metal particles.
If the oil is contaminated with water, it may not be neces-
sary to change the oil and fush the system. Follow the
instructions under Water Removal in this section.
The following equipment and supplies are necessary to
properly fush the hydraulic system.
Approximately 85 gallons (322 l) of proper grade
hydraulic oil
Two return line flter cartridges
Clean, lint-free rags
Four seals for the return line flter housing
Filler breather cap flter (if the component has not
been replaced within one year)
Figure 4.4 Hydraulic Oil Conditions
Condition Possible Cause
Dark color Oxidation; contamination
Cloudiness or milky appearance Presence of water or wax
Rancid or burned odor Oxidation
Increase in viscosity Oxidation; addition of improper fuids; presence of water
Decrease in viscosity Addition of improper fuids; additive deterioration
Separation of water or other fuids from the oil Presence of water; addition of improper fuids
Foreign particles or other visible contamination Contamination; emulsion of water with oil additives
Caution
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
work areas clean.
Use the following procedure to fush the hydraulic sys-
tem.
1. If the oil is being changed because of contamination
due to a hydraulic component failure, proceed to step
2. Otherwise, operate the unit to circulate the oil and
warm it to operating temperature. This will allow many
of the impurities to drain off in suspension.
2. Drain the oil reservoir completely.
3. Wipe off the top of the reservoir, reservoir cover, fller
breather cap, and return line flter.
4. Remove the reservoir cover and the magnetic suc-
tion separator flter. Disassemble and clean it as
described under Suction Filter in this section.
Warning
5. Inspect the inside of the reservoir. If sludge or other
contamination is found, clean it using solvent and
lint-free rags. Remove the return line flter to provide
an additional access hole for cleaning. Disconnect
the pump suction line from the bottom of the reservoir
while cleaning. This will keep dirt and solvent out of
the suction line.
6. Reconnect the suction line immediately after cleaning.
Install the return line flter using new seals on the cap
screws that clamp the flter head to the reservoir.
7. Install the clean magnetic suction separator flter in
the reservoir. Install a new flter in the fller breather
cap.
8. Install the reservoir cover assembly.
9. If hydraulic component failure has contaminated the
system, change the return line flter cartridge.
10. Add approximately 25 gallons (95 l) of new hydraulic
oil of the proper grade to the reservoir. If possible,
the new oil should be pumped through a 10 micron
flter as it is put into the reservoir.
11. If the new oil was not fltered as it was put into the
reservoir, connect a service hose to the tool outlets
and allow the new oil to circulate through the tool
circuit for about 15 minutes.
12. Use a slow engine speed, cycle all the cylinders and
motors to fush the contaminated oil from the lines
and components of the hydraulic system.
13. Change the return line flter cartridge.
14. Drain the reservoir completely.
15. Fill the reservoir with new hydraulic oil of the proper
grade to the Full mark on the dip stick. Filter the oil
through a 10 micron flter as it is put into the reser-
voir.
16. If the new oil was not fltered as it was put into the
reservoir, circulate the oil through the tool circuit as
described in step 12.
17. Change the return line flter cartridge after approxi-
mately 25 hours of operation.
Water Removal
If the hydraulic system was contaminated with water,
special water removal fltration may be necessary. An oil
supplier or a qualifed laboratory can determine whether
water has caused excessive oil oxidation or additive
deterioration.
If analysis shows that oil deterioration beyond an accept-
able level, drain the reservoir and fush the system as
described earlier in this section. Use a water removal flter
cart during the fushing process to remove any residual
water from the system.
If the condition of the oil is acceptable except for the water
content, allow time for it to separate from the oil. Then
drain the water off the bottom of the reservoir. Circulate
the oil in the reservoir through a water removal flter cart.
While doing this, occasionally start the unit and cycle
all the functions. This will fush contaminated oil back
to the reservoir. Continue this process until the water
content in the oil is reduced to an acceptable level. The
preferred method of determining the water content in the
oil is laboratory testing. Another method of determining
water content in the oil is a dielectric test.
Do not attempt to use a water removal cartridge in the
return line flter to remove water from the system. The
fow rate of the pump, even at engine idle, exceeds the
fow at which effcient water absorption occurs.
Electrical System
Maintaining the electrical system is critical for proper
operation of the unit.
Slip Ring
This unit uses an electrical slip ring assembly to transmit
electrical signals between the pedestal and the turntable.
It protects the electrical wiring that passes through the
centerline of rotation. Failure to properly maintain the slip
ring may result in corrosion or degradation of contacting
surfaces, which may lead to malfunction and eventual
need for replacement of the slip ring.
This unit may be equipped with a serviceable slip ring.
The procedure outlined in this section should only be
performed on a serviceable slip ring. Attempting to
perform this procedure on any other slip ring may void
the manufacturers warranty. A serviceable slip ring is
identifed by the presence of fasteners which hold the
metal cover over the slip ring circuit assembly (refer to
Figure 4.5).
Figure 4.5 Slip Ring Identifcation
1. Position the unit on a level surface where the booms
can be elevated and rotated 360 degrees without
contact with fxed objects. Apply the parking brake
and chock the wheels. Engage the PTO and properly
set the outriggers. Disengage the PTO and turn off
the engine.
2. Remove any turntable or pedestal covers required
to access the slip ring assembly. Disconnect any
plumbing necessary to allow removal of the cover
from the slip ring assembly.
3. Remove the cover from the slip ring assembly. Re-
connect any plumbing which was disconnected in
step 2.
Caution
Injury can result from being pinched or trapped be-
tween moving components. Keep hands clear.
4. Spray the slip ring surfaces with DeoxIT cleaner/
protectant (refer to Service Tools and Supplies in
the Appendix). Normally one to two bursts of spray
is suffcient. If access to the slip ring is limited, rotate
the turntable to access all areas. Use care when
rotating the unit, as removed covers may expose
pinch points or other hazards.
5. Following treatment of all contact surfaces, start the
engine, engage the PTO, and rotate the turntable a
minimum of three full revolutions in both directions.
If contact surfaces appear clean and discoloration
from oxidation is greatly reduced, or no oxidation
residue is noted when the slip ring contact surfaces
are wiped with a clean white rag, proceed to step
8.
6. If the slip ring is heavily oxidized (discoloration of the
contact surfaces), spray the slip ring contact surfaces
again and allow it to sit overnight.
7. After sitting overnight, rotate the turntable three full
turns, then wipe all contact surfaces with a clean white
rag or blow off contact surfaces with compressed air
until dry.
8. Spray all contact surfaces again (one to two bursts)
with DeoxIT.
9. Reinstall the slip ring cover and turntable or pedestal
covers that were removed.
10. Test all functions that use the slip ring to conduct
electrical power between the turntable and pedes-
tal.
11. Following a successful test, return unit to service.
Lubrication
Proper lubrication will extend the life of the equipment
and reduce maintenance problems. The frequency of
lubrication will depend on the amount of use and the
conditions the unit is operated in. Operation in extremely
dusty, sandy, or rainy environments will require more
frequent lubrication. After washing and cleaning the unit,
relubricate as necessary.
The Lubrication Chart and Diagram identifes each com-
ponent, type of lubricant, and method of application. Any
brand of lubricant that meets or exceeds the specifca-
tions of the products listed is acceptable. There are fve
Fasteners
intervals of lubrication. Select the appropriate interval and
lubricate components identifed by the symbol(s).
Components may be installed on your unit that require
additional lubrication. Refer to these component manuals
for more information.
Always wipe grease fttings clean before and after greasing
to keep contamination from entering the points of lubrica-
tion. To avoid bearing damage, use manually operated
grease guns. Air-driven grease guns may have enough
force to cause bearing damage.
If the unit is not used, or is stored for any length of time,
apply fresh lubricant at all points shown on the Lubrica-
tion Chart and Diagram. This will help prevent corrosion
during the idle period.
Outriggers
Non-rotating pin connections on the outriggers have
been made with zinc plated pins coated with anti-seize
compound to prevent corrosion. These connections do
not require additional lubrication unless they are disas-
sembled.
Lubricate the inner legs of extendible outriggers as recom-
mended by the Preventive Maintenance and Inspection
Checklist. If the outrigger legs have three stages, lubricate
the inner leg and the second stage.
Use the following procedure to lubricate the outrigger
legs.
1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the PTO and
extend the outrigger legs. Disengage the PTO and
turn off the engine.
2. Wipe the exposed inner leg surfaces to remove any
dirt, moisture, etc.
3. Wipe on a coating of moly grease.
4. Start the engine and engage the PTO. Retract and
extend the outrigger legs several times to spread the
grease evenly on the surface.
5. Extend the outrigger legs and wipe off the excess
grease to prevent buildup of dust and other par-
ticles.
6. Retract the outrigger legs.
Bearings
Spherical bearings are used in several places on the
unit. They require regular lubrication with a chassis
lubricant.
It is very important to grease this type of bearing regu-
larly. If they are not greased properly, the usable life of
the bearing will be greatly reduced. These bearings can
produce enough twisting force on the mounting pins to
break the pin retainers and make removal diffcult if they
are not properly lubricated.
Self-lubricating bearings require no lubrication when they
contact plated shafts. This type of bearing is used at the
boom pin but must be lubricated regularly to protect the
housing from corrosion.
The outboard bearing for the winch output shaft is a
self-lubricating bearing. The output shaft is not plated,
requiring regular lubrication to prevent rust. There is a
grease ftting in the end of the output shaft.
Rotation Bearing
The rotation bearing ball path is lubricated by a grease
ftting on the front of the turntable.
Warning
Death or serious injury can result from being trapped
between moving components. Maintain a safe dis-
tance while components are in motion.
Do not lubricate the bearing while operating the unit.
Stop turntable movement before lubricating. Rotate the
turntable slowly through at least 2 complete 360 degree
revolutions, stopping every 30 to 45 degrees to lubricate.
Operate the manual grease gun three to fve times at
each stop.
Rotation Gear Teeth
Apply an open face gear lubricant to the rotation gear
and pinion teeth.
Caution
Injury can result from contact with pinion and rota-
tion bearing gear teeth. Keep hands clear.
Use caution when access covers have been removed
to service the unit. Pinch points and shear points may
exist between moving parts. Replace the access covers
immediately after servicing.
Remove the pinion cover from the turntable to lubricate
the rotation gear teeth. Replace the cover after the lu-
brication has been completed.
85 hours/ 500 hours/ 1,000 hours/ 2,000 hours/
1 month 6 months 1 year 2 years If disassembled
Letter Lubricant Application Method
A Anti-Seize Compound Extreme pressure lubricant that prevents seizure, Brush
corrosion, rust, and galvanic pitting.
C Chassis Grease Multipurpose lithium base grease with good water Grease gun
resistance, rust inhibition, oxidation stability, and extreme pressure properties.
E EP 80W-90 Gear Oil API Service Designation GL-5. Pour
F ATF, Type F Pour
G Open Face Gear Lubricant Spray lubricant that penetrates and adheres with Spray
good water resistance, is unaffected by temperature extremes, and has extreme
pressure properties.
M Moly Grease Multipurpose lithium base grease with good water resistance, Brush/grease gun
rust inhibition, oxidation stability and extreme pressure properties, with or
without molybdenum disulfde additive.
R Wire Rope Lubricant Penetrating, cleaning, nongumming protective spray; Spray
must minimize friction and eliminate rust.
S General Purpose Spray Lubricant Spray
T AGMA 4EP ISO 150 Industrial Gear Oil (do not use API GL-5 oil) Pour
V Conoco Gear Oil GP460 AGMA Grade 7 compounded with proprietary additives. Pour
W SAE 140 Worm Gear Oil AGMA Grade 7 compounded or 7EP, must be Pour
noncorrosive to bronze.
Lubrication Chart and Diagram
Service items identifed by the symbol(s) at the appropriate level.
Radial Outriggers
Cylinder, Shoe,
and Leg Pins
A
A
Cylinder, Shoe,
and Leg Pins
Corner Mount Outriggers
Cylinder and
Shoe Pins
A
C
M
Outrigger Inner
Leg Surface
Leg and Link
Pivot Pins
A-Frame Outriggers
Outer Surface
M
Cylinder and
Shoe Pins
A
A
Cylinder and
Shoe Pins
Outer Surface M
Out and Down Outriggers
Turntable With Hydraulic Side Load Protection
Cylinder Pin A
Turntable With Electronic Side Load Protection
Lift Cylinder
Spherical
Bearing
C
Fill Plug
Oil Level
Oil Fill
T
Change Oil T
Worm
Bearing
C
Oil Level V
Change Oil V
Lift Cylinder
Spherical
Bearing
C
Fill Plug
Gearbox Oil Level, Oil Fill E
Gearbox Change Oil E
Worm Bearing C
Brake Oil Level F
Brake Change Oil F
Oil Level V
Change Oil V
C
Boom Pin (2)
Lift Cylinder
Spherical Bearing
Trunnion Pin
Heads (2)
A Cylinder Pins
Intermediate Boom
Outer Surface
M
Intermediate Boom
Extension Cylinder Pin
Transferable Flares Retaining
Pin and Bosses
Upper Boom
Slide Bearing
Pivot Pin
C
A
C
Angle Indicator(s)
S
A
Booms
Platform
Mounting Pin
and Socket (2)
M
G
Pole Guide Tong
and Gear Teeth
A
Worm Bearing C
Change Oil V
Winch
Line
Winch Drum
Shaft
Keys
Set Screws
Line Anchor
A
R
Winch Line
Rollers (1 or 2)
C
Fill Plug
Worm Bearing C
C
Outboard Bearing
(Opposite End)
Boom Tip Winch
Platform
Brake Linkage
Brake
Detent
Pin
S
S
Pole Guide Tong and Tilt
Cylinder Trunnions (4)
A
Oil Level V
Winch
Outboard
Bearing
C
Rotation
Gearbox
Eccentric
Ring
A
Rotation Pinion
and Bearing
Gear Teeth
G
Turntable
Rotation Bearing
Ball Race
C
Turntable
Winch Line
Winch Drum
Shaft
Keys
Set Screws
Line Anchor
A
R
Rotary Joint
(If Equipped With
Grease Fitting
on this Side)
C
7
Two-Speed
Mechanically Shifted Digger
E
Change Oil E
Oil Level
Two-Speed
Hydraulically Shifted Digger
Fill Plug
Oil Level
Change Oil
E
E
Auger Stow Bracket
Wire Rope
Windup Sling
Latch
R
C
Ground
Fill Plug
Outrigger Valve Handle
S
Hydraulic Pump
A
Input Shaft
Splines
Digger Hanger Link
Digger Link
Pivot Pin
Digger Link Pivot Tube
C
C
Warning
Do not lubricate the gear teeth while operating the unit.
Stop turntable movement before lubricating. Rotate the
turntable slowly through a complete 360 degree revolu-
tion.
Gearboxes
The need to add oil regularly to any of the gearboxes
(rotation, digger, or winch) is a sign of a leak. Determine
the cause of the leak and correct it. A low oil level can
damage the internal components of a gearbox.
The overall life expectancy of a gearbox may be extended
by regularly draining and reflling the oil. The best time
to drain a gearbox is right after it has been operating.
At this time, the oil is warm and the wear particles are
suspended in the oil. Change the oil as recommended
by the Preventive Maintenance and Inspection Checklist.
If a gearbox is overheated and the oil smells burned,
change the oil immediately.
If the oil level of a gearbox appears to be increasing, this
could be a sign of an internal hydraulic leak from a defec-
tive motor shaft seal. If this occurs in a rotation gearbox,
it may also be a sign of a bad brake piston seal.
Wipe the gearbox clean before removing the plug from
the fll or check hole. Do not overfll the gearbox with oil.
Overflling will cause the gearbox to leak. Tighten the
plugs securely after checking or flling. Wipe excess oil
off of the gearbox to prevent dirt buildup.
The winch gearbox has a vent plug that must be kept free
of paint and dirt. The vent prevents excessive pressure
buildup inside the gearbox as the oil expands during
operation.
The boom tip winch oil level is checked with the boom
fully lowered or as low as possible.
For a mechanically shifted two-speed digger, the oil
should be even with the bottom of the check hole with
the digger tilted at a seven degree angle.
For a hydraulically shifted two-speed digger, the oil level
should be 1
3
/4 to 2
1
/4 (4.45 to 5.72 cm) below the top of
the fll hole with the digger hanging vertically.
For the rotation gearbox used with hydraulic side load
protection, the oil level should be 1
1
/4 to 1
1
/2 (3.18 to
3.81 cm) below the top of the fll hole. It may be neces-
sary to use a slim object such as a plastic wire tie as a
dip stick to check the oil level.
Rotation Brake With Hydraulic Side Load Protection
If the rotation motor leaks into the brake on the rotation
gearbox used with hydraulic side load protection, the
brake fuid will be contaminated. This contamination will
reduce the holding capability of the friction discs inside
the brake. Thus, the holding capacity of the rotation brake
will be reduced.
If the rotation motor has leaked into the rotation brake,
remove the brake from the rotation gearbox. Disassemble
it and discard the friction discs. They must be replaced
with new friction discs. Wash the remaining brake com-
ponents including the separator plates with solvent. Soak
the new friction discs in Type F automatic transmission
fuid for ten minutes before installing them. After installing
the discs, pour Type F automatic transmission fuid over
the discs until the fuid level is even with the top friction
disc. Finish reassembling the brake. Bleed the air from
the rotation brake as described in Section 6 under Rota-
tion Gearbox, Installation. Then adjust the rotation brake
and side load settings as described in Section 8 under
Hydraulic Side Load Protection.
Notice
Proper fuid must be used in the rotation brake. The
use of improper fuid will reduce the holding capac-
ity of the brake.
The rotation brake is permanently lubricated. The fuid
does not replacement beyond the initial fll under normal
conditions. However if the brake has been subjected to
a great amount of slippage over a long period of time,
the fuid can become deteriorated and cause reduced
holding capacity of the brake which cannot be restored
by adjusting the brake. In this case, the fuid in the brake
should be drained and replaced with new fuid. Then
adjust the brake and side load settings as described in
Section 8 under Hydraulic Side Load Protection.
Booms
The internal surfaces of the lower and intermediate
booms are lubricated at the factory. They only need to
be lubricated during a major overhaul of the unit.
The external surface of the intermediate boom is exposed
to the weather and to cleaning. Lubricate this surface
Inspection Checklist to keep the boom sliding freely on
the slide pad bearings.
Use the following procedure to lubricate the intermedi-
ate boom.
extend the intermediate boom. Disengage the PTO
and turn off the engine.
2. Wipe the exposed boom surfaces to remove any dirt,
moisture, etc.
3. Wipe on a coating of moly grease.
4. Start the engine and engage the PTO. Retract and
extend the boom several times to spread the grease
evenly on the surface.
5. Extend the boom and wipe off the excess grease to
prevent buildup of dust and other particles.
6. Retract the intermediate boom.
Structures
The structural components of the unit are identifed in the
Component Identifcation in Section 2. The unit has been
designed to meet or exceed the ANSI specifcations for
vehicle-mounted rotating and elevating derricks.
Regular inspection of the welds and structures is required
to insure that components maintain their strength. Periodic
cleaning of the structures is also recommended. This will
prevent damage that can occur from dirt accumulation.
Caution
Injury can result from slipping and falling. Use care
and the handles and steps provided.
Periodic inspection of the structures is recommended
to be certain there is no deformation, abnormal wear or
abrasion, interference between moving parts, or cracking
of the welds on structural members.
Inspect the structures and welds as recommended by the
Preventive Maintenance and Inspection Checklist.
Care of Exterior Surfaces
Altec units are manufactured out of structural steel, gal-
vanized steel and/or aluminum components with differing
resistance to corrosion. While Altec uses components,
designs and coatings that maximize corrosion resistance,
regular cleaning and maintenance is necessary to pre-
serve the fnish over the life of the equipment.
Frequent and regular washing will lengthen the life of your
new equipments painted fnish and components. Wash
your equipment and truck body frequently with warm or
cold water to remove dirt and preserve the original luster
of the paint. Never wash the equipment in direct sunlight
or when the metal surfaces are hot to the touch as it may
cause streaks on the fnish. Caution must be used in se-
lecting detergents and degreasers that may damage the
fnish. Use only commercially available automotive grade
cleaners. High pressure washing systems should be used
with caution, with the tip of the nozzle maintained at a
distance of 12 (30.5 cm) or more from the surface.
It is particularly important to wash the unit and body during
winter months as salt and other ice melting products are
extremely corrosive and can damage the vehicle. Other
corrosive environments that would necessitate additional
washing may include coastal areas, farming communities
where chemicals are sprayed, or mining operations.
Waxing of the exterior is typically not required, however
waxing will provide additional protection and help restore
the fnish to the original luster. This may not only improve
appearance, but will likely extend the service life of your
truck body and equipment.
It is important to repair any chips or scratches that occur
to prevent further corrosion. If the paint damage exposes
primer, then a liquid touch up paint may be used. Dam-
age that extends to unpainted metal must be primed
prior to applying a top coat. Touch up paint for standard
Altec colors may be ordered by calling 1-877-GO ALTEC.
Your local auto body shop can assist you with matching
a custom color.
Equipment that is used in harsh environments and off road
use needs to have more routine washing and maintenance
to the under body area. When the equipment is washed
it should washed on the underside as well and routinely
checked for any damage to the paint/undercoat. Any
damage discovered should be touched up accordingly
with a good rust preventative material and/or undercoat.
This will help prevent corrosion that could spread from
these areas that are not easily seen.
Accumulated dirt can damage the unit and cause it to
malfunction. Dirt buildup also accelerates wear on the
components.
Caution
work areas clean.
If a pressure washer or steam cleaner is used to clean
the unit, be careful where the spray is directed. Do not
direct the spray where the cleaning liquid might get into
electrical components, such as electrical connections,
switches, or lights. Even though all electrical components
on the unit are designed for all weather use, it is possible
for water pressure from the nozzle to push a seal out of
position. Do not direct the spray at the fller breather cap
of the reservoir. The high pressure can force water and
cleaning liquid into the reservoir and contaminate the
hydraulic oil. Do not clean the rotary joint or spool ends
of any hydraulic valve with direct pressure from a pres-
sure washer. Limit the water pressure to 500 psi (34.47
bar) and keep the spray tip at least 18 (45.72 cm) away
from these components while washing. After washing and
cleaning the unit, relubricate as necessary.
Refer to Fiberglass Care in this section for information
on cleaning the fberglass components.
Welds
All welds on the unit are originally applied in conformance
to AWS standards. Every weld on the unit is important
and should be periodically inspected.
Warning
If paint has lifted off the weld, or if rust is found, a closer
inspection is required. Remove any loose paint or rust
with a wire brush. Clean the area with a solvent such
as acetone. Closely inspect the area for cracks in the
welds. Dye penetration and magnetic particle testing are
simple processes that may be used to verify or disprove
a suspected problem.
Visual inspections can be very effective if conducted
properly. Clean the area to be inspected. Look for vis-
ible cracks in the weld and at the weld-to-parent material
joint. Use a bright light to provide adequate visibility of
the inspection area.
Pay close attention to welds that are located where
changes in cross section take place and near the attach-
ment points of highly loaded components. To assist in the
inspection of the welds on the unit, Figure 4.6 illustrates
these areas. If any cracks or unacceptable conditions are
discovered, report them to your Altec representative.
Any welds added in the feld should be done by qualifed
personnel and also conform to AWS standards.
After doing repair work on the unit, such as weld repair,
some testing of the unit may be required.
Refer to Section 6 for information on repairing mechani-
cal components.
Fasteners
A variety of fasteners are used on the unit. Different
fasteners have different inspection and installation
requirements depending on their use and design. This
section explains different fasteners used on the unit,
torque specifcations, and the use of thread locking and
anti-seize compounds.
The standard grade of fastener used on the unit is a zinc
plated, SAE Grade 5, steel cap screw. SAE Grade 8 cap
screws or special high strength cap screws are used in
highly loaded areas. A variety of other fasteners such
as socket head, fat countersunk head, and button head
cap screws are also used on the unit.
Check all fasteners for tightness as recommended by the
Figure 4.7 represents general locations of fasteners to
inspect. When inspecting fasteners, pay particular atten-
tion to the following fasteners.
Subbase and pedestal shear plate fasteners
Outrigger attachment fasteners
Corner mount Huck bolts
Rotation bearing mounting cap screws
Rotation gearbox mounting cap screws
Riding seat platform mounting cap screws
All pin retainer cap screws at pivot pins
Winch mounting cap screws
Hydraulic motor mounting cap screws on all gear-
boxes
Rotary joint drive bar mounting cap screws
Digger link pin nuts
Auger and auger extension shaft cap screws and
nuts
Upper boom cylinder trunnion pins
A properly installed cap screw applies a clamping force
equal to or greater than the load applied to it. A cap screw
installed at less than the recommended torque value
does not provide enough clamping force. The cap screw
may fatigue, causing it to loosen or fail. If the cap screw
is torqued beyond the recommended torque value, the
elastic range of the cap screw may be exceeded. This
may result in premature failure of the cap screw.
When checking fastener torque value, check at 90 percent
of the original value. For example, if the torque value for
a cap screw is 100 foot-pounds (136 Nm), check the cap
screw for tightness at 90 foot-pounds (122 Nm).
Some fasteners require torque values that differ from
common torque charts. Refer to Figure 4.8 for the proper
tightening torque for these fasteners on this unit.
Figure 4.6 Weld Inspections
Bearing Mounting Plate
(Top and Bottom)
Tie Plate Welds
to Pedestal
and Subbase
Across Subbase Top
Plate (Front and Rear)
Across Top of
Subbase Tubes
(Front and Rear)
Corner Mount Pedestal (Back View)
Bearing Mounting Plate
(Top and Bottom)
Outrigger
Mounting Area
Pedestal Weld to
Horizontal Plates
Outrigger
Link Pivot
Tubes
Rear Mount or Behind
Cab Mount Pedestal
Diagonal
Brace Areas
Subbase Area
Vertical Plates
(Inside Pedestal)
Corner Mount Pedestal (Side View)
Boom Pin
Tube Area
Lift Cylinder
Mounting Area
Lower Boom
Side and Rear Plate
Welds to Base Plate
Lift Cylinder
Mount Area
Boom Pivot
Pin Bosses
Winch Bracket Area
Boom Pivot
Pin Flange
Turntable
Digger Link Tube
Digger Attachment
Digger Hanger Bracket
Area (Both Sides)
Boom Tip
Attachment Area
Steel Boom Tip
Pole Guide
Pivot Pin
Retainers
Digger Link
Pin Nuts
Auger and Auger
Extension Shaft
Cap Screws
Hydraulic
Motor Mounting
Cap Screws
Figure 4.7 Fasteners
All Pin Retainers at Pivot Pins
Pedestal
and Subbase
Mounting Fasteners
Rotation Gearbox
Mounting
Cap Screws
Rotation Bearing
Mounting
Cap Screws
Hydraulic Motor
Mounting Cap
Screws
Winch Mounting
Cap Screw
All Pin Retainers
at Pivot Pins
Rotary Joint Drive
Bar Mounting
Cap Screws
Upper Boom
Cylinder Trunnion
Pins
Many general application fasteners would not normally
require an installation torque or lubrication but instead
would be installed using sound mechanical practices. If
it is desired to more closely control the fastener clamp
load it is recommended that a copper based anti-seize
compound be applied. Refer to Torque Values in the
Appendix as a guide to determine the proper cap screw
torque value.
Inspection Marks
Nuts or cap screws with locking patch element used in
combination with inspection marks are used at specifc
locations on the unit. Many are visible to the operator
during daily inspections.
If any inspection marks are found to be cracked or bro-
ken during inspection, totally remove the original mark.
The fastener torque must be checked (if no damage is
evident) or the fastener replaced and torqued (if damage
is evident), and the inspection mark reapplied.
The inspection lacquer (refer to Service Tools and Supplies
in the Appendix) should not be used after the expiration
date printed on the container.
Use the following procedure to apply a new inspection
mark.
1. Remove the majority of the original inspection mark
by chipping it off with a chisel or other cutting method.
Do not damage the surface on the nut, fastener,
washer, and part or structure being attached to.
Warning
2. Be sure the cleaning operation is performed in a well-
ventilated area. Remove the remaining residue using
Foot-Pounds (Nm)
Rotation bearing cap screws 325 (441)
Rotation gearbox mounting cap screws 325 (441)
Digger motor mounting cap screws 55 (75)
Boom pivot pin nut 225 (305)
Intermediate boom extension mounting nut 225 to 250 (305 to 339)
Upper boom cylinder trunnion pins 150 (203)
Platform mounting cap screws 55 (75)
Riding seat mounting cap screws 75 (102)
Figure 4.8 Torque Values
inspection lacquer cleaner (refer to Service Tools and
Supplies in the Appendix). Apply the cleaner to a rag
and completely remove the inspection stripe.
3. Properly torque the fastener.
4. Clean the area where the inspection stripe is to be
applied with a soft clean cloth and acetone.
5. Start at the center of the cap screw and apply a
1
/32 to
1
/16 (0.8 to 1.6 mm) thick stripe of inspection lacquer
to the head of the cap screw, across the washer, and
onto the surface of the parent material. The stripe
should extend
1
/8 to
1
/4 (3.2 to 6.4 mm) onto the
parent material.
6. The stripe must be continuous across the surfaces.
If it is not, remove the stripe with cleaner and reapply
the inspection lacquer properly.
Thread Locking Adhesives
and Anti-Seize Compounds
Anaerobic thread locking adhesives work in the absence
of air. When a fastener is removed, it must be cleaned
thoroughly. The adhesive must be applied before rein-
serting. Properly torque the fastener before the adhesive
cures (within 15 minutes of application). When installing
trunnion pins, apply thread locking adhesive only to the
frst two or three threads of the male portion. Refer to
Trunnion Pins in this section for proper installation.
Apply high strength anaerobic thread locking adhesive
on the threads of the upper boom cylinder trunnion pins
(male portion) to provide additional security against
loosening.
Warning
Caution
If the threads of the fasteners are not clean and free of
grease and oil, the effectiveness of the thread locking
adhesive will be reduced. Clean the threads of the fasten-
ers with solvent and blow dry with compressed air before
applying the thread locking adhesive.
For optimum thread locking, follow the manufacturers
label for proper use and disposal.

Anti-seize compound may be used to prevent rust and
corrosion from forming on the metal-to-metal contact
areas between a connecting pin and its boss. It is also
recommended for certain fasteners to reduce friction dur-
ing torquing to increase clamping load. Apply anti-seize
compound to the following components.
Pump input shaft splines
Outrigger cylinder and shoe pins
Radial outrigger pivot pins
Rotation gearbox eccentric ring
Winch drum shaft/keys/set screws/line anchor
Intermediate boom cylinder pins
Upper boom cylinder pins
Transferable boom fares and pole guide assembly
retaining pin and bosses
Platform mounting pin and boss
Upper boom cylinder trunnion pin heads
The area on which the anti-seize is applied must be clean
and dry for the anti-seize to be effective.

Chrome pins used with self-lubricating bearings require
special attention. Apply anti-seize compound to the sur-
face of the pin only where the pin and steel bin bosses
make contact. This pin installation procedure is described
under Pins and Pin Retainers in this section.
Rotation Bearing Cap Screws
Special high strength
3
/4 cap screws are used to secure
the rotation bearing to the pedestal and turntable. The
cap screws are coated with a dry flm lubricant and
have a patch lock material permanently bonded to the
threads. The torque value for the cap screws is 325
foot-pounds (441 Nm). They require special inspection
procedures.
Notice
Only use Altec supplied cap screws and washers to
install the rotation bearing.
When rotation bearing cap screws or washers, or nuts
removed, they must be replaced with new ones. Contact
your Altec representative for replacement fasteners.
Insuffcient or uneven cap screw tightness can contribute
to reduced life of the bearing.
Caution
Notice
Use an accurate
3
/4 drive click-type manual torque
wrench for the inspection of these cap screws. Torque
the cap screws by a smooth pull on the torque wrench
without jerking. Do not overtighten the cap screws.
If any cap screws are broken or missing, replace all the
fasteners in that race (refer to Section 6 under Rotation
Bearing Cap Screws). If a cap screw will not remain
properly torqued between normal inspections, further
inspection may be required.
Impacts to and excessive forces on the unit due to ve-
hicular accidents, rollovers, and excessive loading may
result in structural damage not obvious during a visual
inspection. A more detailed inspection by a qualifed
individual may be required to determine if replacement
of the rotation bearing and fasteners is required.
Visual Inspection Procedure
Perform this visual inspection procedure as recom-
Checklist.
Visually inspect all rotation bearing cap screws, looking for
any evidence that a cap screw is loose. Check for loose
washers under the heads of the cap screws by trying to
turn each washer by hand. If movement is indicated, all
the cap screws must be retorqued using the Retorquing
Procedure.
Annual Torque Inspection Procedure
Check the cap screws to be sure they are torqued to
295 foot-pounds (400 Nm), or 90 percent of the normal
installation torque of 325 foot-pounds (441 Nm). Use a
regularly calibrated, accurate torque wrench. If one or
more of these cap screws turns before the wrench clicks,
check the torque on the cap screws as described under
Retorquing Procedure in this section. If the rotation bear-
ing is replaced or removed, the same inspection intervals
must be followed.
Retorquing Procedure
Perform this procedure on the entire bearing race (outer,
inner, or both) if any cap screws were found loose at the
visual or annual inspections.
If all the cap screws have been removed from one or
both races of the rotation bearing, refer to Section 6
under Rotation System for the installation and torquing
procedure.
Some components may need to be removed to make
the rotation bearing cap screws accessible for retorqu-
ing. It is important that experienced, trained mechanics
perform this procedure.
1. Retorque according to the appropriate pattern shown
in Figure 4.9 for the inner race and Figure 4.10 for
the outer race.
Figure 4.9
Inner Race Cap Screw Torque Patterns
Figure 4.10
Outer Race Cap Screw Torque Patterns
2. Begin with cap screw number 1 on the outer race
and torque it to 325 foot-pounds (441 Nm).
8
13
14
4
23
24
9
10
19
20
2
25
26
5
6
15
16
3
X
12
11
22
21
Gearbox
Here
1 27
28
7
18
17
Number one cap screw can be at any
location on the bearing with the remainder
of the pattern shifted accordingly
1
23 14
13 24
6
9
10
4
19
20
7
15
16
8
18
17
3
12
11
5
22
21
2
3. Continue around the pattern, torquing each cap screw
to 325 foot-pounds (441 Nm).
4. Retorque all cap screws to 325 foot-pounds (441
Nm) again beginning at number 1. Go around in a
circular pattern this time instead of the numbered
order.
5. Repeat steps 1 through 4 on the inner race cap
screws, torquing each cap screw to 325 foot-pounds
(441 Nm).
Rotation Gearbox Mounting Cap Screws
Special
3
/4 cap screws are used to secure the rotation
gearbox to the turntable. The torque value for the cap
screws is 325 foot-pounds (441 Nm). The cap screws
require special inspection procedures.
Insuffcient or uneven cap screw tightness can contribute
to reduced life of the gearbox.
Caution
Notice
install the rotation gearbox.
Use an accurate
3
/4 drive click-type manual torque
wrench for the inspection of these cap screws. Torque
the cap screws by a smooth pull on the torque wrench
without jerking. Do not overtighten the cap screws.
For the rotation gearbox used with hydraulic side load
protection, a torque wrench adapter (included with unit,
refer to Service Tools and Supplies in the Appendix) must
be used when removing or installing the rotation gearbox
mounting cap screws or performing the annual torque
inspection (refer to Figure 4.11). The adapter may be
oriented at any angle on the torque wrench when tight-
ening or loosening the cap screws but not torquing them
to a specifc value. It must be oriented at 90 degrees to
the handle of the torque wrench when torquing the cap
screws to a specifc value.
Visual Inspection Procedure
Perform this visual inspection procedure as recom-
Checklist.
Visually inspect all rotation gearbox cap screws, look-
ing for any evidence that a cap screw is loose. Check
for loose washers under the heads of the cap screws
by trying to turn each washer by hand. If movement is
indicated, retorque all the cap screws.
Annual Torque Inspection Procedure
Make sure the cap screws are torqued to 292 foot-pounds
(396 Nm), or 90 percent of the normal installation torque
of 325 foot-pounds (441 Nm). Use a regularly calibrated,
accurate torque wrench. For the rotation gearbox used with
hydraulic side load protection, a torque wrench adapter
(included with unit, refer to Service Tools and Supplies
in the Appendix) must be used. The adapter must be
oriented at 90 degrees to the handle of the torque wrench
when torquing the cap screws to a specifc value (refer to
Figure 4.11). If any of these cap screws turns before the
wrench clicks, retorque all the cap screws to 325 foot-
Top View
Figure 4.11 Torque Wrench Adapter
Side View
Rotation
Gearbox
Used With
Side Load
Protection
Turntable Rotation Gearbox
Mounting Cap
Screw
Torque
Wrench
Adapter
Torque Wrench
Angle Between Adapter and Torque Wrench:
= Any Angle When Tightening or
Loosening, But Not Torquing,
= 90 Degrees When Torquing to Specifc Value
pounds (441 Nm). If the rotation gearbox is replaced or
removed, follow the same inspection intervals.
Digger Motor Cap Screws
The digger motor mounting cap screws are
5
/8 -11 UNC.
Install the cap screws without any lubrication and torque
them to 55 foot-pounds (75 Nm). The upper housing of
the digger gearbox is made of aluminum. Overtightening
the motor mounting cap screws this may damage the
threads in the aluminum housing.
Auger and Auger Extension
Shaft Cap Screws and Nuts
The cap screws and nuts used to retain the auger and
the auger extension shaft do not utilize a specifc torque
value. Install the standard nut on the cap screw with a
slight clearance from the hub of the auger or extension
shaft. Install the jam nut on the cap screw fnger tight
against the standard nut. Then using two wrenches,
hold the standard nut and tighten the jam nut against
it securely.
Slide Pad Bearing Cap Screws
The lower boom, intermediate boom, and the digger
hanger bracket are equipped with slide pad bearings.
They are installed with either hex head or fat countersunk
head, nylon patch cap screws.
Do not reuse the cap screws if they are removed. Replace
them with new cap screws to insure a secure ft.
Overtightening the bearing mounting screws can damage
or split slide pad bearings. Boom Slide Pad Bearings in
this section describes this type of bearing.
Pins and Pin Retainers
A variety of pins and pin retainers are used on the unit.
The type of pin or pin retainer used depends upon the
particular application.
Chrome plated pins are used in many areas such as the
lower boom pivot pin. The chrome plating reduces the
likelihood of rust and provides long wear for pins used
with self-lubricating bearings.
Use a dead blow hammer to remove or install pins. Use
of a steel hammer may distort the pin or close the retain-
ing ring groove. This may make pin installation diffcult or
cause the retaining ring to come out of its groove.
Trunnion Pins
The upper boom cylinder is mounted inside the upper
boom with trunnion pins (refer to Figure 4.12).
Side View
Retaining Rings
Section A-A
Section B-B
Trunnion
Pins
Figure 4.12 Booms
Boom Slide
Bracket
Bearing Bracket
Weldment
Section C-C
C
C
B
B
A
A
Torque Inspection
Visually check the trunnion pins for looseness as recom-
Checklist.
Use the following procedure to check the trunnion pins.
properly set the outriggers.
2. From the lower controls, raise the boom out of the
rest and rotate the turntable to a position where the
intermediate and upper booms can be accessed
when fully extended.
Caution
Keep hands clear while extending and retracting the
booms.
3. Extend the upper and intermediate booms to allow
access to the trunnion pins through the access hole
in the intermediate boom (refer to Figure 4.13). Dis-
engage the PTO and turn off the engine.
Figure 4.13 Intermediate Boom
4. Check the trunnion pins with a torque wrench to be
sure they are torqued to 135 foot-pounds (183 Nm)
or 90 percent of the normal installation torque of 150
foot-pounds (203 Nm).
5. If a trunnion pin is loose, torque it to 150 foot-pounds
(203 Nm).
Warning
Death or serious injury can result from uncontrolled
movement. Secure the booms before removing the
cylinder mounting pins.
6. Start the engine, engage the PTO, and stow the unit.
Forged Pin Retainers
Forged pin retainers are used to retain and prevent ro-
tation of the pivot pins. A forged pin retaining system is
shown in Figure 4.14.
Figure 4.14 Forged Pin Retaining System
During inspection, look for bent or broken stems. A bent
or broken stem may indicate that the bearings within the
joint are worn out. Also, if the pin binds within the joint
and tries to turn, the stem could bend or break. This may
indicate a lack of lubrication. Make sure the cap screw
through the eye of the retainer is tight.
If a forged pin retainer is damaged, determine the cause
of damage. Relubricate or take the connection apart and
replace the necessary parts.

Retaining Rings
Retaining rings are used as a backup retaining system for
some pins and as the only retaining system for others.
Figure 4.14 illustrates how retaining rings are used as a
backup retainer on lift cylinder pivot pins. If the forged pin
retainer should fail or fall out, the retaining rings will hold
the pin in place. However, they will not prevent the pin from
rotating. Immediately determine the cause of the problem
and replace and/or repair the necessary parts.
When inspecting retaining rings, check that they are
properly installed and undamaged.
Install retaining rings with the sharp edge out (refer to
Figure 4.15). This makes it more diffcult for the retain-
ing ring to come off the pin if the pin is being forced out
the other side.
Access Hole
Intermediate Boom
Stem
Forged Pin
Retainer
Retaining Ring
Cylinder Eye
Retaining
Ring
Figure 4.15 Retaining Ring
Lower Boom Pin Retaining System
Figure 4.16 shows the boom pin retaining system. This
pin has an end plate welded to one end. A button head
cap screw and spacer are installed through the hole in the
pivot pin end plate. The tube and button head cap screw
prevent the pin from turning. The other end is retained by
a self-locking nut torqued to 225 foot-pounds (305 Nm).
The nut has a nylon insert that grips the threads on the
pin to prevent the nut from loosening.
Figure 4.16 Boom Pin Retaining System
When inspecting the boom pin, check for cracking of the
end plate weld or elongation of the hole in the end plate.
Make sure the cap screw is tight and the head of the cap
screw is not broken off. The washers under the nut can
be turned by hand if it is loose. Any of these conditions
are signs that the bearings are binding and that the pin
was trying to turn. If any of these conditions are found,
take the connection apart and replace parts as necessary.
The self-locking nut is not reusable. If the nut is removed
from the pin, it must be replaced with a new nut.
Radial Outrigger Pin Retainers
Some pivot pins for the radial outrigger cylinders are re-
tained by two
3
/8 x 4 cap screws (refer to Figure 4.17).
The cap screws are positioned through the midsection of
the pivot pin and secured with a self-locking nut.
When inspecting the pivot pin, check the nuts for proper
tightness. If they are loose, determine the cause of the
problem and replace the necessary parts. Torque the
nuts to the proper value.
Figure 4.17 Radial Outrigger Pin Retainers
Pin Installation Into
Self-Lubricating Bearings
When installing a pin into a self-lubricating bearing, only
lubricate the area where the pin and the boss make
contact (refer to Figure 4.18).
Figure 4.18
Pin Installation Into Self-Lubricating Bearings
Use the following procedure to properly install the pin.
1. Slide the pin through the frst boss and through the
bearing until it reaches the second boss.
2. Apply an anti-seize compound to the second pin boss
and pin surface that is still exposed.
3. Slide the pin completely into the second pin boss
and install the appropriate retaining system.
Pin
End
Plate
Bearing
Weld
Nut
Flat Washer
Button Head
Cap Screw and
Spacer Tube
Section A-A
Cap Screw
A
A
First Boss Second Boss
Bearing
Anti-Seize Compound
Pin
Sharp
Edge
Section A-A
Pin Installation Into Lubricated Joints
When installing a pin into a joint that has a rotating member
which contains a grease ftting, lubricate the area where
the pin and the non-rotating bosses make contact with
anti-seize compound (refer to Figure 4.19).
Figure 4.19 Pin Installation Into Lubricated Joint
Bearings
The unit is equipped with a variety of bearings. The type
of bearing used depends on the particular application.
Spherical Bearings
Spherical bearings are used at both ends of the lift cyl-
inder. Self-aligning bearings such as these are used in
areas where perfect alignment is diffcult to maintain.
This type of bearing allows the component to follow the
movements of the structure without applying a side load
to the internal components of the cylinder.
Periodic lubrication of these bearings is required to pre-
vent the inner rim that maintains alignment from seizing
to the outer rim of the bearing. Lubrication in this section
describes how to properly lubricate these bearings.
Pressure Cast Cylindrical Bearings
A pressure cast bearing is used to connect the outrigger
pad to the rod end of the cylinder on some radial outrig-
gers. This bearing is designed for high strength, high
load situations. Excellent impact, wear, and corrosion
resistance are characteristics of this bearing. Particles of
molybdenum disulfde solid lubricant have been dispersed
throughout the bearing material. This type of bearing
requires no additional lubrication.
Self-Lubricating Bearings
Self-lubricating bearings are designed for long life. Un-
der normal use this type of bearing will provide many
years of service with virtually no maintenance. These
bearings resist impact and shock loads and abrasive
contaminants.
Self-lubricating bearings are made with a braided cord
liner containing Tefon fbers. The liner is bonded to the
outer shell of the bearing with epoxy resin. The epoxy
resin has a self-lubricating fller added to it. A chrome
plated pin is used with this bearing.
The inside diameter of a self-lubricating bearing contains
Tefon fbers. Once a pin is installed in the bearing, some
of the Tefon transfers to the pin surface and provides
lubrication. Applying anti-seize compound to the entire
surface of the pin will prevent the Tefon from transferring.
This may shorten bearing life.
Replace these bearings if the components are disas-
sembled for other purposes. Replacement of this type of
bearing due to wear is not a normal consideration.
If it is desirable to measure the bearing to determine
when it is worn, several factors must be considered. The
only accurate way to measure bearing wear is to keep a
record of the clearance between the chrome pin and the
bearing. Place the magnetic base of a dial indicator in a
position that allows the clearance between the pin and
the bearing to be measured under load. Take an initial
measurement when the unit is new. This will provide a
reference point. Monitor the change in bearing clearance
with subsequent measurements.
For self-lubricating bearings, clearance wear on the bear-
ing of 0.005 (0.13 mm) may suggest that the bearing
needs to be replaced. This fgure takes into account only
the wear of the bearing. Through the course of time, there
may also be pin and pin boss wear. An overall change in
the clearance between the pin and the bearing of 0.020
(0.51 mm) or more indicates the pin and bearing both
need to be replaced.
Replacement
Use the following procedure to remove and install self-
lubricating bearings.
1. Drive out the old bearing. If this is not possible, remove
it with a die grinder, cut point chisel, or hacksaw blade
(refer to Figure 4.20). Be careful not to damage the
inside diameter of the bearing boss.
Figure 4.20 Removal and
Installation of Self-Lubricating Bearings
First Boss Second Boss Grease
Fitting
Pin
Anti-Seize Compound
Removal
Bearing
Installation
Driver
Removal
Tool
method of installation. Light loads and high speeds will
call for a specifc amount of end clearance. Heavy loads
and low speeds will call for a specifc amount of preload
on the bearing. Proper installation and lubrication of the
tapered roller bearing are very important in determining
the useful life of the bearing.
Slide Pad Bearings
The lower and intermediate steel booms and the out-
rigger legs are equipped with slide pad bearings. Slide
pad bearings provide a smooth surface for extension
and retraction.
The most highly loaded slide pad bearings are made of
molybdenum disulfde impregnated nylon. Other slide
pad bearings that are not as heavily loaded are made
of a type of polyethylene. Both types of bearings will last
indefnitely when run against smooth surfaces.
The internal sliding surfaces are lubricated with moly
grease during factory assembly. The internal surfaces and
their mating slide pads require no additional lubrication
unless they are disassembled for major maintenance.
Keep the external surfaces of the intermediate boom and
outrigger smooth and lightly lubricated. The Lubrication
Chart and Diagram in this section specifes the proper
lubrication interval. If the outside surface becomes rusty
or rough, the boom or outrigger may not extend and
retract smoothly. Also, the digger hanger bracket may
bind against the boom.
Allow paint applied to a boom or outrigger to cure thor-
oughly. After the paint has cured, lubricate the surface
before retracting or extending the boom or outrigger over
the slide pad bearings.
The slide pad bearings that the fberglass portion of
the upper boom slides on require no lubrication. They
should last the life of the unit, if abrasive particles are
not allowed to accumulate on the boom or the bearings.
Keeping the fberglass clean will minimize the wear on
the bearings and boom surface. Fiberglass Care in this
section describes how to clean the fberglass.
The slide pad bearings are mounted with either hex head
cap screws or fat countersunk head cap screws. The cap
screws have a nylon patch embedded in the threads.
Slide pad bearings mounted with the fat countersunk
cap screws must have the heads of the mounting screws
located below the sliding surface of the bearing (refer
to Figure 4.22). This prevents the cap screw head from
damaging the boom surface.
2. Use a screwdriver and needle nose pliers to collapse
the bearing and pull it out of the bearing boss.
3. Clean the bearing boss. Do not remove any metal
from the boss surface. If metal is removed, the new
bearing may not ft properly in the boss.
4. Place the new bearing on a bearing driver. Line it
up with the bearing boss and drive the bearing into
place using a dead blow hammer. An old pin may be
used as a driver (refer to Figure 4.20).
5. Inspect the pin before installing it into the bearing.
Use a new pin if the chrome is faked, cracked, or
galled.
6. Slide the pin through the frst pin boss and through
the bearing until it reaches the second pin boss.
7. Apply an anti-seize compound to the second pin boss
and pin surface that is still exposed (refer to Figure
4.18).
8. Slide the pin completely into the second pin boss
and install the appropriate pin retaining system.
9. Pins equipped with fange and lug fasteners require
from 0.010 to 0.080 (0.254 to 2.032 mm) pin play
(end clearance between the bushing and the boss).
This is accomplished by adding or subtracting ma-
chine bushings to obtain the desired dimensions.
Figure 4.21 Machine Bushings Clearance
Tapered Roller Bearings
Tapered roller bearings are often used in gearboxes. This
bearing type can be used at high speeds and will support
radial and axial loading. Depending on the application,
this bearing may be installed with several thousandths
inch end clearance, no clearance, or with a preload.
A preload is 0.000 clearance minus a few thousandths.
Preload is sometimes checked with a torque wrench (stall
torque) or with a line and scale (rolling torque). Shaft load
and speed of the particular application will determine the
Lug
Pin
Bearing
Machine Bushing
Measure Clearance Here
Figure 4.22 Slide Pad Bearing Cap Screws
Slide pad bearings mounted with hex head cap screws
have steel nuts embedded into the bearing itself (refer to
Figure 4.22). The cap screws are installed with the head
located on the opposite side of the steel plate from where
the bearing is located. When replacing a hex head cap
screw on a slide pad bearing, make sure to replace it
with a cap screw of the proper length as specifed in the
Parts Manual. Cap screws that are too short will not fully
engage the nut embedded in the bearing. Cap screws
that are too long will protrude beyond the bearing and
damage the boom or leg surface.
When replacing a slide pad bearing, do not reuse the cap
screws. Once a cap screw is removed, the nylon patch
on the threads of the cap screw will be distorted. This
distortion may not allow the cap screw to tighten properly
if it is reused. Use new nylon patch cap screws of the
proper length when replacing a slide pad bearing. Do not
apply excessive torque when tightening the cap screws.
This will prevent the bearings from splitting.
Shimming
Thin gauge steel shims are used with slide pad bearings
on the top, sides, and bottom of the booms. Shims are
used to obtain the proper ft between the boom sections.
The shims also aid in maintaining the proper alignment
of the extension cylinders and other components.
If new slide pad bearings are installed, use shims where
needed (top, sides, and/or bottom) to obtain proper ft
and alignment.
Rotation Bearing
The turntable rotates on a shear ball bearing called the
rotation bearing. The inner race is mounted to the turn-
table. The outer race is mounted to the pedestal. The outer
race has gear teeth that mesh with the rotation pinion.
The bearing provides for very low torque rotation.
Monitoring Bearing Wear
The internal bearing clearance will increase slightly
during the break-in period. It should then remain essen-
tially constant for many years if the bearing is properly
lubricated and not overloaded. As the bearing raceway
begins to wear, the clearance will increase. It should
increase steadily at frst and accelerate toward the end
of bearing life.
An increase in bearing clearance is one sign of bear-
ing wear. Periodic bearing tilt measurements will help
determine when bearing replacement is necessary.
Perform bearing inspection and turntable tilt measure-
ments as recommended by the Preventive Maintenance
and Inspection Checklist. More frequent inspections are
required when the total increase in turntable tilt measure-
ment reaches 0.050 (1.27 mm).
Take an initial turntable tilt measurement when the unit is
delivered. This will provide a baseline for future bearing
tilt measurements. Future bearing tilt measurements will
be compared to this baseline to determine how much the
bearing tilt has increased since the initial (new bearing)
measurement. The greatest portion of the measured
turntable tilt results from structural defection rather than
bearing internal clearance. It is important that the defec-
tion be held constant by using the same measurement
procedure each time. Keep a maintenance log to monitor
the bearing inspections and turntable tilt measurements
during the life of the unit.
Bearing Replacement Criteria
The rotation bearing must be inspected and evaluated.
The recommended bearing inspection procedures include
the following items.
Monitoring the trend of turntable tilt measurements
Bearing inspections and turntable tilt measurements
can be used to determine when a bearing should be
replaced. Generally, an increase in turntable tilt of
0.065 (1.65 mm) above the initial tilt measurement
indicates that the bearing may be reaching the end
of its useful life. Other factors related to the condition
of the bearing must also be considered. Determine if
the increase in the turntable tilt measurements has
been steady or if it shows a trend of accelerated
wear (refer to Figure 4.23). Example 1 shows a
steady increase in wear, which is normal. Example 2
shows an accelerated increase in wear which would
indicate bearing replacement may be necessary. If
the tilt measurement has reached 0.065 (1.65 mm)
above the initial (new bearing) tilt measurement, and
periodic measurements show a trend of accelerated
wear, replace the bearing.
Flat Countersunk Head Cap Screw
Bearing
Hex Head Cap Screw
Boom
Bearing
Boom
Nut
500 Hour/6 Month
Inspections Example 1 Example 2
1 0.112 (2.84 mm) 0.110 (2.79 mm)
2 0.114 (2.89 mm) 0.114 (2.89 mm)
3 0.116 (2.95 mm) 0.122 (3.10 mm)
Figure 4.23 Turntable Tilt Measurements
Because the major portion of the measured turntable tilt
results from structural defection, the total tilt measurement
varies from model to model. For example, overall turntable
tilt measurements approaching 0.200 (5.08 mm) are not
uncommon on some models, even on bearings which
have not reached the end of their usable life. Severely
worn bearings could have a measured turntable tilt as
much as 0.500 (12.7 mm) or more in addition to other
prominent symptoms of wear such as unusual noise and
roughness. Therefore, the total turntable tilt measurement
itself should not be used to gauge a bearings remain-
ing usable life. The change in turntable tilt and the trend
toward accelerated wear is more important than the total
tilt measurement itself.
Evaluating the feel of the unit
If there is no trend toward accelerated wear, consider
the feel of the unit during load reversals. Operators
may notice an increase in the tilting or rocking of the
turntable.
Checking for rotation bearing noise and roughness
Determine whether there is any presence of rough-
ness or noise in the rotation bearing during rotation.
Severely worn bearings commonly exhibit grinding,
snapping, and popping noises during rotation. These
noises may indicate the bearing has broken ball
spacers, split ball bearings, or excessive galling, the
presence of which would require immediate bearing
replacement. Popping or clicking noises might also
be caused by broken or improperly torqued bear-
ing fasteners, a warped mounting surface, or worn
teeth. A check of the fastener torque and the rotation
bearing grease purged during lubrication will usually
determine if bearing noise is due to internal or external
problems.
Inspecting the condition of
the purged bearing grease
Grease from a well worn, poorly maintained, or dam-
aged bearing will typically contain fairly large rust or
metal particles, instead of metal dust specks which
might be found in any bearing. Fairly large rust or
metal particles indicate the bearing has reached an
accelerated wear condition and immediate bear-
ing replacement is required. The presence of rust
indicates inadequate lubrication. Rust is commonly
indicated by extremely dirty grease. This situation
must be corrected to optimize the performance of
the new bearing. Always check the purged bearing
grease at each inspection and turntable tilt mea-
surement procedure even if there is no presence of
roughness, noise in the bearing, or signifcant change
in the turntable tilt measurement.
One or more of these evaluation criteria should detect the
need for rotation bearing replacement long before there
is any threat of failure. By maintaining proper rotation
bearing lubrication and avoiding overload conditions,
the replacement rotation bearing should provide many
years of service.
Bearing Inspection and Turntable Tilt Measurement
1. Position the unit on a level surface where the booms
can be elevated and rotated. Apply the parking brake
and chock the wheels. Engage the PTO and properly
set the outriggers.
2. Fully extend all boom sections with the booms near
horizontal. Exact boom position is not critical. Slowly
rotate the turntable 360 degrees using the lower
controls while checking for roughness or noise in
the rotation bearing. Repeat using the upper controls
(if so equipped) as roughness may be felt more ac-
curately from the platform. Note in the maintenance
log whether unusual noise or roughness was en-
countered.
3. Test the system pressure and adjust if necessary as
described in Section 8. Record the system pressure
in the maintenance log. The system pressure must
be correct because changes in the system pressure
will affect the structural defection and change the
turntable tilt measurements.
4. Rotate the turntable to the position to be used for
the turntable tilt measurement. If the unit is normally
operated within a particular zone of rotation, the tilt
should be measured with the turntable rotated to
this position. For consistent measurement, always
use the same rotational position each time the tilt
measurement is done. Record the rotational position
in the maintenance log.
5. Remove the platform(s), if so equipped. Fully retract
the upper boom and fully extend the intermediate
boom. Lower the boom to determine if the boom tip
can be placed on the ground (refer to Figure 4.24). If
the boom tip cannot be easily placed on the ground,
an alternate setup using the auger is acceptable.
Retract the intermediate boom, unstow the auger,
and fully extend the intermediate boom.
6. Attach the magnetic base of the dial indicator to the
pedestal, positioning the contact point at the cor-
rect position. The contact point of the dial indicator
should be positioned against the underside of the
turntable base plate under the lift cylinder, as close
as possible to the bearing gear cover. Figure 4.25
shows the position for the dial indicator contact
point. It may be diffcult to position the dial indicator
and contact point in some zones of rotation without
interference with the turntable or pedestal. In this
case, position the dial indicator and contact point to
the area as close as possible to the recommended
position. Once a correct indicator contact point po-
sition is chosen, it is very important that the same
contact point position is used for each subsequent
tilt measurement. Therefore, record the contact point
position in the maintenance or service log where the
tilt measurements are recorded. Some inspectors
prefer to permanently mark the location where the
dial indicator contact point contacts the bearing base
plate to ensure that subsequent measurements are
made in exactly the same spot.
Figure 4.25 Pointer Position
7. Position the boom tip or auger tip a few inches above
the ground. Place a thick wooden plank or similar
material under the boom tip to protect it from dam-
age (refer to Figure 4.24). Operate the boom lower
function until the boom tip contacts the protective
material on the ground or the auger tip contacts the
ground. Continue to operate the boom lower function
until the hydraulic system reaches maximum pres-
sure and the lift cylinder stops retracting. Make sure
the lift cylinder does not bottom out before maximum
system pressure is reached. Set the dial indicator
at zero while holding the system at maximum pres-
sure.
8. Slowly raise the boom until the boom tip is raised off
the protective material or the auger is raised off the
ground. Read and record the indicator reading.
9. Repeat steps 7 and 8 two more times to ensure an
accurate consistent reading.
10. Remove the dial indicator to prevent accidental dam-
age.
Notice
There may be metal particles in the grease. Use a
putty knife to collect and wipe the grease.
11. Stow the auger if it was unstowed for the procedure.
Stow the booms. Lubricate the bearing to purge some
grease for inspection. Wipe some of the purged
bearing grease, which should be visible around the
inside ring of the bearing, on a piece of clean white or
light-colored paper. Smear the grease on the paper
into a very thin layer using a straight edge such as a
putty knife. Using a bright light, look for metal particles
which are larger than normal specks of metal dust.
Normally, particles large enough to be concerned
about will be felt as a rough spot when smearing the
grease. The smaller, insignifcant particles will not
normally be felt under the straight edge. Also, look
for signs of rust which would indicate poor lubrica-
tion. Record information about the condition of the
purged grease in the maintenance log.
a. If there are metal particles found in the grease
that exceed
1
/32 (0.79 mm), the bearing should
be replaced at the next maintenance interval.
Protective Material
Under Boom Tip
Boom Tip
Upper Boom Fully
Retracted
Intermediate Boom
Fully Extended
Figure 4.24 Setup
Dial Indicator Pointer
C
b. If there are any signs of rust in the grease, lubri-
cate the bearing more frequently to purge the old
grease out.
12. Refer to Bearing Replacement Criteria to determine
if bearing replacement is required.
Cylinders
Inspect all cylinders as recommended by the Preventive
Warning
Death or serious injury can result from cylinder
failure. Do not operate a cylinder that has a dented
barrel or a damaged rod.
Visually inspect the cylinders for leaks, loose or missing
pin retainers, broken bearings, bent rods, and dents in
the rod or barrel.
Check for proper operation of the cylinder holding valves
by positioning the boom or outrigger so a load is applied
to the cylinder to put pressure against the holding valves.
Disengage the PTO. Fully shift the manual lever for the
function being tested. Hold the lever momentarily to allow
oil fow from the holding valve to tank. If the cylinder does
not move, the extend holding valve is operating properly.
If the cylinder retracts slowly, the holding valve may be
leaking. Determine the cause of the problem and correct
it before operating the unit.
Hydraulic Lines
Hydraulic hoses and tubes transmit hydraulic oil through-
out the hydraulic system.
Inspect all hoses and tubes as recommended by the
Preventive Maintenance and Inspection Checklist for
wear and/or physical damage. Make sure the hoses
are properly routed to avoid sharp edges, kinking, and
scuffng. Inspect the tubes for dents or other damage
that may restrict oil fow. Make sure all hoses and tubes
are held frmly in their support brackets.
Atmospheric Vents
Atmospheric vents (refer to Figure 4.26) are located at
the boom tip, on the pole guide and tools circuits. Inspect
these vents as recommended by the Preventive Mainte-
nance and Inspection Checklist.
Figure 4.26 Atmospheric Vent
Fiberglass and Plastic Components
The fberglass components are covered with gelcoat to
protect the fberglass and resin composite. The gelcoat
contains ultraviolet inhibitors to retard the effect of ul-
traviolet light on the fberglass. With minimal care, the
sealing and ultraviolet properties of the fberglass can be
maintained for many years. The following sections include
information on the cleaning and repair of fberglass and
plastic components.
Inspect the fberglass components for cleanliness and
any visible damage such as scratched, cracked, or
chipped gelcoat. Surface irregularities may trap dirt and
contaminants, which over time may reduce the dielectric
properties of the fberglass. Of particular concern are
irregularities running lengthwise on the boom. Trapped
contaminants, such as dust particles and water, may
cause tracking, providing a path to ground or possible
dielectric failure.

Search for signs of looseness or movement at the bond
areas (fberglass to steel or fberglass to fberglass con-
nections) at the boom tip and end of the upper boom. If
the fasteners are properly tightened and the chemical
bond is good, it is unlikely damage will be found. If a
chemical bond has failed and the unit is operated using
the mechanical backup fasteners, cracks or elongation
of the holes may develop around the fasteners. The
fasteners will then begin to show frictional wear.
Other fberglass components have a variety of mechani-
cal fasteners that require inspection.
Cleaning
Keep fberglass and plastic components clean and in
good condition to preserve the dielectric properties and
appearance. Clean all components passing through the
boom fberglass section.
Notice
Do not spray water from a high pressure washer
directly at hydraulic or electrical components.
The fberglass upper boom interior may be cleaned (as
necessary) using a pressure washer and directing the
stream of soapy water inside the boom. Rinsing with clean
water will then remove any detergent residue. Elevate
-4 -8
the booms for draining and drying. Allow the booms to
dry thoroughly before operating the unit.
Warning
In some situations, pressure washing may not remove
all of the contaminants from the upper boom interior. A
solvent may be used to clean this type of contamination
with some type of swab device. Suitable solvents, such
as acetone or MEK (Methyl Ethyl Ketone), may be used
to clean these stubborn areas. Refer to the precau-
tions and instructions on the solvent selected for this
cleaning procedure. This may require removal of some
interior boom components. After the contaminated area
is swabbed, use the pressure washer and follow up with
a thorough rinsing with clean water.
The exterior of the upper boom, and other fberglass
components, may be washed with a mild detergent. When
washing these components, take care not to create any
surface scratches.
Notice
Do not coat a fberglass surface with any product
that will reduce its dielectric characteristics or cause
surface fashover.
Do not use petroleum based products to clean the fber-
glass components. Petroleum based products will leave
an oily residue that attracts dust.
Do not use steel wool to clean fberglass components. Re-
tained metallic particles can provide a conductive path.
Surface fashover occurs when a substance causes an
arcing of electricity between two points on the boom. If
this occurs, the dielectric integrity of the boom can be
permanently damaged.
Notice
When using a power buffer to polish fberglass, do
not damage or overheat the gelcoat surface.
After the exterior surfaces are clean and dry, polish with
Formula Five Clean N Glaze. For the best results, polish
fberglass surfaces by hand.
Plastic
Plastic covers on the unit are covered with an acrylic
surface to protect the plastic from damage from ultraviolet
damage. Use a pressure washer and mild detergent to
clean plastic covers. Rinse with clean water to remove
any detergent residue.
Notice
Using solvents (such as acetone, MEK, or lacquer thin-
ner) can damage plastic covers. Use only isopropyl
alcohol (rubbing alcohol) to clean plastic covers.
In some situations, pressure washing may not remove all
of the contaminants from plastic covers. Use isopropyl
(rubbing) alcohol to clean this type of contamination.
After the covers are clean and dry, hand polish using an
automotive type wax.
Determining the Degree of Boom Damage
Minor damage (scratches on the upper boom, the boom
tip, and fberglass control covers) is repairable. If no f-
berglass cloth fbers are cut or damaged, determine if the
scratch or nick affects only the gelcoat or if it is through
to the resin. To do this, look at the color at the bottom of
the scratch. If the color is white, the damage is on the
surface. This damage is minor and can be sanded out as
described under Surface Damage in this section.
Notice
If the fberglass is damaged past the gelcoat and
shows up black, and/or the fberglass cloth fbers
are damaged, contact Altec before any repairs are
started.
If the color at the bottom of the scratch or nick is dark,
and there is no visible damage to the layers of fberglass
cloth, the damage is through the gelcoat and just into the
resin. This requires a more thorough repair of the gelcoat
and is described under Gelcoat in this section.
Any time there is doubt regarding damage to the boom,
use the following procedure to accurately describe the
damage before calling Altec.
1. Identify the quadrant in which the damage has oc-
curred (refer to Figure 4.27).
2. Identify the exact area along the booms length where
the damage is. To do this, measure from the boom
tip to the damage site [example 46 (1,168.4 mm)
from the upper boom tip].
3. Defne the type, size, and the cause of the damage
[example 2 long x 1 wide x
1
/8 deep (50.8 x 25.4
x 3.18 mm); gouge caused by a chain saw].
Figure 4.27 Boom Damage Location
4. When calling Altec to describe the damage in ques-
tion, be sure to explain where you are in relation to
the unit (example front of the unit, facing the boom
tip with the unit in the stowed position).
If the boom has several damaged or cut inner fberglass
cloth layers, it may not be repairable. At this point, the
booms strength may be reduced and repairs will not
restore the boom strength. If such damage is discovered,
contact your Altec representative. They can evaluate the
affect of the damage on the structural integrity of the
boom and determine if the damage is repairable or if the
boom must be replaced.
If it is determined that the extent and location of the dam-
age will not reduce the safety factor of the boom, it may
be acceptable to repair the damaged area with gelcoat
to seal it and place the unit back into service.
Repair
Minor Surface Damage
Minor scratches in the surface of the gelcoat may be
easily repaired. If the bottom of the scratch is the same
color as the gelcoat pigment, repair according to the
following procedure.
Caution
Injury can result from airborne particles entering
the eyes and lungs. Wear appropriate safety equip-
ment.
1. Use a dual acting sander with 320 grit sandpaper to
sand the scratched area. Move the sander to sand
around the circumference of the boom. Do not sand
lengthwise on the boom.
2. When the scratch has almost disappeared, sand by
hand with a 600 grit wet or dry sandpaper until the
scratch is no longer visible.
3. Use Formula Five Clean N Glaze to polish the
area.
Gelcoat
Use an Altec gelcoat repair kit (refer to Service Tools and
Supplies in the Appendix) with the following procedure.
Any scratch that is dark at the bottom is through the
gelcoat and into the resin below.
In order for gelcoat repairs to cure properly, the following
special temperature considerations must be understood.
The highest quality gelcoat repairs are accomplished
indoors in a heated and well ventilated area.
Notice
The gelcoat can be burned during the warming pro-
cess. Continually move the heat gun or paint stripper
during warming.
If the unit has been outside and the temperature is
less than 70 degrees Fahrenheit (21 degrees Cel-
sius), or if this is a feld repair, the boom area must
be warmed before proceeding. Warm the fberglass
using a heat gun until it is warm to the touch. It will
take approximately 40 minutes to do this. A paint
stripper gun will provide a faster method. Do not
concentrate the heat of the gun in one specifc area
for any length of time.
If the outside temperature is below 60 degrees Fahr-
enheit (16 degrees Celsius), a feld gelcoat repair is
not suggested. Makeshift tents over the repair area will
not hold suffcient heat, preventing proper curing.
Caution
ment.
Use the following procedure to repair the gelcoat.
1. Use a die grinder to widen the scratch to
1
/8 (3.18
mm). Do not grind into the fberglass cloth.
2. Inspect the scratch. If the fberglass cloth is cut,
contact your Altec representative. If no fberglass
cloth is damaged, bevel the edges of the
1
/8 (3.18
mm) cut to about 45 degrees.
3. Lightly sand the damaged area by hand to roughen
it up. This will help the resin bond to the surface.
Quadrant 2
Quadrant 3
Quadrant 4
Quadrant 1
12
3
6
9
Warning
4. Use a solvent such as acetone to clean the area and
remove any dust.
5. The Altec gelcoat repair kit contains a can of resin, a
can of fumed silica powder, and a bottle of hardener.
Refer to the material safety data sheet included with
the kit for special precautions and recommendations
for use with this product. Mix the resin, powder, and
hardener according to the kit instructions.
6. Apply the mixture to the damaged area with a plastic
spatula. Work the spatula back and forth to remove
any air bubbles. Build up the area so it is slightly
above the boom surface. The mixture will shrink
slightly as it cures.
7. When the area has cured, sand the area by hand
with 600 grit wet or dry sandpaper. Sand until the
patch is no longer visible.
8. Use Formula Five Clean N Glaze to polish the
area.
Platform and Fiberglass Covers
The frst step in successful repair is to analyze the dam-
age and determine the cause. Cracks in the gelcoat or
outer surface of the platform or cover are easily repaired.
Damage to the fberglass structure can be more serious
and should be carefully evaluated before attempting to
repair the platform.
Structural components of the platform include the rim,
mounting ribs, platform sides, and the bottom (refer to
Figure 4.28). The platform is constructed similar to a
basketball hoop and net. The rim supports the sides
in the same way that the basketball hoop supports the
net. The structural integrity of the platform rim is critical
in determining whether or not the platform can be suc-
cessfully repaired. The platform bottom and the side
with the mounting ribs are substantially thicker than the
other three sides. The mounting ribs are the area where
the platform mounting bracket fastens to the platform.
Consider these factors when determining whether a
successful repair can be made on the platform bottom
or mounting rib side.
Figure 4.28 Platform
Altec cannot determine if the platform is repairable in the
feld. Evaluate the platform and determine whether or not
it can be repaired and safely used for future service. Altec
does not recommend that repairs be made to platforms
which have the following damage.
Cracks through the fberglass of the mounting ribs
Cracks through the fberglass of the rim
A hole through the foor or mounting rib side of the
platform
Altec only assumes responsibility for platform repair
performed by Altec personnel.
Warning
Death or serious injury can result from contact with
energized conductors. Do not operate the unit with
a hole in the platform or liner.
The following items are required to perform feld repair
of the platform or fberglass covers.
Circular grinder with 24 grit sandpaper
Dual acting sander with 320 grit sandpaper
Cleaning solvent (acetone)
Fiberglass cloth or mat
Gelcoat repair kit
Good quality rubber gloves
Dust mask
Safety glasses
Nonmetallic spray paint to match the platform
Use the following procedure as a guide in making a
quality feld repair.
1. Outline the damage with a box that is 1 wider on
all sides of the damaged area. Example If the
damage is 1 x 3 (25.4 x 76.2 mm), the box would
be 3 x 5 (76.2 x 127 mm).
Rim
Mounting
Ribs
Sides
Caution
ment.
2. While wearing safety glasses and a dust mask for
breathing protection, grind the area within the box
to a depth of approximately
1
/8 (3 mm).
3. Cut strips of fberglass cloth to ft the box area.
Warning
4. Clean the area thoroughly with solvent.
5. While wearing rubber gloves, mix the approximate
amount of polyester resin and catalyst according to
the directions in the gelcoat repair kit.
6. While wearing rubber gloves, saturate the fberglass
cloth with the mixed resin and apply it to the dam-
aged area. Work the area to squeeze out any air
bubbles.
7. After the resin has set up completely, grind off any
rough areas or high spots.
8. Mix an additional cup of resin and catalyst according
to the directions in the gelcoat repair kit and apply
smoothly to completely cover the affected area.
9. Sand the area with the dual acting sander and 320
grit sandpaper.
Notice
Do not coat a fberglass surface with any product
that will reduce its dielectric characteristics or cause
surface fashover.
10. Paint the area to match the platform. Do not apply
metallic paint to the platform.
Damage to the gelcoat layer may be repaired using the
instructions that accompany the gelcoat repair kit. This
kit may be ordered from your Altec representative. The
gelcoat provides a protective layer of ultraviolet inhibitors.
The gelcoat layer has no inherent strength.
Before making any repair, the structural integrity of the
platform and the safety of the operator must be kept in
mind. More specifc repair information for a particular
situation should be requested from your Altec repre-
sentative.
Winch Line
The winch drum is designed to accommodate either wire
or synthetic winch line. Inspect the winch line as recom-
Checklist.
Synthetic Winch Line
Warning
Death or serious injury can result when the synthetic
winch line contacts an energized conductor and the
ground. Do not allow the winch line to contact an
energized conductor.
The synthetic winch line is not to be considered an in-
sulator. Contact between an energized conductor and
the ground may result when the winch line is extended
to the ground.
Normal use will gradually reduce the strength of synthetic
winch line. The entire length of the line must be inspected
Inspection Checklist.
Keep a permanent, written, and dated report of the lines
condition and any corrective action taken during the
inspection on fle.
Follow the instructions of the line manufacturer when
splicing a synthetic winch line. A properly made splice is
a strong and effcient means of attachment.
When inspecting the synthetic winch line, use the following
guidelines to determine the condition of the line.
A few damaged strands spaced out along the length
of the line are acceptable. List the location of the
damaged strands in the report. Check these strands
carefully in future inspections.
To determine wear, compare an individual strand in
an area where it is exposed and subjected to wear
with an area of the same strand where it has been
protected from wear. If individual cover strands have
worn to within 50 percent of their original bulk over
an extended area of the line, replace the line.
If half of the cover strands are cut at a given point,
replace the line or cut out the damaged section and
splice the line back together.
Replace a spliced line if it does not meet the length
requirements under Replacement in this section.
If a damaged section is removed near the eye of the
line, put in a new eye splice. Use a standard end-
for-end splice to rejoin the line in other areas.
Knots can reduce rope strength. A winch line should
never have a knot tied in it.
Wash the line with a mild detergent and warm water.
Strong cleaning agents or bleaches may be harmful to
the line and must not be used.
Rinse the line thoroughly after washing. Squeeze out
the water by placing the line under tension. Allow line
to air dry.
Rotate the winch line end-for-end on a periodic basis.
This will vary the high stress and wear points, extending
the useful life of the line. This is not possible if a closed
thimble is spliced into the lifting eye.
Wire Rope Winch Line
Normal use will gradually reduce the strength of wire rope
winch line. The entire length of the line must be inspected
Inspection Checklist.
Keep a permanent, written, and dated report of the lines
condition and any corrective action taken during the
inspection on fle.
Caution
Injury can result from handling wire rope. Wear ap-
propriate safety equipment.
Be careful when using wire rope. Wire rope can be dan-
gerous if not handled properly.
If the wire rope is caked with grease and dirt, clean it with
a wire brush before inspecting it. During the inspection,
the line should be fexed as much as possible and not
be under tension. Wiping the line with a soft cloth may
be helpful in detecting broken wires.
Replace the wire rope if any of the following conditions
exist.
Two or more broken wires at an end connection.
Kinking, crushing, twisting, or other damage that re-
sults in permanent distortion of the rope structure.
Evidence of heat damage or excessive corrosion.
Wear that has reduced the thickness of individual outer
wires to
2
/3 or less of the original wire diameter.
If a damaged section of a wire line is cut off of one
end, the new length of line must meet the winch line
length requirements under Winch in Section 6. If is
does not, replace the winch line.
Reduction in the rope diameter of more than
1
/32 (0.8
mm) for
3
/8 to
1
/2 (9.5 to 12.77 mm) rope diameter
or
3
/64 (1.2 mm) for
9
/16 to
3
/4 (14.3 to 19 mm) rope
diameter.
Three or more broken wires in one strand within one
lay (refer to Figure 4.29).
Figure 4.29 Wire Rope
Six or more randomly broken wires in one lay.
Measure the diameter of wire rope with calipers, across
the crowns of opposite strands (refer to Figure 4.30).
Rotate the caliper around the rope when taking the mea-
surement to obtain the maximum reading. On new wire
rope, initial loading and operation will allow for seating
in of the strands and initial diameter pull down. After the
initial loading, the frst measurements should be made
and recorded for future reference.
Figure 4.30 Wire Rope Measurement
Inspect the rope If it has not been used for a month or
more. The rope must be approved for use before putting
the unit back in service.
One Rope Lay
One Strand
Correct Incorrect
Rotate the winch line end-for-end on a periodic basis.
This will vary the high stress and wear points extending
the useful life of the line.
Proper lubrication is important in extending the life of wire
rope winch line. Periodic lubrication with a spray-on wire
rope lubricant such as Chain and Cable Fluid (refer to
Service Tools and Supplies in the Appendix) will prevent
corrosion. It will also reduce internal friction and wear as
the wires move in relationship to each other.
Replacement
When replacing a synthetic winch line, the replacement
synthetic winch line must be of the same size and at
least the same rated working load as the rope originally
furnished with the unit. The winch line rated working load
of the originally furnished line is shown on the capacity
placard at the lower controls. ANSI requires that the de-
sign factor of synthetic-type ropes shall not be less than
5:1 and that the winch drum diameter be in a ratio of no
less than 8:1 to the rope diameter (d <
D
/8, where D is the
diameter of the drum and d is the diameter of the rope)
for turntable winches. For boom tip winch replacement
line consult your Altec representative. The replacement
winch line must be long enough to provide at least fve
full wraps of the line on the winch drum. This is with the
load hook on the ground and the booms and any jib at
full extension and elevation.
When replacing a wire rope with a synthetic rope, the
synthetic rope must meet the requirements for diameter,
length, and strength stated in the previous paragraph.
Remove any sharp edges that the synthetic rope may
contact. Repair or replace any hardware that is scored
or damaged by the wire rope. This will help to prevent
damage to the new synthetic rope. The fbers of synthetic
ropes can be cut and damaged by sharp edges and burrs
on winch drums, sheaves, shackles, wire slings, etc.
Warning
Death or serious injury can result from loss of load
control. Install the winch line in the proper direction
of the drum rotation.
The winch line must be installed in the proper direction
of drum rotation for the holding valve to be effective.
When spooling new line on the drum, make sure the frst
wrap that exits the anchor pocket is fush with the drum
fange to achieve even spooling of the winch line.
Put the frst layer of line close and tight around the winch
drum. The line should be under a tension of at least 50
pounds (22.68 kg). This will help prevent subsequent
wraps from slipping down between the frst layer of wraps
when a load is applied to the winch.
When replacing a wire rope winch line, the replacement
wire rope winch line must be of the same size and at
least the same rated working load as the rope originally
furnished with the unit. The rated working load of the
winch line originally furnished with the unit is shown on the
load capacity placard at the lower controls. ANSI requires
that the design factor of steel wire ropes be not less than
3.5:1, and the design factor for rotation-resistant-type steel
wire ropes be not less than 5:1. It is also required that
the winch drum shall provide a frst layer wire rope pitch
diameter of no less than 18 times the nominal diameter
of the wire rope for turntable winches. This means that
the sum of the diameter of the drum and the diameter
of the rope divided by the diameter of the rope must be
greater than or equal to 18 [(D+d)/d greater than or equal
to 18 which is equivalent to d less than or equal to D/17,
where D is the diameter of the drum and d is the diameter
of the rope] for turntable winches. For boom tip winch
replacement line consult your Altec representative.
Follow the recommendations of the rope manufacturer
when storing, unreeling, cutting, and installing new wire
rope. The replacement winch line must be long enough
to provide at least fve full wraps of the line on the winch
drum. This is with the load hook on the ground and the
booms and any jib at full extension and elevation.
Warning
Death or serious injury can result from loss of load
control. Install the winch line in the proper direction
of the drum rotation.
The winch line must be installed in the proper direction
of drum rotation for the holding valve to be effective.
When spooling new rope on the drum, make sure the
frst wrap that exits the anchor pocket is fush with the
drum fange. This will help achieve even spooling of the
winch line.
Auger Windup Sling
The unit may be equipped with a wire rope or synthetic
auger windup sling.
Warning
Death or serious injury can result if the auger sling
breaks. Replace a worn or damaged auger sling.
If any of the conditions given in this section are found,
replace the sling with an Altec replacement part to insure
that the proper rope is used.
Wire Rope Sling
Replace the wire rope auger windup sling if any of the
following conditions exist.
Four or more broken wires.
Any signs of wear, kinking, crushing, or corrosion.
If the welded lug (refer to Figure 4.31) that secures
the sling during auger stowage appears to be cutting
wires or strands on the sling. This condition requires
repair or replacement of the lug also.
Lubricate wire rope windup slings regularly as recom-
Checklist. This will extend the life of the wire rope by
preventing corrosion and reducing wear on the wires.
Synthetic Sling
Replace the synthetic auger windup sling if any of the
following conditions exist.
Cuts, snags, holes, punctures, tears, or excessive
abrasive wear in the webbing.
Broken or worn threads in the stitching.
Signifcant bleaching of the webbing from sunlight
exposure.
Any knots in the sling.
If the welded lug (refer to Figure 4.31) that secures the
sling during auger stowage appears to be cutting strands
on the sling, repair or replace the lug.
Auger Stow Bracket Clevis
The auger stow bracket is equipped with a pivoting clevis
attached to the auger windup sling (refer to Figure 4.31).
The clevis is held in its normal position by a shear pin.
If the windup sling is overloaded while stowing the auger,
the shear pin will fail before the sling is damaged. When
the shear pin fails, the clevis tilts to a vertical position
(refer to Figure 4.31). This drops the auger slightly with a
jolt to alert the operator that too much tension is being put
on the auger windup sling. If the shear pin fails, promptly
replace it with a genuine Altec replacement part.
The following may cause the sling to overload while
stowing the auger.
Excessive digger speed
A bent auger or auger extension shaft
Improper adjustment or malfunctioning of the auger
stow switch
When inspecting the shear pin, make sure it is intact. If the
shear pin is broken, replace it with a new one. Determine
the cause of the shear pin failure and correct it.
Accident Prevention Signs
This unit was equipped with accident prevention signs
at the time of manufacture. If any of these are lost or
become illegible, obtain replacements from your Altec
representative.
The location, part numbers, and descriptions of all plac-
ards are listed in the Parts Manual. Refer to the Accident
Prevention Signs Diagram for examples of the placards
and their locations.
Auger Windup
Sling
Welded Lug
Clevis
Figure 4.31 Auger Mechanism
Shear Pin Intact
Clevis
Shear Pin Clevis
Shear Pin Failed
Accident Prevention Signs Diagram
Radio Controls Without Hard Wired Lower Control
37 33 22 2
26 15 6
5
3
23
19
30
31
4
10
17
36
2
Riding Seat (Full View)
26
15
6
4
2
10
17
30 3
36
23
5
31
19
18 28
or On Side
15
6
17
30
36
23 31 5 19 26
4
2
3
10
Riding Seat
9
13
Chassis
13
9 1
1
1
29
Auger Stow Bracket
Control Pedestal
Rear Mount or Corner Mount Pedestal
Both Sides Rear Mount
One Side Corner Mount
27
Turntable
32
16
Out and
Down Outrigger
24
7
Curb and
Street Side
Curb and
Street Side
Personnel
Jib Boom
Platform Stepside
2 4 6 30
31
14
10
17 16
5
Both Sides
25
26
On Tailshelf Near
Control Station
Jib Bracket
33
Behind Cab Mount
Pedestal (Both Sides)
4
37
6 30 27 35 31
3
10
2
19
17
15
5
33
34
2 3 32 19
33
15
17 30 5 6 4
34 35
10
36
37
23
36
7
7
A-Frame,
X-Frame, or Corner
Mount Outrigger
Radial
Outrigger
Units With
Platform Mounting Tubes
With Pullout Section
37
16
Boom Tip Power Package
and/or Upper Controls
Boom Tip Winch
Turntable With Riding Seat
33
31
21
37
34
30
Turntable Winch
Turntable With Riding Seat
Both
Sides
22
Boom Tip
22
34
37
30
31
33
18 28
Control Panels
STANDARD
RASE
CCW CW
ROTATE
LOW SPEED
AUGER
RELEASE
SHFT DGGER
LOWER
BOOM
DG
DIGGER
OPERATE PUSH TO
ROTAFLOAT
CLOSE OPEN
POLE GUIDE
CLEAN
UPPER BOOM
RETRACT EXTEND
E
N
G
N
E Stop
ON
OFF
T
O
O
L
S
T
H
R
O
T
T
L
E
STOP
START
WINCH RASE
BACK FWD
LOWER
POLE GUIDE
U
N
T
RET EXT
INTERM BOOM
STOP
Radio Controls
11
12
8
20
2
4
3
1
5
6
7
9
8
14
13
12
10
11
16
15
20
17
18
19
21
22
25
23
24
26
Death or serious injury may result from
unintended downhill rotation of boom if
rotation float is operated when unit is
located on a slope and screw anchor is
not engaged in soil.
Operate rotation float only while installing
screw anchors.
Operate rotation float only after screw anchor
has engaged soil.
Discontinue operation of unit and refer to
manual for instructions if audible alarm stays on
constantly.
Rotation Float System Operating nstructions:
With screw anchor engaged in soil and digger
operating, activate rotation float to allow
derrick rotation to follow screw anchor
automatically.
When rotation float is activated, audible alarm
will beep once and light will come on.
UNNTENDED MOTON HAZARD
WARNNG
30
32
31
27
29
28

35
33 34
36
37
Section 5 Hydraulic System 57

Section 5 Hydraulic System
The derrick has a closed center hydraulic system with a
variable displacement, load sensing, pressure compen-
sated piston pump. The pump reacts to a sense signal
from the various valves in the system and adjusts its
output fow to maintain the fow and pressure required
by the function(s) being operated. Operation of the pump
is explained under Pumps in this section.
The unit uses a proportional electrohydraulic control valve
to operate the boom, digger, and winch functions. The
hand controls for these functions are electrical. When
a function is operated, the speed of the function is pro-
portional to the distance the hand control is shifted. For
example, if the boom hand control is shifted in the Raise
position at half of the maximum handle travel, the boom
rises at about half of its maximum speed.
Figure 5.1 illustrates the basic path of power through the
electrohydraulic control system. This variable electrical
signal travels through a cable, the below rotation valve
driver, a slip ring assembly, and an above rotation valve
driver. From the below rotation valve driver, an electrical
signal also travels to the selector valve. From the above
rotation valve driver, the electrical signal travels to a pulsar.
The variable electrical signal directs the pulsar to send
pilot pressure to move the valve spool in proportion to the
amount of hand control movement. The fow produced
by the pump is sent to the spool in the control valve. The
spool directs the oil fow to the appropriate actuator.
Hydraulic schematic drawings are an important tool in
understanding the operation of a hydraulic system. The
symbols identify the fow paths and operation of the
components in the system. A thorough understanding of
these symbols can reduce downtime and increase the
accuracy of diagnosing malfunctions. Basic hydraulic
schematic symbols are identifed in the Appendix.
This section includes a description of the hydraulic
components and an illustration of the components. Hy-
draulic schematics of the components can be found in
the Appendix.
Protection Systems
The unit is equipped with protection systems that are
intended to protect it from being overloaded due to opera-
tor error. However, even with these protection systems,
the unit can be damaged if the operator disregards the
recommended methods and procedures described in the
Operators Manual.
Hydraulic Overload Protection (HOP)
The HOP system prevents excessive overloading of the
derrick. The system consists of hydraulic and electrical
components.
Load Indicator Gauge
The load indicator gauge is located at the lower control
station. It shows the percentage of the derricks rated
hydraulic capacity that is being used when lifting a load.
The gauge has two zones. At 100 percent, the load is
at rated hydraulic capacity. The area to the right of the
100 percent mark represents loads that are over rated
From Pump
Selector Valve
Pulsar
To
Reservoir
Vehicle
Battery
Below
Rotation
Valve Driver
Hand
Control
Slip
Ring
Above Rotation Valve Driver
Cylinder
Pulsar
Boom Functions
or Digger/Winch
Valve Section
Figure 5.1 Electrohydraulic Control System
58 Section 5 Hydraulic System
hydraulic capacity. At the point marked HOP, the hydraulic
overload protection system will activate. By noting the
reading on the gauge, the operator is aware of the per-
centage of the units rated hydraulic capacity used when
lifting a load. The gauge in Figure 5.2 illustrates a load
that is 75 percent of the units rated hydraulic capacity.
Figure 5.2 Load Indicator Gauge
Warning
Death or serious injury can result from overloading
the unit. Do not exceed the rated capacity values.
Notice
The load indicator gauge only measures the load as
a percentage of the units rated hydraulic capacity.
It does not refect stability of the unit, which can
cause the load capacity to be less than the hydraulic
capacity.
Operation
The derrick is designed so that at rated hydraulic capacity,
regardless of boom angle or extension, the pressure in
the base end of the lift cylinder will be 2,850 psi (197 bar).
This is 100 percent on the load indicator gauge. When the
derrick is overloaded, a higher pressure will be induced
in the base end of the cylinder. A pressure transducer in
the valve block on the base end of the cylinder (refer to
Figure 5.3) senses pressure. When the pressure reaches
3,150 psi (217 bar) (HOP mark on gauge), or 110 percent
of rated hydraulic capacity, HOP engages. HOP electri-
cally interrupts the following functions.
Winch raise Intermediate boom extend
Digger dig Upper boom extend
Boom lower
The following functions remain operational so the op-
erator can relieve the overload when the HOP system
is engaged.
Winch lower Intermediate boom retract
Digger clean Upper boom retract
Boom raise
Figure 5.3
HOP Pressure Transducer Connection
When the overload is eliminated, the system automatically
restores operation to the functions that were temporarily
shut off.
The electrical connection runs from the pressure trans-
ducer in the valve block on the base end of the lift cylinder
to the above rotation valve driver.
Test the hydraulic overload protection system (refer
to Section 8 under Hydraulic Overload Protection) for
proper operation as recommended by the Preventive
Hydraulic Side Load
Protection (HSLP) System
If the rotation gearbox appears as shown in Figure 5.4,
the unit is equipped with hydraulic side load protection.
The lower control panel, if so equipped, will not contain
a side load gauge. The hydraulic side load protection
system helps prevent damage to the unit structures when
an excessive side load is developed on the booms.
Figure 5.4 Rotation Gearbox
With Hydraulic Side Load Protection
Side loads are commonly caused by winching a load in
from the side or corkscrewing an auger into the ground.
Side loads are also caused by failing to follow the move-
ment of a screw anchor with the boom, rotation, and
Lift Cylinder
Pressure
Transducer
LOAD INDICATOR
0
%
2
5
%
50% 75%
1
0
0
%
H
O
P
Rotation
Gearbox
Rotation/Side
Load Protection
Valve
Turntable
Rotation Motor
intermediate boom controls or applying excessive down
force when setting a screw anchor.
When properly adjusted, the hydraulic side load protec-
tion system allows the rotation system to back drive
when excessive side loading occurs due to operator error
during digging and winching operations. The side load
protection system allows the booms to rotate toward the
side load, which relieves the load.
Notice
Repeatedly engaging the side load protection system
can damage the unit.
Avoid excessive side loading of the booms. Rotate the
booms toward the load instead of depending on the side
load protection system. Never exceed the load the rota-
tion system can pull under its own power. Side loading
can result in damage to the structures or rotation system
and can adversely affect vehicle stability.
Operate the unit in a manner that avoids developing a
side load on the booms. Do not rely on the side load
protection system to prevent side loads from developing
on the booms. The system is intended to protect the unit
from excessive side loading due to operator error. Each
time the side load protection system operates, the unit
is subjected to an overload. Repeated overloads could
cause fatigue failure of unit components.
The rotation/side load protection valve has two purposes.
It controls hydraulic oil fow to the rotation motor and
operates the side load protection system. The rotation/
side load protection valve is mounted on the rotation
gearbox motor (refer to Figure 5.4).
The housing of the rotation/side load protection valve
(refer to Figure 5.5) contains two counterbalance valve
cartridges, and a shuttle valve. Each counterbalance
valve cartridge controls one direction of rotation.
Figure 5.5 Rotation Hydraulic
Circuit With Hydraulic Side Load Protection
Normal Rotation Operation
A spring applied, hydraulically released brake, located
on the rotation gearbox, prevents rotation of the booms
when all controls are in neutral. When the rotation con-
trol is operated, pressure from the rotation motor circuit
releases the brake, and the rotation motor powers the
rotation mechanism to rotate the booms.
Hydraulic Side Load Protection Operation
When excessive side loading is created on the booms
during operation, the friction discs inside the rotation
brake begin to slip and the rotation system will attempt
to back drive. This causes the rotation motor to act as a
pump, building pressure against a counterbalance valve
cartridge in the rotation/side load protection valve. When
the pressure reaches the counterbalance valve cartridge
setting, the valve cartridge opens and the rotation motor
begins to pump oil through the open valve, through the
open port of the spool valve for the rotation circuit, and
back to the motor while the rotation system back drives.
This allows the booms to sideslip in the direction of the
side pull. Separate counterbalance valve cartridges allow
the sideslip to be adjusted individually in the clockwise
and counterclockwise directions.
Notice
Overriding the side load protection system with the
rotation hand control can damage the unit.
Never attempt to counteract the side load protection sys-
tem by shifting the rotation hand control in the opposite
direction of the sideslip.
Test the side load protection system for proper operation
Inspection Checklist. Also, check the side load protection
system any time excessive sideslipping occurs during
normal digging or winching operation.
Refer to Section 8 under Hydraulic Side Load Protection
for procedures to properly test and adjust the side load
protection system.
Electronic Side Load
Protection (ESLP) System
the unit is equipped with electronic side load protection.
The lower control panel, if so equipped, will contain a
side load gauge.
The electronic side load protection system helps prevent
damage to the unit structures when an excessive side
load is developed on the booms. Side loads are com-
monly caused by winching a load in from the side or
corkscrewing an auger into the ground. Side loads are
Rotation
Gearbox
Rotation
Valve
Load Sense
Port
Pressure
Transducer
Rotation
Motor
Turntable
also caused by failing to follow the movement of a screw
anchor with the boom, rotation, and intermediate boom
controls or applying excessive down force when setting
a screw anchor.
When properly adjusted, the electronic side load protec-
tion system engages the HOP system when excessive
side loading occurs due to operator error during derrick
operation. HOP shuts down functions that could be cre-
ating the side load.
Notice
Repeatedly engaging the side load protection system
Operate the unit in a manner that avoids developing a
side load on the booms. Do not rely on the side load
protection system to prevent side loads from developing
on the booms. The system is intended to protect the unit
from excessive side loading due to operator error. Each
time the side load protection system operates, the unit
is subjected to an overload. Repeated overloads could
cause fatigue failure of unit components.
The rotation valve controls hydraulic oil fow to the rotation
motor (refer to Figure 5.6) system. The valve is mounted
on the rotation gearbox motor.
With Electronic Side Load Protection
The housing of the rotation valve (refer to Figure 5.7)
contains two counterbalance valve cartridges and a shuttle
valve. Each counterbalance valve cartridge controls one
direction of rotation.
Normal Rotation Operation
A spring applied, hydraulically released brake, located
on the rotation gearbox, prevents rotation of the booms
when all controls are in neutral. When the rotation con-
trol is operated, pressure from the rotation motor circuit
releases the brake, and the rotation motor powers the
rotation mechanism to rotate the booms.
Electronic Side Load Protection Operation
The rotation gearbox contains a load sensing mechanism
that senses the amount of torque on the output shaft.
Pilot pressure from the lower control valve inlet section
is supplied to a pressure reducing valve. The reduced
pressure from the pressure reducing valve is directed
through a check valve and connected to the load sense
port of the gearbox to charge the system (refer to Fig-
ure 5.7). The pressure at the load sense port increases
above the initial charge level in proportion to the amount
of torque applied to the rotation gearbox output shaft
by operation of the rotation motor or by side loading of
the booms. This pressure is measured by a pressure
transducer installed in the load sense port, which sends
a signal to a circuit board in the above rotation valve
driver. The circuit board is connected to the electronic
side load protection gauge at the lower control panel. A
thermal compensation cylinder is connected to the load
sense port to prevent pressure in the load sense system
from increasing due to increases in temperature.
The electronic side load pressure gauge indicates the
pressure in the side load system (how much side load
is being applied to the boom). The gauge will show the
operator when the system is not functioning, the accept-
able range of side load on the system during derrick
operation, and when the system has engaged HOP. The
red zone to the left on the gauge shows that the system
is not functional and will provide no protection from
excessive side load. The acceptable range of side load
on the system is indicated by the yellow range on the
gauge. When the unit is operating and there is no side
load applied, the needle of the gauge will be somewhere
between the left end and the middle of the yellow range.
The red zone to the right on the gauge shows that the
system has overloaded and HOP has been engaged.
HOP shuts off the digger dig, winch raise, boom lower,
and boom extend functions to prevent further side load-
ing of the booms.
The electronic side load pressure light also indicates
the operation of the system. The light will stay off until a
preset pressure value in the system is reached by side
loading. The light will come on when the pressure in the
side load pressure system reaches the preset pressure
value and HOP will be engaged. The light will stay on
until the pressure drops below the preset and the system
resets itself.
The preset value for electronic side load protection actua-
tion is adjusted with the CADI (refer to Section 8 under
Protection Systems).
Figure 5.7 Rotation Hydraulic Circuit With Electronic Side Load Protection
Test the side load protection system for proper operation
Inspection Checklist. Also, check the side load protection
system any time excessive side load protection actua-
tion occurs during normal digging or winching operation.
Refer to Section 8 under Electronic Side Load Protection
for procedures to properly test and adjust the side load
protection system.
Boom Stow Protection
The derrick has a proximity switch in the boom stow
bracket on the underside of the lower boom (refer to
Figure 5.8).
Figure 5.8 Boom Stow Bracket
The boom stow switch is actuated when the boom is
stowed in the boom rest. The switch engages the HOP
system. One of the functions the HOP system shuts off
is the boom lower function. With the boom lower func-
tion shut off, damage to the chassis is prevented if the
boom hand control is not immediately released once the
boom is stowed.
The boom stow switch may be used to test the operation
of the electrical portion of the HOP system. With the boom
in the boom rest, all of the functions which are disabled
by actuation of the HOP system should be inoperable,
as described under Hydraulic Overload Protection (HOP)
in this section.
Test the boom stow switch (refer to Section 8 under Boom
Stow Protection) as recommended by the Preventive
Auger Stow Protection
A proximity switch is located in the auger stow bracket
on the side of the lower boom (refer to Figure 5.9).
Lower Boom
Boom Stow Switch (Inside)
Auger Stow Switch
Figure 5.9 Auger Stow Bracket
The auger stow switch is actuated when the auger reaches
the top of its travel during stowing, shutting off the digger
dig function. With the digger dig function shut off, damage
to the unit is prevented if the digger hand control is not
immediately released once the auger is stowed.

On derricks equipped with a two-speed digger, the dig-
ger must be in low speed when stowing the auger. If the
digger is in high speed when the auger is stowed, the
digger motor may not turn off quickly enough after the
auger stow switch is contacted. This may cause damage
to the auger stowage mechanism or windup sling.
Test the auger stow switch (refer to Section 8 under Auger
Stow Protection) as recommended by the Preventive
Load Moment Limiter
The load moment limiter system (if equipped) limits the
maximum load the unit can lift in order to prevent over-
turning due to instability. Units with an anti-two-block/load
moment limiter override switch on the lower control panel
and/or anti-two-block and load moment limiter override
switches on the lower radio control transmitter have the
optional load moment limiter system.
Warning
Death or serious injury may result from overloading
the unit. Overloading may damage the unit or cause
it to tip over. Do not exceed the rated capacity val-
ues. Only use the override switch after evaluating
the load and load position to verify that the unit will
remain stable.
The HOP pressure transducer in the valve block on
the base end of the lift cylinder senses the amount of
pressure in the cylinder. This pressure can be used to
determine the load moment of the unit. When the pres-
sure reaches a predefned value that may result in the
load moment approaching instability, the load moment
limiter system is actuated. This temporarily shuts off the
following functions that could cause instability if their
motion is continued.
Winch raise
Digger dig
Boom lower
Intermediate boom extend
Upper boom extend
The following functions remain operational so the operator
can relieve the overload when the load moment limiter
system is engaged.
Winch lower
Digger clean
Boom raise
Intermediate boom retract
Upper boom retract
When the overload is eliminated, the system automatically
restores operation to the functions that were temporarily
shut off.
The hydraulic pressure setting required to actuate the
load moment limiter system varies from unit to unit. This
value is determined when the unit is stability tested after
it is manufactured. If the unit has suffcient stability, the
load moment limiter setting will be equal to the HOP
setting.
Anti-Two-Block (ATB)
The ATB system (if equipped) prevents the load hook
from contacting the boom tip during boom and winch
operations. Units with an ATB/load moment limiter over-
ride switch on the lower control panel and/or ATB and
load moment limiter override switches on the lower radio
control transmitter have the optional ATB system.
A wireless ATB switch located at the boom tip, along
with an ATB weight and chain, are used to determine
when the load hook on the winch line nears the boom
tip. The ATB switch communicates with the ATB monitor
located in the turntable. The ATB monitor is connected to
the above rotation valve driver. When the load hook lifts
the ATB weight, the ATB system causes the valve driver
to engage HOP. This temporarily shuts off the following
functions that could cause two-blocking if their motion
is continued.
Winch raise
Boom lower
Intermediate boom extend
Upper boom extend
Digger dig is also shut off due to the actuation of HOP.
Shutoff valves are provided in the lines connected to
the reservoir to allow the hydraulic system to be ser-
viced with minimal loss of oil from the reservoir (refer to
Figure 5.10). These are located in the suction line and
case drain line below the reservoir and in the return line
beside the reservoir. Close all three shutoff valves when
servicing or removing the pump. The shutoff valve in the
return line should also be closed before major hydraulic
connections below rotation are opened for service, to
prevent oil from siphoning out of the reservoir and back
through the hydraulic system.
Notice
Damage to the pump, return line flter, or other hy-
draulic system components can result if the unit is
operated with any of the shutoff valves closed in the
suction line, case drain line, or return line. Fully open
all three of these shutoff valves before engaging the
hydraulic system.
When service is completed, open the shutoff valves in
the suction line, case drain line, and return line and install
cable ties to hold the levers in the open position before
operating the unit.
A shutoff valve is also located in the reservoir drain line
beneath the reservoir. Open this shutoff valve to drain
hydraulic oil from the reservoir, or to drain off water that
may have accumulated in the bottom of the reservoir.
While these functions are temporarily shut off, the follow-
ing functions remain operational to relieve the impending
two-blocking condition.
Winch lower
Boom raise
Intermediate boom retract
Upper boom retract
Digger clean also remains operational.
When the operator eliminates the contact between the
load hook and the ATB weight and the weight is again
hanging freely, the system automatically restores opera-
tion to the functions that were temporarily shut off.
Oil Reservoir
The 60 gallon (227.12 l) reservoir is vented. An internal
return line flter with a replaceable cartridge is located
at the inlet of the reservoir. A magnetic suction separa-
tor flter is located at the outlet. A fller breather cap is
also located on top of the fll hole of the reservoir. The
cap contains a flter that cleans the air as it enters the
hydraulic system. The cap also has a strainer basket that
keeps large particles from entering the reservoir when
oil is poured into it. Refer to Section 4 under Filtration
for information on the flters in the reservoir.
Figure 5.10 Hydraulic Oil Reservoir
Filler Breather
Cover
Assembly
Suction
Filter
Return Line Filter
Outlet
Pipe
Return Line (Close valve to service
pump or before opening major
hydraulic connections below rotation)
Case Drain Line
(Close valve to
service pump)
Reservoir Drain
Line (Open valve
to drain reservoir)
Suction Line (Close
valve to service pump)
Shutoff Valves
Pump
The unit uses a variable displacement, load sensing,
pressure compensated piston pump driven by the ve-
hicle engine (refer to Figure 5.11). The pump utilizes a
compensator to vary the output fow and pressure in re-
sponse to the demand of the hydraulic system. The pump
compensator limits the maximum operating pressure of
the hydraulic system to 3,000 psi (206.84 bar). When
no functions are being operated, the pump maintains a
standby pressure of approximately 400 psi (27.58 bar).
Adjustment of the compensator and standby settings is
described in Section 8 under Standby Pressure and Sys-
tem/Compensator Pressure. Maximum pump fow is 43
gpm (162.77 lpm). Testing of the pump fow is described
in Section 8 under Pump Flow.
Figure 5.11 Hydraulic Pump
Before servicing the pump, close the shutoff valves in
the suction line and case drain line below the reservoir
and in the return line beside the reservoir (refer to Figure
5.10.)
Notice
Damage to the pump, return line flter, or other hy-
draulic system components can result if the unit is
operated with any of the shutoff valves closed in the
suction line, case drain line, or return line. Fully open
all three of these shutoff valves before engaging the
hydraulic system.
When service is completed, open the shutoff valves in
the suction line, case drain line, and return line and install
cable ties to hold the levers in the open position before
operating the unit.
In case of catastrophic pump failure, the hydraulic system
must be fushed. This procedure is described in Section
4 under Changing Oil and Flushing the System. Flushing
the system will remove most of the metallic contamina-
tion from the system.
Hydraulic Shock Absorber
The hydraulic shock absorber (refer to Figure 5.12) is a
small accumulator that stabilizes the inlet pressure and
prevents vacuum spikes that could cause the pump to
cavitate. It is installed near the pump, connected to a tee
in the suction hose. The accumulator is maintenance free
because it requires no precharge pressure and is vented
to the atmosphere. The hydraulic shock absorber is only
installed on units where the horizontal distance from the
pump inlet to reservoir outlet is greater than 86.
Figure 5.12 Hydraulic Shock Absorber
Rotary Joint
The rotary joint (refer to Figure 5.13) permits continuous
rotation of the turntable without twisting the hydraulic
hoses in the pedestal and turntable.
Figure 5.13 Rotary Joint
The hydraulic lines connected through the rotary joint
include one pressure, one return, and one sense line
below rotation, and two pressure, three return, and one
sense line above rotation. Hydraulic fttings on the rotary
joint are the SAE straight thread type.
The outer housing of the rotary joint is bolted to the
turntable. The inner core is held stationary with a drive
Turntable
Rotary Joint
Drive Bar
Figure 5.14 Valve Locations
Auxiliary Functions
Selector
Lower Control
(Opposite Side)
Lower Tool Circuit Flow Divider
Outrigger/Tool Control
Outrigger
Control
bar. As the turntable is rotated, the outer housing rotates
with the turntable.
Valves
When describing hydraulic valves, position identifes
the number of operating positions of the valve spool. A
two-position blocking valve has two operating positions,
open and closed.
The word way identifes the number of ports in a valve
section. A four-way control valve has four ports. One port
is for a pressure connection, one is for a return line con-
nection, and the other two ports are the working ports.
Refer to Figure 5.14 for the general locations of the
hydraulic system valves.
Outrigger Control Valve and
Outrigger/Tools Control Valve
The outrigger control and outrigger/tools control valves
are usually located on the tailshelf, at the rear of the chas-
sis. Units usually have a two spool valve with a power
beyond or through center to the three spool valve (refer
to Figure 5.15). A unit with out and down outriggers will
have two additional spools on each valve. These valves
operate the cylinders to lower and raise the outriggers.
The lower tool spool on the three or fve spool valve has
a detent position in one direction to provide fow to the
lower tool circuit on the chassis. The system pressure
for the outrigger circuit is 2,500 psi (172.37 bar). The
system pressure for the lower tool circuit is set at 2,000
psi (137.90 bar) unless otherwise requested. These pres-
sures are individually controlled by pressure reducing
valves located in the selector valve. Adjustment of these
pressure settings is described in Section 8 under Outrig-
ger System Pressure and Lower Tools System Pressure.
Figure 5.15 Outrigger Control
and Outrigger/Tools Control Valves
Lower Tool Circuit Flow Control Valve
The hydraulic fow of the lower tool circuit is controlled
by an adjustable fow valve located in the pressure line
of the tools pressure outlet (refer to Figure 5.16). The
system pressure for the lower tool circuit is controlled by
a pressure reducing valve located in the selector valve.
Figure 5.16 Lower Tool Circuit Flow Control Valve
Selector Valve
The selector valve (refer to Figure 5.17) is a manifold lo-
cated in the pedestal containing several cartridge valves,
including four solenoid valves, two pressure reducing
valves, two shuttle valves, a fow control valve, an orifce,
and a secondary relief valve.
When the outriggers and tools/derrick selector switch on
the tailshelf is in the Derrick position with the outriggers
properly set but no derrick functions being operated, the
derrick blocking valve (DS1) and outrigger/tool blocking
valve (DS2) are both closed, blocking all fow through
the selector valve. The piston pump is destroked to zero
fow and maintains standby pressure. When a function
control or switch is operated on the derrick lower or up-
per control panel or radio control transmitter, the DS1
solenoid is energized, opening the valve and directing
the fow of the pump to the lower control valve on the
turntable and the auxiliary functions valve on the lower
boom. No functions above rotation will operate until this
valve opens. When the control or switch in use is returned
to neutral and if no other functions are in use, the DS1
solenoid is deenergized. The valve then closes and blocks
the oil fow above rotation. This ensures positive shutoff
of the derrick functions when all controls and switches
are returned to neutral.
When the outriggers and tools/derrick selector switch
is in the Outriggers and Tools position, the outrigger/
tool blocking valve (DS2) solenoid is energized, open-
ing the valve and directing the fow of the pump to the
outrigger valves. The oil passes through the outrigger/
tool fow control valve (FC1), which limits the fow to 15
gpm (56.78 lpm). The outrigger sense dump valve (DS4)
is also energized, which causes it to close. This blocks
a connection between the outrigger/tool circuit and tank
circuit and allows the outrigger/tool circuit to build pres-
sure. When the selector switch is moved to the Derrick
Derrick Blocking Valve Cartridge
and Solenoid (DS1)
Toward
Pedestal
Side Plate
Figure 5.17 Selector Valve
Outrigger/Tool Sense Dump
Valve Cartridge and Solenoid
(DS4)
Outrigger/Tool Blocking
Valve Cartridge and
Solenoid (DS2)
Toward Pedestal
Side Plate
Shuttle Valve
Cartridge (SV1)
Shuttle Valve
Cartridge (SV2)
Secondary System
Relief Valve
Cartridge (RV1)
Outrigger Pressure
Reducing Valve
Cartridge (ORP)
Outrigger/Tool
Pressure Selector
Valve Cartridge and
Solenoid (DS3)
Outrigger/Tool Flow Control
Valve Cartridge (FC1)
Tool Pressure
Reducing Valve
Cartridge (TP)
position, DS2 closes to block fow to the outrigger/tool
circuit, and DS4 opens to dump any trapped pressure
in the outrigger/tool circuit to tank to prevent sending a
false sense signal to the pump.
When the outriggers and tools/derrick selector switch is
in the Outriggers and Tools position and the derrick winch
control is operated, the DS1 solenoid is energized, allow-
ing winch operation at the same time as lower tools. With
the switch in this position, if the winch is being operated
and then the control for another derrick function is oper-
ated at the same time, the DS1 solenoid is deenergized.
The derrick blocking valve then closes and blocks the oil
fow above rotation.
When the lower tools function is being operated, the out-
rigger/tool pressure selector valve (DS3) is deenergized.
This valve directs pressure from the outrigger/tool circuit
in the selector valve to the tool pressure reducing valve
(TP). The output pressure from TP is sent to the pump
sense circuit. This causes the pump to output a maximum
pressure equal to the pressure from TP plus the 400 psi
(27.58 bar) pump standby pressure. TP is adjustable to
vary the lower tools system pressure from 600 to 3,000
psi (206.84 bar). Unless otherwise requested, TP is fac-
tory set at 1,600 psi (110.32 bar) to produce a lower tools
system pressure of 2,000 psi (137.90 bar). Adjustment
of this pressure setting is described in Section 8 under
Lower Tools System Pressure.
When one or more of the outrigger functions is being
operated, the electrical signal from the outrigger motion
alarm causes DS3 to be energized. This valve shifts
to direct pressure from the outrigger/tool circuit in the
selector valve to the outrigger pressure reducing valve
(ORP). The output pressure from ORP is sent to the
pump sense circuit. This causes the pump to output a
maximum pressure equal to the pressure from ORP plus
the 400 psi (27.58 bar) pump standby pressure. ORP
is set at 2,100 psi (144.79 bar) to produce an outrigger
system pressure of 2,500 psi (172.37 bar). Adjustment
of this pressure setting is described in Section 8 under
Outrigger System Pressure.
The pressure signal from the outrigger/tool circuit to
the outrigger/tool pressure selector valve (DS3) passes
through an orifce plug located at the bottom of the cavity
for the outrigger/tool fow control valve (FC1).
The shuttle valves (SV1) and (SV2) send the proper sense
signal to the pump, based on signals from TP, ORP, and
the lower control valve.
The secondary system relief valve (RV1) is set to open at
3,300 psi (227.53 bar). It prevents the hydraulic system
from building excessive pressure if the compensator in
the piston pump malfunctions and fails to limit maximum
system pressure to 3,000 psi (206.84 bar). Adjustment
of this valve is described in Section 8 under Secondary
System Relief Pressure.
Lower Control Valve
The lower control valve (refer to Figure 5.18) is an elec-
trohydraulic proportional control valve located on the right
side of the turntable (as viewed from the boom tip looking
toward the turntable). It uses electrically controlled pulsars
(solenoid pilot valves) to control valve spools operating
the turntable rotation motor, lift cylinder, intermediate and
upper boom cylinders, and digger and winch functions.
Figure 5.18 Lower Control Valve
The lower control valve is equipped with manual override
handles. The handles may be used to manually oper-
ate the spool valves. Operation of the manual override
handles is described in the Operators Manual.
Notice
Structural damage can result from overloading the
unit. The HOP system is not operational when the
lower control valve is operated by the manual over-
ride handles.
Spool Valves
The valve has four spool valves used for the boom func-
tions and three spools used for the winch and digger
Manual Override
Control Handles
Upper Boom
Intermediate
Boom
Lower Boom
Rotation
Digger
Winch
functions. These valves are three-position, four-way, pro-
portional valves. The spool valves direct hydraulic fow to
the actuators that operate the functions. Maximum travel
of the spools may be adjusted with the CADI to control
the speeds of the functions, as described in Section 8.
The spool valve for the boom raise and lower functions
is a closed work port spool. This means that in neutral,
no hydraulic fow can enter or leave the work ports.
The spool valves for the rotation, intermediate, and up-
per boom functions are foat center spools. In neutral,
the work ports are connected to tank. This allows the
intermediate and upper boom cylinders to creep down
if they are overloaded. In the rotation circuit, this allows
the hydraulic side load protection system to operate.
The rotation, lower, intermediate, and upper boom
spools have pressure limiter cartridges. Adjustment of
these pressure limiters is described in Section 8 under
Protection Systems.
The winch spool valve and both digger spool valves
are foat center spools. In neutral, the work ports are
connected to tank. This allows oil fow to accommodate
changes in the length of the feeder tubes as the booms
are extended and retracted.
Load Sense Shuttles
A shuttle is located between each spool valve in the load
sense circuit. When more than one function is operated
at the same time, the shuttles send the highest pressure
requirement to the pump sense circuit.
Individual Pressure Compensators
A pressure compensator is installed in each spool valve
section of the lower control valve. These help maintain
constant fow to the work ports as supply and load pres-
sures fuctuate when more than one function is operated
at the same time.
Pilot Pressure Reducing Cartridge
The pilot pressure reducing cartridge in the inlet section
is set between 150 and 170 psi (10.3 and 11.7 bar). This
valve supplies the pulsars with the required pilot pres-
sure. Adjustment of this cartridge is described in Section
8 under Pilot System Pressure.
Pulsars (Solenoid Pilot Valves)
Pulsars are driven by a pulse width modulation (PWM)
signal to vary the modulation ratio. This digital signal varies
the on time versus the off time to provide smooth valve
operation. The solenoid controls the pilot pressure applied
to shift a work section spool. Thus the valve spool posi-
tion and corresponding function speed are proportional
to the handle position of the electrical control.
Auxiliary Functions Valve
The auxiliary functions valve (refer to Figure 5.19) is on
the left side of the lower boom near the turntable (when
standing at the boom tip, looking toward the turntable). It
contains solenoid-operated valves for the pole guide tilt,
pole guide tong, auger release, digger shift, and boom
tip tool functions, a tool fow control valve, and pressure
reducing valves for digger shift and tools.
Figure 5.19 Auxiliary Functions Valve
Spool Valves
The spool valves are solenoid operated. The spool valves
that operate the upper tools and pole guide functions are
three-position, four-way valves. The auger release spool
valve is a two-position, three-way valve.
The spool valves for the upper tools and auger release
functions are open port, closed center spools. In neu-
tral, the tools and auger release ports are connected to
tank.
When the upper tools are operated, hydraulic pressure
and fow are sent to the tools pressure outlet at the boom
tip for operation of the tool.
When the auger release switch is operated, hydraulic
fow and pressure are sent to the auger latch cylinder.
The latch cylinder then extends. When the auger release
switch is released, an internal spring in the latch closes
the latch and retracts the latch cylinder.
The spool valves for the pole guide functions are closed
center, closed port valves. The valves direct hydraulic oil
fow to the pole guide tilt and tong cylinders for operation
of the pole guide functions.
A check valve in the digger shift circuit allows free fow
to the digger shift cylinder, but will hold suffcient pres-
sure in the shift line to keep the digger shifted if it is in
high speed.
Tools Pressure Reducing Valve
The tools pressure reducing valve limits the pressure in the
upper tools circuit. The valve limits pressure in the circuit
to the maximum value desired for hydraulic tools. The
pressure reducing valve is adjustable from 500 to 2,000
psi (34.47 to 137.9 bar). Unless otherwise requested, it
is factory set at 2,000 psi (137.9 bar). Adjustment of this
valve is described in Section 8 under Upper Tools.
Tools Flow Divider
The tools fow divider limits the hydraulic oil fow in the
tools circuit. The tools fow divider valve is adjustable from
0 to 8 gpm (0 to 30.38 lpm). Unless otherwise requested,
it is factory set at 8 gpm (30.38 lpm). Adjustment of this
valve is described in Section 8 under Upper Tools.
Rotation Float Valve
The rotation foat valve is located in the housing of the
rotation valve on the rotation gearbox motor (refer to Figure
5.20 or 5.21). It is a two-position, two-way, solenoid oper-
ated valve. When the rotation foat system is engaged,
the valve allows oil to fow between the work ports of the
rotation motor through a fow control cartridge (one for
each direction of fow). This allows the booms to rotate
to follow the installation of a screw anchor.
Rotation Float Brake Release Valve
The rotation foat brake release valve is located inside the
rear of the turntable or above the rotation valve on the
rotation gearbox motor (refer to Figure 5.20 or 5.21). It is
a two-position, three-way, solenoid operated valve. When
Figure 5.21 Rotation Float Valve With Electronic SIde Load Protection
Rotation
Float Valve
Figure 5.20 Rotation Float Valve With Hydraulic SIde Load Protection
Rotation
Float Valve
Rotation Float
Brake Release
Valve
Rotation
Gearbox
Rotation
Gearbox
Rotation Float
Brake Release
Valve
rotation foat is not being operated, this valve directs the
brake release signal from the rotation valve to the brake
release port of the rotation gearbox. When rotation foat
is engaged, this valve sends pressure from the digger
circuit to the brake release port. This releases the brake
so that the booms can rotate to follow the installation of
a screw anchor.
Holding Valves
The unit uses holding valves to insure that various
actuators maintain their position under load or if there
is hydraulic line failure. These holding valves block the
hydraulic oil in the actuators to prevent movement. Pilot
operated check valves and counterbalance valves are
types of holding valves.
Testing of pilot operated check valves and counterbalance
valves is described in Section 8 under Hydraulic System.
Pilot Operated Check Valves
Pilot operated check valves are used to block fow out of
the pole guide tong and tilt cylinders and the base end
of the outrigger cylinders. The valve allows free fow into
the actuator and blocks return fow. It is equipped with an
internal pilot piston that allows the valve to be hydraulically
piloted open to allow fow out of the actuator.
Counterbalance Valves
Counterbalance valves are used to block fow out of the
following actuators.
Lift cylinder
Rotation motor
Upper boom cylinder
Intermediate boom cylinder
Winch motor
Outrigger cylinders (rod end)
A counterbalance valve is a combination of a check valve
and a relief valve. The check valve allows free fow into
the function and blocks the fow from coming back out.
The relief valve function can be piloted open to allow
fow out of the function. It also allows the valve to relieve
excess pressure and prevents damage from thermal
expansion of the oil.
The counterbalance valves used with the rotation motor
and intermediate and upper boom cylinders are installed
in pairs and are cross-ported. Oil sent to one side of the
actuator is used to pilot open the counterbalance valve
on the other side of the actuator.
Cavitation and Aeration
Cavitation and aeration can cause pump damage.
Cavitation occurs when inlet oil does not entirely fll the
cavities that open during the intake part of the pumping
cycle and the pump tries to draw a vacuum. The char-
acteristic sound of cavitation is a high pitched scream.
This sound increases with the degree of cavitation and
increased fow. The following items are possible causes
of cavitation.
Excessive pump operating speed
Clogged suction flter
Excessive oil viscosity (thickness)
Restrictions or sharp bends in hose
Excessive inlet hose length
Pump inlet too high above reservoir level
Shutoff valve in suction line not fully open
Notice
Cavitation can quickly destroy the pump. If signs of
pump cavitation are noticed, determine the cause
and promptly repair the problem.
If pump cavitation is due to excessive oil viscosity caused
by cold temperatures, allow the oil to warm up before
operating the unit.
Aeration occurs when air bubbles are introduced into the
hydraulic oil and carried along as the oil fows through
the pump. Aeration can be caused by the following
conditions.
Low oil level in the reservoir. This can cause a whirl-
pool at the suction line opening, which sucks air into
the system along with the oil.
Leaking connections in the suction line between the
reservoir and the pump.
Return line outlet is located above the oil level in the
reservoir. This causes turbulence as the return oil
stream discharges above the surface of the oil.
Notice
Air circulating through the pump can cause unit
malfunctions or pump damage. Determine the cause
and repair the problem.
An air leak in the suction line can occur even if there
is no oil leak when the system is shut down. A leak in
the suction line can often be located by slowly squirting
clean hydraulic oil around each connection in the suction
line. Do this with the pump running at normal operating
speed. Be sure to check for leaking around the O-ring
where the four bolt fange attaches to the pump. A suc-
tion leak will suck oil in. The pump may temporarily run
quietly as the air leak is sealed by the oil. The leak can
then be eliminated.
When aeration occurs, the oil in the reservoir is likely to
become foamy. The pump may also become noisy.
Air Bleeding
The presence of air in any hydraulic system will cause
abnormal operation, noise, and damage to the pump.
The presence of air in the hydraulic system can usually
be traced to one of the following.
If the oil level in the reservoir gets too low, the pump
suction can cause a whirlpool to form in the reservoir
which will allow air to be sucked into the system.
A leak in the plumbing between the reservoir and
the pump can suck air in and not leak out when the
system is shut down.
Loose connections in the pressure system will normally
leak externally during unit operation, but can suck air
into the system after the unit is shut down as the oil
tries to fnd its way to the low points of the system.
Hydraulic lines taken loose during maintenance
operations.
Notice
Air circulating through the pump can cause unit
malfunctions or pump damage. Determine the cause
and repair the problem.
Air entering the system due to low oil levels or leaks in
the suction line will cause the most problems and should
be corrected immediately. Most of the lines in the system
will purge the air from the circuit during normal use.
If the rotation gearbox utilized with hydraulic side load
protection is removed or the hydraulic line connected to
the brake release port is disconnected, air can enter the
rotation brake. Air in the rotation brake may cause the
brake to release sluggishly when rotating the booms.
This may cause some hesitation or unusual noise from
the brake when the unit begins to rotate. An increased
pressure reading on the system pressure gauge during
rotation operation may also be noticed. Bleed the air from
the rotation brake according to the procedure in Section
6 under Rotation Gearbox, Installation.
If the rotation gearbox utilized with electronic side load
protection is removed or the hydraulic line connected
to the load sense port is disconnected, air can enter
the electronic side load protection load sense system.
Air in this system will cause improper operation of side
load protection. Bleed the air from load sense system
according to the procedure in Section 6 under Rotation
Gearbox, Installation.
Leakage
If components and connections are installed properly,
leakage can be kept to a minimum. Small external leaks
are usually easy to fnd because dust will collect on the
hydraulic oil flm.
Improperly tightened fttings are a primary cause of ex-
ternal leakage. Follow the torque and tightening specif-
cations explained under Fittings and Valve Cartridges in
this section to properly tighten hydraulic fttings.
Warning
Death or serious injury can result from hydraulic
oil being injected into the fesh. Do not use hands
or other body parts to check hydraulic lines and ft-
tings for leaks.
Seek immediate medical attention if injured by escap-
ing hydraulic oil. Serious infection or reaction can re-
sult if medical treatment is not given immediately.
work areas clean.
If a connection is properly tightened but continues to
leak, disassemble the connection. Seal the necessary
parts and/or replace the defective part.
Worn or damaged parts such as scratched cylinder rods
can cause leaks. A worn or scratched output shaft on a
hydraulic motor can also cause a leak. Such conditions
must be repaired or replaced. A new seal should also
be installed.
Internal leaks allow pressurized hydraulic oil to escape
to tank or another hydraulic circuit. Most hydraulic com-
ponents have a small internal leak due to machining
tolerances.
An internal leak can cause a variety of problems in a
hydraulic system. An internal leak in a cylinder can cause
drifting or malfunction of a cylinder. Internal leakage in
a rotary joint will cause functions to slow down and/or
fail to build pressure. Replacing the seals in the leaking
component will usually stop an internal leak.
A leaking holding valve in a cylinder can cause drifting
or malfunction of the cylinder. It may be stopped by re-
placing the holding valves in the component. However,
some types of damage, such as scoring of the inside of
a cylinder barrel, require more extensive repair.
Heat Generation
Heat is the result of pressurized fuid escaping to the
reservoir. Most hydraulic components have a small in-
ternal leak due to machine tolerances. This type of leak
generates a very small amount of heat that is taken into
account when the component is designed. The amount
of heat in the system has a direct relationship to the
pressure and volume of leakage.
Internal leaks in the system may be caused by internal
housing cracks, bad relief valves, or leaking seals. This
type of leak allows a large volume of pressurized oil to
return to the reservoir, creating excessive heat in the
hydraulic system. Continuous operation with excessive
heat will damage the hydraulic oil, seals, and O-rings
throughout the system.
The following conditions cause heat generation.
Excessive pump speed during high fow operations
(such as digging)
Worn or defective pump
Defective pulsar valve
Low hydraulic oil level
Improper hydraulic oil
Internal leakage in rotary joint
Incorrectly set or defective secondary relief valve
cartridge in selector valve
Leaving an open center tool connected with tools
circuit turned on and the tool not in use
Leakage past power beyond seal in outrigger valve
Refer to Section 8 under Hydraulic System for information
about troubleshooting specifc components for internal
leaks.
Hydraulic Lines
Hydraulic lines provide a passageway for fuid fow
between components in the hydraulic system. Fluid is
transmitted through the lines from the pump to the ac-
tuator to operate the unit. A variety of lines may be used
on the unit depending on the specifc application. The
lines may be conductive or nonconductive rubber hoses,
fexible plastic, or rigid steel tube.
Most hoses and have a lay line on them. The lay line
contains the following information.
Manufacturers name
Manufacturers part number
SAE rating
Burst pressure (sometimes)
Nonconductive appears on nonconductive hoses
The hoses connected to the pole guide and platform tools
are non-pin perforated, nonconductive, thermoplastic
hoses. These hoses are located in the hose carriers.
The hose carriers are on the left side of the boom (when
standing at the boom tip looking toward the turntable).
Danger
Death or serious injury can result from unprotected
contact with energized conductors. Never replace a
nonconductive hose with a conductive hose.
Replace the hoses in the hose carriers with hoses of
the same type. Do not use wire braid hoses in the hose
carriers.
When servicing a hose carrier, do not pull the hoses
tight. Pulling the hoses tight may cause failure of the
electrical cable for the upper controls. It may also cause
a hose to kink.
When replacing a hose, use one the same size, length,
and pressure rating. If hose size is doubled, four times
the amount of oil will fow at the same pressure. If hose
size is decreased, the fow in the circuit will decrease and
back pressure will increase. The increase in back pressure
will cause heat to build up and system malfunction.
Warning
movement. Purge the air from the actuator before
operating the unit.
oil being injected into the fesh when loosening or
disconnecting hydraulic components. Remove the
pressure before loosening or disconnecting hydraulic
components.
work areas clean.
After removing a hydraulic line from a cylinder, do not
operate the unit from the upper controls until all air is
purged from the cylinder after the hydraulic lines are
reinstalled. The presence of air in the cylinder can cause
inadvertent retraction or extension of the cylinder, result-
ing in death or serious injury.
If the suction line and/or case drain line has been dis-
connected from the pump, be sure to purge the air from
these lines when reconnecting them to the pump before
engaging the PTO. Then slowly cycle an outrigger func-
tion at low pressure with the engine at idle to ensure that
the pump is fully charged with oil before putting the unit
back into service.
Caution
ment.
Remove all fuid pressure from a hydraulic circuit before
disconnecting lines or fttings.
Mark all hydraulic line fttings before disconnecting them
to ease installation later. Place a container under the
hoses to catch the hydraulic oil. Cap or plug all open
ports, hoses, and fttings to prevent contamination.
Warranty will be denied on components returned to
Altec if ports are not plugged and cylinder rods are not
retracted.
Properly torque all connections. Refer to the Torque and
Tightening Procedures in this section.
After completing a procedure, check the oil level in the
hydraulic oil reservoir and add oil if necessary.
Fittings and Valve Cartridges
Most hydraulic ports and fttings are SAE straight thread
O-ring or 37 degree fared JIC straight thread. These types
of fttings provide a good seal and resist vibration.
Use the proper torque and tightening specifcations when
installing a hydraulic ftting to reduce the likelihood of leaks
in the system. Use caps and plugs during the handling
and storage of hydraulic components to prevent damage
to sealing surfaces and ftting threads.
When installing a valve cartridge into a valve body,
properly torque the cartridge. Tightening the cartridge
less than the specifed torque value may cause a leak.
Overtorquing a cartridge can damage the valve, valve
body, or bind internal parts.
Torque and Tightening Procedures
Overtorquing a component can distort the part and cause
a leak. When a leaking ftting is found, check to see if
it is tight. If it is not tight, torque it to the proper value.
Replace the ftting if it will not stay tight.
If the ftting is tight, stop the unit, determine the cause
of the leak and take corrective action. When making a
connection that uses a swivel nut, use one wrench to hold
the hose, tube, or ftting and another wrench to turn the
nut. This is necessary to prevent damage to the sealing
surface of the JIC connections.
The following procedure describes proper torque and
tightening procedures for various types of hydraulic
fttings. Refer to Torque Values in the Appendix for the
appropriate torque chart.
Warning
Tapered Pipe Thread Fittings
1. Clean the male threads of the ftting with a cleaning
solvent.
2. Apply pipe sealant to the male threads of the ftting,
being careful not to get sealant on the frst two male
threads. Apply enough sealant to form a ring of sealant
on the outside of the connection when the threads
are tightened into the mating body.
3. Screw the ftting into the mating part and fnger
tighten.
4. Turn the ftting with a wrench the appropriate turns
from fnger tight (T.F.F.T.), taking the fnal position of
the tube end into consideration.
5. Follow the sealant manufacturers directions for cure
time. The ring of sealant described in step 2 will not
completely harden due to its exposure to air.
SAE O-Ring Fittings With Locknuts
1. Lubricate the O-ring and threads with hydraulic oil
or light grease, such as petroleum jelly.
2. Screw the ftting into the SAE straight thread boss
until the backup washer bottoms out on the boss
face with the O-ring squeezed into the boss cavity.
3. Unscrew the ftting (maximum of one full turn) to align
the ftting with the mating part.
4. Tighten the locknut with a wrench and torque to the
proper value for the size and material (stainless steel
or steel) so the backup washer contacts the boss
face.
SAE O-Ring Fittings Without Locknuts
1. Lubricate the O-ring and threads with hydraulic oil
or light grease, such as petroleum jelly.
2. Turn the ftting in full length until fnger tight.
3. Use a wrench to tighten the ftting to the proper
value.
Tube and JIC Fittings
1. Clean the male threads of the ftting with a cleaning
solvent.
2. Tighten the nut until frst wrench resistance [approxi-
mately 30 inch-pounds (3.4 Nm)].
3. Using a felt tip pen or marker, mark a line lengthwise
on the nut and extend it onto the adapter body (refer
to Torque Values in the Appendix).
4. Determine the proper number of hex fats the nut
must be turned with a wrench. Using a wrench to
hold the adapter body, rotate the nut with another
wrench the proper number of hex fats from wrench
resistance (F.F.W.R.).
5. Use the marks to count the proper number of hex fats
to turn the nut. The marks also serve as a visual in-
dicator that the ftting has been properly tightened.
Compression Fittings
1. Cut the tubing to length, allowing for bend, equipment
movement, etc.
2. Fit the brass insert into the nylon pilot tubing with the
fanged end out. The insert should ft snug in the pilot
tubing. The color coded
5
/16 (7.9 mm) outer diameter
tubing requires the use of an insert.
3. With the threaded end of the compression nut facing
the ftting body, slide the nut onto the nylon tubing,
followed by the compression sleeve.
Notice
To prevent damaging the nut and threads, do not
overtighten compression fttings.
4. Insert the tubing into the ftting body. Making sure the
tubing rests frmly on the shoulder of the ftting, hand
tighten the compression nut. Tighten the compression
nut the proper number of turns.
Four-Bolt Split Flange Assembly
SAE Code 61 [3,000 psi (206.84 bar)]
1. Clean the sealing surface of any burrs, scratches,
or foreign particles.
2. Lubricate the O-ring with hydraulic oil.
3. Position the fange and clamp halves. Put the bolts
with the lock washers in place (refer to Figure 5.22)
and hand tighten the bolts.
Figure 5.22 Four-Bolt Flange Assembly
4. Follow the pattern in Figure 5.23 to torque the bolts
in place.
Figure 5.23 Four-Bolt Flange Torque Pattern
5. Use small increments to torque the bolts.
Valve Cartridges
1. Clean the male threads of the cartridge with a clean-
ing solvent.
2. Lubricate the threads and O-ring with hydraulic oil.
3. Turn the cartridge in until it is fnger tight.
4. Use a wrench to tighten the cartridge to the proper
value.
Cylinders
Hydraulic cylinders operate the outriggers, booms,
pole guide, and the auger latch. The unit may also be
O-Ring
Flange Clamping Bolt
Split
Clamp
Half
Lock
Washer
equipped with a digger shift cylinder that shifts the two
speeds of the digger.
The cylinders used to operate the digger shift and auger
latch are single-acting cylinders. This type of cylinder
only produces force in the extend direction. It is retracted
by a spring.
The cylinders used to operate the pole guide, booms,
and outriggers are double-acting cylinders. This means
the cylinder produces force in both the extend and retract
directions.
Holding valves are often used to maintain cylinder position
if there is hydraulic line failure. The boom cylinders use
counterbalance holding valves. The outrigger and pole
guide cylinders use pilot operated check valves.
The holding valves may be installed in cavities machined
directly into the cylinders. They may also be installed
in a valve block in the hydraulic lines connected to the
cylinder or directly mounted on the cylinder.
All cylinder rods are chrome plated to prevent rust and
corrosion. The chrome plating also provides a smooth
surface for the end gland bearing and seal.
Warning
movement. Use a sling and hoist of adequate capac-
ity.
failure. Do not operate a cylinder that has a dented
barrel or a damaged rod.
failure. Never reuse a self-locking piston nut or re-
tention device.
Death or serious injury can result from cylinder fail-
ure. Properly install and torque a piston nut or gland
retention device.
Death or serious injury can result from hydraulic oil
being injected into the fesh. Properly cap or connect
hydraulic lines before operating the unit.
components.
work areas clean.
movement. Purge the air from the actuator before
operating the unit.
Caution
ment.
Pinch points exist at both ends of the cylinder. Be extremely
careful when removing or installing cylinders.
Never install a cylinder with side pressure on the rod. Do
not operate a cylinder if the cylinder barrel is dented or
if the rod is damaged.
Altec does not recommend repairing cylinders in the feld.
Most repairs require cylinder disassembly which should
be done in a clean, properly equipped shop. The Parts
Manual contains a drawing of each cylinder. The drawing
lists the Altec part numbers for the seal kits and provides
torque specifcations for piston nuts and end glands.
Hydraulic cylinder piston nuts and end glands must be
torqued to the proper values at assembly. Many piston
nuts and end glands have retention devices, such as
cotter pins and set screws. These retention devices must
be installed properly.
If the internal size tolerance of the cylinder barrel is
exceeded, the piston seal could be pushed out when
the cylinder is put under a load. This will cause cylinder
failure.
After reconnecting a hydraulic line from any cylinder, ex-
tend and retract the cylinder fve to six times to purge the
air out of the cylinder and to check for hydraulic leaks.
Forged Pin Retainer
Base End
Rod End
Pin and Two
Cap Screws or
Forged Pin Retainer
Pin and Forged Pin Retainer
Cap
Screws
Mark all hydraulic line fttings before disconnecting them
to ease installation later. Place a container under the
hoses to catch the hydraulic oil. Cap or plug all open
ports, hoses, and fttings to prevent contamination.
Warranty will be denied on components returned to
Altec if ports are not plugged and cylinder rods are not
retracted.
Properly torque all connections and cap screws. Refer to
Torque and Tightening Procedures in this section.
After completing a procedure, check the oil level in the
hydraulic oil reservoir and add oil if necessary.
Radial Outrigger Cylinder
A sling and hoist are needed to perform the following
procedures.
Removal
brake, and chock the wheels.
2. Engage the PTO and lower the outrigger until it just
makes contact with the ground.
3. Remove the forged pin retainer from the pin con-
necting the rod end of the cylinder to the outrigger
leg and the fold-up shoe (refer to Figure 5.24).
Figure 5.24 Radial Outrigger Cylinder Fasteners
4. Secure the cylinder with a sling and hoist. Carefully
retract the cylinder to avoid scratching the rod. With
the cylinder fully retracted, disengage the PTO and
5. Release any pressure in the hoses connected to the
cylinder by shifting the outrigger control handle for
the cylinder in both directions several times.
6. Remove the hoses from the fttings on the pilot
operated check valve block on the base end of the
cylinder.
7. Remove the two cap screws or forged pin retainer
that secure the pin at the base end of the cylinder
(refer to Figure 5.24).
8. On some units, it may be necessary to use a puller
threaded into a
1
/2 -13 UNC tapped hole in the end
of the pin to remove the pin.
9. With the hoist, carefully lift the cylinder out of the
outrigger weldment.
Installation
1. Secure the cylinder to the hoist. Lift the cylinder
above the outrigger leg weldment. Carefully guide
the cylinder as it slides into the outrigger leg weld-
ment.
2. Install the pin that secures the base end of the cylinder
in the weldment. Install the cap screws or forged pin
retainer that secures the pin.
3. Reconnect the hoses to the pilot operated check
valve housing.
4. Start the engine and engage the PTO. With the cylin-
der properly secured, extend the cylinder. Be careful
not to scratch the rod. Line up the pin hole in the rod
end with the bosses in the outrigger leg and fold-up
shoe. Make sure the bearings for the outrigger leg
and fold-up shoe are in place.
5. Install the pin connecting the cylinder, leg, and shoe.
Install the forged pin retainer that secures the pin.
6. Extend and retract the outrigger leg fve to six times
to purge any air in the cylinder while checking for
hydraulic leaks and proper operation.
A-Frame, X-Frame, and Modifed
A-Frame Outrigger Cylinder
The removal and installation of A-frame, X-frame, and
modifed A-frame outrigger cylinders may be done from
the top or bottom of the cylinder leg. Depending upon the
mounting and body style of the unit, one method may be
easier than the other.
A sling and a hoist are needed to perform the following
procedures.
Removal From the Top
1. Position the unit on a level surface. Apply the park-
ing brake, chock the wheels, and engage the PTO.
Extend the outriggers until they almost touch the
ground.
2. Remove the two retaining rings that secure the pin
located at the rod end of the cylinder (refer to Figure
5.25). Wrap the sling around the cylinder. Use the
hoist to support the cylinder.
Figure 5.25 A-Frame, X-Frame, and
Modifed A-Frame Outrigger Cylinder Fasteners
3. Remove the pin at the rod end of the cylinder.
4. Carefully retract the cylinder to avoid scratching the
rod. Disengage the PTO and turn off the engine.
6. Remove the hoses from the fttings on the pilot
operated check valve block on the base end of the
cylinder.
7. Remove the two retaining rings from the pin located
at the base end of the cylinder. Use a brass drift and
a dead blow hammer to remove the pin.
outrigger weldment.
Installation From the Top
1. Make sure the cylinder is completely retracted. Apply
anti-seize compound to both pin bores in the cylinder
and to the pins that will be installed in the cylinder.
2. Position the sling around the cylinder. Lift the cylin-
der with the hoist. Position it inside the outrigger leg
weldment.
3. Install the pin that secures the base end of the cylinder
to the outrigger weldment. Install the two retaining
rings that secure the pin. Install the retaining rings
with the sharp edge out (refer to Figure 5.25).
4. Reconnect the hoses to the check valve housing.
5. Start the engine and engage the PTO. With the cyl-
inder properly secured, extend the cylinder, being
careful not to scratch the rod. Line up the pin bosses
in the cylinder and outrigger leg weldment.
6. Install the pin connecting the rod end of the outrigger
cylinder to the outrigger weldment. Install the retaining
rings that secure the pin with the sharp edge out.
to purge any air in the cylinder while checking for
hydraulic leaks and proper operation.
Removal From the Bottom
Removal of the outrigger cylinder from the bottom of the
outrigger requires positioning the unit on the edge of a
loading dock or over a deep hole.
brake, and chock the wheels. Disengage the PTO
2. Place a sling around the outrigger leg at the shoe
and connect it to a hoist.
4. Remove the cover from the top of the outrigger leg.
Disconnect the hoses from the pilot operated check
valve block.
5. Remove the retaining rings from the pin connecting
the base end of the cylinder and the outer leg (refer
to Figure 5.25).
6. Remove the pin from the base end of the outrigger
cylinder.
7. Lower the inner leg and cylinder out of the outer
leg.
8. Remove the retaining rings from the rod end of the
cylinder.
Retaining Ring
Retaining Ring
Rod End
Base End
Sharp
Edge
Section A-A
A
A
Figure 5.26 Out and Down Outrigger Fasteners
Pin and Retaining Rings
Pin and Forged
Pin Retainer
Forged Pin Retainer
Rod End
Base End
Rod
End
Base
End
9. Remove the pin from the shoe, outrigger leg, and
cylinder rod connection.
10. Slide the cylinder out of the inner leg.
Installation From the Bottom
1. Position the cylinder in the inner leg.
2. Apply anti-seize compound to the pin bosses in the
inner leg and the pin bores in the rod end of the cyl-
inder. Also, apply anti-seize compound to the pin.
3. Install the pin through the outrigger shoe, the rod end
of the cylinder, and inner leg (refer to Figure 5.25).
4. Install the retaining rings on the pin.
5. Place the sling on the outrigger leg. Use a hoist to
position the inner leg and cylinder in the outer leg.
6. Apply an anti-seize compound to the pin bosses in
the outer leg and pin bores in the base end of the
cylinder. Also, apply anti-seize compound to the
pin.
7. Install the pin through the outer outrigger leg and
base end of the outrigger cylinder.
8. Install the retaining rings on the pin.
9. Connect the hydraulic hoses to the pilot operated
check valve block.
10. Remove the sling and hoist.
to purge any air that may be in the rod side of the
cylinder while checking for hydraulic leaks and proper
operation.
12. Install the cover at the top of the outer leg.
Out and Down Outrigger
Vertical Leg Cylinder
Removal
The removal and installation of the vertical leg cylinder
from the bottom of the outrigger weldment requires po-
sitioning the unit on the edge of a loading dock or over
a deep hole. A sling and hoist are needed to perform the
following procedures.
brake and chock the wheels.
2. Turn off the engine and disengage the PTO. Release
any pressure in the hoses connected to the cylinder
by shifting the outrigger control handle for the cylinder
in both directions several times.
3. Place a sling around the outrigger leg at the shoe
and connect it to a hoist.
4. Remove the cover from the top of the outrigger leg.
Remove the hoses from the fttings on the base end
of the cylinder.
5. Remove the retaining rings from the pin connecting
the base end of the cylinder to the outer leg weldment
6. Use a brass drift and a dead blow hammer to remove
the pin from the base end of the outrigger cylinder.
7. Lower the inner leg and cylinder out of the outer leg
weldment.
8. Remove the retaining rings from the rod end of the
cylinder.
the pin connecting the rod end of the cylinder to the
inner outrigger leg.
Sharp
Edge
Section A-A
A
A
inner leg weldment. Remove the fttings from the
cylinder.
Installation
1. Install the fttings on the new cylinder.
2. Position the cylinder in the inner leg.
inner leg and the pin bores in the rod end of the cyl-
inder. Also apply anti-seize compound to the pin.
4. Install the pin through the inner leg weldment and
the rod end of the cylinder (refer to Figure 5.26).
5. Install the retaining rings on the pin with the sharp
edge out.
6. Place the sling on the outrigger inner leg. Use a hoist
to position the inner leg and cylinder in the outer leg
weldment.
outer leg and pin bores in the base end of the cylinder.
Also apply anti-seize compound to the pin.
8. Install the pin through the outer outrigger leg weld-
ment and base end of the outrigger cylinder.
edge out.
10. Connect the hydraulic hoses to the cylinder.
11. Remove the sling and hoist.
12. Lower and raise the outrigger leg fve to six times to
purge any air in the cylinder while checking for hy-
draulic leaks and proper operation. Install the cover
at the top of the outer leg.
Out and Down Outrigger
Horizontal Leg Cylinder
Removal
brake and chock the wheels.
2. Turn off the engine and disengage the PTO. Release
by shifting the outrigger control handle for the cylinder
3. Remove the cover from the end of the outrigger
weldment. Disconnect the hoses from the fttings on
the base end of the cylinder.
4. Remove the pin retainers from the pin connecting the
base end of the cylinder and the outrigger weldment
the pin from the base end of the outrigger cylinder.
6. Support the vertical outrigger leg with a sling and a
hoist. Pull out to remove the horizontal leg assembly
from the outrigger weldment.
7. Remove the retaining rings from the pin at the rod
end of the cylinder.
the pin from the outrigger leg and cylinder rod con-
nection.
9. With the hoist, carefully slide the cylinder out of the
inner leg weldment. Remove the fttings from the
cylinder.
Installation
1. Install the fttings on the new cylinder.
2. Position the cylinder in the outrigger leg assembly.
leg and the pin bores in the rod end of the cylinder.
Also apply anti-seize compound to the pin.
4. Install the pin through the leg weldment and the rod
end of the cylinder (refer to Figure 5.26).
edge out.
6. Use a sling and hoist to support the vertical outrig-
ger leg. Position the outrigger leg assembly and
slide it into the outrigger weldment. Position the leg
assembly to align the pin bosses at the base end of
the cylinder.
outrigger weldment and pin bores in the base end
of the cylinder. Also apply anti-seize compound to
the pin.
8. Install the pin through the outrigger weldment and
base end of the outrigger cylinder. Install the pin
retainers on the pin.
9. Connect the hydraulic hoses to the cylinder.
10. Extend and retract the outrigger leg fve to six times to
purge any air that may be in the cylinder while check-
ing for hydraulic leaks and proper operation. Install
the cover at the top of the outrigger weldment.
Lift Cylinder
Removal
properly set the outriggers. Position the boom in the
rest.
2. Disengage the PTO and turn off the engine. Release
any pressure in the hoses connected to the lift cylinder
by shifting the boom manual override control handle
3. Use a sling and hoist to support the rod end of the
cylinder.
4. Remove the two hoses and pressure transducer
that are connected to the lift cylinder. Mark the hose
connections to ease installation later. Cap or plug the
open ports.
5. Figure 5.27 illustrates the fasteners securing the pin
at each end of the cylinder. Unscrew the cap screw
and remove the forged pin retainer from the cylinder
pin. Remove the two retaining rings from the pin.
Figure 5.27 Lift Cylinder Mounting Pin
6. Remove the pin from the rod end of the cylinder and the
cylinder attachment bracket on the lower boom.
7. As described in step 5, remove the cap screw, forged
pin retainer and retaining rings from the base end of
the cylinder.
8. Making sure the cylinder is supported, carefully re-
move the pin from the base end of the cylinder and
the cylinder attachment bracket on the turntable.
9. Immediately lower the cylinder to the ground.
Installation
1. Remove the fttings from the old lift cylinder and install
the components on the new lift cylinder.
2. Secure the sling around the cylinder barrel.
3. Lift the cylinder with the hoist and align the base end
of the cylinder with the cylinder attachment bracket
on the turntable. Install the cylinder pin through the
frst hole of the attachment bracket, the bearing in
the base end of the cylinder and the second pin hole
in the cylinder attachment bracket.
4. Connect the two hydraulic hoses and pressure trans-
ducer to the cylinder.
5. Align the rod end of the cylinder with the cylinder at-
tachment bracket on the lower boom. If necessary,
start the engine, engage the PTO and operate the
lower controls to extend the rod to help in alignment.
Install the rod end cylinder pin through the frst hole
in the cylinder attachment bracket, the bearing in the
rod end of the cylinder and the second hole in the
cylinder attachment bracket.
6. Install a retaining ring, with the sharp edge out, in
the groove at each end of the cylinder pin. Insert the
forged pin retainer through the cylinder pin. Install
the cap screw through the forged pin retainer and
torque it to the proper value. Repeat this step on the
pin at the base end of the cylinder.
7. Make sure the outriggers are properly set. Start the
engine and engage the PTO. Using the lower controls,
raise and lower the boom several times to remove
air from the cylinder. While operating the lift cylinder,
check the cylinder for leaks and proper operation.
Intermediate Boom Cylinder
Removal
2. Rotate the boom to the side of the unit. Unstow the
digger as described in the Operators Manual.
3. Extend the intermediate boom 2 to 3 (60.96 to 91.44
cm). Disengage the PTO and turn off the engine.
4. The intermediate boom cylinder is shown in Figure
5.28. Wrap a sling around the base end of the cylin-
der. Use a hoist or other lifting device to support the
cylinder.
Stem
Cylinder Eye
Retaining
Ring
Retaining
Ring
Forged Pin
Retainer
Lock
Washers
Warning
Failure to secure the intermediate boom hood to the
lower boom can result in uncontrolled extension of the
intermediate boom when the cylinder anchor cap screw
is removed from the intermediate boom.
5. Use rope or chains to secure the hood of the inter-
mediate boom to the lower boom.
6. The base end of the cylinder is mounted to the in-
termediate boom by a cap screw and nut (refer to
Figure 5.28). Remove the nut. Use a brass drift and
a dead blow hammer to remove the cap screw.
7. Start the engine and engage the PTO. Make sure
the intermediate boom cylinder is supported. Care-
fully retract the cylinder out of the digger hanger
bracket.
by operating the intermediate boom manual override
control handle for both directions.
9. The midsection of the intermediate boom cylinder
is supported by a cylinder guide. Adjust the hoist or
other lifting device so that the cylinder is not touching
the bottom portion of the cylinder guide. Remove the
bottom portion of the cylinder guide by removing the
cap screws shown in Figure 5.28.

10. It may be necessary, depending upon its position,
to disconnect the wires from the boom stow bracket
weldment, and remove it from the under side of the
lower boom.
11. There is a counterbalance valve block mounted to
the rod end of the cylinder. Remove the two hydraulic
hoses that are connected to this valve block. Remove
the fttings from the ports in the block. Cap or plug
all open ports and hose ends.
12. Slowly lower the base end of the cylinder to the
ground.
13. Position the sling and hoist or other lifting device to
support the rod end of the cylinder.
14. The rod end of the extension cylinder is mounted to
the lower boom by a pin secured by two retaining
rings. Remove these retaining rings and pin (refer
to Figure 5.28).
Figure 5.28 Booms
Boom Stow Bracket Counterbalance Valve Block Cap Screw and Nut
Pin and Two
Retaining Rings
Intermediate
Boom Cylinder
Side View
Cap Screw
Cylinder Guide
A
A
Section A-A
15. Use the sling and hoist or other lifting device to lower
the rod end of the cylinder to the ground.
Installation
1. Before installing the cylinder on the unit, test operate
the cylinder and check for leaks. This may be done
by connecting the extend and retract ports on the
counterbalance valve block to a lower tool circuit.
Be careful not to damage the cylinder rod.
2. Make sure the cylinder is completely retracted. Posi-
tion the sling around the rod end of the cylinder. Lift
the cylinder with the hoist or other lifting device. Align
the mounting hole in the rod end of the cylinder with
the mounting holes in the lower boom weldment.
3. Install the pin and retaining rings that secure the
rod end of the cylinder to the lower boom weldment
(refer to Figure 5.28). Make sure the retaining rings
are installed with sharp edge toward the end of the
pin.
4. Reconnect the hoses to the counterbalance valve
block at the rod end of the cylinder.
5. Position the sling around the midsection of the cylin-
der. Lift the cylinder into its position under the boom.
Install the cylinder guide (refer to Figure 5.28).
6. Position the sling around the base end of the cylin-
der. Start the engine and engage the PTO. Extend
the intermediate boom cylinder through the digger
hanger bracket. Extend the cylinder until the mounting
hole in the base end of the cylinder lines up with the
cylinder mounting holes in the intermediate boom.
7. Install the cap screw and nut that mount the base
end of the cylinder to the intermediate boom hood
(refer to Figure 5.28). Torque the nut to 225 to 250
foot-pounds (305 to 339 Nm).
8. Install the boom stow bracket weldment and con-
nect the wires to the boom stow switch if they were
removed.
9. Make sure the outriggers are properly set, start
the engine, and engage the PTO. Using the lower
controls, extend and retract the intermediate boom
several times. While operating the intermediate boom
cylinder, check for leaks and proper operation.
Upper Boom Cylinder
Removal
2. Rotate the boom to the side of the unit. Use chains
or rope to secure the upper boom tip to the lower or
intermediate boom.
Warning
Failure to secure the upper boom tip to the lower or
intermediate boom can result in uncontrolled extension
of the upper boom when the cylinder mounting pin is
removed from the intermediate boom.
by operating the upper boom manual override control
handle for both directions.
4. Pin the transferable boom fares and pole guide as-
sembly to the upper boom assembly.
5. Remove any components on the unit attached to the
upper boom assembly such as the platform or jib,
that may interfere with upper boom removal. Remove
anything on the unit, such as a winch line, that make
a connection between the upper and intermediate
boom when the upper boom is removed.
6. Remove the lower boom access covers closest to
the turntable.
7. There are two access holes on each side of the lower
boom near the turntable. Reach through the access
hole closest to the boom tip on each side of the boom.
Remove the two retaining rings and the pin that secure
the rod end of the upper boom cylinder to the lower
end of the intermediate boom (refer to Figure 5.29).
If the pin cannot be reached through the hole, extend
the intermediate boom slightly until it can be reached.
If the boom tip is secured to the lower boom, loosen
the rope or chain. If this is done, be sure to retighten
the chain or rope after removing the pin.
8. Reach through the access hole closest to the boom
tip. Disconnect the two hydraulic hoses connected to
the bulkhead fttings at the cylinder mounting bracket.
Cap or plug all open ports and hose ends. Disconnect
the electrical cable and the additional hose containing
the cable from the bulkhead bracket.
9. Use another derrick, forklift, or a hoist, to support the
upper boom. Protect the fberglass boom from nicks
or scratches from the lifting device. Unhook the rope
or chain securing the boom tip to the lower boom.
10. With the aid and support of another vehicle (derrick,
forklift, etc.), carefully pull the upper boom assembly
partially out of the intermediate boom allowing it to
slide out on the boom slide bracket.
11. With the upper boom becoming more fully supported
by the pulling vehicle, carefully remove the pin and
boom slide bracket. Carefully pull the upper boom
out of the intermediate boom. Set the boom on the
ground.
12. At the base end of the upper boom, remove the two
trunnion pins fastened to the upper boom cylinder
13. Pull the cylinder out of the upper boom.
Installation
1. Before installing the cylinder, operate the cylinder and
check for leaks. This may be done by connecting the
extend and retract ports on the cylinder to a lower
tool circuit. Be careful not to damage the rod.
2. Remove the rubber blocks, clamps, pole guide
switch bracket, bulkhead bracket, bulkhead fttings,
and hydraulic lines from the old cylinder. Install all
the components on the new cylinder as they were
installed on the old cylinder. Adjust the pole guide
interlock switch (refer to Section 8 under Pole Guide
Interlock System).
3. Use a sling and hoist or other lifting device to position
the cylinder inside the upper boom.
4. Apply cleaner to both the trunnion pin threads and
the female threads in the cylinder. Allow the cleaner
to thoroughly dry. Apply high strength thread lock-
ing adhesive to the frst two or three threads of the
male part, and apply chassis lube, moly grease, or
anti-seize around the head of the trunnion pin (refer
to Figure 5.30). Install the two trunnion pins through
the base end of the upper boom and into the cylinder
(refer to Figure 5.29). Torque the trunnion pins to 150
to 180 foot-pounds (203 to 244 Nm).
Figure 5.30 Upper Boom Cylinder
5. Use another derrick, forklift, or other heavy equipment
to slide the upper boom into the intermediate boom.
Take care not to damage the fberglass boom and
boom tip.
6. Raise the upper boom enough to install the boom
slide bracket and pin. Lower the boom onto the boom
slide bracket and install the bearing bracket and the
shims.
Figure 5.29 Booms
Upper Boom Cylinder
Side View
Pin
Retaining Rings
Section A-A
Trunnion
Pins
Section B-B
A
A
B
B
Trunnion Pin
Upper Boom Cylinder
Apply Thread Locking
Adhesive Here
Apply
Lube
Here
7. Install the pin and two retaining rings to secure the
rod end of the cylinder to the base end of the inter-
mediate boom (refer to Figure 5.29). The retaining
rings should be installed with the sharp edge toward
the end of the pin.
8. Connect the two hydraulic hoses to the bulkhead
fttings on the bracket mounted to the upper boom
cylinder. Connect the electrical cable and the ad-
ditional hose containing the cable to the bulkhead
bracket.
engine and engage the PTO. Extend and retract the
upper boom several times. This will purge any air
that is in the hoses or cylinder. While operating the
cylinder, check it for leaks and proper operation.
10. Install the boom access covers.
11. Install other components, such as the winch line, that
were removed.
Auger Latch Cylinder
The cylinder used to operate the auger latch is a single-
acting cylinder (refer to Figure 5.31). This type of cylinder
only produces force in the extend direction. It is retracted
by an internal spring in the auger latch weldment.
Figure 5.31 Auger Latch
When the auger release switch is operated, hydraulic
fow and pressure are sent to the auger latch cylinder.
The latch cylinder then extends. When the auger release
switch is released, an internal spring in the latch closes
the latch and retracts the latch cylinder.
Warning
Injury can result from uncontrolled movement. Care-
fully install or remove the auger latch.
Injury can result from uncontrolled movement. Do
not pressurize the auger latch cylinder when it is
removed from the latch.
The internal spring in the auger latch contains a great
amount of stored energy. Use caution when removing
or installing the auger latch. Failure to do so may cause
serious injury. Removal or installation of the auger latch
should be performed only by personnel who are familiar
with this procedure.
The auger latch cylinder does not contain a piston or
other means of retaining the rod in the cylinder when
it is fully extended. The cylinder is limited by the latch
mechanism when it is installed on the auger stow bracket.
Do not pressurize the cylinder when it is removed from
the latch. When the cylinder is removed, pressure will
eject the rod from the cylinder.
Digger Shift Cylinder
The mechanically shifted two-speed digger is shifted by
a small hydraulic cylinder. The digger shift cylinder is a
single-acting cylinder. It only produces force in the extend
direction. It is retracted by an internal spring. It is located
within the digger bail (refer to Figure 5.32).
Figure 5.32 Digger Bail
When the digger speed switch on the lower control panel
is in the High position, the digger shift line becomes pres-
surized. This causes the cylinder to extend, moving the
shift lever on the digger gearbox to the High Speed posi-
tion. When the digger speed switch on the lower control
panel is in the Low position, the pressure in the digger
shift line is dumped to the reservoir. The spring returns
the cylinder and shift lever to the Low Speed position.
On units with a two-speed digger that is shifted mechani-
cally by a hydraulic cylinder, an electrical interlock circuit
prevents the valve from shifting to the opposite position
unless the digger hand control is in neutral.
Removal and installation of the digger shift cylinder is a
simple procedure. To remove or install this cylinder in-
volves removing and installing the mounting cap screws
Cylinder Spring
Adjustable
Rod End
Digger Shift
Cylinder
Shift Lever
and hose connection. Bleed the oil from the hydraulic
circuit before removing a hose from any cylinder.
Pole Guide Cylinders
Removal and installation of the pole guide cylinders are
simple procedures. To remove or install these cylinders
only involves removing and installing the mounting pins
and hose connections. Make sure to remove the hydraulic
load from the pilot operated check valves. This can be done
by moving the pole guide switch back and forth in both
positions until the cylinder can be rocked by hand.
Thermal Compensation Cylinder
A thermal compensation cylinder is installed on the rota-
tion gearbox utilized with electronic side load protection.
The cylinder contains a coil spring and a stepped piston.
Thermal expansion or contraction of the hydraulic oil
contained in the area between the steps of the piston
moves the piston toward or away from the spring. This
movement changes the volume of oil in the electronic
side load protection load sense circuit to adjust for ther-
mal expansion or contraction of the oil. This prevents
the pressure in the load sense circuit from increasing
due to temperature increases and causing a false side
load reading.
Removal
1. Open the bleeder ftting on the side of the rotation
gearbox to remove the pressure in the load sense
circuit, and retighten the bleeder ftting.
2. Remove the clamp that attaches the cylinder to the
mounting bracket.
3. Disconnect the straight hydraulic adapter from the
tee adapter in the end of the cylinder, and remove
the cylinder.
Inspection
1. Remove the tee adapter from the port in the hex
adapter in the end of the cylinder. The end of the
piston is visible through this port.
2. Measure the depth from the end of the hex adapter
in the cylinder to the end of the piston (refer to Figure
5.33). If this dimension is less than 0.62, the cylinder
must be repaired or replaced.
Repair
1. Clamp the fats on the round end cap of the cylinder
in a vise.
2. Remove the hex adapter from the end of the cylinder
barrel.
3. Use a strap wrench to unscrew the cylinder barrel
from the end cap, and remove the coil spring from
the barrel.
4. Remove the hex socket plug from port in the side of
the barrel, and drain the hydraulic oil from the port.
5. Remove the piston from the cylinder barrel.
6. Inspect the large and small diameter bores of the
cylinder barrel. If any scratches or defects are seen
that could cause the seals to leak, the cylinder must
be replaced. If the bores are acceptable, continue
with the next step.
7. Obtain a seal kit for the cylinder from your Altec
representative.
8. Replace the O-rings and backup rings on the piston
with new seals from the seal kit. Locate both backup
rings toward the end of the piston that contacts the
spring.
9. Clean the bores of the cylinder barrel.
10. Lubricate the seals with hydraulic oil or light grease
such as petroleum jelly, and install the piston in the
cylinder barrel. Push the piston in only until the seals
on the small end are started into the small ID of the
barrel. Do not push the piston in so far that these
seals contact the threaded area in the barrel.
Figure 5.33 Thermal Compensation Cylinder Piston Depth
Section A A
0.62
Min
A
A
11. Install the hex adapter in the end of the cylinder barrel.
12. Screw the cap screw and washer from the seal kit
into the port on the hex adapter.
13. Install the coil spring in the cylinder barrel, and screw
the round end cap into the cylinder barrel until it
contacts the spring.
14. Clamp the fats on the round end cap in a vise. Use
a strap wrench to tighten the cylinder barrel onto the
end cap.
15. Lay the cylinder on its side with the port in the side of
the barrel facing upward. Fill the cylinder with clean
hydraulic oil through this port until the oil is about half
way up onto the threads in the port. Use the same
type hydraulic oil as is used in the derrick hydraulic
system.
16. Tip the cylinder back and forth about 45 degrees
several times to allow any air bubbles to come out
of the port.
17. Install the hex socket plug in the port in the side of
the barrel.
18. Remove the bolt and washer from the port in the hex
adapter.
Installation
1. Install the tee adapter in the port in the hex adapter
in the end of the cylinder.
2. Loosely attach the straight hydraulic adapter on the
gearbox to the tee adapter in the end of the cylin-
der.

3. Place the cylinder against the mounting bracket, and
install and tighten the clamp around the cylinder and
the bracket.
4. Tighten the straight adapter connection to the tee
adapter.
5. Bleed all air from the load sense system according to
the procedure in Section 6 under Rotation Gearbox
Installation.
Section 6 Mechanical Systems 87
Section 6 Mechanical Systems
A mechanical system consists of unit components ar-
ranged so the motion of one mechanically moves the other.
Examples of mechanical components are the rotation
bearing, rotation gearbox, and the booms. Mechanical
components may be moved by each other or by hydraulic
or electrical actuators.
When welding on the unit, a welding ground clamp must
be attached to the same structure on which the welding is
being performed. This is necessary to prevent electrical
current from being sent through components.
Components such as the rotation bearing, rotary joint,
wire braid hoses, and hydraulic cylinders can be damaged
by electrical current. Electrical current fowing through a
component can be very intense, causing serious internal
damage to the component.
Follow these safety procedures when servicing the unit.
1. Select a work site large enough to operate the required
functions.
brake, and chock the wheels. Check the hydraulic oil
level, engage the PTO, and properly set the outriggers.
Warning
movement. Use a sling and hoist of adequate capacity.
3. Use a hoist to safely support heavy components
before loosening the fasteners on that component.
Warning
components.
work areas clean.
4. Never loosen or remove a pressurized hose or ftting.
5. Mark all hydraulic line fttings before disconnecting
them to ease installation later. Place a container under
the hoses to catch the hydraulic oil. Cap or plug all
open ports immediately.
6. After reconnecting a hydraulic line, operate the con-
trols in the system fve to six times to purge the air
out of the system and to check for hydraulic leaks.
7. Properly torque all connections and cap screws.
Refer to Section 5 under Torque and Tightening
Procedures.
8. Perform a dielectric test as described in Section 9
after any component is installed that could affect the
dielectric integrity of the unit.
Caution
Rotary Joint
The rotary joint permits continuous rotation of the turntable
without twisting the hydraulic hoses and electrical cables
that pass between the pedestal and turntable.
The outer housing of the rotary joint is bolted to the
turntable. The inner core is held stationary with a drive
bar. As the turntable is rotated, the outer housing rotates
with the turntable.
Two cap screws secure the drive bar on the bottom of
the inner core of the rotary joint. The drive bar fts in a
slotted bracket welded to the pedestal. As the turntable
rotates, the drive bar holds the inner core of the rotary
joint stationary.
Figure 6.1 shows the location of the hydraulic ports of
the rotary joint.
S1
T3
P1
T
P
P2
T2
S
T4 T1
88 Section 6 Mechanical Systems
Various electrical circuits also pass through the center-
line of rotation by way of the slip ring. The slip ring is
mounted to the top of the rotary joint. It is mounted by
three cap screws. The cap screws are inserted through
metal spacer tubes for support.
Removal
1. Turn off the engine and disengage the PTO.
2. The riding seat, if so equipped, may be removed.
a. Disconnect the electrical connection for the riding
seat control panel from the above rotation valve
driver.
b. Support the riding seat with a hoist or other suit-
able lifting device. Remove the cap screws that
secure the riding seat assembly to the turntable.
Remove the riding seat assembly.
3. Remove the turntable covers.
4. Disconnect the connectors from the above rotation
valve driver and remove the cap screws that secure
the valve driver to the turntable. Remove the valve
driver.
5. Disconnect the electrical connections from the slip
ring that are routed to the above rotation valve driver.
Disconnect the electrical connections from the below
rotation valve driver that are routed through the rotary
joint.
6. Remove the three cap screws and spacers that con-
nect the slip ring to the rotary joint. Remove the slip
ring and set it out of the way.
7. Inside the turntable, disconnect the hydraulic hoses
that are connected to the rotary joint. Inside the
pedestal, disconnect the hoses from the selector
valve that are connected to the rotary joint. Cap or
plug all open ports and hoses.
8. Remove the four cap screws that mount the outer
housing of the rotary joint to the turntable.
9. Remove the rotary joint through the access hole on
the side of the turntable.
Installation
1. Remove the hydraulic fttings, hoses, and drive bar
from the old rotary joint and install them on the new
rotary joint in corresponding locations. Properly torque
the drive bar cap screws.
2. Guide the three hoses through the hole in the turntable
and position the rotary joint in the turntable. Make
sure the drive bar is inserted in the bracket on the
pedestal. Line up the holes in the outer housing of
the rotary joint with the holes in the turntable.
3. Install and properly torque the four cap screws
through the rotary joint outer housing and into the
turntable.
4. Position the slip ring inside the turntable and route
the cable through the rotary joint. Position the slip
ring on top of the rotary joint.
5. Insert a cap screw through a tab on the rotary joint
and through a spacer tube into the slip ring. Repeat
this step for the other two cap screws and spacers
that mount the slip ring to the rotary joint.
6. Connect the electrical connectors in the pedestal to
the below rotation valve driver.
7. Connect all the hydraulic hoses to the rotary joint
and the selector valve.
8. Install the valve driver on the turntable and connect
the electrical connectors.
9. Install the turntable covers.
10. Install the riding seat assembly to the turntable and
connect the electrical connectors.
11. Start the engine, engage the PTO, and properly set
the outriggers. Operate the unit while checking for
leaks at the rotary joint.
Rotation System
The units turntable rotates on a large shear ball bearing,
referred to as the rotation bearing. The inner race of the
bearing is fastened to the turntable. The outer race of
the bearing is fastened to the pedestal. It has gear teeth
cut on the outside surface of the outer race.
Rotation is accomplished by a gearbox mounted on the
turntable. The gearbox is driven by a hydraulic motor.
The rotation pinion meshes with the teeth on the rota-
tion bearing.
A spring applied, hydraulically released brake is located
on the rotation gearbox (refer to Figure 6.2). When the
rotation control is in neutral, the counterbalance valves
in the rotation valve are closed. The closed valves trap
oil in the rotation motor. The spring applied brake locks
the rotation gearbox in place.
Figure 6.2 Rotation System
When the rotation function is operated, the counterbal-
ance valve for the direction of operation (clockwise or
counterclockwise) opens. The open valve allows hydraulic
oil to fow through the rotation motor. Hydraulic pressure
acts on a piston in the brake chamber. The piston moves
against the springs, which releases the brake discs. This
causes the rotation brake to be hydraulically released. The
motor powers the rotation pinion. As the rotation pinion
drives the rotation bearing, the turntable rotates.
When a side load is created on the booms during opera-
tion, the side load protection system operates. Section
5 under Protection Systems describes the side load
protection systems.
Rotation Bearing
The rotation bearing provides for very low torque rota-
tion. The bearing should provide many years of service
if properly maintained.
A grease tube is connected to the inner race of the rota-
tion bearing and to a grease ftting on the front of the
turntable. Lubricate the bearing race, the gear teeth on
the outer race, and the rotation pinion as recommended
by the Preventive Maintenance and Inspection Checklist.
Refer to Section 4 under Lubrication for information.
Procedures for measuring turntable tilt and inspecting
the rotation bearing cap screws are found in Section 4
under Rotation Bearing.
Removal
Components may need to be removed to access the
rotation bearing cap screws for removal.
properly set the outriggers. Disengage the PTO and
3. Disconnect the hydraulic lines from the selector valve
that are connected to the rotary joint (refer to Rotary
Joint in this section) and the electrical cable that is
connected to the slip ring from the below rotation
valve driver. It may be necessary to remove above
rotation valve driver or other components from the
turntable to gain access to the cap screws.
4. Disconnect the grease tube inside the turntable
from the bearing. Adjust the rotation drive gearbox
backlash to move the rotation pinion away from the
rotation bearing gear teeth. Refer to the backlash
adjustment procedure in Section 8 under Rotation
Gearbox.
Warning
movement. Properly support the component before
loosening fasteners and removing hydraulic com-
ponents.
5. Support the turntable (and booms, if still attached) to
prevent it from accidentally coming off the pedestal
after the cap screws are removed. Remove the cap
screws and washers from the inner race.
6. Use a hoist or other lifting device to lift the turntable
from the rotation bearing. The boom may or may not
be still attached to the turntable.
7. Remove the cap screws and washers from the outer
race of the rotation bearing.
8. Lift the bearing off the pedestal weldment.
Installation
New rotation bearings shipped from Altec include new
cap screws, hardened washers, cleaner, and installation
instructions.
Warning
1. Clean the rotation bearing mounting surfaces on
the pedestal, turntable, and the bearing with a cloth
and solvent to remove any dirt or grease. Allow the
surfaces to completely dry.
2. Remove the grease ftting from the old rotation bear-
ing and install it in the new bearing.

Motor
Brake
Gearbox
3 Agitate the adhesive compound by shaking the bottle.
Apply the adhesive to the pedestal bearing surface
in the pattern shown in Figure 6.3. Apply a
3
/16 to
1
/4
(0.48 to 0.64 cm) bead of adhesive. Keep the bead
far enough away from the holes so that adhesive will
not get in the holes when the bearing is installed.
The bearing must be completely installed within 30
minutes of applying the adhesive.
Figure 6.3
Anaerobic Adhesive Application Pattern
4. Position the new rotation bearing on the pedestal
weldment. Locate the high tooth, marked by yellow
or blue paint, in the proper position (refer to Figure
6.4). Align the mounting holes with the mating cap
screw holes in the bearing.
Figure 6.4 Rotation Bearing High Tooth Location
Notice
install the rotation bearing.
If a rotation bearing cap screw is removed, it must be
replaced with a new cap screw. Contact your Altec repre-
sentative for replacement rotation bearing cap screws.
5. Install the cap screws with washers in the outer race
of the bearing. Notice that the washer has a more
rounded edge on one side. Install the washer with
the rounded edge toward the cap screw head. Do
not torque the cap screws until all of them have been
installed on the outer race.
6. Torque the cap screws in three phases.
a. Torque the cap screws to 165 foot-pounds (224
Nm) using the alternating star pattern shown in
Figure 6.5.
Figure 6.5 Outer Race Cap Screw Torque Pattern
b. Set the torque to 325 foot-pounds (441 Nm).
Follow the same alternating star pattern.
c. Keep the torque wrench set for 325 foot-pounds
(441 Nm). Torque each cap screw a third time
using a circular pattern starting with cap screw
number one.
7. Agitate the adhesive compound by shaking the bottle.
Apply the adhesive to the turntable side of the bearing
surface in the pattern shown in Figure 6.6. Apply a
3
/16 to
1
/4 (0.48 to 0.64 cm) bead of adhesive. Keep
the bead far enough away from the holes so that
adhesive will not get in the holes when the bearing
is installed. The bearing must be completely installed
within 30 minutes of applying the adhesive.
8. Rotate the inner race to position the grease ftting
as shown in Figure 6.7.
High Tooth
Location
Number one cap screw can be at any
location on the bearing with the remainder
of the pattern shifted accordingly
1
23 14
13 24
6
9
10
4
19
20
7
15
16
8
18
17
3
12
11
5
22
21
2
Figure 6.6
Anaerobic Adhesive Application Pattern
Figure 6.7 Inner Race Cap Screw Torque Pattern
9. Use a sling and hoist to position the turntable on top
of the rotation bearing. Align the turntable mounting
holes with the mating cap screw holes in the bear-
ing.
10. Install the cap screws in the inner race of the bearing
in the same manner as the outer race cap screws.
11. Torque the cap screws in three phases with the same
procedure used on the outer race in step 5. Follow
the alternating star pattern shown in Figure 6.7.
12. Install all components that were removed to access
the cap screws. Reconnect all hydraulic lines and
the electrical cable. Connect the grease tube to the
turntable.
13. Adjust the backlash between the rotation pinion and
the rotation bearing gear teeth as described in Sec-
tion 8 under Rotation Gearbox.
14. Lubricate the rotation bearing raceway and gear teeth
as described in Section 4 under Lubrication.
15. From the lower controls, operate each function fve
or six times to purge any air that may have entered
the system.
16. Perform a stability test as described in Section 9.
Rotate the turntable through three complete revolu-
tions.
17. Torque the rotation bearing cap screws to 325 foot-
pounds (441 Nm) (both inner and outer race) again,
using the star pattern as shown in Figures 6.5 and
6.7.
19. Inspect the rotation bearing cap screws as recom-
mended by the Preventive Maintenance and In-
spection Checklist as described in Section 4 under
Rotation Bearing Cap Screws.
Rotation Bearing Cap Screws
Use this procedure when only the rotation bearing cap
screws are being replaced.
Notice
Only use Altec supplied cap screws and washers.
When rotation bearing cap screws or washers are re-
moved, they must be replaced with new ones. Contact
your Altec representative for replacement fasteners.
brakes, and chock the wheels. Engage the PTO and
Warning
movement. Replace only one cap screw at a time.
2. Loosen and replace only one cap screw at a time.
3. Install the new cap screw and washer. Notice the
washer has a more rounded edge on one side. Install
the washer with the rounded edge toward the cap
screw head.
1 27
28
7
8
13
14
4
23
24
9
10
19
20
2
25
26
5
6
15
16
3
X
18
17
12
11
22
21
Grease
Fitting
4. Torque the cap screw to 100 percent of the normal
installation torque value.
5. Repeat steps 2 through 4 for each cap screw in the
race, going around in a circular pattern.
6. Perform a stability test as described in Section 9.
Rotate the turntable through three complete revolu-
tions.
7. Torque the rotation bearing cap screws to 100 per-
cent of the normal installation torque value using a
circular pattern.
Resume regular inspection of the rotation bearing cap
screws as recommended by the Preventive Maintenance
and Inspection Checklist. Use the inspection procedures
as described in Section 4 under Rotation Bearing Cap
Screws.
Rotation Gearbox
Removal
Warning
rotation gearbox.
2. Secure the boom with a strap so the turntable cannot
rotate when the gearbox is removed.
Caution
Wear eye protection while adjusting the eccentric ring
to prevent particles of metal or dirt from entering the
eyes.
3. Remove any wiring, control lines, hoses, or tubes
that are in the way of the gearbox removal. Cap or
plug all open connections to prevent contamination
from entering the system.
4. Remove the pinion cover. Remove the eccentric ring
lock located on top of the turntable bottom plate,
under the rotation gearbox. Loosen the four cap
screws securing the rotation gearbox. For the rotation
gearbox used with hydraulic side load protection, a
torque wrench adapter (included with unit, refer to
Service Tools and Supplies in the Appendix) must
be used to loosen these cap screws.
5. Engage an eccentric ring spanner wrench (refer to
Service Tools and Supplies in the Appendix) or a bar
or drift pin made of a soft material such as brass, in
a drive slot of the eccentric ring. Do not use a bar,
punch, or drift pin made of steel, as it will damage the
drive slots in the eccentric ring. Rotate the eccentric
ring using the spanner wrench or using light blows
from a hammer against the bar or drift pin so as to
position the gearbox the maximum distance from the
rotation bearing gear teeth.
6. Manually operate the rotation control valve spool
to relieve the pressure from the rotation function
lines.
7. Remove the rotation motor hydraulic hoses. Plug
and cap the openings.
8. Place a nylon sling around the gearbox.
9. Connect the sling to a hoist. Remove the four gear-
box mounting cap screws. Lift the gearbox out of the
turntable and lower it to the ground.
Installation
1. Clean the mounting surface and eccentric ring. Ap-
ply anti-seize compound to the inside and outside
surface of the eccentric ring and boss. Install the
eccentric ring in a position so that adjusting
1
/4 turn
one way will produce full adjustment and
1
/4 turn the
other way will completely loosen the gearbox.
2. Position the nylon sling on the gearbox as before
and connect it to the hoist. Position the gearbox on
the turntable.
3. Install the gearbox mounting cap screws loosely.
4. Reconnect the rotation motor hoses. Reconnect any
other wiring, hoses, tubes, and control lines that may
have been removed for this procedure. Remove the
strap(s) used to secure the boom.
5. Adjust the rotation pinion to the rotation bearing
following the procedure in Section 8 under Rotation
Gearbox.
6. Position the unit on a level surface with suffcient
clearance for full boom movement. Apply the park-
ing brake and chock the wheels. Engage the PTO
and properly set the outriggers. Leave the engine
running.
7. Go to step 8 if the derrick is equipped with hydraulic
side load protection (refer to Figure 6.8) or to step 9
if it is equipped with electronic side load protection
8. If the derrick is equipped with hydraulic side load
protection, bleed the air out of the rotation brake
according to the following steps.
a. Raise the boom a few inches out of the boom
rest.
b. Loosen the bleeder plug on the rim of the rotation
brake housing (refer to Figure 6.8).
c. Operate the rotation hand control slightly until the
stream of oil fowing from the loose plug is clear,
with no air bubbles.
d. Tighten the plug on the rotation brake.
e. Proceed to step 10.
9. If the derrick is equipped with electronic side load pro-
tection, bleed the air out of the rotation gearbox load
sense system according to the following steps.
Notice
Do not bleed the electronic side load protection load
sense system if the unit is not level or while there is
any side loading on the boom.
a. Place the digger shift selector in High, if so
equipped.
b. Place a clean container suitable for holding hydrau-
lic oil under the bleeder ftting located on the side
of the rotation gearbox away from the turntable
c. Loosen the bleeder ftting slightly until air and
hydraulic oil start fowing from the ftting. Allow at
least 2 cups (16 ounces) of oil to drain out. Con-
tinue the fow until clear oil with no air has fowed
from the ftting for several seconds.
d. Tighten the bleeder ftting, and pour the collected
oil back into the hydraulic reservoir.
e. Place the clean container under the male quick
disconnect ftting located above the thermal com-
pensation cylinder on the rotation gearbox (refer
to Figure 6.9).
f. Slightly loosen the quick disconnect ftting. Watch
for air and hydraulic oil to start fowing from the
joint. Continue the fow until clear oil with no air
has fowed from the ftting for several seconds.
g. Tighten the quick disconnect ftting, and pour the
collected oil back into the hydraulic reservoir.
h. Return the digger shift selector to Low.
10. Operate the unit through all boom angles and rotation
from the lower controls while checking for leaks and
proper operation.
11. Operate the unit through all boom angles and rotation
from the upper controls while checking for smooth-
ness of rotation.
12. Inspect the rotation gearbox mounting cap screws
as recommended by the Preventive Maintenance
and Inspection Checklist.
Rotation Brake
Bleeder Plug
Turntable
Male Quick
Disconnect
Fitting
Bleeder
Fitting
Rotation
Gearbox
Rotation
Gearbox
Upper Boom
Removal
Warning
Failure to secure the upper boom tip to the lower or
intermediate boom can result in uncontrolled extension
of the upper boom when the cylinder mounting pin is
removed from the intermediate boom.
2. Rotate the boom to the side of the unit. Use chains
or rope to secure the upper boom tip to the lower or
intermediate boom.
by operating the upper boom manual override control
handle for both directions.
4. Pin the transferable boom fares and pole guide as-
sembly to the upper boom assembly.
5. Remove any components on the unit attached to the
upper boom assembly such as the platform or jib,
that may interfere with upper boom removal. Remove
anything on the unit, such as a winch line, that make
a connection between the upper and intermediate
boom when the upper boom is removed.
6. Remove the lower boom access covers closest to
the turntable.
7. There are two access holes on each side of the
lower boom near the turntable. Reach through the
access hole closest to the boom tip on each side of
the boom. Remove the two retaining rings and the pin
that secure the rod end of the upper boom cylinder
to the lower end of the intermediate boom (refer to
Figure 6.10). If the pin cannot be reached through
the hole, extend the intermediate boom slightly until
it can be reached. If the boom tip is secured to the
lower boom, loosen the rope or chain. If this is done,
be sure to retighten the chain or rope after removing
the pin.
8. Reach through the access hole closest to the boom
tip. Disconnect the two hydraulic hoses connected to
the bulkhead fttings at the cylinder mounting bracket.
Cap or plug all open ports and hose ends. Disconnect
the electrical cable and the additional hose containing
the cable from the bulkhead bracket.
9. Use another derrick, forklift, or a hoist, to support the
upper boom. Protect the fberglass boom from nicks
or scratches from the lifting device. Unhook the rope
or chain securing the boom tip to the lower boom.
Figure 6.10 Booms
Upper Boom Cylinder
Side View
Pin
Retaining Rings
Section A-A
Trunnion
Pins
Section B-B
A
A
B
B
10. With the aid and support of another vehicle (derrick,
forklift, etc.), carefully pull the upper boom assembly
partially out of the intermediate boom, allowing it to
slide out on the boom slide bracket.
11. With the upper boom being more fully supported by the
pulling vehicle, carefully remove the pin and boom
slide bracket. Carefully pull the upper boom out of the
intermediate boom. Set the boom on the ground.
12. At the base end of the upper boom, remove the two
trunnion pins fastened to the upper boom cylinder.
13. Pull the cylinder out of the upper boom.
Installation
1. Before installing the cylinder, operate the cylinder and
check for leaks. This may be done by connecting the
extend and retract ports on the cylinder to a lower
tool circuit. Be careful not to damage the rod.
2. Remove the rubber blocks, clamps, bulkhead bracket,
bulkhead fttings, and hydraulic lines from the old cyl-
inder. Install all the components on the new cylinder
as they were installed on the old cylinder. Adjust the
pole guide interlock switch (refer to Section 8 under
Pole Guide Interlock System).
3. Use a sling and hoist or other lifting device to position
the cylinder inside the upper boom.
4. Apply cleaner to both the trunnion pin threads and
the female threads in the cylinder. Allow the cleaner
to thoroughly dry. Apply high strength thread locking
adhesive to the frst two or three threads of the male
part (refer to Figure 6.11). Install the two trunnion
pins through the base end of the upper boom and
into the cylinder. Torque the trunnion pins to 150 to
180 foot-pounds (203 to 244 Nm).
Figure 6.11 Upper Boom Cylinder
5. Use another derrick, forklift, or other heavy equipment
to slide the upper boom into the intermediate boom.
Take care not to damage the fberglass boom and
boom tip.
6. Raise the upper boom enough to install the boom
slide bracket and pin. Lower the boom onto the boom
slide bracket and install the bearing bracket and the
shims.
7. Install the winch, if it was removed.
8. Install the pin and two retaining rings to secure the
rod end of the cylinder to the base end of the inter-
mediate boom. Install the retaining rings with the
sharp edge toward the end of the pin.
9. Connect the two hydraulic hoses to the bulkhead
fttings on the bracket mounted to the upper boom
cylinder. Connect the electrical cable and the ad-
ditional hose containing the cable to the bulkhead
bracket.
engine and engage the PTO. Extend and retract the
upper boom several times. This will purge any air
that is in the hoses or cylinder. While operating the
cylinder, check it for leaks and proper operation.
11. Install the boom access covers.
12. Install other components, such as the winch line, that
were removed.
Winch
The unit is equipped with either a boom tip winch or a
turntable winch. The boom tip winch is mounted at the
end of the intermediate boom. The winch has a rated
capacity of 12,000 or 15,000 pounds (5,443 or 6,804 kg).
The winch can raise the rated capacity with one layer of
1
/2 wire rope left on the winch drum.
The winch is a worm gear winch driven by a hydraulic
motor. Operation of the winch valve directs hydraulic
system oil to the winch motor. The winch motor powers
the worm gear set. The worm gear set drives an output
shaft keyed to the winch drum.
Drum
The winch drum contains a set screw that prevents the
drum from moving along the winch output shaft.
The mounting of the turntable winch allows the winch
to be removed from the turntable without loosening the
set screw. However, the set screw must be loosened
before the output shaft may be withdrawn from the drum
when servicing this winch. Once service is completed,
the set screw must be frmly tightened before the winch
is installed on the unit.
Trunnion Pin
Upper Boom Cylinder
Apply Thread Locking
Adhesive Here
Apply
Lube
Here
When servicing a boom tip mounted winch, the set screw
must be loosened before the winch may be removed
from the boom tip. In addition, the fastener that provides
the attachment point for the synthetic winch line must
be removed. Once service is completed, the set screw
must be frmly tightened when the winch is installed on
the unit.
While removing either type of winch, make sure that the
weight of the winch is supported after the gearbox mount-
ing fasteners are removed. This will prevent the output
shaft from binding in the outboard bearing.
When installing either type of winch, check whether there
is a gap between any of the gearbox mounting feet and
the winch mounting surface (refer to Figure 6.12). If there
is a gap of 0.060 (1.524 mm) or more beneath one or
more mounting feet with the remaining feet tight against
the mounting surface, use shims (washers or machinery
bushings) to take up the gap. If this is not done, the winch
may be put into a bind when the mounting cap screws
are tightened.
Figure 6.12 Turntable Winch
The load on the winch line is held in place primarily by
the non-back drivable gear set in the gearbox and a
supplemental holding valve.
Platform Brake
The personnel platform is equipped with a caliper-type
disc brake in the platform mounting bracket.
When the brake is unlocked, the platform is free to pivot
on its mounting shaft to provide gravity leveling as the
boom angle changes. Figure 6.13 illustrates the brake
in the locked and unlocked positions.
The brake can be locked at any boom angle to keep the
platform from swinging while working from the platform.
The brake should also be locked after the platform is re-
turned to its stowed position before road travel. The brake
is locked by rotating the brake lever downward toward
the rim of the platform. An overcenter mechanism locks
the brake in the fully applied position when the handle
reaches the bottom of its travel. Adjustment of the brake
is described in Section 8 under Platform Brake.
Figure 6.13 Platform Brake
Digger Transfer Mechanism
The digger hanger bracket is equipped with a digger
transfer mechanism (refer to Figure 6.14). The digger
transfer mechanism uses a latch weldment and a latch
keeper to secure the digger hanger bracket to the lower
boom. The latch weldment is equipped with a latch bar.
When the digger is stowed, the latch bar engages in
the latch keeper welded to the lower boom, locking the
digger hanger bracket against the lower boom when the
intermediate boom is extended.
When the digger is unstowed, the latch bar automatically
disengages from the latch keeper. At the same time, a
welded lug on the latch bar enters a slot in the intermediate
boom. This allows the digger to be automatically trans-
ferred from the lower boom to the intermediate boom.
In order for the digger transfer mechanism to work prop-
erly, the intermediate boom must be fully retracted during
stowing and unstowing of the digger.
If the intermediate boom is not fully retracted when the
digger is unstowed, the digger hanger bracket will not
attach itself to the intermediate boom. When the opera-
tor extends the intermediate boom to position the auger
for digging, the auger will be left behind. If this happens,
the intermediate boom may be retracted without frst
stowing the auger.
To keep the digger transferring properly, lubricate the
outer surfaces of the intermediate boom and the digger
hanger bracket pivot pin (refer to the Lubrication Chart
and Diagram in Section 4).
Mounting Feet
Counterbalance Valve
Unlocked Locked
Figure 6.14 Digger Transfer Mechanism
Section A-A
Section B-B
Digger Stowed
Digger Transferred to Intermediate Boom
Intermediate
Boom
Digger Hanger
Link
Lug
Disengaged
Digger
Holdback
Bracket
Latch
Keeper
Engaged in Latch Keeper
Intermediate
Boom
Digger Hanger
Link
Lug Engaged
in Slot
Digger Hanger
Bracket
Latch
Keeper
Disengaged From Latch Keeper
Digger
Holdback
Bracket
Digger Unable to Transfer
Intermediate
Boom
Lower
Boom
Digger Hanger Link
Slot
Section 7 Electrical System 99
Section 7 Electrical System
Electrical power is supplied from the vehicle battery to
control nearly all operations of the electrohydraulic control
system. Figure 7.1 shows a comparison between electri-
cal and hydraulic components.
Caution
Injury can result from electric shock. Severe arcing
can occur even when working with low voltage vehicle
electrical systems. Use caution when working with
any electrical device.
Voltage levels of this system are based on a constant
vehicle power source. Voltage may vary from 11 volts
to 14 volts and still be considered normal in a 12 VDC
system.
The major electrical components and their operation
are described in this section. Wiring Line Diagrams in
the Appendix illustrate the component wiring. Refer to
Section 8 for troubleshooting information.
The electrical system uses two basic types of circuits
an on/off circuit and a proportional circuit.
On/Off Circuit
The on/off circuit supplies constant 12 volts power to
a solenoid or other component when a switch or relay
is closed. When the circuit is opened, the power is re-
moved.
On/off circuits are used to control solenoid valves that
operate the following functions.
Pole guide open/close
Pole guide forward/store back
Auger release
Digger shift high/low
Platform tools on/off
Proportional Circuit
Certain functions of the derrick require variable speeds
of operation with slow starts and stops. They cannot be
operated with on/off solenoid valves, but must be oper-
ated by a proportional control system. Each function
uses a different hand control and operates a different
pulsar valve.
A proportional control system allows the functions
speed to be proportional to the distance the hand con-
trol is shifted. For example, if the boom hand control is
shifted in the Raise position at maximum hand control
travel, the boom rises at maximum speed. The boom
will continue to rise until the handle is shifted to neutral
or the boom reaches its maximum travel for the boom
raise function.
Function Performed
Source of energy or power
Creates a potential energy difference between two points in
a system
Allows potential energy to become kinetic and do useful
work
Transmits power from place to place
Protects system from overload
Allows power to fow in one direction but not the other
Blocks power or allows it to fow
Varies the amount of power which passes through it de-
pending upon the distance the control handle is moved
Restricts the fow of power
Allows power to fow through upon receiving a signal from
another source
Causes axial movement of its central element when power
is applied to it
Transmits power through a continuously rotating connection
Hydraulic Component
Pump
Pressure
Oil fow
Hose or tube
Relief valve
Check valve
Shutoff valve
Control valve
Orifce
Pilot operated
check valve
Cylinder
Rotary joint
Electrical Component
Battery
Voltage
Current
Wire
Fuse or circuit breaker
Diode
Switch
Controller
Resistor
Relay
Solenoid
Slip ring assembly
Figure 7.1 Electrical/Hydraulic Comparison
100 Section 7 Electrical System
The following functions use proportional circuits.
Boom raise/lower
Rotation left/right
Intermediate boom extend/retract
Upper boom extend/retract
Winch raise/lower
Digger dig/clean
Multiplexed Controls
Multiplexing is used on the unit to combine and transmit
multiple signals over a single channel (or pair of wires).
This eliminates the need for individual channels for each
signal.
Below Rotation Valve Driver
The below rotation valve driver (refer to Figure 7.2) is
located in the pedestal. It is the connection between the
PDM, selector valve, outrigger interlock module, below
rotation controls, and the electrical functions of the unit.
Multiplexing for the unit begins with the below rotation
valve driver. LEDs indicate the condition of the processor
and the on/off output circuits.
Above Rotation Valve Driver
The above rotation valve driver (refer to Figure 7.3) is
located on the turntable. It is the connection between the
following control system components.
Boom, digger and winch functions, auxiliary func-
tions, and above rotation control panels
Upper controls or radio controls and the boom,
digger/winch, and auxiliary functions
HOP/load moment limiter, system pressure, and
electronic side load protection pressure transduc-
ers
Boom stow, auger stow, pole guide interlock, and
boom position switches
Anti-two-block monitor
Electrical circuits running through the slip ring to
the below rotation valve driver
LEDs on the upper valve driver indicate the presence
of proper voltages and the condition of the processors
and interlock switches when the valve driver is receiving
+12V power (refer to Figures 7.3 and 7.4).
Cable Assemblies
Cable assemblies made up of electrical conductors
are used to send and receive all the multiplexed com-
munication signals (and some analog signals) between
the various control system components. All multiplexed
communication is accomplished with two wires that serve
as the communications channel.
Various electrical cable assemblies are used on the unit.
Each of these cable assemblies establishes a common
ground between the various control system components.
Certain cables also establish a common multiplex com-
munication link. Individual cable assemblies are used
for various connections between components, including
those as described below.
Between the proportional valve pulsars and the above
rotation valve driver.
Between the auxiliary functions valve and the above
rotation valve driver.
Between the input driver and the right hand switches
in the control panel.
Between the input driver and the left hand switches
in the control panel.
Between the input driver and the hand controls in
the control panel.
Between the below rotation valve driver and the se-
lector valve, outrigger interlock module, and PDM.
Between the below rotation valve driver and the
above rotation valve driver via the slip ring.
Between the upper control panel or radio controls
and the above rotation valve driver.
Between the lower control panel and the above or
below rotation valve driver depending on the location
of the lower control panel.
Between the above rotation valve driver and the
pressure transducers, protection system switches,
boom position switches, and anti two-block monitor
installed above rotation.
The CADI also uses a permanently attached, multiplex
cable [refer to Calibration and Diagnostic Instrument
(CADI) in this section].
Multiplex Cable Connectors
There are 8, 14, 23, and 35-pin weatherproof quick con-
nectors used to connect the multiplex cable assemblies
to the control system components.
G = Green LED
Figure 7.2 Below Rotation Valve Driver and Diagnostic Indicator LEDs
LED Label
+12V
Throttle 1
Throttle 2
Start/stop
Winch/
combination
valve
Blocking/un-
loading valve
Spare
digital 1
Spare
digital 2
MO-1
On Indication
+12V power supplied to below
rotation valve driver
+12V signal present, low engine
speed is selected
+12V signal present, high engine
speed is selected
Ground signal present, engine
start/stop switch is actuated
+12V signal present, function above
rotation is operating which sends
winch or combination valve signal
+12V signal present, any function(s)
above rotation is operating
+12V signal present
+12V signal present
Enabled and functional
Description
Input power, CON2
pins 1 and 2
Throttle preset 1
output, CON2 pin 4
Throttle preset 2
output, CON2 pin 5
Start/stop output,
CON2 pin 9
Winch/combination
valve output, CON2
pin 10
Blocking/unloading valve
output, CON2 pin 11
Custom option output 1,
CON2 pin 13
Custom option output 2,
CON2 pin 14
Microprocessor input/
output
* LED is off when emergency stop is actuated
Off Indication
No power supplied to below rotation
valve driver (possible causes: PDM circuit
breaker tripped, damaged wiring harness)
No signal present*
No signal present*
+12V signal present*
No signal present*
No signal present*
No signal present*
No signal present*
Off line, not receiving data/inoperative (pos-
sible causes: communication through slip
ring disrupted, damaged wiring harness/
below rotation valve driver malfunction)*
R = Red LED
LED Label
+5V
+12V
Interlock
MO-4, MO-5,
MO-6
MI-1
ESLP
+12V XDCR
+12V switch
On Indication
Enabled and functional,
+5V is present at all con-
nectors where required
+12V power supplied to
above rotation valve driver
One or more interlocked func-
tions are being operated.
transducers
limit switches
Description
5V regulated supply
Input power
Function interlock
Microprocessor output
Microprocessor input
Electronic side load
protection
Self-resetting protected
power to above rotation
pressure transducers
Self-resetting protected
power to above rotation
limit switches
Figure 7.3 Above Rotation Valve Driver and Diagnostic Indicator LEDs for Internal Functions/Systems
Off Indication
Inoperative*
No power supplied to above rotation valve driver (pos-
sible causes: PDM circuit breaker tripped, damaged
wiring harness)
No interlocked functions are being operated*
Inoperative (try moving a function control on/off to cycle
interlock and reset output driver)*
Inoperative*
Inoperative*
No power supplied to transducers (possible causes: ex-
cessive current draw on a CON6 terminal, external short
from power to ground in wiring harness or transducer)*
No power supplied to limit switches (possible causes:
excessive current draw on a CON6 terminal, external
short from power to ground in wiring harness or switch)*
G =Green R =Red
LED Label
Two block
Upper boom
Pole guide
Boom stow
Auger stow
Boom pos 1
Boom pos 2
On Indication
+12V power received from
ATB monitor, unit is not two-
blocked / The no ATB jumper
is installed
switch, upper boom is not
fully retracted, pole guide tilt
forward is disabled if ares
are pinned to intermediate
boom
switches, ares are pinned
to intermediate boom and
pole guide is fully tilted back
to stowed position or else
ares are pinned to upper
boom, upper boom extension
is enabled
switch, boom is out of rest
switch, auger is not against
switch
switch, upper boom is fully
extended, Extend at upper
controls operates intermedi-
ate boom extend
switch, intermediate boom
is fully retracted, Retract at
upper controls operates up-
per boom retract
Description
Input from ATB monitor
(if equipped with ATB)/
The no ATB jumper
is installed (if not
equipped with ATB)
Input from pole guide
interlock upper boom
extension limit switch
(if equipped)
Input from pole guide
interlock transfer pin
and tilt limit switches
(if equipped)
Input from boom stow
limit switch
Input from auger
stow limit switch (if
equipped)
Input from boom
position 1 (upper boom
extended) limit switch
(if equipped)
Input from boom posi-
tion 2 (intermediate
boom retracted) limit
switch (if equipped)
Figure 7.4 Above Rotation Valve Driver and Diagnostic Indicator LEDs for External Functions/Systems
Off Indication
No power received from ATB monitor, unit is two-blocked,
HOP is engaged / The no ATB jumper is missing, HOP is
engaged (other possible causes: damaged wiring harness,
dead ATB switch battery, ATB component malfunction)*
No power received from switch, upper boom is fully re-
tracted, pole guide tilt forward is enabled if ares are pinned
to intermediate boom (other possible causes: damaged
wiring harness, switch malfunction, not equipped with up-
per boom extension limit switch)*
No power received from switches, ares are pinned to
intermediate boom and pole guide is not fully tilted back to
stowed position, upper boom extension is disabled (other
possible causes: damaged wiring harness, switch malfunc-
tion, not equipped with transferable pole guide)*
No power received from switch, boom is in rest, HOP is
engaged (other possible causes: damaged wiring harness,
switch malfunction)*
No power received from switch, auger is against switch,
digger dig is disabled (other possible causes: damaged
wiring harness, switch malfunction, not equipped with
digger)*
No power received from switch, upper boom is not fully
extended, Extend at upper controls operates upper boom
extend (other possible causes: damaged wiring harness,
switch malfunction, not equipped with sequential exten-
sion limit switches)*
No power received from switch, intermediate boom is not
fully retracted, Retract at upper controls operates intermedi-
ate boom retract (other possible causes: damaged wiring
harness, switch malfunction, not equipped with sequential
extension limit switches)*
G =Green R =Red
When connecting a multi-pin connector, make sure it is
properly aligned before pushing the plug fully into the
receptacle. Make sure the rubber insulating ring between
the connector and receptacle is in place and is in good
condition.
Immediately after disconnecting one of these connec-
tors, cap the plug or wrap it in a plastic bag to prevent
contamination.
Calibration and Calibration
Diagnostic Instrument (CADI)
The CADI (refer to Figure 7.5) is a separate, self-contained
component of the control system. The CADI does not
come with the unit, but is available from your service
representative (refer to Service Tools and Supplies in the
Appendix). A Quick Reference Guide is included with the
CADI containing full instructions for its operation.
When use of the CADI is required, it is temporarily con-
nected to the CADI connection socket at one of the loca-
tions shown in Figure 7.6. The CADI is used to set the
following control parameters for the lower, intermediate,
and upper booms, rotation, digger, and winch functions.
Each parameter is adjustable from 0 to 99.
Threshold (TH)
Max out (MX)
Low speed (LMX)
It is also used to set the HOP and electronic side load protec-
tion settings and the engine speed for the foot throttle.
The CADI displays the following additional parameters
which must remain at factory settings. Do not change
the settings for any of these parameters.
Frequency (FREQ)
Speed Curve (SC)
Ramp (RA)
Figure 7.5 CADI
Lower Controls Confguration CADI Connection Socket Location
Traditional control panel with six hand controls Bottom of control panel
or with one joystick and two hand controls
Full view riding seat with two joysticks Front of boom functions control module
Radio controls only with no lower control panel Back of radio control receiver mounting bracket on turntable
Socket not accessible at above locations On pedestal or turntable, connected by cable to lower or
upper valve driver
Figure 7.6 CADI Connection Socket
Connection
Socket
LCD
Push Button
Key Pad
The CADI is the only major component of the control sys-
tem that is both an input and output device. This allows the
CADI to send and receive information in order to calibrate
the operating parameters of the control system.
Controls on the CADI are provided for selecting the op-
erating mode, moving left and right through the menu,
selecting the parameter desired, and increasing or de-
creasing the value of the parameter selected.
Power Distribution Module (PDM)
The PDM is the central connection point between the
unit electrical system and the vehicle electrical system.
The PDM is used when electronic circuits are required
to operate the unit and additional accessories or when
electronic engine controls are used. Refer to the PDM
Information Manual for introduction, familiarization, and
onboard diagnostic system information.
Outrigger Interlock System
The outrigger interlock system is a combination of electric
and hydraulic components designed to prevent boom
operation until all outriggers are lowered.
There is one outrigger interlock electrical switch for each
outrigger leg extension. On A-frame, X-frame, modifed
A-frame, out and down, and corner mount street side out-
riggers, the switches are mounted on the outrigger outer
legs. On radial and corner mount curb side outriggers,
they are mounted on a moving part of the outrigger or
on an adjacent stationary surface. Figure 7.7 shows the
switches. When the outriggers are lowered or extended,
the switches close. The interlock switches are connected
to the outrigger interlock control module. When all the
switches are closed, electrical power will be sent to the
solenoid of the unloader valve when a function on the
control panel is operated.
Figure 7.7 Outrigger Interlock Switches
When the outriggers are in the stored position, the outrig-
ger interlock switches are open. Therefore, the solenoid
for the unloader valve will not be energized when a func-
tion on the control panel is operated. This prohibits oil
from fowing to the lower control valve, thus preventing
boom operation.
If one switch is defective or out of alignment, the system
will not operate. Testing of these switches is described
in section 8 under Electrical System.
A-Frame, X-Frame, Modifed A-Frame,
Out and Down, or Corner
Mount Street Side Outriggers
Proximity Switch Removal
Remove the fasteners that secure the switch assembly
to the outrigger frame. Remove the fasteners that se-
cure the switch to the cover. Disconnect the electrical
connector at the end of the switch wiring. Remove the
switch and wiring.
Proximity Switch Installation
Connect the electrical connector of the new switch. At-
tach the switch to the cover with the original fasteners.
Secure the switch assembly to the outrigger frame in the
same orientation as the original switch using the original
fasteners.
Radial or Corner Mount
Curb Side Outriggers
Proximity, Tilt, or Mercury Switch Removal
Remove the cap screws that hold the switch to the out-
rigger leg or adjacent surface. Disconnect the electrical
connector at the end of the switch wiring. Remove the
switch and wiring.
Proximity or Tilt Switch Installation
Connect the electrical connector of the new switch. Attach
the new switch to the outrigger leg or adjacent mounting
surface in the same orientation as the original switch
using the original fasteners.
Mercury Switch Installation
Connect the electrical connector of the new switch. Attach
the new switch to the outrigger leg with one cap screw.
The wired end of the switch must be located toward
the outrigger shoe. Use the other cap screw to lock the
switch in place after it has been adjusted as described
in Section 8 under Outrigger Interlock System.
Rotation Interlock
Units with out and down outriggers may be equipped
with a rotation interlock system. This system allows the
turntable to be rotated only to the side of the vehicle that
has the horizontal outrigger legs extended.
Components of this system include electromagnets, reed
switches and an electrical control module. The electro-
magnets and reed switches are used to sense the posi-
tion of the turntable as it is rotated. The control module
receives input from the reed switches and disrupts the
electrical power to the appropriate rotation pilot valve on
the boom functions valve.
Mercury Switch Proximity Switch Tilt Switch
When a horizontal outrigger leg is retracted, the correspond-
ing limit switch is closed providing a path for current fow.
Current fow energizes the electromagnets for that side
of the vehicle. As the turntable is rotated toward the side
of the vehicle with the retracted horizontal outrigger leg,
a reed switch will pass over one of the energized electro-
magnets. At that point, the contacts in the reed switch are
closed, sending electrical current to the control module.
A relay in the control module then opens the electrical
circuit for the rotation function in that direction.
Lower Control Panel
The lower control panel is used to operate all unit func-
tions except the outriggers and lower tool circuit. As
shown in Figure 7.8, hand controls, switches, gauges,
and panel lights are mounted in the top cover of the
control panel.
Dual Lower Control Panels
On units with dual lower control panels, one control panel
is the master panel and the other is the slave panel. The
master panel on a behind cab mounted unit is normally
located to the right as viewed from the tailshelf of the
chassis.
Hand Controls
The control panel is equipped with a hand control (refer
to Figure 7.9) for each proportional function.
When the interlock on a hand control knob is lifted and the
hand control is moved just out of neutral, a microswitch
is activated. The microswitch sends electrical power
to close the interlock relays and energize the derrick
blocking valve solenoid. This causes the derrick block-
ing valve to open, directing the fow of the pump to the
lower control valve.
Figure 7.9 Hand Control
As the hand control is moved farther out of neutral, it sends
an electrical signal to the pulsar for the function being
operated which varies in proportion to the distance the
hand control is moved. Based on this signal, the pulsar
controls how far the control valve spool shifts, thus caus-
ing the function speed to be proportional to the position
of the hand control.
Figure 7.8 Lower Control Panel
Interlock
Microswitch
Joysticks
The joysticks (refer to Figure 7.10) allow two or four
functions to be operated from one control. They are avail-
able on the lower control panel for the boom, rotation,
intermediate, and upper boom functions. The winch and
digger functions on the control panel are operated by a
separate joystick control.
Figure 7.10 Joysticks
The joystick is spring centered, but it is not locked in the
centered (neutral) position. However, there is an interlock
trigger on the control (refer to Figure 7.10). This trigger
must be engaged to close the interlock relays and ener-
gize the derrick blocking valve solenoid before moving
the joystick. This causes the derrick blocking valve to
open, directing the fow of the pump to the lower control
valve. Function movement will not occur unless the derrick
blocking valve is open. Therefore, the interlock trigger
prevents accidental function movement due to bumping
of the joystick.
As the joystick is moved out of neutral, it sends an elec-
trical signal to the pulsar for the function being operated
which varies in proportion to the distance the joystick is
moved. Based on this signal, the pulsar controls how far
the control valve spool shifts, thus causing the function
speed to be proportional to the position of the joystick.
Slip Ring
This unit uses an electrical slip ring assembly to transmit
electrical signals between the pedestal and the turntable.
It protects the electrical wiring that passes through the
centerline of rotation (refer to Figure 7.11).
The slip ring is attached to the hydraulic rotary joint. Other
than changing or cleaning the brush and arm assemblies,
do not attempt to repair the slip ring in the feld. If the slip
ring malfunctions, it should be removed and returned to
Altec for repair.
Figure 7.11 Slip Ring
Removal
2. Disconnect the electrical connections from the slip
ring that are routed to the above rotation valve driver.
Disconnect the electrical connections from the below
rotation valve driver routed through the rotary joint.
Disconnect the ground wire from the ground block.
3. Remove the three cap screws that connect the slip
ring to the rotary joint. Remove the slip ring.
Installation
1. Position the slip ring inside the turntable and route
the cable through the rotary joint. Position the slip
ring on top of the rotary joint.
2. Insert a cap screw through a tab on the rotary joint
and through a spacer tube into the slip ring. Repeat
this step for the other two cap screws and spacers
that mount the slip ring to the rotary joint.
3. Connect the electrical connectors in the pedestal to
the below rotation valve driver.
4. Connect the electrical connectors to the above rotation
valve driver. Connect the ground wire to the ground
block.
Interlock
Trigger
Slip Ring
Rotary Joint
Cap Screws
Figure 7.12 Upper Control Panel
Upper Controls
Upper controls at the boom tip (refer to Figure 7.12)
give the operator full proportional control of the boom,
extension, rotation, and winch functions. There is an up-
per controls on/off selector and a tools on/off and start/
stop control.
The control handles on the upper control panel are
connected to long fberglass rods. The fberglass rods
actuate electrical potentiometers and switches inside
the fberglass upper control tube. They are several feet
away from the control panel. This design maintains the
electrical isolation of the upper control panel.
The electrical circuits for the boom, extension, rotation,
and winch functions are proportional circuits. The electri-
cal circuits for the upper controls on/off, start/stop, and
the tools functions are on/off circuits.
When the controls selector switch on the lower control
panel is in the upper position, the upper control circuit
is energized.
Operation
The multiple lever upper control panel is turned on by
pushing the upper controls on/off selector knob sideways
in the direction shown on the top of the knob until it
latches in the on position. This actuates the upper control.
The upper control on/off selector handle is turned off by
pushing down on the top of the red upper controls on/off
selector knob until it releases and returns to the off posi-
tion. This cuts off electrical power to the upper controls.
The four boom function control handles on the panel will
not respond to movement when the upper controls are
turned off. The tools function at the upper control panel
is not operational when the upper controls are turned off.
When the unit is operated from the upper controls, the
functions operate at the low speed setting, approximately
half of the standard speed setting.
A single extension control handle operates intermediate
and upper boom extension and retraction in a sequential
manner. In the extend direction, the upper boom will extend
fully before the intermediate boom begins to extend. In the
retract direction, the intermediate boom will retract fully
before the upper boom begins to retract. There are two
proximity switches in the sequential extension system. A
switch mounted in the upper controls hose carrier tube
senses when the upper boom reaches the fully extended
position. A switch mounted on the side of the lower boom
at the lower end senses when the intermediate boom
reaches the fully retracted position.
When a function control handle is moved just out of neu-
tral, a microswitch is activated. The microswitch sends
electrical power to close the interlock relays and open the
derrick blocking valve, directing the fow of the pump to
the lower control valve. Power is also sent to the engine
throttle circuit to increase the engine speed.
As the control handle is moved further out of neutral, a
potentiometer inside the upper control tube is actuated
to send an electrical signal to the pulsar for the function
being operated. The electrical signal varies in proportion
to the distance the control handle is moved. Based on this
signal, the pulsar controls how far the control valve spool
shifts, thus causing the function speed to be proportional
to the position of the control handle.
When the tools on/off control is pushed and released,
the tools switch in the upper control tube is momentarily
Slide Gate
closed, sending a signal to a latching circuit in the valve
driver. The tools circuit directs power to the derrick block-
ing valve solenoid and the upper tools valve solenoid.
The blocking valve opens and directs pump fow to the
auxiliary functions valve. The upper tools valve in the
auxiliary functions valve shifts and directs hydraulic fow
to the tools function.

When the tools on/off control is again pushed and re-
leased, the tools switch in the upper control tube is mo-
mentarily closed, sending a signal that deactivates the
latching circuit. The two solenoids listed previously are
deenergized. The derrick blocking valve closes, and the
upper tools valve in the auxiliary functions valve shifts to
neutral. The tool pressure and return lines are also con-
nected to tank. This prevents pressure from becoming
trapped in the tool hose and allows the tool to be easily
disconnected.
Pole Guide Interlock System
Units equipped with transferable fares and a pole guide
assembly are also equipped with a pole guide interlock
system. This system prevents damage to the pole guide,
boom tip, and upper boom. There are three electrical
switches in the pole guide interlock system. A mechani-
cal button switch senses when the transferable fares
retaining pin is installed in the position which pins the
transferable fares to the intermediate boom. A proximity
switch senses when the pole guide is tilted back into the
fully stowed position. A second proximity switch senses
when the upper boom is fully retracted.
The pole guide interlock system will not allow the upper
boom to extend when the transferable fares and pole
guide assembly is pinned to the intermediate boom unless
the pole guide is fully stowed. The pole guide interlock
system will also prevent the pole guide from tilting down
while the upper boom is extended. This prevents damage
to the pole guide, boom tip, and upper boom.
Section 8 Troubleshooting, Testing, and Adjustments 111
Section 8 Troubleshooting, Testing, and Adjustments
Troubleshooting Procedure
For troubleshooting procedures involving specifc operat-
ing symptoms, refer to the unit specifc Troubleshooting
Manual. This manual is included with all new digger
derricks or is available by calling 1-800-Go-Altec. If the
Troubleshooting Manual is unavailable, or does not cover
a specifc symptom, establish a troubleshooting proce-
dure to be followed. This procedure will provide a starting
point for determining the root cause of the malfunction
and increase troubleshooting accuracy. Consider using
the following procedure.
brake, and chock the wheels. Check the oil level in
the reservoir.
2. Engage the PTO, warm the hydraulic oil to operating
temperature, and properly set the outriggers.
3. Before testing each function through its full travel
capabilities, try small movements to be certain the
function is operating properly. Test each function for
full travel capabilities.
Warning
Death or serious injury can result from falling from
the platform. All platform occupants must properly
use an appropriate OSHA approved personal fall
protection system.
4. Operate the unit from the lower controls and then
the upper controls to identify the malfunction.
5. Use the Hydraulic System Schematic and Wiring Line
Diagrams in the Appendix to determine the fow path
required to operate the failed function. Make a list of
the components used to operate the failed function.
Cross off components used to operate other func-
tions that are operating properly. This should leave
only three or four items to check.
6. Check the easiest component frst. Verify the proper
operation of each component remaining on the list
until the bad component is found.
7. Use accurate test equipment to verify fow, pressure,
voltage, and current.
Once the symptom has been positively identifed, use
the Troubleshooting Chart in the Appendix for suggested
causes and corrective actions.
Hydraulic System
Hydraulic fuid pressure and fow are required to operate
the hydraulic system functions.
Pressure is the force applied on a given area. The amount
of pressure determines whether or not the actuator will
move. Movement occurs when suffcient pressure is
applied to the movable component of an actuator. If an
actuator does not move, the cause may be insuffcient
pressure.
Flow is a measure of the amount of fuid displaced dur-
ing a specifed amount of time. The fow rate determines
the speed of actuator movement. The more fuid that is
displaced, the faster the actuator will move. If an actuator
moves slowly, the cause may be low fow.
Cycle Times
Figure 8.1 shows average cycle times in seconds (refer
to Boom Functions Speeds in this section for the testing
procedure).
The Hydraulic System Schematic (refer to the Appendix)
identifes the paths of oil fow in the system. It also identi-
fes the operation of every hydraulic component. A thor-
ough understanding of JIC symbols and their meanings
is helpful in troubleshooting (refer to Basic JIC Symbols
in the Appendix).
Function D2045B D2050B D2055B D3050B D3055B D3060B
Boom raise 28 to 32 28 to 32 28 to 32 33 to 39 33 to 39 33 to 39
Boom lower 28 to 32 28 to 32 28 to 32 33 to 39 33 to 39 33 to 39
Intermediate boom extend 20 to 23 23 to 27 28 to 32 23 to 27 28 to 32 30 to 34
Intermediate boom retract 17 to 21 20 to 24 24 to 28 20 to 24 24 to 28 26 to 30
Upper boom extend 18 to 22 21 to 25 21 to 25 21 to 25 21 to 25 28 to 34
Upper boom retract 16 to 20 19 to 23 19 to 23 19 to 23 19 to 23 26 to 31
Rotate left or right (360) 58 to 64 58 to 64 58 to 64 58 to 64 58 to 64 58 to 64
Figure 8.1 Average Cycle Times (Seconds)
112 Section 8 Troubleshooting, Testing, and Adjustments
Use an accurately calibrated gauge to test the pressure
of a particular circuit. A calibrated gauge will provide an
accurate reading, which is essential for proper hydraulic
adjustments.
Before testing or adjusting unit functions, position the
unit on a level surface, apply the parking brake, and
chock the wheels.
Pilot System Pressure
When the derrick blocking valve is open, a constant, con-
trolled fow of oil is sent to the pilot system. Pilot pressure
is maintained by an adjustable reducing valve cartridge
in the lower control valve (refer to Figure 8.2).
The pilot system pressure is 160 psi (11.03 bar) nomi-
nal, with an acceptable range of 150 to 170 psi (10.3 to
11.7 bar). If the pilot pressure is too low, the spools may
not reach full stroke. If the pilot pressure is too high, all
functions may exhibit a loss of metering. Pilot pressure
should not need to be adjusted. If it is adjusted, control
of the fow from all functions could be affected.
Testing
2. Remove the turntable cover from the right side of
the turntable (as viewed from the boom tip looking
toward the turntable). Install an accurate 0 to 600 psi
(0 to 41 bar) pressure gauge to the pilot pressure
quick disconnect on the lower control valve (refer to
Figure 8.2).
3. Start the engine, engage the PTO, and move the
outriggers and tools/derrick control to the Derrick
position. With the engine running at idle, move the
hand control of a function out of neutral to energize
the pilot system.
4. The pressure gauge should indicate between 150
and 170 psi (10.3 and 11.7 bar). If the pilot pressure
is above or below this range, adjust the pressure.
5. Disengage the PTO and turn off the engine. Discon-
nect the pressure gauge and replace the turntable
cover.
Adjustment
1. Remove the cap and loosen the jam nut on the pilot
pressure reducing cartridge on the lower control valve
(refer to Figure 8.2). Turn the adjusting screw clock-
wise to increase the pressure or counterclockwise
to decrease the pressure. Hold the adjusting screw
to keep it from turning and tighten the jam nut.
2. Test the pressure.
3. Repeat the adjustment until the gauge indicates
between 150 and 170 psi (10.3 and 11.7 bar).
4. Replace the cap on the pilot pressure reducing car-
tridge. Disengage the PTO and turn off the engine.
Disconnect the pressure gauge and replace the
turntable cover.
System Pressure
Quick Disconnect
Load Sense
Quick Disconnect
Pilot Pressure
Quick Disconnect
Pilot Pressure
Reducing Cartridge
Standby Pressure
The pump standby pressure is 400 psi (27.58 bar) nomi-
nal, with an acceptable range of 380 to 400 psi (26.2 to
27.58 bar). The load sensing valve in the compensator
housing of the hydraulic pump controls the standby pres-
sure. Operation of the load sensing valve for the standby
pressure function is similar to a direct-acting relief valve.
When the pump output exceeds the spring tension of the
valve, a spool is shifted to direct this pressure to stop
pump fow.
Testing
To test standby pressure, make sure all functions are
turned off so that no signals are being sent to the
pump.
1. Position the unit on a level surface. Apply the parking
brake and chock the wheels. Disengage the PTO
2. Remove the access covers from the pedestal. Install
a pressure gauge [1,000 psi (68.95 bar) minimum]
on the system pressure quick disconnect in the PG
port on the selector valve (refer to Figure 8.3).
3. Move the outriggers and tools/derrick switch to the
Derrick position. Failure to do so may result in dam-
age to the pressure gauge.
4. Start the engine and engage the PTO.
5. With the engine running at idle and all functions turned
off, the pressure gauge should indicate 380 to 400
psi (26.2 to 27.58 bar). If the pressure is above or
below this range, adjust the standby pressure.
6. If the pressure is correct, disengage the PTO, turn
off the vehicle engine, and disconnect the pressure
gauge.
Adjustment
1. Disengage the PTO and turn off the vehicle en-
gine.
2. Loosen the jam nut on the standby pressure adjust-
ing screw on the pump (refer to Figure 8.4). Turn the
adjusting screw clockwise to increase the pressure
or clockwise to decrease the pressure. Use small
adjustment increments. Hold the adjusting screw to
keep it from turning and tighten the jam nut.
Figure 8.4 Pump
4. Repeat the adjustment until the pressure gauge
indicates between 380 and 400 psi (26.2 and 27.58
bar).
5. Disengage the PTO, turn off the engine, and discon-
nect the pressure gauge.
System/Compensator Pressure
The system pressure for the boom, digger, and winch
functions is set at 3,000 psi (206.84 bar) at full fow. The
System Pressure Quick
Disconnect (PG)
Toward
Pedestal
Side Plate
Toward Pedestal
Side Plate
Secondary System
Relief Valve
Cartridge (RV1)
Outrigger Pressure Reducing
Valve Cartridge (ORP)
Tool Pressure
Reducing Valve
Cartridge (TP)
Compensator Pressure
Adjustment
Standby Pressure
Adjustment
system pressure is controlled by the compensator spring in
the pressure compensator valve housing on the hydraulic
pump. When the pump output pressure reaches 3,000
psi (206.84 bar), it overcomes the compensator spring
tension and moves the compensator spool. Pressure is
then directed to the stroking piston to stop pump fow or
control fow at the level necessary to maintain a pressure
of 3,000 psi (206.84 bar).
Testing
brake and chock the wheels. Engage the PTO and
2. Disengage the PTO and turn off the engine.
outriggers and tools/derrick switch to the Derrick
position.
5. Check the standby pressure as described under
Standby Pressure in this section.
6. With the engine running at idle and the boom stowed,
move the upper or intermediate boom control to the
Retract position and hold it there while reading the
pressure.
7. The pressure gauge should indicate 3,000 psi (206.84
bar). If the pressure is above or below this value,
adjust the system pressure.
8. If the pressure is correct, stow the outriggers, disen-
gage the PTO, turn off the engine, and disconnect
the pressure gauge.
Adjustment
2. Loosen the jam nut on the compensator pressure
adjusting screw on the pump (refer to Figure 8.4).
Turn the adjusting screw clockwise to increase the
pressure or clockwise to decrease the pressure. Use
small adjustment increments. Hold the adjusting screw
to keep it from turning and tighten the jam nut.
3. Test the pressure. If the system pressure cannot be
increased by adjusting the compensator, the second-
ary system pressure relief valve may be set too low.
Refer to Secondary System Relief Pressure in this
section.
indicates 3,000 psi (206.84 bar).
5. Stow the outriggers, disengage the PTO, turn off the
engine, and disconnect the pressure gauge.
Secondary System Relief Pressure
The secondary system relief valve cartridge, marked RV1,
is located in the selector valve in the pedestal.
Notice
To prevent excessive heat generation, the secondary
system relief pressure must be properly set higher
than the compensator pressure setting.
The secondary system relief valve cartridge is set to open
at 3,300 psi (227.5 bar). It prevents the hydraulic system
from building up excessive pressure if the compensator
in the piston pump malfunctions and fails to limit the
maximum system pressure to 3,000 psi (206.84 bar).
Testing
brake and chock the wheels. Engage the PTO and
4. Following the testing and adjustment procedures
described under System/Compensator Pressure in
this section, gradually increase the system pressure
until further adjustment causes no further increase
in the pressure gauge reading.
5. The system pressure is now being relieved by the
secondary system relief valve cartridge in the selector
valve.
adjust the secondary system pressure.
7. If the correct pressure is obtained, readjust com-
pensator pressure to 3,000 psi (206.84 bar) (refer
to System/Compensator Pressure in this section).
Adjustment
1. Loosen the jam nut on the secondary system relief
valve cartridge (RV1) in the selector valve (refer
to Figure 8.3). Turn the adjusting screw clockwise
to increase the pressure or counterclockwise to
decrease the pressure. Hold the adjusting screw to
keep it from turning and tighten the jam nut.
4. Adjust the system pressure to 3,000 psi (206.84
bar) (refer to System/Compensator Pressure in this
section).
Outrigger System Pressure
The outrigger system pressure is 2,500 psi (172.37 bar).
The outrigger system pressure is controlled by the pres-
sure reducing valve cartridge marked ORP located in the
selector valve in the pedestal. This pressure reducing
valve sends a controlled pressure signal to the pump
sense circuit when the outriggers and tools/derrick switch
is in the Outriggers and Tools position and an outrigger
motion alarm is activated.
Testing
1. Proper standby pressure must be verifed before
checking Outrigger System Pressure. Refer to
Standby Pressure in this section.
outriggers and tools/derrick switch to the Outriggers
and Tools position.
5. With the outriggers fully stowed, move an outrigger
control to the Retract position and hold it there while
reading the pressure.
adjust the outrigger system pressure.
off the engine, and disconnect the pressure gauge.
Adjustment
1. Loosen the jam nut on the outrigger pressure reduc-
ing valve cartridge (ORP) in the selector valve (refer
to Figure 8.3). Turn the adjusting screw clockwise to
increase pressure or counterclockwise to decrease
pressure. Hold the adjusting screw to keep it from
turning and tighten the jam nut.
4. Disengage the PTO, turn off the engine, and discon-
nect the pressure gauge.
Lower Tools System Pressure
The lower tools system pressure may vary based on
customer requirements. Unless otherwise specifed, the
factory setting for lower tool system pressure is 2,000
psi (137.89 bar). It is controlled by the pressure reducing
valve cartridge marked TP located in the selector valve
in the pedestal. This pressure reducing valve sends a
controlled pressure signal to the pump sense circuit
when the outriggers and tools/derrick switch is in the
Outriggers and Tools position and the outrigger motion
alarm is off.
Testing
1. Proper standby pressure must be verifed before
checking lower tool system pressure. Refer to Standby
Pressure in this section.
and Tools position.
bar) or the customer specifed lower tools system
pressure. If the pressure is above or below the desired
value, adjust the lower tools system pressure.
Adjustment
1. Loosen the jam nut on the tools pressure reducing
valve cartridge (TP) in the selector valve (refer to
Figure 8.3). Turn the adjusting screw clockwise to
increase pressure or counterclockwise to decrease
pressure. Hold the adjusting screw to keep it from
turning and tighten the jam nut.
3. Repeat the adjustment until the gauge indicates 2,000
psi (137.9 bar) or the customer specifed lower tools
system pressure.
Pump Flow
A slow down in unit movement may indicate a worn or
defective pump. If a worn or defective pump is suspected,
perform the following procedure to determine if full fow
can be generated.
Warning
hydraulic pressure before loosening or disconnect-
ing hydraulic components.
Spilled hydraulic oil creates slick surfaces and may
work areas clean.
Testing
brake, and chock the wheels.
2. Disengage the hydraulic system and turn off the
engine.
3. Disconnect the pump pressure line from the pump. If
multiple pumps are used, test only one pump section
at a time.
Warning
Death or serious injury will result from contact with
rotating components in the pump driveline. Keep
hands and clothing clear of the pump driveline.
4. Connect the inlet of the fowmeter (refer to Figure 8.5)
to the pump using a long section of hydraulic hose.
The hose diameter must be the same size or larger
than the hose used on the unit and long enough to
Figure 8.5 Pump Flow Test Connections
Fixed Displacement Pump Variable Displacement Pump
allow reading the fowmeter without possible contact
with the pump driveline.
5. If the pump is equipped with a compensator, con-
nect the pump sense line to the pump pressure line
entering the fowmeter (refer to variable displacement
pump in Figure 8.5).
6. Connect the outlet of the fowmeter to a reservoir
return line. Fully open any shutoff valves on the
fowmeter.
Warning
Death or serious injury can result from pump or hy-
draulic system failure. Do not perform this procedure
without a pressure relief installed.
7. Install a pressure relief to bypass the pump fow
around the fowmeter and shutoff valve. Refer to
Figure 8.5 for relief placement. The relief should
be set no more than 200 psi (13.8 bar) above the
required unit system pressure. System pressure is
stamped on the unit serial number placard. Cap and
plug any open connections.
8. Start the vehicle engine and engage the hydraulic
system.
Notice
If the pump is equipped with a compensator, test full
fow at 500 psi (34.5 bar) below the pressure listed
in the following step.
9. The fowmeter will indicate the fow from the pump.
Increase the load on the pump by slowly closing
the load inducing shutoff valve. Do not exceed the
unit system pressure as indicated on the unit serial
number placard. At full throttle, the fowmeter should
indicate approximately 43 gpm (162.8 lpm) at 3,000
psi (172.37 bar). Flow at idle will vary based on the
PTO ratio. If the maximum pump fow is less than
specifed, the pump may be defective or worn, or
the full throttle engine speed may be set too low. If
the maximum pump fow is greater than specifed,
the full throttle engine speed is set too high. Con-
frm the proper engine speed based on the original
specifcations for the unit, and make any necessary
adjustments. If the maximum pump fow is still less
than specifed, repair or replace the pump.
10. If the pump fow is correct, disengage the hydraulic
system and turn off the engine.
11. Open the load inducing shutoff valve. Remove the
fowmeter, temporary lines, and fttings. Reconnect
the unit lines to their original positions.
Outriggers
Outrigger cylinders and holding valves must operate
properly to assure unit stability. Any leak must be cor-
rected before placing the unit in service.
Warning
components.
work areas clean.
Use the appropriate test to determine the cause of out-
rigger drift.
Drift Up
If an outrigger drifts up several inches when it is loaded,
the holding valve in the extend circuit may be leaking. If
the outrigger drifts up a little and stops, there may be an
internal leak in the piston seal.
Testing Internal Cylinder Leakage
A liquid container is required to perform this test.
brake, chock the wheels, and engage the PTO.
2. Retract the cylinder completely. Disengage the PTO
3. Shift the outrigger control handle in both directions
several times to relieve any pressure in the hoses.
4. Disconnect the outrigger cylinder hose from the ex-
tend port of the outrigger control valve. Allow the oil
remaining in the hose to drain into a container. Cap
the ftting at the valve.
5. Hold the open end of the hose over a container and
engage the PTO. Shift the outrigger control handle
to the Raise position.
6. If a heavy stream of oil drains from the hose with the
control handle in the Raise position, the cylinder is
leaking internally. Reconnect the hose to the outrig-
ger control valve. Repair or replace the cylinder.
Testing Piston Seal and Check Valve
A vehicle jack, a liquid container, and the ability to let the
unit sit overnight is required to perform this test.
brake, chock the wheels, and engage the PTO.

2. Extend the outrigger cylinder completely. Disengage
the PTO and turn off the engine.
3. Raise the vehicle with a jack so the outrigger does
not carry its own weight.
5. Disconnect the retract hose from the control valve
and place the hose in a liquid container. Disconnect
the extend hose from the valve and place the hose
in another liquid container.
6. Let the jack down so the outrigger carries its own
weight. Let the unit sit overnight.
a. If the extend hose container has oil in it, the hold-
ing valve is defective.
b. If the cylinder moved a few inches and stopped,
the cylinder piston seal is leaking.
c. If the cylinder retracts all the way in and there
is oil in the retract hose container, the cylinder
piston seal is leaking and the holding valve is
defective.
7. The holding valve port marked V1 controls cylinder
extension and the port marked V2 controls cylinder
retraction. Both ports are located in the valve hous-
ing. This housing is on the base end of the outrigger
cylinder (refer to Figure 8.6). Replace the appropriate
valve cartridge as described under Holding Valves
in this section and repeat the test.
Drift Down
If the outrigger drifts down from the raised position over-
night or over the weekend, the cylinder may be leaking
internally or the holding valve in the retract circuit may
be leaking.
Testing Internal Cylinder Leakage and Check Valve
A vehicle jack, a liquid container, and the ability to let the
unit sit overnight are required to perform this test.
1. Place a jack under the outrigger shoe to support
the outrigger. Disengage the PTO and turn off the
engine.
3. Disconnect the retract hose from the control valve
and place the hose in a liquid container. Remove the
jack and let the unit sit overnight.
a. If the outrigger extended and there is liquid in
the container, the retract holding valve is leaking.
Place a jack under the outrigger shoe to support
the outrigger. Replace the holding valve in the V2
port of the valve housing (refer to Holding Valves
in this section).
b. If the outrigger extended but there is no liquid in
the container, the cylinder is leaking internally.
Replace or repair the cylinder.
Lower Tool Circuit
Flow
The output fow of the lower tool circuit, factory set at
8 gpm (30.28 lpm) is controlled by an adjustable fow
divider valve located in the pressure line of the tools
pressure outlet.
Testing
2. Connect a fowmeter to the lower tool circuit.
3. Start the engine, engage the PTO, and move the tool
control handle to the full detented On position.
4. The fowmeter should indicate approximately 8 gpm
(30.28 lpm).
Warning
components.
Figure 8.6 Outriggers
Holding Valve
Modifed A-Frame
Rod End
Holding Valve
Base End
Base End
Holding Valve
Rod End
A-Frame
Rod End
Holding Valve
Base End
Out and Down
Radial
Rod End
Base End
Holding Valve
X-Frame
Rod End
Base End
Holding Valve
work areas clean.
Upper Tool Circuit
Pressure
The output pressure of the upper tool circuit is adjustable
to accommodate hydraulic tools with various pressure
requirements. Pressure is adjustable from 500 to 2,000
psi (34.47 to 137.90 bar). The upper tools circuit pressure
is factory set at 2,000 psi (137.90 bar). The output fow
of the upper tool circuit is adjustable from 0 to 8 gpm (0
to 30.28 lpm) and is factory set at 8 gpm (30.28 lpm).
Testing
properly set the outriggers. Position the boom so the
boom tip is accessible. Move the controls switch on
the lower control panel to the Upper position.
2. Connect a 3,000 psi (206.84 bar) minimum pressure
gauge to the upper tools quick disconnect coupler
pressure connection.
3. Turn on the upper tools.
bar).
5. If necessary, adjust the upper tool circuit pressure to
operate tools that require a pressure setting below
2,000 psi (137.90 bar).
Adjustment
1. Locate the auxiliary functions valve mounted on the
left side of the lower boom (when standing at the
boom tip, looking toward the turntable).
2. The pressure reducing valve cartridge controls the
pressure of the upper tool circuit (refer to Figure
8.7).
Warning
Death or serious injury can result from hydraulic oil
being injected into the fesh if the tool hoses burst
or the tool ruptures. Do not adjust the pressure of
the tool circuit above the hydraulic power tools
manufacturers rating for the tool.
work areas clean.
3. Loosen the jam nut.
4. Turn the adjusting screw clockwise to increase the
output pressure of the tools circuit. Turn the adjust-
ing screw counterclockwise to decrease the output
pressure of the tools circuit. Make the proper adjust-
ment.
5. After making the proper adjustment, tighten the jam
nut.
6. Test the output pressure again.
Flow
The upper tool circuit fow is adjustable to accommodate
tools with various fow requirements. Flow is adjustable
from 0 to 8 gpm (0 to 30.28 lpm). The upper tool circuit
fow is factory set at 8 gpm (30.28 lpm).
Testing
properly set the outriggers. Move the boom so that
the boom tip is accessible. Move the controls switch
on the lower control panel to the Upper position.
2. Connect a fowmeter to the upper tool quick discon-
nect couplers.
3. Turn on the upper tools.
4. Note the reading on the fowmeter.
Adjustment
1. Locate the auxiliary functions valve mounted on the
left side of the boom (when standing at the boom tip,
looking toward the turntable). Figure 8.7 illustrates
the cartridge that controls the fow in the upper tool
circuit.
2. Loosen the jam nut.
Upper Tool
Circuit Flow
Upper Tool Circuit Pressure
fow of the tool circuit. Turn the adjusting screw coun-
terclockwise to decrease the fow of the tool circuit.
4. After making the proper adjustment, tighten the jam
nut.
5. Test the output pressure again.
Derrick Blocking Valve (DS1)
Whenever the PTO is engaged, the outriggers are properly
set, the outriggers and tools/derrick switch is in the Derrick
position, and a function is operated at the lower, upper,
or radio controls, the derrick blocking valve should be
energized, opening the valve to direct hydraulic oil fow
to the lower control valve. In addition, if the outriggers
and tools/derrick selector switch is in the Outriggers and
Tools position and the derrick winch control is operated,
the derrick blocking valve should be energized, allow-
ing winch operation at the same time as lower tools. If
none of the derrick functions will operate, the problem
may be that the derrick blocking valve will not open. A
defective component in the electrical system can prevent
the derrick blocking valve from being energized. Also, if
the solenoid valve cartridge or coil is defective, the valve
will not open.
The following procedure will determine if the defective
component is in the electrical system or if the derrick
blocking valve is defective.
1. With the ignition switch on and the PTO engaged, if
the lower control panel lights are dead, the problem
may be a tripped circuit breaker (refer to Circuit
Protection in this section). If the lower control panel
lights are on, proceed to step 2.
2. Remove the access covers from the pedestal. Locate
the derrick blocking valve (DS1) in the selector valve
mounted inside the pedestal (refer to Figure 8.8).
3. With the PTO engaged and the ignition switch on
but the engine not running, shift and hold a hand
control out of neutral on the lower control panel or
place the digger speed switch in the High position.
Check whether the DS1 solenoid is energized by
touching the stem inside the nut on the end of the
solenoid with a steel tool such as a screwdriver blade
or feeler gauge. If the tool is magnetically attracted to
the stem, this confrms that the solenoid is receiving
12 volts and becoming energized. Proceed to step 4.
If the tool is not magnetically attracted, the solenoid
is not receiving 12 volts or is defective. Proceed to
step 5.
4. Failure of the derrick blocking valve to open when the
solenoid is energized indicates that the valve cartridge
is most likely contaminated or defective. Remove
the locking spacer on the DS1 valve cartridge, if so
equipped. Remove the DS1 valve cartridge from
the selector valve. Inspect and clean the cartridge.
Install the cartridge. Install the locking spacer if so
equipped. Start the engine, engage the PTO, and
operate a boom function to check whether proper
derrick blocking valve operation has been restored.
If the blocking valve still does not open when the
solenoid is energized, turn off the engine and replace
the derrick blocking valve cartridge assembly. If the
boom needs to be stowed for transport to a service
facility to replace the cartridge, refer to Bypassing
Derrick Blocking Valve in this section. Then stow the
outriggers, and take the unit out of service until the
problem is corrected.
Derrick Blocking Valve Cartridge
and Solenoid (DS1)
Toward
Pedestal
Side Plate
(DS4)
Outrigger/Tool Blocking
Valve Cartridge and
Solenoid (DS2)
Locking Spacer
(If Equipped)
Outrigger/Tool Pressure Selector
Valve Cartridge and Solenoid (DS3)
Outrigger/Tool Flow Control
Valve Cartridge (FC1), Orifce
Located Under Cartridge
System Pressure Quick
Disconnect (PG)
5. Unplug the electrical harness connector from the
DS1 solenoid on the selector valve. Shift and hold a
hand control out of neutral on the lower control panel
or place the digger speed switch in the High posi-
tion. Check for 12 volts between the two pins of the
DS1 connector. If 12 volts is found at the connector,
proceed to step 6. If 12 volts is not found, proceed
to step 7.
6. Failure of the DS1 solenoid to energize when receiving
12 volts indicates that the solenoid coil is defective
(refer to Open Circuit under Electrical System in this
section). Replace the derrick blocking valve solenoid
or the entire valve cartridge assembly. If the boom
needs to be stowed for transport to a service facility
to do this, remove the solenoid from the DS1 car-
tridge. Unplug the connector from the DS2 solenoid,
remove the solenoid from the DS2 cartridge, install
it on the DS1 cartridge, and plug the DS1 connec-
tor into the solenoid (refer to Figure 8.8). Start the
engine, engage the PTO, stow the booms, and turn
off the engine. Return the DS1 and DS2 solenoids
to their original positions and plug the DS1 and DS2
connectors back into the DS1 and DS2 solenoids.
Stow the outriggers, and take the unit out of service
until the problem is corrected.
7. No power at the DS1 connector when a function
is operated at the lower, upper, or radio controls
indicates that the defective component is in the
electrical system. The outrigger interlock switches
may be a possible cause. Outrigger Interlock System
in this section describes how to troubleshoot these
switches. Determine the cause of the problem and
correct it. If the issue with the electrical system can-
not be resolved and the boom needs to be stowed
for transport to a service facility, proceed to step 8.
8. Unplug the electrical harness connectors from the
DS1, DS2, and DS4 solenoids on the selector valve
(refer to Figure 8.8). Plug the connector from the DS4
solenoid into the DS1 solenoid. Move the outriggers
and tools/derrick switch to the Outriggers and Tools
position. Start the engine, engage the PTO, and slowly
attempt to operate a function. If the function operates,
the derrick blocking valve is now open. Slowly and
cautiously stow the boom, and turn off the engine.
Unplug the DS4 connector from the DS1 solenoid,
and plug the DS1, DS2, and DS4 connectors back
into the DS1, DS2, and DS4 solenoids. Stow the
outriggers, and take the unit out of service until the
Outrigger/Tool Blocking Valve (DS2)
Whenever the outriggers and tools/derrick switch is in the
Outriggers and Tools position, the outrigger/tool blocking
valve should be energized, opening the valve to direct
hydraulic fow to the outrigger and tool valves. If the out-
riggers and lower tools will not operate, the problem may
be that the outrigger/tool blocking valve will not open. A
defective component in the electrical system can prevent
the outrigger/tool blocking valve from being energized.
Also, if the solenoid valve cartridge or coil is defective,
the valve will not open. The problem may also be that
the outrigger/tool sense dump valve will not close (refer
to Outrigger/Tool Sense Dump Valve in this section) or
that the orifce in the selector valve is clogged (refer to
Selector Valve Orifce in this section).
component is in the electrical system or if the outrigger/
tool blocking valve is defective.
1. With the ignition switch on and the PTO engaged, if
the lower control panel lights are dead, the problem
may be a tripped circuit breaker (refer to Circuit
Protection in this section). If the lower control panel
lights are on, proceed to step 2.
2. Stow the booms and turn off the engine. Move the
and Tools position.
port on the selector valve which is mounted inside
the pedestal (refer to Figure 8.8).
4. Start the engine and engage the PTO. With no
functions operating, if the pressure gauge indicates
the proper lower tools system pressure, proceed to
step 5. If the pressure gauge indicates a pressure
somewhat above standby pressure but well below
the proper lower tools system pressure, and there is
a distinct hissing sound from oil fowing in the selec-
tor valve, there may be a problem with the outrigger/
tool sense dump valve (DS4) (refer to Outrigger/Tool
Sense Dump Valve in this section). If the pressure
gauge indicates standby pressure and there is no
sound of oil fowing in the selector valve, the selector
valve orifce may be clogged (refer to Selector Valve
Orifce in this section).
5. Turn off the engine and leave the ignition switch on.
Locate the outrigger/tool blocking valve (DS2) in the
selector valve (refer to Figure 8.8). Check whether
the DS2 solenoid is energized by touching the stem
inside the nut on the end of the solenoid with a steel
tool such as a screwdriver blade or feeler gauge. If
the tool is magnetically attracted to the stem, this
confrms that the solenoid is receiving 12 volts and
becoming energized. Proceed to step 6. If the tool is
not magnetically attracted, the solenoid is not receiv-
ing 12 volts or is defective. Proceed to step 7.
6. Failure of the outrigger/tool blocking valve to open
when the solenoid is energized indicates that the
valve cartridge is most likely contaminated or defec-
tive. Remove the locking spacer on the DS2 valve
cartridge, if so equipped. Remove the DS2 valve
cartridge from the selector valve. Inspect and clean
the cartridge. Install the cartridge. Install the locking
spacer if so equipped. Start the engine, engage the
PTO, and operate an outrigger function to check
whether proper outrigger/tool blocking valve opera-
tion has been restored. If the blocking valve still does
not open when the solenoid is energized, turn off
the engine and replace the outrigger/tool blocking
valve cartridge assembly. If the outriggers need to be
stowed for transport to a service facility to replace the
cartridge, refer to Bypassing Outrigger/Tool Blocking
Valve in this section. Then take the unit out of service
until the problem is corrected.
DS2 solenoid on the selector valve. Check for 12
volts between the two pins of the DS2 connector. If
12 volts is found at the connector, proceed to step
8. If 12 volts is not found, proceed to step 9.
section). Replace the outrigger/tool blocking valve
solenoid or the entire valve cartridge assembly. If
the outriggers need to be stowed for transport to a
service facility to do this, remove the solenoid from
the DS2 cartridge. Unplug the connector from the
DS1 solenoid, remove the solenoid from the DS1
cartridge, install it on the DS2 cartridge, and plug
the DS2 connector into the solenoid (refer to Figure
8.8). Start the engine, engage the PTO, stow the
outriggers, and turn off the engine. Return the DS1
and DS2 solenoids to their original positions and plug
the DS1 and DS2 connectors back into the DS1 and
DS2 solenoids. Take the unit out of service until the
9. No power at the DS2 connector indicates that the
defective component is in the electrical system.
Determine the cause of the problem and correct it.
If the issue cannot be resolved and the outriggers
need to be stowed for transport to a service facility,
proceed to step 10.
10. Turn off the ignition switch. Use jumper wires to con-
nect a 12 volt source and ground to the terminals of
the DS2 solenoid. Start the engine and engage the
PTO. Stow the outriggers and turn off the engine.
Remove the jumper wires. Plug the DS2 connec-
tor back into the DS2 solenoid. Take the unit out of
service until the problem is corrected.
Outrigger/Tool Sense Dump Valve (DS4)
Whenever the outriggers and tools/derrick switch is in the
Outriggers and Tools position, the outrigger/tool sense
dump valve should be energized, closing the valve allow
pressure to build for the outrigger and tool valves. If the
outriggers and lower tools will not operate, the system
pressure is somewhat above standby but well below the
lower tools system pressure, and there is a hissing sound
from oil fowing in the selector valve (refer to Outrigger/
Tool Blocking Valve in this section), the problem may be
that the outrigger/tool sense dump valve will not close.
This will allow oil to fow through this valve to tank, and
the outriggers and lower tools will not operate. A defec-
tive component in the electrical system can prevent the
outrigger/tool sense dump valve from being energized.
Also, if the solenoid valve cartridge or coil is defective,
the valve will not close.
tool sense dump valve is defective.
1. Stow the booms. Turn off the engine but leave the
PTO engaged and the ignition switch on. Move the
and Tools position.
the outrigger/tool sense dump valve (DS4) in the
selector valve which is mounted inside the pedestal
3. Check whether the DS4 solenoid is energized by
step 5.
4. Failure of the outrigger/tool sense dump valve to
close when the solenoid is energized indicates that
the valve cartridge is most likely contaminated or
defective. Remove the locking spacer on the DS4
valve cartridge, if so equipped. Remove the DS4 valve
whether proper outrigger/tool sense dump valve
operation has been restored. If the sense dump valve
still does not close when the solenoid is energized,
turn off the engine and replace the outrigger/tool
sense dump valve cartridge assembly. If the outriggers
need to be stowed for transport to a service facility to
replace the cartridge, refer to Bypassing Outrigger/
Tool Blocking Valve in this section. Then take the
unit out of service until the problem is corrected.
DS4 solenoid on the selector valve. Check for 12
volts between the two pins of the DS4 connector. If
12 volts is found at the connector, proceed to step
6. If 12 volts is not found, proceed to step 7.
section). Replace the outrigger/tool sense dump valve
solenoid or the entire valve cartridge assembly. If
the outriggers need to be stowed for transport to a
service facility to do this, remove the solenoid from
the DS4 cartridge. Unplug the connector from the
DS3 solenoid, remove the solenoid from the DS3
cartridge, install it on the DS4 cartridge, and plug
the DS4 connector into the solenoid (refer to Figure
8.8). Start the engine, engage the PTO, and stow the
outriggers. (Outrigger system pressure will be reduced
to the lower tools system pressure value.) Turn off the
engine. Return the DS3 and DS4 solenoids to their
original positions and plug the DS3 and DS4 connec-
tors back into the DS3 and DS4 solenoids. Take the
unit out of service until the problem is corrected.
7. No power at the DS4 connector indicates that the
defective component is in the electrical system.
Determine the cause of the problem and correct it.
If the issue cannot be resolved and the outriggers
need to be stowed for transport to a service facility,
proceed to step 8.
8. Turn off the ignition switch. Use jumper wires to con-
nect a 12 volt source and ground to the terminals of
the DS4 solenoid. Start the engine and engage the
PTO. Stow the outriggers and turn off the engine.
Remove the jumper wires. Plug the DS4 connec-
tor back into the DS4 solenoid. Take the unit out of
service until the problem is corrected.
Selector Valve Orifce
Whenever the outriggers and tools/derrick switch is in
the Outriggers and Tools position and pressure builds in
the outrigger/tool circuit, a sense signal is provided to the
pump. The sense signal must pass through the orifce in
the selector valve. If the outriggers and lower tools will
not operate, the system pressure remains at standby,
and there no sound of oil fowing in the selector valve
(refer to Outrigger/Tool Blocking Valve in this section), the
problem may be that this orifce is clogged, preventing
the sense signal from reaching the pump.
The following procedure describes how to remove and
clean the orifce.
1. Stow the booms, turn off the engine, and remove the
access covers from the pedestal. Locate the outrig-
ger/tool fow control cartridge (FC1) in the selector
valve in the pedestal (refer to Figure 8.8).
2. Remove the locking spacer on the FC1 valve cartridge,
if so equipped. Remove the FC1 valve cartridge from
the selector valve.
3. Use an Allen wrench to remove the orifce plug from
the bottom of the FC1 cavity in the selector valve.
4. Use a pick or wire to clean out the orifce hole in the
plug.
5. Install the orifce plug in the bottom of the FC1 cav-
ity.
6. Install the FC1 cartridge. Install the locking spacer
if so equipped.
Outrigger/Tool Pressure
Selector Valve (DS3)
Whenever one or more outrigger controls are being oper-
ated, the outrigger/tool pressure selector valve should be
energized, shifting to direct the sense signal through the
outrigger pressure reducing valve to produce the proper
2,500 psi (172.37 bar) outrigger system pressure. If the
system pressure remains at the lower tools pressure set-
ting when the outriggers are being operated, the problem
may be that the outrigger/tool pressure selector valve
will not shift. This will cause the outriggers to operate at
the lower tools system pressure. A defective component
in the electrical system can prevent the outrigger/tool
pressure selector valve from being energized. Also, if
the solenoid valve cartridge or coil is defective, the valve
will not shift.
tool pressure selector valve is defective.
1. Stow the booms. Turn off the engine but leave the
PTO engaged and the ignition switch on. Move the
and Tools position.
the outrigger/tool pressure selector valve (DS3) in the
selector valve which is mounted inside the pedestal
3. Shift and hold an outrigger control out of neutral.
Check whether the DS3 solenoid is energized by
step 5.
4. Failure of the outrigger/tool pressure selector valve
to close when the solenoid is energized indicates
that the valve cartridge is most likely contaminated
or defective. Remove the locking spacer on the DS3
valve cartridge, if so equipped. Remove the DS3 valve
whether proper outrigger/tool pressure selector valve
operation has been restored. If the pressure selector
valve still does not open when the solenoid is ener-
gized, turn off the engine and replace the outrigger/
tool pressure selector valve cartridge assembly.
DS3 solenoid on the selector valve. Shift and hold
an outrigger control out of neutral. Check for 12 volts
between the two pins of the DS3 connector. If 12
volts is found at the connector, proceed to step 6. If
12 volts is not found, proceed to step 7.
6. Failure of the DS3 solenoid to energize when receiv-
ing 12 volts indicates that the solenoid coil is defec-
tive (refer to Open Circuit under Electrical System
in this section). Replace the outrigger/tool pressure
selector valve solenoid or the entire valve cartridge
assembly.
7. No power at the DS3 connector when an outrigger
control is operated indicates that the defective com-
ponent is in the electrical system. The motion alarm
switches on the outrigger valves may be a possible
cause. Determine the cause of the problem and cor-
rect it.
Sense Lines and Sense Shuttle Valves
Several sense lines carry load sense signals from various
valves on the derrick to the pump, to signal the pump to
stroke up to meet hydraulic fow and pressure demands.
Shuttle valves are used in certain valve assemblies to route
the load sense signals from particular function(s) to the
sense line running to the pump. A blockage in one of the
sense lines or shuttle valves will cause certain functions
to be inoperable or operate very slowly. To troubleshoot
for possible sense line contamination, perform the steps
shown under procedure A, B, C, or D below, based on
which functions are malfunctioning.
Warning
work areas clean.
Procedure A
All functions above rotation and below rotation are inop-
erable or slow. Proper operation of the derrick blocking
valve (DS1) and the outrigger/tool blocking valve (DS2)
in the selector valve in the pedestal has been verifed,
along with proper adjustment of the pump system/com-
pensator pressure and standby pressure.
on the load sense pressure quick disconnect in the
LSG port on the selector valve in the pedestal (refer
to Figure 8.9).
position. Leave the boom stowed.
4. With the engine running at idle, move the upper or
intermediate boom control to the Retract position
and hold it there while reading the pressure.
bar). If the pressure is signifcantly below this value,
proceed to step 6. If the pressure is correct, the sense
circuit is working properly. Stop this procedure, and
continue troubleshooting for a different cause for the
issue.
6. If the pressure reading is low in step 5, the SV2
shuttle valve cartridge in the selector valve may be
contaminated (refer to Figure 8.9). Remove the SV2
cartridge from the selector valve and inspect it for
contamination.
7. Clean or replace the cartridge, and reinstall it in the
selector valve. Then repeat the pressure test proce-
dure.
Procedure B
All functions above rotation are inoperable or slow, and
all functions below rotation operate normally. Proper op-
eration of the derrick blocking valve (DS1) in the selector
valve in the pedestal has been verifed, along with proper
adjustment of the pump system/compensator pressure
and standby pressure.
to Figure 8.9).
3. Remove the cover from the right side of the turn-
table (as viewed from the boom tip looking toward
the turntable). Install a pressure gauge [4,000 psi
(275.80 bar) minimum] on the load sense pressure
quick disconnect in the LSG port on the lower control
valve in the turntable (refer to Figure 8.10).
intermediate boom control to the Retract position
and hold it there while reading the pressure on both
gauges.
6. Both pressure gauges should indicate 3,000 psi
(206.84 bar). If the pressure is signifcantly below
this value on both gauges, proceed to step 7. If the
pressure reading is correct at the lower control valve
but reads low on at the selector valve, proceed to
step 8. If the pressure is correct on both gauges, the
sense circuit is working properly. Stop this procedure,
and continue troubleshooting for a different cause for
the issue.
7. If the pressure reading is low on both gauges in step
6, there may be contamination in the sense circuit
within the lower control valve. Call Altec Technical
Support at 877-462-5832 (877-GO ALTEC) for further
assistance.
Shuttle Valve
Cartridge (SV2)
Load Sense Pressure
Quick Disconnect (LSG)
Shuttle Valve
Cartridge (SV1)
Toward Pedestal
Side Plate
Load Sense Pressure
Quick Disconnect (LSG)
8. If the pressure reading is correct on the lower control
valve gauge but low on the selector valve gauge in
step 6, the SV2 shuttle valve cartridge in the selec-
tor valve may be contaminated (refer to Figure 8.9).
Remove the SV2 cartridge from the selector valve
and inspect it for contamination.
9. Clean or replace the cartridge and reinstall it in the selec-
tor valve. Then repeat the pressure test procedure.
Procedure C
One or more of the functions that are controlled by the
auxiliary functions valve (pole guide, auger release, digger
shift, and upper tools) are inoperable, slow, or operating
at a reduced pressure, but all functions controlled by the
lower control valve operate normally, and all functions
below rotation operate normally. Proper operation of the
solenoid valves on the auxiliary functions valve on the
lower boom has been verifed. If the upper tools function
is operating at a reduced pressure, adjustment of the
pressure has been attempted as described under Upper
Tool Circuit in this section.
2. Remove the cover from the right side of the turn-
table (as viewed from the boom tip looking toward
the turntable). Install a pressure gauge [4,000 psi
(275.80 bar) minimum] on the load sense pressure
quick disconnect in the LSG port on the lower control
valve in the turntable (refer to Figure 8.10).
intermediate boom control to the Retract position and
hold it there while reading the pressure. The pressure
gauge should indicate 3,000 psi (206.84 bar).
5. Test the pressure as described below under step a,
b, or c.
a. If all the auxiliary functions valve functions are
malfunctioning, or if only the pole guide and auger
release functions are malfunctioning, operate pole
guide Close and hold it there while reading the
pressure. The pressure gauge should indicate
3,000 psi (206.84 bar).
b. If only the upper tools function is malfunctioning,
turn on the upper tools function while reading the
pressure. The pressure gauge should indicate
1,600 psi (110.32 bar) or 400 psi (27.58 bar) less
than the customer specifed upper tools system
pressure.
c. If only the digger shift function is malfunctioning,
place the digger shift switch in High while reading
the pressure. The pressure gauge should indicate
about 400 psi (27.58 bar).
6. If the pressure reading is correct in step 4 and the
pressure reading is signifcantly below the correct
value shown in step 5a, 5b, or 5c, proceed to step
7. If the pressures are correct in step 4 and in step
5a, 5b, or 5c, the sense circuit is working properly.
Stop this procedure, and continue troubleshooting
for a different cause for the issue.
7. If the pressure reading is correct in step 4 and is low
in step 5a, 5b, or 5c, the SV1 or SV2 shuttle valve
cartridge in the auxiliary functions valve may be
contaminated (refer to Figure 8.11). Remove both
cartridges from the auxiliary functions valve and
inspect them for contamination.
8. Clean or replace the cartridges, and reinstall them in
the auxiliary functions valve. Then repeat the pres-
sure test procedure.
Shuttle Valve
Cartridge (SV2)
Shuttle Valve Cartridge (SV1)
Procedure D
The outrigger functions are inoperable or slow and/or
the lower tools function is inoperable or at reduced pres-
sure, but all functions above rotation operate normally.
Proper operation of the outrigger blocking valve (DS2),
the outrigger/tool selector valve (DS3), and the outrigger/
tool sense dump valve (DS4) in the selector valve in the
pedestal has been verifed. If the outrigger functions are
slow or operating at a reduced pressure, adjustment of
the pressure has been attempted as described under
Outrigger System Pressure in this section. If the lower
tools function is operating at a reduced pressure, adjust-
ment of the pressure has been attempted as described
under Lower Tools System Pressure in this section.
to Figure 8.9).
and Tools position.
4. With the engine running at idle, move an outrigger
control to the Retract position and hold it there while
reading the pressure. The pressure gauge should
indicate 2,100 psi (144.79 bar).
5. Move the lower tools control to the On position while
reading the pressure. The pressure gauge should
indicate 1,600 psi (110.32 bar) or 400 psi (27.58 bar)
less than the customer specifed lower tools system
pressure.
6. If the pressure reading is signifcantly low in either
step 4 or step 5 or both steps, proceed to step 7.
If the pressure reading is correct in both steps, the
sense circuit is working properly. Stop this procedure,
and continue troubleshooting for a different cause for
the issue.
7. If the pressure reading is low only in step 4 or only
in step 5, the SV1 shuttle valve cartridge in the se-
lector valve may be contaminated (refer to Figure
8.9). Remove the SV1 cartridge from the selector
valve and inspect it for contamination. If the pressure
reading is low in both steps 4 and 5, there may be
contamination in either the SV1 or SV2 shuttle valve
cartridge. Remove both cartridges from the selector
valve and inspect them for contamination.
8. Clean or replace the cartridge(s) and reinstall them
in the selector valve. Then repeat the pressure test
procedure.
If no functions above rotation will operate and the outrig-
gers are properly set, the problem may be that the derrick
blocking valve will not open or the outrigger interlock
switches are not working properly. The procedure for
checking the derrick blocking valve is described in this
section. If the outrigger interlock switches are properly
adjusted (refer to Electrical System in this section), it is pos-
sible that one of the switches is not working properly.
Rotary Joint
A leaking seal in the rotary joint can cause oil fowing to
any hydraulic circuit above rotation to be diverted directly
to the return line. This will cause functions to slow down
and/or fail to build pressure. A leaking seal in the rotary
joint can also cause pressure in the pressure circuit to
leak into the sense circuit. This will cause the pump to
stroke up to full system/compensator pressure whenever
the derrick blocking valve is open. The rotary joint can
be tested for internal leakage.
Testing
A liquid container is required to perform this test.
3. Remove the turntable covers and the pedestal cov-
ers.
4. In the turntable, disconnect the hydraulic lines listed
below from the indicated ports on the rotary joint
housing (refer to Figure 8.12) or from the associated
ports on the valves that these lines run to. Cap or
plug all open ports on the rotary joint and valves.
Plug all open hose ends.
Pressure line P1, return lines T1 and T2, and
sense line S1, running to the lower control valve
Pressure line P2 and return line T3, running to the
auxiliary functions valve
5. In the pedestal, disconnect the return line running
from the T port on the bottom of the rotary joint at
the T port on the selector valve. Cap the T port on
the selector valve, and allow the return line to drain
into a liquid container until no oil remains in the line.
Return Line
Port (T3)
Derrick Blocking Valve
Cartridge and Solenoid
(DS1)
Toward
Pedestal
Side Plate
Toward Pedestal
Side Plate
Unit Sense
Port (US)
Outrigger/Tool Blocking Valve
Cartridge and Solenoid (DS2)
(DS4)
Tank Port (T)
Pressure Line
Port (P1)
Sense Line
Port (S1)
Return Line
Port (T2)
Pressure Line
Port (P2)
Return Line
Port (T4)
Return Line
Port (T)
Return Line
Port (T1)
Pressure
Line Port (P)
Sense Line
Port (S)
Disconnect the sense line running from the S port
on the bottom of the rotary joint at the US port on
the selector valve. Cap the US port and allow the
sense line to drain into the liquid container until no
oil remains in the line.
6. Unplug the electrical harness connectors from the
DS1, DS2, and DS4 solenoids on the selector valve in
the pedestal (refer to Figure 8.13). Plug the connector
from the DS4 solenoid into the DS1 solenoid.
7. Start the engine and engage the PTO. Move the
and Tools position. This will pressurize the pressure
circuit in the rotary joint.
8. If oil starts to drain from the return line or from the
sense line into the liquid container, the seals in the
rotary joint are leaking. Disengage the PTO and turn
off the engine. Reseal or replace the rotary joint. After
the rotary joint has been resealed or replaced, return
the hose and electrical connections back to normal.
Proceed to step 10.
9. If no oil drains into the liquid container, disengage
the PTO and turn off the engine. Return the hose
and electrical connections back to normal.
10. Start the engine and engage the PTO. Operate the
unit from the ground level and lower controls to
ensure proper operation and check for leaks. Install
the turntable covers and the pedestal covers.
Pulsar Valves and Hand Controls
If one direction of a major function stops working, the
problem may be in the hydraulic or electrical portion of
the electrohydraulic control system. The boom, rotation,
intermediate and upper boom, digger and winch functions
are considered major functions.
The following procedure will isolate the cause of the
problem by attempting to operate the disabled function
with an alternate hand control.
Manual Override
Control Handles
Upper Boom
Intermediate
Boom
Lower Boom
Rotate
Digger
Winch
brake, and chock the wheels. Engage the PTO, and
3. Open the derrick blocking valve by operating a hand
control on the lower control panel for an operating
function. Turning the digger shift switch to the High
position will also open the derrick blocking valve.
4. Once the derrick blocking valve is open, attempt to
operate the disabled function with the manual override
control handle (refer to Figure 8.14). If the function
operates, all other hydraulic system problems may
be ruled out, except for the pulsar. However, it may
also be an electrical system problem.
If the function does not operate with the manual over-
ride handle, the problem is in the hydraulic system
other than the pulsar. Continue troubleshooting the
hydraulic system.
5. Use Figure 8.15 to locate the pulsar for the disabled
function. There are labels attached to the wiring har-
ness for each pulsar. The labels identify the pulsar
connections.
6. Switch the connector for the disabled function with
one that operates properly. The hand control for the
working function will become the alternate hand
control for the disabled function.
Figure 8.15 Wiring Harness Labels
7. Attempt to operate the disabled function with the
alternate control. If the disabled direction of the
function will now operate, the problem is likely in the
electrical portion of the function. Proceed to step 8.
If the function will not operate, proceed to step 9.
Labels
Connectors
Pulsars
8. Return the pulsar connectors to the proper pulsars.
Continue to troubleshoot the electrical portion of the
function. Also check other electrical components such
as the slip ring and hand control.
9. If the disabled function does not operate with an al-
ternate control, then it is likely that there is an issue
with the pulsar. Return the pulsar connector for the
alternate hand control to the correct pulsar, but leave
the connector disconnected from the pulsar for the
disabled function.
10. Measure the resistance through the pulsar using an
ohmmeter (refer to Section 8 under Electrical Sys-
tem, Failure Identifcation for the procedure and the
resistance specifcations). If the resistance measure-
ment is correct, proceed to step 11. If the resistance
measurement is signifcantly below the specifed
value, or zero or infnite, proceed to step 13.
11. If the pulsar resistance is correct, check whether the
pulsar is properly torqued. Overtorquing can cause
a pulsar to malfunction. Loosen the pulsar
1
/4 to
1
/2
turn. Then tighten it with a torque wrench to 60 to
78 inch-pounds (6.8 to 8.8 Nm). Special wrench
adapters which attach to a
1
/4 drive torque wrench
for removing and installing pulsars are available from
your Altec representative (refer to Service Tools and
Supplies in the Appendix).
12. Reconnect the pulsar connector to the pulsar for the
disabled function, and attempt to operate the func-
tion. If the function now operates correctly, retorquing
of the pulsar has resolved the issue. If the function
does not operate, proceed to step 13.
13. If the pulsar resistance is incorrect, or if the function
does not operate correctly after retorquing the pulsar,
it is likely that the pulsar is defective. Replace the
pulsar. A new pulsar may be ordered from your Altec
representative. The lower control valve contains two
different types of pulsars. Order the correct pulsar part
number corresponding to the disabled function.
Notice
Remove the old O-ring when replacing a pulsar.
14. Remove the defective pulsar from the control valve.
Carefully use a pick to remove the O-ring from the
bottom of the pulsar cavity.
Notice
Properly seat the new O-ring when installing a new
pulsar.
15. Install the new O-ring which is packaged with the new
pulsar in the bottom of the pulsar cavity. Make sure
that the O-ring is sitting fat against the bottom surface
and contacting all around the circumference.
16. Install the new pulsar in the cavity. Tighten it with a
torque wrench to 60 to 78 inch-pounds (6.8 to 8.8
Nm). Special wrench adapters which attach to a
1
/4 drive torque wrench for removing and installing
pulsars are available from your Altec representative
(refer to Service Tools and Supplies in the Appendix).
Connect the pulsar connector to the pulsar.
Lift Cylinder
If the boom drifts down under load or under its own
weight, frst rule out external causes such as pulsar valve
malfunction or electrical slip ring cross talk.
If the components controlling the cylinder are working
properly, the problem may be caused by leakage past the
counterbalance valve. It may also be caused by internal
leakage in the cylinder. Use the following test procedure
to isolate the cause.
Testing
1. With the unit positioned on a level surface, apply the
parking brake, and chock the wheels. Engage the
PTO and properly set the outriggers.
2. Raise the boom several inches out of the stowed
position. Disengage the PTO. Remove the cover
on the left side of the turntable (while standing at
the back of the turntable near the gearbox). The
lower control valve is equipped with manual override
handles. Locate the handle for the boom function
(refer to Figure 8.14). Make sure no other function is
operating and that the digger speed switch is in the
Low position. Shift the manual override handle for
the boom in the lower direction. Watch for a change
in speed of the boom as it drifts down.
a. If the speed of the boom changes from a slow
drift to a more rapid descent as the handle is
shifted, the counterbalance valve is leaking or its
relief pressure is set too low. Return the manual
override to neutral. Discontinue testing. Replace
the counterbalance valve or adjust its relief set-
ting. Refer to Section 5 under Counterbalance
Valves.
b. If the speed of the boom changes as the handle
is shifted in the Raise position, this indicates the
cylinder piston seal is leaking. Return the manual
override to neutral. Repair or replace the cylinder.
Refer to Section 5 under Lift Cylinder.
c. If there is no change in the speed of the drift with
the manual override handle shifted, return it to
neutral. Proceed to step 3.
3. Start the engine, engage the PTO, and raise the
boom several inches above the boom rest. Disen-
gage the PTO. Shift the valve spool with the manual
override handle to release any trapped pressure in
the circuit.
Warning
components.

work areas clean.
Disconnect the extend and retract hoses from the 90
degree elbows at the base end of the lift cylinder. Plug
the open ends of the hoses. Let the oil initially remain-
ing in the elbows drain out. Watch both open elbows for
continuous dripping of oil as the boom drifts down.
a. If oil fows from the open extend port elbow, this
indicates the counterbalance valve is leaking.
b. If oil fows from the open retract port elbow, this
indicates the cylinder piston seal is allowing oil to
leak past it.
4. Reconnect the hoses to the proper elbows. Repair
or replace the cylinder.
The lift cylinder does not have a holding valve in the retract
side. It is held in position under tensile load by the blocked
cylinder port in the lower control valve. Normal leakage
past the blocked cylinder port will allow slow outward drift
of the cylinder rod with the boom hand control in neutral
during operations that put the cylinder in tension. Such
leakage will occur when applying downward force with
the boom against the auger while digging.
Intermediate and Upper
Boom Extension Cylinders
If an extension cylinder creeps in or out or does not
respond properly to the hand control, frst check the
components associated with controlling the cylinder for
proper operation.
If no external cause is found, then the problem is most
likely due to leakage past a counterbalance valve or
internal leakage in the cylinder.
Internal Leakage Testing
parking brake and chock the wheels. Engage the
PTO and properly set the outriggers. Make sure the
boom is stowed. Completely retract the malfunction-
ing cylinder. Disengage the PTO.
2. Locate the spool valve section on the lower control
valve that controls the cylinder that is being tested
(refer to Figure 8.14). Disconnect the cylinder extend
hose from the 90 degree elbow on the spool valve.
Cap the elbow at the valve. Allow the oil remaining
in the hose to drain into a container.
3. Hold the open hose end over the container. Start the
engine and engage the PTO.
4. Shift the hand control for the cylinder in the Retract
position. There may be an initial surge of oil out of
the open hose end as pressure is frst applied to the
cylinder. Watch whether oil continues to fow while
holding the system at maximum pressure [3,000 psi
(206.84 bar)].
a. If a heavy stream of oil continues to fow from the
hose, this indicates internal leakage in the cylin-
der. Reconnect the hose to the boom functions
valve. Discontinue testing. Repair or replace the
cylinder.
b. If no oil continues to fow from the hose, there is
no internal leakage in the cylinder. Reconnect the
hose to the boom functions valve. Proceed to the
counterbalance valve leakage test.
c. If oil continues to drip steadily or fows in a small
stream (pencil lead size or less), this test cannot
determine the cause of the problem. The oil fow
may be due to internal cylinder leakage or normal
oil fow through the pilot section of the counter-
balance valve. Reconnect the hose to the boom
functions valve. Proceed to step 5 to confrm or
rule out internal leakage.
Warning
movement. Fully unload the actuator or position it so
it cannot move, before removing a holding valve.
components.

work areas clean.
5. Remove the trapped pressure in the circuit. This can
be done by shifting the manual override control for
both directions. Slowly loosen the test port plug on
the cylinder or the valve block marked TR to bleed
off the pressure in the cylinder. If the test port cannot
be reached then the valve cartridge adjusting screw
must be turned in to relieve the pressure. Remove
the retract counterbalance valve cartridge from the
cylinder (located in the cavity labeled R or Ret) if the
pressure was relieved by using the test port. Section
5 under Counterbalance Valves describes how to
properly remove a counterbalance valve.
Warning
Death or serious injury can result from unexpected
movement. Counterbalance valves that have had the
relief setting changed must be replaced or reset to
the proper setting using an Altec test block before
the unit is operated.
6. Set the retract counterbalance valve aside if it was
removed without changing its setting. Install a test
counterbalance valve cartridge. Turn the adjusting
screw on the test valve all the way in (clockwise) to
hold the valve open.
7. Start the engine and engage the PTO. Extend and
retract the cylinder completely two or three times to
purge any air that entered when the counterbalance
valve was removed.
8. Extend the cylinder about 12 (30 cm). Mark the ex-
tended boom stage with chalk or a felt tip marker. This
will provide a reference point to check for drift.
9. Raise the boom to the maximum boom angle. Dis-
engage the PTO.
10. Disconnect the cylinder retract hose from the 90
degree elbow on the spool valve. Cap the elbow at
the boom functions valve. Allow the oil remaining in
the hose to drain into a container.
11. Hold the open hose end over the container. Watch for
oil fow from the open hose end as the boom drifts in.
If the boom does not drift in under its own weight, lift
a load with the winch line of suffcient weight (within
load capacity) to initiate the drift.
a. If oil does not continue to drain from the hose as
the boom drifts in, the drift is due to leakage past
the extend counterbalance valve.
b. If oil continues to drain steadily from the hose as
the cylinder drifts, this indicates internal leakage
in the cylinder.
12. Reconnect the hose to the lower control valve. Install
the original counterbalance valve cartridge in the
retract cavity of the cylinder. Take the necessary
corrective action to correct the leakage problem.
Warning
components.

work areas clean.
Counterbalance Valve Leakage Testing
1. This procedure checks for leakage in the counter-
balance valve cartridge in the extend cavity labeled
E or Ext. If the symptoms indicate possible leakage
in the retract cartridge, remove both cartridges and
switch them to the opposite cavities. Before remov-
ing the counterbalance valves, make sure the load is
removed from the circuit. This can be done by shifting
the manual override control for both directions until
the cylinder can be rocked by hand. To relieve the
pressure in the cylinder, slowly loosen the test port
plug on the cylinder or the valve block marked TR. If
the test port cannot be reached, the valve cartridge
adjusting screw must be turned in to relieve the
pressure. Remove the retract counterbalance valve
cartridge from the cylinder (located in the cavity la-
beled R or Ret) if the pressure was relieved by using
the test port. Section 5 under Counterbalance Valves
describes how to properly remove a counterbalance
valve.
Warning
parking brake and chock the wheels. Engage the PTO
and properly set the outriggers. Extend the boom to
be checked about 12 (30 cm). Mark the extended
stage with chalk or a felt tip marker. This will provide
a reference point to check for drift.
3. Raise the boom to the maximum boom angle and
shut off the pump.
4. Locate the spool valve section on the boom functions
valve that controls the cylinder that is being tested.
Disconnect the cylinder extend hose from the spool
valve. Cap the elbow at the boom functions valve.
Allow the oil remaining in the hose to drain into a
container.
5. Watch for oil fow from the open hose end and for
drift of the extension cylinder. If the boom does not
drift in under its own weight, lift a load with the winch
line of suffcient weight (within load capacity) to start
the drift.
a. If oil continues to drain steadily from the hose as
the boom drifts in, the drift is due to leakage past
the extend counterbalance valve. Reconnect the
hose to the boom functions valve. Replace or
adjust the counterbalance valve (refer to Section
5 under Counterbalance Valve).
b. If oil does not continue to drain from the hose as
the boom drifts in, this indicates that the extend
counterbalance valve is holding properly. If the
boom does not drift in, this also indicates that the
extend counterbalance valve is holding properly.
In either case, reconnect the hose to the boom
functions valve. Check for internal leakage in the
cylinder as described in this section.
Holding Valves
The unit uses holding valves to insure that various
actuators maintain their position under load or if there
is hydraulic line failure. These holding valves block the
hydraulic oil in the actuators to prevent movement. The
types of holding valves used are pilot operated check
valves and counterbalance valves.
If the valve stops holding the load, or malfunctions in
some other way, it is most likely contaminated. Do not
disassemble a holding valve in the feld. Holding valves
should only be disassembled by the manufacturer.
When removing a holding valve cartridge, do not allow
dirt, water, or other contaminants to enter the holding
valve cavity when the cartridge is removed.
Warning
components.
work areas clean.
Caution
Pilot Operated Check Valves
A pilot operated check valve provides a positive lock
against hydraulic fow or leakage until it is opened by
pressure from a control valve. Pole guide tong and tilt
cylinders use pilot operated check valves.
Pilot operated check valves assure the cylinder will main-
tain its position if there is hydraulic line failure.
Notice
Pilot operated check valves are not adjustable and
must be replaced if defective.
Testing
There are two methods for testing pilot operated check
valves.
Switching Valve Cartridges
1. Securely stow the booms.
2. Relieve the fuid pressure from the pilot operated
check valve by shifting the control handle for that
function in both directions several times.
3. Support the structure the pilot operated check valve
supports. Switch the cartridges with those of another
function. Make sure not to switch the location of the
cartridges in the block.
4. If the problem moves to the other location, replace
the valve cartridge. If the problem does not move,
the pilot operated check valve is not the cause of the
malfunction.
Loading the Function
1. Load the function protected by the pilot operated
check valve.
3. Move the control handle for the function to connect the
function to tank. If the function moves, the pilot oper-
ated check valve is leaking and must be replaced.
Counterbalance Valves
A counterbalance valve provides a positive lock against
hydraulic fow or leakage until it is opened by pressure
from a control valve.
Counterbalance valves are used to block fow out of the
following actuators.
Lift cylinder
Rotation motor
Upper boom cylinder
Intermediate boom cylinder
Winch motor
Outrigger
Counterbalance valves assure the cylinder or motor will
maintain its position if there is hydraulic line failure.
Testing
There are two methods for testing counterbalance
valves.
Switching Valve Cartridges
properly set the outriggers. Stow the booms.
2. Move the control selector to the Lower Controls posi-
tion. Remove the hydraulic load from the valves by
shifting the manual override control handle in both
directions until the cylinder can be rocked by hand.
Disengage the PTO and turn off the engine.
3. Locate the plugs in the extend and retract test ports
at the base end of the cylinder. Use an Allen wrench
to slowly unscrew the test plugs. Allow the pressure
to bleed off before completely removing the plugs.
If the cylinder is under pressure and the plugs are
unscrewed quickly, hydraulic oil may spray out of the
test ports. Replace the test plugs.
4. Switch the position of the two valve cartridges.
5. If the problem moves to the other location, replace the
valve. If the problem does not move, the counterbal-
ance valve is not the cause of the malfunction.
Loading the Function
1. Load the function protected by the counterbalance
valve.
2. Turn off the engine and disengage the PTO.
3. Move the control selector to the Lower Controls
position.
4. Move the manual override control handle for the
function to connect the function to tank. If the func-
tion moves, the counterbalance valve is leaking and
must be replaced.
Relief Pressure
Counterbalance valves are set to relieve pressure at dif-
ferent settings. The counterbalance valves used in the
lower, intermediate, and upper boom cylinders are set to
relieve pressure at 3,500 psi (241 bar). The counterbal-
ance valves used with the rotation motor are set to 3,000
psi (206.84 bar). The counterbalance valve used with
the winch motor is set to relieve pressure at 2,000 psi
(137.90 bar). Do not adjust counterbalance valves in the
feld. If the setting on a counterbalance valve has been
changed, the cartridge must be removed and adjusted
with a test block or replaced.
Warning
Do not adjust a counterbalance valve without a test
block. Using a test block and pressure gauge is the only
accurate way to determine that the proper setting has
been obtained.
A test block and instruction sheet for 1
1
/8 hex cartridges
and
7
/8 hex cartridges are available from your Altec
representative (refer to Service Tools and Supplies in
the Appendix).
Removal
Before removing a counterbalance valve, the cylinder
must be unloaded. Use the following procedure to remove
a counterbalance valve.
properly set the outriggers. Stow the booms.
2. Shift the lower control valve manual override con-
trol handle for the function until the cylinder can be
rocked by hand. Disengage the PTO and turn off the
engine.
3. Locate the plugs in the extend and retract test ports
at the base end of the cylinder or counterbalance
valve block. Use an Allen wrench to slowly unscrew
the test plugs. If the cylinder is under pressure and
the plugs are unscrewed quickly, hydraulic oil may
spray out of the test ports. If the test ports are not
available, slowly screw the counterbalance valve
cartridge from its housing.
4. Carefully unscrew the cartridge from its housing to
allow the pressure to bleed off before the cartridge
is fully unscrewed from the cavity.
Testing
1. Lubricate the O-rings on the counterbalance valve
cartridge and install the cartridge in the test block.
2. Connect a hydraulic pressure source and an accurate
pressure gauge to port 1 (refer to Figure 8.16). The
pressure source and gauge must be adequate for
a pressure greater than the desired counterbalance
valve relief setting.
Figure 8.16 Counterbalance Valve Test Block
3. Install a straight adapter in port 2 to aid in observing
the oil fow from this port during the procedure.
4. Gradually increase the pressure at port 1 with the
pressure source. The counterbalance valve relief
setting is the pressure at which a fne stream of oil
begins to fow from port 2. Note this pressure reading
and then remove the pressure from port 1.
5. If the relief setting is correct, relieve the pressure
of the pressure source by turning off the pressure
source and moving the control several times in both
directions.
6. Disconnect the pressure source from port 1 and
remove the counterbalance valve cartridge.
7. If the relief setting is incorrect, adjust the relief setting
as described in the following procedure.
Adjustment
1. Loosen the jam nut and turn the adjusting screw
clockwise to decrease the setting or counterclockwise
to increase the setting.
2. Hold the adjusting screw from turning and tighten
the jam nut.
3. Repeat the test procedure until the proper relief set-
ting is obtained.
4. Repeat the test procedure at least three more times
to confrm the proper setting.
5. Relieve the pressure of the pressure source by turn-
ing off the pressure source and moving the control
several times in both directions.
6. Disconnect the pressure source from port 1 and
remove the counterbalance valve cartridge.
Mechanical System
Rotation Gearbox
Adjustment
The rotation gearbox is equipped with a spring-applied,
hydraulically released brake. This means the brake is
engaged until it is released by hydraulic pressure. When
the rotation hand control is shifted, pressure begins to
build up in the rotation motor. This pressure releases the
brake and allows the motor to rotate the turntable. When
the hand control is returned to neutral, the hydraulic pres-
sure in the motor decreases to zero. As the pressure in
the motor decreases, the brake is applied and rotation
motion is stopped.
Adjusting Screw Jam Nut
Counterbalance
Valve Cartridge
Port 1
Port 2
The rotation pinion can be adjustable to mesh properly
with the rotation bearing. Proper adjustment minimizes
backlash in the mesh between the pinion and rotation
bearing gear teeth. Adjustment is accomplished with the
eccentric ring and eccentric ring lock.
Excessive backlash will appear as excessive side-to-side
boom movement when the rotation function is stopped. It
can also appear as excessive side-to-side boom move-
ment when a load suspended from the winch line is
swinging from side to side. Adjustment of the backlash
may be necessary to compensate for wear after extended
operation. It is also necessary if a new rotation gearbox
and/or rotation bearing is installed.
Use the following procedure to check and adjust the mesh
between the rotation pinion and the rotation bearing.
Caution
2. Remove the pinion cover from under the turntable
bottom plate.
3. Rotate the boom to the position that seems to have
the least amount of movement between the rotation
pinion and the rotation bearing. This is normally where
the pinion meshes with the high tooth of the rotation
bearing gear teeth. The high tooth is the point on the
bearing where the rotation pinion meshes with the
rotation bearing when the booms are stowed (refer
to Figure 8.17).
The high tooth of a new rotation bearing is painted
yellow or blue. However, the high tooth may not al-
ways be the area with the least amount of movement
between the rotation pinion and the rotation bearing.
In some situations, there has been a greater amount
of concentrated wear in this area than on other areas
of the bearing. If this is the case, rotate the booms to
the area that does have the least amount of move-
ment between the pinion and the bearing teeth.
Figure 8.17
Rotation Bearing High Tooth Location
4. With another person rocking the boom tip back and
forth, observe the movement of the pinion. If side-to-
side movement between the pinion and rotation gear
teeth is seen at the point of gear mesh, the mesh
between the pinion and rotation bearing is loose. Do
not confuse backlash with slight lost motion within
the rotation gearbox. Internal gearbox backlash will
cause the pinion to rotate back and forth slightly.
This cannot be reduced externally. If adjustment is
necessary to bring the pinion into closer mesh with the
rotation bearing, continue with the following steps.
Caution
Wear eye protection at all times to prevent particles of
dirt, metal, or hydraulic oil from entering the eyes.
5. Remove the eccentric ring lock located on top of the
turntable bottom plate, under the rotation gearbox
Figure 8.18 Eccentric Ring Adjustment
Eccentric
Ring Lock
Eccentric
Ring
High Tooth
Location
6. Loosen, but do not remove, the four cap screws that
mount the rotation gearbox to the turntable base plate.
For the rotation gearbox used with hydraulic side
load protection, a torque wrench adapter (included
with unit, refer to Service Tools and Supplies in the
Appendix) must be used to loosen these cap screws.
The adapter may be oriented at any angle on the
torque wrench when loosening the cap screws (refer
to Figure 8.19).
7. The eccentric ring is located on top of the turntable
base plate, under the gearbox. Since the bore of
the eccentric ring is
1
/16 (1.59 mm) off center from
the outside diameter of the ring, rotating the ring will
move the gearbox and pinion toward or away from
the rotation bearing. The gearbox mounting holes
are
1
/8 (3.18 mm) oversize to accommodate this
movement.
Engage an eccentric ring spanner wrench (refer to
Service Tools and Supplies in the Appendix) or a bar
or drift pin made of a soft material such as brass, in
a drive slot of the eccentric ring. Do not use a bar,
punch, or drift pin made of steel, as it will damage the
drive slots in the eccentric ring. Rotate the eccentric
ring using the spanner wrench or using light blows
from a hammer against the bar or drift pin until the
pinion bottoms out in the rotation gear teeth. At this
point, the ring will stop rotating. Do not use excessive
force to drive the eccentric ring past this point.
8. The eccentric ring lock has fve holes in it. There are
two holes in the turntable base plate. This provides
ten locking increments. Mate the lock to the eccentric
ring so that one of the holes in the lock lines up with
one hole in the turntable plate. It is possible none of
the holes in the lock will line up with the holes in the
turntable plate. If this happens, rotate the eccentric
ring slightly to loosen the adjustment until the lock
can be installed. Install the cap screw through the
turntable plate and lock. Install the nut and torque it
to the proper value.
9. Tighten the gearbox cap screws frmly. For the rota-
tion gearbox used with hydraulic side load protection,
the torque wrench adapter must be used to tighten
these cap screws. The adapter may be oriented at
any angle on the torque wrench when tightening the
cap screws but not torquing them to a specifc value
(refer to Figure 8.19). Rotate the turntable slowly
through at least two revolutions.
a. If the unit rotates smoothly, proceed to step 10.
b. If rotation binds or hesitates in any position, the
backlash may have been set too tight. Loosen the
mounting cap screws. Rotate the eccentric ring to
loosen the adjustment by one locking increment
(refer to step 8). Repeat step 9.
10. Torque each gearbox mounting cap screw to 325
foot-pounds (441 Nm). For the rotation gearbox used
with hydraulic side load protection, the torque wrench
adapter must be used to torque these cap screws.
The adapter must be oriented at 90 degrees to the
handle of the torque wrench when torquing the cap
screws to a specifc value (refer to Figure 8.19).
11. If a new gearbox was installed, or if the rotation gear
teeth are dry, apply an open face gear lubricant as
recommended in Section 4 under Lubrication.
12. Install the pinion cover.
Top View
Figure 8.19 Torque Wrench Adapter
Side View
Rotation
Gearbox
Used With
Side Load
Protection
Turntable Rotation Gearbox
Mounting Cap
Screw
Torque
Wrench
Adapter
Torque Wrench
Angle Between Adapter and Torque Wrench:
= Any Angle When Tightening or
Loosening, But Not Torquing,
= 90 Degrees When Torquing to Specifc Value
Rotation Brake With Hydraulic
Side Load Protection
The torque setting of the brake on the rotation gearbox
used with hydraulic side load protection is adjustable.
The torque setting must be properly adjusted for the side
load protection system to operate properly. Testing of the
rotation brake adjustment is performed as part of the side
load protection testing procedure as described in Section
8 under Hydraulic Side Load Protection System.
Rotation Brake With Electronic
The torque setting of the brake on the rotation gearbox
used with electronic side load protection is not adjustable.
It is set to a torque level that will prevent brake slippage
during normal derrick use. If it is suspected that the torque
setting has decreased due to normal wear of the friction
discs to a level that allows slippage during normal use,
the brake should be rebuilt.
Platform Brake
When properly adjusted, the brake will support 300 pounds
(136 kg) at the platform lip and should not slip when the
operator leans over the side of the platform. If slippage
occurs under this condition, the brake should be checked
and adjusted according to the following procedure.
Notice
Do not overtighten the platform brake.
Overtightening will make the brake diffcult to operate
and can cause failure of the cam lever.
Adjustment
1. Remove the cover from the platform mounting bracket
assembly.
2. Measure the thickness of the friction pad material
on each caliper plate. The pads are
1
/4 (6.35 mm)
thick when new. If there is more than
1
/8 (3.18 mm)
of pad material remaining, proceed with step 4. If
the pads are
1
/8 (3.18 mm) thick or less, they may
be worn down to the rivet heads. Proceed to step 3
to determine if the pads are worn to the rivets.
3. Disassemble and remove the caliper assembly from
the bracket and inspect the pad surfaces. If there is
suffcient material remaining above the rivet heads,
reassemble the brake and proceed to step 4. If the
pads are worn down to the rivet heads, they must be
replaced. Inspect the actuating surfaces of the cam
lever (refer to Figure 8.20). If there is substantial wear,
the entire brake caliper assembly must be replaced.
If the cam is in good condition, only the caliper plates
on which the pads are mounted need to be replaced.
Refer to the Parts Manual for the necessary part
numbers. Reassemble the brake with the required
new parts and proceed with step 4.
4. Back the jam nut on the adjusting cap screw away
from the yoke. To tighten the brake, screw the adjust-
ing cap screw clockwise farther into the yoke. If new
pads were installed, screw the adjusting cap screw
farther out of the yoke (counterclockwise) to loosen
the brake and allow for the increased thickness of
the new pads.
If the self-locking nuts on the brake mounting cap
screws are tightened completely and the brake pads
are new, the brake may not release completely with
the brake handle unlocked. If this occurs, the nuts
should be unscrewed just to the point that the brake
does not drag in the unlocked position. As the pads
become worn, the nuts can be tightened completely to
obtain full use of the adjustable range of the brake.
Cam Lever
Yoke
Jam Nut Adjusting Bolt
Inside Caliper Plate
Brake Disc
Outside Caliper Plate
Figure 8.20 Platform Brake Components
Adjustable
Rod End
Digger Shift
Cylinder
Shift Lever
5. Tighten the jam nut against the yoke once the proper
adjustment is attained.
6. Install the cover on the platform mounting bracket.
Digger Shift Cylinder
Adjustment
If the digger jumps out of high or low gear during operation,
this may indicate an improper shift cylinder adjustment. It
may also be a sign of gear damage within the digger.
This procedure describes how to check the shift action
and adjust the shift cylinder. If the shift cylinder or shifter
shaft assembly ever needs to be replaced, the cylinder
must be properly adjusted before returning the unit to
service.
1. Position the unit on a level surface, apply the park-
ing brake, and chock the wheels. Engage the PTO
and properly set the outriggers. Rotate the boom to
the side of the vehicle. Raise the boom and unstow
the digger. The Operators Manual describes how to
safely unstow the digger. Lower the digger so that
the output shaft can be turned by hand. Disengage
the PTO and turn off the engine.
2. Remove the cap screw that attaches the adjustable
rod end in the base of the cylinder to the lug on the
bail (refer to Figure 8.21). Leave the other end of the
cylinder attached to the shift lever.
Figure 8.21 Digger Bail
3. Move the shift lever from the full up position (toward
motor) to the full down position (away from motor).
There should be approximately 1 (2.54 mm) of
travel as measured at the cylinder attachment point
on the lever. Move the cylinder up and down and
check the lever for proper travel. When moving the
lever, it should not contact the housing at any point.
Use a grinder to remove material from the housing
if there is interference.
Be certain that the lever is moving through its full arc
of travel. To check this, rotate the digger output shaft
by hand until the gears are aligned for shifting. If full
gear engagement is being obtained at each end of
the shift lever travel, the output shaft can be rotated
freely only when the shift lever is within a very narrow
range of position near the middle of the lever travel.
As the lever is moved either way from this middle
position, a positive indication of the digger going into
gear should be felt, and the output shaft should not
turn.
If the shift lever does not exhibit full travel and/or
if the gears do not seem to be engaging properly,
discontinue this procedure. The gears in the digger
are damaged. Contact your Altec representative for
digger repair.
4. Move the shift lever to the full up position (toward
motor) and hold it there. The length of the rod end
in the base of the cylinder is adjustable (refer to
Figure 8.21). Loosen the jam nut on the rod end.
Turn the rod end in or out until the hole in the rod
end is closely aligned with the hole in the lug on the
bail. Verify this alignment by inserting the cap screw
through the hole in the rod end and checking that it
can be easily turned into the lug. Then remove the
cap screw. Turn the rod end out (counterclockwise)
1
/2 turn from the position just determined and tighten
the jam nut on the rod end.
5. Move the cylinder down slightly so that the holes in
the rod end and bail lug line up again. Install the cap
screw.
Notice
A mechanically shifted, two-speed digger must come
to a complete stop before moving the digger speed
switch to prevent damage.
6. Start the engine and engage the PTO. Operate the
digger and shift cylinder hydraulically. Check for
proper shift lever travel and gear engagement.
Electrical System
A basic understanding of electrical components and
system failure will aid in troubleshooting the units elec-
trical system.
Failure Identifcation
Three types of failures in the electrical system will cause
the system to operate improperly or not at all. They are
listed as follows.
Short circuit
Open circuit
Defective component
This section describes how to identify these electrical
system problems.
Short Circuit
A short circuit occurs when a contact of low resistance
between a power conductor and a ground diverts electric-
ity from a component of greater resistance. Resistance
refers to how well the component conducts electricity.
Electricity always fows in the path of least resistance.
A short circuit will usually trip one or more circuit breakers.
A short circuit can be caused by the following items.
Pinched wires
Worn insulation
Defective component
Loose connection touching a ground
To fnd the location of a short circuit, frst analyze the
location of the circuit breaker that is opening and what
is being operated when it opens.
It may be necessary to progressively isolate the loca-
tion of a short by disconnecting circuits until the short
disappears. A short can also be detected by turning off
power to the unit and using an ohmmeter to check the
resistance to ground at connections and terminals that
would have a voltage applied during normal operation.
Zero resistance between ground and one of these loca-
tions indicates a short circuit. This checking procedure
should begin closest to the power source.
Open Circuit
An open circuit prevents the normal fow of current through
component(s) of the electrical system. This interrupts
the operation of the components. An open circuit may
be caused by the following items.
Broken wire
Corrosion
Wire pulled from a connection
Poor contact where an electrical component is
grounded to the unit structure
Begin the search for an open circuit at the point closest
to the component that is not operating. Trace the wiring
from the component. Look for a broken connection or cor-
rosion. Also, look for other visible damage to the cable or
wires. If the component is grounded to the unit structure,
make sure the ground connection is good.
If the wiring looks good and the ground contact is
good, disconnect the leads to the component. Check
the resistance reading through the component with an
ohmmeter.
If the component is a switch, an infnite resistance reading
on the ohmmeter indicates an open circuit.
If the component is a solenoid coil, the typical resistance
at 70 degrees Fahrenheit (21 degrees Celsius) is given in
Figure 8.22. If the resistance reading is much higher than
shown, the problem is most likely an open coil. It could
also be a defective connection in the lead to the coil.
An exact normal reading should not be expected. Many
ohmmeters will not accurately measure resistance in
the fve to six ohm range. If normal resistance is found
in the component, check that the proper voltage is being
applied to the components.
Component Failure
A component malfunction is sometimes the most diffcult
problem to locate. It may appear as an open or a short
circuit, or the component may not perform to its design
capacity.
To accurately determine that a component is defective,
decide what functions are affected and what components
could be causing the problem. If no open or short circuits
can be located, and the proper voltage is being applied
to the components, the problem may be hydraulic or
mechanical rather than electrical.
Resistance
Solenoid Coil (ohms)
Derrick blocking valve 5
Outrigger/tool blocking valve 5
Outrigger/tool pressure selector valve 8
Outrigger/tool sense dump valve 8
Figure 8.22 Solenoid Coil Resistance Readings
Auxiliary Functions Valve Selector Valve
Resistance
Enabler/tools valve 6
Pole guide valves 8
Auger release valve 7
Digger shift valves 7
Resistance
Rotation foat valve 6
Pulsars 12
Rotation foat brake 10
release valve
If one direction of a major function stops working, the
problem may be in the hydraulic or electrical portion of
the system. The boom, rotation, intermediate and up-
per boom, digger, and winch functions are considered
major functions. The troubleshooting procedures in this
section can help pin point whether it is an electrical or
hydraulic problem.
Make every effort to locate the problem component
before installing new components. Many times good
parts are replaced needlessly when parts are replaced
by trial and error.
Pin and Circuit Identifcation
To troubleshoot the electrical system, the selector switch
in the vehicle cab must be in the Machine position. Also,
the controls selector switch on the lower control panel must
be in the Lower position. However, if the upper controls
or platform tools are the areas to troubleshoot, the lower
control panel must be in the Upper position.
Circuit Protection
Circuit breakers protect certain wiring and components
from electrical overload during a short circuit or other
electrical fault. When an electrical circuit is overloaded,
the breaker for that circuit will trip. If a circuit breaker trips
repeatedly, determine the cause of the problem promptly
and correct it.
Notice
Damage to the electrical system can result if a circuit
breaker trips repeatedly.
Thermal Self-Resetting Circuit Breakers
The unit has several thermal self-resetting type breakers.
This type of circuit breaker will normally reset within a few
minutes when the electrical overload is removed.
There is a thermal circuit breaker in the main power
supply running from the battery to the lower control
panel. The unit may also be equipped with an electric
two-speed throttle control circuit, which is also equipped
with a circuit breaker. Both of these circuit breakers are
located in the power distribution module, which is located
in the vehicle cab.
If the circuit breaker for the main power supply trips open,
all functions above rotation will stop working. Also, the
lower control panel lights will be dead. The breaker will
normally reset within a few minutes if the cause of the
electrical overload is removed.
Proximity Switches
Normally open and normally closed proximity switches are
used in various derrick systems (refer to Figure 8.23). A
square sensing face on one side of the proximity switch
actuates the switch when this surface is within a certain
distance of a metal surface. Each switch is equipped with
two LED lights on one side. The green light indicates
there is power to the switch. On a normally closed switch,
the yellow light is on when metal is not sensed (switch
closed), and is off when metal is sensed (switch open).
On a normally open switch, the yellow light is off when
metal is not sensed (switch open), and is on when metal
is sensed (switch closed).
Switch Type Yellow LED Status
Normally Normally Metal Not Metal
Switch Description Open (NO) Closed (NC) Sensed Sensed
Boom stow Yes On Off
Auger stow Yes On Off
Outrigger interlock Yes On Off
Pole guide interlock tilt Yes Off On
Pole guide interlock upper boom Yes On Off
Sequential extension intermediate boom position 1 Yes Off On
Sequential extension lower boom position 2 Yes On Off
Sensing Face
Green LED
Yellow LED
Figure 8.23 Proximity Switch
Testing
In addition to the testing and adjustment procedures
provided in this section for each system that contains a
proximity switch, use the following procedure to test a
proximity switch for proper operation.
1. If the switch is mounted on the side of the lower boom,
remove the boom side cover over the switch.
2. When testing a sequential extension switch, the
controls selector switch on the lower control panel
can be in either the Lower or Upper position.
3. Check that the green light on the switch is on.
4. Each proximity switch is located to sense the presence
or absence of a metal component in the associated
system. The yellow light should be on or off in accor-
dance with Figure 8.23 depending on the presence
or absence of metal within a sensing range of about
0.75 (1.9 cm) from the switch sensing face. Test the
switch using one of the following methods.
a. Operate the appropriate derrick function to move
the sensed component within and beyond the
sensing range of the switch.
b. Move a metal object such as a screwdriver or
wrench within and beyond the sensing range of
the switch.
c. Remove the switch or switch/cover assembly from
the structure, and move the sensing face toward
and away from a fat metal surface within and
beyond the sensing range.
5. If the green and yellow lights do not operate as de-
scribed, the switch may be defective or there may be
a fault in the electrical cable leading to the switch.
Tilt Switches
Radial outriggers in which the cylinders are located above
the outrigger legs may use electronic tilt switches as outrig-
ger interlock switches (refer to Figure 8.24). The tilt switch
is attached to the outrigger leg. When the leg is lowered
from the stored position, the switch actuates and closes
when the leg is at or below an approximately horizontal
position. When the leg is raised from the deployed posi-
tion, the switch becomes deactuated and opens when the
leg is at or above an angle of approximately 8.5 degrees
above horizontal. A tilt switch is equipped with two red
LED lights on the top surface. The red light closest to the
switch cable indicates there is power to the switch. The
red light farthest from the cable is on when the switch
is actuated (switch closed) and is off when the switch is
deactuated (switch open).
Testing
Use the following procedure to test a tilt switch for proper
operation (refer to Figure 8.24).
1. Check that the red power light on the switch (LED
closest to the cable) is on.
2. Operate the outrigger function to lower the outrigger
leg from the stored position. The second red light on
the switch (LED farthest from the cable) should be
off until the base of the switch reaches a horizontal
position. It should turn on at horizontal and stay on
throughout the remaining downward travel of the leg.
Figure 8.24 Tilt Switch
Red Light
Actuated
(Closed)
Switch Actuation Zone
When Raising Outrigger Leg
Switch Actuation Zone
When Lowering Outrigger Leg
Switch Base
Leg Motion
Leg Motion
8.5
Actuated
0
Off
Cable
Red Light
Power On
Actuated
Off
3. Operate the outrigger function to raise the outrigger
leg from the fully deployed position. The second red
light on the switch should be on until the base of the
switch reaches an angle of 8.5 degrees above hori-
zontal with the cable end of the switch downward. It
should turn off at 8.5 degrees and stay off throughout
the remaining upward travel of the leg.
4. If the red lights on the switch do not operate as de-
scribed, the switch may be defective or there may be
a fault in the electrical cable leading to the switch.
The outrigger interlock electrical switches are connected
to a control module. If one switch is defective, the out-
rigger interlock will not operate. If all the switches are
functioning properly, and in proper alignment, there may
be an electrical wiring problem.
Proximity Interlock Switches on A-Frame,
X-Frame, Modifed A-Frame, Out and Down,
Corner Mount Street Side, and Corner Mount
Curb Side Outriggers, and on Radial Outriggers
With Cylinders Located Within Frame
The proximity switches used in the outrigger interlock
system are normally closed. The mounting locations of
the switches are not adjustable. Each switch is equipped
with two LED lights. The green light indicates there is
power to the switch. The yellow light is off when the
outrigger leg is retracted or raised above a certain point
(switch open), and on when the leg is extended or lowered
beyond this point (switch closed). The switches can be
tested for proper operation using the procedure under
Proximity Switches in this section.
Tilt Interlock Switches on Radial Outriggers
With Cylinders Located Above Legs
The electronic tilt switches used in the outrigger interlock
system are open or closed depending on the angle of the
radial outrigger leg. The mounting locations and actuation
angles of the switches are not adjustable. Each switch is
equipped with two red LED lights. The red light closest to
the switch cable indicates there is power to the switch.
The red light farthest from the cable is off when the leg is
raised above a certain point (switch open), and on when
the leg is lowered below a certain point (switch closed).
The switches can be tested for proper operation using
the procedure under Tilt Switches in this section.
Mercury Interlock Switch on Radial
or Corner Mount Curb Side Outriggers
The mercury switches used in the outrigger interlock
system are open or closed depending on the angle of
the outrigger leg. On corner mount curb side units, the
switch is set to close the when the outrigger shoe lowers
into a range of 6 to 10 (15 to 25 cm) above the ground.
For radial outriggers, the switch is set to close when the
outrigger shoe lowers into a range of 10 to 14 (25 to 36
cm) above the ground. If adjustment is required, loosen
the mounting cap screws and rotate the switch to obtain
the proper range above the ground. Then tighten the cap
screws to lock the switch in place..
Programmable Settings
All of the units programmable functions are set at the
factory. The control system parameters and average set-
ting values are shown in Figure 8.25. The parameters are
adjusting using a CADI, which is temporarily connected
to the CADI connection socket [refer to Calibration and
Diagnostic Instrument (CADI) in Section 7 and to the
Quick Reference Guide included with the CADI]. The
parameters are adjusted to the individual unit for proper
performance, thus they may vary from the values shown
in Figure 8.25. For example, if a function does not start or
stop smoothly, or does not operate at the proper speed,
the functions threshold and/or max out may require ad-
justment. The CADI allows each function direction to be
adjusted independent of the opposite function direction.
Changing the threshold or max out for boom up has no
effect on boom down. Do not change the settings for
frequency, speed curve, or ramp from those shown in
Figure 8.25. If they are different, use the CADI to return
them to their proper value.
The control system settings are stored in the above rotation
valve driver. If the above rotation valve driver needs to be
replaced, use the CADI to determine the current settings
for each parameter and write these down before removing
the original valve driver from the unit. After installing the
new valve driver, use the CADI to adjust the settings to
the values recorded from the original valve driver. If the
original values could not be obtained, adjust the settings
to the preliminary values shown in Figure 8.25, and then
further calibrate the settings for proper performance.
The LCD and keypad push buttons are shown in Figure
8.26. The LCD provides four rows of information. The
last two rows are broken up into six columns. The mode
selected is shown in the frst row of the display. The calibra-
tion mode is used to set the parameters of the functions.
The function is shown in the second row. The third row
lists all the parameters that can be adjusted. The fourth
row lists all the current values. The value that is currently
selected for change will be fashing in the display.
Figure 8.26 CADI
Use the mode push button to select the calibration mode.
This mode is for setting or fne tuning the operating pa-
rameters for the programmable control functions. The
left and right menu buttons are used to scroll through all
the programmable functions (boom up/down, rotation
clockwise/counterclockwise, intermediate boom extend/
retract, upper boom extend/retract, winch pay in/pay out,
digger dig/clean, throttle, HOP, and electronic side load
protection). The display wraps around to the frst func-
tion after the last function is selected when scrolling in
either direction. The select push button is used to scroll
through all the parameters (frequency, speed curve,
threshold, max out, ramp, and low max). The display
wraps around to the frst parameter after the last param-
eter is selected. The up and down value push buttons
are used to incrementally increase or decrease the value
of the parameter selected. Once a value is selected, the
controls can be used to test the operation of the function
without unplugging the CADI. When all the parameters
are properly set, unplug the CADI. Note that there is no
Enter button settings are entered into the system as
soon as they are changed.
Frequency Speed Curve Threshold Max Out Ramp Low Speed
Function (FREQ)
5
(SC)
5
(TH)
1
(MX)
1
(RA)
5
(LMX)
1
Boom up 0075 00 30 80 99 55
Boom down 30 80 99 55
Clockwise 0075 00 30 65 99 50
Counterclockwise 30 65 99 50
Interm extend 0075 00 40 80 99 55
Interm retract 40 80 99 55
Upper extend 0075 00 40 80 99 55
Upper retract 40 80 99 55
Winch in 0075 00 30 80 99 60
Winch out 30 80 99 60
Digger dig 0075 00 40 90 99 70
Digger clean 40 90 99 70
Throttle 0392 00 02
3
42
3
99 42
3
HOP meter 0392 00 00 53
4
99 53
4
HOP trip 82
ESLP clockwise 00
2
ESLP counterclockwise 20
2
Figure 8.25 CADI Programmable Parameter Settings
1
Values for these functions are preliminary settings only. Unit must be calibrated to proper settings. If replacing above rotation valve driver, adjust
to same settings as contained in original valve driver.
2
Set to 99 if no electronic side load protection installed.
3
Set to 00 if no variable foot throttle installed. Set MX and LMX to same value if variable foot throttle is installed.
4
Set HOP meter MX and LMX to same value.
5
Do not change FREQ, SC, and RA settings from values shown.
LCD
Push Button
Key Pad
Frequency refers to the pulsar frequencies measured in
hertz. Speed curve defnes the relationship of the hand
control position to the function speed. The threshold ad-
justment changes the amount of hand control travel out
of neutral before the function begins to move. Max out is
used to determine the function speed or cycle time set-
ting. Ramp controls how fast a function speed increases
as compared to the movement of the control.
Low speed controls the following parameters.
Maximum speed setting of a function when the low
speed/standard switch is in the Low Speed posi-
tion.
Settings for the four lever upper controls.
Maximum speed of the digger and winch when another
function is operated. (Low speed of the winch sets
winch operation to keep up with the boom extend
function. Low speed of the digger function adjusts
the priority boom fow so there is enough fow and
pressure to operate boom functions when digging.)
Boom Functions Speeds
Changing the speed of the boom functions is done with
the CADI. This adjustment changes the valve spool travel.
The valve spool travel controls the fow of hydraulic oil
to a function. This determines the maximum speed of
the function.
Testing
1. Testing of the boom functions requires an open area
with suffcient clearance to fully extend and raise the
booms.
3. Warm the oil in the hydraulic system to operating
temperature.
4. Before testing the speed of a function, use a fowmeter
to verify that the pump is delivering the proper amount
of hydraulic oil fow as described under Pump Flow
in this section.
5. The following paragraphs describe how to properly
check the cycle times for each function. A stop watch
is needed to do this. The lower controls should be
used to test all boom function cycle times. Hold
each hand control in the full stroke position during
the entire timing. Maintain maximum pump speed
when performing the test. Run only one function at
a time.
Checking the Speeds of the Rotation Functions:
Raise the boom until the lift cylinder is fully extended.
Using a stop watch, time the seconds it takes for the
unit to rotate 360 degrees clockwise. Write this time
down. With the lift cylinder still extended, time the
seconds it takes to rotate the turntable 360 degrees
counterclockwise. Write this time down.
Checking the Speeds of the Boom Raise and Lower
Functions: Starting with the lift cylinder fully extended,
time the seconds it takes to lower the boom until the
lift cylinder is fully retracted. Write this time down.
Starting with the lift cylinder fully retracted, determine
the seconds it takes to raise the boom until the lift
cylinder is fully extended. Write this time down.
Checking Speeds of Intermediate Boom Extend and
Retract Functions: Position the boom 10 degrees
above horizontal. On units equipped with a turntable
winch, pay out enough winch line to accommodate
the full length of the intermediate boom when it is
extended. Starting with the intermediate boom fully
retracted, time the seconds it takes to fully extend the
boom. Write this time down. Starting with the interme-
diate boom fully extended, time the seconds it takes
to fully retract the boom. Write this time down.
Checking Speeds of the Upper Boom Extend and
Retract Functions: Pay out enough winch line to ac-
commodate the length of the upper boom when it is
fully extended. Repeat the process in the previous
paragraph using the upper boom extend and retract
functions. Write these times down.
6. Compare the speed that was recorded for each func-
tion to the average cycle times in seconds shown in
Figure 8.27. If the speed that was recorded is within
the range, the functions speed is properly set and
does not need adjustment. If the speed that was
recorded is above or below the range, the speed of
the function may be adjusted.
Adjustment
1. Connect the CADI to the CADI connection socket
[refer to Calibration and Diagnostic Instrument (CADI)
in Section 7].
2. Use the mode button to select the calibration
mode.
3. Use the menu button to select the function to be
adjusted. On units with lower controls, the settings
entered for the upper boom are also used as the
settings for the intermediate boom. There are no
separate settings made for the intermediate boom.
4. Use the select button to scroll to the max out param-
eter.
5. Use the value button to increase or decrease the
speed of the function.
6. Retest the speed of any function that is adjusted.
Make adjustments as needed.
7. Disconnect the CADI from the lower control panel.
Upper Control Sequential Boom Extension
Test the intermediate and upper boom sequencing
operation from upper controls as recommended by the
The upper control sequential extension system contains
two proximity switches (refer to Figure 8.28).
The boom position 1 switch is a normally open proximity
switch mounted inside the upper right portion of the inter-
mediate boom hood (as viewed looking from the boom
tip looking toward the turntable). When the upper boom
is fully extended, the switch senses a small metal insert
installed in the fberglass boom near the lower end.
It is equipped with two LED lights on the outboard surface.
The green light indicates there is power to the switch.
The yellow light is off when the upper boom is less than
fully extended, and turns on when the upper boom is
fully extended.
The boom position 2 switch is a normally closed proximity
switch mounted at the lower end of the lower boom on
the right side (as viewed from the boom tip looking toward
the turntable). The switch is equipped with two LED lights
on the outboard surface. The green light indicates there
is power to the switch. The yellow light is on when the
intermediate boom is not fully retracted, and turns off
when the intermediate boom is fully retracted.
If the upper and intermediate booms do not extend or
retract in the proper sequence from upper controls, the
system may have been put out of sequence by the op-
erator moving the controls selector switch on the lower
control panel to the Upper position when the intermedi-
ate boom was not fully retracted. A properly functioning
system is reset by simply retracting the booms fully from
the lower control panel. If resetting the system does not
restore proper operation, use the following procedure to
isolate the problem.
Testing
Function D2045B D2050B D2055B D3050B D3055B D3060B
Boom raise 28 to 32 28 to 32 28 to 32 33 to 39 33 to 39 33 to 39
Boom lower 28 to 32 28 to 32 28 to 32 33 to 39 33 to 39 33 to 39
Intermediate boom extend 20 to 23 23 to 27 28 to 32 23 to 27 28 to 32 30 to 34
Intermediate boom retract 17 to 21 20 to 24 24 to 28 20 to 24 24 to 28 26 to 30
Upper boom extend 18 to 22 21 to 25 21 to 25 21 to 25 21 to 25 28 to 34
Upper boom retract 16 to 20 19 to 23 19 to 23 19 to 23 19 to 23 26 to 31
Rotate left or right (360) 58 to 64 58 to 64 58 to 64 58 to 64 58 to 64 58 to 64
Figure 8.27 Average Cycle Times (Seconds)
Mounting
Bracket
Proximity
Switch (NC)
Figure 8.28 Upper Control Sequential Switches
Lower Boom
Proximity
Switch (NO)
Intermediate Boom Hood
(Looking Toward Turntable)
Top Side
Bracket
Boom Position 1 Boom Position 2
Upper Boom
2. Rotate and lower the boom to a position where the
boom tip can be reached from the ground. Make sure
the booms are fully retracted.
3. Move the controls selector switch on the lower control
panel to the Upper position.
4. Pin the upper control panel to the upper boom tip.
5. Move the upper control on/off selector to the On
position.
6. Shift the extension control handle to the Extend
position. The upper boom should extend fully before
the intermediate boom begins to extend. Then shift
the extension control handle to the Retract position.
The intermediate boom should retract fully before the
upper boom begins to retract.
7. If sequential extension and retraction do not function
as described, test the switches for proper operation
as described under Proximity Switches in this sec-
tion. Also check the status of the Boom Position 1
and Boom Position 2 diagnostic indicator LEDs on
the above rotation valve driver vs. the LED indication
descriptions shown in Figure 7.4, with the upper boom
and intermediate boom extended and retracted or
with a metal object moved close to and away from
the sensing face of the each of the boom position
proximity switches (refer to Section 7 under Above
Rotation Valve Driver). If both switches operate prop-
erly, perform the adjustment procedure described
below.
Adjustment
1. Fully retract both booms from the lower control panel.
Remove the cover closest to the boom pivot on the
side of the lower boom where the boom position 2
switch is mounted.
2. Return the controls selector switch on the lower
control panel to the Upper position, and move the
on/off selector on the upper control panel to the On
position.
3. Look at the boom position 2 switch on the side of
the lower boom (refer to Figure 8.28). The yellow
light should be off with the intermediate boom fully
retracted. If the yellow light is on, loosen the cap
screws mounting the switch bracket, and adjust the
position of the switch so that it senses the lower end
of the intermediate boom and turns the yellow light
off. Tighten the cap screws.
4. Have one person watch the boom position 1 switch
on the intermediate boom hood (refer to Figure 8.28),
while a second person extends the booms from the
upper control panel. The yellow light on the switch
should be off as the upper boom is extending, and
should turn on when the upper boom reaches the
fully extended position. If the yellow light is not on
with the upper boom fully extended, loosen the cap
screws mounting the switch bracket to the boom or
the screws mounting the switch to the bracket, and
adjust the position of the switch so that it senses the
metal actuator plate on the side of the upper boom
and turns the yellow light on. Tighten the cap screws.
5. Repeat the test procedure and adjust as necessary
until the booms extend and retract in the proper
sequence from the upper controls.
Pole Guide Interlock System
Test the pole guide interlock system operation as recom-
Checklist.
The pole guide interlock system contains three switches
(refer to Figure 8.29). The retaining pin sensor switch is
a normally closed button switch installed in the transfer-
able fare pinning boss on the intermediate boom hood.
The pole guide interlock tilt switch is a normally open
proximity switch mounted on the side of the intermedi-
ate boom hood that senses the pole guide tilt position.
It is equipped with two LED lights on the side opposite
from the sensing face. The green light indicates there
is power to the switch. The yellow light is on when the
pole guide is tilted fully back to the stored position, and
turns off when the pole guide is tilted forward out of the
stored position.
The pole guide interlock upper boom switch is a normally
closed proximity switch mounted inside the upper left por-
tion of the intermediate boom hood (as viewed looking
from the boom tip looking toward the turntable). When the
upper boom is fully retracted, the switch senses a small
metal insert installed in the fberglass boom just behind
the boom tip. The switch is equipped with two LED lights
on the side opposite from the sensing face. The green
light indicates there is power to the switch. The yellow
light is off when the upper boom is fully retracted, and
turns on when the upper boom is not fully retracted.
If the button switch is replaced, shim the switch so that it is
actuated when the retaining pin is inserted in the pinning
hole but causes minimum drag on the retaining pin.
If the pole guide assembly is removed for service, it
may be necessary to adjust the position of the proximity
switch.
Testing
2. Rotate and lower the boom to a position where the
boom tip can be reached from the ground.
3. Make sure the booms are fully retracted and the pole
guide is tilted fully back. Pay out several feet of winch
line.
4. Pin the transferable fares to the intermediate boom.
5. Operate the upper boom extend function. The upper
boom should extend normally.
6. Operate the pole guide tilt forward function. The pole
guide should not move forward.
7. Fully retract the upper boom. Operate the pole guide
tilt forward function. The pole guide should move
forward normally. Tilt the pole guide forward about
20 degrees.
8. Operate the upper boom extend function. The upper
boom should not extend. Be ready to stop extending
the upper boom immediately if it starts to extend so
that it does not hit the pole guide.
9. If the pole guide interlock system does not function
as described, test the switches for proper operation.
Test the retaining pin sensor switch with an ohmmeter
or continuity sensor. It should be closed when the
transferable fares are pinned to the upper boom and
open when the fares are pinned to the intermediate
boom. Test the pole guide interlock tilt and upper boom
switches as described under Proximity Switches in
this section.
Also check the status of the Pole Guide and Upper
Boom diagnostic indicator LEDs on the above rota-
tion valve driver vs. the LED indication descriptions
shown in Figure 7.4. Do this with the transferable
fares pinned to the intermediate boom, with the pole
guide tilted fully back and tilted forward and with the
upper boom fully retracted and partially extended, or
else with a metal object moved close to and away
from the sensing face of the each of the pole guide
interlock proximity switches (refer to Section 7 under
Above Rotation Valve Driver). If all three switches
operate properly, perform the following adjustment
procedure.
Adjustment
1. Have one person watch the pole guide interlock tilt
switch (refer to Figure 8.29) on the intermediate boom
hood while a second person operates the pole guide
tilt function. The yellow light on the switch should be
on with the pole guide tilted fully back to the stored
position, and should turn off when the pole guide is
tilted forward about 10 degrees. If the yellow light
does not operate as described, loosen the cap screws
mounting the switch bracket to the boom or the screws
mounting the switch to the bracket, and adjust the
position of the switch. Tighten the cap screws.
2. Repeat the test procedure and adjust the proximity
switch position as necessary, until the pole guide
interlock system operates properly.
Mounting
Bracket
Pole
Guide
Tilt Proximity
Switch (NO)
Top Slide
Bracket
Upper
Boom
Figure 8.29 Pole Guide Interlock Switches
Button Switch
(NC)
Upper Boom
Proximity
Switch (NC)
(Looking Toward Turntable)
Protection Systems
The functions that are temporarily shut off by the HOP
system are the boom lower, intermediate and upper
boom extend, winch raise, and digger dig functions. If
these functions stop working, but the opposite direction
of each function operates, the HOP system is engaged.
If the unit is not overloaded, there are several possible
causes for this. Use the following procedure to isolate
the problem.
1. The HOP pressure transducer engages HOP if it is
defective. If the transducer is working properly, the
electrical cable leading to the HOP pressure trans-
ducer may be disconnected or faulty.
2. The boom stow proximity switch engages HOP when
it is actuated or if it is malfunctioning. If the boom stow
switch is not actuated, the switch may be defective,
or the electrical cable leading to the switch may be
disconnected or defective.
3. On units with electronic side load protection, this
system engages HOP when actuated. Check for
proper operation of the electronic side load protection
system (refer to Electronic Side Load Protection in
this section). If the system is not being actuated by
side loading, a side load pressure transducer may
be defective, or the electrical cable leading to a side
load pressure transducer may be disconnected or
defective.
4. On units with a load moment limiter system, this sys-
tem engages HOP when actuated. Check for proper
operation of the load moment limiter system. If the
system is not being actuated by exceeding the rated
lift capacity of the unit, the HOP pressure transducer
may be defective, or the electrical cable leading to
the HOP pressure transducer may be disconnected
or defective. Refer to Load Moment Limiter System
in this section.
5. On units with anti-two-block protection, this system
engages HOP when actuated. Check for proper
operation of the anti-two-block protection system. If
the system is not being actuated when the load hook
has contacted the ATB weight, the ATB switch may
be defective, the battery in the switch may be low, or
the electrical cable leading to the ATB monitor may
be disconnected or defective. Refer to Anti-Two-Block
(ATB) in this section.
6. Once the component causing the malfunction has
been isolated, check the component and the electri-
cal wire connected to it. Determine the cause of the
problem and correct it.
For the HOP system to operate properly, HOP must
engage when the pressure in the base end of the lift
cylinder reaches 3,150 psi (217.18 bar). If HOP does
not engage, the functions that are inoperative when the
HOP system is operating will be operational. This allows
overloading to continue. Test the operation of the HOP
system as recommended by the Preventive Maintenance
and Inspection Checklist. Use the following procedure
to test the system. Do not use any other method to test
the pressure transducer.
Notice
Do not use the winch raise function to test the HOP
system.
Do not test the HOP system by using the winch Raise
function with the winch line. An improper setting will
result because a rapid rise in the pressure occurs in the
lift cylinder as a load is applied to the winch line.
Testing
To test the operation of the system, a test load is neces-
sary. The test load must be within the load capacity of
the derrick at a given boom angle with the booms fully
retracted. The load must create a suffcient overload to
induce 3,150 psi (217.18 bar) in the lift cylinder as the
intermediate and upper booms are extended.

2. Verify that the system/compensator pressure is
properly adjusted (refer to System/Compensator
Pressure in this section).
3. Verify that the load indicator gauge is properly calibrat-
ed (refer to Load Indicator Gauge is this section).
4. Position the booms so the lift cylinder can be fully
retracted. Lower the booms until the lift cylinder is
fully retracted.
5. Install a pressure gauge [4,000 psi (275.80 bar)
minimum] to the quick disconnect on top of the lift
cylinder valve block. If residual pressure in the cyl-
inder causes diffculty in connecting the gauge, shift
the boom hand control to the Lower position while
connecting the gauge.
6. Start the engine and engage the PTO. Rotate the
boom to the load.
7. Make sure the intermediate and upper booms are
fully retracted. Determine the boom angle that will
keep the test load within the load capacity by using
the derrick capacity placard by the lower control
station. Raise the booms to this angle.
8. Attach the test load to the winch line. Pick up the
load with the winch line.
9. Slowly extend the boom while observing the load
indicator gauge. Pay out the winch line while extend-
ing the boom. This will keep the load from coming
up against the boom tip. The reading on the gauge
should rise slowly as the boom is extended.
10. When the pressure reaches 3,150 psi (217.18 bar),
the extend function should automatically stop. The
load indicator gauge needle should be in the area
marked HOP.
Notice
Property damage can result from overloading the
unit. Stop extending the boom if pressure exceeds
the area marked HOP on the load indicator gauge.
11. If the extend function stops when the pressure reaches
3,150 psi (217.18 bar), the pressure setting is cor-
rect. No adjustment is needed. Make a note of how
far the boom was extended before the HOP system
engaged.
12. Remove the load from the booms. Position the booms
so the lift cylinder can be fully retracted. Lower the
booms until the lift cylinder is fully retracted.
13. Remove the pressure gauge from the quick discon-
nect on the lift cylinder valve block. If residual pres-
sure in the cylinder causes diffculty in connecting
the gauge, shift the boom hand control to the Lower
position while connecting the gauge.
14. If the extend function shuts off before or after proper
pressure, then the pressure setting needs adjust-
ing.
Adjustment
1. If the extend function shuts off before the pressure
reaches 3,150 psi (217.18 bar), the setting must be
increased. If the extend function continued to operate
after the pressure gauge indicated 3,150 psi (217.18
bar), the setting must be lowered.
in Section 7].
3. Use the mode button on the CADI to select the Cali-
bration Mode. Use the menu button to select HOP
Trip. The HOP setting is displayed under LMX. Use
the value buttons to adjust the HOP setting.
4. Retract the booms and repeat the test procedure until
the extend function shuts off at the proper pressure.
5. Remove the load from the booms. Position the booms
so the lift cylinder can be fully retracted. Lower the
booms until the lift cylinder is fully retracted.
6. Remove the pressure gauge from the lift cylinder
valve block quick disconnect. If residual pressure
in the cylinder causes diffculty in disconnecting the
gauge, shift the boom hand control to the Lower
position while disconnecting the gauge. Disconnect
the CADI.
Load Indicator Gauge
The load indicator gauge should be checked to ensure
that the gauge gives a proper indication of the load being
applied to the base end of the lift cylinder.
Testing
2. Use the lower controls to raise the lower boom to full
extension of the lift cylinder.
3. The pressure in the base end of the lift cylinder should
be maximum system pressure and the load indicator
gauge needle should be at 100 percent.
4. If the needle is not at 100 percent the gauge needs
adjusting.
Adjustment
1. Connect the CADI to the CADI connection socket [re-
fer to Calibration and Diagnostic Instrument (CADI) in
Section 7]. Make sure the low speed/standard switch
on the control panel is in the Standard position.
bration Mode. Use the menu button to select HOP
Meter. Use the select button to scroll across to MX.
Use the value buttons to adjust the gauge. Make the
adjustments until the gauge indicates 100 percent
when the pressure on the base end of the lift cylinder
is maximum system pressure.
3. Use the select button on the CADI to scroll across to
LMX. Use the value buttons to increase or decrease
the LMX value until it is the same as the MX value.
4. Repeat the test procedure to ensure a proper reading
on the load indicator gauge. Disconnect the CADI.
Hydraulic Side Load Protection (HSLP)
the unit is equipped with hydraulic side load protection.
The lower control panel, if so equipped, will not contain a
side load gauge. If an excessive side load is developed
on the booms, the hydraulic side load protection system
allows the rotation system to back drive. This allows
the booms to sideslip in the direction of the side pull to
relieve the load. The system resets when the side load
is removed.
When testing the hydraulic side load protection system,
the operation of the rotation brake must also be tested.
Steps for testing the brake are included in the following
procedure.
To test the hydraulic side load protection system, the fol-
lowing tools will be needed. They are available from your
Altec representative (refer to Service Tools and Supplies
in the Appendix).
Dynamometer
Side load test bracket
HSLP brake spanner wrench (included with unit)
Two different types of side load test bracket are avail-
able. The frst type requires a platform mounting tube on
the boom tip for attachment (refer to Figure 8.31). The
second type mounts on the fberglass upper boom, and
does not require a platform mounting tube on the boom
tip (refer to Figure 8.32). The test setup varies for the two
brackets, as described in the following sections.
Setup With Test Bracket
Mounted to Platform Mounting Tube
1. To have an accurate test of the side load protection,
the backlash between the rotation pinion and rotation
bearing gear teeth must be properly set. Check the
backlash between the rotation pinion and rotation
bearing gear teeth as described under Rotation
Gearbox in this section. Adjust if necessary.
Rotation
Gearbox
Rotation/Side Load
Protection Valve
Turntable
Rotation Motor
Rotation Motor
Mounting
Cap Screw
Counterclockwise Side Pull Clockwise Side Pull
Boom Tip
Winch Line
Test bracket sheave pinned in hole
closest to direction of winch line pull
Side Load
Test Bracket
3
/4 Pin
Platform
Mounting Tube
Figure 8.31 Side Load Test Bracket Mounted to Platform Mounting Tube
3. Operate the unit to warm the oil in the hydraulic
system.
4. Fully extend the intermediate boom and fully retract
the upper boom.
5. Lower the boom tip until it can be reached from the
ground.
6. Attach the side load test bracket to the boom tip (refer
to Figure 8.31).
7. Adjust the boom angle to position the bottom of the test
bracket 3 to 6 (8 to 15 cm) above the ground.
8. Run the winch line through the side load test bracket
9. Figure 8.31 shows the proper holes used for pinning
the test bracket sheave. Pin the test bracket sheave
in the hole closest to the direction of winch line pull.
Make sure the winch line clears the side of the boom
tip and runs properly over the sheaves of the boom
tip and side load test bracket. Pay out the winch line
to at least 10 (3 m) beyond the test bracket.
10. Proceed with Testing of Rotation Brake.
Setup With Test Bracket Mounted to Upper Boom
system.
Fully extend the intermediate boom, and extend the
upper boom about 3 (0.91 m).
ground.
6. Attach the side load test bracket to the upper boom,
and slowly retract the upper boom until the bracket
just touches the transferable fares (refer to Figure
8.32). Measure the distance D shown in Figure
8.32. Retract the intermediate boom by distance D.
9. Make sure the winch line runs properly over the
sheaves of the boom tip and side load test bracket
as shown in Figure 8.32. The test bracket contains
two sheaves for use with both clockwise and counter-
Figure 8.32 Side Load Test Bracket Mounted to Upper Boom
Side View End View
Full
Extension
Minus D
Winch Line
Clockwise
Side Pull
Counterclockwise
Side Pull
Side Load
Test Bracket
Transferable
Flares
Intermediate
Boom
Upper Boom
Test
Bracket Pin
D Transferable
Flares Pin
clockwise side pull testing without changing pinning
positions. Pay out the winch line to at least 10 (3 m)
beyond the test bracket.
10. Proceed with Testing of Rotation Brake.
Testing of Rotation Brake
1. Complete the setup and installation of the test bracket
as described above.
2. Attach the winch line to the dynamometer.
3. Attach the other end of the dynamometer to a solid
structure. The solid structure must be located so that
the winch line is horizontal between the side load test
bracket and dynamometer and makes a 90 degree
angle to the side of the booms (refer to Figure 8.31
or 8.32). It may be necessary to rotate the booms
and adjust the length of the winch line to obtain this
winch line arrangement. There must be at least 10
(3 m) between the boom tip and the dynamometer.
4. Remove the rotation motor and valve from the rotation
gearbox without disconnecting any hydraulic lines.
This is done by removing the two rotation motor
mounting cap screws (refer to Figure 8.30).
Notice
Do not exceed the upper brake setting limit specifed
for the model being tested.
5. Refer to Figure 8.33 for the appropriate brake slip
settings range. Meter the winch hand control in the
Raise direction. Slowly tighten the winch line while a
second person watches the dynamometer. Operate
the winch control until the rotation brake begins to
slip and the boom tip begins to sideslip toward the
load pull or until the upper brake slip limit is reached.
Release the winch control immediately if the upper
limit is reached without sideslip occurring.
Model Pounds (kg) [N]
D2045B 1,275 to 1,400 (578 to 635) [5,671 to 6,228]
D2050B 1,150 to 1,250 (522 to 567) [5,115 to 5,560]
D2055B 1,000 to 1,075 (454 to 488) [4,448 to 4,782]
D3050B 1,150 to 1,250 (522 to 567) [5,115 to 5,560]
D3055B 1,000 to 1,075 (454 to 488) [4,448 to 4,782]
D3060B 950 to 1,025 (430 to 465) [4,226 to 4,559]
Figure 8.33 Rotation Brake Slip Settings
6. If sideslip occurs within the range shown for the
applicable model in Figure 8.33, no adjustment is
needed. If the boom sideslips before the lower limit
is reached or if it does not occur by the time the up-
per limit is reached, the rotation brake needs to be
adjusted.
7. Once the proper rotation brake setting has been
confrmed, install the rotation motor and valve back
onto the rotation gearbox. Torque the mounting bolts
to 55 foot-pounds (75 Nm).
Adjustment of Rotation Brake
1. Remove any side load on the booms.
2. Locate the adjusting ring in the top of the rotation
brake housing (refer to Figure 8.34).
Figure 8.34 Rotation Brake
Adjustment With Hydraulic Side Load Protection
3 Use the HSLP brake spanner wrench to turn the
adjusting ring. Turn the adjusting ring clockwise to
increase the brake slip setting. Turn the adjusting
ring counterclockwise to decrease the brake slip
setting.
4. Repeat the rotation brake test procedure in this sec-
tion until the proper setting is obtained at least three
consecutive times. This will ensure the consistency
of the system.
If the brake adjusting ring has been turned clockwise
as far as it will go and the brake slip setting is still be-
low the range in Figure 8.33, the fuid in the brake may
have become deteriorated. Drain the fuid in the brake
and refll it with new fuid as recommended in Section 4
under Lubrication. Then retest the brake as described in
this section. If the proper brake slip setting still cannot be
obtained using new fuid, the brake must be rebuilt using
new friction discs. The discs must be presoaked in fuid
as described in Section 4 under Lubrication.
Testing of Side Load Protection
1. Complete the testing of the rotation brake as described
above.
Brake Adjusting
Ring
Rotation
Gearbox
HSLP Brake
Spanner
Wrench
2. Refer to Figure 8.35 for the appropriate side load
Raise direction. Slowly tighten the winch line while
a second person watches the dynamometer. Oper-
ate the winch control until the side load protection
system engages and the boom tip begins to sideslip
toward the load pull or until the upper side load limit
is reached. Release the winch control immediately if
the upper limit is reached without sideslip occurring.
D2045B 1,525 to 1,900 (692 to 862) [6,784 to 8,452]
D2050B 1,350 to 1,700 (612 to 771) [6,005 to 7,562]
D2055B 1,150 to 1,450 (522 to 658) [5,115 to 6,450]
D3050B 1,350 to 1,700 (612 to 771) [6,005 to 7,562]
D3055B 1,150 to 1,450 (522 to 658) [5,115 to 6,450]
D3060B 1,125 to 1,400 (510 to 635) [5,004 to 6,228]
Figure 8.35 Side Load Settings
3. If sideslip occurs within the range shown for the
applicable model in Figure 8.35, no adjustment is
needed. If the boom sideslips before the lower limit
is reached or if it does not occur by the time the up-
per limit is reached, the side load protection system
needs to be adjusted.
Adjustment of Side Load Protection
2. Locate the rotation/side load protection valve mounted
on the side of the rotation motor.
3. Figure 8.36 identifes the two counterbalance valve
cartridges in the rotation/side load protection valve.
One valve cartridge controls the left (counterclock-
wise) sideslip. The other valve cartridge controls
the right (clockwise) sideslip. Determine the valve
cartridge that must be adjusted for the direction of
rotation that is being adjusted.
4. Loosen the jam nut on the adjusting screw (refer to
Figure 8.36).
5. Turn the adjusting screw counterclockwise to increase
the load at which sideslipping will occur. Turn the
adjusting screw clockwise to decrease the load at
which sideslipping will occur. Make the appropriate
adjustment.
6. Tighten the jam nut while holding the adjusting screw
to keep it from turning.
Figure 8.36 Rotation/Side Load Protection
Valve With Hydraulic Side Load Protection
7. Repeat the test procedure in this section until the
proper setting is obtained at least three consecutive
times. This will insure the consistency of the system.
If it is diffcult to obtain the proper setting, refer to the
notes at this end of this section.
8. Repeat the side load protection testing and adjusting
procedures on the opposite direction of rotation.
If the side load protection setting is one direction is unaf-
fected by adjusting the counterbalance valve cartridge,
the valve cartridge for that direction of rotation may be
defective. A valve that is sticking in the closed position
will cause an abnormally high setting. A valve that is leak-
ing will cause an abnormally low setting. If either occurs,
replace the appropriate valve cartridge.
The side load protection relies on the rotation motor to
act like a pump when the rotation gearbox back drives.
A motor that has internal leakage could affect the adjust-
ability of the system. A defective motor may cause a low
sideslip value in both directions.
Use the following procedure to test for a defective motor.
Top View
Front View
Adjusting Screw
Clockwise (Right)
Sideslip
Counterclockwise
(Left) Sideslip
Valve Ports
Jam Nut
Counterbalance
Valve Cartridges
1. Follow steps 2 through 9 of the appropriate setup and
test bracket installation procedure in this section.
2. Then follow steps 2 and 3 of the rotation brake testing
procedure in this section.
Warning
components.
work areas clean.
3. Disengage the PTO and turn off the engine. Dis-
connect all three hoses from the rotation/side load
protection valve mounted on the motor. Plug the
hoses and cap the port fttings.
Notice
Do not exceed the upper side load limit specifed for
the model being tested.
4. Start the engine and engage the PTO. Meter the
winch hand control in the Raise direction. Slowly
tighten the winch line while a second person watches
the dynamometer. Operate the winch control until
the boom tip begins to sideslip toward the load pull
or until the upper side load limit is reached. Release
the winch control immediately if the upper limit is
reached without sideslip occurring.
5. If the boom sideslips at the same abnormally low
reading on the dynamometer as was seen when
attempting to adjust side load protection, there is
excessive internal leakage in the motor. Replace or
repair the motor. If the upper side load limit is reached
with no sideslip occurring or with only a very slow
drift, the motor does not have excessive internal
leakage.
Electronic Side Load Protection (ESLP)
the unit is equipped with electronic side load protection.
The lower control panel, if so equipped, will contain a
side load gauge.
If an excessive side load is developed on the booms, the
side load protection system engages the HOP system,
shutting off the boom lower, boom extend, winch raise,
and digger dig functions. The system resets when the
side load is removed.
Testing
To test the side load protection system, the following
tools will be needed. They are available from your Altec
representative (refer to Service Tools and Supplies in
the Appendix).
Dynamometer
CADI
Two different types of side load test bracket are avail-
able. The frst type, requires a platform mounting tube on
the boom tip for attachment (refer to Figure 8.38). The
second type mounts on the fberglass upper boom, and
does not require a platform mounting tube on the boom
tip (refer to Figure 8.38).
Setup With Test Bracket
Mounted to Platform Mounting Tube
system.
Rotation
Gearbox
Rotation
Valve
Load Sense
Port
Pressure
Transducer
Rotation
Motor
Turntable
4. Fully extend the intermediate boom and fully retract
the upper boom.
ground.
6. Attach the side load test bracket to the boom tip (refer
to Figure 8.38).
9. Figure 8.38 shows the proper holes used for pinning
the test bracket sheave. Pin the test bracket sheave
in the hole closest to the direction of winch line pull.
Make sure the winch line clears the side of the boom
tip and runs properly over the sheaves of the boom
tip and side load test bracket. Pay out the winch line
to at least 10 (3 m) beyond the test bracket.
10. Proceed with testing.
Setup With Test Bracket Mounted to Upper Boom
system.
Fully extend the intermediate boom, and extend the
upper boom about 3 (0.91 m).
ground.
6. Attach the side load test bracket to the upper boom,
and slowly retract the upper boom until the bracket
just touches the transferable fares (refer to Figure
8.39). Measure the distance D shown in Figure
8.39. Retract the intermediate boom by distance D.
9. Make sure the winch line runs properly over the
sheaves of the boom tip and side load test bracket
as shown in Figure 8.39. The test bracket contains
two sheaves for use with both clockwise and counter-
clockwise side pull testing without changing pinning
positions. Pay out the winch line to at least 10 (3 m)
beyond the test bracket.
10. Proceed with Testing.
Counterclockwise Side Pull Clockwise Side Pull
Boom Tip
Winch Line
Test bracket sheave pinned in hole
closest to direction of winch line pull
Side Load
Test Bracket
3
/4 Pin
Platform
Mounting Tube
Figure 8.38 Test Bracket Mounted to Platform Mounting Tube
Testing
1. Complete the setup and installation of the test bracket
as described above.
2. Attach the winch line to the dynamometer.
3. Attach the other end of the dynamometer to a solid
structure. The solid structure must be located so
that the winch line is horizontal between the side
load test bracket and dynamometer and makes a
90 degree angle to the side of the booms (refer to
Figure 8.39). It may be necessary to rotate the booms
and adjust the length of the winch line to obtain this
winch line arrangement. There must be at least 10
(3 m) between the boom tip and the dynamometer.
Notice
Side loading will result if the winch line becomes
tight at a side angle while raising the booms, which
If it is necessary to raise the boom with the winch line
attached to the dynamometer, pay out the winch line so
that no side load is applied to the boom. The side load
protection system does not protect against side loading
developed by operation of the boom raise function.
Notice
Do not exceed the upper side load limit specifed for
the model being tested.
Do not open the electronic side load protection
bleeder ftting on the rotation gearbox if the unit is
not level or while there is any side loading on the
boom.
4. Refer to Figure 8.40 for the appropriate side load
Raise direction. Slowly tighten the winch line while
a second person watches the dynamometer read-
ing. Operate the winch control until the side load
protection system engages HOP and the winch raise
function is disabled or until the upper side load limit
is reached. Release the winch control immediately
if the upper limit is reached without the side load
protection system engaging HOP.
D2045B 1,525 to 1,900 (692 to 862) [6,784 to 8,452]
D2050B 1,350 to 1,700 (612 to 771) [6,005 to 7,562]
D2055B 1,150 to 1,450 (522 to 658) [5,115 to 6,450]
D3050B 1,350 to 1,700 (612 to 771) [6,005 to 7,562]
D3055B 1,150 to 1,450 (522 to 658) [5,115 to 6,450]
D3060B 1,125 to 1,400 (510 to 635) [5,004 to 6,228]
Figure 8.40 Side Load Settings
5. If the side load protection system engages HOP
within the range shown for the applicable model in
Figure 8.40, no adjustment is needed. If the side
load protection system engages HOP before the
lower limit is reached or if it does not engage HOP
by the time the upper limit is reached, the side load
protection system needs to be adjusted.
Adjustment
Figure 8.39 Test Bracket Mounted to Upper Boom
Side View End View
Full
Extension
Minus D
Winch Line
Clockwise
Side Pull
Counterclockwise
Side Pull
Side Load
Test Bracket
Transferable
Flares
Intermediate
Boom
Upper Boom
Test
Bracket Pin
D Transferable
Flares Pin
in Section 7].
bration Mode. Use the menu button to select ESLP
CW. Use the select button to select LMX. Confrm
that the ESLP CW setting is 00. If it is above 00, use
the down value button to return the setting to 00.
4. Use the menu button on the CADI to select ESLP
CCW. Use the select button to select LMX. The ESLP
CCW LMX setting is used to adjust the side load
setting for both the clockwise and counterclockwise
directions. Use the value buttons to adjust the setting
up or down as required.

5. Repeat the test procedure until the proper side load
setting is obtained at least three consecutive times.
This will insure the consistency of the system.
6. Repeat the side load protection testing and adjust-
ing procedures in the opposite direction of rotation.
Adjust the ESLP CCW LMX setting as required so
that the side load setting is within the specifed range
in both directions of rotation.
7. Disconnect the CADI.
Boom Stow Protection
Test the boom stow switch as recommended by the Pre-
ventive Maintenance and Inspection Checklist.
The boom stow switch is a normally closed proximity
switch. It is equipped with two LED lights which are vis-
ible through the hole in the switch cover. The green light
indicates there is power to the switch. The yellow light is
on when the boom is unstowed, and turns off when the
boom is stowed.
Testing
2. Raise the lower boom several inches above the boom
rest bracket on the chassis.
3. Shift the boom hand control to the Lower position. The
boom lower function should shut off as the boom is
seated in the boom rest. If the boom lower function is
shut off before the boom is seated or fails to shut off
once the boom is seated, test the boom stow switch
as described under Proximity Switches in this section.
Also check the status of the Boom Stow diagnostic
indicator LED on the above rotation valve driver vs.
the LED indication descriptions shown in Figure 7.4,
with the boom stowed and unstowed or with a metal
object moved close to and away from the sensing face
of the boom stow proximity switch (refer to Section
7 under Above Rotation Valve Driver).
Auger Stow Protection
Test the actuation point of the auger stow switch as
recommended by the Preventive Maintenance and In-
spection Checklist.
The auger stow switch is a normally closed proximity
switch. It is equipped with two LED lights which are vis-
ible through the large round hole in the side of the auger
stow bracket. The green light indicates there is power to
the switch. The yellow light is on when the auger tube is
more than a certain distance from the switch, and turns off
when the switch senses the auger tube during stowing.
Testing
2. Raise the boom out of the boom rest. Make sure the
digger is in low speed.
3. Shift the digger hand control slightly in the dig direc-
tion. If the dig function shuts off just before the auger
tube contacts the top of the arch in the auger stow
bracket, the system is operating properly. If the dig
function is shut off before the auger tube rises to just
below the top of the arch or if it fails to shut off before
the tube contacts the top of the arch, test the switch
operation as described under Proximity Switches in
this section. Also check the status of the Auger Stow
diagnostic indicator LED on the above rotation valve
driver vs. the LED indication descriptions shown in
Figure 7.4, with the auger tube at the top of the arch
and moved below the top of the arch or with a metal
object moved close to and away from the sensing face
of the auger stow proximity switch (refer to Section
7 under Above Rotation Valve Driver). If the switch
operates properly, adjust the actuation point of the
auger stow switch.
Adjustment
1. Rotate and lower the boom until the auger stow
bracket can be reached from the ground. Unstow
the auger, allowing it to rest on the ground.
2. Loosen the two cap screws that attach the switch
mounting bracket to the side plate of the auger stow
bracket (refer to Figure 8.41).
Figure 8.41 Auger Stow Switch
3. If the dig function shuts off too early when stowing the
auger, raise the position of the switch. If the dig func-
tion does not shut off before the auger tube contacts
the top of the arch in the auger stow bracket, lower
the position of the switch. Do not move the bottom
of the switch below the top of the arch, as the switch
can be damaged by contact with the auger tube.
Tighten the cap screws.
4. Repeat the test procedure and adjust as necessary
until the switch turns off the digger dig function just
before the auger contacts the top of the arch in the
auger stow bracket.
Rotation Pressure Limiter
The rotation spool valve in the lower control valve contains
a pressure limiter (refer to Figure 8.42). The pressure
limiter limits pressure when the rotation system pressure
reaches a specifc value.
Figure 8.42
Lower Control Valve Pressure Limiters
Testing
To test the rotation pressure limiter, a 4,000 psi (275.80
bar) pressure gauge and a side load test bracket (refer
to Figures 8.38 or 8.40) are needed. These items are
available from your Altec representative (refer to Service
Tools and Supplies in the Appendix).
2. Operate the unit to warm the oil in the hydraulic sys-
tem. Cold oil can result in a pressure limiter setting
that is too low for normal operation.
4. Remove the turntable cover on the right side of the
turntable as viewed from the boom tip. Connect a
4,000 psi (275.80 bar) pressure gauge to the load
sense pressure test port quick disconnect on the
lower control valve (refer to Figure 8.43).
5. Start the engine and engage the PTO. From the lower
controls, fully extend the intermediate boom and
fully retract the upper boom if using a side load test
bracket that mounts to the platform mounting tube
(refer to Figure 8.38). Fully extend the intermediate
boom and extend the upper boom about 3 (0.91m)
if using a side load test bracket that mounts to the
upper boom (refer to Figure 8.39).
ground.
7. Attach the side load test bracket to the boom tip.
8. Adjust the boom angle to position the bottom of the
test bracket 3 to 6 (7.62 to 15.24 cm) above the
ground.
9. Run the winch line through the side load test bracket.
10. If using a side load test bracket that mounts to the
platform mounting tube, pin the sheave in the hole
closest to the direction of winch line pull (refer to Figure
8.38). Make sure the winch line clears the side of the
boom tip and runs properly over the sheaves of the
boom tip and side load test bracket. Pay out the winch
line to at least 10 (3 m) beyond the test bracket.
11. Attach the winch line to a solid structure. The solid
structure must be located so the winch line between
the test bracket and the structure is horizontal. The
winch line must make a 90 degree angle to the side
of the booms with at least 10 (3 m) between the
boom tip and the structure.
Rotation Intermediate Boom
Upper Boom Lower Boom
Mounting
Bracket
Proximity Switch (NC)
Auger Stow
Bracket Side Plate
Two Cap
Screws
12. Shift the rotation hand control in the direction of rota-
tion to place the winch line in tension. Slowly rotate
the boom while watching the reading on the pressure
gauge. The pressure gauge should indicate a maxi-
mum pressure of 2,300 psi (159 bar). The pressure
limiter should be limiting any excess pressure.
If the gauge indicates a value lower than the given
value, the pressure limiter is set too low. If the gauge
indicates a value above the given value, it is set too
high. In both cases, adjustment is necessary.
13. Repeat the test procedure in the other direction of
rotation.
Adjustment
The single pressure limiter affects both directions of
rotation. Therefore, it may be necessary to adjust the
setting of the pressure limiter to obtain an average set-
ting between the two rotation directions.
Use the following procedure to adjust the rotation pres-
sure limiter.
2. Remove the plug on the rotation pressure limiter
cartridge (refer to Figure 8.42).
pressure. Turn the adjusting screw counterclockwise
to decrease the pressure. Make the appropriate
adjustment. Install the plug.
4. Repeat the test procedure. If necessary, make adjust-
ments until the pressure limiter relieves pressure at
the proper value.
5. Repeat the test procedure until the proper limit is
obtained at least three consecutive times. This will
insure the consistency of the pressure limiter.
6. If necessary, repeat the adjustment procedure in the
other direction of rotation.
7. Remove the pressure gauge and replace the turntable
cover.
Lower Boom Pressure Limiter
The lower boom spool valve in the lower control valve
contains a pressure limiter (refer to Figure 8.42). The
pressure limiter is set to limit pressure to 2,850 psi (197
bar) in both the extend and retract directions.
Testing
A 4,000 psi (275.80 bar) pressure gauge is necessary to
test the lower boom pressure limiters.
System Pressure
Quick Disconnect
Load Sense
Quick Disconnect
Pilot Pressure
Quick Disconnect
Pilot Pressure
Reducing Cartridge
sense test port quick disconnect on the lower control
valve (refer to Figure 8.43). When the boom is oper-
ated to the fully raised position or lowered position,
the gauge will read the pressure limiter pressure.
5. Start the engine and engage the PTO. From the lower
controls, fully raise the boom or raise the boom out
of the rest and rotate it to a position where the boom
can be fully lowered. The pressure gauge should
indicate a maximum pressure of 2,850 psi (197 bar)
when the boom is fully raised or fully lowered. The
pressure limiter should be limiting any excess pres-
sure.
indicates a value above the given value, it is set too
high. In both cases, adjustment is necessary.
6. Repeat the test procedure for the other boom.
Adjustment
The single pressure limiter affects both the raise and
lower functions of the lower boom. Therefore, it may be
necessary to adjust the setting of the pressure limiter to
obtain an average setting between the two functions.
2. Remove the plug on the lower boom pressure limiter
cartridge (refer to Figure 8.42).
pressure. Turn the adjusting screw counterclockwise
to decrease the pressure. Make the appropriate
adjustment. Install the plug.
the proper value.
5. Repeat the test procedure until the proper value is
Extension Pressure Limiter
The intermediate and upper boom spool valves in the
lower control valve contain pressure limiters for the ex-
tend functions (refer to Figure 8.42). The pressure limiter
is set to limit extension pressure to 2,850 psi (197 bar).
The hydraulic pressure in the retract circuit is not limited.
Testing
A 4,000 psi (275.80 bar) pressure gauge is necessary to
test the extension pressure limiters. The procedure is the
same for either the intermediate or upper boom.
sense test port quick disconnect on the lower control
valve (refer to Figure 8.43). When the boom is oper-
ated to the fully extended position the gauge will read
the extension pressure limiter pressure.
5. Start the engine and engage the PTO. From the
lower controls, fully extend the boom. The pressure
gauge should indicate a maximum pressure of 2,850
psi (197 bar) when the boom reaches full extension.
The pressure limiter should be limiting any excess
pressure.
indicates a value above the given value, the pressure
limiter is set too high. In both cases, adjustment is
necessary.
6. Repeat the test procedure for the other boom.
Adjustment
2. Remove the plug on the intermediate boom or upper
boom pressure limiter cartridge (refer to Figure 8.42).
3. Turn the adjusting screw clockwise to increase pres-
sure and counterclockwise to decrease pressure.
Make the appropriate adjustment. Install the plug.
the proper value.
5. Repeat the test procedure until the proper value is
6. Remove the pressure gauge and replace the turntable
cover.
Load Moment Limiter
The load moment limiter system (if equipped) is an op-
erational aide which assists the operator by limiting the
maximum load the unit can lift in order to prevent over-
turning. When the load moment limiter system detects a
potential overload condition that could cause instability, it
shuts off machine functions that could cause increased
overloading. The functions that are temporarily shut
off by the load moment limiter system are boom lower,
intermediate and upper boom extend, winch raise, and
digger dig. When the operator eliminates the overload
from the unit, the system automatically restores operation
to the functions that were temporarily shut off. If these
functions stop working, but the opposite direction of each
function operates, the load moment limiter system, HOP
system, electronic side load protection, or ATB protection
may have been engaged.
If the load being lifted is well below the rated capacity as
indicated on the capacity chart, refer to Hydraulic Overload
Protection (HOP) in this section for troubleshooting.
Warning
Death or serious injury can result from overloading
the unit. Do not exceed the rated capacity values.
Only use the override switch after evaluating the
load and load position to verify that the unit will
remain stable.
If the load being lifted is near the rated capacity as
indicated on the capacity chart, it may be possible to
override load moment limiter actuation by using the
override switch located on the lower control panel or
lower radio control transmitter. This should only be used
when the load moment limiter system prevents the lifting
of a load that the operator has determined is within the
rated capacity of the derrick and does not pose a risk for
unit instability. The load moment limiter override switch
does not allow the operator to override HOP. The load
moment limiter override switch is a momentary switch.
Once the load moment limiter system has been actuated,
the operator may press and release the override switch.
This will override the load moment limiter pressure set-
ting and allow additional load to be lifted until reaching
the rated hydraulic capacity of the derrick. Once the load
condition has been removed and the pressure in the
base end of the lift cylinder falls below the load moment
limiter pressure setting, the load moment limiter system
will automatically reset.
Anti-Two-Block (ATB)
The ATB system (if equipped) is an operational aide to
assist the operator in preventing the load hook from con-
tacting the boom tip. A wireless ATB switch is located at
the boom tip, along with an ATB weight and chain. When
the load hook contacts the weight and lifts up on it, the
limit switch closes. This signals the ATB monitor located
at the turntable that two-blocking is imminent. This moni-
tor communicates with the electronic control system of
the unit to shut off machine functions that could cause
two-blocking if their motion is continued. The functions
that are temporarily shut off by the ATB system are boom
lower, intermediate and upper boom extend, winch raise,
and digger dig. When the operator eliminates the contact
between the load hook and the ATB weight and the weight
is again hanging freely, the system automatically restores
operation to the functions that were temporarily shut off.
If these functions stop working, but the opposite direc-
tion of each function operates, the ATB protection, HOP
system, electronic side load protection, or load moment
limiter system may have been engaged.
If the load hook is not near the ATB weight, look at the ATB
monitor mounted in the left hand turntable side cover (as
viewed from the boom tip looking toward the turntable)
to check for system faults (refer to Figure 8.44). If only
the green LED is illuminated, this indicates that the ATB
system is not actuated, and has not stopped the unit
functions. If this condition occurs, refer to HOP informa-
tion outlined earlier in this section for troubleshooting.
If the green, yellow, and red LEDs are illuminated (the
buzzer will also sound) the communication link between
the monitor and switch has been interrupted. Check for
antenna damage, and turn off other radio transmitting
equipment to see if signal is restored. If the yellow LED
fashes at four blinks per second, this is an indication
of a low battery in the ATB switch. Replace the battery
immediately (refer to Service Tools and Supplies in the
Appendix).
Figure 8.44 ATB Monitor
LEDs
Left Hand Turntable
Side Cover
If the load hook has contacted and lifted the ATB weight,
the ATB system has been actuated. This will be indicated
on the ATB monitor by illumination of the green and red
LEDs. A buzzer will also sound from the monitor. Oper-
ate winch lower, boom retract, or boom raise to remove
the two-block condition.
Indicator Lights on ATB Monitor
Green LED only on Power is supplied to moni-
tor, ATB switch is not actuated. Unit is not two-
blocked.
Green and red LEDs on ATB switch has been
actuated, unit is two-blocked.
Green, yellow, and red LEDs on Communication link
has been interrupted, bad radio frequency signal.
Green LED on, yellow LED fashing (four blinks/
second) Low battery indicator, replace battery in
ATB switch.
Green, yellow, and red LEDs scroll on and off
Monitor is in power up mode, and is locating wireless
ATB switch.
Warning
Death or serious injury can result from two-blocking
the unit. The winch can break the load line if two-
blocked. Two-blocking may cause the load line to
fail and load/hook block to fall. Do not allow hook
block to contact the boom tip.
The lower control panel or lower radio control transmitter
is equipped with a switch that can be used to override
the ATB system. This may be used by the operator for a
purpose such as stowing the unit for travel. The override
switch is a momentary switch. If the ATB system has been
actuated but the operator needs to move the load hook
closer to the boom tip, the operator may press and release
the override switch. This will override the ATB system
and allow the load hook to be raised closer to the boom
tip. The load hook should not be allowed to contact the
boom tip. Once contact between the load hook and the
ATB weight is removed and the weight is again hanging
freely, the ATB system will be automatically reset.
An ATB lock out fag is provided for removal of the weight
and chain when work practice allows for operation with-
out ATB protection. This fag may be inserted between
the cable eyelet and the switch. This fag must also be
installed if the entire ATB switch and bracket assembly
is removed from the boom tip.
Warning
Death or serious injury can result from two-blocking
the unit. Remove the lock-out fag prior to unit opera-
tion when ATB protection is required.
Notice
The ATB switch must stay with the unit after remov-
ing it from the boom tip. Removing the switch from
the vicinity of the vehicle will cause the system to
default to a two-blocked state. The wireless ATB
switch is paired with the monitor on each unit. Do
not interchange switches between units.
Manually Lowering/Stowing the Unit
The following text explains how to manually rotate the
turntable and to retract the lower boom and outrigger
cylinders.
Danger
Death or serious injury will result from improper use
of the unit. Do not manually operate the unit without
proper training.
It is not possible to manually retract the booms, stow
the digger, or raise and lower the winch line. Internal
holding valves in the extension cylinders prevent the
booms from being manually retracted. The digger cannot
be manually stowed. If the booms are extended or the
auger is unstowed and the unit does not have a major
hydraulic leak, an auxiliary power source can be used
to stow the unit. The winch cannot be raised or lowered
without hydraulic power.
Warning
between moving components while adjusting the
holding valve. Allow an exit path from the area.
Death or serious injury can result if the unit becomes
unstable. If the unit looses hydraulic power, remove
the load on the winch line before manually stowing
the unit.
Death or serious injury can result if the unit becomes
unstable. Properly stow the booms before raising
the outriggers.
If the unit has a load on the winch line, determine if
the load is heavy enough to cause the unit to become
overloaded or unstable when the booms are manually
rotated and lowered. If the load will cause the vehicle to
be unstable or overloaded, remove the load with other
heavy equipment.
Caution
Injury and property damage can result from contact
of the booms or platform with fxed objects. Make
sure there is suffcient clearance before operating
the unit.
Rotating the Turntable
To rotate the turntable manually, another piece of heavy
equipment, such as a crane or derrick, is needed to as-
sist in rotation. Use the following procedure to manually
rotate the turntable.
Warning
unit movement. Maintain control of the booms when
using another piece of equipment to rotate the turn-
table.
All rotation braking is released during manual rotation. If
the disabled unit is not level, the booms must be positively
restrained. This may be done by hooking the booms to an
operable unit that is positioned uphill from the disabled
unit. Proceed with caution when using another piece of
equipment to rotate or restrain the booms. If the booms
are not restrained and the rotation brake is released,
uncontrolled rotation of the booms could result.
Caution
components.
work areas clean.
1. Secure the booms of the disabled units upper boom
tip to an operable unit.
2. Locate the hydraulic hose which is connected to
the brake release port on the rotation gearbox. The
brake release port is the upper port on the side of the
gearbox facing the turntable. Disconnect the hose
from the ftting in the brake release port, and install
a plug in the end of the hose.
3. Remove the two cap screws that secure the rota-
tion motor to the rotation gearbox (refer to Figure
8.45). Remove the rotation motor and valve as one
assembly from the gearbox. Place the motor and
valve assembly out of the way.
Figure 8.45 Turntable
4. Connect a portable hydraulic hand pump to the ft-
ting in the brake release port. Operate the pump to
pressurize the brake to about 500 psi to fully release
the brake.
5. Use the operable unit to rotate the booms until they
are positioned above the boom rest.
6. Bleed the pressure off of the hand pump. Disconnect
the pump from the ftting in the brake release port.
7. Install the rotation motor and valve. Properly torque
the cap screws.
8. Remove the plug from the brake release hose. Re-
connect the hose to the ftting in the brake release
port.
Lowering the Booms
1. Locate the lower boom manual override handle on the
lower control valve on the right side of the turntable
(refer to Figure 8.46). Move the handle down to the
Boom Lower position.
Counterbalance
Valve
Lift Cylinder
Rotation
Motor Cap
Screws
Rotation
Gearbox
Brake Release
Port (Upper Port)
Warning
Take care when turning the counterbalance valve adjust-
ing screw. As the adjusting screw is turned, the boom
will begin to lower. The rate of movement will increase
as the boom is lowered.
The rate of movement can be adjusted by how far the
counterbalance valve adjusting screw is turned after
movement of the boom starts.
2. Loosen the jam nut on the holding valve cartridge
located in the cavity in the base end of the lift cylinder
3. Using an Allen wrench, turn the holding valve adjust-
ing screw clockwise until the boom begins to lower.
Speed of descent should be controlled with the
adjusting screw. Make note of the number of turns
the adjusting screw is turned in.
Warning
the unit operated.
4. When the boom has been lowered to the rest, re-
turn the adjusting screw to its original position and
tighten the jam nut. Replace or properly adjust the
counterbalance valve to its original setting. Return
the lower control handle to neutral.
Manually Raising the Outriggers
Use the following procedure to manually raise the out-
riggers.
Notice
Follow the stowing procedure to prevent damage
to the unit.
1. Stow the booms.
2. If the equipment is available, raise the vehicle to
remove the load from the outrigger leg.
3. Locate the two holding valves installed near the base
end of the cylinder (refer to Figure 8.47). One of the
valves has a screw in the top of the cartridge. Turn
the screw in (clockwise) until the cylinder begins to
retract. Control the speed of cylinder retraction using
the hex screw. If the unit has out and down outriggers,
use a come-along to retract the horizontal outrigger
leg.
4. When there is no vehicle weight on the outrigger,
lift the outrigger leg with a come-along or a pry bar.
Block up the outrigger shoe at intervals if lifting in
successive steps with a pry bar. Use the come-along
to completely retract the extended outrigger leg.
5. Secure the outrigger legs in the stowed position until
the hydraulic system is again operational.
6. Turn the screw out (counterclockwise) to close the
valve before again using the outrigger.
Auxiliary Power Source
Another hydraulically powered unit may be used as an
auxiliary power source to stow a unit that has lost its hy-
draulic power. The alternate power source must contain
compatible hydraulic oil and should produce a fow no
greater than 16 gpm (60.57 lpm).
Only use the alternate power source to stow the unit for
road travel. It should not be used to operate the unit for
an extended period of time.
Before beginning the following procedure, disengage the
PTO and turn off the engine on both the disabled unit
and operable unit.
The following procedure refers to the disabled unit, except
where specifed.
Manual Override
Control Handles
Upper Boom
Intermediate
Boom
Lower Boom
Rotate
Digger
Winch
Figure 8.47 Outriggers
Holding Valve
Modifed A-Frame
Rod End
Holding Valve
Base End
Base End
Holding Valve
Rod End
A-Frame
Rod End
Holding Valve
Base End
Out and Down
Radial
Rod End
Base End
Holding Valve
X-Frame
Rod End
Base End
Holding Valve
Figure 8.48 Auxiliary Power Source Plumbing
Pressure
Hose
Plug or Cap
Close
Shutoff
Valve
Return Hose
Connect Return Hose
From Operable Unit
Plug or Cap
Connect Pressure Hose
From Operable Unit
Close
Shutoff Valve
1. Close the shutoff valve below the oil reservoir in the
suction line of the pump. Close the shutoff valve in
the return line beside the reservoir.
2. Locate the pressure hose that runs from the pump to the
selector valve inlet (refer to Figure 8.48). Disconnect
this line from the pump and plug the pump outlet.
3. Connect a pressure outlet from the operable unit to
the pressure hose or the valve inlet that was discon-
nected from the disabled unit in step 2. If the operable
unit is equipped with a power tools hose reel, use
the pressure hose on the reel for this purpose. If a
tools reel is not available, use another pressure hose
from the operable unit of suffcient length. Appropriate
fttings will need to be added to the pressure hose
on the disabled unit to do this.
4. Locate the return hose that runs from the selector
valve to the return line shutoff valve (refer to Figure
8.48). Disconnect this hose at one end, and cap or plug
the return line shutoff valve side of this connection.
5. Connect a return inlet from the operative unit to the
return line disconnected from the disabled unit in step
4. If available, use the return hose on the tools reel
on the operable unit for this purpose. Otherwise, use
another hose of suffcient length from a return inlet
on the operable unit. Appropriate fttings will need to
be added to the return hose of the disabled unit to
do this.
If a return inlet is not available, connect a hose to the
return line disconnected in step 4. Insert the free end
of the hose in the fll opening on top of the reservoir
of the operable unit.
6. Start the engine and engage the PTO on the operable
unit. If the electrical system on the unit is still oper-
able, use the lower controls to stow the unit. Use the
outrigger control handles to raise the outriggers.
If the electrical system is not working, use the manual
control handles on the lower control valve to stow the
unit. Manual Operation of Lower Control Valve in the
Operators Manual describes the manual operation of
these valves. To manually raise the outriggers, refer
to Manually Raising the Outriggers in this section.
7. Once the unit is stowed, disengage the PTO and
turn off the engine on the operable unit. Return all
the hydraulic hoses to their original connections on
both units. Open the shutoff valve on the disabled
unit.
Bypassing the Derrick Blocking Valve
If no functions will operate from the lower, upper, or radio
controls, and the troubleshooting procedures described
in Derrick Blocking Valve in this section indicate that the
derrick blocking valve is not opening, this valve can be
temporarily bypassed so the boom can be stowed for
transport to a service facility.
Warning
work areas clean.
2. Disconnect the pressure hose from the pump at the
P port of the selector valve. Disconnect the pressure
hose running from the selector valve to the bottom
of the rotary joint at the UP port of the selector valve
(refer to Figures 8.49 and 8.50).
3. Plug the open valve ports, and use appropriate
adapters to connect the pump pressure hose to the
rotary joint pressure hose (refer to Figure 8.50).
5. Slowly and cautiously operate the controls to stow
the boom.
7. Take the unit out of service until the problem is cor-
rected.
Bypassing the Outrigger/
Tool Blocking Valve
If the outriggers and lower tools will not operate, and the
troubleshooting procedures described in Outrigger/Tool
Blocking Valve and Outrigger/Tool Sense Dump Valve in
this section indicate that the blocking valve is not opening
or the dump valve is not closing, the outrigger/tool block-
ing valve can be temporarily bypassed so the outriggers
can be stowed for transport to a service facility.
Warning
work areas clean.
2. Disconnect the pressure hose from the pump at the
P port of the selector valve. Disconnect the pressure
hose running from the selector valve to the outrigger
and tool valves at the OR port of the selector valve.
Disconnect the sense hose running from the selector
valve to the pump at the LS port of the selector valve
(refer to Figures 8.49 and 8.51).
Toward Pedestal
Side Plate
UP Port
OR Port
P Port
LS Port
Toward Pedestal
Side Plate
Figure 8.50 Bypassing the Derrick Blocking Valve
Pressure Hose
to Rotary Joint
Plug or Cap
Plug or
Cap
Pressure Hose
From Pump
Connection to
Bypass Derrick
Blocking Valve
Figure 8.51 Bypassing the Outrigger/Tool Blocking Valve
Pressure
Hose
From Pump
Sense Hose
to Pump
Tee Connection
to Sense Hose
Connection to
Bypass Outrigger/
Tool Blocking Valve
Pressure Hose to Outrigger
and Tool Valves
Plug or Cap Three Places
3. Plug the open valve ports, and use appropriate
adapters to connect the pump pressure hose to the
outrigger and tool valves pressure hose, with a tee
connection to the sense hose (refer to Figure 8.51).
5. Slowly and cautiously operate the controls to stow
the outriggers.
7. Take the unit out of service until the problem is cor-
rected.
Section 9 Dielectric and Stability Testing 173
Section 9 Dielectric and Stability Testing
This unit has been factory tested, and at the time of
delivery, all applicable ANSI requirements were met or
exceeded. Any time an alteration is made that may affect
the units stability or dielectric insulation, testing must be
performed to confrm that the unit operates safely and in
compliance with all governing organizations.
Dielectric
ANSI requires that manufacturers conduct an AC dielec-
tric qualifcation test on each device before it is sold to
a customer. Once the unit is in the hands of the owner,
ANSI permits the use of a less stringent periodic dielectric
test. This test is to be done at least annually, but typically
in 1 to 12 month intervals. Since the AC periodic test as
defned by ANSI uses the very same procedure but with
less voltage, Altec suggests using the qualifcation test
to avoid confusion. However, some owners prefer to use
DC to do periodic dielectric testing.
This unit is tested to a rating listed on the serial num-
ber placard at the time of delivery. The platform liner,
if furnished, will carry the certifcation test of the liner
manufacturer.
Danger
Death or serious injury will result from contact with
or proximity to an energized conductor. Maintain the
dielectric characteristics of the fberglass boom(s).
Surface irregularities such as scratched, cracked, or
chipped gelcoat can trap dirt and contaminants, which
over time may reduce the dielectric properties of the
fberglass. Of particular concern are irregularities running
lengthwise on the boom. Trapped contaminants, such
as dust particles and water, can cause tracking, provid-
ing a path to ground. Surface fashover occurs when a
substance causes an arcing of electricity between two
points on the boom. If this occurs, the dielectric integrity
of the boom may be permanently damaged.
Dielectric tests that can be performed only after installation
are the responsibility of the installer, whether the installer
is a dealer, owner, or user. After the completed unit is in
the possession of the owner or user, subsequent testing
becomes the responsibility of the owner or user.
The importance of dielectric testing cannot be overem-
phasized. Understand the dielectric test procedures in
ANSI publications. Provide for periodic inspection and
dielectric testing of insulated components at intervals of
1 to 12 months. This recommendation is not intended to
alter more frequent inspection or testing of other com-
ponents as defned in ANSI publications.
In addition to regular tests, conduct tests any time the
dielectric strength of the insulating components is in
doubt.
If it is necessary to change or replace any component
which is part of the units insulation, including booms, tool
lines, control lines, etc., a dielectric test must be performed.
If there is any doubt about the dielectric strength of the
hydraulic oil, perform a dielectric test.
The leakage monitor system, if so equipped, is a tool
used to measure the leakage of electrical current through
the components it is attached to and for dielectric tests
of all voltages. This system consists of wires connected
to components internal to the upper boom and to a test
electrode that extends through the bottom of the fber-
glass upper boom. A test electrode may also be located
on the turntable.
Dielectric test forms can be found in the Appendix. Choose
the appropriate form, thoroughly document all tests, and
maintain records in a permanent fle.
Stability
Due to the possible affect on stability, this unit and/
or vehicle should never be altered or modifed without
the specifc written approval from Altec Industries, Inc.
Component replacement with original equipment parts
will not affect the stability of this unit.
ANSI A10.31 requires tests when the unit mounting is
complete on the vehicle. These stability tests are not re-
quired to be performed again unless signifcant changes
are made in the original vehicle and body mounting or
the unit is remounted on another vehicle.
Warning
movement. Do not permit anyone to occupy the plat-
form until the unit has passed applicable tests.
Death or serious injury can result if the mobile unit
becomes unstable. Provide a suitable restraint while
the stability tests are performed.
Notice
Carefully load the test weight to prevent damage to
the platform or liner.
Test Forms
Stability test forms are provided in the Appendix. The
forms designate the proper boom and jib positions and the
proper test loads to be used. They show the unit loading
confguration(s) that would most likely cause overturning.
174 Section 9 Dielectric and Stability Testing
Completed forms should be dated and signed by the test
technician after conducting the stability tests and should
be retained as part of the original unit documentation.
Two test forms are provided. Engineering must deter-
mine which stability test is required on each mobile unit
to ensure that the worst case stability test is conducted.
If it cannot be determined which of the two tests would
represent the worst case, both tests must be conducted.
All mobile units must be stability tested using the Dig-
ger Derrick Use test regardless of which Use Type is
chosen by the customer. The Combined Digger Derrick
and Platform Use test is not required on units which are
specifed by the customer as Digger Derrick Use only.
It may be required on a unit that is specifed by the cus-
tomer as Combined Digger Derrick and Platform Use.
If it is determined that the test for Digger Derrick Use is
a more stringent test than the test for Combined Digger
Derrick and Platform Use the test for Combined Digger
Derrick and Platform Use may be omitted.
Digger Derrick Use
General Test Conditions
Remove all tools and material including removable
boom supports, extra platforms (not attached to the
unit), and all removable cargo.
Restrict the amount of total fuel in all tanks to 20
gallons (75.71 l) or less.
Only the test technician can be on the unit during
the test.
Do not use outrigger pads.
Perform the test only while operating from the lower
controls.
Provide a suitable restraint during all stability tests to
prevent the mobile unit from overturning in the event
a condition of instability is reached. A typical restraint
method is a loose loop of chain around each side
of the rear axle (allows the axle to raise off the test
surface at least 8 to 10 (20 to 25 cm) before tight-
ening the chain), near the wheel, which is securely
anchored to the ground. Increase the length of the
chain to allow further movement if there is any doubt
about whether the mobile unit has reached a condi-
tion of instability. Raising of outriggers or tires does
not necessarily indicate a condition of instability.
Testing
1. Position the unit on a level, hard surface, apply the
PTO.
2. Properly set the outriggers. Extend the outriggers to
remove the bulge from the tires while still maintain-
ing at least some tire-to-surface contact at each tire.
Level the mobile unit side-to-side with the outriggers.
If equipped with two sets of outriggers, use the out-
riggers to level in the front to back direction.
3. Position the booms for the test as described on the
capacity chart.
4. Apply the proper stability test load to the winch line
(refer to the capacity chart).
5. Rotate the turntable in a full rotation cycle, watching
for any evidence of instability. Note that the full rota-
tion cycle may involve multiple test weights in cases
where the derrick is zone rated for Digger Derrick Use.
Outriggers and tires may lift off the surface during
the test without indicating a condition of instability as
long as the mobile unit does not tend to overturn.
6. If the initial test shows that the mobile unit is unstable,
adjust the outriggers to determine any effect on
stability. Rotate the turntable again in a full rotation
cycle watching for any evidence of instability. Note
that the full rotation cycle may involve multiple test
weights in cases where the derrick is zone rated for
Digger Derrick Use.
7. If it is determined that the mobile unit will not pass
the test as originally built, permanent counterweight,
unit capacity reduction, zone capacity rating, or other
similar solutions must be evaluated to ensure that
the fnished unit will pass the test. Use temporary
counterweight to determine how much permanent
counterweight is needed and where the counterweight
should be added. Rotate the turntable in a full rota-
tion cycle watching for any evidence of instability
after adding the temporary counterweight. If the unit
passes the test with the temporary counterweight,
remove the temporary weight and add the permanent
counterweight. Perform the test again.
8. When a derrick has a zone rated capacity chart,
each zone must be tested. A different test weight
is required for each zone. A separate test form is
required for each zone.
9. After the test has been completed, torque all acces-
sible rotation bearing cap screws to 325 foot-pounds
(441 Nm) using a circular pattern (only required
following initial stability test at the time of initial instal-
lation of unit on chassis).
10. After the test has been completed, torque the rotation
gearbox mounting cap screws to 325 foot-pounds
Section 9 Dielectric and Stability Testing 175
(441 Nm) (only required following initial stability test
at the time of initial installation of unit on chassis).
Combined Digger Derrick and
Platform Use General Test Conditions
Remove all tools and material including removable
boom supports, extra platforms (not attached to the
unit), and all removable cargo.
Restrict the amount of total fuel in all tanks to 20
gallons (75.71 l) or less.
Only the test technician can be on the unit during
the test.
Do not use outrigger pads.
Perform the test only while operating from the lower
controls.
Provide a suitable restraint during all stability tests to
prevent the mobile unit from overturning in the event
a condition of instability is reached. A typical restraint
method is a loose loop of chain around each side
of the rear axle (allows the axle to raise off the test
surface at least 8 to 10 (20 to 25 cm) before tight-
ening the chain), near the wheel, which is securely
anchored to the ground. Increase the length of the
chain to allow further movement if there is any doubt
about whether the mobile unit has reached a condi-
tion of instability. Raising of outriggers or tires does
not necessarily indicate a condition of instability.
The unit must pass the Level Surface Test before
conducting the Five Degree Slope Test.
Level Surface Test
1. Position the unit on a level, hard surface, apply the
PTO.
2. Properly set the outriggers. Extend the outriggers to
remove the bulge from the tires while still maintain-
ing at least some tire-to-surface contact at each tire.
Level the mobile unit side-to-side with the outriggers.
If equipped with two sets of outriggers, use the out-
riggers to level in the front to back direction.
3. Pin the 4.2 (1.28 m) material jib to the boom tip.
Install a single platform to the boom tip. The platform
must be empty but in a load carrying position. The
test may be conducted without a platform by adding
125 pounds (56.70 kg) to the test weight. Pin the
transferable boom fares to the upper boom.
capacity chart.
5. Apply a load to the jib winch line equal to 1.5 times the
capacity shown on the capacity chart for Combined
Digger Derrick and Platform Use at full extension and
boom angles with the jib pinned in a near horizontal
position.
for any evidence of instability. Outriggers and tires
may lift off the surface during the test without indicat-
ing a condition of instability as long as the mobile
unit does not tend to overturn.
7. If the initial test shows that the mobile unit is unstable,
adjust the outriggers to determine any effect on
stability. Rotate the turntable again in a full rotation
cycle watching for any evidence of instability.
8. Add permanent counterweight if it is determined that
the mobile unit will not pass the test as originally built.
Use temporary counterweight to determine how much
permanent counterweight is needed and where the
counterweight should be added. Rotate the turntable
in a full rotation cycle watching for any evidence of
instability after adding the temporary counterweight.
If the unit passes the test with the temporary coun-
terweight, remove the temporary weight and add the
permanent counterweight. Perform the test again.
The unit must pass this test before moving on to the
Five Degree Slope Test.
Five Degree Slope Test
1. Position the unit on a level, hard surface with the
centerline of the vehicle positioned approximately
perpendicular to the direction of the slope. If the Level
Surface Test showed the mobile unit has a greater
tendency to overturn about one side than another,
position the least stable side on the low side of the
slope. Apply the parking brake and chock the wheels.
Engage the PTO.
2. Properly set the outriggers. Extend the outriggers
fully on the low side of the slope. The mobile unit
does not have to be level or maintain tire contact on
the low side for this test. (The mobile unit is usually
the most stable when the low side outriggers are at
maximum penetration and the high side outriggers
are at minimum penetration.) Extend the outriggers
on the high side of the slope, enough to complete a
full cycle of rotation without any intermediate read-
justment of any of the outriggers. Do not extend the
high side outriggers enough to cause the front tire or
outside dual rear tires on the high side of the slope
to lose surface contact.
3. Pin the 4.2 (1.28 m) material jib to the boom tip.
Install a single platform to the boom tip. The platform
must be empty but in a load carrying position. The
176 Section 9 Dielectric and Stability Testing
test may be conducted without a platform by adding
125 pounds (56.70 kg) to the test weight. Pin the
transferable boom fares to the upper boom.
capacity chart.
5. Apply a load to the jib winch line equal to 1.33 times
the capacity shown on the capacity chart for Combined
Digger Derrick and Platform Use at full extension and
boom angles with the jib pinned in a near horizontal
position.
for any evidence of instability. Outriggers and tires
may lift off the surface during the stability test without
indicating a condition of instability as long as the
mobile unit does not tend to overturn.
7. If the initial Five Degree Slope Test shows that the
mobile unit is unstable, adjust the outriggers to de-
termine any effect on stability. Rotate the turntable
again in a full rotation cycle watching for any evidence
of instability.
8. Add permanent counterweight if it is determined that
the mobile unit will not pass the test as originally built.
Use temporary counterweight to determine how much
permanent counterweight is needed and where the
counterweight should be added. Rotate the turntable
in a full rotation cycle watching for any evidence of
instability after adding the temporary counterweight.
If the unit passes the test with the temporary coun-
terweight, remove the temporary weight and add the
permanent counterweight. Perform the test again.
The mobile unit must pass this test.
9. After the test has been completed, torque all acces-
sible rotation bearing cap screws to 325 foot-pounds
(441 Nm) using a circular pattern (only required
following initial stability test at the time of initial instal-
lation of unit on chassis).
10. After the test has been completed, torque the rotation
gearbox mounting cap screws to 325 foot-pounds
(441 Nm) (only required following initial stability test
at the time of initial installation of unit on chassis).
Load Moment Limiter
Notice
Units equipped with the load moment limiter sys-
tem must be stability tested with the transferable
pole guide pinned to the upper boom. Units should
be tested with all boom components installed, and
positioned where they will cause the maximum pos-
sible load moment.
Testing
1. Perform the appropriate stability test as described
earlier in this section. Leave the unit set up the same
as was used for the stability test.
2. Once the stability test load has been used to verify
unit stability (refer to the capacity chart), set the load
on the ground by lowering the winch.
Make sure the boom is still at the stability test
angle.
Make sure that the booms are still fully extended.
If the HOP pressure transducer was bypassed for
the stability test, reconnect the transducer.
3. Connect the CADI to the CADI connection socket.
4. Use the mode button on the CADI to select the cali-
bration mode. Use the menu button to select HOP
trip. The HOP trip value is displayed under LMX.
Record the HOP trip value.
5. Use the menu button to select LML trip. The LML trip
value is displayed under LMX. Use the value buttons
to adjust the LML trip value equal to the HOP trip
value.
6. Shift the winch control slightly toward the Raise posi-
tion and attempt to lift the stability test load. Lift very
slowly to avoid spikes caused by jerking or bouncing
the load.
7. If the HOP system engages and shuts off the winch
before the weight comes off the ground, the LML trip
value must remain equal to the HOP trip value. Lower
the load to the ground and proceed to step 10.
8. If the winch will lift the stability test load off the ground
without engaging HOP, reduce the LML trip value
to provide the necessary load moment protection.
Lower the load to the ground and proceed to step 9.
9. Using the CADI, reduce the LML trip value one number
at a time and continue to retest until the HOP system
engages and prevents the winch from raising the
stability test load off of the ground. For example, if
the winch will raise the load at LML trip=84, but will
not raise the load at LML trip=83, set the LML trip to
83.
10. Record the LML trip value on the Stability Test Form.
Disconnect the CADI from the CADI connection
socket.
Appendix
1 Appendix Glossary
Glossary
2nd stage boom see intermediate boom.
3rd stage boom see upper boom.
A-frame outrigger an extendible outrigger having two diagonal
members which are connected at the top and joined near the midsection
by a horizontal cross piece. Resembles a broad based A.
above rotation in reference to a position on or about a unit that is
vertically above the rotation bearing.
absolute a measure having as its zero point or base the complete
absence of the item being measured.
absolute pressure a pressure scale with the zero point at a perfect
vacuum.
access hood hinged part of the disc housing used to access the
cutter disc.
accumulator a container used to store fuid under pressure as
a source of hydraulic power or as a means of dampening pressure
surges.
actuator a device for converting hydraulic energy into mechanical
energy, such as a motor or cylinder.
adapter a device used to connect two parts of different type or
diameter.
adhesion promoter surface prepping solvent for UV coating.
adjusting stud a component of a cable drive system that is threaded
on both ends and has a hex adjusting fat in the center. It secures the
drive cable to the cylinder rod and can be used to adjust the tension
of the drive cable.
aeration the entrapment of air in hydraulic fuid. Excessive aeration
may cause the fuid to appear milky and components to operate errati-
cally because of the compressibility of the air trapped in the fuid.
aerial control valve the control valve on the turntable of an elevator
unit which operates the movement functions of the aerial device.
aerial device a vehicle-mounted device with a boom assembly
which is extendible, articulating, or both, which is designed and used
to position personnel. The device may also be used to handle material,
if designed and equipped for that purpose.
Allen wrench a six-sided wrench that fts into the hex socket of a
cap screw or set screw.
American National Standards Institute (ANSI) a self-governing
body of professionals whose primary objective is to prevent accidents
by establishing requirements for design, manufacture, maintenance,
performance, use and training for manufactured goods including aerial
devices and digger derricks.
anaerobic adhesive a bonding agent or adhesive that cures in
the absence of air.
analog signal an electrical signal that communicates information
by the continuous variation of voltage or current level within a defned
range, in proportion to an input parameter such as pressure or control
lever position.
annular area a ring shaped area. Usually refers to the piston area
minus the cross-sectional area of the rod of a hydraulic cylinder.
ANSI see American National Standards Institute.
anti-two-block (ATB) system the system that helps prevent dam-
age to the winch line or boom by preventing a two-blocking condition
from occurring, by shutting off certain functions when the load hook,
overhaul ball, hook block, or other lifting component that is attached
to the winch line approaches near the boom tip.
antirotation fork a two-pronged retainer which is fastened to the
inside of the turntable and used to prevent movement of the rotary
joint outer housing.
antifoam additive an agent added to hydraulic fuid to inhibit air
bubbles from forming and collecting together on the surface of the
fuid.
antiwear additive an agent added to hydraulic fuid to improve
the ability of the fuid to prevent wear on internal moving parts in the
hydraulic system.
anvil The stationary blade on a chipper cutting mechanism.
arbor bar the shaft or spindle that is used to support a cable reel.
arbor bar collar a cylindrical device that is used to secure a cable
reel on an arbor bar.
arm 1: the primary load-carrying structure of an articulating arm. 2:
the primary load-carrying structure of a single elevator. 3: the articulat-
ing structure which supports the arbor bar for reel lifting.
arm cylinder the hydraulic cylinder that moves the arm of a single
elevator up and down.
articulating arm a system located between the turntable and lower
boom of an aerial device which is used for lifting the boom assembly
to increase the platform working height. This system includes the arm,
link(s), riser and articulating arm cylinder.
articulating arm cylinder the hydraulic cylinder that moves an
articulating arm up and down.
articulating-boom aerial device an aerial device with two or more
boom sections that are connected at joint(s) which allow one boom to
pivot with respect to the adjacent boom.
ASTM American Society for Testing and Materials.
atmosphere (one) a pressure measure equal to 14.7 psi.
atmospheric pressure pressure on all objects in the atmosphere
because of the weight of the surrounding air. At sea level, about 14.7
psi absolute.
atmospheric vents a vacuum prevention device designed to allow
air to enter a hydraulic line that has encountered an internal pressure
below that of the atmosphere (vacuum).
attention information that must be followed to reduce the likelihood
of property damage. Property damage could include structural damage
to the unit, component failure, or damage to nearby property.
auger the hole boring tool of the digger, consisting of a hollow tube
with hardened teeth attached at one end to dig into and break up soil
and/or rock as the auger is rotated. Several turns of fighting are welded
to the tube to carry the loose material away from the teeth.
auger extension shaft a shaft which fts into the auger tube to
connect the digger output shaft to the auger.
auger rotation hydraulic system the hydrostatic system on a pres-
sure digger which operates the auger transmission gearbox.
auger stow bracket the bracket on a digger derrick lower boom
which stores the digger and auger assembly when it is not in use.
auger stow switch a limit switch which is actuated by the auger
to shut off digger operation in the stowing direction when the auger
reaches its fully stowed position in the auger stow bracket.
auger transmission gearbox the gearbox mounted on the mast
weldment of a pressure digger that is used to rotate the kelly bar.
auger tube the hollow tube at the centerline of an auger to which
the auger fighting is welded.
auger windup sling the cable or strap attached to the auger stow
bracket which is used to store the digger and auger.
auxiliary engine a separately mounted engine that is used to provide
power for the units hydraulic system.
auxiliary hydraulic system the secondary hydraulic system of a
pressure digger that operates all the hydraulic functions except auger
rotation.
AWS American Welding Society.
back pressure pressure existing in the discharge fow from an ac-
tuator or hydraulic system. It adds to the pressure required to operate
an actuator under a given load.
backlash the clearance at the tooth contact point between the
adjacent gear teeth of two or more meshing gears.
baffe a device, usually a plate, installed in a reservoir to separate
the return line inlet from the suction line outlet.
band of arrows decals used on extendible and articulating upper
booms to defne the boom tip area and the insulating portions of the
upper boom and lower boom insert.
bare-hand work a technique of performing live line maintenance on
energized conductors and equipment whereby one or more authorized
persons work directly on an energized part after having been raised
and bonded to the energized conductors or equipment.
barrel the hollow body of a hydraulic cylinder into which the piston
and rod are assembled.
base boom see lower boom.
base end 1: the closed end of a hydraulic cylinder, opposite from the
end that the rod extends from. 2: the end of an extendible boom that is
2 Appendix Glossary
closest to the turntable. 3: the end of an articulating boom that remains
positioned closest to the turntable when the boom is fully unfolded.
basket see platform.
battery charger a device used to restore the electrical charge in
a battery.
bearing a machine part that is installed between two adjacent machine
parts to allow those parts to rotate or slide with respect to each other.
Commonly used to decrease friction or wear on components.
behind cab mount a pedestal mounting position located immediately
behind the vehicle cab on the longitudinal centerline of the chassis.
below rotation in reference to a position on or about a unit that is
vertically below the rotation bearing.
below rotation controls controls that are located on the chassis,
used for operating some or all of the functions of the unit.
bleed-off to reduce the trapped pressure in a hydraulic system,
line, or component, to a zero state by allowing fuid to escape under
controlled conditions through a valve or outlet.
blocking valve a two-position, two-way valve that blocks pump fow
to a hydraulic circuit or system when it is not actuated, and opens to
allow fuid when actuated.
body a structure containing compartments for storage of tools,
materials, and/or other payload which is installed on a vehicle frame
or subbase.
body belt a component in a personal fall protection system consisting
of a strap which is secured about the waist of a person, with a means
for attaching it to a lanyard. (As of January 1, 1998, the use of a body
belt for personal fall protection is prohibited by OSHA.)
body harness a component in a personal fall protection system
consisting of an assembly of straps which are secured about the waist,
chest, shoulders, and legs of a person, with a means for attaching the
assembly to a lanyard.
bolt a cylindrical fastener with external screw threads at one end
and a head confguration such hexagonal, square, or round at the other
end, which conforms to the dimensional and material specifcations
published for bolts. (These specifcations are different from those for
cap screws.)
boom a movable, mechanical structure that is used to support a
platform, material handling components and/or other attachments on
a unit.
boom angle indicator a device which indicates the angle between
the boom centerline and a horizontal plane.
boom fares steel structures mounted on the boom tip of a digger
derrick which are used to protect the boom tip from loads and support
poles carried on the winch line.
boom functions valve the control valve on a digger derrick that
directs hydraulic pressure and fow to the boom functions (boom, rota-
tion, intermediate boom, upper boom) hydraulic circuits.
boom limiting system the system of hydraulic cylinders or a
combination of switches that prevent the platform from moving into a
non-working position.
boom pin the horizontal pin that connects the lower boom to the
turntable or riser.
boom rest the structural member attached to the chassis or body
to support the lower boom in the travel or rest position.
boom stow switch a limit switch which is actuated to shut off the
boom lower function when the boom reaches its stowed position in
the boom rest.
boom stow valve a mechanically actuated hydraulic valve that limits
the downward pressure of a boom as it is placed in its rest.
boom tip the area at the end of an extendible or articulating upper
boom that is farthest from the turntable when the boom assembly is
extended or unfolded. This area includes all components at the end
of the boom above the band of arrows.
boom tip idler sheave the upper sheave in a digger derrick upper
boom tip containing two sheaves, which carries the winch line as it
travels from the winch to the lower sheave (boom tip sheave).
boom tip pin a horizontal pin at the upper boom tip. Platform mounting
bracket(s) and material handling devices are fastened to this pin.
boom tip sheave 1: the sheave in a digger derrick upper boom tip
containing only one sheave, which carries the winch line as it travels
from the winch to the load. 2: the lower sheave in a digger derrick up-
per boom tip containing two sheaves, which carries the winch line as it
travels from the upper sheave (boom tip idler sheave) to the load.
boom tip tools see upper tool circuit.
boom tip winch a winch located at the tip of a boom.
bore the inside diameter of a pipe, tube, cylinder barrel, or cylindrical
hole in any of various other components.
boss protruding material on a part which adds strength, facilitates
assembly, provides for fastenings, etc.
brake a device used to slow or stop the rotation or movement of a
component such as a rotation gearbox, winch, gravity leveled platform,
or arbor bar.
brake caliper mechanical assembly that houses the brake pads
and piston used to apply stopping force on the brake rotor.
brake controller interface between tow vehicle and electric trailer
brakes. Can be inertia activated or based on time delay from activation
of vehicle brakes. Typically in the tow vehicles driving compartment
with electrical line running to the trailer wiring connector. Most require
the user to adjust brake gain to compensate for varying trailer load.
Necessary for the use of electric trailer brakes.
brake rotor rotating disk attached to a shaft that transfers the force
from the brake caliper to the shaft.
break-away switch a device which automatically activates the
breaking system of a towed unit when unintentionally separated from
the towing vehicle.
breather a device that permits air to move in and out of a container
or component to maintain atmospheric pressure.
bridge mount a unit mounting confguration in which the turntable
is mounted on a pedestal structure which forms a bridge over the
cargo area.
broadband a high speed telecommunication system utilizing fber
optic and/or coaxial cable.
bucket see platform.
buckeye see forged pin retainer.
bullwheel assembly an assembly of steel rollers used as a portion
of a cable stringing system.
burst pressure the minimum internal pressure that will cause a
hose, tube, cylinder, or other hydraulic or pneumatic component to
rupture or split open.
button head a type of cap screw with a rounded head containing a
socket into which a tool can be inserted to turn the cap screw.
bypass a secondary passage for fuid fow.
bypass valve a hydraulic valve that allows for an alternate pas-
sage for fuid fow.
cable 1: a wire or wire rope by which force is exerted to control or
operate a mechanism. 2: an assembly of two or more electrical conduc-
tors or optical fbers laid up together, usually by being twisted around a
central axis and/or by being enclosed within an outer covering.
cable chute a device used to guide cable into strand for lashing
the cable to the strand when placing cable. A trolley allows the device
to ride on the strand as cable is fed through the chute.
cable drive system an upper boom drive mechanism which utilizes
cables to produce upper boom movement.
cable guide a bracket which is mounted on a boom to guide the
winch line.
cable keeper 1: a mechanical device attached to a cable that is used
to maintain the position of the cable on a sheave. 2: a component used
to prevent a cable or winch line from coming off a sheave.
cable lasher a mechanical device which wraps lashing wire in a
spiral confguration around a length of suspension strand and adjacent
communication cable.
cable lug a mechanical device attached to a cable that is used to
maintain the position of the cable on a sheave.
cable placer a type of aerial device which contains a cable string-
ing system and associated components for use in erecting overhead
communication cable.
cable slug the steel end ftting at each end of the drive cable in an
upper boom drive system. One end is attached to the cylinder rod and
the other is secured in a pocket on the elbow sheave.
3 Appendix Glossary
cable stringing system the group of steel rollers, bullwheel as-
semblies, strand sheave assemblies and fairlead which directs com-
munication cable or suspension strand from the reel it is stored on to
the working position of the operator.
calibrate to check, adjust, or determine by measurement in com-
parison with a standard, the proper value of each scale reading or
setting on a meter or other device.
caliper a measuring instrument with two legs or jaws that can be
adjusted to determine the distance between two surfaces.
cam a rotating or sliding piece that imparts motion to a roller moving
against its edge or to a pin free to move in a groove on its face or that
receives motion from such a roller or pin.
candling a method of inspecting flament wound fberglass booms
by slowly passing a light through the inside of the boom in a darkened
area. Cracks, crazing, and other damage show up as dark spots or
shadows.
cap a device located on the hand of a reel lifter that is used to
retain the arbor bar.
cap end see base end.
cap screw a cylindrical fastener with external screw threads at
one end and a head confguration such as hexagonal, hex socket, fat
countersunk, round, or slotted at the other end, which conforms to the
dimensional and material specifcations published for cap screws.
capacitive coupling the transfer of electrical energy from one
circuit to another through a dielectric gap.
capacity chart a table or graph showing the load capacity, rated
capacity, or rated load capacity fgures for a unit or accessory.
captive air system a closed circuit, low pressure pneumatic system
used to actuate a pressure switch by means of a manually operated
air plunger.
cartridge 1: the replaceable element of a fuid flter. 2: the replace-
able pumping unit of a vane pump, composed of the rotor, ring, vanes
and side plates. 3: A removeable hydraulic valve that is screwed into
place in a cavity in a hydraulic manifold or cylinder.
catrac see hose carrier.
caution information that indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
cavitation the formation of gaseous voids in hydraulic fuid caused
by a low pressure condition which typically occurs when inlet starvation
prevents the pump from flling completely with fuid. The characteristic
sound of cavitation is a high pitched scream.
center mount see behind cab mount.
center of gravity the point in a component or assembly around
which its weight is evenly balanced.
centerline of rotation the vertical axis about which the turntable
of a unit rotates.
centrifugal pump a pump in which motion and force are applied
to fuid by a rotating impeller within a housing.
chain a series of identical rigid segments connected to each other
at joints which allow each segment to pivot with respect to adjacent
segments, used to transmit mechanical force.
chain extension system a mechanical system consisting of a mo-
tor, gearbox, chains, and sprockets that is used to extend and retract
an extendible upper boom.
chain sling an inverted Y-shaped length of chain used for lifting a
strand reel with an aerial device and placing it in a strand carrier.
chamber a compartment within a hydraulic component that may
contain elements to aid in operation or control, such as a spring cham-
ber or drain chamber.
channel a fuid passage that has a large length dimension compared
to the dimension of the cross-section.
charge to fll an accumulator with fuid under pressure.
charge pressure the pressure, above atmospheric pressure, at
which replenishing fuid is forced into the hydraulic system.
charge pump the hydrostatic hydraulic system pump that provides
fuid at low pressure to make up for internal leakage, provides cooling
fuid fow, and tilts the hydrostatic pump swash plate.
chassis a vehicle on which a unit is mounted, such as a truck,
trailer, or all-terrain vehicle.
check valve a valve that permits fow of fuid in one direction, but
not in the reverse direction.
chip curtain rubberized defection curtain attached to the infeed
chute.
chip defector directs chip discharge.
circuit the complete path of fow in a hydraulic or electrical sys-
tem.
circuit breaker a form of electrical switch which opens (trips) to
interrupt a circuit when it senses excessive current fow that may be
caused by a short circuit, to protect wiring and components from damage.
Some types of circuit breakers reset automatically when the excessive
current discontinues and others must be reset manually.
clean out clean out area under the lower feed roll.
clevis a U-shaped fastening device secured by a pin or bolt through
holes in the ends of two arms.
closed center a directional valve design in which pump output is
blocked by the valve spool(s) when the valve spool(s) is in the center
or neutral operating condition.
clutch 1: the device on a reel lifter which allows the connection and
disconnection of the arbor bar and the driver. 2: controlled transfer of
rotational power from engine to output PTO shaft.
coaxial cable a type of shielded cable used for conducting tele-
communication signals, in which the signal carrier is a single wire at
the core, surrounded by a layer of insulating material, which is in turn
surrounded by a metallic, conductive layer which serves as a shield,
with an overall outer layer of insulation.
combined digger derrick and platform use the stability criteria
for a digger derrick mobile unit which indicates that the load capacity
chart and stability requirements apply to the use of the derrick for lifting
of loads with the winch line at the upper boom tip or material handling
jib tip, with the platform occupied.
come-along a device for gripping and putting tension into a length
of cable, wire, rope, or chain by means of two jaws or attaching devices
which move closer together when the operator pulls on a lever.
communication cable a copper wire, coaxial, or fber optic cable
used for conducting telecommunication signals.
compensating link a mechanical linkage that serves as a connector
between the turntable and the upper boom drive mechanism. As the
lower boom is raised or lowered, this linkage causes the upper boom
to maintain its relative angle in relationship to the ground.
compensator a valve spool that is used to maintain a constant
pressure drop regardless of supply or load pressure.
compensator control a control for a variable displacement pump
that alters displacement in response to pressure changes in the system
as related to its adjusted pressure setting.
component a single part or self-contained assembly.
compressibility the change in volume of a unit volume of a fuid
when it is subjected to a unit change in pressure.
conductive having the ability to act as a transmitter of electricity.
Electricity will fow through metal, therefore metal is conductive.
conductive shield a device used to shield the lower test electrode
system from capacitive coupling.
conductor a wire, cable, or other body or medium that is suitable
for carrying electric current.
constant resistivity monitor device used to continuously measure
the electrical resistance of the wash water in the tank of an insulator
washer.
contaminate to render unft or to soil by introduction of foreign or
unwanted material.
continuous rotation a rotation system in which the turntable is
able to rotate an unlimited number of revolutions about the centerline
of rotation without restriction.
control a device, such as a lever or handle, which is actuated by
the operator to regulate the direction and speed of one or more func-
tions of a unit.
control bar when manually activated, controls the movement of
feed roll(s) on a chipper.
control feed a wood chipper which controls the infeed rate to the
cutting mechanism.
4 Appendix Glossary
control station a position where controls for unit operation are
located. These positions may include the platform, upper boom tip,
turntable, pedestal or vehicle tailshelf.
control valve a directional valve controlled by an operator, used to
control the motion or function of an actuator or system.
cooler a heat exchanger used to remove heat from hydraulic fuid.
corner mount a pedestal mounting position located behind the
rear axle(s) with the centerline of rotation located to one side of the
chassis.
corona ring see gradient control device.
counterbalance valve a load holding valve that can be opened
to allow fow in the normally blocked direction by applying hydraulic
pressure to a pilot port, and which contains a relief capability to allow
fow from the blocked direction if the blocked pressure exceeds a
certain value.
courtesy cut partial cut through limbs so as to allow limbs to fold
towards tree trunks and allow ease of feeding chipper.
cracking pressure the pressure at which a pressure actuated valve,
such as a relief valve, begins to pass fuid.
crazing a network of fne cracks on or below the fberglass surface.
Crazing often occurs when the fberglass is struck with a blunt object,
sometimes causing deformation and breakdown of the fberglass
resin.
crosstalk a form of interference in which one circuit or channel
receives some unintentional signal from another.
cross-ported a hydraulic path connected between the two opposite
fow paths of a hydraulic circuit that allows a route for fow between
the two paths in lieu of fow thru an actuator. To allow sensing of the
pressure in one path by a component installed in the other path.
cSt (centistoke) a metric unit of kinematic viscosity. In customary
use, equal to the kinematic viscosity of a fuid having dynamic viscosity
of one centipose and a density of one gram per cubic centimeter.
curb side the side of a vehicle which is opposite from oncoming
traffc when the vehicle is traveling forward in the normal direction in
a lane of traffc.
cushion a device built into a hydraulic cylinder that restricts the fow
of fuid at the outlet port to slow the motion of the rod as it reaches
the end of its stroke.
custom option an option which is not shown on a standard order
form and which requires additional engineering work to supply.
cylinder a device that converts fuid power into linear mechanical
force and motion. It usually consists of a moveable piston and rod, or
plunger, operating within a cylindrical bore.
danger information that indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury. This signal
word is to be used in the most extreme situations.
DC pump a pump which is powered by a direct current electric
motor.
dead band the area or range near the center rest position of a
hand control where the function does not respond to movement of
the lever or handle.
decal a thin sheet of fexible material which is attached to another
surface by adhesive, and is used to convey instructions, information
and warnings.
deenergize to remove electrical power from a device, as from the
coil of a solenoid valve.
delivery the volume of fuid discharged by a pump in a given time,
usually expressed in gallons per minute (gpm).
demulsibility the ability of a liquid to expel another type of liquid.
Commonly used to describe a fuids ability to cause water to separate
out rather than being held in suspension.
design voltage the maximum rated line voltage for which an aerial
device has been designed, and for which it can be qualifed.
desolve surface prepping solvent for low voltage coating.
detent a device for positioning and holding one mechanical part in
relation to another so that the device can be released by force applied
to one of the parts.
diagnostic relating to the practice of investigation or analysis of the
cause or nature of a condition, situation, or problem.
diagonal brace the structural member attached near the top of a
corner mount pedestal and extending downward and forward to a point
of attachment on the subbase or vehicle frame between the pedestal
and the vehicle cab.
dial indicator a meter or gauge with a calibrated circular face and
a spring-loaded plunger, used as a measuring device.
diegrinder a small, hand held, rotary grinding tool.
dielectric nonconductive to electrical current.
differential cylinder any cylinder that has two opposed piston
areas that are not equal.
digger the mechanism which drives the auger.
digger bail a tubular housing attached to the gearbox portion of a
digger, which surrounds the motor and provides an attachment point
to the digger link.
digger derrick a multipurpose, vehicle-mounted device with an
extendible boom which may accommodate components that dig
cylindrical holes, set utility poles, and position materials, apparatus,
and/or personnel.
digger derrick use the stability criteria for a digger derrick mobile
unit which indicates that the load capacity chart and stability require-
ments apply to the use of the derrick for lifting of loads with the winch
line at the upper boom tip or material handling jib tip, with the platform
stowed or removed, if so equipped.
digger hanger bracket the structural member on a digger derrick
which supports the digger link on the extendible boom.
digger latch mechanism a mechanism which secures the digger
to the lower boom when it is stowed and to the extendible boom when
it is unstowed.
digger link the structural member which attaches the digger to the
digger hanger bracket.
digger/winch valve the control valve on a digger derrick that
directs hydraulic pressure and fow to the digger and winch hydraulic
circuits.
digital signal an electrical signal that communicates information
by the use of two distinct levels of voltage or current, a high on level
and a low off level, which are sent in a series of pulses. The timing
of the pulses is used to indicate the level of an input parameter such
as control lever position, or information such as the address setting of
a radio control transmitter linking it to its receiver.
diode an electrical component that allows current fow in one direc-
tion but not in the reverse direction.
directional valve a valve that selectively directs or prevents fuid
fow through desired passages.
disc the rotating component, housing the knifes on a disc chip-
per.
disc chipper a wood chipper which utilizes a disc shaped, rotating
cutter mechanism.
disc housing weldment housing the cutting disc, comprising of the
base, stationary hood and access hood.
discharge chute directs chip discharge from the cutter mechanism
in the desired direction.
displacement the quantity of fuid that can pass through a pump,
motor or cylinder in a si ngle revolution or stroke.
docking station a device used to mount a remote control transmit-
ter on a platform.
dog clutch see drum clutch.
double-acting cylinder a cylinder in which fuid pressure can be
applied to either side of the piston to move the rod in either direction.
double elevator an elevator lift with two load carrying arms. The
double elevator system includes a lower pedestal, lower arm, lower arm
cylinder(s), riser, upper arm, upper arm cylinder(s), and upper pedestal,
plus parallel links in both the lower and upper sections.
double-pole, double-throw (DPDT) switch a six-terminal electrical
switch or relay that connects, at the same time, one pair of terminals
to either of two other pairs of terminals.
double-pole, single-throw (DPST) switch a four-terminal electrical
switch or relay that, at the same time, opens or closes two separate
circuits or both sides of the same circuit.
down load the downward force created when an external force is ex-
erted on the boom, such as a winch pulling cable on a cable placer.
5 Appendix Glossary
energize to send electrical power to a device, as to the coil of a
solenoid valve.
energized conductor an apparatus that is transmitting electric
current.
energy the ability or capacity to do work, measured in units of
work.
engine protection system a system which detects when the
auxiliary engine oil pressure or temperature is out of the proper range
and shuts the engine off.
extendible capable of linear movement of one or more portions of
an assembly to increase the overall length or reach of the assembly.
extendible-boom aerial device an aerial device with a telescopic
or extendible boom assembly.
extension cylinder a hydraulic cylinder which extends and retracts
an extendible boom(s).
fairlead the group of steel rollers at the platform of a cable placer which
guide the cable or suspension strand during the placing process.
fairlead receptor tube part of the pulling arms used to support
the fairlead.
fall protection system a system consisting of a body harness or
body belt, a decelerating lanyard, connectors, and an anchor point at
the boom tip, used to catch and hold a person who falls from a plat-
form. (As of January 1, 1998, the use of a body belt for personal fall
protection is prohibited by OSHA.)
fan part of the disc or drum chipper which propels chipped debris
and increases airfow into the discharge chute.
feed box assembly housing the feed roll(s).
feed roll a mechanical controlled roll or rollers used to control the
feed rate to the cutter mechanism.
feed table folding or fxed position guard which restricts operators
access to the cutter mechanism.
feedback (feedback signal) the return of part of an output signal to
the input for the purpose of modifcation and control of the output.
feeder tube a telescopic hydraulic tube assembly mounted on an
extendible boom which carries pump fow to a device mounted on the
extendible portion of the boom such as a digger or boom tip winch.
FeedSense Automatically maintains cutter mechanism speed.
fber optic cable a type of cable used for conducting control or
telecommunication signals, in which the signal carrier(s) is one or more
optical fbers, enclosed within an outer covering.
fber optic receiver an electronic module that collects fber optic
signals and converts them into electrical signals.
fber optic transmitter an electronic module that converts elec-
trical signals into fber optic signals and sends them through a fber
optic cable.
fber optics the use of transparent fbers of glass or plastic which
transmit light signals throughout the length of the fber. Commonly used
to transmit signals from a remote control.
fberglass glass in fbrous form added as a reinforcement to a plastic
for use in making various products.
fller breather cap the component on the top of a reservoir that
allows air to enter and exit the reservoir as the fuid level changes,
and which can be removed to access a fll hole when adding hydraulic
fuid to the reservoir.
flter a device through which fuid is passed to remove and retain
insoluble contaminants from a fuid.
flter cart a portable device which can be connected to a units
hydraulic system to flter water and/or other contaminants out of the
hydraulic system fuid.
flter cartridge a component containing fltration material which is
installed within a flter housing or attached to a flter receptacle for use,
and can be removed and replaced as a self-contained unit.
frm footing outrigger placement and extension in accordance with
the instructions in a units operators manual to ensure proper leveling
of the vehicle and adequate stability when operating the unit.
fxed displacement pump a pump in which displacement is con-
stant, so that the output fow can be changed only by varying the
drive speed.
drain a passage or a line from a hydraulic component that returns
leakage fuid to the reservoir.
drift 1: a gradual, uncontrolled change from a set position of an
actuator or component. 2: a tool for ramming or driving something.
driver the gearbox and motor assembly on a reel lifter which is
connected to and disconnected from the arbor bar through the clutch
assembly.
drop pocket an open top tool storage area on the chassis of a
unit.
drum the rotating component, housing the knifes on a drum chip-
per.
drum chipper a wood chipper which utilizes a drum shaped, rotat-
ing cutter mechanism.
drum clutch a clutch consisting of two or more drive lugs that engage
similar driven lugs to transmit torque. Commonly used between the
gearbox and cable drum on front or bed mounted winches.
dump valve a normally open, two-position, two-way valve that sends
pump fow through a path going directly to the reservoir or bypassing
hydraulic circuit when it is not actuated, preventing operation of the
hydraulic system or circuit. When it is actuated, it closes off this path,
redirecting fow to the hydraulic system or circuit to allow operation.
dynamometer an instrument for measuring mechanical force or
power.
earth anchor see screw anchor.
eccentric ring a ring with the center hole located in a position off the
geometric center, commonly used to adjust the position of the rotation
pinion with respect to the rotation bearing gear teeth.
eccentric ring lock a device which engages a hole or notch in an
eccentric ring to prevent the ring from rotating.
effciency the ratio of output to input. Volumetric effciency of a pump
is the actual output in gpm divided by the theoretical or design output.
The overall effciency of a hydraulic system is the output power divided
by the input power. Effciency is usually expressed as a percent.
elbow the structure on an articulating-boom aerial device that con-
nects the upper boom to the lower boom. The elbow allows the upper
boom to pivot relative to the lower boom.
elbow bearing the rotating member that allows the upper boom to
rotate around the end of the lower boom. Used on aerial devices with
the upper and lower booms mounted side by side.
elbow pin the horizontal pin that attaches the upper boom to the
lower boom on an articulating-boom aerial device. Used on aerial
devices with the upper boom mounted over the lower boom.
electrical harness an assembly of electrical wires that is used to
deliver electrical current between components.
electrocution receiving an electrical shock resulting in death.
electrohydraulic a combination of electric and hydraulic control
mechanisms in which an electrically controlled actuator is used to shift
the spool in a hydraulic control valve.
electrohydraulic control system a control system in which the
function control handles are connected to electric controls. The elec-
tric controls actuate electrohydraulic valves to operate the functions
of the unit.
electrohydraulic valve a directional valve that receives a vari-
able or controlled electrical signal which is used to control or meter
hydraulic fow.
elevator lift a system located between the turntable and subbase
of an aerial device which is used for lifting the aerial device to increase
the platform working height. This system may be confgured as a single
elevator or a double elevator.
elevator unit the overall device including the subbase, elevator lift
and the aerial device.
emergency operating DC pump see secondary stowage DC
pump.
emergency operating system see secondary stowage system.
end gland a hollow, cylindrical part that screws into or is retained
in the open end of a hydraulic cylinder barrel, through which the rod
protrudes.
end-mounted platform a platform which is attached to a mounting
bracket that extends beyond the boom tip, positioning the platform
(and platform rotation pivot, if so equipped) beyond the end of the
upper boom.
6 Appendix Glossary
gripper tool a component used for grasping an object or electrical
lines through the use of an articulated mechanism.
ground 1: a large conducting body with a potential of zero volts
used as a common current return for an electric circuit. 2: an object that
makes an electrical connection with a ground or with the earth.
ground fault interrupter (GFI) a fast acting form of circuit breaker
that opens to interrupt an electrical circuit if it senses a very small
current leakage to ground, to protect personnel against a potential
shock hazard from defective electrical tools or wiring. It does this by
monitoring for any difference in current fow between the hot and neu-
tral wires in the circuit. An imbalance exceeding a very small preset
value indicates that current is fnding an improper path to ground, and
causes the breaker to trip.
guard ring see conductive shield.
hand an extension of the reel lifter arm that allows for loading the
arbor bar.
hand control a hand operated control lever or handle located at a
control station used to regulate a function of a unit, where the speed of
the function is proportional to the distance the control is moved.
hand latch mechanical device used to retain the arbor bar in the
reel lifter or strand carrier hand.
heat the form of energy that has the capacity to create warmth or
to increase the temperature of a substance. Any energy that is wasted
or used to overcome friction is converted to heat. Heat is measured in
calories or British thermal units (Btu). One Btu is the amount of heat
required to raise the temperature of one pound of water one degree
Fahrenheit.
heat exchanger a device that transfers heat through a conducting
wall from one fuid to another or into the atmosphere.
hertz (Hz) a unit of frequency equal to one cycle per second.
high tooth the individual tooth out of all the gear teeth on a rotation
bearing at which the minimum backlash occurs with the rotation pinion.
This is because of a slight difference between the actual and theoretical
tooth pitch lines due to manufacturing tolerances.
HLIW hot line insulator washer.
holding valve see load holding valve.
hood pin in conjunction with bolts, secures the two top halves of
the disc housing together.
HOP see hydraulic overload protection system.
horsepower (HP) the power required to lift 550 pounds one foot in
one second or 33,000 pounds 1 foot in one minute. One horsepower
is equal to 746 watts or to 42.4 British thermal units per minute.
hose carrier a fexible component which contains hydraulic, elec-
trical, and/or air lines, usually mounted inside or along the side of an
extendible boom. As the boom is extended, the hose carrier unfolds in
a rolling motion to allow the lines to extend with the boom.
hose carrier tube a rigid, enclosed tube which contains hydraulic,
electrical, and/or air lines, and may contain components for upper
controls. It is usually attached to a hose carrier on the side of an
extendible boom.
hot line insulator washer (HLIW) a vehicle-mounted device which
is designed and used for cleaning pole and structure mounted transmis-
sion and distribution insulators.
HTMA Hydraulic Tool Manufacturers Association.
Huck bolt a bolt-like fastener that is placed in position and then
stretched while an end ftting is swaged on. Commonly used to attach
a pedestal, subbase, and/or outriggers to a vehicle frame.
hydrant a discharge pipe with a valve and spout at which water
may be drawn from a water main.
hydraulic control a control that is actuated by hydraulically induced
forces.
hydraulic leveling system an automatic hydraulic control system
which keeps the bottom of a platform parallel to or at a fxed angle to
the turntable base plate as the boom is raised or lowered. One means
of accomplishing this is by transferring hydraulic fuid between a master
cylinder actuated by movement of the lower boom and a slave cylinder
mounted between the platform and the upper boom.
hydraulic overload protection (HOP) system the system on a
digger derrick that shuts off certain functions to help prevent damage
to the digger derrick structure when an overload is applied to the boom
in the downward direction.
fange on a fange and lug pin retaining system, an end plate that is
welded to one end of the pin. The purpose of the fange is to position
the pin in the connection.
fange and lug pin retaining system a connecting pin retention
system in which an end plate is welded to one end of the pin and a
retaining plate is attached with cap screws to the other end to hold
the pin in position.
fashover a disruptive electrical discharge at the surface of electrical
insulation or in the surrounding medium, which may or may not cause
permanent damage to the insulation.
fats from fnger tight (F.F.F.T.) a method of counting the number
of wrench fats when tightening a hydraulic adapter to establish a
torque value.
fat-shoe outrigger an outrigger which has a shoe that is fxed in
a horizontal position.
fighting a curved plate or series of curved plates welded together,
spiraling along the axis of an auger tube or screw anchor rod.
fow the movement of fuid generated by pressure differences.
fow control valve a valve that regulates the rate of fuid fow.
fow rate the volume, mass or weight of a fuid passing through any
conductor per unit of time.
fow straightener a component part of a nozzle used to straighten
or remove any swirling motion of fuid going through the nozzle.
fowmeter an instrument used to measure the fow rate of fuid in
a hydraulic tube or hose.
fuid a liquid that is specially compounded for use as a power
transmitting medium in a hydraulic system.
fold to move a pivoting structure such an articulating upper boom
toward its stowed position.
fold-up shoe outrigger an outrigger which has a shoe that pivots
into a vertical position when the outrigger is fully retracted.
force any push or pull measured in units of weight.
forged pin retainer a pin retainer made from forged steel, consisting
of a slender, cylindrical body with a fattened, circular head at one end,
with a mounting hole through the head perpendicular to the body. The
body is inserted through a hole in the pin to be retained, and the head
is fastened to the adjacent structure with a cap screw.
four-way valve a valve having four ports for direction of fuid fow.
FPS Fluid Power Society.
frequency the number of times an action occurs in a unit of time.
gasket a packing made of a deformable material, usually in the
form of a sheet or ring, used to make a pressure tight ft between
stationary parts.
gate valve see shutoff valve.
gauge pressure a pressure scale that ignores atmospheric pres-
sure by establishing atmospheric pressure as its zero point. Its zero
point is 14.7 psi absolute.
gauge snubber see snubber valve.
gearbox an assembly with internal speed changing gears; a transmis-
sion. Gearboxes are commonly used to transmit power from a hydraulic
motor to operate a function through an output shaft.
gelcoat a protective coating used on fberglass components to
prevent the wicking of moisture into the fberglass strands and to retard
the degrading effect of ultraviolet light on the fberglass.
GFI ground fault interrupter.
gib assembly secures cutter knives in place on drum chippers.
gin pole a vertical phase-holding apparatus which is attached to a
platform or upper boom tip.
gpm gallons per minute.
gradient control device a device at the upper end of an insulating
boom that reduces electrical stress level(s) below that considered to
be disruptive.
gravity leveling system a system which uses the force of gravity
to keep the bottom of a platform parallel to level ground as the boom
is raised or lowered. One means of accomplishing this is by allowing
the platform to pivot freely about a horizontal shaft attached above the
platforms center of gravity.
grease ftting a small ftting that acts as the connection between a
grease gun and the component to be lubricated.
7 Appendix Glossary
hydraulic schematic a drawing that uses common hydraulic symbols
to represent the hydraulic system of the unit.
hydraulic swivel a fuid conducting ftting having two joined parts
that are capable of pivoting freely about each other to accommodate
motion of an attached hydraulic line.
hydraulically extendible jib a jib boom that may be extended or
retracted by hydraulic power.
hydraulics an engineering science pertaining to liquid pressure
and fow.
hydrostatic hydraulic system any hydraulic drive in which a posi-
tive displacement pump and motor transfer rotary power by means of
fuid under pressure.
individual address setting the code that identifes a specifc
transmitter as the one emitting the signal corresponding to a specifc
receivers reception address.
infeed chute tapered weldment attached prior to the feed/cutter
mechanisms, assisting in the centering of the tree canopy.
in-line the installation of a component in series between two por-
tions of a hydraulic line or electrical conductor so that fow in the line
or conductor toward the component passes through the component
and continues on in the line or conductor on the other side.
instability a condition of a mobile unit where the sum of the mo-
ments tending to overturn the mobile unit is equal to or exceeds the
sum of the moments tending to resist overturning.
insulating aerial device an aerial device with dielectric components
designed and tested to meet the specifc electrical insulating rating
consistent with the manufacturers name plate.
insulating digger derrick a digger derrick designed for and manu-
factured with a fberglass boom(s) for use around energized conductors
at a maximum of 46 kV phase to phase.
insulating liner see platform liner.
insulating portions those sections which are designed, main-
tained, and tested in accordance with the electrical requirements of
ANSI A92.2.
insulator a device that isolates the energized conductor of a power
line from the support structure.
intercom system a transmitter and receiver system that allows
two-way verbal communication between a platform operator and a
person at ground level.
interference any energy that inhibits the transmission or reception
of electrical or radio signals.
intermediate boom (INT BOOM) an extendible boom section
which is located between the upper boom and the lower boom in an
extendible boom assembly.
ISO International Standards Organization.
jam nut a nut that is screwed down frmly against another nut to
prevent loosening.
jaw clutch see drum clutch.
jib an auxiliary boom which attaches to the upper boom tip to extend
the reach of the boom.
JIC Joint Industry Conference.
joystick a two or three axis control lever which allows the operator
to simultaneously control multiple functions.
junction box an enclosed central connecting point for electrical
wiring.
kelly bar 1: for derricks see auger extension shaft. 2: the auger drive
shaft of a pressure digger which is extendible from the ram cylinder.
key a parallel-sided piece that fts into grooves in two adjacent parts
to prevent movement between the parts. Often used as the driving
member between a shaft and a sheave or winch drum.
keyway a groove that is cut in a shaft or bore for a key to ft into.
kilovolts (kV) a unit of potential difference equal to 1,000 volts.
knife the rotating blade on a chipper cutting mechanism.
knuckle see elbow.
L-bracket an L-shaped weldment that is used to connect a splicer
platform to the upper boom tip.
lanyard a component in a personal fall protection system consisting
of a fexible, nonmetallic strap or rope with a connector at each end
for connecting a body harness or body belt to a specifed anchor point
provided at the boom tip, used to catch and decelerate a person in a
fall from the platform. (As of January 1, 1998, the use of a body belt
for personal fall protection is prohibited by OSHA.)
lashing wire a thin, solid wire which is wrapped in a helix confgura-
tion around a length of suspension strand and adjacent communication
cable so that the suspension strand carries the weight of the cable.
lay the length of wire rope in which one strand makes one complete
spiral around the rope.
layer all wraps of winch line on a winch drum which are on the same
level between drum fanges.
leakage monitor system a means by which current leakage is
measured through the insulating section(s) of a boom to confrm of
dielectric integrity.
leveling cable the wire rope portion of a mechanical leveling system
that passes over the sheaves.
leveling chain the chain portion of a mechanical leveling system
that passes over the sprockets.
leveling cylinder 1: a cylinder that is used in a master/slave arrange-
ment in a hydraulic leveling system to hydraulically level the platform. 2:
the hydraulic cylinder that is used to tilt the pivot and mast weldments
of a pressure digger to either side of the vertical position.
leveling rod a slender, round, fberglass rod used in a mechani-
cal leveling system that passes through a units boom to connect the
leveling chains or cables at each end of the boom.
leveling system see platform leveling system.
leverage a gain in output force over input force; mechanical advan-
tage or force multiplication.
lift cylinder the hydraulic cylinder that moves the lower boom up
and down on a digger derrick or extendible-boom aerial device.
lifter cylinder the hydraulic cylinder that moves the reel lifter
arms.
lifting eye a shackle or weldment used for attaching chain, cable,
rope, etc. to a boom for material handling.
light emitting diode (LED) a semiconductor diode that emits light
when subjected to an applied voltage. LEDs are used for electronic
display.
line a tube, pipe or hose used as a passageway to move hydraulic
fuid.
linear in a straight line.
linear actuator a device for converting hydraulic energy into linear
motion such as a cylinder or ram.
linear position transducer an extendible length measuring device
which produces a variable electrical signal that is proportional to the
length to which the device is extended.
liner see platform liner.
link the secondary load-carrying structure of an articulating arm.
load capacity (as defned by ANSI for digger derricks) the maximum
load, specifed by the manufacturer, that can be lifted by the mobile unit
at regular intervals of load radius or boom angle, through the specifed
ranges of boom elevation, extension and rotation, with options installed
and inclusive of stability requirements.
load holding valve a hydraulic valve which blocks fuid fow from
a hydraulic actuator, such as a cylinder or motor, to prevent motion
when the control valve is not being operated or in case of a hydraulic
line failure.
load radius the horizontal distance from the centerline of rotation
to the winch line load attachment point.
load sensing (see sense line) the signal when a function is operated
that tells the hydraulic pump to stroke up from a non-stroked (neutral)
position to supply oil to that function.
lock washer a solid or split washer that is placed underneath a nut
or cap screw to help prevent loosening by exerting pressure against
the fastener.
locknut see self-locking nut.
lockwire a wire that is installed to prevent loosening of fasteners
or components.
low voltage coating a sprayed on layer that provides low voltage
insulating properties.
8 Appendix Glossary
mercury switch a switch that is closed or opened when an inter-
nal globule of mercury moves to or away from the contacts when the
switch is tilted.
meter to regulate the amount of fuid fow.
meter-in to regulate the amount of fuid fow into an actuator or
system.
meter-out to regulate the fow of the discharge fuid from an actua-
tor or system.
micron (micrometer) one-millionth of a meter or about 0.00004.
micron rating the minimum size of the particles that a flter is
designed to remove.
microswitch a small electrical device that is used to turn an electrical
current on or off, or to change the connections in a circuit.
minimum approach distance the three dimensional area sur-
rounding a conductor into which a person may not enter nor bring any
conductive object unless they are: qualifed electrical workers, wearing
insulating gloves (and sleeves when required), protected against contact
with any other objects at a different electrical potential.
mobile operation the use of the aerial device or digger derrick while
the mobile unit is traveling.
mobile unit the combination of a unit, its chassis and related per-
manently attached equipment.
modifed A-frame outrigger an extendible outrigger that is confg-
ured like a large broad based A with an open top.
modulation ratio the on time vs. the off time of a pulse width
modulated digital signal. This ratio is determined by dividing the on
time during one cycle by the total cycle time.
moly see molybdenum disulfde.
molybdenum disulfde a black inorganic chemical that is used as
a dry lubricant and as an additive for grease and oils. Molybdenum
disulfde has a very high melting point and is insoluble in water.
molydisulfde see molybdenum disulfde.
moment a force multiplied by the perpendicular distance from the
line of action of the force to an axis or point. The force may be the
weight of an item, with the vertical line of action located at the items
center of gravity. Moment is measured in units of force times distance;
for example, pound-feet or foot-pounds.
monitor head remotely controlled articulated assembly with a nozzle,
mounted at the upper end of an HLIW.
motor a device that converts hydraulic or electrical energy into
continuous rotary motion and torque.
multiple-part line the arrangement of the winch line in which the
winch line is routed between the boom tip and the load two or more
times. A snatch block is used at the load and a snatch block or additional
boom tip sheave(s) is used on the boom to reverse the direction of
the winch line. The end of the winch line is connected to a stationary
attachment point on the boom or lower snatch block. A multiple-part
line is used to reduce the tension in the winch line to a value below
the winch line rated working load when a lifting load that exceeds the
winch line rated working load.
multiplexing a process by which signals from multiple inputs are
combined and transmitted simultaneously over a single channel.
multiviscosity the viscosity characteristic of a fuid which contains
additives that increase the viscosity index. The fuid does not become
as thin at high temperatures or as thick at low temperatures as a fuid
without these additives. This allows the fuid to be used over a wider
temperature range.
nonconductive the characteristic of a substance that allows it to
transmit electricity only in a very small degree when it is clean, dry and
properly maintained.
noncontinuous rotation a rotation system in which the turntable is
prevented from rotating more than approximately one revolution about
the centerline of rotation.
non-insulating aerial device or digger derrick an aerial device
or digger derrick which is not designed, manufactured, or tested to
meet any dielectric rating.
nonmetallic formed of materials which are not any type of metal.
non-overcenter aerial device a type of articulating-boom aerial
device on which the upper boom will not unfold from the stored posi-
tion to beyond a vertical position regardless of the position of the
lower boom.
lower arm the primary load-carrying structure of a double elevator
which is located between the lower pedestal and the riser.
lower arm cylinder the hydraulic cylinder that moves the lower arm
of a double elevator up and down.
lower boom (LWR BOOM) the boom section in a boom assembly
which is attached to the turntable or riser, and which supports the upper
boom or intermediate boom.
lower boom cylinder the hydraulic cylinder that moves the lower
boom about its pivot point on an articulating-boom aerial device.
lower boom insulator the part of the lower boom made of high
dielectric strength material (usually fberglass reinforced plastic or
equivalent) to interrupt the conductive path for electricity through the
lower boom.
lower boom winch a winch that is located on the lower boom.
lower control valve the hydraulic valve on the vehicle, turntable,
or pedestal of an aerial device used for operating some or all of the
functions of the aerial device.
lower controls the controls on the vehicle, turntable, or pedestal,
used for operating some or all of the functions of the unit.
lower pedestal the structure within an elevator lift that connects
the elevator lift to the subbase.
lower test electrode system a system on an insulating aerial
device utilizing conductive bands installed permanently on the inside
and outside surfaces of the insulating portion of the upper boom and
conductive connections to components inside that portion of the boom
such as leveling rods and hydraulic lines. All the bands and component
connections are connected to a common pickup point for use in mea-
suring current leakage to confrm of dielectric integrity.
lower tool circuit a hydraulic tool circuit with quick disconnect
couplings located on the pedestal or on the vehicle.
lug a metal part which serves as a cap, handle, support, or ftting
connection.
lunette eye a round metal ring used in place of a ball coupler on a
trailer. It attaches to a pintle hook on the towing vehicle.
magnetic suction separator flter see magnetic suction strainer.
magnetic suction strainer a suction flter consisting of a strainer
which contains one or more magnets to trap ferrous metallic contami-
nants that are small enough to pass through the strainer.
mainframe see pedestal.
man-and-a-half platform an oversized one-man platform.
manifold a fuid conductor that provides multiple connection
ports.
manual lowering valve a manually operated hydraulic valve used
to lower the boom in the event of power failure.
manual override a means of manually actuating an automatically
or remotely controlled device.
manually extendible jib a jib that is capable of being extended and
retracted by human force.
mast the structure on a pressure digger which supports the auger
transmission gearbox, ram cylinder, kelly bar, and pole setter.
master control panel the primary derrick lower control panel which
contains the electrical connections between the derrick control system
and components such as the power module and the dump or blocking
valve. The master control panel is used in conjunction with a slave
panel to provide dual station lower controls.
master cylinder a cylinder in which motion of the piston under an
external force transfers hydraulic fuid to a slave cylinder to produce
corresponding motion.
material handling having the ability to use the boom or attachments
on the boom to lift and position materials.
material handling system the system on an aerial device that
consists of a jib and winch used to lift material to the upper boom tip.
mechanical leveling system a mechanical system which keeps
the bottom of a platform parallel to or at a fxed angle to the turntable
base plate as the boom is raised or lowered. One means of accom-
plishing this is by utilizing a parallelogram arrangement of leveling rods
attached to cables or chains operating around sheaves or sprockets
at boom pivot points.
9 Appendix Glossary
nontransferable boom fares boom fares that are permanently
attached to the boom tip of a digger derrick.
nontransferable upper controls an upper control panel on a digger
derrick that is permanently attached to the upper boom tip.
normally closed switch a switch which is closed to allow current
to fow through it when it is not actuated, and opens to interrupt current
fow when actuated.
normally closed valve a two-way valve which is closed to block
fuid from fowing through it when it is not actuated, and opens to allow
fow when actuated.
normally open switch a switch which is open to prevent current
from fowing through it when it is not actuated, and closes to allow
current fow when actuated.
normally open valve a two-way valve which is open to allow fuid
to fow through it when it is not actuated, and closes to block fow
when actuated.
nozzle a tube-like device for accelerating and directing the discharge
fow of fuid.
NPT National Pipe Thread.
NPTF National Pipe Thread Fluid, a pipe thread form which is
modifed from the NPT form to improve the resistance to fuid leakage
through the threads in a connection.
O-ring a ring of material with a circular cross section that is used
as a gasket, usually made of synthetic rubber.
ohmmeter an instrument used to measure the resistance in ohms
between two points in an electrical component or circuit.
on/off circuit circuit that supplies constant electrical power to a
solenoid or other component when a relay or switch is closed and
removes the power when the relay or switch is opened.
one-man platform a platform designed to carry one person. It is
usually 24 wide x 30 wide or 24 wide x 24 wide.
open center a directional valve design in which pump output re-
turns freely to the reservoir when the valve spool(s) is in the center
or neutral position.
open circuit an electric circuit that has infnitely high resistance,
resulting in no current fow. An open circuit may be caused by a loose
connection, broken wire, corrosion or poor contact where an electrical
component is grounded to the unit structure.
operational area the area surrounding a chipper effected by chip
discharge, noise, or any chipper operations.
operator a person trained, authorized and engaged in the opera-
tion of the unit.
optical fber a thin strand of transparent glass or plastic used to
transmit signals using light throughout the length of the strand.
orifce a restriction in a hydraulic or pneumatic circuit, the length of
which is small in respect to its diameter.
OSHA Occupational Safety and Health Administration.
out and down outrigger an outrigger that has independently-
controlled horizontal and vertical extendible outrigger legs.
outboard bearing a bearing which supports the end of a gearbox
output shaft farthest from the gearbox.
output signal a radio wave intended to pass communication from
a source to a destination.
outrigger a structural member, which when properly extended or
deployed on frm ground or outrigger pads, assists in stabilizing the
mobile unit.
outrigger controls the controls for operating the outriggers.
outrigger cylinder the hydraulic cylinder which extends and retracts
or unfolds and folds an outrigger leg.
outrigger interlock system a system which requires all outriggers
to be extended to a specifed position before other unit functions are
allowed to operate.
outrigger interlock valve a valve which prevents above rotation
sense line signals from reaching the pump until the outriggers have
been lowered.
outrigger leg 1: the moveable structural component of an outrigger
which extends or unfolds to position the outrigger shoe on the ground,
and which retracts or folds to return the outrigger shoe to the stored
position. 2: the stationary structural component of an extendible outrig-
ger from which the moveable outrigger leg extends.
outrigger motion alarm an audible warning system to alert person-
nel that outriggers are being lowered or moved.
outrigger pad a portable piece of rigid material which is placed
under an outrigger shoe to increase the contact area with the ground
surface when the ground surface is not frm enough to support direct
contact from the outrigger shoe.
outrigger shoe the component of an outrigger that is attached to
the moveable leg and that contacts the ground or outrigger pad to
stabilize the mobile unit.
outrigger signal valve a valve used to provide a signal to the pump
when the outriggers are being operated and to allow a separate signal
system to control the aerial device operation.
outrigger spread the distance between the outer edges on fxed
shoes, or between pin centerlines on pivoting shoes, of opposite outrig-
gers which have been extended or deployed to a given position.
over travel movement of a mechanism beyond its normal stop-
ping point.
overcenter aerial device a type of articulating-boom aerial device
on which the upper boom can unfold from the stored position to beyond
a vertical position.
overframe an outrigger weldment mounting position located above
the vehicle chassis frame.
overload the condition existing when a load greater than the rated
capacity or design lead is applied to a unit or component.
override the takeover of boom movement control functions from
the platform controls by the activation of the lower control station
controls.
overtighten to torque a threaded fastener beyond the recommended
torque value.
oxidation the reaction of a substance with oxygen.
paddle part of the disc assembly which propels chipped debris into
the discharge chute.
panic bar a safety system which when manually activated stops
movement of the feed roll(s) on a chipper.
parallel link the secondary load-carrying structure of an elevator
lift.
particle count a visual count of the numbers of particulate contami-
nants in a quantity of a hydraulic fuid.
passage a machined or cored fuid conducting path that lies within
or passes through a component.
payload any tools, materials, fuel and occupants carried by the
mobile unit that are not permanently attached.
pedestal the stationary base of a unit that supports the turntable
and is attached to the subbase or vehicle frame.
pedestal mount a mounting confguration for an aerial device in
which the turntable is mounted on a pedestal consisting of a box-like
structure.
penetration the distance the vehicle frame is lifted after the outrig-
gers contact the ground surface.
phase a conductive wire or cable used for transmitting high voltage
electrical current. The phrase phase to phase can be referenced as
any two conductors of a three-phase electrical power line system.
pilot operated condition in which a valve is actuated by hydraulic
fuid pressure.
pilot operated check valve a check valve that can be opened
to allow fow in the normally blocked direction by applying hydraulic
pressure to a pilot port.
pilot pressure auxiliary pressure used to actuate or control hydraulic
components.
pilot valve an auxiliary valve used to control the operation of
another valve.
pin a cylindrical structural device used to allow a pivoting joint or
to connect mating parts.
pin retainer a device which is used to hold a pin in place in an
assembly.
pinch point a particular location in which a human body or a part
of the body may become pinched or pinned between moving mechani-
cal parts.
10 Appendix Glossary
pole guide tongs moveable arms on a pole guide used to stabilize
and guide a utility pole as it is being raised or lowered with the winch
line.
pole puller an apparatus consisting of a hydraulic cylinder, chain
and other components used to loosen a utility pole from the ground.
pole setter an assembly attached to the mast of a pressure digger
that is used to pick up, position, and set a pole.
polyethylene a moisture proof plastic.
poppet that part of certain valves that prevents fow when it closes
against a seat and allows fow when it moves away from the seat.
port an internal or external opening for intake or exhaust of fuid
in a component.
portable resistivity tester a device used for testing the electrical
resistance of water. Commonly used for testing the wash water for
insulator washers.
position a term which describes the number of possible positions
a valve spool or mechanism can be shifted to.
post mount a mounting confguration for an aerial device in which
the turntable is mounted on a pedestal which utilizes a round vertical
tube as its primary load-carrying structure.
potentiometer a variable resistor that is connected to act as an
electrical voltage divider.
pour point the lowest temperature at which a fuid will fow or pour
under specifc conditions.
power work per unit of time, measured in horsepower (HP) or
watts.
power module the central connection point between the chassis and
unit electrical systems. This device is used to provide battery power to
the unit when the truck/machine selector is in the machine position.
power take-off (PTO) a supplementary mechanism enabling ve-
hicle engine power to be used to operate non-automotive apparatus
such as a pump.
precharge pressure the pressure of compressed gas in an ac-
cumulator before any fuid is added.
pressure the force applied in a given area. It can be expressed in
pounds per square inch (psi).
pressure compensator a device on a variable displacement
pump that adjusts pump output fow to develop and maintain a preset
maximum pressure.
pressure differential the difference in pressure between two points
in a system or component.
pressure drop the reduction in pressure between two points in a
line or passage due to the energy required to maintain fow.
pressure gauge an instrument which displays the hydraulic or
pneumatic pressure sensed at a port on the device.
pressure line the line carrying fuid from a pump outlet to the pres-
surized port of a valve or actuator.
pressure override the difference between the cracking pressure of
a valve and the pressure reached when the valve is passing full fow.
pressure reducing valve a pressure control valve whose primary
function is to limit its outlet pressure.
pressure switch an electric switch which is actuated when the hy-
draulic or pneumatic pressure applied to a port on the switch reaches
a specifed value.
pressure transducer a pressure measuring device which produces
a variable electrical signal that is proportional to the hydraulic pressure
applied to a port on the device.
proportional circuit a circuit that supplies a varying voltage to a
coil in a pilot valve as electrical current applied to the circuit is varied
by a hand control.
proximity alarm a system which measures the distance from a
detector to another object, and sounds an alarm when this distance
is less than a specifed value. Commonly used to inform the operator
of an HLIW of the distance between the boom tip nozzle and a power
line insulator or support structure.
psi pounds per square inch.
PTO see power take-off.
pulling arms mechanical structure used to attach the platform to
the boom tip and supports the fairlead receptor tube.
pinion a gear with a small number of teeth that has been designed
to mesh with a larger gear.
pintle hitch a common heavy duty coupling type which utilizes a pintle
hook attached to a tow vehicle to pull a trailer having a lunette eye.
pintle hook the jaw portion of a pintle hitch which attaches to
the tow vehicle.
piston a cylindrically shaped part that fts within a cylinder or cy-
lindrical bore and transmits or receives linear motion by means of a
connecting rod or other component.
piston pump a pump in which motion and force are applied to fuid
by a reciprocating piston(s) in cylindrical bore(s).
pivot weldment the structure located above the slide frame on a
pressure digger which supports the mast.
placard 1: a thin sheet of rigid material which is attached to another
surface by adhesive and/or mechanical fasteners, and is used to convey
instructions, information and warnings. 2: May also refer to a decal.
planetary gear set an assembly of meshed gears consisting of a
central gear (sun gear), a coaxial internal tooth ring gear and several
intermediate pinions (planet gears) supported on a revolving carrier.
planetary gearbox a gearbox containing one or more planetary
gear sets.
platform the personnel-carrying component of a unit, mounted at
the upper boom tip.
platform elevator a mechanism, at the boom tip, to which the plat-
form is mounted, allowing vertical motion of the platform with respect
to the rest of the boom tip.
platform heater an electrically powered device mounted in a splicer
platform which is used to warm the occupant.
platform leveling system a system which keeps the bottom of a
platform parallel to or at a fxed angle to the base plate of the turntable,
or parallel to level ground, as the boom is raised or lowered. The system
may be mechanically, hydraulically, or gravity operated.
platform liner a component made of material having a high dielectric
strength which is designed to be inserted into a platform to cover the
walls and bottom of the platform.
platform pin the horizontal pin that is used to fasten a platform
mounting bracket to the upper boom tip. The mounting bracket pivots
about this pin for platform leveling or positioning.
platform rest the structural member attached to the chassis or body
to support and cushion the platform in the travel or rest position.
platform ring a metal band around the lip of a splicer platform
which supports and guides the platform as it is rotated about its verti-
cal centerline.
platform rotation override system a system which allows the
zone of platform rotation to extend beyond a predetermined limit when
actuated by the operator.
platform rotator a system which allows the operator to rotate the
platform about a vertical axis. This permits the position of the platform
to be changed with respect to the boom tip.
platform tilt system a system which allows the operator to adjust
the orientation of the platform about a horizontal axis. Some systems
allow the operator to adjust the working position of the platform foor
and tilt the platform for cleaning. Other systems allow tilting of the
platform for cleaning but do not provide for operator adjustment of the
working position.
platform use the stability criteria for a digger derrick mobile unit
which indicates that the load capacity chart and stability requirements
apply to the use of the derrick with the platform occupied, with no lifting
of loads with the winch line.
plunger a cylindrically shaped part that is used to transmit thrust;
a ram.
pole a long cylindrical piece of material such as wood, metal, or
concrete which is installed in a vertical position for use as a support
structure for power and communication lines.
pole guide a mechanism at the tip of a boom used for guiding and
stabilizing a utility pole while using the winch line to raise or lower
the pole.
pole guide tilt cylinder the hydraulic cylinder which is used to tilt
(raise or lower) the pole guide.
pole guide tong cylinder the hydraulic cylinder which opens and
closes the pole guide tongs.
pullout upper controls an upper control panel on a digger derrick
which is mounted on a housing that can be extended from inside an
outer housing when additional length is needed, such as to attach the
control panel to a personnel jib with the outer housing attached to the
upper boom tip, or to attach the upper control panel to the upper boom
tip with the outer housing attached to the transferable boom fares.
pulse width modulation (PWM) a means of transmitting a digital
signal in continuous cycles of pulses where the total length of time for
a cycle of one on pulse and the following off period is constant, and
the length of time (width) of the on pulse within each cycle is varied
(modulated) in proportion to the level of an input parameter such as
control lever position.
pump a device that converts mechanical force and motion into
hydraulic fow and pressure.
purge system a system of check valves that allows hydraulic
fuid fow in a reverse manner through the hydraulic system, usually
from the lower control valve to the upper controls. This actions frees
or purges the control system of any trapped air and restores a solid
column of fuid for precise control. The purge system may also be used
to warm up the control system in cold weather conditions if the fuid
in the reservoir is warm.
purge/upper/lower controls selector valve a valve which is used
to direct hydraulic fuid to the purge system, the upper control valve,
or the lower control valve.
PWM pulse width modulation.
quick disconnect couplings hydraulic fttings designed for fast
and easy attachment and separation.
radial ball bearing an antifriction bearing with rolling ball contact
in which the direction of action of the load transmitted is perpendicular
to the axial centerline of the bearing.
radial outrigger an outrigger in which the moveable outrigger leg
pivots in an arc around a pin connection between the leg and a sup-
porting structure as the leg is lowered and raised.
radio communication communication by means of radio waves.
ram 1: a single-acting cylinder with a single diameter plunger rather
than a piston and rod. 2: the plunger in a ram-type cylinder.
ram cylinder the hydraulic cylinder that is used to retract and extend
the kelly bar on a pressure digger.
ramp an adjustable delay to govern the response of the hydraulic
valve when a unit is operated from the electronic controls.
range diagram a diagram which shows the load radius and sheave
height of a digger derrick at all the confgurations of boom extension
and boom angle covered by the corresponding load capacity chart
.
rated capacity (as defned by ANSI for digger derricks) the maximum
load, specifed by the manufacturer, that can be lifted by the digger
derrick at regular intervals of load radius or boom angle, through the
specifed ranges of boom elevation and extension, with specifed op-
tions installed, and exclusive of stability requirements.
rated line voltage the nominal voltage, phase to phase, at which
electrical systems are rated.
rated load capacity (as defned by ANSI for aerial devices) the
maximum loads, specifed by the manufacturer, which can be lifted
by the aerial device through the specifed range of boom elevation
and extension with specifed options installed and in consideration of
stability requirements.
reach diagram a drawing that shows the horizontal and vertical
limits of travel of the platform, upper boom tip, and/or jib tip throughout
all possible confgurations of lower boom angle, boom extension, upper
boom angle, articulating arm travel, and/or elevator lift travel.
rear jack stand adjustable rear support used when the chipper is
in operation and not coupled to the tow vehicle.
rear mount a pedestal mounting position located over or near the
rear axle(s) on the longitudinal centerline of the chassis.
receiver a device that converts radio waves into electrical signals
for communication and/or control purposes.
reel brake a component of the reel driver which prevents the over-
running of cable reels carried by a strand carrier and reel lifter. The
brake is used to maintain tension in the cable or suspension strand
when used with the reel driver.
reel driver a component of a strand carrier and reel lifter used for
paying in or paying out cable or suspension strand.
reel lifter a device used to support and move cable reels from the
ground to the vehicle.
reel lifter arms the structure on a reel lifter used to lift and store
reels of cable or suspension strand on the chassis.
reengage to repeat the activation of a function after it has been
momentarily halted.
relay an automatic switch with contacts that can be closed or opened
by electrical current in a coil.
relief valve a pressure operated valve that bypasses pump delivery
to the reservoir to limit system pressure to a predetermined maximum
value.
remote arm a remotely operated jib used to handle equipment or
electrical lines.
remote assist a vehicle-mounted device with a boom assembly
which is extendible, articulating, or both, which is designed and used to
accommodate attachments for performing operations such as supporting
or cutting electrical conductors, lifting or holding objects, or cutting tree
branches. It is operated by remote control from the ground or from the
platform of an adjacent personnel lifting device. It may be mounted on
the vehicle by itself or in addition to a personnel lifting device.
remote control system a system used for operating some or all
of the functions of a unit from a portable control station. The control
station may be a transmitter which sends signals by radio waves to a
receiver on the unit, or a control module which sends signals through
a fber optic or electrical cable to the unit.
remote operated auxiliary control system (ROACS) a radio
controlled system for starting and stopping certain functions of the
mobile unit.
remote start/stop system the components used to actuate a
function of the unit from a location other than for normal operation.
The most common functions controlled are engine start/stop and the
secondary stowage DC pump.
reservoir a container for storage of liquid in a fuid power system.
resistance the opposition to the fow of electricity or hydraulic
fuid.
restriction a reduced cross-sectional area in a line or passage that
produces a pressure drop.
retaining ring a hardened, washer-like ring that may be spread
apart or compressed and installed into a groove or recess to serve
as a retaining device.
return line a hydraulic line used to carry discharge fow from a
hydraulic system or actuator back to the reservoir at low pressure.
return line flter a flter located in a hydraulic system return line or
at the inlet of a hydraulic reservoir which cleans fuid fowing from the
hydraulic system to the reservoir.
reversing valve a four-way directional valve used to change the di-
rection of movement of a double-acting cylinder or reversible motor.
ribbon hose a group of hoses that are attached side by side to
produce a fat bundle. Commonly used to carry hydraulic fuid, air and/
or electrical cable(s) to the boom tip or upper controls.
riding seat an operators control station attached to the side of the
turntable, with a seat on which the operator rides with the rotation of
the unit.
riser 1: the structure on a double elevator that connects the lower
elevator arm to the upper elevator arm. 2: the structure within an ar-
ticulating arm to which the lower boom is connected.
ROACS see remote operated auxiliary control system.
rod the cylindrically shaped part of a cylinder which extends and
retracts from the barrel to actuate or move a component.
rod end the end of a cylinder that the extending component or
rod is on.
roller a cylindrical device which spins freely about a pin or shaft,
used to guide the motion of another component.
rollpin a pin that has been formed by rolling up a thin, fat strip of
metal to form a cylinder. Commonly used by being driven into a hole
to serve as a retaining device.
rope a stout, fexible cord, which consists of many strands of wire
or fbers that are twisted or braided together.
rotary actuator a device for converting hydraulic energy into rotary
motion and torque in which the rotary motion is restricted to within
certain angular limits.
rotary joint a multiple port manifold that has a rotating portion and
a stationary portion, used to provide a continuous hydraulic connection
between rotating and stationary hydraulic lines. Commonly used at the
centerline of rotation of units equipped with continuous rotation.
rotate frame the structure located above the stationary frame on a
pressure digger that is used to support and rotate the slide frame.
rotating platform a platform which can be rotated about a vertical
axis to change its position in relationship to the boom tip.
rotation bearing the rotating member, usually a shear ball bear-
ing, located between the pedestal and the turntable which allows the
turntable to rotate and which contains gear teeth that mesh with the
rotation pinion.
rotation chain a chain attached to the stationary frame of a pressure
digger that is used by the rotation gearbox to rotate the rotate frame.
rotation gearbox the gearbox which drives the rotational motion
of the turntable.
rotation pinion the gear on the output shaft of the rotation gearbox
which meshes with the rotation bearing gear teeth and drives the
turntable rotational motion.
rotation resistant wire rope wire rope which is constructed to resist
the tendency to untwist or rotate when carrying a suspended load. This
is accomplished by laying the outer strands in the opposite direction
to the lay of the inner strands or core.
rotation system the system which drives the rotation of the turntable
about the centerline of rotation. It typically consists of a rotation bearing,
rotation gearbox, hydraulic motor, and load holding valve.
rpm revolutions per minute.
running torque the torque produced by a rotating device such as
a motor or gearbox at a specifed rotational speed.
SAE Society of Automotive Engineers.
safety belt see body belt.
safety chains the chains that are attached to the trailer tongue with
hooks on their free ends. These chains keep the trailer connected to
the tow vehicle should the coupler or hitch ball detach from the tow
vehicle. Safety chains must be secured every time you tow.
saybolt universal viscosity A measure of viscosity equal to the time
it takes in seconds for 60 milliliters of fuid to fow through a capillary
tube in a Saybolt universal viscosimeter at a given temperature.
scissor link the mechanical linkage on a reel lifter used to connect
the lifter cylinder to the arm.
screw anchor a rod with an eye on one end and auger fighting on
the opposite end. It is designed to screw into the ground and serve as
an anchor to hold an attached cable such as a guy wire.
seating in an initial microscopic surface deformation of components
that are clamped together with threaded fasteners. This causes a slight
reduction in the dimension of the components, reducing the clamping
force applied by the fasteners.
secondary stowage DC pump a low fow hydraulic pump driven by a
direct current electric motor. This pump is used to provide hydraulic fow
to stow the unit when the system for normal operation has failed.
secondary stowage system those components used to stow the
unit when the system for normal operation has failed.
selector switch a switch which is used to direct electrical current
to one of two or more electrical circuits.
selector valve a valve which is used to direct hydraulic fuid to one
of two or more hydraulic circuits.
self feed a wood-chipper with no control of the infeed rate to the
cutting mechanism.
self-locking nut a nut which contains a built-in device or shape to
increase thread friction so as to resist loosening due to vibration or
repeated loading.
self-lubricating bearing an antifriction bearing in which lubricating
material is incorporated in the bearing.
sense line a line that carries a hydraulic pressure signal from a
valve or actuator to the compensator control on a variable displace-
ment pump.
sense selector valve a valve which prevents hydraulic fuid in
the sense line from reaching the pump until a certain function(s) is
operated.
sequence 1: the order of a series of operations or movements. 2:
to divert fow to accomplish a subsequent operation or movement.
sequence valve a pressure operated valve that diverts fow to a
secondary actuator while holding pressure on the primary actuator at
a predetermined minimum value after the primary actuator completes
its travel.
sequential extension the operation by which one boom section
in an extendible boom assembly reaches full extension or retraction
before the next boom section begins movement.
set screw a short screw, typically with an Allen type head, that is
used as a clamp to bind parts together.
shackle see clevis.
shear an action or stress resulting from opposing applied forces that
attempt to separate a part into two pieces that would then slide along
each other in opposite directions along the plane of separation.
shear ball bearing an antifriction bearing with rolling ball contact
in which the direction of load transmitted through the balls is parallel
to the axial centerline of the bearing, producing shear loading on the
balls. The bearing can support axial, radial, and tilt loading. Commonly
used as a rotation bearing.
shear pin a replaceable pin which prevents motion between two
adjacent parts by the production of shear loading in the pin, and which
may be designed to fail under overload to protect other parts.
shear stability resistance of a hydraulic fuid viscosity index improver
additive to shearing.
shearing molecular damage or breakdown of the viscosity index
improver additive in hydraulic fuid. Shearing can occur when the fuid
fows through fne clearances at high velocity. Shearing can cause
permanent loss in fuid viscosity.
sheave a grooved wheel used to support and guide a winch line
or leveling cable at a point of change in the direction of motion of the
line or cable.
sheave height the vertical distance from ground level to the centerline
of the boom tip sheave in a digger derrick upper boom tip.
short circuit an inadvertent path of low resistance established
between two points of an electrical circuit. A short circuit will result in
excessive current fow.
shutoff valve a device which is used to stop hydraulic fuid fow.
shuttle valve a three-port valve that accepts hydraulic fuid pres-
sure from two inlets and allows only the highest pressure fuid to pass
through it to a single outlet while keeping the inlet fuid pressure isolated
from one another.
side gun a hand held water nozzle and hose that can be used from
the ground for washing or fre fghting.
side load an external horizontal load placed on a boom from one
side.
side load protection system the system on a digger derrick that
helps prevent damage to the digger derrick structure when excessive
side loads are applied to the booms.
side-mounted platform a platform which is attached to a mount-
ing bracket that extends from one side of the boom tip, positioning
the platform (and platform rotation pivot, if so equipped) beside the
boom tip.
sideslip sideways motion of a component caused by an externally
applied sideways force which overcomes resistive forces from hy-
draulics, friction, etc. Commonly used to describe rotation of a digger
derrick boom caused by side loading which exceeds the side load
protection setting.
signal a command or indication of a desired position, velocity, fow
or pressure.
signal line see sense line.
single-acting cylinder a cylinder in which fuid pressure can be ap-
plied to move the rod in only one direction. Return motion is produced
by an external force such as a spring or gravity.
single elevator an elevator lift with one load carrying arm. The
single elevator system includes a lower pedestal, arm, arm cylinder(s),
parallel links, and upper pedestal.
single handle control a control, with an interlock trigger incorpo-
rated in the handle, which allows the operator to simultaneously control
multiple functions of the booms and turntable from the platform.
single-pole, double-throw (SPDT) switch a three-terminal electri-
cal switch or relay that connects one terminal to either of two other
terminals.
single-pole, single-throw (SPST) switch a two-terminal electrical
switch or relay that opens or closes one circuit.
slave control panel a secondary derrick lower control panel that
is confgured as a remote terminal of the master panel. The slave
panel is used in conjunction with a master panel to provide dual sta-
tion lower controls.
slave cylinder a cylinder in which motion of the piston is produced
by the transfer of hydraulic fuid from a master cylinder, resulting in
corresponding motion.
slide frame the structure on a pressure digger used to support the
auxiliary engine, hydraulic reservoir, control station, and pivot weldment.
The slide frame can be extended horizontally from its stowed position
to adjust the distance of the kelly bar from the rotate frame.
slide pad a rectangular block used as a bearing between extend-
ible boom or outrigger sections, usually composed of a non-metallic
material.
slip ring an assembly of one or more conductive, rotating rings and
stationary brushes used to provide a continuous electrical connection
between rotating and stationary conductors. Commonly used at the
centerline of rotation of units equipped with continuous rotation.
slug face the extreme end of the cable slug which is secured to the
cylinder rod or adjusting stud.
SMA connector metal connector used for connecting fber optic
components.
snatch block a device which has a means of attachment to connect
it to a boom or load, and which can be opened to receive a winch line
around an internal sheave.
snubber valve a two-port valve with a manually adjustable orifce
that restricts the fow of fuid through the valve.
socket head a cylindrical cap screw head design containing a
hexagonal (six-sided) female socket into which an Allen wrench can
be inserted to turn the cap screw.
solenoid a coil of insulated wire that produces a magnetic feld within
the coil when electrically energized. When attached to a hydraulic valve,
the magnetic feld acts upon the valve to move internal valve parts.
solenoid valve a valve which is actuated by a solenoid to controlling
the fow of hydraulic fuid.
speed reducer see gearbox.
spherical bearing a bearing with a spherically shaped inner race
that is allowed to move freely inside a stationary outer race to accom-
modate misalignment.
splicer platform a fberglass platform equipped with a door and
latch.
spline one of a number of equally spaced, load carrying teeth that
have been cut on the outside diameter of a shaft or inside diameter of
a bore, parallel to the shaft or bore centerline.
spool a moving, cylindrically shaped part of a hydraulic valve that
moves to direct fow through the valve.
spring lockouts a mechanical system which is engaged to keep
a vehicles suspension system from fexing during operation of the
unit.
sprocket a wheel with teeth along the circumference which are
shaped so as to engage with a chain, used to support and guide the
chain at a point of change in the direction of motion of the chain.
SSU (Saybolt Second Universal) the unit of measure for Saybolt
universal viscosity.
stability a condition of a mobile unit in which the sum of the mo-
ments which tend to overturn the mobile unit is less than the sum of
the moments tending to resist overturning; the mobile units ability to
resist tipping.
stabilize to provide adequate stability for a mobile unit to allow
operation of the vehicle-mounted device(s).
stabilizer a device used to assist in stabilizing a mobile unit, such
as an outrigger, torsion bar or spring lockout.
stake to slightly deform the threads of a fastener or material at the
joint between two components by placing the blade of punch or chisel
on the threads or joint and tapping on the handle with a hammer. The
deformed material serves to prevent loosening of the components.
stall torque the torque produced by a rotating device such as a
motor or gearbox at zero rotational speed.
standard option an option which can be ordered from a standard
order form and can be supplied without additional engineering work.
start/stop control module an electrical device that relays sig-
nals from the units remote start/stop system to the component(s) or
system(s) being controlled, such as the secondary stowage DC pump
and/or vehicle ignition system.
static mixer a tube with no moving parts used to combine two or
more fuids.
stationary frame the structure attached to the subbase of a pressure
digger that supports the outriggers and rotate frame.
stationary hood normally non-removable part of the disc housing
in which the discharge chute attaches.
stationary platform a platform which can not be rotated about a
vertical axis to change its position in relationship to the boom tip.
stow to place a component such as a boom or digger derrick auger
in its rest position.
strainer a coarse flter.
strainer basket a coarse, basket shaped flter which is mounted in
the fll hole of a reservoir and projects into the reservoir.
strand 1: one of the groups of individual fbers or wires within a
synthetic winch line or wire rope. 2: see suspension strand.
strand carrier a device used to support and transport strand reels
on a vehicle.
strand reel a reel or spool used for carrying suspension stand.
street side the side of a vehicle toward oncoming traffc when the
vehicle is traveling forward in the normal direction in a lane of traffc.
stroke 1: total linear movement in either direction of a piston or
plunger. 2: to change the displacement of a variable displacement
pump or motor.
subbase a structural mounting interface between the pedestal and
the vehicle frame. It provides torsional stiffness and strength in addition
to that which would be provided from the vehicle frame alone.
subweldment a smaller welded subassembly used within a more
complex welded structure.
suction flter a flter located in a hydraulic system suction line or at
the outlet of a hydraulic reservoir which cleans fuid fowing from the
reservoir to the pump inlet.
suction line the hydraulic line connecting the pump inlet port to
the reservoir outlet.
surge a momentary rise of pressure in a circuit.
surge brake system a surge brake system is entirely self-contained
on the trailer and is activated when the tow vehicle decelerates. The
momentum of the trailer pushes the surge brake housing forward. This
drives the push rod that is connected to the coupler into the master
cylinder. Brake fuid is then forced out of the master cylinder into the
wheel cylinders or pistons that apply the trailer brakes. The entire
activation process is completed in less than one second.
suspension strand a type of wire rope which is used to support
the weight of an attached communication cable suspended between
poles or other overhead support structures.
swage to taper or reduce the diameter of a rod, tube or fastener by
forging, squeezing or hammering.
synthetic winch line a winch line made from nonmetallic synthetic
fbers which are formed into strands that are then braided together to
make a complete rope.
T-stand a T shaped weldment for mounting lower controls to the
vehicle.
tachometer an instrument used for displaying the speed of rotation
of an engine output shaft.
tailshelf the rear portion of the mobile unit above and behind the
rear axle.
tailshelf tools see lower tool circuit.
tank the hydraulic reservoir.
telescopic having sections that slide within or over one another to
change overall length.
tension spring springs controlling downward force of the upper
feed roll.
terminal block an insulating mounting used for making electrical
terminal connections.
test block a manifold with ports for connecting a hydraulic pressure
source, pressure gauge and a cartridge valve such as a counterbalance
valve or relief valve used for testing and adjusting the relief setting of
the valve.
thimble a metal ring around which a rope is passed and spliced to
make a loop or eye.
thread locking adhesive an anaerobic adhesive that is applied
to fastener threads to prevent loosening due to vibration or repeated
loading.
three-phase a system for transmitting high voltage, alternating cur-
rent, electrical power along three separate conductors, with 120 degrees
between the voltage waveform cycles of any two conductors.
three-position valve a valve having three positions for direction
of fuid fow, such as neutral, fow in one direction, and fow in the op-
posite direction.
three-way valve a valve having three ports for direction of fuid
fow.
threshold the amount of signal (starting power) given to a control
valve when the control is just moved from neutral position.
throttle control a manual, hydraulic, or electrical device used to
regulate vehicle or auxiliary engine speed.
toggle switch an electrical switch operated by a short projecting
lever combined with a spring to quickly open or close a circuit when
the lever is pushed through a small arc.
tongue weight the downward weight applied by the towable equip-
ment on the hitch ball. Generally tongue weight should not be more
than 10 percent of the gross trailer weight.
topping cylinder see lift cylinder.
torque 1: a rotational twisting force. 2: to preload a threaded fastener
by application of a rotational twisting force.
torque converter a rotary device for transmitting and amplifying
torque, especially by hydraulic means.
torsion bar a rod-like spring which is fexed by being twisted about
its axis, used to assist in stabilizing a mobile unit.
tow line winch a winch located on a cable placer which is used
for tensioning suspension strand or self-supporting cable or towing a
cable lasher.
tow vehicle (towing vehicle) the vehicle that pulls a trailer or
towed vehicle.
trace element analysis analysis of a small sample of hydraulic fuid
to determine contamination level and condition of additives.
tracking a current leakage path created across the surface of
insulating material when a high-voltage current forms a carbonized
path within a foreign material on the surface.
transducer a device that converts input energy of one form into
output energy of another, such as hydraulic pressure into an electri-
cal signal.
transferable boom fares boom fares, on which a pole guide may
be mounted, that can be pinned to either the intermediate boom tip or
the upper boom tip of a digger derrick.
transferable upper controls an upper control panel on a digger
derrick that can be attached to either the upper boom tip or the trans-
ferable boom fares by the use of a detent pin.
transition the area between the feed box and the cutter mecha-
nism.
transmitter a device used to generate and emit a radio frequency
carrier signal. The signal is sent to a receiver which translates the
signal into usable information.
trim pot a potentiometer which is used to make fne adjustments
in a circuit during manufacture or calibration, typically by turning a
slotted adjusting screw.
troubleshoot to locate and diagnose problems in a system or a
component.
trunnion a mounting device consisting of a pair of opposite, projecting
cylindrical pivots on which something can be rotated or tilted.
trunnion bearing a bearing that a trunnion pin pivots in.
trunnion pin a cylindrical pivot pin that is a part of a trunnion.
turnbuckle a link with screw threads at both ends that is turned to
bring the ends closer together for tightening purposes.
turns from fnger tight (T.F.F.T.) a method of counting the number
of turns of a hydraulic adapter to establish a torque value.
turntable the structure located above the rotation bearing which
supports the lower boom or articulating arm, and rotates about the
centerline of rotation.
turntable winch a winch located on the turntable.
turret see turntable.
two-blocking a condition in which the load hook, overhaul ball, hook
block, or other lifting component that is attached to the winch line comes
in contact with the boom tip during winch or boom operation.
two-man platform a platform designed to carry two people. It is
usually 24 wide x 48 wide.
two-part line a multiple-part line on a digger derrick in which the
winch line is routed from the boom tip sheave down to a snatch block
at the load and then back up to a stationary attachment point on the
boom.
two-position valve a valve having two positions for direction of
fuid fow, such as open and closed.
two-speed motor a motor which has two operating speed and torque
modes (a low-speed, high-torque mode, and a high-speed, low-torque
mode) that can be selected by the operator.
two-way valve a valve having two ports for direction of fuid fow,
with one internal fow path which can be open or blocked.
ultraviolet inhibitor coating a sprayed or brushed on layer that
provides ultraviolet light resistant properties.
UNC Unifed National Coarse, a thread description.
underframe an outrigger weldment mounting position located
beneath the unit subbase or vehicle chassis frame.
undertighten to torque a threaded fastener below the recom-
mended value.
UNF Unifed National Fine, a thread description.
unfold to move a pivoting structure such as an articulating upper
boom away from its stowed position.
unit the Altec device(s), subbase, outriggers, body and associated
interface items mounted on a chassis, but not including the chassis
itself.
unload to release hydraulic fow, usually directly to the reservoir, to
prevent pressure buildup.
unloaded vehicle weight the total weight of the completed mobile
unit without payload.
unloading valve a valve that bypasses fow to the reservoir when
a set pressure is maintained on its pilot port.
upper arm the primary load-carrying structure of a double elevator
which is located between the riser and the upper pedestal.
upper arm cylinder the hydraulic cylinder that moves the upper
arm of a double elevator up and down.
upper boom (UPR BOOM) the boom section in a boom assembly
which is farthest from the turntable when the boom assembly is fully
extended or unfolded, and which supports the boom tip sheave and/
or platform(s).
upper boom cylinder the hydraulic cylinder that moves the upper
boom about its pivot point on an articulating-boom aerial device.
upper boom drive mechanism the components used to produce
upper boom movement on an articulating boom-aerial device, such as
linkage, cables, sheaves and/or gears.
upper boom rest the structural member that supports the upper
boom in the rest or travel position.
upper boom tip the boom tip of an upper boom.
upper control valve the hydraulic valve on or beside the platform
of an aerial device used for operating some or all of the functions of
the aerial device.
upper controls the controls located on or beside the platform used
for operating some or all of the functions of the unit.
upper controls primary battery the preferred source of power for
fber optic upper controls.
upper controls secondary battery the backup power source for
fber optic upper controls.
upper pedestal the structure within an elevator lift that connects
the elevator lift to the aerial device rotation bearing.
upper tool circuit a tool hydraulic circuit with quick disconnect
couplings located at the upper boom tip.
vacuum the absence of pressure. A perfect vacuum is the total
absence of pressure; a partial vacuum is some condition less than
atmospheric pressure. Vacuum is measured in inches of mercury
(in. Hg.).
valve a device that controls fuid fow direction, pressure or fow
rate.
vane pump a type of pump with a rotor and several sliding vanes in
an elliptical chamber. Hydraulic fuid enters the expanding area and is
forced out as the fuid is moved to the decreasing chamber area.
variable displacement pump a pump in which the size of the
pumping chamber(s) can be changed, so that the output fow can
be changed by moving the displacement control or varying the drive
speed or both.
vehicle a carrier for a unit.
velocity the speed of linear motion in a given direction.
velocity fuse a hydraulic valve that is used to stop fuid fow through
it when the fow rate reaches a predetermined cut-off value.
vent an air breathing device on a fuid reservoir or hydraulic line.
VI see viscosity index.
viscosity a measure of the internal friction or resistance to fow
of a fuid.
viscosity index (VI) a measure of the resistance to change in vis-
cosity of a fuid with change in temperature. The higher the number,
the less the viscosity will change as the temperature changes.
voltmeter an instrument used to measure the potential difference
in volts between two points in an electrical circuit.
volume 1: the size of a space or chamber in cubic units. 2: loosely
applied to the output fow of a pump in gallons per minute (gpm).
vortex a whirlpool of liquid.
waist harness a belt device worn by the operator of a radio remote
control system to which the transmitter is attached.
walking beam outrigger an extendible outrigger which has a pivot
point at the top of the nonextending leg and a linkage attached to the
extending leg, so that the leg assembly rotates about the pivot point
to increase the outrigger spread as it is extended.
warning an instruction that indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
water monitor an articulating mechanism that is used to direct the
fow of a high pressure water stream.
water removal flter cartridge a special flter cartridge designed
to absorb and remove water from hydraulic fuid. It is not intended
for use during normal operation, but is for use when water removal
is required.
way a term which describes how many ports are in a valve or valve
section.
weldment a structural unit formed by welding together an assembly
of pieces.
wheel chock a wedge or block placed on the ground in front of or
behind the wheel of a vehicle to block the movement of the wheel.
winch a mechanism consisting of a gearbox with a cylindrical rotating
drum on which to coil a line for load hoisting or line tensioning.
winch capacity the maximum load, specifed by the manufacturer,
that can be pulled on the frst layer of line on the winch drum at rated
system pressure.
winch line a load hoisting line consisting of a synthetic or wire
rope.
winch line rated working load the average breaking strength of
a winch line (as specifed by the line manufacturer) divided by the ap-
propriate design factor as specifed by ANSI.
wire rope a rope made from steel wires which are formed into strands
that are then twisted about each other in a spiral confguration.
wood chipper reduces above ground tree materials to uniform
chips.
work the exertion of a force moving through a defnite distance.
Work is measured in units of force multiplied by distance; for example,
pound-feet.
worm gearbox a gearbox that utilizes a gear which has a continuous
helix tooth or teeth similar to a large screw thread along shaft (worm),
that drives a gear which has teeth cut at an angle along a its outside
diameter (worm gear). The rotational axis of the worm is perpendicular
to the rotational axis of the worm gear.
wrap a single coil of winch line on a winch drum.
X-frame outrigger an extendible outrigger having two diagonal
members which are connected at the top in an overlapping manner.
Resembles a broad based X.
Y-cable an electrical cable assembly which contains three branches
joined at a common point, similar to a Y.
zerk see grease ftting.
Service Tools and Supplies
Appendix Service Tools and Supplies
Most routine maintenance and service of the unit can be
performed with common hand tools and shop supplies
available from a tool supply company. Some special tools
and supplies are available from your Altec representative
that may be useful or required to perform certain main-
tenance procedures. These items are categorized with
their corresponding Altec part number. The list contains
items for both aerial devices and derricks. An Accessory
and Replacement Parts Catalog is also available for
ordering other items that may not be shown in the Parts
Manual. This catalog can be obtained through your Altec
representative.
Part Number
099-00017
099-00018
099-00025
099-00033
099-00050
099-00273
099-00019
099-00020
099-00037
099-00069
099-00123
099-00124
099-00021
099-00039
099-00040
099-00041
099-60007
Product
Lubrication
Gear Shield
Chain and Cable Fluid
Moly grease
Anti-seize compound (16 oz can)
Anti-seize compound (
1
/4 lb tube)
Worm gear oil (5 gallon container)
Fasteners
Thread locking adhesive
(Purple 50 ml)
(Blue 50 ml)
(Red 50 ml)
(Red 50 ml)
Inspection lacquer, blue (
1
/2 oz)
Cleaner for inspection lacquer (
1
/2 oz)
Stainless steel safety wire
(5 lb roll)
Cleaning solvent (12 oz)
Primer (Grade N 6 oz)
Primer (Grade T 6 oz)
Wire twisting pliers
Purpose/Use
Lubricate rotation gears and pinions.
Lubricate cables such as wire rope winch line, auger windup
sling, and leveling cables or chains.
Component lubrication.
Conoco gear oil GP460 worm gear winch lubrication only.
Low strength thread locking and sealing agent for small
diameter screws.
Medium strength thread locking and sealing agent for bolts
and nuts.
High strength thread locking and sealing agent for large
diameter bolts and cap screws.
Medium/high strength thread locking agent.
Visual inspection stripe.
Visual inspection stripe removal.
Lockwiring fasteners.
Quick drying, nonfammable solvent used for cleaning parts
prior to bonding. Leaves no residue.
Anaerobic solvent reduces cure time on thread locking
adhesive.
Anaerobic solvent reduces cure time on thread locking
adhesive.
Lockwiring fasteners.
Product
Fiberglass Care
Gelcoat kit
Formula Five Clean N Glaze
Plastic Kleen #2 Polish
Bonding kit
White paint
Hydraulic System Care
Pipe sealant (50 ml)
Flowmeter
Test block small bore (
7
/8 hex)
Test block large bore (1
1
/8)
Filler breather flter
Diagnostic test kit
Oil warming kit
Corrosion suppressant
Electrical System Care
Conformal coating (14 oz)
FD Electrical Contact Cleaner
DeoxIT
Anti-two-block battery
Purpose/Use
Repair fberglass platforms and booms.
Cleaning and polishing fberglass.
Nontoxic plastic cleaner.
Rebond fberglass booms.
Nonmetallic spray paint.
General purpose pipe sealant for use on pipes to 2.
Testing hydraulic system.
Testing counterbalance valve.
Testing counterbalance valve.
Filters air as it enters the reservoir.
Testing hydraulic systems.
Warm hydraulic oil to operating temperature in cold weather.
Chrome cylinder rod protection.
Silicon based electrical component protection.
Clean and degrease electrical systems.
Cleaner/protectant.
Powers wireless ATB switch.
Part Number
041-90001
041-90002
099-00062
703-50039
099-00008
099-00038
099-00034
352-79006
352-79008
356-10029
356-90002
750-40039
099-00051
099-00042
970176850
099-00185
970355765
Product
Miscellaneous
4,000 lb dynamometer
CADI
Slip ring bypass cable
Pulsar torque wrench adapter, short
Pulsar torque wrench adapter, long
Eccentric ring spanner wrench 7 OD
HSLP torque wrench adapter
HSLP brake spanner wrench
Purpose/Use
Test side load protection system (mounts on platform mounting tube).
Test side load protection system (mounts on fberglass upper boom).
Test side load protection system.
Calibration instrument.
Test for a defective or contaminated slip ring.
Remove and install lower pulsars on lower control valve.
Remove and install upper pulsars on lower control valve.
Adjust rotation gearbox eccentric ring.
Remove and install rotation gearbox mounting bolts.
Adjust HSLP rotation brake.
Part Number
702-90428
970112987
099-00022
650-30003
970064398
970341872
970341888
970362151
970381997
970378911
Preventive Maintenance and Inspection Checklist
Vehicle No. ________________________ Location __________________________ Date _________________
Service Request # ____________________ Model # ____________________ Serial # ______________________
Odometer ________________ Hours Meter ________________ Inspector ______________________________
Perform all inspections, adjustments, repairs, and lubrication according to Altec specifcations in the Maintenance
Manual. Refer to any MABs, CSNs, or other applicable documents provided by Altec for servicing the unit.
If you are tracking PTO hours utilizing an approved method or device, follow the recommended hourly maintenance
intervals, or if you are performing maintenance based upon a calendar-based schedule, follow the recommended
monthly intervals. The required items apply to both interval-tracking systems.
Intervals
Prior to placing unit in service 85 PTO hours/1 month 500 PTO hours/6 months
1,000 PTO hours/1 year 2,000 PTO hours/2 years Required maintenance
Symbols
/O = Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
Prior to Placing Unit in Service
85 PTO Hours/1 Month
Perform the Daily Preoperational Inspection
(refer to the Operators Manual)
Covers/Placards
Condition, in place
Hydraulic Reservoir
Oil level
Auger Stow Bracket
Auger windup sling (condition)
Perform the Daily Preoperational Inspection
(refer to the Operators Manual)
Hydraulic Reservoir and System
Check oil and collect oil sample for analysis
1
Rotation Bearing
Turntable tilt measurement
2
: ___________
Auger windup sling clevis shear pin intact
Upper Boom
Fiberglass cleanliness
Lubrication
Rotation bearing ball race
Lift cylinder spherical bearings
Rotation pinion and bearing gear teeth
Perform the 85 hour/1 month inspection
Supplemental Brake Lock
Operation (holding, no bleed-off)
Chassis Underside
Hoses (routing, condition)
Exhaust shields (in place, secure, condition)
Electrical components and wiring (no cracks or split
insulation)
Electrical connections (secure, no corrosion)
Pump
Mounting bolts secure
4-bolt fange bolts secure
Drive line
Noise level
No leaks
Unit Mounting
Subbase mounting (fasteners secure, welds intact,
no cracks)
Subbase structure (welds intact, no cracks)
Boom rest (welds intact, no deformation or cracks)
Pedestal mounting (fasteners secure, welds intact,
no cracks)
Hydraulic Reservoir
Mounting (cap screws secure, welds intact, no cracks)
No leaks
Shutoff valves fully open
Drain water from bottom
Filters
Change return line flter cartridge
Appendix Preventive Maintenance and Inspection Checklist
D2000B/D3000B
may 12
500 PTO Hours/6 Months
Hoses and tubes (routing, condition), no leaks
Rotary joint mounting cap screws secure
insulation)
Turntable
Structure (welds intact, no deformation or cracks)
Boom pin and retainers secure
Lift cylinder pivot pin and retainers secure
Hoses and tubes (routing, condition, no leaks)
Rotary joint drive bar cap screws secure
insulation)
Hydraulic valve spools (return to neutral, no sticking
or leaks)
Hydraulic valve housings (no cracks or leaks)
Slip ring (cleaning, lubrication)
Slip ring mounting cap screws secure, drive bracket
secure
Rotation Bearing and Gearbox
Gearbox mounting cap screws visual inspection
Motor mounting cap screws secure
Eccentric ring lock in place and secure
No leaks
Rotation bearing/pinion gear teeth (no distortion,
cracks, or signifcant wear)
Pinion to rotation bearing gear backlash
Gearbox internal lost motion
Operation (smoothness and noise level)
Rotation bearing inspection and measurement (after
0.050 increased wear from initial measurement)
2
Rotation bearing cap screws visual inspection
Lift Cylinder
Pivot bearings secure within cylinder eyes
Operation, no leaks
Holding valves (operation, no leaks)
Rod (no scores, nicks, or dents)
Barrel (no dents)
Extension Cylinders
Upper boom cylinder trunnion pins secure
Upper and intermediate boom cylinder pins and
retaining rings secure
Intermediate boom cylinder cap screw and jam nut secure
Intermediate boom cylinder rod (no scores, nicks, or dents)
Outriggers
Mounting (welds intact, no deformation or cracks)
Two-speed throttle switch operation
Interlock system operation
insulation)
Hydraulic valve spools (return to neutral, no sticking
or leaks)
Hydraulic valve housings (no cracks or leaks)
Motion alarm operation
Operation (holding without drift, no leaks)
Pins and retainers secure
Hoses and tubes (routing, condition)
Slide bearing nuts and cap screws secure
Slide bearings (no cracks or excessive wear)
Cylinder rods not inside legs (no scores, nicks, or dents)
Cylinder barrels not inside legs (no dents)
Lower Tools Circuit
Operation, no leaks
Tool couplers (condition, operation, dust caps)
Hose reel operation
Hydraulic System Pressures
Pilot system (150 to 170 psi)
Standby (380 to 400 psi)
System/compensator (3,000 psi)
Outrigger system (2,500 psi)
Lower tools (2,000 psi or customer spec _______ psi)
Upper tools (2,000 psi or customer spec _______ psi)
Lower Control Station
insulation)
Panel night lights operation
Engine start/stop switch operation
Lower/upper control switch operation
Controls (rubber boots intact)
Switches (safety covers and seals intact)
Digger speed switch (interlock circuit)
Pressure gauges
Cold oil/change flter light
Tachometer
Pedestal
Rope retaining pin above upper sheave in place
Pole Guide
Tongs (no deformation or cracks)
Cap screws secure
Operation, no leaks
Pole guide interlock operation
Boom Tip Power Package and Upper Controls
Hose carrier track (links pivot freely)
Fiberglass tube condition
Hoses and tubes (routing, condition, no leaks)
Upper controls cable (condition, routing, wire ties)
Tools couplers (condition, operation, dust caps)
Control handles (throttle pickup)
Engine start/stop control
No operation in upper controls Off position
Intermediate and upper boom sequencing operation
Transfer operation and retaining pin alignment
Platform
Mounting fasteners and pins secure
Storage lock detent pin operation
Brake (adjustment, pad and rotor condition)
Platform (condition, cleanliness)
Fall protection system condition
Jib
Fiberglass condition (clean, undamaged)
Bracket and mounting pins
Sheave(s) (condition, turn freely)
Sheave pin(s) and retainer(s) secure
Winch
Gearbox mounting cap screws secure
Motor mounting cap screws secure
Outboard output shaft bearing secure
Drum (welds intact, no deformation or cracks)
Operation, no leaks
Winch line (condition, anchor point secure)
Winch drum set screw secure against output shaft
Auger Stow Bracket
Fasteners secure
Auger stow switch operation
Auger release mechanism operation
No leaks
Intermediate boom cylinder barrel (no dents)
Operation, no leaks
Feeder Tubes
Mounting nuts secure
No leaks
Rods (no scores, nicks, or dents)
Lower Boom
Lift cylinder pivot pin and retainers secure
Fasteners secure
insulation)
Boom stow switch operation
Boom angle indicators
Intermediate Boom
Surface condition
Winch rope rollers turn freely
Pins and retainers secure
Fasteners secure
Two-part load line attachment (secure)
insulation)
Upper Boom
Fiberglass fasteners secure
Fiberglass condition (clean, undamaged)
Transferable Flares
Transfer operation and pin alignment
Fasteners secure
Upper Boom Tip
Mounting to upper boom secure
Platform mounting tubes and fasteners secure
Sheave(s) (condition, turn freely)
Sheave pin(s) and retainer(s) secure
Annual Testing
Dielectric test unit
Dielectric test platform liner(s)
Atmospheric vents (visually inspect all, verify operation)
Perform the 500 hour/6 month inspection
Rotation bearing cap screws annual torque inspection
Rotation gearbox mounting cap screws annual torque
inspection
Lubrication
Pump input shaft splines
Hydraulic Reservoir
Collect oil sample for analysis
1
Operators Station
Seat (secure, condition)
Standup platform (secure, condition)
Originally Equipped Access and Protection Equipment
Steps, ladders, handrails, guards (in place, secure,
condition)
Chassis
Engine (condition, operation)
Exhaust (condition, no leaks)
Steering (operation)
Brakes (operation)
Fasteners and pins
All fasteners included on 500 hour/6 month checklist
(no signifcant corrosion)
All pins and retainers included on 500 hour/6 month
checklist (no signifcant corrosion)
Required Maintenance (Regardless of Hours)
1,000 PTO Hours/1 Year
Digger
Operation, no leaks
Noise level
Two-speed shift operation
Bail pivot pin nuts secure
Digger Link and Hanger Bracket
Structures (welds, slide bearing, no deformation,
cracks)
Link pivot pin or retainers secure
Fasteners secure
Latch and latch keeper (alignment, operation)
Latch weldment lug operation
Auger and Extension Shaft
Flighting condition
Teeth and pilot bit condition
Windup sling lug, weld intact
Extension shaft, auger retaining cap screws secure
Extension shaft and auger straight
Winch raise, digger dig, boom lower, intermediate
and upper boom extend disabled by HOP,
opposite function direction operational
Counterclockwise setting: _______ lbs
Clockwise setting: _______ lbs
Anti-Two-Block
ATB override switch enables functions disabled by ATB
Winch raise, boom lower, intermediate and upper
boom extend disabled by ATB, opposite function
direction operational
Lubrication
Boom pin
Upper boom slide bearing pivot pin
Auger stow bracket latch
Winch gearbox outboard bearing
Intermediate boom winch line roller(s)
Winch worm bearings
Rotary joint
Digger link pivot pins
Corner mount outrigger pivot pins
Platform brake detent pin
Digger hanger bracket latch pivot point
Pole guide tong gear teeth
Boom angle indicators
Platform brake linkage
Outrigger valve handle linkages
Auger windup sling (wire rope)
Winch line (wire rope)
Transferable boom fares retaining pin and bosses
Platform mounting pin and socket
Intermediate boom outer surface
Outrigger inner leg outer surface
Digger gearbox oil level
Rotation gearbox oil level
Winch gearbox oil level
1
Periodic laboratory analysis is the most accurate method of determining the condition of the hydraulic oil and determining when it should be changed. If laboratory
analysis is used, take baseline sample. Compare future lab tests on subsequent samples to the original to establish a trend.
2
Initially measure turntable tilt as a baseline. Check rotation bearing wear every 2 years until it measures 0.050 increased wear from initial measurements. After
reaching 0.050 increased wear, measure every 6 months. Refer to the Maintenance Manual for the proper procedure.
Comments __________________________________________________________________________________
___________________________________________________________________________________________
Perform the 1,000 hour/1 year inspection
Rotation bearing inspection and measurement (before
0.050 increased wear from initial measurement)
2

Hydraulic Reservoir and System
Flush hydraulic system
Clean inside of reservoir
Clean magnetic suction separator flter
Clean or change fller hole strainer
Change fller/breather cap flter
Reservoir cover gasket condition
Change hydraulic oil
Lubrication
Change digger gearbox oil
Change winch gearbox oil
Change rotation gearbox oil
Structures
All structures and welds included on 500 hour/6 month
checklist (no signifcant corrosion)
Anti-Two-Block
Replace battery in ATB switch at boom tip
2,000 PTO Hours/2 Years
Appendix Accessory Checklist
Accessory Checklist
* DOT items
Unit Accessories
Platform liners
Platform covers
Tool holders (mounting and condition)
Scabbard (mounting and condition)
Spare augers
Screw anchor wrench
Lifting slings and chains
Hydraulic cooler (mounting, condition and fan operation)
Hydraulic oil heater (operation and condition)
ROACS system (operation)
Radio controls
Auxiliary power unit (mounting, pump to bellhousing
bolts, exhaust system, cooling system, fuel system)
Body Accessories
Body (structure, mounting)
Outrigger pads and holders
Pole rack mounting
Access steps (condition and mounting)
Cargo area retention (mounting and condition)
Dump bed operation (dump hoist and body prop)
Spotlights and work lights
Beacons
Wheel chocks and holders
Mud faps
Cones and holders
Inverters (operation and mounting)
Generators (operation and mounting)
Platform rest (condition and mounting)
Fire extinguishers*
First aid kit
Flare kit/warning triangles (3)*
Grounding reel
Power cord reel
Hotstick tube or box
Ladder rack
Spare fuse pack*
Chassis Accessories
Front winch (mounting and operation)
PTO and driveline
Bed winch
Capstan
Collapsible reel
Secondary brake system
Pintle hitch (condition and mounting)
Safety chain eyebolts
Trailer plug
Tow hooks
Cab guard
Brake controller (mounting and operation)
Back up alarm (mounting and operation)
Torsion bar
Hydraulic Tools and Hoses
Hose reel and hoses
Pole puller, chain and base
Impact
Chain saw
Tamp
Quick disconnects
1,000 PTO Hours or as Recommended by the Manufacturer
Vehicle No. ________________________ Location __________________________ Date _________________
Model Number _________________ Serial Number ___________________ Inspector ____________________
Symbols
/O = Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
Appendix Accessory Checklist
Appendix Torque Values
Fitting Size T.F.F.T. Fitting Size T.F.F.T.

1
/8 2 to 2
1
/2
3
/4 1
1
/2 to 2

3
/16 2 to 2
1
/2
7
/8 1
1
/2 to 2

1
/4 2 to 2
1
/2 1 1
1
/2 to 2

5
/16 2 to 2
1
/2 1
1
/8 1
1
/2 to 2

3
/8 1
1
/2 to 2 1
1
/2 1
1
/2 to 2

1
/2 2 to 2
1
/2 2 1
1
/2 to 2

5
/8 2 to 2
1
/2
Pipe Thread T.F.F.T. Valve Cartridges (Standard SAE Cavity)
Wrench Size Fitting Size Torque ft-lbs (Nm)

7
/8 -8 20 (27)
1 -10 25 (34)
1
1
/8 -10 25 (34)
1
1
/4 -12 35 (48)
1
1
/2 -16 50 (68)
2 -20 65 (88)
Compression Fittings
Tube Size Fitting Size T.F.F.T.

1
/8 thru
1
/4 2 thru 4 1
1
/4

5
/16 5 1
3
/4

3
/8 thru 1 6 thru 16 2
1
/4
Split Flanges
Flange Size Thread Torque in-lbs (Nm)

3
/4
3
/8-16 250 to 350 (28 to 40)
1
3
/8-16 325 to 425 (37 to 48)
1
1
/4
7
/16-14 425 to 550 (48 to 62)
1
1
/2
1
/2-13 550 to 700 (62 to 79)
2
1
/2-13 650 to 800 (73 to 90)
Torque Values
Grade 8
Bolt Size - Grade 5 Hex Hex Head, Socket Head, Button Head Cap Screw
Thread Pitch Head Cap Screw and 12 Point Cap Screw and Flat Head Socket Screw

1
/4 - 20 5 (7) 7 (10) 6 (8)

5
/16 - 18 10 (14) 15 (20) 13 (17)

3
/8 - 16 19 (25) 26 (35) 22 (30)

7
/16 - 14 30 (40) 42 (57) 36 (49)

1
/2 - 13 45 (61) 64 (87) 55 (74)

9
/16 - 12 65 (89) 92 (125) 79 (107)

5
/8 - 11 90 (122) 127 (172) 109 (148)

3
/4 - 10 160 (217) 226 (306) 193 (262)

7
/8 - 9 258 (349) 364 (493) 312 (422)
1 - 8 386 (524) 545 (739) 467 (633)
Fasteners
1
Values are foot-pounds (Nm).
2
Values apply for both lubed and not lubed applications with any style nut or threaded hole.
3
Values apply for torque applied to either the head of the bolt or the nut.
4
This chart only applies for general application fasteners where a specifc torque is not defned. Refer to the fastener section for special applica-
tions where the torque is specifcally defned.
SUN Counterbalance Valves
Wrench Size Torque ft-lbs (Nm)

7
/8 30 to 35 (41 to 47)
1
1
/8 45 to 50 (61 to 68)
1
1
/4 150 to 160 (203 to 217)
Appendix Torque Values
Torque With Self-Locking Nuts Torque Without Self-Locking Nuts
Fitting Size in-lbs (Nm) in-lbs (Nm)
-2 60 to 70 (7 to 8) 85 to 95 (10 to 11)
-3 120 to 140 (14 to 16) 160 to 180 (18 to 20)
-4 180 to 200 (20 to 23) 205 to 235 (23 to 27)
-5 245 to 275 (28 to 31) 245 to 275 (28 to 31)
-6 300 to 340 (34 to 38) 300 to 340 (34 to 38)
-8 545 to 595 (62 to 67) 545 to 595 (62 to 67)
-10 690 to 750 (78 to 85) 1,010 to 1,110 (114 to 125)
-12 910 to 1,010 (103 to 114) 1,250 to 1,350 (141 to 153)
-14 1,675 to 1,825 (189 to 206) 1,675 to 1,825 (189 to 206)
-16 1,845 to 1,995 (208 to 225) 1,895 to 1,945 (214 to 220)
-20 2,550 to 2,850 (288 to 322) 2,550 to 2,850 (288 to 322)
-24 2,850 to 3,150 (322 to 356) 2,850 to 3,150 (322 to 356)
-32 3,700 to 4,100 (418 to 463) 3,700 to 4,100 (418 to 463)
Upper values are for stainless steel.
SAE O-Ring Fittings
Misalignment of
marks show how much
nut was tightened
Tube and JIC Fittings
Tube Connection Swivel Nut or Hose
Size Thread Size F.F.W.R. Connection F.F.W.R.
-4
7
/16-20 2 2
-5
1
/2-20 2 2
-6
9
/16-18 1
1
/2 1
1
/4
-8
3
/4-16 1
1
/2 1
-10 1-16 1
1
/2 1
-12 1
1
/16-12 1
1
/4 1
-16 1
5
/16-12 1 1
-20 1
5
/8-12 1 1
-24 1
7
/8-12 1 1
-32 2
1
/2-12 1 1
Basic JIC Symbols
Appendix Basic JIC Symbols
Methods of Operation
Spring
Manual
Manual, rotary
Push button
Push/pull lever
Pedal or treadle
Mechanical
Detent
Pressure compensated
Solenoid, single winding
Servo motor
Pilot pressure
Lines
Remote supply
Internal supply
Line, pressure or tank
Line, sense (for control)
Component enclosure
Flow, direction of
Lines crossing
Lines joining
Line with fxed restriction
Flow control adjustable, non-compensated
Flow control adjustable
(temperature and pressure compensated)
Station, testing, measurement,
power take-off or plugged port
or
)
Hydraulic
Pneumatic
Double-acting
Single-acting, internal spring
Single-acting, external spring
Check
Counterbalance
On - off (manual shut-off)
Pressure relief
Pressure reducing
Two-position, two connection
Two-position, three connection
Two-position, four connection
Three-position, four connection
Two-position, in transition
Valves capable of infnite
positioning (horizontal bars
indicate infnite positioning ability)
Shuttle valve
Typical closed center spool
Typical open center spool
Logic element, poppet type
Cylinders Valves
Reservoir
Line, to reservoir
Vented manifold
Vented
Pressurized
Above fuid level
Below fuid level
Fluid Storage
Hydraulic oscillator
Hydraulic motor
Fixed displacement
Variable displacement
Bidirectional
Motors
Pumps
Hydraulic pump
Fixed displacement
Variable displacement
)
Variable component
(run arrow through symbol at 45 degrees)
Pressure compensated units
(arrow parallel to short side of symbol)
Direction of shaft rotation
(assume arrow on near side of shaft)
Flowmeter
Pressure switch
Pressure gauge
Pressure sensor
Temperature gauge
Quick disconnect
Internal combustion engine
Accumulator, spring loaded
Accumulator, gas charged
Weighted
Filter, strainer
Filter with adjustable bypass
Heater
Cooler
Temperature controller
Temperature cause or effect
Miscellaneous
(
(
Hydraulic System Schematics
Appendix Hydraulic System Schematics
Electronic Side Load Protection
Hydraulic Side Load Protection
Reservoir
Selector Valve
Pump Rotary Joint
Outrigger and
Tool Control Valve
Outrigger Control Valve
Rotation Float
Brake Release Valve
Auxiliary Functions Valve
Lower Tools
Flow Divider Valve
Counterbalance
Valve
Cross-Ported
Pilot Operated
Check Valve
Lower Control Valve
Pressure
Reducing Valve
ESLP Rotation Valve With Rotation Float ESLP Rotation Valve Without Rotation Float
HSLP Rotation Valve With Rotation Float HSLP Rotation Valve Without Rotation Float
D2000B/D3000B/D4000B
Appendix Basic Electrical Symbols
Basic Electrical Symbols
Relays
Switches
Transistors
Motor
Circuit breaker
Fuse
Capacitor
Coil
Connection
No connection
Battery
Ground
Diodes
Resistors
Chassis or common return connected
to one side of voltage source
Chassis or common return not
connected to voltage source
Fixed
Variable
Rectifer
Photoemissive diode (LED)
Simple
Bistable
Latching
Logic
Single-pole, single-throw (SPST)
Single-pole, double-throw (SPDT)
Double-pole, single throw (DPST)
Double-pole, double-throw (DPDT)
NPN
PNP
Air-core
Iron-core
K A
K A
M
B
C
E
B
C
E
Appendix Basic Electrical Symbols
Wiring Line Diagrams
Appendix Wiring Line Diagrams
Above Rotation
Below Rotation
Pin Color Function
1 Blue Intermediate boom retract
2 White/green Rotation left
3 Green Rotation right
4 White/yellow Boom lower
5 Yellow Boom raise
6 White/blue Intermediate boom extend
7 White/brown Upper boom extend
8 Brown Upper boom retract
9 Violet Digger dig 1
10 White/violet Digger clean 1
11 Violet/black Digger dig 2
12 Violet/white Digger clean 2
13 White/orange Winch raise
14 Orange Winch lower
Connector A
1 Red 12 V
2 Red 12 V
3 Red 12 V
4 Red 12 V
5 Red 12 V
6 Red 12 V flter
7 White/brown ESLP counterclockwise
8 Brown ESLP clockwise
9 Orange Filter change
10 White Tools
11
12 Pink Pole guide interlock
13 Blue Boom stow
14 Black Ground
15 Black Ground
16 White/yellow Boom position 2
17 Yellow Boom position 1
18 White/violet Auger limit
19 White/red/black Platform interlock
20 Violet/black Load indicator
21 White/red ATB
22 Orange/black System pressure
23 Violet/black Load indicator
Connector B
Pin Color Function
1 Black 1 Can high
2 Black 2 Can low
3 Black 3 12 V
4 Black 4 Emergency stop in
5 Black 5 Emergency stop out
6 Black 6
7 Yellow/green Ground
Connector C
1 Pink Pole guide back
2 White/red Pole guide forward
3 Gray Pole guide open
4 White/gray Pole guide close
5 Yellow/black Rotation foat
6 Red Start/horn
7
8 Blue/white Third stage interlock
9 White Auger release
10 White/black Digger shift
11 Red/yellow Winch shift
12 Red/black Tools
13 Tan Enable
14
Connector D
1 Brown Communication B
2 White Communication A
3 Red 12 V
4 Black Ground
5 Green Interlock
6
7
8
Connector E
Pin Color Function
3 Red 12 V
4 Black Ground
5 Green Interlock
6 Blue 12 V upper control
7 Yellow Emergency stop in
8 Orange Emergency stop out
Connector F
3 Green Interlock
4 Black Ground
5 Red/yellow Spare 12 V out
6 Orange Emergency stop
7 Red 12 V
8 Red 12 V
Connector G
3 Red 12 V
4 Black Ground
5 Green Interlock
6 Blue 12 V upper control
7 Yellow
9 Black 5 Emergency stop out
10 Black 4 Emergency stop in
11 Yellow/green Ground
12 Black 3 12 V
13 Black 2 Can high
14 Black 1 Can Low
Connector H
Pin Color Function
1
2
3 Red 12 V
4
5
6
7
Connector J
1 Red 12 V
2 Black Ground
3 Red/black 5 V
4 Tan Start/stop
5 Pink System pressure
6 Gray Digger shift interlock
7 Violet Digger
8 Red/green Rotation foat
9 Red/yellow Emergency stop out
10 Yellow Emergency stop in
11 Green Interlock
12 Orange Winch
13 White Rotation foat lamp
14 Brown Lower control
15 Blue Upper control
16 White/black Cold oil lamp
17 White/green Digger speed lamp
18 White/yellow Standard/low speed
19 White/red Spare
20-37 Unused
Connector K
3 Blue 12 V
4 Black Ground
Connector L
Pin Color Function
A Black Ground
B Red 12 V
C Orange/black 0.5 V - 4.5 V signal
Connector M
A Black Ground
B Red 12 V
C Violet/black 0.5 V - 4.5 V signal
Connector N
A Black Ground
B Green 0.5 V - 4.5 V signal
C Red 5 V
Connector P
A Black Ground
B Red 0.5 V - 4.5 V signal
C White 5 V
Connector Q
Pin Color Function
3 Red 12 V
4 Black Ground
5 Green Interlock
6
Connector R
A Black Ground
B Red 12 V
C White/brown 0.5 V - 4.5 V signal
Connector S
3
4 Black Ground
5 Green Interlock
6
7
Connector U
Appendix Dielectric Test Forms
Dielectric Test Form for Digger Derricks
Without Personnel Jib (46 kV and Below)
Procedure
1. Read and understand Section 9 in the Maintenance Manual and applicable ANSI requirements.
2. Insulate the vehicle from ground by placing polyethylene pads beneath each tire and outrigger leg.
3. If the unit is so equipped:
Pin the transferable fares to the upper boom.
Pin the upper controls to the upper boom.
Install the platform(s) on the boom tip.
4. Fully retract the intermediate boom.
5. Extend the upper boom so the minimum extension placard is beyond the farthest extent of all metal compo-
nents on or attached to the intermediate boom tip.
6. The winch line must not bridge extended upper boom.
7. Electrically bond all metal at the boom tip to ensure all possible current paths are considered. Include all con-
ductive brackets, air plunger switches, hydraulic valves, controls, cylinders, jib brackets, etc.
8. Attach the ground return lead to the intermediate boom.
9. Attach the high voltage test lead (insulated from ground) to the boom tip.
10. Position the boom at the same angle as recorded on previous test report(s) for this unit. Record the boom
angle used during the test.
11. Do not use cancel (null) circuit if the tester is so equipped.
12. Gradually increase the voltage to 100 kV (60 hertz).
13. Hold at 100 kV (60 hertz) for 3 minutes continuously. If fashover occurs, or the leakage rate exceeds 1,000
microamps, the unit has failed the test. Record leakage reading below.
General Information
Model number ________________________________ Serial number _________________________________
Test device number ____________________________ Boom angle (degrees) ___________________________
Polyethylene Pad
Ground
Return Lead
High Voltage
Test Lead
Controls High Voltage
Transformer Ground
Minimum Extension
Placard
Bonding Jumper
Conclusion
Leakage reading (microamp) ___________________________________________________________________
Pass _____ Fail (reason) _____________________________________________________________________
Comments _________________________________________________________________________________
__________________________________________________________________________________________
Signature of technician ______________________________________ Date of test ______________________
Procedure
Refer to the illustration Position A for steps 1 through 15.
1. Read and understand Section 9 in the Maintenance Manual and applicable ANSI requirements.
2. Insulate the vehicle from ground by placing polyethylene pads beneath each tire and outrigger leg.
Pin the transferable fares to the upper boom.
Pin the upper controls to the upper boom.
Install the platform(s) on the boom tip.
5. Extend the upper boom so the minimum extension placard is beyond the farthest extent of all metal compo-
nents on or attached to the intermediate boom tip.
6. The winch line must not bridge extended upper boom.
7. Electrically bond all metal at the boom tip to ensure all possible current paths are considered. Include all con-
ductive brackets, air plunger switches, hydraulic valves, controls, cylinders, jib brackets, etc.
8. Attach the ground return lead to the intermediate boom.
9. Attach the high voltage test lead (insulated from ground) to the boom tip.
10. Position the boom at the same angle as recorded on previous test report(s) for this unit. Record the boom
angle used during the test.
microamps, the unit has failed the test. Record the leakage rating and correct before retesting.
14. Reposition the boom to access the boom tip from the ground.
15. Remove the bonding jumper at the boom tip and the ground return and test leads.
Refer to the illustration Position B for steps 16 through 24.
16. Install the personnel jib in its operational position.
17. Install the platform(s) on the jib tip.
Pin the transferable fares to the intermediate boom.
Extend and pin the pullout upper controls to the bracket near the jib tip.
20. Retract the upper boom as far as the jib bracket will allow.
21. Electrically bond the following items.
All metal at the jib tip.
The jib mounting bracket to the metal at the end of the intermediate boom.
22. Attach the ground return lead to the jib mounting bracket.
Position A
Dielectric Test Form for Digger Derricks
With Personnel Jib (46 kV and Below)
Polyethylene Pad
Ground
Return Lead
High Voltage
Test Lead
Bonding Jumper
Transformer Ground
Minimum Extension
Placard
23. Attach the high voltage test lead (insulated from ground) to the jib tip.
24. Position the boom at the same angle as in step 10.
microamps, the unit has failed the test. Record leakage reading.
General Information
Test device number ____________________________ Boom angle (degrees) ___________________________
Position A Conclusion
Pass _____ Fail (reason) _____________________________________________________________________
Comments _________________________________________________________________________________
__________________________________________________________________________________________
Position B Conclusion
Pass _____ Fail (reason) _____________________________________________________________________
Comments _________________________________________________________________________________
__________________________________________________________________________________________
Polyethylene Pad
Ground
Return Lead
Bonding Jumper
Transformer Ground
Position B
Bonding
Jumper
High
Voltage
Test Lead
DC Periodic Dielectric Test For All Category A, B, and C
Insulating Telescopic Aerials and Insulating Digger Derricks
(For DC Test Device With Output Current Metering Only)
Procedure
1. Read and understand the dielectric test information in the Maintenance Manual, ANSI requirements, and the
manual for the test device being used.
2. This procedure is for a DC test device with output current metering only. Do not use this procedure when using a
DC test device that measures the return current instead of the output current. If equipped with a selector switch,
set the switch to Ground Return.
3. The test area should be dry and appropriately roped off to prevent bystanders from entering the test area.
4. Ground chassis, test device or control box, and discharge stick as shown.
5. No isolation pads are required under the vehicle tires or outriggers.
6. Set up booms to maintain at least 2 (61 cm) of clearance between conductive components as shown.
7. Electrically bond all metal at the boom tip to ensure all possible current paths are considered. Include all conduc-
tive brackets, air plunger switches, hydraulic valves, controls, cylinders, jib brackets, etc.
8. Extend upper boom to minimum extension length for dielectric test. If possible, fully retract all intermediate
booms extending only the insulating upper boom. Attach a bonding jumper between intermediate boom tip, if so
equipped, and lower base boom.
9. Attach the high voltage test lead and bonding jumpers as shown for the upper boom test.
10. It is not necessary to use the meter receptacle on the upper boom of Category A and B machines for the upper
boom test. However, whether the meter receptacle is used or not, all internal connections to this receptacle must
be checked to verify that all current paths through the boom are properly connected to ensure proper function.
11. Voltage and maximum allowable leakage for the upper boom test are as follows.
a. Derricks and Category C 46 kV and below 56 microamps at 56 kV after 3 minutes
b. Category A/B 46 kV and below 28 microamps at 56 kV after 3 minutes
c. Category A/B 69 kV 42 microamps at 84 kV after 3 minutes
d. Category A/B 138 kV 84 microamps at 168 kV after 3 minutes
12. To test the upper boom, it may be helpful, though not required, to increase the angle of the boom to help keep
the high voltage lead from contacting the ground or other conductive components. Gradually increase the volt-
age to the proper level. Hold for 3 minutes. If fashover occurs or the leakage rate exceeds the maximum value,
the unit has failed the test. Record leakage reading.
High Voltage
Test Lead
Upper Boom Test
Drawing not intended to represent a specifc model
Minimum
Extension
Control Box
Discharge Stick
Bonding Jumper for
Intermediate Boom
2 Minimum
Upper Boom Extension
35 Minimum 40 Minimum
AT30-G D2/3/4A
AT30-GV D2/3/4B
LS40/45 DB
DC
DL/DM
DLB/DMB
Ground Post
13. If the derrick is equipped with a personnel jib, perform a second test with the jib in place, platform mounted and
pull-out controls connected. Attach high voltage lead to the new platform position at the end of the jib with all
conductive components properly bonded. Repeat the upper boom test procedure and record leakage reading.
General Information
Test device number ____________________________ Category/voltage rating _________________________
Conclusion
Upper boom leakage reading (microamp) _______________________________________________________
Pass _____ Fail (reason) _____________________________________________________________________
Comments _________________________________________________________________________________
__________________________________________________________________________________________
Signature of technician _____________________________________ Date of test _______________________
Either method may be used.
Wet Method Setup
1. Connect a ground lead to the steel tank.
2. Immerse the liner in the tank and fll with conductive fuid
until the level around both the inner and outer surfaces of the
liner is within 6 (15.24 cm) of the top of the liner.
3. Suspend the high voltage lead in the fuid within the liner.
Dry Method Setup
1. Refer to TRS-0001 to apply conductive foil to the liner and
conduct the test.
2. Connect a ground to the outer conductive foil.
3. Connect the high voltage lead to the inner conductive foil.
Testing (Wet or Dry)
1. Apply the test voltage to the conductive fuid or foil. Voltage may be either 35 kV (60 hertz) for 1 minute or 100
kV DC for 3 minutes.
2. If fashover occurs, or the liner wall punctures, the liner has failed the test.
3. Turn off the test voltage (be sure the voltage meter indicates zero voltage). Remove the high voltage lead.
Remove the liner from the tank or remove the foil covering.
4. The test for more than one liner may be recorded on the same form providing the same setup is used to elimi-
nate external variables.
Conclusion
Unit Serial No. Liner Part No. Liner Serial No. Pass (Initials) Fail (Reason)
_____________ _____________ _____________ ___________ __________________________________
_____________ _____________ _____________ ___________ __________________________________
_____________ _____________ _____________ ___________ __________________________________
_____________ _____________ _____________ ___________ __________________________________
_____________ _____________ _____________ ___________ __________________________________
_____________ _____________ _____________ ___________ __________________________________
_____________ _____________ _____________ ___________ __________________________________
Wet/dry __________ Test voltage _________ Test device number ____________________________________
Date _____________________ Test performed by _________________________________________________
Comments _________________________________________________________________________________
__________________________________________________________________________________________
Periodic Dielectric Test Form for Platform Liners
Ground
Liner
Ground
Liner
Tank
Conductive
Foil
High Voltage Lead
Conductive
Fluid
High Voltage Lead
6 (15.24 cm) Maximum
6 (15.24 cm) Maximum
Appendix Stability Test Forms
Test
Weight
Stability Test Form for Digger Derrick Use
Procedure
1. Perform the stability test in accordance with applicable ANSI or CSA requirements.
2. If the unit is zone rated for digger derrick use, a separate stability test must be conducted for each zone of
rotation.
3. Fill out all information on this form as a record of a completed stability test.
4. Remove all platforms, personnel and material handling jibs before conducting this stability test. If so equipped,
pin the transferable tip to the upper boom.
5. Position the unit on a level surface with the booms fully extended. Test weight and boom angle are shown on
the capacity chart for digger derrick use located on the pedestal.
6. After the test has been completed, torque all accessible rotation bearing cap screws to 325 foot-pounds using
a circular pattern (only required following initial stability test at the time of initial installation of unit on chassis).
7. After the test has been completed, torque the rotation gearbox mounting cap screws to 325 foot-pounds (only
required following initial stability test at the time of initial installation of unit on chassis).
General Information
Winch line test weight (lbs) ___________ Thickness of outrigger pads (inches N/A if not used) ____________
Boom angle (degrees) _________________ Zone (N/A if unit is not zone rated) __________________________
Conclusion
Rotation bearing cap screws torqued __________ Rotation gearbox mounting cap screws torqued __________
Load moment limiter trip value (if so equipped) _____________________________________________________
Pass _____ Fail (reason) _____________________________________________________________________
Comments _________________________________________________________________________________
__________________________________________________________________________________________
Procedure
1. Perform the stability test on a level surface and on a fve degree slope in accordance with applicable ANSI
requirements.
2. If the unit is zone rated, a separate stability test must be conducted for each zone of rotation. If a particular
zone is unique to either the street or curb side, that side (as defned by the zone), is to be placed on the low
side of the test slope during the fve degree slope stability test.
4. Pin the 4.2 material handing jib so it is near horizontal. Mount a single platform at the boom tip. The platform
must be empty but in a load carrying position.
5. If the unit is so equipped, pin the transferable tip to the upper boom.
6. Remove all boom tip options except the single platform and jib.
7. Fully extend the intermediate and upper booms.
8. The boom angle for the test is shown on the capacity chart for digger derrick use located on the pedestal.
Readjust the boom angle as necessary, to compensate for the test slope angle and/or roll angle.
9. Calculate the test weight by multiplying 1.5 (level surface) and 1.33 (fve degree slope) times the capacity
shown on the capacity chart for combined digger derrick and platform use at full extension and boom angles
as described above. Carry all of the test weight on the jib load line with no weight in the platform.
10. This test may also be conducted without a platform by adding 125 pounds to the test weight. The 4.2 material
handling jib may not be omitted.
General Information
Rated personnel and material capacity (lbs at full extension and boom angle above) ____________________
Thickness of outrigger pads (inches N/A if not used) _____________________________
Stability Test Form for Combined
Digger Derrick and Platform Use (ANSI)
Test
Weight
Level Surface Test
Test weight with platform = 1.5 x rated capacity = _____________ lbs
Test weight without platform = 125 lbs + (1.5 x rated capacity) = _____________ lbs
Five Degree Slope Test
Test weight with platform = 1.33 x rated capacity = _____________ lbs
Test weight without platform = 125 lbs + (1.33 x rated capacity) = _____________ lbs
Side of vehicle on low side of slope __________________________________________
Conclusion
Pass _____ Fail (reason) _____________________________________________________________________
Comments _________________________________________________________________________________
__________________________________________________________________________________________
Test
Weight
Stability Test Form for Combined
Digger Derrick and Platform Use (CSA)
Procedure
1. Perform the stability test on a level surface and on a fve degree slope in accordance with CSA applicable
requirements.
2. If the unit is zone rated, a separate stability test must be conducted for each zone of rotation. If a particular
zone is unique to either the street or curb side, that side (as defned by the zone), is to be placed on the low
side of the test slope during the fve degree slope stability test.
4. Pin the 4.2 material handing jib so it is near horizontal. Mount a single platform at the boom tip. The platform
must be empty but in a load carrying position.
5. If the unit is so equipped, pin the transferable tip to the upper boom.
6. Remove all boom tip options except the single platform and jib.
7. Fully extend the intermediate and upper booms.
8. Boom angles of 20, 40, 60 and 80 degrees must be tested. Use a separate form for each boom angle. Read-
just the boom angle as necessary, to compensate for the test slope angle and/or roll angle during each test.
9. Calculate the test weight by multiplying two times the capacity shown on the capacity chart for combined dig-
ger derrick and platform use at full extension and each boom angle). Carry all of the test weight on the jib load
line with no weight in the platform.
10. This test may also be conducted without a platform by adding 125 pounds to the test weight. The 4.2 material
handling jib may not be omitted.
General Information
Rated personnel and material capacity (lbs at full extension and boom angle above) ____________________
Thickness of outrigger pads (inches N/A if not used) _____________________________
Test weight with platform = 2 x rated capacity = _____________ lbs
Test weight without platform = 125 lbs + (2 x rated capacity) = _____________ lbs
Side of vehicle on low side of slope (fve degree slope test only) _______________________________________
Conclusion
Pass _____ Fail (reason) _____________________________________________________________________
Comments _________________________________________________________________________________
__________________________________________________________________________________________

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Section 5 Hydraulic System 57

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