am800-900 m

Copyright 2006 by Altec Industries, Inc.All rights reserved. No part of this publication may be used or reproduced by any means, or stored in a

database or retrieval system, without prior written permission of the publisher. Making copies of any part of this publication for any purpose other than personal use is a violation of United States copyright laws.

Altec Industries, Inc. reserves the right to improve models and change specifications without notice.

749-20009March 2006

AM800/900

Maintenanceand Parts Manual

Preface

This unit is the result of Altecs advanced technology and quality awareness in design,engineering, and manufacturing. At the time of delivery from the factory, this unit met orexceeded all applicable requirements of the American National Standards Institute. Allinformation, illustrations, and specifications contained within this manual are based on thelatest product information available at the time of publication. It is essential that all personnelinvolved 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 manualsprovided, this unit will provide many years of excellent service before requiring majormaintenance.

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

Warning

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

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

Danger

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

No unit can provide absolute safety when in proximity to energized conductors. No unit isdesigned or intended to replace or supersede any protective device or safe work practicerelating to work in proximity to energized conductors. When in proximity to energizedconductors, this unit shall only be used by trained personnel using their companys acceptedwork methods, safety procedures, and protective equipment. Training manuals are availablefrom a variety of sources.

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

7-04

Table of Contents

About This Manual ............................................................................................................ 1Special Cautions .................................................................................................................. 1Disclaimer of Liability ........................................................................................................... 2Structures ............................................................................................................................. 2Equipment Storage ............................................................................................................... 2

Protective Measures ...................................................................................................... 2Cleaning the Unit and Fiberglass .......................................................................................... 3

Plastic ............................................................................................................................ 3Tightening of Fasteners ........................................................................................................ 3Lockwiring ............................................................................................................................ 4Inspection Marks .................................................................................................................. 4Pins ...................................................................................................................................... 5Bearings ............................................................................................................................... 5Inspections ........................................................................................................................... 5

Elbow Bearing Cap Screw Torque Inspection Procedure ............................................... 6Rotation Bearing Cap Screw Inspection Procedure ....................................................... 7Rotation Gearbox Mounting Cap Screws ....................................................................... 8

Lubrication ............................................................................................................................ 9Lubrication Chart and Diagram ..................................................................................... 10

Adjustment of Rotation Pinion to the Rotation Bearing ....................................................... 12Hydraulic Plumbing, Hoses, and Fittings ............................................................................ 12Single Handle Control and Control Handle Covers .............................................................. 13Atmospheric Vents ............................................................................................................. 13Oil Filtration ........................................................................................................................ 13Oil Selection ....................................................................................................................... 13Changing the Oil ................................................................................................................. 14Visual Inspection of Hydraulic Oil ...................................................................................... 14Flushing the Hydraulic System........................................................................................... 14Air Bleeding ........................................................................................................................ 15Troubleshooting Procedure ................................................................................................. 15Engine Throttle Control ....................................................................................................... 15Removing the Rotary Joint ................................................................................................. 16Removal of Upper Boom Lift Cylinders ............................................................................... 16Leveling Cable Inspection, Replacement, and Adjustment ................................................. 17

Inspection of Leveling and Holdback Cables ............................................................... 17Replacement of Leveling Cables .................................................................................. 18Procedure for Removing Leveling Cables and Rods .................................................... 18Installation of Cables and Rods ................................................................................... 19Adjustment of Leveling Cable Tension ......................................................................... 21

Non-Overcenter Cam Valve Adjustment ............................................................................. 22Main System Pressure/Standby Pressure Adjustment ...................................................... 23

Standby Pressure ........................................................................................................ 23Main System Pressure ................................................................................................ 23Pilot System Pressure Adjustment .............................................................................. 24Tool System Pressure Adjustment .............................................................................. 24Setting Main Control Valve Flow Controls/Boom Function Speed ............................... 24

Upper Boom Stow .............................................................................................................. 25Holding Valves ................................................................................................................... 25Winch Brake ....................................................................................................................... 26Upper Control Linkage ........................................................................................................ 27Upper Controls Interlock Trigger ......................................................................................... 28Outrigger Interlock Switches .............................................................................................. 28Testing ............................................................................................................................... 29

Dielectric ...................................................................................................................... 29Structural ..................................................................................................................... 29Stability ........................................................................................................................ 30

AppendixGlossaryService Tools and SuppliesPreventive Maintenance and Inspection ChecklistAccessory ChecklistTorque ValuesBasic JIC SymbolsHydraulic System SchematicsTroubleshooting ChartDielectric Test FormsStability Test Forms

Maintenance Manual 1

The terms danger, warning, and caution represent varyingdegrees of personal injury and/or property damage thatcould result if the preventive instructions are not followed.The following paragraphs from ANSI publications explaineach term.

DangerIndicates an imminently hazardous situation which,if not avoided, will result in death or serious injury.This signal word is to be limited to the mostextreme situations.

WarningIndicates a potentially hazardous situation which,if not avoided, could result in death or seriousinjury.

CautionIndicates a potentially hazardous situation which,if not avoided, may result in minor or moderateinjury. It may also be used to alert against unsafepractices.

The term attention is used to alert personnel of specialinformation to assist in the maintenance of the unit orinstructions that must be followed to prevent the possibil-ity of damage to structures, components, or other prop-erty.

Special Cautions

Several operating cautions are pointed out in the OperatorsManual and a number of maintenance cautions are de-scribed in this Maintenance Manual. Adherence to thecautions will mean safer operating practices and betterservice from unit.

The following is an additional list of special cautions andreminders to assist maintenance personnel and servicemen in doing their job most efficiently.

1. Most hydraulic ports and fittings on a unit are SAE orJIC straight thread. Do not attempt to connect pipethread fittings to them without being certain it isintended to be a pipe thread connection.

2. Cleanliness is extremely important in a hydraulicsystem. When hydraulic lines are disconnected orcomponents are removed, the ports should be pluggedor other precautions taken to prevent oil dry or othercontaminants from entering the hydraulic system.

3. Even new hydraulic oil from a barrel or other containerfrom the petroleum company is highly contaminatedcompared to the filtered oil of the hydraulic system. Alloil being added to the reservoir must be filtered before

About This Manual

This manual provides instruction to safely inspect, repair,and troubleshoot the unit. Charts and figures are providedto support the text. Because options vary from one modelto another, some figures may only be a representation ofwhat is actually on the unit.

Knowledge of the information in this manual combined withproper skills and training in hydraulic, electrical, andmechanical systems, provide a basis for safely maintain-ing the unit. Read and understand the applicable procedurebefore beginning.

Contact the following organizations for additional informa-tion.

American National Standards Institute (ANSI)A92.2 for aerial devices; A10.31 for digger derricks

American Public Power Association(Safety Manual for an Electric Utility)

American Society for Testing and Materials (ASTM) American Welding Society (AWS) Canadian Standards Association (CSA) European Committee for Standardization (CEN) Fluid Power Society (FPS) Hydraulic Tool Manufacturers Association (HTMA) International Electrotechnical Commission (IEC) International Organization for Standardization (ISO) Occupational Safety and Health Administration

(OSHA)

Dealers, installers, owners, users, operators, rentors,lessors, and lessees must comply with the appropriatesections of the applicable ANSI standard.

The Appendix contains reference items to help maintainthe unit. A glossary of industry terms is provided for yourconvenience. This glossary provides an understanding ofthe industry terms and phrases used in Altec manuals.Throughout the manual, the term unit is used to describethe Altec device, subbase, outriggers, and the associatedinterface with the vehicle.

Additional copies of this manual may be ordered throughyour Altec representative. Supply the model and serialnumber found on the serial number placard and the manualpart number from the front cover to assure that the correctmanual will be supplied.

This symbol is used throughout this manual toindicate danger, warning, and caution instruc-tions. These instructions must be followed toreduce the likelihood of personal injury and/or propertydamage.

2 Maintenance Manual

using it to power the unit. This is most effectively doneby running the oil through a micron filter as it is put intothe reservoir. If this is not possible, allow the oil tocirculate through the system for approximately 15minutes before operating the unit. Change the filtercartridges soon after using them to filter any substan-tial quantity of new hydraulic oil. A new barrel of oil ismoisture free, however, this may not be true of barrelswhich have not been stored properly.

4. Always be certain that the shutoff valve between thereservoir and the pump inlet and the shutoff valve atthe return line filter are completely open before oper-ating the pump.

5. Inspect hoses and wire cables frequently to be certainthey are routed in such a way to avoid sharp edges,kinking, scuffing, etc.

Disclaimer of Liability

Altec Industries, Inc. will not be liable for unauthorizedalterations or modifications of the unit. Altec Industries,Inc. will not be liable for improper or abusive operation ofthe unit.

Do not alter or modify this unit in any way that might affectits structural integrity, dielectric integrity, or operationalcharacteristics without specific written approval fromAltec Industries, Inc.

Unauthorized alterations or modifications will void thewarranty. However, of a greater concern is the possibilitythat unauthorized changes could adversely affect theunits operation that could endanger personnel and/ordamage property. Altec will not be responsible for unautho-rized alterations or modifications that cause death, seri-ous injury, and/or property damage.

Altec Industries, Inc. assumes no liability for any personalinjury and/or property damage related to the use of thismanual when performing testing, operating, maintenanceand/or repair procedures on this Altec unit.

Structures

The basic structural components are the pedestal, turn-table, lower boom, upper boom, and the outriggers. Thesteel structures are made in the form of a closed boxstructure in order to resist torsional loading as well astension, compression and bending loads to which the unitmay be subjected. Careful consideration has been givento the elimination of stress risers caused by sharp cor-nered openings and abrupt changes in section, to mini-mize the possibility of fatigue cracks forming.

Periodic inspection of the structures is recommended tobe certain that there has been no deformation, abnormalwear or abrasion, interference between moving parts, orcracking of the welds on structural members. Any suchproblem found should be brought to the attention of anAltec representative so that the cause can be determinedand steps taken to prevent a recurrence.

Equipment Storage

Mobile hydraulic equipment needs maintenance whenstored, or not used, for extensive periods of time. Depend-ing upon the climate, lack of use may begin to have anegative effect in as little as two weeks. Storage for aperiod of several months will almost certainly producesome deterioration of the equipment.

Rust will form on unprotected ferrous metal surfaces veryquickly and water will collect inside unit structures. In dryclimates, gaskets will begin to shrink during long periodsof non-use, and lubricants will lose their ability to providelubrication. In cold climates, condensation may occur influid reservoirs and other components.

Even when protective measures have been taken prior tostorage, some degradation of performance must be ex-pected when the equipment is put back into use.

One of the most noticeable effects of prolonged periods ofnon-use is seal deformation. By its nature, hydraulicequipment generally has a number of heavy, cylindricalactuators. As these components are allowed to rest in oneposition for a period of time, the seals on the piston willtend to flatten along the loaded side. Since the sealmaterial is synthetic, its elasticity is limited and it may notresume its original shape completely. At best, there will besome failure to seal well for a short period of time afterputting the equipment back into use. At worst, the seal willnever resume its original shape and will have to bereplaced.

Protective MeasuresIf it is known that equipment will be stored for a month ormore, some steps should be taken to preserve theequipment.

1. The best preservative is to fully cycle (operate) theequipment once weekly if even for a short time.

2. Coat exposed ferrous (iron or steel) bare metal sur-faces with a light grease or heavy oil compatible withsystem hydraulic oil. This includes cylinder rods,shafts, gears, linkages, and unpainted parts.


3. Top off fluid reservoirs to allow as little air space aspossible, to limit the effects of condensation. Removeexcess oil before operating to limit the chance ofoverflow when cylinders are cycled.

4. Cover or wrap exposed rubber or neoprene parts withan ultraviolet resistant covering to shield the partsfrom sun exposure.

5. Unplug electrical connectors and apply a dielectricgrease or an aerosol product designed for protectingelectrical connectors. Plug the connector back to-gether.

6. Cover switch panels and control panels to preventdirect intrusion of rain or moisture, while allowing air tocirculate over the panel.

7. Cover personnel platforms to prevent the accumula-tion of water in the platform.

8. Shield fiberglass components from the sun and otherelements, if stored outside.

Cleaning the Unit and Fiberglass

Any piece of equipment which is kept clean and neatlooking is the reflection of a maintenance departmentwhich has pride in its work. It will also have a positive effecton the operators. They are more likely to treat the unit withreasonable care if they see that the maintenance crewcares enough to keep it looking good.

When washing inside the pedestal with the cover off, donot spray water on or around the fill cap of the oil reservoir.This could spray water inside the oil cap.

It is common for debris to accumulate in the bottom of theplatforms or liners. Regularly clean out all such materialbecause of the abuse to the platform or liner bottomaggravated by the weight of the lineman standing on it.

Operators and maintenance personnel should make surethere is no build-up of tree branches, etc. in the area of theleveling cable sheave at the platform and the area of thelower boom near the turntable. This is most likely to occuron units used in tree-trimming work.

The interior and exterior of the fiberglass boom and lowerboom insert must be kept in good condition to preserve thedielectric integrity of the insulating components. Clean theinterior as necessary using a pressure washer and milddetergent. After pressure washing, thoroughly rinse the

interior to remove detergent and elevate the booms to thevertical position for draining and drying. Wash the exteriorof the upper boom, lower boom insert, and the fiberglassplatform with a mild detergent, using care not to makesurface scratches. After the exterior surfaces are cleanand dry, polish them with Formula 5 Clean N GlazeCompound or an equivalent. The booms should be pol-ished by hand, not with a buffer. Nothing should be usedfor coating a fiberglass component which will reduce thedielectric strength or cause surface flashover.

In the event that cuts or deep scratches are discovered inthe fiberglass components, it is recommended that anAltec representative be contacted to evaluate the effect ofthe damage on structural integrity and to determine if thedamage is repairable. Surface nicks that only effect thegelcoat can be filled with a gelcoat kit. Fill the nick andsand smooth with a 600 grit wet or dry sandpaper. Cleanafterwards with Formula Five Clean n Glaze compound.

PlasticPlastic covers on the unit are covered with an acrylicsurface to protect the plastic from damage from ultravioletdamage. Use a pressure washer and mild detergent toclean plastic covers. Rinse with clean water to remove anydetergent residue.

AttentionUsing solvents (such as acetone, MEK, or lacquerthinner) can damage plastic covers. Use only isopro-pyl alcohol (rubbing alcohol) to clean plastic covers.

In some situations, pressure washing may not remove allof 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 anautomotive type wax.

Tightening of Fasteners

The standard quality fastener used on the unit is a zincplated, SAE Grade 5, steel cap screw. SAE Grade 8 capscrews are used where the higher strength is required inthe design. Special cap screws are used at the elbowbearing and the rotation bearing to handle the loads onthese components. A variety of other fasteners such asflat head screws, socket head screws, and button headscrews are also used on the unit. It is good maintenancepractice to check all of the fasteners occasionally to makecertain they are tight. Use the Torque Values in theAppendix as a guide to determine how tight the variousbolts should be tightened.


The following is a list of fasteners to which particularattention should be given.

Pedestal mounting bolts Rotation gearbox mounting bolts All pin retainer bolts Outrigger attachment bolts Boom end attachment bolts Boom insert attachment bolts Elbow bearing attachment bolts Attachment bolts for upper boom to elbow weldment Platform mounting bolts

Lockwiring

All critical fasteners on the unit must be Iockwired. Thisincludes bolts through forged pin retainers in pins, allturnbuckles on leveling cables and insulator rods, andcertain other mounting or retaining bolts. Lockwires mustbe installed in a way that tends to pull the fastener in thedirection which would tighten it. An aircraft type wireshould be used. It should be relatively soft. This wire iseasy to work with and will produce neat and effectiveIockwires.

Twist lockwires between the fastener and the anchor point.At least three full twists should remain on the standing endof the Iockwire when it is trimmed off. Overtwisting aIockwire will tend to work harden the wire which may causeit to break.

Pliers used in Iockwiring should have smooth, flat sur-faces to minimize working or cutting the wire, thus weak-ening it. With a small amount of practice, a mechanic canbecome skilled at installing neat and effective Iockwires.

Figure 1 Forged Pin Retainer

Figure 2 Two Bolts

The Iockwires used to secure the turnbuckles and adjust-ments on the Ieveling cables and Ieveling rods areillustrated in the section on cable replacement and adjust-ment.

Inspection Marks

Nuts or cap screws with locking patch element used incombination with inspection marks are used at specificlocations on the unit that are visible to the operator duringdaily inspections.

If any inspection marks are found to be cracked or brokenduring inspection, the original mark must be totally re-moved. The fastener torque must be checked (if nodamage is evident) or the fastener replaced and torqued (ifdamage is evident), and the inspection mark reapplied.

The inspection lacquer (refer to Service Tools and Sup-plies in the Appendix) should not be used after theexpiration date printed on the container.

Use the following procedure to apply a new inspectionmark.

1. Remove the majority of the original inspection mark bychipping it off with a chisel or other cutting method. Donot damage the surface on the nut, fastener, washer,and part or structure being attached to.

Warning

Death or serious injury can result from improper useof solvents. Follow the manufacturers label for properuse and disposal.

2. Be sure the cleaning operation is performed in a well-ventilated area. Remove the remaining residue usinginspection lacquer cleaner (refer to Service Tools andSupplies in the Appendix). Apply the cleaner to a ragand completely remove the inspection stripe.

3. Properly torque the fastener.

4. Clean the area where the inspection stripe is to beapplied with a soft clean cloth and acetone.

5. Start at the center of the cap screw and apply a 1/32to 1/16 thick stripe of inspection lacquer to the head ofthe cap screw, across the washer, and onto thesurface of the parent material. The stripe shouldextend 1/8 to 1/4 onto the parent material.

6. The stripe must be continuous across the surfaces. Ifit is not, remove the stripe with cleaner and reapply theinspection lacquer properly.


Pins

All pins on the unit have been plated to prevent rusting andto provide long wear for those pins mating with self-lubricating bearings.

Pins which are non-rotating or static connections are zinc-plated to prevent rusting.

Pay particular attention to the lubrication information toassure proper lubrication of those pins and parts whichrequire it. It is also important to know which pins and partsdo not require lubrication. Pins mated with self-lubricatingbushings do not require lubrication.

The pin retention means used on the unit are shown inFigure 3. When inspecting the forged pin retainers, Iook forbent or broken stems. The stem could bend or break if thepin that it is retaining tries to turn. On the lower boomcylinder, this might indicate a lack of Iubrication of thespherical bearings. A bent pin retainer on the idler sheaveswould indicate that the sheave is binding up. The weld onpins with welded caps must be inspected. A cracked weldor an elongated bolt hole indicates that the pin may betrying to turn. If this is the case, replace the pin andbearings. A sheared pin would also indicate bindingbearings and the connection should be disassembled andnecessary parts replaced.

Figure 3 Pin Retainers

Other welds to inspect are anywhere a change in crosssection takes place on the booms, turntable, or pedestal.Pay particular attention to where the lower boom cylindermeets the turntable and lower boom.

Bearings

The main rotation bearing on the unit is a shear ball bearingwith integral bullgear machined on the outer race. Theouter race is solidly bolted to the pedestal top plate on amachined surface and the inner race is bolted to themachined bottom surface of the turntable. The mountingbolts are 3/4 -10 UNC alloy cap screws x 21/2 long. Ahardened washer is used beneath the head of each capscrew. The mounting bolts are tightened to 325 foot-pounds torque and should be retorqued if any indication oflooseness appears. Properly lubricated, this bearing shouldgive many years of satisfactory service.

The lower boom cylinder is equipped with spherical bear-ings to assure alignment.

The main hinge pin for the lower boom, the upper boomcylinders, the platform shaft, and the links at the elbow areequipped with self-lubricating bearings. Also the platformrotator pins, platform rotator cylinders, jib tilt cylinders, jibtilt support bracket, and fiberglass jib sleeve are equippedwith self-lubricating bearings.

The articulating elbow bearing on the unit is a shear ballbearing. The outer bearing race bolts securely to the upperboom end weldment. The inner race bolts to the lowerboom upper weldment. Both bearing mounting surfacesare machined flat. The bearing is secured with 5/8-11 UNCBowmalloy brand cap screws x 21/2 long. A hardenedwasher is used beneath the head of each fastener. Themounting bolts are tightened to 225 foot-pounds torqueand should be retightened if any indication of loosenessappears. Properly lubricated, this bearing will providemany years of dependable service.

Inspections

Proper unit maintenance will reduce downtime, loweroperating and repair costs, and extend equipment life.Safety alone justifies a preventive maintenance program.This type of program is less expensive than making majorrepairs.

This section contains information on properly inspectingthe hydraulic system, structures, individual unit compo-nents, and lubrication. Use the Lubrication Chart andDiagram in this section when lubricating the unit.

Lockwire

Stem

Cylinder Eye

RetainingRing

RetainingRing

Forged PinRetainer

LockWashers

Weld

Pivot TubeLockwire

RetainingPlate

Pin

Bearing

End Plate

Rollpin


A Preventive Maintenance and Inspection Checklist isprovided in the Appendix. Use this checklist when per-forming routine maintenance and inspections to insure noareas are overlooked. Keep permanent, written, and datedrecords of all service performed on the unit.

Routine maintenance is performed on different compo-nents of the unit at different times (refer to the PreventiveMaintenance and Inspection Checklist in the Appendix).

More frequent maintenance may be necessary if the unitis operated under severe conditions. In addition to thePreventive Maintenance and Inspection Checklist recom-mendations, follow these recommendations on new units.

Measure the turntable tilt before using a new unit. Change the return line filter after the first 15 to 25 PTO

hours. Gearbox manufacturers recommend an initial oil

change after the first 15 to 25 PTO hours.

Elbow Bearing Cap ScrewTorque Inspection ProcedureThe 5/8-11 UNC X 21/2 Bowmalloy brand cap screwssecuring the elbow bearing have a patch lock materialpermanently attached to the threads and are coated withan anti-seize compound at installation. The lubricationprovided by the anti-seize compound allows for a consis-tent torque when a calibrated click-type torque wrench isused with the proper torquing procedure. This helpsmaintain the clamping force of the cap screws andprevents wear or damage to the elbow bearing. It alsomakes possible an accurate check of the prevailing torqueof the cap screws when they are inspected during regularmaintenance procedures.

The torque value of these cap screws is 225 foot-pounds.To identify the fasteners, the cap screw heads are paintedwhite. Plastic caps are installed over the heads to protectthem from being painted over at installation.

Check the torque of the elbow bearing cap screws asrecommended by the Preventive Maintenance and In-spection Checklist. Check the cap screws at 90 percent ofthe recommended torque or 200 foot-pounds. This allowschecking of the cap screws for the proper torque withoutrotating all the cap screws.

Initial and Annual Torque Inspection ProcedureUse an accurately calibrated, 1/2 drive click-type torquewrench for the inspection of these cap screws.

Upper Boom Side Inspection 1. Remove and discard the protective plastic caps from

the cap screw heads.

2. Inspection should be done in a star or crisscrosspattern as shown in Figure 4.

Figure 4 Upper Boom

3. If 50 percent or more of the cap screws are found tobe loose on either side of the bearing, examine thebearing for excessive wear.

4. Begin with cap screw number 1, torquing the elbowbearing cap screw to 200 foot-pounds while watchingfor any fastener movement.

5. Torque cap screw number 2 to 200 foot-pounds, againwatching for any fastener movement. Continue aroundthe pattern of fasteners shown in Figure 4 until all havebeen torqued to 200 foot-pounds. If none of thefasteners moved while retorquing, the inspection iscomplete and the covers can be replaced. If any of thecap screws moved when retorquing, retorque eachcap screw again. This torquing should de done at 225foot-pounds in a circular pattern beginning with capscrew number 1 instead of a star pattern.

6. If 50 percent or more of the elbow bearing cap screwsare found to be loose, see instructions for furtherinspections in step 3.

6

14

10

12

1

3

13

5

11

8

1718

4

91627

15


Lower Boom Side Inspection 1. Remove the cover from the elbow area to gain access

to the elbow bearing cap screws inside the lowerboom. If the plastic caps are on the cap screw heads,remove and discard them.

2. On the lower boom side, only inspect one cap screwper quadrant (refer to Figure 5).

Figure 5 Lower Boom

3. Check the torque on a cap screw at 200 foot-pounds.

4. If any of the cap screws that are checked move, theyshould be marked and all the remaining cap screwschecked in the pattern shown in Figure 5. To check thetorque on all the cap screws, it may be necessary toremove the leveling cable sheave at the elbow.

5. The retorquing procedure, steps 4-6, on the upperboom side, should be followed when loose cap screwsrequire all cap screws to be inspected on the lowerboom side.

Visual Inspection ProcedureVisually inspect both sets of cap screws retaining theelbow bearing. Check for loose washers under the headsof the cap screws. Also check for evidence of movementbetween the bearing and boom weldment. Movement canbe checked by raising the upper boom a few feet out of theboom rest and rocking the upper boom side to side. If thereis any indication or movement or a loose washer, retorquethe cap screws as described in the Annual InspectionProcedure.

Rotation Bearing Cap ScrewInspection ProcedureSpecial high-strength 3/4 cap screws are used to securethe rotation bearing to the pedestal and the turntable. Therotation bearing cap screws are torqued at the factory to325 foot-pounds. Rotation bearing cap screw heads maybe colored and/or plastic caps are installed over the headsto help identify the new fasteners.

AttentionUse a 3/4 drive click-type manual torque wrench,accurately calibrated, for the installation of the rota-tion bearing cap screws. Torque the cap screws byapplying a smooth pull on the torque wrench withoutjerking. Do not overtighten the cap screws.

Depending on the particular unit this procedure is beingperformed on, components will need to be removed tomake the rotation bearing cap screws accessible forremoval. It is important that experienced. Trained me-chanics perform this procedure and are aware of theprocess needed to make the rotation bearing accessiblefor removal.

Caution

Failure to keep the rotation bearing cap screws prop-erly tightened may lead to fatigue failure of the capscrews and consequent damage to the unit. Insuffi-cient or uneven cap screw tightness may also contrib-ute to reduced life of the rotation bearing.

Visual Inspection ProcedureVisually inspect both sets of rotation bearing cap screwslooking for any evidence that a cap screw is loose. Checkfor loose washers under the heads of the cap screws bytrying to turn each washer by hand. If movement is shown,all the cap screws must be retorqued using the RetorquingProcedure.

Annual Torque Inspection ProcedureSome seating in of the cap screw threads and mountingsurfaces may occur in any bolted joint during the initialbreak-in period, causing a partial loss of cap screwtightness without any cap screw rotation. Randomly selectfour to five cap screws each on both the turntable andpedestal that are accessible with a torque wrench withoutremoving major components. Select cap screws that areevenly spaced around the pattern. Remove and discardany protective caps from these cap screws. Check theselected cap screws to be sure they are torqued to 295foot-pounds or 90 percent of the normal installation torque

6

14

10

12

113

5

11

4

9

16

27

15

3

8


of 325 foot-pounds. Use an accurate torque wrench,calibrated on a regular basis. If one or more of these capscrews are loose, check the torque on all the cap screwsin the pattern as described in the Retorquing Procedure. Ifthe rotation bearing is replaced or removed, follow thesame inspection intervals.

Retorquing ProcedureAttention

Use a 3/4 drive click-type manual torque wrench,accurately calibrated, for the inspection of these capscrews. Torque the cap screws by applying a smoothpull on the torque wrench without jerking. Do notovertighten the cap screws.

Depending on the particular unit this procedure is beingperformed on, various components will need to be re-moved to make the rotation bearing cap screws acces-sible for retorquing. It is important that experienced,trained mechanics will perform this procedure and thatthey are aware of the process needed to properly torquerotation bearing cap screws.

1. Remove and discard any remaining protective plasticcaps from the cap screw heads on the turntable.

2. Begin with cap screw number 1 and torque it to 325foot-pounds. Watch to see if the cap screw rotatesbefore reaching this torque. If any of the cap screwsrotate, replace it with a new one. New cap screws havea patch lock material permanently bonded to thethreads and have a dry film lubricant preapplied to theentire surface of the part. Anti-seize compound is nolonger needed for installation.

Figure 6 Pedestal

3. Look at the hole in the washer. Notice that it has amore rounded edge on one side of the washer. Installthe washer with the rounded edge of the washer towardthe cap screw head. Reinstall it into the bearing andtorque it to 325 foot-pounds.

4. Torque cap screw number 2 to 325 foot-poundswatching it for any rotation.

5. Continue around the pattern shown in the figure,torquing each cap screw and watching it for rotationuntil the entire pattern is complete.

6. If any of the cap screws rotated when being torqued insteps 3 through 5, retorque all cap screws againbeginning at number 1. Go around in a circular patternthis time instead of in the numbered order.

7. Do steps 1 through 6 on the pedestal side of therotation bearing.

The same pattern applies to all unit types and mountingarrangements. Number one cap screw can be at anylocation on the bearing with the remainder of the patternshifted accordingly. Components will need to be removedfor access to all cap screws.

Figure 7 Turntable

Rotation Gearbox Mounting Cap ScrewsSpecial 5/8 cap screws are used to secure the rotationgearbox to the turntable. The torque value for the capscrews is 225 foot-pounds. The cap screws require specialinspection procedures.

Insufficient or uneven cap screw tightness can contributeto reduced life of the gearbox.

Caution

Injury can result from being pinched or trapped be-tween moving components. Keep hands clear.

3

4

6

12

10

14 11

15

2 1

13

517

8

18

9

7

166

5

8

11

1

12 9

14

3 4

10

7

15216

13


Use caution when access covers have been removed toservice the unit. Pinch points and shear points may existbetween moving parts. Replace the access covers imme-diately after servicing.

AttentionOnly use Altec supplied cap screws and washers toinstall the rotation gearbox.

Use an accurate 3/4 drive click-type manual torquewrench for the inspection of these cap screws. Torquethe cap screws by a smooth pull on the torque wrenchwithout jerking. Do not overtighten the cap screws.

Visual Inspection ProcedurePerform this visual inspection procedure as recommendedby the Preventive Maintenance and Inspection Checklist.

Visually inspect all rotation gearbox cap screws, lookingfor any evidence that a cap screw is loose. Check for loosewashers under the heads of the cap screws by trying toturn each washer by hand. If movement is indicated,retorque all the cap screws.

Annual Torque Inspection ProcedureCheck the cap screws to be sure they are torqued to 203foot-pounds or 90 percent of the normal installation torqueof 225 foot-pounds. Use a regularly calibrated, accuratetorque wrench. If one or more of these cap screws turnsbefore the wrench clicks, retorque all the cap screws to225 foot-pounds. If the rotation gearbox is replaced orremoved, follow the same inspection intervals.

Lubrication

Proper lubrication on a regular basis will extend the life ofthe equipment and help to avoid maintenance problems inthe future. The frequency of lubrication coincides with aninspection interval. The PTO hours should be used orestimated for the inspection and lubrication intervals. If aunit is seldom used, monthly intervals should be followed.Particular areas of inspection and lubrication points isprovided in the Lubrication Chart and Diagram. Thisinformation should be recorded and kept up to date. Anynotes on repairs or dielectric testing should also berecorded and filed.

Lubricate the unit as recommended by the PreventiveMaintenance and Inspection Checklist.

As mentioned in the bearings section of this manual, theself-lubricating and oil impregnated bronze bushings areself-lubricating, and require no lubrication. The self lubri-cating bearings are used at both boom pivots, the largeleveling sheaves, the upper boom linkage pivots, and theplatform rotators. Oil impregnated bronze bushings areused on the rest of the idler sheaves and the upper controllinkage.

There are bearings that require lubrication with a chassislubricant. The spherical bearings in the ends of the lowerboom cylinder require periodic lubrication. The rotationgear has a fitting located on the front of the turntable.Rotate the unit through two full revolutions while lubricatingthe bearings. The top bearing on the rotation gearboxrequires periodic lubrication. The elbow rotation bearinghas a fitting located on the outside of the outer race.Lubricate the bearing in several positions of the upperboom. After lubrication, fold/unfold the upper boom throughtwo full cycles.

Lubricate the inner outrigger legs with a molygrease.Excessive lubricant on or around the legs will attract dustand form an abrasive substance.

The rotation gearbox requires SAE 140 Worm Gear Oil. Itshould be checked and maintained at a level approxi-mately half full.

The cables for the leveling system require lubrication witha wire rope Lubricant. It is extremely important that theleveling cables not be allowed to run dry. The uppercontrols should be periodically lubricated with a lightIubricant. The wire rope lubricant could be used as asubstitute for the upper controls linkage.

Apply an open face gear lubricant to the rotation gear andpinion teeth. Remove the pinion cover from the turntableand lubricate the rotation gear teeth.

Use a small amount of general purpose spray lubricant onthe single handle control linkage pivot points. Wipe off theisolating links and any excess lubricant. Isolating linksmust be clean and dry.


Lubrication Chart and Diagram

Service items identified by the symbol(s) at the appropriate level.

85 hours/1 month 500 hours/6 months 1,000 hours/1 year 2,000 hours/2 year If disassembled

Letter Lubricant Application Method

A Anti-Seize Compound Extreme pressure lubricant that prevents seizure, Brushcorrosion, rust, and galvanic pitting.

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

G Open Face Gear Lubricant Spray lubricant that penetrates and adheres with Spraygood water resistance, is unaffected by temperature extremes, and has extremepressure properties.

M Moly Grease Multipurpose lithium base grease with molybdenum disulfide Brush/grease gunadditive, good water resistance, rust inhibition, oxidation stability, and extremepressure properties.

R Wire Rope Lubricant Penetrating, cleaning, nongumming protective spray; Spraymust minimize friction and eliminate rust.

S General Purpose Spray Lubricant Spray

W SAE 140 Worm Gear Oil AGMA Grade 7 compounded or 7EP, must be Pournoncorrosive to bronze.

W

Drain PlugChange Oil Oil Level

Rotation Gearbox

Output ShaftUpper Bearing

Drain Plugon Bottom

W

A

Input ShaftSplines

Hydraulic PumpWinch Gearbox

C

Change Oil

Oil Level

W

W


M

A

Lower Boom Leveling Cables

Upper BoomLeveling Cables

G

C

C A

C

Rotation Pinion andBearing Gear Teeth

Rotation BearingBall Race

Rotation GearboxEccentric Ring

Lower Boom CylinderSpherical Bearings

Elbow BearingBall Race

Turntable/Booms

A-Frame Outriggers

Inner LegOuter Surface

Cylinder andShoe Pins

Control Handle Linkage Single handle control All control handle linkages at platform Lower control valve Outrigger control valve

Valve Spools Outrigger Tool Jib/winch Platform rotate

Leveling System

SS

R

R


Adjustment of RotationPinion to the Rotation Bearing

At the time of unit shipment, the mesh or backlashbetween the rotation pinion and the rotation bearing gearteeth was properly adjusted. Readjustment may be neces-sary after an extended period of operation or a gearboxchange. An eccentric ring provides 1/8" of adjustment. Useof the eccentric ring is explained later in this section.

Excessive backlash in the gear set may appear as boommovement. To visually inspect the gear set, remove thepinion cover. With another person rocking the boom elbowback and forth, the rotation pinion should be observed. Ifmovement between the pinion and the rotation gear teethis noted, the backlash is excessive. Be careful not toconfuse backlash in the gear set with slight lost motionwithin the gearbox. If the pinion does not move in relation-ship to the rotation bearing, but tries to rotate, the backlashprobably cannot be further reduced.

If adjustment is necessary to bring the pinion into closermesh with the rotation bearing, perform the followingprocedure.

Caution

Eye protection must be worn at all times to preventparticles of dirt or metal from entering the eyes.

Hands and fingers must be kept off the pinion androtation bearing gear teeth to avoid serious injury.

1. Lower the outriggers as for normal operation.

2. The gear lash must be set on the high tooth of therotation bearing. The high tooth is located over thefront side of the pedestal.

3. Remove the pinion cover and the lock bar. Loosen thefour cap screws which clamp the rotation gearbox inplace on the turntable socket head bolts plate.

4. Using a soft punch, preferably brass, and a hammer,the eccentric ring can be rotated. This ring is locatedon top of the turntable plate under the gearbox. Sincethe eccentric ring can be rotated in either direction, itmust be determined that the pinion is being tightened.Should the gear mesh become Iooser, the ring mustbe turned in the opposite direction.

5. The pinion will bottom out in the rotation bearing as theeccentric ring is turned.

6. Install the lock bar. The bar can be installed twodifferent ways (refer to Figure 8). This gives twice as

many locking increments as there are holes. If theIocking bar does not line up with any holes, theeccentric ring may have to be backed off slightly.

Figure 8 Eccentric Ring

7. After installing the locking bar, torque the gearboxmounting bolts to 225 foot-pounds.

8. Install the pinion cover and rotate the unit through atleast two rotations to determine that the backlash hasbeen properly adjusted. It should not bind or hesitatein any position. If a new gearbox was installed or theteeth on the rotation bearing are dry, apply an openface gear lubricant.

Hydraulic Plumbing,Hoses, and Fittings

The unit is manufactured with hydraulic components,hoses, lines, and fittings which meet ANSI requirements.

Certain hoses used on insulated units must be of thenonconductive type. The hoses will be found in usethrough the insulated upper boom, the fiberglass insert inthe lower boom and generally on hydraulic tools which maybe used with the unit. Insulated hoses in the applicationsmentioned above, as well as in other possible applica-tions, are orange in color. The small lines which connectthe platform controls to the lower part of the unit are alsononconductive lines. These lines are color coded for theconvenience of maintenance and repair.

The Parts Manual identifies all nonconductive hoses. Italso identifies fittings and other plumbing hardware.

It is extremely important that nonconductive hoses bereplaced only with hoses of the same type and size.Replacement fittings, lines, tubes, etc. should be thesame type and size that were furnished with the unit. Neveruse wire braid hoses or any hose that is not fully insulatedin an insulated location. If there is ever any doubt concern-ing the proper hose to be used for replacement, contact anAltec representative.

Lock Bar

Drive SlotsEccentric

Ring


Caution

Never substitute a conductive type hose for any insu-lated or nonconductive hose. Death or serious injurymay result from the bridging of an insulated gap witha conductive hose. Nonconductive hoses must benon-pin perforated.

Single Handle Controland Control Handle Covers

Inspect and dielectric test the insulated single handlecontrol, if so equipped, as recommended by the Preven-tive Maintenance and Inspection Checklist.

Keep the green insulated single handle control clean, dry,in good condition, and periodically tested to maintain itslimited dielectric properties. Wipe any contaminants ormoisture from the surface of the control handle assemblyand the insulating linkages with a clean dry cloth. Isopropylalcohol may be used to clean these components. Replaceany damaged components with replacement parts fromyour Altec representative and perform a dielectric test onthe control.

Inspect the rubber control valve handle covers as recom-mended by the Preventive Maintenance and InspectionChecklist. Keep the rubber control valve handle covers inplace and in good condition. Replace damaged covers withreplacement parts from your Altec representative.

Atmospheric Vents

Atmospheric vents are located at the boom tip/platformarea. Inspect these vents as recommended by the Pre-ventive Maintenance and Inspection Checklist. On Cat-egory A units these vents must also be tested for properoperation. An atmospheric vent testing kit may be ob-tained from your local Altec representative.

Oil Filtration

The unit is equipped with a complete filtration system.Filtration starts when the oil reservoir is filled. The reser-voir has a 30 mesh strainer basket to prevent large

particles from entering the reservoir during filling. Thereservoir breather cap has a 40 micron element to filter theair which enters and leaves the reservoir as the oil levelchanges.

Oil leaving the reservoir on its way to the pump passesthrough a 150 micron strainer. The strainer prevents largeparticles from getting into the pump. Oil returning to thereservoir from all parts of the system passes through a 10micron return line filter. The return line filter has thereplaceable, spin-on type cartridge. While the spin-onreplacement cartridge resembles an automotive filter, donot use an automotive filter because of differences in thebypass characteristics.

Frequency of servicing of filters will vary with the condi-tions under which the unit is being used. Shorter intervalsbetween filter servicing may be necessary in unusuallydirty or dusty conditions.

A new unit should have the return line filter cartridgechanged, and the 150 micron strainer cleaned after the first15 to 25 hours of operation. During this initial run-in period,the pump, motor, and cylinders may deposit wear particlesin the oil. Subsequent return line filter cartridge changesshould be as recommended by the Preventive Mainte-nance and Inspection Checklist.

Caution

After filter servicing, the shutoff valve in the suctionline must be fully open before starting the pump.Failure to do so will result in serious damage to thepump or other components.

Oil Selection

The hydraulic oil selected should contain rust and oxida-tion inhibitors, antifoam, and antiwear additives. Oils usedin insulated equipment must also pass ASTM D877-67,the dielectric breakdown voltage of insulating liquids, at 25KV or better, and possess high demulsibility. Do not usedetergent oils because of their ability to retain water. Allmajor oil companies have an oil to comply with thesespecifications.

Specification Cold Weather Oil All Weather Oil Warm Weather Oil

Ambient temperature range -50 to 60F (-46 to 16C) -10 to 90F (-23 to 32C) 40F (4C) and above

Viscosity @ 100F (38C) 85 SSU (17 cSt) 90 SSU (20.2 cSt) 150 SSU (30 cSt)

Viscosity @ 210F (99C) 35 SSU (4.5 cSt) 43 SSU (5.0 cSt) 46 SSU (5.5 cSt)

Pour point -80F (-62C) -55F (-48C) -30F (-34C)

Maximum oil temperature 160F (71C)

Minimum pump start-up temperature -15F (-26C)

Figure 9 Hydraulic Oil Viscosity Recommendations


Warning

Death or serious injury can result if the recommendedhydraulic oil is not used. Use of other fluids in thehydraulic system can affect the insulating capability ofthe unit.

AttentionOnly use hydraulic oil as recommended. Other fluidsadded to the hydraulic system can increase compo-nent wear and affect the lubricating characteristics ofthe oil.

Only use oils meeting the viscosity rating for militaryspecification MIL-5606 in extremely cold climates.These oils have fewer antiwear characteristics and arenot recommended for full time use.

Changing the Oil

Check the oil level in the reservoir weekly. Booms must bestored and outriggers retracted. In this condition, the oillevel should be within two inches of the top of the reservoir.Overfilling or filling with the cylinders other than asinstructed may result in the reservoir overflowing.

It is extremely important that hydraulic oil be clean and freeof moisture. Moisture or impurities can reduce the insulat-ing capability of the oil or shorten the life of the hydrauliccomponents.

Visual Inspection of Hydraulic Oil

In addition to the regular checking of the quantity ofhydraulic oil, it is strongly recommended that samples ofthe oil be inspected at maintenance intervals. This can bedone conveniently by draining a quart of oil from thepetcock at the drain pipe in the reservoir. Use a glasscontainer to permit visual examination of the oil (refer toFigure 10). Water content in the oil may give it a cloudyappearance or it may separate from the oil. A rancid orburned odor emanating from the oil may indicate the needfor change. If visible foreign particles are noted, the oilshould be changed. If desirable, oil samples may be

dielectrically tested in an ASTM test cup by a qualified testlaboratory.

Flushing the Hydraulic System

If there is ever any doubt about the insulating or lubricatingquality of the oil, it should be changed. If the oil is changedfor other than seasonal or routine maintenance, the sys-tem should be flushed using the following steps.

1. Drain the reservoir completely. This will leave approxi-mately one-third of the system capacity in cylindersand lines.

2. Using a short fill of five to six gallons of new oil, fromthe lower controls operate the cylinders, rotation,purge the control system, and operate the power toolsystem through a few cycles.

3. Drain the reservoir again.

4. Clean the screens in the suction strainer. Replace thecartridge in the return line.

5. Fill the reservoir.

6. Operate the unit as instructed above and recheck theoil level in reservoir. Add oil if necessary.

7. After 20-30 hours of operating service, clean thesuction strainer and replace return filter cartridgeagain.

If there is a major component failure, such as a pump,cylinder, or motor, which has dumped contamination intothe system, thoroughly clean the hydraulic system. Changethe defective component and drain the oil. Remove thecover to the reservoir and clean out completely. Clean thesuction strainer. Replace the return line filter and run ashort fill. The new return line filter should catch anycontaminants left in the cylinders or hoses. Drain the fivegallons of oil and replace with new oil. Replace the returnline filter again and a third time after 20 or 30 hours ofoperation.

Figure 10 Hydraulic Oil Conditions

Condition Possible Cause

Dark color Oxidation; contamination

Cloudiness or milky appearance Presence of water or wax

Rancid or burned odor Oxidation

Increase in viscosity Oxidation; addition of improper fluids; presence of water

Decrease in viscosity Addition of improper fluids; additive deterioration

Separation of water or other fluids from the oil Presence of water; addition of improper fluids

Foreign particles or other visible contamination Contamination; emulsion of water with oil additives


Air Bleeding

The presence of air in any hydraulic system will causeabnormal operation, noises, and damage to the pump. Thepresence of air in a hydraulic system can usually be tracedto one of the following.

1. If the oil level in the reservoir is allowed to get too low,the pump suction can cause a vortex to form in thereservoir which will allow air to be sucked into thesystem along with the oil.

2. A leak in the plumbing between the reservoir and thepump can suck air even though it will not leak out whenthe system is shut down. These leaks may be foundby filling a pump type oil can with clean hydraulic oiland squirting oil slowly at each connection in thesuction line with the pump operating at normal operat-ing speed. A suction leak will suck the oil in. Be sureto check the connection at the attachment to thepump.

3. Loose connections in the pressure system normallywill leak externally during unit operation, but can suckair into the system after the unit is shut down as theoil tries to find its way to the low points of the system.

4. Hydraulic lines taken loose during maintenance op-erations will contain air until it is purged out. Some ofthese lines will purge during normal use but others willrequire specific bleeding operations.

Air entering the system due to low oil levels or leaks in thesuction line will cause the most problems and should becorrected immediately.

Warning

Serious pump damage and unit malfunctions arelikely to occur if conditions allowing air to enter thesuction side of the pump are present.

Troubleshooting Procedure

Establish a troubleshooting procedure to be followed anytime there is a malfunction. This procedure will provide astarting point for determining the root cause of the mal-function and increase troubleshooting accuracy. Considerusing the following procedure.

1. Position the unit on a level surface. Apply the parkingbrake and chock the wheels. Check the oil level in thereservoir.

2. Engage the PTO, warm the hydraulic oil to operatingtemperature, and properly set the outriggers.

3. Before testing each function through its full travelcapabilities, try small movements to be certain thefunction is operating properly. Test each function forfull travel capabilities.

Warning

Death or serious injury can result from falling from theplatform. All platform occupants must properly use anappropriate OSHA approved personal fall protectionsystem.

4. Operate the unit from the lower controls and then theupper controls to identify the malfunction.

5. Use the Hydraulic System Schematic in the Appendixto determine the flow path required to operate thefailed function. Make a list of the components used tooperate the failed function. Cross off componentsused to operate other functions that are operatingproperly. This should minimize the number of items tocheck.

6. Check the easiest component first. Verify the properoperation of each component remaining on the listuntil the bad component is found.

7. Use accurate test equipment to verify flow, pressure,voltage, and current.

Once the symptom has been positively identified, use theTroubleshooting Chart in the Appendix for suggestedcauses and corrective actions.

Engine Throttle Control

The oil pressure in the signal line to the pump actuates theengine throttle cylinder. When the signal pressure ex-ceeds 200-300 psi, the throttle cylinder begins to extenduntil it reaches its full stroke at about 450 psi.

The piston rod actuates the throttle linkage which causesthe engine to accelerate to the adjusted rpm. The adjustedrpm should provide a pump shaft speed of 1,800 rpm athigh pressure standby. The correct pump speed whenoperating all boom functions simultaneously is 1,450 rpm.The difference between the high pressure standby settingof 1,800 rpm and the full load setting of 1,450 rpm allowsthe engine to reach the top of its torque curve.

The mechanism of the engine throttle linkage is easy toadjust and can be set to give the desired engine rpm tomatch the desired pump rpm. A set screw on the end of thethrottle cylinder piston rod can be adjusted in or out andlocked into place with the jam nut on the screw.


Removing the Rotary Joint

The rotary joint permits continuous rotation of the turntablewithout imposing torsional or twisting loads on the hydrau-lic hoses.

The inner core of the rotary joint is bolted to the stationarypedestal. The outer housing rotates with the turntable,driven by a drive bar on the side of the housing. Hydraulicfittings used in the rotary joint are the SAE straight threadtype. Pipe fittings will not fit these threads and shouldnever be used.

Removal of the rotary joint should begin with the boomsstored and the hydraulic pump disengaged. As the hydrau-lic connections are removed, they should be capped toprevent loss of oil or foreign material from entering therotary joint. The rotary joint can be removed by thefollowing method.

1. Disconnect all hydraulic fittings on the bottom of therotary joint in the pedestal.

2. Disconnect the hydraulic lines from the main controlvalve to the lower boom cylinder and to the upperboom cylinders. Move the lines to the rear of theturntable out of the way of the rotary joint.

3. Disconnect all hydraulic connections to the rotary jointinside the turntable.

4. Remove the four 3/8 x 3/4 bolts which fasten the rotaryjoint mounting plate to the pedestal on the top of thepedestal.

5. Remove the rotary joint through the access cutawayon the side of the turntable below the main controlvalve.

Replace the rotary joint by reversing this sequence.

On units equipped with an air plunger type remote start/stop system, an electric slip ring will be mounted on top ofthe rotary joint. This must be removed before the rotaryjoint can be removed from the turntable.

Removal of Upper Boom LiftCylinders

The hydraulic cylinders which articulate the upper boomare mounted between the Iower and upper boom structuresat the upper portion of the lower boom. The base end ofeach cylinder is connected directly to the lower boom bya pin and self-Iubricating bearing. The rod end of eachcylinder is connected to one of the elbow links of thearticulation mechanism. This walking link arrangement

allows the elbow link to wrap around the elbow pivot as theboom is unfolded or folded. When the upper boom is in thefolded position for transport, the top upper boom cylinderis completely retracted and the bottom upper boom cylin-der is completely extended.

If it should become necessary to remove one or both of theupper boom cylinders, it is very important to use a safe andreliable means of lifting the upper boom away from thelower boom. It will be necessary to be able to lift the upperboom at least five feet above the lower boom and at a pointabove the boom rest saddle. Care should be used inhandling the upper boom to avoid the possibility of damag-ing the fiberglass surface.

Caution

When removing and installing the upper boom cylin-der or linkage, safeguards must be used to prevent thefall of the upper boom for any reason because it will benecessary for personnel to be under the suspendedupper boom during at least part of the work.

The upper boom cylinders elevate the boom hydraulically.Lowering the boom at the end of its travel is done bygravity. Because of this, it is necessary to have a hoist orlifting device with a capacity of at least one ton. The hoistshould be connected to the fiberglass boom near the outerend. Lifting the fiberglass should be done with a nylon strapconnected as a choker. It is important that the choker berestrained from sliding up the boom as the boom is lifted.It is also important to protect the fiberglass from damagewhile lifting.

To remove the bottom upper boom cylinder, the unit shouldbe in the stored booms position. The lower booms shouldbe rotated to the side of the unit. Be sure to lower theoutriggers before rotating the booms. With the hoist, raisethe upper boom approximately two feet out of the boomrest. With the hoist supporting the load, remove the pinfrom the rod end of the bottom upper boom cylinder.Support the cylinder from falling with a fork truck or otherhoist mechanism. After the rod end of the cylinder isdisconnected, disconnect and cap the hydraulic line to thebase end of the cylinder to prevent oil loss or systemcontamination. Remove the pin from the base end of thecylinder. The cylinder must be supported. Lower thecylinder safely to the ground with a fork truck or hoist.

To remove the top upper boom cylinder, position thebooms in the stored booms position. Position the unit sothe top upper boom cylinder is under a hoist. With the unithydraulic system, raise the upper boom about five feet outof the upper boom rest. Disconnect the hose to the middleport on the top upper boom cylinder. Cap the hose and thefitting on the cylinder. Lower the upper boom to about two


feet out of the rest - just high enough to allow access to thetop upper boom cylinder base end pin.

Support the cylinder with a hoist and choker strap. Discon-nect and cap the other two hoses on the top upper boomcylinder. Remove the base end cylinder pin. Lift thecylinder with the hoist to allow access to the rod end pinand remove the pin. Remove the cylinder with the hoist.

If the cylinders are going to be left off the unit for anextended period of time, the upper boom should be loweredby the hoist into the boom rest and the unit stored. Toreinstall the cylinders, reverse the procedure.

It may be necessary during installation or removal toextend the individual upper boom cylinders. It will benecessary to attach an auxiliary hydraulic power source tothe base end ports of the cylinder being actuated. Toactuate the cylinder, one hydraulic line should be attachedto the R port on the cylinder. Attach the second line to theE port on the cylinder base. It will also be necessary toconnect the E and P ports on the base end of the cylinderin order to open the counterbalance holding valve to allowthe cylinder to extend. Once the cylinder has beenplumbed in this manner, use the auxiliary power source toextend or retract the individual cylinder as desired. Whenreinstalling the bottom upper boom cylinder, completelyextend the cylinder. When reinstalling the top upper boomcylinder, extend it approximately three inches from its fullyretracted position.

Warning

Do not articulate the upper boom overcenter until youare certain there is oil in the rod end of both upperboom cylinders.

To be sure both cylinders are full of oil, use the lowercontrols to articulate the upper boom up and down about60 degrees from the boom rest for 5 or 6 cycles.

Upon completion of this job, structurally test the boom inaccordance with the section under Testing, and dielectri-cally test the unit.

Leveling Cable Inspection,Replacement, and Adjustment

The Ieveling system functions to maintain the floor of theplatform parallel to the turntable. This is a positive,mechanical system operated through cables, insulatedrods, sheaves, etc. The two principle parts of the Ievelingsystem are identified as the Ieveling cables and Ievelingrods. Each of the cables is anchored at the turntable andat the platform sheave. Because of the geometric arrange-ment, movement of the booms results in platform move-ment.

The Ieveling cables are an IWRC type cable 1/2 in size witha minimum strength of 20,600 pounds when new. In theinsulated section of the upper and lower booms, theIeveling cable is connected to a fiberglass insulator rod 3/4 in diameter to preserve the dielectric integrity of theinsulated components. Threaded end terminals on theIeveling cables are mechanically swaged onto the wirerope. Turnbuckles are provided in the upper boom and inthe lower boom for proper adjustment for the entire Ievelingsystem. Leveling cables and insulator rods are thoroughlytested before they are installed in the unit.

Movement of the booms and the resultant movement ofthe Ieveling cable system is transmitted to the platformthrough the keyed shaft at the elbow and through the keyedplatform shaft. Persons who perform inspections, makeadjustments, etc., should be familiar with the entireleveling system before beginning disassembly.

Inspection of Levelingand Holdback CablesA cable is a mechanism within itself, consisting of movingparts which are called strands and wires. Cable wiresmove in relationship to other wires under operating condi-tions. Two of the operating conditions with which the cableinspector must be concerned are as follows.

The movement of wires against each other as thecable is loaded and unloaded.

The flexibility and bending of the cable, strands, andwires as the cable passes over.

Inspection is an important part of satisfactory cable life, aswell as the safety and reliability of the cable. Lubricationplays a very important part in extending cable life byreducing internal wear as the wires move in relationship toeach other. While the platform Ieveling system is designedwith a safety factor several times greater than the ratedloads applied to the platform, periodic inspection andlubrication must be performed.

Adjustment of the cables may be required after extendedperiods of operation. This method of adjustment is ex-plained in a later section. Specific inspection of Ievelingcables must be performed as recommended by the Pre-ventive Maintenance and Inspection Checklist. This is thesame interval recommended for other inspections andlubrication of the completed unit.

Cable wear will be greatest where the cables are contact-ing sheaves. To perform a thorough inspection, all coversmust be removed from the booms. It will also be necessaryto inspect the cables with the unit in three differentpositions. During the inspection, it would be advisable toalso lubricate the cables.


Look for broken wires. Feeling by hand or by wiping with asoft cloth will expose broken wires. If four or more brokenwires are found, replace that cable. If it is determined thatthere are broken wires, but not enough to cause replace-ment, perform more frequent inspections. Any time thereis doubt in the mind of the inspector concerning the safetyof a cable, it should be changed.

While operating the unit, observe the sheaves for freedomof movement. It is extremely important that all idlersheaves turn as the cable moves. Evidence of a frozen orslipping sheave would be a very shiny groove. As the cableslips, it wipes the lubrication off.

Position 1The booms stored. Inspect the cables at the turntable.Also inspect the sheave grooves for evidence of scuffing.Inspect the cables and sheaves at the elbow. The cablesor rods should not touch anything. Make sure the cablekeepers are in place. Reach inside the upper boom at theplatform through the side access holes at the boom tip.Pay particular attention to the cable that comes off the topof the 12 sheave. Reach into the boom past the idlersheaves for inspection.

Position 2Raise the lower boom vertical and the upper boom fullydown. This exposes a new length of cable. Inspect thecables at the turntable and boom tip. With another aerialplatform, inspect the cables at the elbow. Have someoneraise the upper boom and make sure no cables are ridingon each other. If they do, they can be pried in place on thecast sheaves with a screwdriver.

Position 3Place the lower boom horizontal and the upper boomovercenter. Reach inside the upper boom and inspect asin Position 2.

Note the general condition of the leveling system compo-nents including leveling rods, boom interiors, control lines,hydraulic hoses, leakage monitor wires, etc. Check boominteriors for hydraulic leaks and the accumulation of debrisor other foreign material, particularly units used in treetrimming activity. Check cables for rust even if they aregalvanized. Tree sap, etc., may act as an acid which mayproduce rust.

Caution

If the unit is washed with a high pressure washer orchemical degreasers are used the leveling cablesmust be lubricated within a 24 hour period or beforethe unit is operated.

Replacement of Leveling CablesOne type of leveling cable must be replaced at least every5 years or 5,000 hours, whichever comes first. The other,newer type, of leveling cable must be replaced at leastevery 8 years or 8,000 hours, whichever comes first. Thenewer type is recognized by yellow paint on the endcoupling of the cable. This requirement is based on normaluse, proper care, regular inspection, and lubrication. If theunit is operated under severe conditions, or not properlyserviced, replace cables, leveling rods, or sheaves morefrequently. This emphasizes the need to perform regularinspections as instructed in this manual.

Before any attempt is made to remove or replace levelingcables or rods, study Figure 3 in the Parts Manual. It isvery important that the correct procedures be followed toassure proper routing of cables for the safety of operation.Several inspections will be required during the replace-ment of cables. Use only genuine Altec replacement parts.Substitution of inferior parts can lead to dangerous condi-tions.

Procedure for RemovingLeveling Cables and Rods 1. Remove all access covers from the booms. This will

permit access to the leveling system which is mostlyhoused within the booms.

2. Remove the platform(s) for access to the boom tip.This can be done by detaching the fiberglass platform(s)from the mounting shaft. If the platform can besupported while it is removed, it may not be necessaryto remove the control head.

3. Disconnect the current leakage monitoring bondingwires from the leveling rods inside the upper boom atthe elbow.

4. Remove the cable keepers (retainers) from all sheaves.

5. Release the lower boom Ieveling rods from the cablesby unscrewing the turnbuckles in the lower boom.Push the lower boom Ieveling rods through the lowerboom to extend outside at the elbow.

6. Remove the idler sheave at the elbow end of the lowerboom.

7. Release the upper boom Ieveling rods from the cablesby unscrewing the turnbuckles at the lower end of theupper boom.

8. Make note of the Ieveling rods to become familiar withthe right hand and left hand threads at the ends of therods.


9. Release the upper boom Ieveling rods from the elbowcables by unscrewing the turnbuckles in the upperboom.

10. Remove the platform mounting shaft from the upperboom tip. Note the orientation of the 12 sheaves atthe tip and at the elbow.

11. Remove the pins from the 8 idler sheaves at the boomtip and the lower 8 idler sheave at the elbow end of theupper boom.

12. Slide the 8 idler sheaves at the boom tip, the 12boom tip sheave, the boom tip cable, and the Ievelingrods out of the boom tip.

13. Remove the cables at the boom tip from the Ievelingrods.

14. By removing the anchor pin from the mounting bracketinside the turntable, the lower end cables can beremoved.

Inspection 1. Thoroughly inspect all Ieveling rods to determine if

they are suitable for reuse. Check rods for severescratches, signs of rubbing, cleanliness, or any otherpossible damage or wear. Inspect the terminals at theends of the rods for secure attachment and condition.Replace the rods if there are any signs of cracks,damage, or wear.

2. Inspect all idler sheaves. Sheaves must not be reusedif they show signs of scuffing on the surface whichcontacts the cable. All sheaves must turn freelywithout excessive looseness in the bearing.

3. Inspect the large sheaves at the elbow. If there are anybroken flanges or excessive wear, replace the sheave.If excessive wear is noted in the shaft bearings, theymust be replaced.

4. New sheaves, bearings, and pins are furnished withthe cable kit. It is recommended that these parts bereplaced at cable replacement.

5. Inspect all cable keepers for wear, damage, or defor-mation. Never use a cable keeper which is not in goodcondition.

6. If the Ieveling rods have been determined to bereusable, clean the surface of the rods to avoiddegrading their dielectric strength.

Installation of Cables and RodsBefore installing or reassembling the leveling system,carefully study the boom assembly. Becoming familiarwith these two diagrams and using them for reference willgreatly assist the assembly and eliminate confusion.

1. Spray the new Ieveling cables with wire rope lubricant.Wipe them with a clean cloth to remove excessivelubricant. Do not allow lubricant to dry on fiberglasssurfaces because dirt can collect and reduce thedielectric strength of the fiberglass. Avoid getting dirtor grit on the cable.

2. Install the long end of the elbow upper boom Ievelingcable to the top upper boom Ieveling rod lower endusing jam nuts and 11/2 outside hex turnbuckle.Screw the turnbuckle onto the Ieveling rod and thecable end fitting at least 11/4. Slide the top upper boomrod toward the tip until the upper end of the rodprotrudes out of the boom tip weldment. Slide thebottom rod so that its upper end protrudes from theboom tip weldment. Attach the boom tip Ieveling cableassembly to the top upper boom leveling rod. Engagethe cable end fitting threads at least 11/4, tighten thejam nuts securely against the Ieveling rod end fittings,and lockwire the assembly according to Figure 11.Attach the long end of the boom tip Ieveling cable tothe bottom upper boom Ieveling rod. Lockwire theassembly according to Figure 11.

3. Orient the boom tip leveling sheaves according toFigure 6, wrap the cable as shown and engage thedrive lug on the cable assembly into the recess on theIeveling sheave. Be sure to wrap the cables correctlyas shown.

4. Install the 8 Nylatron idler sheaves at the boom tip.Use the appropriate thrust washers, retaining pin,buckeye pin retainer, and drilled head fasteners.Lockwire the fasteners as shown in the Iockwiringsection.

5. Install the platform mounting shaft and drive keythrough the boom tip assembly and the platformIeveling sheave. Use an appropriate rust preventivelubricant such as Never Seize on the keyways, keys,and the inside bore of the platform Ieveling sheaves.Install the idler sheave cable keepers.

6. Orient the elbow upper boom leveling sheave. Installthe 8 Nylatron idler sheaves spacer, thrust washers,pins, retainers, and retaining bolts. The pivot pins forthe idler sheaves will retain the cables in their sheavegrooves and eliminate the need for additional cable


keepers. Attach the bottom upper boom Ieveling rodto the short end of the elbow upper boom Ievelingcable using the 11/2 hex turnbuckle and jam nuts. Thedrive lug on the elbow upper boom Ieveling cable mustbe secured into the recess on the elbow Ievelingsheave. Tighten the lower turnbuckle hand tight andthen an additional five turns. This will provide theproper pretension on the Ieveling system for the initialrun-in of the new cables. Tighten the jam nuts se-curely. Do not lockwire at this time.

7. Install the Iower cables to the turntable anchor pointand wrap them around the main boom pivot pinsheave. Install the 8" Nylatron sheaves, pins, bush-ings, thrust washers, pin retainers, and retaining boltsat the Iower boom. Install the lower boom elbowIeveling cable with the long end on the upper side ofthe lower boom elbow sheave. Engage the drive luginto the recess on the Ieveling sheave securely.Attach the end fittings of the lower boom elbowassembly to the lower boom Ieveling rods, engagingthe end fittings at least 11/4. Tighten the jam nuts andlockwire as shown in Figure 11. Install the 6 idlersheave, thrust washers, pivot pin, pin retainer, andretaining bolts at the elbow end of the lower boom.Lockwire the pin retainer bolt according to the lockwir-ing section.

8. Slide the lower boom Ieveling rods toward the lowerend of the lower boom being sure to keep themseparate as to which is the top one and which is thebottom one.

9. Connect the lower end of the Ieveling rod to the cableat the lower boom main pivot with the turnbuckle in thelower boom. Tighten the turnbuckle sufficiently topermit operation of the Ieveling system but do notadjust the platform at this time. It is very important thatall cables and rods be held with wrenches while the

turnbuckle is tightened. Otherwise, severe twist candamage the cable and Ieveling rods.

10. Inspect the entire Ieveling system throughout to makecertain cables are not crossed and they will operatefreely without rubbing. The cable wrap at the mainboom pivot sheave, the elbow sheave, and the boomtip sheave can be pushed into alignment for goodtracking without rubbing.

11. Install the platforms onto the platform mounting shaft.

12. Using the lower controls, with outriggers set, operatethe boom throughout all positions with rated load in theplatform

Caution

Do not permit anyone to occupy the platform until afterthe operations have been tested and structural testshave been passed.

Inspect cables, rods, pins, etc. at the turntable, elbow,and boom tip to determine that there is no rubbingbetween the moving parts. This inspection can bemade from another unit

13. Perform a structural test as explained in Testing. Finaladjustment of the cables as explained in the sectionof Adjustment of Leveling Cable Tension will give theproper cable tension and level the platform properly.

14. Connect all current leakage monitoring wires at theelbow end of the upper boom. Install all covers.

15. The unit be given a dielectric test anytime work hasbeen performed which might affect the insulatingproperties of the fiberglass. Records of dielectric testshould be retained and filed for future reference.

Figure 11 Leveling Rod/Cable

L.H. Thread R.H. Thread

Section C-C Section D-D


Figure 12 Adjusting Turnbuckles

Section A-A

Turnbuckle

Section B-B

R.H. Thread L.H. Thread

Adjustment of Leveling Cable TensionThe adjustment of platform Ieveling cables is a simple,very important operation. It is necessary to have theproper tension in order that the platform will be carried ina position parallel to the turntable so that unnecessaryplatform movement will be eliminated. However, betweenthe adjustments on the Ieveling cable system in the upperand lower booms, the system can be greatly overtensioned.This serves no purpose but does shorten the life of cables,sheaves, bearings, etc.

Cable adjustment will most likely not be required until afterextended periods of operation. Loose cables can bereadily noticed when the platforms are loaded. Withoutproper tension, the platforms will lean away from the boomand the operators will find it uncomfortable to perform workfrom the platforms. In addition, loose cables will allow theIeveling rods, cables, and platforms to bounce while thevehicle is being driven.

To properly tension the Ieveling cables, raise both boomsuntil they clear the boom rests. By removing the coverplate from the side of the lower boom and upper boom, theturn buckles will be visible through the access hole. Theturnbuckles in the lower boom adjust the level of theplatforms and the upper boom turnbuckles adjust theupper boom cable tension. The back turnbuckle inside thelower boom at the access hole adjusts the platform tiltwhile the front turnbuckle adjusts the tension in the lowerboom cables. As in any turnbuckle, one thread is righthand pitch and one thread is left hand pitch. In the lowerboom, the left hand threads are on the turntable cables. Inthe upper boom, the left hand threads are on the upperboom Ieveling rods. Anytime the turnbuckle is beingturned, the end of the Ieveling rods and the end of the cablemust be held with wrenches to avoid twisting. To adjust theupper boom system, loosen the turnbuckle and jam nuts

on the bottom upper boom Ieveling rods. Tighten theturnbuckle hand tight and then an additional five turnsusing a wrench. This will provide a proper tension in theupper boom Ieveling system. Tighten the jam nuts on theturnbuckle and secure the turnbuckle with lockwire asshown in Figure 12. Unfold the upper boom overcenter untilthe other turnbuckle is accessible at the upper boom elbowaccess hole. Tighten the jam nuts securely and lockwirethis turnbuckle also.

Rotating PlatformsWith rotating type platforms, the plat