D2-3-4B Op 749-10066

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
749-10066
Operators Manual
D2000B/3000B/4000B
Electrical Hazards
Always wear insulating protective equipment, use conductor cover-ups, and maintain required clear-
ances when in the vicinity of energized conductors.
Aerial devices and digger derricks with insulating booms can only isolate the operator from grounding through the
boom and vehicle. They cannot provide protection against phase-to-phase or phase-to-ground contacts occurring at
the boom-tip, above the insulating boom sections.
Boom-tips of aerial devices and digger derricks, of necessity, must contain metal components. Metal conducts
electricity. Moreover, under certain circumstances, and to varying degrees, electricity will track across or through
non-metallic components (fiberglass covers and structures, hoses, etc.). Electricity can even arc through air. Thus,
the boom-tip of an aerial device or a digger derrick must be considered conductive!
If any part of the boom-tip contacts an energized conductor, the entire boom-tip, including the control
handle, must be considered energized.
If any part of the boom-tip contacts a grounded object, the entire boom-tip, including the control
handle, must be considered grounded.
Hydraulic fluid is flammable. If electricity flows through the boom-tip, it can cause the hydraulic fluid to burn or to
explode. Contact by any part of the boom-tip with an energized conductor while the boom-tip also is in
contact with another energized source or a grounded object can cause the hydraulic fluid at the boom-
tip to burn or explode.
These are among the reasons aerial devices
1
and digger derricks are never considered primary protection for the
operator from electrical contact. An operators primary protection comes through use of protective equip-
ment (insulating gloves, insulating sleeves, hot sticks) and maintenance of appropriate clearances.
Do not rely on the boom-tip of an aerial device or digger derrick to protect you from an energized
conductor or a ground. It cannot do so. Rely, instead, on the only things that can protect you, use of
appropriate protective equipment and maintenance of appropriate clearances.
1
Except ANSI Category A units
Safety Bulletin
1-10
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. Keep this manual
with the unit.
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.
Impacts to and excessive forces on the hydraulic utility equipment, through vehicular acci-
dents, 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.

Section 1 Introduction
About This Manual..................................................................................................... 1
Section 2 Unit Specifcations
Purpose of the Unit ....................................................................................................... 3
General Specifcations .................................................................................................. 3
Component Identifcation .............................................................................................. 5
Section 3 Safety
Safety Instructions ........................................................................................................ 7
Capacity ........................................................................................................................ 7
Accident Prevention Signs ............................................................................................ 9
Accident Prevention Signs Diagram ..................................................................... 10
Section 4 Before You Operate
Capacity and Stability ................................................................................................. 21
Boom Raise Capacity Test .................................................................................. 22
Operation Near Energized Conductors ....................................................................... 22
Inspection Diagram ............................................................................................... 24
Daily Preoperational Inspection .................................................................................. 24
Preparing for Operation .............................................................................................. 28
Cold Weather Start-Up ................................................................................................ 29
Section 5 Protection Systems
Hydraulic Overload Protection (HOP) ......................................................................... 31
Boom Stow Protection ................................................................................................ 32
Auger Stow Protection ................................................................................................ 32
Hydraulic Side Load Protection ................................................................................... 32
Electronic Side Load Protection .................................................................................. 33
Load Moment Limiter .................................................................................................. 34
Anti-Two-Block (ATB) .................................................................................................. 35
Section 6 Operation
Ground Level Controls ................................................................................................ 37
Outriggers and Tools/Derrick Selector Switch ...................................................... 37
Outriggers ................................................................................................................... 37
Interlock System ................................................................................................... 38
Motion Alarm ......................................................................................................... 38
Lower Controls ............................................................................................................ 38
Foot Throttle ........................................................................................................ 39
Digger Shake ........................................................................................................ 41
Auger Release ...................................................................................................... 41
Digger Shift ........................................................................................................... 41
Low Speed/Standard ............................................................................................ 41
Pole Guide Forward/Back .................................................................................... 41
Pole Guide Open/Close ........................................................................................ 41
Emergency Stop ................................................................................................... 41
Lower/Upper/Radio ............................................................................................... 41
Engine Speed ....................................................................................................... 41
Engine Start/Stop ................................................................................................. 41
Cold Oil/Change Filter Light ................................................................................ 42
Control Panel Lights ............................................................................................. 42
Hand Controls ...................................................................................................... 42
Table of Contents
Rotation Float ....................................................................................................... 42
Rotation Float Light .............................................................................................. 42
Rotation Float Alarm ............................................................................................. 42
Side Load Protection Light .................................................................................. 42
Joysticks ............................................................................................................... 42
Gauges ................................................................................................................ 43
Horn ...................................................................................................................... 44
Anti-Two-Block/Load Moment Limiter Override .................................................... 44
Upper Controls ............................................................................................................ 44
Radio Controls ............................................................................................................ 45
Lower Remote Control ......................................................................................... 46
Upper Remote Control .......................................................................................... 48
Battery Charger .................................................................................................... 50
Booms ......................................................................................................................... 51
Lower Boom ........................................................................................................ 51
Intermediate and Upper Booms ........................................................................... 52
Boom Storage ....................................................................................................... 53
Rotation ....................................................................................................................... 53
Interlock System .................................................................................................. 53
Winch .......................................................................................................................... 54
Winch Line ............................................................................................................ 55
Digger ......................................................................................................................... 57
Unstowing ............................................................................................................ 58
Operation .............................................................................................................. 59
Setting Anchors ................................................................................................... 60
Rotation Float System .......................................................................................... 61
Stowing ................................................................................................................. 61
Pole Guide .................................................................................................................. 63
Interlock System ................................................................................................... 63
Boom Flares ................................................................................................................ 63
Transferring the Boom Flares and Pole Guide Assembly .................................... 64
Pole Puller ................................................................................................................... 64
Lower Tools ................................................................................................................. 65
Upper Tools ................................................................................................................. 66
Personnel Platform ..................................................................................................... 67
Unstowing ............................................................................................................ 67
Operation ............................................................................................................. 68
Stowing ................................................................................................................. 69
Removal .............................................................................................................. 69
Lanyard Anchor .................................................................................................... 69
Transferable Upper Controls ....................................................................................... 69
Pinning Confgurations With Boom Flares Pinned to the Intermediate Boom ...... 70
Pinning Confgurations With Boom Flares Pinned to the Upper Boom ............... 70
ROACS Remote Start/Stop System ............................................................................ 72
Fiberglass Jibs ............................................................................................................ 72
Material Handling Jibs ......................................................................................... 72
Personnel Jib ....................................................................................................... 72
Other Methods of Lowering/Stowing the Unit ............................................................. 72
Manual Operation of Lower Control Valve ............................................................ 74
Manual Operation of Lower Control Valve
(Units With Radio Controls Only as Lower Controls) ..................................... 75
Manually Raising the Outriggers ......................................................................... 75
Section 7 Troubleshooting
Circuit Breakers .......................................................................................................... 77
Thermal Self-Resetting Circuit Breakers ............................................................. 77
Pulsars and Hand Controls ......................................................................................... 77
Outrigger/Tool Blocking and Sense Dump Valves ...................................................... 78
Derrick Blocking Valve ................................................................................................ 78
Section 8 Care of the Unit
Hydraulic System ........................................................................................................ 81
Fiberglass ................................................................................................................... 81
Structures and Mechanical Systems ........................................................................... 81
Appendix
Glossary
Derrick Preoperational Checklist
Standard Hand Signals for Controlling Crane Operations
Troubleshooting Chart
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 for the operation of the
unit. The operator must be familiar with the unit and its
capabilities before using the unit on the job. This manual
is written to provide an understanding of the unit, safety,
proper set-up, and operation.
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.
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 assist in unit
operation. 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
Purpose of the Unit
This unit has been designed and built for service to the
utility industry. It is a multipurpose unit that can accom-
modate components that dig holes, set poles, and position
material and personnel at the work site.
General Specifcations
This unit uses a telescopic boom design. Unit height
specifcations are based on 40 (101.6 cm) frame height,
but common frame heights vary from 29 (73.7 cm) to
40 (101.6 cm). Figures 2.1 and 2.2 provides general
specifcations.
This unit is ANSI rated for use at 46 kV and below. This
ANSI rating is printed on the serial number and capacity
placard located near the lower controls. Insulated digger
derricks are designed and manufactured for work in which
the fberglass upper boom is considered the secondary
protection, with the primary protection being rubber gloves,
hotsticks, and other insulated equipment. Dielectric testing
of the insulating components and proper maintenance
are necessary to maintain optimum dielectric protection.
Some of the hazards, but not all hazards, of operating
the unit near energized conductors are presented in this
manual in Section 4 under Operation Near Energized
Conductors.
This unit shall be used near energized conductors only
by fully trained and qualifed operators who are trained
and profcient as electrical linemen and are familiar with
the hazards of contact with energized conductors.
A derrick may be specifed by the customer for use in
one of two ways.
Digger Derrick Use for derrick use only, such as
lifting with the winch line, digging with the auger,
and setting screw anchors, without any personnel
platform use.
Platform Use or Combined Digger Derrick and
Platform Use for use as a personnel platform or
combined personnel platform and material handling
device.
Every unit is tested by the installer before delivery to
meet the stability requirements for Digger Derrick Use
according to ANSI. A load capacity chart for digger der-
rick use is located near the lower controls.
The specifcation for Platform Use or Combined Dig-
ger Derrick and Platform Use is required on all derricks
equipped with upper controls and/or a platform, and on
any other unit as specifed by the customer. Each unit
with this specifcation is tested by the installer before
delivery to meet the stability requirements for Combined
Digger Derrick and Platform Use according to ANSI. Der-
ricks with this specifcation will be equipped with a load
capacity chart for platform and combined digger derrick
and platform use and a boom angle indicator which are
visible from the platform. A derrick may not be used for
personnel lifting or for combined personnel lifting and
material handling unless it has been stability tested and
equipped to comply with this specifcation.
Item Specifcation
Maximum hydraulic pressure setting 3,000 psi (206.84 bar)
Adjustable lower tool circuit pressure factory set 2,000 psi (137.90 bar)
Adjustable lower tool circuit flow factory set 8 gpm (30.38 lpm)
Adjustable upper tool system pressure factory set 2,000 psi (137.90 bar)
Adjustable upper tool circuit fow factory set 8 gpm (30.38 lpm)
Hydraulic pump output at 2,200 rpm 43 gpm (162.66 lpm)
Oil reservoir capacity 60 gallons (227.12 l)
Platform capacity
Single platform 300 pounds (136.08 kg)
Dual platforms installed on personnel jib 500 pounds (226.80 kg)
Figure 2.1 Unit Specifcations
4 Section 2 Unit Specifcations
Figure 2.2 Unit Specifcations (by Model)
1
From centerline of rotation
1
From centerline of rotation
Item D2045B D2050B D2055B D3050B D3055B
Maximum sheave height 45.4 (13.8 m) 50.0 (15.0 m) 54.9 (16.7 m) 49.6 (15.1 m) 54.5 (16.6 m)
Sheave height
Both booms retracted 29.0 (8.8 m) 30.9 (9.4 m) 33.4 (10.2 m) 30.7 (9.4 m) 33.2 (10.1 m)
One boom extended 37.5 (11.4 m) 40.7 (12.4 m) 45.7 (13.9 m) 40.4 (12.3 m) 45.3 (13.8 m)
Both booms extended 45.4 (13.8 m) 50.0 (15.0 m) 54.9 (16.7 m) 49.6 (15.1 m) 54.5 (16.6 m)
Horizontal reach
1
One boom extended 27.7 (8.4 m) 31.0 (9.4 m) 36.0 (10.9 m) 31.0 (9.4 m) 36.0 11.0 m)
Boom extension
Intermediate boom 8.5 (2.6 m) 9.8 (3.0 m) 12.3 (3.8 m) 9.8 (3.0 m) 12.3 (3.8 m)
Upper boom 8.0 (2.4 m) 9.3 (2.8 m) 9.3 (2.8 m) 9.3 (2.8 m) 9.3 (2.8 m)
Boom articulation -17 to 83 -17 to 83 -17 to 83 -15 to 80 -15 to 80
Digging radius
Minimum 16.8 (5.1 m) 18.7 (5.7 m) 21.2 (6.5 m) 18.7 (5.7 m) 21.2 (6.5 m)
Maximum 25.3 (7.7 m) 28.5 (8.7 m) 33.5 (10.2 m) 28.5 (8.7 m) 33.5 (10.2 m)
Stowed travel height
Boom tip winch 11.5 (3.5 m) 11.5 (3.5 m) 11.5 (3.5 m) 11.5 (3.5 m) 11.5 (3.5 m)
Turntable winch 11.9 (3.6 m) 11.9 (3.6 m) 11.9 (3.6 m) 11.9 (3.6 m) 11.9 (3.6 m)
Item D3060B D4050B D4055B D4060B D4065B
Maximum sheave height 59.5 (18.2 m) 49.6 (15.1 m) 54.5 (16.6 m) 59.5 (18.2 m) 64.9 (19.8 m)
Sheave height
One boom extended 47.0 (14.3 m) 40.4 (12.3 m) 45.3 (13.8 m) 47.0 (14.3 m) 50.6 (15.4 m)
Horizontal reach
1
One boom extended 37.6 (11.5 m) 31.0 (9.4 m) 36.0 11.0 m) 37.6 (11.5 m) 41.3 (12.6 m)
Boom extension
Intermediate boom 13.2 (4.0 m) 9.8 (3.0 m) 12.3 (3.8 m) 13.2 (4.1 m) 15.0 (4.6 m)
Upper boom 12.7 (3.9 m) 9.3 (2.8 m) 9.3 (2.8 m) 12.7 (3.9 m) 14.5 (4.4 m)
Boom articulation -15 to 80 -15 to 80 -15 to 80 -15 to 80 -15 to 80
Digging radius
Minimum 22.0 (6.7 m) 18.7 (5.7 m) 21.2 (6.5 m) 22.0 (6.7 m) 23.9 (7.3 m)
Maximum 35.2 (10.7 m) 28.5 (8.7 m) 33.5 (10.2 m) 35.2 (10.8 m) 38.9 (11.9 m)
Stowed travel height
Boom tip winch 11.6 (3.5 m) NA NA NA NA
Turntable winch 11.9 (3.6 m) 11.9 (3.6 m) 11.9 (3.6 m) 11.9 (3.6 m) 11.9 (3.6 m)
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
Safety Instructions
This unit is designed and manufactured with many fea-
tures intended to reduce the likelihood of an accident.
Safety alerts throughout this manual highlight situations
in which accidents can occur. Pay special attention to
all safety alerts.
Danger
Death or serious injury will result from careless or
improper use of the unit. Do not operate the unit
without proper training.
Warning
Death or serious injury can result from careless
or improper use of the unit. The operator bears
ultimate responsibility for following all regulations
and safety rules of their employer and/or any state
or federal law.
It is very important that all personnel are properly trained
to act quickly and responsibly in an emergency, knowing
the location of the controls and how they operate. Keep
any tools or equipment needed to perform manual opera-
tions in a well-marked, designated area.
Danger
Death or serious injury will result from unprotected
contact with energized conductors. Maintain safe
clearances from electrical power lines and apparatus.
Allow for platform or line sway, rock, or sag.
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.
contact with energized conductors. Read and under-
stand the contents of Section 4 before operating the
unit near energized conductors.
Knowledge of the information in this manual and proper
training provide a basis for safely operating the unit. Follow
your employers safe work practices and the procedures
in this manual when operating the unit.
General Operating Information
Do not operate the unit without proper training.
Be sure that the unit is operating properly, and has
been inspected, maintained, and tested in accordance
with the manufacturers and governments require-
ments.
Use the personal fall protection system if operating
the unit from the platform.
Be aware of the surroundings.
Perform the Daily Preoperational Inspection before
operating the unit each day.
Apply the parking brake, chock the wheels, start
the engine, and engage the PTO. Properly set the
outriggers.
Properly set up the unit before moving the booms
from the rest.
Operate the controls smoothly, avoiding sudden
starts and stops.
Never exceed the listed capacity values.
Follow all of your employers work rules and ap-
plicable government regulations.
Capacity
A sample range diagram, digger derrick use capacity
placard, platform or combined digger derrick and platform
use capacity placard, and associated notes are shown
in Figure 3.1.
Considerations when using the digger derrick use load
capacity chart are listed below.
The load is lifted with the winch line at boom tip or
material handling jib.

The personnel platform(s) is (are) unoccupied.
The load being lifted must not exceed the smallest
of the following values.
Load capacity shown in the chart minus the weight
of all options mounted on the boom.
Winch line rated working load multiplied by the
number of parts of winch line.
Winch capacity multiplied by the number of parts
of winch line.
Rated capacity shown in rated capacity chart for
material handling jib (if jib is in use).
If the actual load radius is not shown in the chart, use
the load capacity at the next longer radius shown.
When lifting with the material handling jib, use the
actual load radius at the jib tip. Do not exceed the
maximum load radius in the chart when lifting with
the jib. Boom angles in the chart do not apply for jib
use.
If a boom is extended to a length not shown in the
chart, use the load capacity at the next longer length
of extension shown for that boom.
8 Section 3 Safety
Figure 3.1 Sample Range Diagram and Capacity Placards
Section 3 Safety 9
The multiple part winch line must be used when the
load being lifted exceeds the winch line rated working
load or the winch capacity. Winch line pull (obtained
by dividing load weight by number of parts of line)
must not exceed winch line rated working load or
the winch capacity. The upper boom must be fully
retracted when using a multiple part line if the winch
line anchor point is on the intermediate boom.
Load capacities in the chart do not exceed 85 percent
of actual tipping loads on a level surface, based on
the unloaded vehicle weight shown. If the unit is
remounted or if the vehicle is modifed in any way
affecting stability, contact Altec to determine if a new
load capacity chart is required.
Considerations when using the platform or combined
derrick and platform use load capacity chart are listed
below.
The personnel platform(s) is (are) occupied.
The winch line may or may not be used for lifting a
load at the boom tip or material handling jib tip.
The load being lifted must not exceed any of the
following conditions.
Total personnel and material load [load in platform(s)
plus load on winch line] must not exceed 3,000
pounds for any confguration.
The load on the winch line must not exceed either
of the following values.
Winch line rated working load.
Rated capacity shown in the rated capacity chart
for material handling jib (if jib is in use).
The load in platform(s) must not exceed either of
the following values.
The rated platform capacity.
The rated capacity shown in the rated capacity
chart for personnel jib (if jib is in use).
No load is permitted on the winch line when the
personnel jib is in use.

If the actual boom angle is not shown in the chart, use
the load capacity at the next lower boom angle.
If a boom is not fully retracted, use the load capacity
for the extended boom.
Load capacities in the chart do not exceed 67 percent
(50 percent for CSA) of tipping loads on a level surface
or 75 percent (50 percent for CSA) of tipping loads
on a 5 degree slope, based on the unloaded vehicle
weight shown. If the unit is remounted, or modifed in
any way affecting stability, contact Altec to determine
if a new load capacity chart is required.
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 descrip-
tions of all placards are listed in the Parts Manual. Refer
to the Accident Prevention Signs Diagram for examples
of the placards and their locations.
10 Section 3 Safety
Accident Prevention Signs Diagram
Radio Controls Without Hard Wired Lower Control
Riding Seat (Full View)
26
15
6
4
2
10
17
30 3
36
23
5
31
19
37 33 22 2
26 15 6
5
3
23
19
30
31
4
10
17
36
2
18 28
or On Side
15
6
17
30
36
23 31 5 19 26
4
2
3
10
Riding Seat
Section 3 Safety 11
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
12 Section 3 Safety
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
18 28
Control Panels
21
37
34
30
Turntable Winch
Turntable With Riding Seat
Both
Sides
22
Boom Tip
22
34
37
30
31
33
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
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Section 3 Safety 13
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Section 3 Safety 15
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Section 3 Safety 17
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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
18 Section 3 Safety
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Section 3 Safety 19
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20 Section 3 Safety
Section 4 Before You Operate 21
Section 4 Before You Operate
All operators involved in the use and/or care of this unit
must know the location and understand the operation of
each control on the unit. Control locations are pointed out
in Component Identifcation. Operation of the controls is
explained in Section 6.
Capacity and Stability
A chart showing the digger derrick use load capacities of
the particular model is located near the lower controls.
This chart is used when lifting a load without personnel
in the platform. A range diagram is also located near the
lower controls. If the unit is specifed for platform use or
combined digger derrick and platform use there will also
be a capacity chart and a boom angle indicator visible
from the platform. This chart is used when lifting loads
with personnel in the platform. Sample placards and
associated notes are shown in Figure 3.1. Refer to the
placards on the unit for actual capacities.
The values on the load capacity charts refect vehicle
stability. The rated working load of the winch line may
limit the loads lifted by the unit. The load capacity values
on the chart near the lower controls show the maximum
loads that may be lifted by the unit at regular intervals
of load radius, through the full range of boom elevation,
extension, and rotation, and still maintain vehicle stability.
The operator may use the capacity chart or the boom
raise capacity test to determine whether or not a load
may be lifted.
Stability will be maintained if the values listed in the chart
are not exceeded and the outriggers are properly posi-
tioned to level the unit as described in Section 6 under
Outriggers. It is recommended that the load capacity
chart be used as a guide when lifting a load. Also refer
to other considerations listed in Section 3 when using
the capacity charts. The operator must be aware that
the rated hydraulic capacity of the derrick only includes
hydraulic and structural limitations and does not include
stability factors. Therefore, some units may be able to
lift loads exceeding the load capacity chart values and
could become unstable. If this is the case, stability must
be considered frst. The unit may need to be repositioned
for maximum stability.
Warning
Death or serious injury can result if the unit becomes
unstable. If the platform is occupied, determine the
weight of the load before lifting.
Death or serious injury can result from overloading
the unit. Do not exceed the rated capacity values.
Determine the weight of the material before moving it. Use
the placards on the unit to determine the available rated
lifting capacities. Do not exceed rated lift capacities.
Notice
Refer to the platform or combined digger derrick
and platform use capacity chart for limitations when
personnel are in the platform.
Stability, or resistance to tipping, is determined by many
factors including the size and weight of the chassis and
the location of the unit mounting on the chassis. The
unit is equipped with outriggers to help stabilize the unit
while it is in use.
Warning
unstable. Properly set the outriggers to level the unit
before moving the booms from the rest.
Understand the stability characteristics of this unit before
using it. As delivered, this unit will meet or exceed the
requirements for stability as set forth in ANSI publica-
tions.
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.
Caution
Injury and property damage can result from abrupt
reversals in direction, starts, or stops. Operate the
controls smoothly.
Using the unit in an unsafe manner or overloading the
unit can cause weld fatigue and eventual failure.
The stability characteristics of a vehicle vary as the
booms are rotated to different positions around the ve-
hicle. Therefore, any load being rotated should be kept
as close to the ground as possible. This will allow the
load to settle to the ground, rather than tip the unit over,
if the vehicle becomes unstable.
Lowering or extending the booms increases the load
radius. Use caution when lowering or extending the
22 Section 4 Before You Operate
booms with a load on the winch line. The units capac-
ity and stability decrease as the booms are lowered or
extended. While lowering or extending the boom with
a load, perform the boom raise capacity test at several
points to ensure the rated hydraulic capacity of the unit
is not exceeded. Also make sure that stability is main-
tained at all times.
Warning
Park on a frm surface before operating the unit. Use
parking brakes and wheel chocks. On units equipped
with outriggers, use of outriggers is mandatory.
On such units, outriggers must be extended as in-
structed under Outriggers. Use outrigger pads on
all unpaved surfaces, asphalt pavement, and other
soft surfaces.
It is impossible to foresee all situations and combina-
tions for set up of the unit. Establish criteria for stable
operation of the unit based on actual conditions, work
procedures, and experience. The owner and operator
bear ultimate responsibility for insuring that the unit is
properly set up.
Boom Raise Capacity Test
The lift cylinder is designed to lift loads within the rated
hydraulic capacity of the derrick, regardless of boom
angle or extension. This feature provides a way for the
operator to determine if a load is within the rated hydraulic
capacity of the derrick. The operator simply attempts to
lift the load slightly, no more than 6 (15.24 cm) off the
ground, by shifting the boom control handle to the Raise
position. If the load can be lifted in this manner, rated
hydraulic capacity of the derrick is not being exceeded.
If stability has been maintained, then the load may then
be winched up to the required position. If it is necessary
to lower or extend the booms with a load, then perform
the boom raise capacity test and consider stability along
several points of the lowering or extension.
Operation Near Energized Conductors
Warning
or federal law.
This unit is manufactured with a fberglass upper boom
and associated nonconductive components. When these
components are properly used and maintained, the unit
will provide secondary insulation so that the unit will
perform its function as an insulated work platform. This
unit is manufactured to meet the dielectric requirements
of ANSI in effect at the time of its manufacture. The rating
of the unit must be known and understood by its users.
Insulated units rated at 46 kV and below are designed
and manufactured for work in which the boom is not
considered as primary insulation, but secondary to other
protective equipment such as insulating (rubber) gloves,
sleeves, and hot sticks.
Danger
Death or serious injury will result from careless or
improper use of the unit. Do not operate the unit
without proper training.
All personnel using this unit must understand the hazards
of contact with energized conductors, for the protection
of themselves, their coworkers, and the public.
Electricity seeks earth ground by any means avail-
able. Non-insulated units or insulated units not known
to be in good condition, must not be taken close to
energized conductors. OSHA regulations prescribe
minimum clearances required for such equipment.
Danger
Death or serious injury will result from contact with
or proximity to an energized conductor. Maintain the
dielectric characteristics of the fberglass boom.
The dielectric characteristics of the fberglass upper
boom are effective only if all of the following condi-
tions are satisfed.
The fberglass upper boom is clean, dry, free of
tracking, and in good condition as established by
dielectric testing.
The fberglass upper boom is extended so the
minimum extension placard on the upper boom
is beyond the farthest extent of all metal compo-
nents on or attached to the intermediate boom tip.
Examples of the correct extension are shown in
Figure 4.1.
No winch line shall bridge the nonconductive gap
between the boom tip and the end of the interme-
diate boom.
Fiberglass upper controls components, noncon-
ductive hoses, and other nonconductive com-
ponents originally furnished with the fberglass
upper boom have not been replaced by conductive
components.
The lower or intermediate steel boom or part
thereof are not in contact with nor in proximity to
any energized conductor.
An operators primary protection from electrical con-
tact comes through the use of protective equipment
(insulated gloves, insulated sleeves, conductor cover-
ups) and maintenance of appropriate clearance. The
unit itself only provides secondary protection for the
operator by insulating the operator from grounding
through the boom and vehicle.

The fberglass platform and nonconductive covers
will not provide protection against electrical continuity.
Properly ftted with a platform liner, designed, tested,
and maintained for the dielectric rating, the platform
will offer some protection for the lower extremities of
the occupants body when they are entirely within the
liner and not in contact with other objects including
the boom tip area. It cannot protect against contact
between an occupant and either two conductors or
a single conductor and grounded elements of the
pole.
Occupants of a fberglass platform must not touch
two energized conductors, or an energized conduc-
tor and a grounded wire or component without using
personal protective equipment for primary protection.
The boom tip area should be considered conductive
and at the same electrical potential as objects it is in
contact with or near.
Contact by the conductive components, or even
any nonconductive component, with an energized
conductor may energize the entire vehicle. If the
vehicle becomes energized, it is an extreme hazard
to anyone who might touch the vehicle or unit. All
personnel must remain clear of the vehicle or unit
any time the booms are elevated near energized
wires.
Danger
Death or serious injury will result from hydraulic oil
burning or exploding. Avoid contact of the boom
tip with two energized conductors or an energized
conductor and a ground.
Death or serious injury will result from failure to follow
safe electrical work practices. The OSHA minimum
approach distances for qualifed electrical workers
and line clearance tree trimmers must be maintained.
All other workers must stay at least 10 (3 m) from
energized conductors.
Only qualifed electrical workers using appropri-
ate personal protective equipment (rubber gloves/
sleeves) may come closer than the minimum approach
Upper Boom Placard
Intermediate
Boom
Figure 4.1 Minimum Extension Placard
Upper Boom Placard
Intermediate
Boom
distance to an unguarded energized conductor. When
using rubber gloves/sleeves to work on an energized
conductor, the minimum approach distance must be
maintained between the operator/aerial device and
any other unguarded energized conductors.
Contact by any part of the boom tip with an ener-
gized conductor while the boom tip is also in contact
with another energized source or a grounded object
can cause hydraulic oil at the boom tip to burn or
explode.
Tools, supplies, and metal components of the unit,
including the boom tip and controls, may be conduc-
tive and should be used with care.
Hydraulic oil must be kept free of water and other
contaminants to maintain its dielectric properties.
Sample and test the hydraulic oil periodically.
In addition to these hazards, other hazardous situations
may endanger personnel. Personnel must be aware
of and practice all regulations and safety rules of their
employer and/or any state or federal law.
Daily Preoperational Inspection
Inspect the unit at the beginning of each work day before
going out on the job. If the unit is being used during more
than one shift in a day, inspect it at the beginning of each
shift. Potential service and safety problems may be de-
tected by inspecting the unit prior to each shift. Check the
following items during the preoperational inspection (refer
to Inspection Diagram). To help guide the preoperational
inspection, a preoperational checklist placard is installed
at one or more places on the unit (refer to Figure 4.2).
In addition, a preoperational checklist is included in the
Appendix of this manual. A copy of this checklist may be
used during the pre-shift/daily inspection.
On a monthly basis, a copy of the checklist should be
completed, signed, dated, and fled in accordance with
OSHA requirements.
Components may be installed on your unit that require
additional inspection. Refer to these component manuals
for more information. If any problem is found, including oil
leaks or improper operation, stop and have the problem
corrected before placing the unit in service.
Inspection Diagram
This diagram is for representational purposes only.
The operator bears ultimate responsibility for properly inspecting all components.
Fiberglass
Cylinders
Winch Line
Weldments
Outriggers
Auger Windup Sling
Reservoir
Oil Level
Counterbalance Valves
Steel Tubes
Hoses
Boom Pivot Pin
Fasteners
Platform/Liner
Platform
Mounting Bracket

Figure 4.2 Preoperational Checklist Placard
1. Check that the tires on the vehicle are in good condi-
tion and are properly infated.
2. Position the unit on a level surface. Clean any dirt,
mud, or other residue off of the top of the hydraulic
reservoir. With the booms and outriggers stowed,
check the oil level of the hydraulic reservoir. The oil
level must be between the Add and Full marks on
the dipstick. If necessary, add oil as described in the
Maintenance Manual. The need to add oil regularly
indicates a leak in the hydraulic system that should
be corrected.
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.
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
work areas clean.
Caution
Injury can result from slipping and falling. Use care
and the handles and steps provided.
3. Visually inspect the unit for hydraulic leaks. Continue
to look for hydraulic leaks while performing the in-
spection.
4. Throughout the inspection, pay particular attention
when inspecting the following components looking
for proper operation and any damage, cracks or cor-
rosion, missing or loose fasteners, cracked or broken
inspection marks, and excessive wear. Also check
for any oil leakage from each of the gearboxes.
Rotation bearing
Rotation gearbox
Boom pivot pin
Lift cylinder mounting pins
Digger gearbox
Digger link
Auger tube
Auger extension shaft
Pole guide pivot pins
Winch gearbox
5. Inspect all covers to make sure they are in place,
secure, and in good condition.
6. Check visual and audible safety devices for good
condition and proper operation. Replace missing
and/or illegible placards.
Danger
contact with energized conductors. The platform
and covers carry no dielectric rating. They cannot
protect against contact between an operator and
either two conductors or a single conductor and
grounded elements of the pole. The fberglass plat-
form, properly ftted with a platform liner, designed,
tested, and maintained for the dielectric rating, will
offer some protection for the lower extremities of
the occupant.
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.
Keep the lanyard used with the OSHA approved
personal fall protection system in place and in good
condition. Never replace it with a lanyard made of
conductive material.
7. Apply the parking brake, chock the wheels, start the
engine, and engage the power take-off (PTO).
Notice
Do not put the unit in service and run the pump at
normal operating speeds until the hydraulic oil res-
ervoir feels warm to the touch.

8. If the temperature outside is below 32 degrees
Fahrenheit (0 degrees Celsius), the hydraulic oil
may need to be warmed before operating the unit.
The procedure for warming the oil is described in
this section under Cold Weather Start-Up. Do not
operate the pump or engine at more than a fast idle
until the hydraulic oil has warmed up.
9. With the outriggers stowed, test the outrigger inter-
lock system. Move the outriggers and tools/derrick
selector to the Derrick position. Move the lower boom
control to the Raise position. If boom movement oc-
curs, the outrigger interlock system is not functioning
properly.
10. Properly set the outriggers to level the unit as de-
scribed in Section 6 under Outriggers. Check for
proper operation and audible motion alarm.
11. Test the outriggers. Place the outriggers and tools/
derrick selector in the Derrick position. Hold the control
for one outrigger in the Raise position momentarily
while watching the corresponding outrigger for move-
ment. If the cylinder retracts slowly with the control
shifted, the outrigger cylinder or its holding valve is
not functioning properly. Repeat this test for each
outrigger. Then make note of how far each outrigger
is extended.
12. Test the operation of the chassis mounted winch and/
or capstan, if so equipped.
a. Operate each control with the emergency stop
engaged. If movement occurs, the emergency
stop is not functioning properly.
b. Disengage the emergency stop.
c. Operate each control through the full range of
motion. All controls must operate smoothly and
consistently, and must return to neutral after being
released. While the gearbox is operating, check
for malfunctioning components and oil leaks. With
the controls in neutral, watch for any winch drum
or capstan shaft movement. If movement occurs,
the gearbox or control may not be functioning
properly.
Danger
contact with energized conductors. Maintain safe
clearance from electrical power lines and apparatus.
Allow for platform or line sway, rock, or sag.
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.
controls smoothly.
13. Test the electrical portion of the hydraulic overload
protection (HOP) system. With the booms stowed,
operate the winch raise, digger dig, boom lower,
intermediate and upper boom extend functions. If
any of these functions are operational, the switch
in the bottom of the boom stow rest is not properly
actuating the HOP system.
14. Test the operation of the Anti-Two-Block (ATB) system,
if so equipped.
a. Check the yellow low battery indicator light on the
ATB monitor in the left hand turntable side cover
(as viewed from the boom tip looking toward the
turntable) (refer to Section 5 under Anti-Two-Block).
If the yellow light is fashing at four blinks per sec-
ond, the battery in the ATB switch at the boom
tip is low and must be replaced. If replacement is
required, use a genuine Altec replacement part
to ensure that the proper battery is used. Refer
to the Maintenance Manual for the battery part
number.
b. If the battery is good, raise the boom out of the rest
and lower the load hook several inches below the
ATB weight. Operate the winch raise function to
slowly raise the load hook. Verify that winch raise
shuts off when the hook contacts and lifts the ATB
weight. If the winch raise function does not shut
off when the ATB weight is lifted, the ATB system
is not functioning properly.
c. Push and release the ATB override switch, operate
the winch raise function again, and confrm that
winch raise is operational. Do not allow the load
hook to contact the boom tip. If the winch raise
function does not restart when the ATB override
switch is operated, the ATB system is not function-
ing properly.
15. Test the pole guide interlock. With the booms out of
the boom rest and the transferable fares pinned to
the intermediate boom, make sure the upper boom will
not extend if the pole guide is not fully tilted back to
the stowed position. If the upper boom extend function
is operational, the pole guide interlock system is not
functioning properly. Do not allow the upper boom to
contact the pole guide while testing the interlock.
16. Test the operation of the lower controls with no per-
sonnel in the platform, if so equipped.
a. Operate each control with the emergency stop
engaged. If movement occurs, the emergency
stop is not functioning properly.
c. Operate each function through the full range of
motion. All functions must operate smoothly and
consistently, and the controls must return to neutral
after being released. While the unit is operating,
look for malfunctioning components and oil leaks.
With the controls in neutral, watch for any boom
movement. If movement occurs, a cylinder or its
holding valve may not be functioning properly.
d. When the control selector is in the Lower Control
position, all upper controls should not function. The
lower controls must override the upper controls.
17. Test the operation of the upper controls, if so
equipped.
a. Operate a control with the emergency stop en-
gaged. If movement occurs, the emergency stop
is not functioning properly.
c. Operate each function. While the unit is operating,
look for oil leaks.
18. Test the operation of the remote controls, if so
equipped, with no personnel in the platform.
a. Inspect the condition of the remote control trans-
mitter. Verify there are no holes or cracks in the
housing and that joysticks and switches are not
damaged.
b. Test the operation of the emergency stop function
of the transmitter by pushing the emergency stop
button while operating the unit. No function should
operate. Pull the emergency stop button outward
and reset the transmitter. Tilt the transmitter more
than 75 degrees for at least 5 seconds. No func-
tion should operate. Return the transmitter to an
upright position and reset the transmitter. If either
pushing the emergency stop button or tilting the
transmitter does not stop operation of the func-
tions, do not operate the remote control system
until the problem is corrected.
c. Operate the unit with the radio controls from
the ground. Operate each function through the
full range of motion. All functions must operate
smoothly and consistently, and the controls must
return to neutral after being released.
d. If the derrick is not equipped with lower controls,
look for malfunctioning components and oil leaks
while the unit is being operated with the radio
controls. With the controls in neutral, watch for
any boom movement. If movement occurs, a cyl-
inder or its holding valve may not be functioning
properly.
19. Test the operation of the remote control system
transmitter when it is installed in the docking station
(if so equipped) for use from the platform as upper
controls. Slowly shift each joystick that is labeled
push to operate (refer to Figures 6.8 and 6.10)
out of neutral without pushing down on the joystick,
and verify that the functions do not operate. If the
transmitter contains controls for digger and pole
guide, shift each of these controls out of neutral
briefy and verify that the functions do not operate.
If any of these functions operate, the docking station
interlock system is not functioning properly. Do not
operate the remote control in the docking station until
the problem is corrected.
20. Inspect the fberglass upper boom and boom tip,
and the fberglass jib, if so equipped. Check for any
condition that could reduce the structural integrity
and/or the limited dielectric properties. Inspection
should include the following items.
a. No dirt and foreign objects.
b. No damage, including chipped or scratched
surfaces.
c. No moisture, oil, or grease on surfaces.
21. If the unit is equipped with a fberglass platform(s),
check the platform(s), liner(s), and platform
attachment(s) for any condition that could reduce
the structural integrity and/or the limited dielectric
properties. Also inspect the personal fall protection
system(s) for any damage or deterioration. Inspection
should include the following items.
a. No dirt and foreign objects.
b. No damage to platform or liner surfaces, including
chipped or scratched surfaces.
c. No holes in the platform or liner.
d. Platform mounting pin and platform mounting
fasteners secure.
e. No moisture, oil, or grease on surfaces.
f. No fraying or damage to the harness straps or
lanyard of the personal fall protection system.
g. Connectors at the ends of the personal fall pro-
tection system lanyard are in good condition with
properly functioning latches.
Warning
Death or serious injury can result if the winch line
breaks. Replace a worn or damaged winch line.
22. Inspect the winch line for good condition, proper reev-
ing at the boom tip, and proper spooling on the winch
drum. If replacement is required, use a genuine Altec
replacement part to ensure that the proper rope and
design is used. Refer to the Maintenance Manual for
requirements and procedures for replacement.
23. Inspect the load hook or other lifting attachment on
the end of the winch line for good condition, and
confrm that any originally equipped latch on the load
hook is in place and working properly.
Warning
Death or serious injury can result if the auger sling
breaks. Replace a worn or damaged auger sling.
Notice
Do not operate the unit with a damaged digging
system.
24. If the derrick is equipped with a digger, inspect the
auger windup sling for good condition. If a wire rope
auger windup sling shows signs of wear and/or four
or more broken wires, replace it immediately. If a
synthetic auger windup sling has cut strands and/or
external wear, replace it immediately. A worn auger
windup sling could fail causing a free swinging au-
ger. If replacement is required, use a genuine Altec
replacement part to ensure that the proper design is
used. Refer to the Maintenance Manual for require-
ments and procedures for replacement. Inspect the
digger storage and transfer systems for any damage
that could impair proper operation. Also inspect the
auger extension shaft for the proper cap screws and
nuts that secure it to the digger and auger.
25. Verify that each outrigger is still extended to the
position noted in step 11. If any retraction has oc-
curred, the outrigger cylinder or its holding valve is
not functioning properly.
26. If the derrick is being inspected at the location where
it will be used, confrm that the ground conditions are
adequate for proper support of the outriggers, and
verify that the unit is level within specifcations.
Warning
unstable. Properly stow the booms before raising
the outriggers.
27. If the derrick is not being inspected at the location
where it will be used, stow the booms, raise the
outriggers, and disengage the PTO.
Preparing for Operation
Before using this unit each day or before each shift if the
unit is being used during more than one shift in a day,
perform the preshift/daily preoperational inspection. This
unit may be operated in accordance with the following
procedure on frm surfaces. Consider the reach of the unit
and the work to be done when positioning the unit.
1. Place the transmission in neutral and apply the park-
ing brake. Apply the supplemental holding brake, if
so equipped, and chock the wheels.
Warning
soft surfaces.
properly set up.
2. Engage the PTO according to the manufacturers
operating instructions.
3. If so equipped, move the PTO switch in the vehicle
cab to the On position.
Caution
Notice
4. If the temperature is below 32 degrees Fahrenheit
(0 degrees Celsius), warm the hydraulic oil before
operating the unit. The procedure for warming the
oil is described under Cold Weather Start-Up in this
section. Do not operate the pump or engine at more
than a fast idle until the hydraulic oil has warmed
up.
5. If the unit has an outriggers and tools/derrick control
on the tailshelf, the control must be in the Outrigger
position. Properly set the outriggers to level the unit
as described in Section 6 under Outriggers.
6. After properly setting the outriggers, the unit functions
may be made operational by moving the outriggers
and tools/derrick control to the Derrick position.
7. While operating the unit, continuously monitor the
outriggers and booms for any unintended movement
that could be an indication of a malfunction. Stow the
unit and remove it from service if any malfunction is
suspected.
Cold Weather Start-Up
When operating the unit in temperatures of 32 degrees
Fahrenheit (0 degrees Celsius) or below, follow the cold
weather start-up procedure. Refer to the Maintenance
Manual for cold weather oil recommendations.
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.
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.
The engine and pump speeds should be no greater than
a fast idle until the oil has warmed up. Cold, thick oil
does not fow well and may cause delays in response to
control movement, as well as cavitation and consequent
pump damage.
Use the following procedure to warm up the hydraulic
oil.
1. Attach a quick disconnect coupler to each end of a
3
/8 (0.95 cm) hydraulic hose that is 2 to 3 (60 to 100
cm) long and rated for at least 3,000 psi (206.8 bar)
working pressure. An oil warming kit (refer to Figure
4.3) containing all necessary parts for this assembly
can be found under Service Tools and Supplies in
the Maintenance Manual Appendix.
Figure 4.3 Oil Warming Kit
2. Connect each end of the hose to the lower tool circuit.
If the Altec oil warming kit is being used, adjust the
needle valve
1
/2 turn counterclockwise (out) from fully
closed.
3. Start the vehicle engine and engage the PTO.
4. Move the outriggers and tools/derrick selector to the
Outriggers and Tools position.
5. Move the control handle for the lower tool circuit to
the Tools On position.
6. After the hydraulic oil has warmed up, return the
control handle for the lower tool circuit to the Tools
Off position, and disconnect the hose or oil warming
kit.
Hydraulic
Hose
Needle
Valve
Male Quick
Coupler
Female
Quick
Coupler
Section 5 Protection Systems 31
Section 5 Protection Systems
The unit is equipped with protection systems that are
intended to protect the unit from being overloaded due
to operator errors. However, even with these protec-
tion systems, the unit can be damaged if the operator
disregards the recommended methods and procedures
described in this manual.
Hydraulic Overload Protection (HOP)
The HOP system prevents excessive overloading of the
unit. This system is an important safety feature that helps
prevent accidents and damage to the unit. All operators
should understand the system and its importance.
The HOP system is built into the units hydraulic system.
A pressure transducer in the valve block on the base end
of the lift cylinder senses the amount of pressure in the
lift cylinder (refer to Figure 5.1). When the unit is loaded
to its rated capacity, the pressure in the base end of the
lift cylinder is equal to the maximum system pressure,
regardless of boom angle or extension. When the pres-
sure reaches approximately 10 percent over maximum
system pressure due to overloading of the booms, the
HOP system is activated. The HOP system temporarily
shuts off the following functions that can cause further
overloading.
Winch raise Intermediate boom extend
Boom lower Upper boom extend
Digger dig
While these functions are temporarily shut off, the following
functions remain operational to relieve the overload.
Winch lower Intermediate boom retract
Boom raise Upper boom retract
Digger clean
When the operator eliminates the overload from the unit,
the system automatically restores operation to the func-
tions that were temporarily shut off.
Do not use the HOP system to determine the load the
unit will lift. Use the load indicator gauge, the boom raise
capacity test, and the load capacity chart to determine if
a load is within the capacity of the unit. The boom raise
capacity test is described in Section 4 under Capacity
and Stability. The load indicator gauge is located at the
lower control panel. The gauge shows the percentage of
the derricks rated hydraulic capacity that is being used
when lifting a load. This gauge is described in Section 6
under Lower Controls.
Warning
Notice
The load indicator gauge only measures the load as
a percentage of the units rated hydraulic capacity.
Above Rotation
Valve Driver
Boom Stow
Switch
Boom Stow Protection
Overload and Load
Moment Protection
HOP/Load Moment Limiter
Pressure Transducer
(In Cylinder Valve Block)
Auger Stow
Protection
Auger Stow
Switch
Figure 5.1 Protection Systems
ATB Protection
ATB Switch
32 Section 5 Protection Systems
It does not refect the stability of the unit, which can
cause the load capacity to be less than the hydraulic
capacity.
Repeatedly engaging the HOP system can damage
the unit.
The HOP system is intended to prevent overloading of the
unit due to operator error when lifting a load. Repeated
operation at load levels that activate the HOP system
Any time the booms are positioned out of the boom
rest and above the minimum boom angle, the needle of
the load indicator gauge should move with any change
in boom angle or loading. If the reading on the gauge
remains at zero when the boom is out of the boom rest
and above the minimum boom angle, the HOP system
is not functioning properly. Take the unit out of service
and have the problem corrected.
Notice
Property damage can result from overloading the unit.
Never operate the unit with a disabled or improperly
functioning HOP system.
Do not disable the HOP system in an attempt to allow
the unit to perform a task prevented by this protection
system.
The electrical portion of the HOP system should be
checked daily before operating the unit. With the boom
stowed, operate the winch raise, digger dig, boom lower,
intermediate and upper boom extend functions. If any of
these functions are operational, the switch in the bottom
of the boom stow bracket is not properly activating the
HOP system. Take the unit out of service and have the
problem corrected.
Boom Stow Protection
The boom stow protection system prevents damage
to the chassis from the boom lower function when the
boom is stowed.
Notice
Meter the lower boom control to slow the speed of
the lower boom to avoid shock loads as the boom
contacts the rest.
Damage to the unit can result if the lower boom
bounces during road travel. Stow the lower boom
frmly in its rest.
A switch is located in the boom rest on the underside
of the boom. The switch is actuated when the boom is
stowed. The switch engages the HOP system. One of
the functions the HOP system shuts off is the boom lower
function. If the boom hand control is not immediately
released, damage to the chassis is prevented because
the boom lower function is shut off.
Auger Stow Protection
The auger stow protection system prevents damage
to the auger stow mechanism and windup sling when
stowing the auger.
Notice
Select low speed and meter the digger control in
the dig direction when stowing the auger and in the
clean direction when unstowing the auger to prevent
damage to the unit.
A limit switch is located in the auger stow bracket (refer
to Figure 5.1). The switch is actuated when the auger
reaches the top of its travel during stowing, shutting off
the digger dig function. If the digger hand control is not
immediately released, damage to the unit is prevented
because the digger dig function is shut off.
Hydraulic Side Load Protection
If the rotation gearbox appears as shown in Figure 5.2,
the unit is equipped with hydraulic side load protection.
The lower control panel, if so equipped, will not contain
a side load gauge (refer to Section 6 under Lower Con-
trols). The hydraulic side load protection system helps
prevent damage to the unit structures when a side load
is developed on the booms.
Figure 5.2 Rotation Gearbox
With Hydraulic Side Load Protection
Turntable
Rotation Gearbox
With Hydraulic Side
Load Protection
Side loads may be caused by a variety of unit operations.
The following list describes some operating practices
that cause side loads.
Winching a load in from the side.
Raising the boom with the winch line at an angle to
the side.
Corkscrewing an auger into the ground when working
at an angle to one side.
Failing to follow the movement of a screw anchor
with the boom, rotation, and intermediate boom
controls.
Lowering the boom against an auger or screw anchor
that is angled to the side of the boom.
Operation on excessive slopes.
If an excessive side load is developed on the booms,
the rotation brake will slip and the gearbox and rotation
motor will backdrive. This allows the booms to rotate
toward the load.
Notice
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 component failure.
Notice
Overriding the hydraulic side load protection system
with the rotation hand control can damage the unit.
Never attempt to counteract the hydraulic side load
protection system by shifting the rotation hand control
in the opposite direction of the sideslip.
If a load being winched up causes a suffcient side load
to activate the side load protection system, the booms
will rotate. The rotation can be stopped by lowering the
load back to the ground.
Electronic Side Load Protection
If the rotation gearbox appears as shown in Figure 5.3,
the unit is equipped with electronic side load protection.
The lower control panel, if so equipped, will contain a side
load gauge (refer to Section 6 under Lower Controls).
Figure 5.3 Rotation Gearbox
With Electronic Side Load Protection
The electronic side load protection system helps prevent
damage to the structures when a side load is developed
on the booms. Side loads may be caused by a variety
of operations. The following list describes some derrick
operating practices that cause side loads.
Winching a load in from the side.
Raising the boom with the winch line at an angle to
the side.
Corkscrewing an auger into the ground when working
at an angle to one side.
Failing to follow the movement of a screw anchor
with the boom, rotation and intermediate boom
controls.
Lowering the boom against an auger or screw anchor
that is angled to the side of the boom.
Operation on excessive slopes.
Turntable
Rotation Gearbox
With Electronic Side
Load Protection
Notice
When the electronic side load protection system pres-
sure has engaged the HOP system, remove the side
load from the booms before operating any function
that would cause increased loading of the booms.
The side load protection system is connected to a load
sensing mechanism in the rotation gearbox. If an exces-
sive 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.
The side load pressure gauge (refer to Figure 5.4) gives
the operator an indication of how much side load is being
applied to the boom. When the pressure in the side load
pressure system reaches the preset value, the gauge
needle will be in the right hand red zone, the system will
engage HOP, and the side load protection light will come
on. The gauge measures side load during the operation
of all derrick functions including turntable rotation. The
fashing mode of the side load protection light shown
on the placard (refer to Figure 5.4) next to the side load
pressure gauge is not applicable to this model.
Figure 5.4 Side Load Pressure Gauge and Light
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 component failure.
Notice
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. This system is an important safety feature that
helps prevent accidents. All operators should understand
the system and its importance.
This system is built into the units hydraulic system. A
pressure transducer in the valve block on the base end
of the lift cylinder senses the amount of pressure in the
cylinder (refer to Figure 5.1). When the boom is loaded,
the pressure in the base end of the lift cylinder can be
used to determine the load moment of the unit. When
the pressure reaches a pre-defned pressure that may
result in the load moment exceeding stability, this system
is actuated. Like the HOP system mentioned earlier in
this section, the load moment limiter system temporarily
shuts off the following functions that can cause further
overloading.
Winch raise
Boom lower
Digger dig
Intermediate boom extend
Upper boom extend
While these functions are temporarily shut off, the following
functions remain operational to relieve the overload.
Winch lower
Boom raise
Digger clean
Intermediate boom retract
Upper boom retract
When the operator eliminates the overload from the unit,
the system automatically restores operation to the func-
tions that were temporarily shut off.
The hydraulic pressure required to actuate the load mo-
ment limiter system varies from unit to unit. This value
is determined when the unit is stability tested during the
FLASHING = SLP DISABLED & GAUGE
SHOWING ROTATION PRESSURE
LIGHT ON = SLP ACTIVATED
SIDE LOAD PROTECTION STATUS
Gauge
Light
Red
Red
Yellow
manufacturing process. Units that can lift a higher load
moment before becoming unstable will have a higher
pressure setting than units that are less stable, and will
therefore be allowed to lift greater loads without actuating
the this system. The following lists some of the factors
affecting unit stability.
Finished chassis weight with no payload
Outrigger confguration
Chassis frame
Unit options and accessories
Notice
The load moment limiter actuation value is based on
having the vehicle is set up as described in Section
6 under Properly Setting on a Level Surface. This in-
cludes setting up the vehicle level, on a level surface,
with the outriggers deployed to remove the bulge
from the tires. Deviating from this setup will affect
the accuracy of the load moment limiter system.
The lower control panel and/or lower remote control are
equipped with a switch that can be used to override the
load moment limiter system actuation (refer to Section 6
under Load Moment Limiter Override). 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 which will allow
the unit to remain stable. The override switch does not
allow the operator to override HOP. The 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 setting and allow additional load
to be lifted. An indicator light in the load moment limiter
side of the override switch on the lower control panel will
turn on to indicate that the load moment limiter override
is actuated. The override does not affect the operation of
the HOP system, and the load should not be allowed to
exceed 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 system will automati-
cally reset, turning off the override and restoring normal
operation. The indicator light in the override switch on
the lower control panel will turn off.
Warning
Only use the override switch after evaluating the
load and load position to verify that the unit will
remain stable.
Anti-Two-Block (ATB)
The ATB system (if equipped) is an operational aide
to assist the operator in preventing the load hook from
contacting the boom tip. This system is an important
safety feature that helps prevent accidents and damage
to the unit. All operators should understand the system
and its importance.
The ATB system is integrated into the units electronic
control system. A switch located at the boom tip, along
with an anti-two-block weight and chain, are used to
determine when the load hook on the winch line nears
the boom tip (refer to Figure 5.1). When the load hook
lifts the ATB weight, the ATB system engages 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.
While these functions are temporarily shut off, the fol-
lowing functions remain operational to relieve the 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.
The lower control panel and/or lower remote control are
equipped with a switch that can be used to override the
ATB system actuation (refer to Section 6 under Anti-Two-
Block (ATB) Override). 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. An indicator light in the Anti-Two Block
side of the override switch on the lower control panel will
turn on to indicate that the ATB override is actuated. The
load hook should not be allowed to contact the boom tip.
If contact between the load hook and the ATB weight
is removed and the weight is again hanging freely, the
system will be automatically reset, turning off the override
and restoring normal operation. The indicator light in the
override switch on the lower control panel will turn off.
An ATB lock out fag is provided to allow the removal of
the weight and chain from the ATB switch at the boom
tip when work practices allow for operation without ATB
protection. This fag must be inserted between the cable
eyelet and the switch when the weight and chain are
removed (refer to Figure 5.5). This fag must also be
installed if the entire ATB switch and bracket assembly
is removed from the boom tip.
Figure 5.5 ATB Lockout Flag
Warning
Death or serious injury can result from two-blocking
the unit. Remove the lock-out fag prior to unit opera-
tion when anti-two-block protection is required.
Notice
The ATB switch must stay with the vehicle if it is
removed 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 ATB monitor on each unit.
Do not interchange ATB switches between units.
The ATB switch at the boom tip contains a battery. The
yellow LED indicator light on the ATB monitor mounted
in the left hand turntable side cover (as viewed from the
boom tip looking toward the turntable) indicates the condi-
tion of this battery (refer to Figure 5.6). If the yellow LED
is fashing at 4 blinks per second, the battery is low and
must be replaced (refer to Service Tools and Supplies in
the Maintenance Manual Appendix). If the battery voltage
drops too low, the ATB system will be actuated, shutting
off certain functions as described above.
Figure 5.6 ATB Low Battery Indicator
Yellow Low Battery Light
(Four Blinks per Second)
Left Hand Turntable
Side Cover
ATB Lockout
Flag
ATB Switch
on Boom Tip
ATB Cable Eyelet
Section 6 Operation 37
tools, and derrick winch are operational, and the remain-
ing derrick functions are disabled. With the switch in this
position, if the winch is being operated and the operator
then attempts to operate another derrick function at the
same time, the winch will be shut off. With the switch in
the Derrick position, the derrick functions are operational,
and the outriggers and lower tools are disabled.
Outriggers
The controls for the outriggers are located at the
tailshelf.
Warning
soft surfaces.

properly set up.
Warning
unstable. Properly set the outriggers to level the unit
before moving the booms from the rest.
Section 6 Operation
Caution
controls smoothly.
Outriggers help stabilize and level the unit while it is in
use. Before operating the unit, follow the procedure in
Section 4 under Preparing for Operation. Properly set the
outriggers as described in the following section.
Warning
wheel chocks and parking brakes. On units equipped
soft surfaces.

properly set up.
Ground Level Controls
Outriggers and Tools/
Derrick Selector Switch
The outriggers and tools/derrick selector switch, located
on the tailshelf of the unit (refer to Figure 6.1), controls
which functions of the unit are operational. With the switch
in the Outriggers and Tools position, the outriggers, lower
Selector
Switch
Figure 6.1 Ground Level Controls
38 Section 6 Operation
Death or serious injury can result from contact with
a moving outrigger. Clear the area around the outrig-
gers before operating the unit.
unstable. Properly stow the booms before raising
the outriggers.
The surface that the outrigger shoe will rest on must
be frm and capable of supporting a substantial load in
a concentrated area. If necessary, place outrigger pad
supports beneath each outrigger shoe to increase the
support area and load holding capability.
Shifting an outrigger control handle to the Lower position
lowers the outrigger and shifting the outrigger control
handle to the Raise position raises the outrigger. The
control returns to neutral when released.
Properly Setting on a Level Surface
Radial or A-Frame Outriggers
With the booms stowed, lower the outriggers to a
frm footing.
Out and Down Outriggers
With the booms in the stowed position, fully extend
the horizontal outrigger legs from both sides of the
vehicle. On units with the rotation interlock system,
the horizontal legs must be fully extended on the
side the boom will be rotated toward, but may be
left retracted or partially extended on the opposite
side. Lower all four vertical outrigger legs to a frm
footing.
Extend the outriggers as far as possible, while allowing the
vehicle to be level, with all tires maintaining contact with
the ground surface. Although the tire-to-surface contact
pressure may vary, extend the outriggers to remove the
bulge from the tires. Lower the outriggers approximately
3 (7.5 cm) after reaching ground level. This will usually
be enough to remove the bulge and still be able to see
some tire-to-surface contact at each tire.
To insure proper outrigger spread when using outrigger
pads or blocks, extend the outriggers approximately 3
(7.5 cm) after reaching ground level (not pad surface
level). This may result in tires coming off the ground.
Properly Setting on a Sloping Surface
Radial or A-Frame Outriggers
With the booms stowed, lower the low side outriggers
to a frm footing.
Extend the high side outriggers only after a frm footing
has been reached with the low side outriggers. Lower
the high side outriggers approximately 3 (7.5 cm) after
reaching the ground level. Adjust outrigger extension to
establish a level vehicle.

Out and Down Outriggers
With the booms in the stowed position, fully extend
the horizontal outrigger legs from both sides of the
vehicle. On units with the rotation interlock system,
the horizontal legs must be fully extended on the
side the boom will rotated toward, but may be left
retracted or partially extended on the opposite side.
Lower the low side vertical outrigger legs to a frm
footing.
The high side vertical outrigger legs should only be
lowered after a frm footing has been reached with
the low side outriggers. The high side vertical outrig-
gers should be lowered with penetration adjusted to
establish a level vehicle chassis.
Extend the outriggers as far as possible, while allowing
the vehicle to be level, with all tires on the high side
maintaining contact with the ground surface. Tires on the
low side of the slope may not remain in contact with the
ground, depending on how much slope is present.
To insure proper outrigger spread when using outrigger
pads or blocks, extend the outriggers approximately 3
(7.5 cm) after reaching ground level (not pad surface
level). This may result in tires coming off the ground.
Interlock System
The unit is equipped with an outrigger interlock system.
This system requires the outriggers to be deployed before
the booms can be moved from the boom rest. Operation
of the turntable and boom functions is prevented until the
outriggers are deployed. The interlock system does not
assure full stability. The unit may also have an outrigger
interlock override control in the vehicle cab. This control
overrides the interlocks until the PTO is disengaged. The
next time the PTO is engaged the outrigger interlocks
are reactivated.
Motion Alarm
The unit is equipped with an outrigger motion alarm. An
audible alarm alerts personnel in or near the work area
that the outriggers are in motion.
When an outrigger control handle is moved from neutral,
the warning is sounded. Returning the handle to neutral
turns the alarm off.
Lower Controls
The unit has a proportional electrohydraulic control sys-
tem. The lower control panel is equipped with electric
hand controls rather than control handles that are directly
connected to hydraulic valve spools. When a function
is operated, the functions speed is proportional to the
distance the hand control is shifted. For example, if the
boom hand control is shifted in the Raise direction 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.
Figures 6.2 and 6.3 illustrate the lower control panels.
Depending on the options on the unit, the lower control
panel may not have all the controls shown and may be
at various locations on the unit including on a T-stand,
the riding seat, or the full view riding seat. The location
of the full view riding seat left hand and right hand control
panels may be switched.
Foot Throttle
The foot throttle is located below the lower control panel.
It increases the engine speed in proportion to how far it is
pressed. The hydraulic pump responds to higher engine
speeds by increasing the amount of oil fow it outputs.
When operating a single boom function, full function
speed can be obtained without the foot throttle. When
operating the winch or digger functions or when operating
two or more proportional functions at the same time, it
is necessary to use the foot throttle to obtain maximum
function speeds. Do not press the foot throttle farther
than needed for maximum function speed. Operating at a
higher engine speed than needed for maximum function
speed wastes engine fuel and may cause accelerated
component wear. Consult your Altec representative for
Figure 6.2 Standard and Joystick Lower Controls
Side Load
Hydraulic
Pressure
Load
Indicator
Side Load
Hydraulic
Pressure
Load Indicator
Interlock
Trigger
(on Front)
Figure 6.3 Full View Lower Controls
Hydraulic
Pressure
Load
Indicator
Side Load
Interlock Trigger
(on Front)
the maximum recommended engine speeds for the ve-
hicles particular engine, transmission, PTO, and pump
combination.
Digger Shake
The digger shake switch is used to remove dirt from the
auger fights. The digger shake switch is a two-position
switch that is spring returned to the lower position. Mov-
ing the digger shake switch up and down with the digger
control in the Dig position causes the auger to rapidly
reverse its direction of motion. This rapid reversal of
motion causes dirt to fall off the auger fights. Refer to
Digger in this section for more information on removing
soil from the auger fights.
Auger Release
The auger release switch is used to retract the auger
latch when stowing and unstowing the auger. There is a
guard around the switch. The guard prevents acciden-
tal lowering of the auger due to bumping of the switch.
The auger release switch is a two-position switch that is
spring returned to the Extend position. Moving the auger
release switch up retracts the auger latch. Releasing the
switch cuts off electrical power to the auger latch circuit.
With the power cut off, the latch extends. Refer to Digger
in this section for more information on unstowing and
stowing the auger.
Digger Shift
The digger shift switch is used to shift between the low
and high speeds of the digger.
Moving the digger shift switch to the High position and
releasing it shifts the digger speed to high. A red indicator
light comes on when the digger speed is in high. Moving
the digger shift switch to the High position again and re-
leasing it shifts the digger speed to low. Refer to Digger in
this section for more information on digger operation.
Notice
A mechanically shifted, two-speed digger must come
to a complete stop before moving the digger shift
switch to prevent damage.
Shifting a mechanical shift two-speed digger while it
is turning may severely damage the diggers internal
gears.
Low Speed/Standard
Moving the switch to the Low Speed position provides
more meterability of the functions allowing precise po-
sitioning of the unit.
Moving the switch to the Standard position returns the
operation of the functions to the normal setting.
Pole Guide Forward/Back
The pole guide forward/back switch tilts the pole guide
through its range of motion. The pole guide switch is
spring-centered to the Off position. Jogging the switch will
produce small amounts of movement, allowing precise
positioning of the pole guide. Refer to Pole Guide in this
section for more information on pole guide operation.
Pole Guide Open/Close
The pole guide open/close switch operates the open
and close motion of the pole guide tongs. The pole guide
switch is spring-centered to the Off position. Jogging
the switch will produce small amounts of movement,
allowing precise positioning of the pole guide. Refer to
Pole Guide in this section for more information on pole
guide operation.
Emergency Stop
The emergency stop control stops the operation of all
functions. Press the control down to engage the emer-
gency stop. Turn the control clockwise to disengage the
emergency stop.
Lower/Upper/Radio
The switch has two positions: Lower, which allows op-
eration from the lower controls and Upper/Radio, which
allows operation from the upper or radio controls. If
the unit is equipped with dual station lower controls, (a
master panel and a slave panel) the master panel will
be on the curb side of the unit. To operate the upper or
radio controls on a unit with dual station lower controls,
the switch on the slave panel must be in the Upper/Radio
position and the switch on the master panel must be in
the Upper/Radio position.
Engine Speed
The lower position of the switch selects the engine speed
to low, which is between idle and high. The middle switch
position selects the engine speed to Idle. The upper
position selects the engine speed to High.
speed can be obtained with the idle engine speed se-
lected. When operating the winch or digger functions,
or when operating two or more proportional functions at
the same time, it is necessary to select the low or high
engine speed to obtain maximum function speeds.
Engine Start/Stop
The engine start/stop switch (refer to Figure 6.2) may be
used to start and stop the vehicle engine from the lower
control panel. To start the engine, push the switch until
the engine is running and then release. If the engine does
not start, push the switch and release. Then repeat the
procedure. To turn off the engine, push the switch and
release. The switch is operational only when the cab
ignition switch is on, the PTO switch in the cab is in the
On position, and the emergency stop is not engaged.
Caution
Injury and property damage can result from vehicle
movement if the transmission is not in neutral or park
when the engine is started. Make sure the transmis-
sion is in neutral or park before remotely starting
the engine.
Cold Oil/Change Filter Light
This light alerts the operator when the return line flter
needs changing or when the hydraulic oil is cold.
The light will come on when the hydraulic system oil is
cold and the engine is at operating speeds. In this situa-
tion, the light should go out when the oil has warmed up.
Section 4 under Cold Weather Start-Up fully describes
how to properly warm the hydraulic system oil. If the
light continues to come on when the oil is warm, the flter
needs to be changed. Changing the return line flter is
described in the Maintenance Manual.
Control Panel Lights
The lower control panel has lights that provide light for
night time operation. The lights are on when the PTO
switch in the cab is in the On position.
Hand Controls
The standard lower control panel has separate hand
controls for the boom, rotation, intermediate boom, upper
boom, winch, and digger functions. Figure 6.2 illustrates
the hand controls.
Each hand control is spring-centered and mechanically
latched in neutral. This prevents accidental movement
of a function due to bumping of a hand control.
Warning
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 boom tip by hoisting up, extending
or lowering boom.
To operate a hand control, grasp the handle of the desired
function so that the underside of the knob is pulled up
to unlock the handle for travel. Move the handle to the
desired position. As the hand control is moved further
out of neutral, the speed of the function is proportional to
the distance the hand control is shifted. The foot throttle
or the engine speed switch must be used as described
in the Foot Throttle or Engine Speed section to obtain
full function speed when operating the digger, winch, or
multiple boom functions. The handles may be operated
individually or in any combination.
Rotation Float
The rotation foat control, if so equipped, is a toggle switch
beside the digger control or a push button at the top of
the digger/winch joystick. This control allows the unit to
rotate toward a screw anchor while using the digger to
screw the anchor into the ground. To activate rotation
foat, push and hold the toggle switch in either direction
or press the push button and operate the digger control.
Refer to Rotation Float System in this section for more
information.
Rotation Float Light
The rotation foat light is illuminated when the switch is
pushed and the digger control is operated.
Rotation Float Alarm
Rotation foat uses an audible alarm along with the
indicator light to signal the operator when the system
is activated. The alarm sounds for half a second each
time the switch is pushed. The alarm will then turn off
until the switch is pushed again. If the alarm continues
to sound, it is a warning that there is a problem with the
system. Refer to Rotation Float System in this section
for more information.
Side Load Protection Light
The side load protection light indicates the operation
of the electronic side load protection system. Refer to
Section 5 under Electronic Side Load Protection for more
information.
Joysticks
The joystick on the standard control panel shown in
Figure 6.2, allows four functions to be operated from
one control. It is available on the lower control panel for
the boom, rotation, intermediate, and upper boom func-
tions. The winch and digger functions are operated by
individual hand controls.
The joystick is spring-centered, but it is not locked in
the centered (or neutral) position. However, there is
an interlock trigger on the joystick (refer to Figure 6.2).
Boom movement will not occur unless the interlock trig-
ger has been engaged. Therefore, the interlock trigger
prevents accidental boom movement due to bumping
of the joystick.
When facing the control panel, moving the joystick to
the left retracts the upper boom. Moving the joystick to
the right extends the upper boom. Engaging the button
on top of the joystick and moving the joystick to the left
retracts the intermediate boom. Engaging the button and
moving the joystick to the right extends the intermediate
boom. At customer request on some units, the function-
ality of the push button is reversed so that the button is
released to operate the intermediate boom and pressed
to operate the upper boom. The placard at the base of
the joystick indicates the functionality as manufactured.
Pulling the joystick back raises the boom. Pushing the
joystick forward lowers the boom. Rotating the joystick left
causes the turntable to rotate left, or counterclockwise.
Rotating the joystick right causes the turntable to rotate
right, or clockwise.
The joysticks on the full view riding seat control panels
shown in Figure 6.3, allow two or four functions to be
operated from each control. The boom function joystick
operates the boom, rotation, intermediate, and upper
boom functions. The digger/winch joystick operates the
digger and winch functions.
The joysticks are spring-centered, but are not locked in
the centered (or neutral) position. However, there is an
interlock trigger on each joystick (refer to Figure 6.3).
This trigger must be engaged to close the unloader valve
before moving the joystick. Boom movement will not oc-
cur unless the unloader valve is closed. Therefore, the
interlock trigger prevents accidental boom movement
due to bumping of the joystick.
When facing the control panel, moving the boom function
joystick to the left retracts the upper boom. Moving the
joystick to the right extends the upper boom. Engaging
the button on top of the joystick and moving the joystick
to the left retracts the intermediate boom. Engaging the
button and moving the joystick to the right extends the
intermediate boom. At customer request on some units,
the functionality of the push button is reversed so that
the button is released to operate the intermediate boom
and pressed to operate the upper boom. The placard
at the base of the joystick indicates the functionality as
manufactured. Pulling the joystick back raises the boom.
Pushing the joystick forward lowers the boom. Rotating
the joystick left causes the turntable to rotate left, or
counterclockwise. Rotating the joystick right causes the
turntable to rotate right, or clockwise.
When facing the control panel, moving the digger/winch
joystick to the left operates the digger clean function.
Moving the joystick to the right operates the digger
function. Pulling the joystick back operates the winch
pay-in function. Pushing the joystick forward operates the
winch pay-out function. The button on top of the joystick
activates rotation foat.
To operate a function with a joystick, grasp the control
and engage the interlock trigger. Move the control in the
direction of the desired function. The function will oper-
ate at a speed proportional to the distance the control is
shifted. The foot throttle or engine speed switch must be
used as described in the Foot Throttle or Engine Speed
section to obtain full function speed when operating the
digger, winch, or multiple boom functions.
Gauges
There may be two, three, or four gauges located on
the control panel. The options chosen for the unit will
determine the mounting location of the gauges. One of
the gauges indicates the pressure in the hydraulic sys-
tem. The second gauge is the load indicator gauge and
shows the percentage of the rated hydraulic capacity
that is being used when the unit is lifting a load. The third
gauge that may be on the unit is the electronic side load
protection gauge, which indicates the side load pressure.
The fourth gauge that may be on the unit indicates the
engines speed.
The gauge for the hydraulic system gives the operator an
idea of how hard the unit is working. To do this, note the
reading on the gauge when the load begins to move. Com-
pare this reading with the maximum system pressure of
3,000 psi (206.84 bar). Some troubleshooting techniques
in the Maintenance Manual also use this gauge.
The gauge labeled load indicator shows the percentage
of the rated hydraulic capacity being used when lifting
a load (refer to Figure 6.4). 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 the rated hydraulic capacity. At the
point marked HOP, the HOP system will activate. Sec-
tion 5 under Hydraulic Overload Protection (HOP) fully
describes this protection system. By noting the reading
on the gauge, the operator is aware of the percentage
of the units rated hydraulic capacity used when lifting
a load. For example, the gauge in Figure 6.4 illustrates
a load that is 75 percent of the rated hydraulic capacity
of the unit.
Figure 6.4 Load Indicator Gauge
Warning
LOAD INDICATOR
0
%
2
5
%
50% 75%
1
0
0
%
H
O
P
Notice
The load indicator gauge only measures the load as
a percentage of the units rated hydraulic capacity.
It does not refect the stability of the unit, which can
cause the load capacity to be less than the hydraulic
capacity.
Repeatedly engaging the HOP system can damage
the unit.
The HOP system is intended to prevent overloading of the
unit due to operator error when lifting a load. Repeated
operation at load levels that activate the HOP system
The electronic side load pressure gauge (refer to Figure
6.5) 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 acceptable 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 the
system is not functional and will provide no protection
from excessive side load. The acceptable range of side
load 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 been overloaded and HOP has been engaged to
stop the side load.
Figure 6.5 Electronic Side Load Pressure Gauge
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 pressure and
the system resets itself.
Horn
The horn switch, if so equipped, is a two position mo-
mentary switch. Pressing the switch will sound the horn/
alarm. Releasing the switch will return the switch to the
off position, turning off the horn/alarm.
Anti-Two-Block/
Load Moment Limiter Override
The override switch, if so equipped, is a three-position
momentary switch. If the ATB system has been actuated,
moving the switch to the upper position will activate the
anti-two-block override. Releasing the switch will allow
it to return to the neutral position. An indicator light in
the anti-two block side of the override switch will turn on
while the ATB override is actuated. The ATB system will
remain overridden until the two-block condition has been
removed. Refer to Anti-Two-Block in Section 5 under
Protection Systems for ATB operation.
If the unit has reached the load moment limiter pressure,
moving the switch to the lower position will activate the load
moment limiter override. Releasing the switch will allow it to
return to the neutral position. An indicator light in the load
moment limiter side of the override switch will turn on while
the load moment limiter override is actuated. The load mo-
ment limiter will remain overridden until the load moment
pressure has been reduced below the load moment limiter
setting. Refer to Load Moment Limiter in Section 5 under
Protection Systems for load moment limiter operation.
Upper Controls
Upper controls at the boom tip give the operator full pro-
portional control of the boom and winch functions. Figure
6.6 shows the control handle confguration.
The control panel has a separate handle for the boom,
extension, rotation, and winch functions, an upper controls
on/off control, and a tools on/off and start/stop control.
An interlocking slide gate is provided to help prevent
unintentional actuation of the boom positioning controls
(boom, extension, and rotation). Before operating the up-
per controls, put the controls switch on the lower control
panel in the Upper/Radio position and move the upper
control on/off control to the On position. To operate the
winch, move the control handle to produce the desired
direction and speed of operation. To operate a boom
positioning control, push the slide gate toward the boom
and then move the control handle for the desired function
to produce the desired direction and speed of function
operation. The gate only needs to be pushed and held
into the unlocked position during the initial actuation of a
boom position control. Once the lever is shifted, it will hold
the gate in its unlocked position until the lever is returned
to neutral. The speed of function operation is proportional
to the distance the control handle is moved. More than
one function can be operated at the same time. When
the unit is operated from upper controls, the functions
operate at the low speed setting, approximately half of
the standard speed setting.
Red
Red
Yellow
The transferable upper control panel may be pinned
to the transferable fares or the boom tip on the upper
boom. If the unit is equipped with a personnel jib and
pullout upper controls, the pullout upper controls may be
pinned to the jib. Pinning the transferable upper control
panel is described under Transferable Upper Controls
in this section.
When the control knob on the upper controls is moved to
the On position, the engine speed automatically increases
to a preset value when a function is operated to produce
proper oil fow.
Return the control knob to the Off position when the up-
per controls are not in use, so the unit will not respond
to movement of the control handle.
Warning
or lowering boom.
A single extension control handle operates intermediate
and upper boom extension and retraction because the
booms operate sequentially from the upper controls.
This means the upper boom will fully extend before
the intermediate boom begins to extend. In the retract
direction, the intermediate boom will fully retract before
the upper boom begins to retract. Sequential boom ex-
tension is operational only from the upper controls. The
lower control panel has independent hand controls for
the intermediate and upper booms.
To operate the tools, move the upper controls on/off
control to the On position and move the tools control
forward and release it. To turn the tool circuit off, push
the tool control forward again and release it.
To operate the start/stop function, push the control back
and release it as soon as the engine starts. To stop the
engine, push the control back and release it.
Radio Controls
The radio control system allows remote operation of unit
functions when the outriggers and tools/derrick selector
switch is placed in the Derrick position and the lower
control panel switch is placed in the Upper/Radio posi-
tion. Check all safety functions before working with the
remote control system. Refer to Section 4 under Daily
Preoperational Inspection.
Warning
soft surfaces.
properly set up.
Properly set up and start the unit.
Figure 6.6 Upper Control Panel
Slide Gate
Warning
Always check the capacity and range placards and associ-
ated notes on the unit before operating the radio remote
control system. Exceeding capacity limits indicated on
the placards could result in death, serious injury and/or
property damage.
Lower Remote Control
Warning
or lowering boom.
Docking Station
When using the lower remote control system from the
platform, place the transmitter in the docking station (refer
to Figure 6.7). The docking station disables the digger
and pole guide functions and actuates an interlock sys-
tem to help prevent unintentional actuation of the boom
positioning joysticks (boom/rotate or intermediate boom/
upper boom) while the unit is being operated from the
platform. To operate a boom positioning joystick when
the transmitter is installed in the docking station, push
down on the joystick before moving it out of neutral and
continue to hold it down while the joystick is shifted.
Figure 6.7 Docking Station
Warning
Death or serious injury can result from unexpected
movement. Place the transmitter in the docking sta-
tion before using it from the platform.
1. Place the top of the assembly over the lip of the
platform.
2. Slide the lock down knobs on each side of the station
up until the top bumpers meet the underside of the
platform lip. Tighten both lock down knobs.
3. Slide the transmitter anchors into the snap clips on
the top of the docking station.
4. Let the transmitter rest against the bumpers on the
outside of the platform.
Warning
movement. Turn the transmitter off or engage the
emergency stop when the transmitter is unat-
tended.
Start-Up Procedure
Turn the on/off key switch on the transmitter to the On
position (refer to Figure 6.8). A long beep and then a
short beep will be emitted and the green LED on the
transmitter control panel will fash, indicating a signal is
being transmitted.
Push the start/horn button on the side of the transmitter
and hold it in until the system enable horn sounds. The
remote control is now operational and the desired func-
tions can be operated.
If radio communication is interrupted due to interference
or distance between the transmitter and the receiver,
the remote control receiver stops sending signals to
all unit functions. The remote control system will stop
operation and must be reset by performing the start-up
procedure.
Emergency Stop
Push the emergency stop control on the transmitter con-
trol panel to immediately stop operation of all functions
from the receiver. Pull the control out to disengage the
emergency stop, and reset the transmitter by performing
the start-up procedure.
Auger Release
Push the auger release switch forward to retract the auger
latch when stowing and unstowing the auger. Releasing
the switch closes the latch. The switch is spring returned
to the original position when released.
Digger Speed
Push the digger shift switch forward to shift the digger
speed to high. Push the digger shift switch again to shift
the digger speed to low.
Transmitter
Bumper
Snap Clip
Lock
Down Knob
Platform
Lip
STANDARD
RAISE
CCW CW
ROTATE
LOW SPEED
AUGER
RELEASE
SHIFT
DIGGER
LOWER
BOOM
DIG
DIGGER
OPERATE
PUSH TO
ROTAFLOAT
CLOSE OPEN
POLE GUIDE
CLEAN
UPPER BOOM
RETRACT EXTEND
E
N
G
I
N
E
Stop
ON
OFF
T
O
O
L
S
T
H
R
O
T
T
L
E
STOP
START
WINCH
RAISE
BACK FWD
LOWER
POLE GUIDE
U
N
I
T
RET EXT
INTERM BOOM
STOP
(STOW) (UNSTOW)
Tools
The tools on/off switch starts and stops hydraulic oil fow
to the upper tool circuit. Push the switch forward once to
supply power to the tool circuit. Push the switch forward
again to cut off hydraulic power to the tool circuit. Always
turn the tool circuit off when not in use.
Low Speed/Standard
sitioning of the unit.
Moving the switch to the Standard position returns the
operation of the functions to the normal setting.
Notice
Shifting a mechanical two-speed digger while it is turning
may severely damage the diggers internal gears.
Digger Shake
The digger shake switch is a momentary push button
switch. Press and release the digger shake toggle switch
while the digger joystick is in the Dig position. This causes
the auger to rapidly reverse its direction of motion. This
rapid reversal of motion is used to clean the auger.
STANDARD
RAISE
CCW CW
ROTATE
LOW SPEED
AUGER
RELEASE
SHIFT
DIGGER
LOWER
BOOM
DIG
DIGGER
OPERATE
PUSH TO
ROTAFLOAT
CLOSE OPEN
POLE GUIDE
CLEAN
UPPER BOOM
RETRACT EXTEND
E
N
G
I
N
E
Stop
ON
OFF
T
O
O
L
S
T
H
R
O
T
T
L
E
STOP
START
WINCH
RAISE
BACK FWD
LOWER
POLE GUIDE
U
N
I
T
RET EXT
INTERM BOOM
STOP
O
I DIGGER
SHAKE
LML
OVERRIDE
ATB
OVERRIDE
Figure 6.8 Lower Remote Control System Transmitter
Start/Horn
Button
On/Off Key
Switch
Digger Shake
Button
ATB Override Button
(If So Equipped)
Load Moment Limiter
Override Button (If So Equipped)
Engine Start/Stop
The engine start/stop switch may be used to start and stop
the vehicle engine from the transmitter control panel.
Push the on/off switch forward until the engine starts.
Push the switch down to stop the engine.
Throttle
position selects the engine speed to Idle. The upper
position selects the engine speed to High.
speed can be obtained with the idle engine speed se-
lected. When operating the winch or digger functions,
or when operating two or more proportional functions at
the same time, it is necessary to select the low or high
engine speed to obtain maximum function speeds.
Joysticks
The joysticks (refer to Figure 6.8) control movement
of the boom, digger, winch, and pole guide functions.
They are spring-centered. The booms may be raised,
lowered, and rotated with the joystick on the left side of
the transmitter control panel. The second joystick from
the left extends and retracts the intermediate and upper
boom. The second joystick from the right operates the
pole guide functions. The joystick on the right side of
the transmitter control panel operates the digger and
the winch functions.
To operate a function, grasp the joystick and move it in
the desired direction. The boom, digger, and winch func-
tions will operate at a speed proportional to the distance
the joystick is moved. The pole guide functions are op-
erated by jogging the control to produce small amounts
of movement.
To operate a boom positioning joystick (boom/rotate or
intermediate boom/upper boom) when the transmitter is
installed in the docking station, push down on the joystick
before moving the it out of neutral and continue to hold
it down while the joystick is shifted.
Rotation Float
Rotation foat, if so equipped, is engaged by pushing
down on the digger control while operating the dig
function. This allows the unit to rotate toward a screw
anchor while using the digger to screw the anchor into
the ground. Refer to the Rotation Float System in this
section for more information.
ATB Override
The ATB Override switch, if so equipped, is a momentary
push button switch. If the ATB system has been actu-
ated, pressing the switch will activate the ATB override.
Releasing the switch will allow it to return to the neutral
position. An indicator light in the anti-two block side of
the override switch on the lower control panel will turn
on while the ATB override is actuated. The ATB will re-
main overridden until the two-block condition has been
removed. Refer to Anti-Two-Block in Section 5 under
Protection Systems for ATB operation.
Load Moment Limiter Override
The load moment limiter override switch, if so equipped, is
a momentary push button switch. If the unit has reached
the load moment limiter pressure, pressing the switch
will activate the load moment limiter override. Releasing
the switch will allow it to return to the neutral position.
An indicator light in the load moment limiter side of the
override switch on the lower control panel will turn on
while the load moment limiter override is actuated. The
load moment limiter will remain overridden until the load
moment pressure has been reduced below the load
moment limiter setting. Refer to Load Moment Limiter
in Section 5 under Protection Systems for load moment
limiter override operation.
Tilt Switch
The transmitter is equipped with a tilt switch that will
cause the transmitter to stop sending signals when it
is tilted more than 75 degrees in any direction for 4 to
5 seconds. The vehicle engine will continue to run, but
the units functions will not respond to movement of the
transmitter controls.
To make the transmitter operational, return it to a level posi-
tion and reset it by performing the start-up procedure.
Sleep Circuit
The transmitter is equipped with a sleep circuit that will
shut down the transmitter and vehicle engine automati-
cally. Shut down occurs when the engine rpm switch is
in the Idle position and the transmitter is not used for
approximately 10 minutes.
To reset the transmitter after it has entered the sleep
mode, turn it off and perform the start-up procedure.
Upper Remote Control
Warning
movement. Turn the transmitter off or engage the
emergency stop when the transmitter is unattended.
or lowering boom.
Docking Station
To use the upper remote control system, place the
transmitter in the docking station (refer to Figure 6.9).
The docking station actuates an interlock system to help
prevent unintentional actuation of the joysticks while the
unit is being operated from the platform. To operate a
joystick, push down on the joystick before moving it out
of neutral and continue to hold it down while the joystick
is shifted.
Figure 6.9 Docking Station
Warning
movement. Place the transmitter in the docking sta-
tion before using it from the platform.
1. Place the top of the assembly over the lip of the
platform.
2. Slide the lock down knobs on each side of the station
up until the top bumpers meet the underside of the
platform lip. Tighten both lock down knobs.
3. Slide the transmitter anchors into the snap clips on
the top of the docking station.
4. Let the transmitter rest against the bumpers on the
outside of the platform.
Start-Up Procedure
Turn the on/off key switch on the transmitter to the On
position (refer to Figure 6.10). A short beep will be emitted
and the green LED on the transmitter control panel will
fash, indicating a signal is being transmitted.
Push the start/horn button on the side of the transmitter
and hold it in until the system enable horn sounds. The
remote control is now operational and the desired func-
tions can be operated.
If radio communication is interrupted due to interference
or distance between the transmitter and the receiver,
the remote control receiver stops sending signals to
all unit functions. The remote control system will stop
operation and must be reset by performing the start-up
procedure again.
Emergency Stop
Push the emergency stop control on the transmitter con-
trol panel to immediately stop operation of all functions
from the receiver. Pull the control out to disengage the
emergency stop and reset the transmitter by performing
the start-up procedure.
Tools
The tools on/off switch starts and stops hydraulic oil fow
to the upper tool circuit. Push the switch forward once to
supply power to the tool circuit. Push the switch forward
again to cut off hydraulic power to the tool circuit. Always
turn the tool circuit off when not in use.
Low Speed/Standard
sitioning of the unit. Moving the switch to the Standard
position returns the operation of the functions to the
normal setting.
Engine Start/Stop
The engine start/stop switch may be used to start and stop
the vehicle engine from the transmitter control panel.
Push the switch forward until the engine starts. Push the
switch down to stop the engine.
Throttle
position selects the engine speed to idle. The upper posi-
tion selects the engine speed to high.
When operating a single boom function, full function speed
can be obtained with the idle engine speed selected.
When operating the winch function, or when operating
two or more proportional functions at the same time, it
is necessary to select the low or high engine speed to
obtain maximum function speeds.
Joysticks
The joysticks (refer to Figure 6.10) control movement of the
boom and winch functions. They are spring-centered.
Transmitter
Bumper
Snap Clip
Lock
Down Knob
Platform
Lip
To operate a function, grasp the joystick, push it down
before moving the joystick out of neutral and continue
to hold it down while moving it in the desired direction.
The functions will operate at a speed proportional to the
distance the joystick is moved.
A single extension control operates intermediate and up-
per boom extension and retraction because the booms
operate sequentially from the upper remote controls.
This means the upper boom will fully extend before the
intermediate boom begins to extend. In the retract direc-
tion, the intermediate boom will fully retract before the
upper boom begins to retract.
Tilt Switch
The transmitter is equipped with a tilt switch that will
cause the transmitter to stop sending signals when it
is tilted more than 75 degrees in any direction for 4 to
5 seconds. The vehicle engine will continue to run, but
the units functions will not respond to movement of the
transmitter controls.
To make the transmitter operational, return it to a level posi-
tion and reset it by performing the start-up procedure.
Sleep Circuit
The transmitter is equipped with a sleep circuit that will
shut down the transmitter and vehicle engine automati-
cally. Shut down occurs when the engine rpm switch is
in the Idle position and the transmitter is not used for
approximately 30 minutes.
To reset the transmitter after it has entered the sleep
mode, turn it off and perform the start-up procedure.
Battery Charger
The battery charger will restore the electrical charge
to the rechargeable transmitter batteries. The battery
charger automatically stops when the charging process
is complete. This allows the charged battery to be stored
safely in the charger until it is needed. When a battery is
placed in the charger, the Charge LED turns on to indi-
cate the battery is charging (refer to Figure 6.11). When
charging is complete, the Charge LED turns off and the
Ready LED turns on.
O
II
O
Figure 6.10 Upper Remote Control System Transmitter
STANDARD
RAISE
CCW CW
ROTATE
LOW SPEED
LOWER
BOOM
RETRACT EXTEND
E
N
G
I
N
E
Stop
T
H
R
O
T
T
L
E
STOP
START
WINCH
RAISE LOWER
U
N
I
T
STOP
ON
OFF
T
O
O
L
S
BOOM
Start/Horn
Button
On/Off Key
Switch
Figure 6.11 Radio Controls Battery Charger
A fast charge mode is available to reduce the charging
time for a depleted battery. Using the fast charge mode
is not recommended on a fully charged battery due to
the possibility of damage occurring to the battery. Press
the Fast Charge switch to activate the fast charge mode
after placing the depleted battery in the charger. The
Fast Charge LED will turn on in addition to the Charge
LED. When charging is complete, the Charge and Fast
Charge LEDs both turn off and the Ready LED turns on.
Booms
The booms may be operated using the lower control panel,
the upper control panel, or the radio control transmitter.
When operating one or more boom than one function
from the lower control panel or radio control transmitter,
the foot throttle or engine speed switch must be used as
described in the Foot Throttle, Engine Speed, or Throttle
section to obtain full function speed. Use the foot throttle
or engine speed switch just enough to allow for maximum
function speeds.
When starting and stopping any boom movement, me-
ter the hand control to avoid shock loads. This is very
important when handling heavy loads.
Lower Boom
The boom hand control is used to move the lower boom
through its arc of travel. Operation of the boom functions
valve to raise the lower boom directs hydraulic oil to
extend the lift cylinder. Operation of the boom functions
valve to lower the lower boom directs hydraulic system
oil to retract the lift cylinder.
The lift cylinder is held in position at all angles by a pilot
operated counterbalance holding valve located in the
base end of the lift cylinder. This valve prevents loss of
oil from the cylinder if hydraulic line failure occurs, thus
preventing free fall of the booms. Due to the counterbal-
ance valves load holding capability, it is necessary to
power the booms down, rather than allowing them to
lower by gravity.
Before handling a load, refer to the load capacity chart as
a guide or use the boom raise capacity test to determine
whether the load is within the rated hydraulic capacity of
the derrick. The boom raise capacity test is described in
Section 4 under Capacity and Stability. The boom lower
function is one of the functions that is temporarily turned
off when the HOP system is activated due to an overload.
Section 5 under Hydraulic Overload Protection (HOP)
describes the operation of this system.
Consult the load capacity chart to determine if reposition-
ing the vehicle or booms will allow the load to be lifted.
Use extreme caution when lowering the booms with a
load on the winch line. The units capacity and stability
decrease as the booms are lowered. While lowering the
boom with a load, refer to the load capacity chart and
use the boom raise capacity test at several points to
make sure that the hydraulic capacity of the unit is not
exceeded. Be aware of the stability limits of the particular
unit. Read and understand Section 4 under Capacity
and Stability.
Warning
fail and load/hook block to fall. Do not allow the
hook block to contact the boom tip by hoisting up,
extending, or lowering the boom.
As the boom is lowered on a turntable winch unit, pay
out the winch line to compensate for the increased rope
length required between the winch drum and the boom
tip sheave. If the winch line is not payed out suffciently
during boom lowering, the winch line hook will catch on
the boom tip. If the hook catches on the boom tip, damage
to the unit or breaking of the winch line could result.
Notice
Side loading will result if the winch line becomes
tight at a side angle while raising the booms, which
Before lifting any load, rotate the booms to the load
to prevent the winch line from pulling sideways on the
booms.
CHARGE
READY
FAST CHARGE
Indicator
LEDs
Fast Charge
Button
Battery
Pocket
Notice
Applying excessive downward force causes side
loading to develop on the booms, which can dam-
age the unit.
During digging operation, applying too much downward
force with the boom lower function may cause the au-
ger to corkscrew into the ground. This means the auger
acts like a screw, rather than cutting the soil loose for
the fights to pick up. If the auger begins to corkscrew,
shift the digger hand control to the Clean position. Back
the auger out of the hole until normal digging can be re-
sumed. Avoid corkscrewing the auger because it creates
great stress on the booms. It is especially important to
avoid corkscrewing the auger when it is positioned at a
side angle to the boom. This may cause side loading to
develop on the booms.
Screw anchors are designed to corkscrew into the ground.
When setting screw anchors, use the boom hand control
to follow the anchor as it advances into the ground. This
prevents the screw anchor from pulling downward on
the booms.
Intermediate and Upper Booms
The intermediate boom is a box type design. When oper-
ated, the intermediate boom extends from and retracts
into the lower boom. The upper boom is a fberglass
boom and is hydraulically operated. It is equipped with
a fberglass boom tip. When operated, the upper boom
extends from and retracts into the intermediate boom.
The fberglass upper boom is a full capacity boom. This
means the upper boom, when fully extended, can lift
the maximum rated capacity of the unit. This feature is
especially useful when working near energized conduc-
tors with an insulated unit.
Danger
or proximity to equipment that has become electri-
cally energized. Maintain safe clearances from all
energized conductors and any grounded device,
material, or equipment.
The fberglass upper boom, when properly used and
maintained, as determined by dielectric testing, may be
used for work around energized conductors. A minimum
extension placard on the upper boom is provided as a
guide for the operator to use in obtaining the extension
distance of the fberglass boom required to obtain sec-
ondary dielectric protection. The upper boom must be
extended so the minimum extension placard is beyond
the farthest extent of all metal components on or attached
to the intermediate boom tip, as shown in Figure 4.1.
On the lower control panel, the intermediate and upper
boom hand controls operate the telescoping action of the
hydraulically extendible intermediate and upper booms.
On the upper control panel, a single extension control
handle operates the sequential telescopic action of the
intermediate and upper booms. A joystick operates the
intermediate and upper boom functions from the radio
control transmitter.
The term sequential means 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. Sequen-
tial boom extension is operational only from the upper
controls and the upper remote control.
The intermediate and upper boom extension cylinders
are equipped with double pilot operated counterbal-
ance holding valves. The counterbalance valves hold
the extension cylinders in any desired extension length.
The counterbalance valves prevent loss of oil from the
cylinders if hydraulic line failure occurs, thus preventing
accidental retraction of the booms.
Caution
controls smoothly.
Avoid sudden starts, stops, or direction reversals of the
intermediate and upper boom controls. Be especially
careful of sudden movements when the digger is being
transferred to and from the intermediate boom. Sudden
movements of the hand control while transferring the
digger may cause shock loads to develop.
Warning
or lowering boom.
As the booms extend (upper boom on boom tip winch
models, intermediate and upper boom on turntable winch
models), pay out the winch line to compensate for the
increased rope length required between the winch drum
and the boom tip sheave. If the winch line is not payed
out suffciently during boom extension, the winch line
hook will catch on the boom tip. If the hook catches on
the boom tip, damage to the unit or breaking of the winch
line could result.
Use caution when extending the booms with a load
on the winch line. Unit capacity decreases as the load
moves farther away from the units centerline of rotation.
Determine whether the load is within the load capacity
of the unit by referring to the capacity chart and using
the boom raise capacity test at several points along the
extension. Following the values in the capacity chart will
insure that the stability limit of the unit is not exceeded
as the load moves outward.
Notice
Follow the procedure for transferring the boom
fares and pole guide assembly to prevent damage
to the unit.
Tilt the pole guide back and properly pin the transferable
upper controls to the upper boom or transferable fares,
before extending the upper boom with the transferable
fares pinned to or permanently mounted on the inter-
mediate boom.
Transferable Upper Controls in this section, describes
how to properly pin the transferable upper controls.
Boom Storage
Warning
unstable. Properly stow the boom before raising the
outriggers.
When stowing the booms for transportation, frst fully
retract the intermediate and upper booms. If the unit is
equipped with a personnel platform, properly stow the
platform and lock the platform brake as described under
Personnel Platform in this section. Then position the lower
boom carefully in the boom rest.
When stowing the lower boom, lower it into the rest gently.
The boom and rest are protected by the boom stow pro-
tection system described in Section 5. When the system
is engaged, it shuts off the boom lower function.
Notice
Meter the lower boom control to slow the speed of
the lower boom to avoid shock loads as the boom
contacts the rest.
Damage to the unit can result if the lower boom
bounces during road travel. Stow the lower boom
frmly in its rest.
Rotation
The unit can be rotated through 360 degrees continuously
after the booms are elevated out of the boom rest. There
is no restriction in either direction.
The rotation hand control is used to rotate the turntable
to the right (clockwise) or to the left (counterclockwise).
Avoid rapid starts, stops and reversal of directions to
minimize shock loads to the unit.
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.
There are several precautions that must be observed
when handling a load while rotating the turntable and
booms. Before lifting the winch line, rotate the booms to
the load. Rotating the booms to the load will prevent the
winch line from pulling sideways on the booms. Never
winch a load in from the side if the rotation function does
not have the power to rotate the load.
Warning
unstable. Make sure the unit is stable before rotat-
ing a load.
Before rotating a load that is lifted off the ground, be
certain there is adequate stability for the load.
Interlock System
On units with out and down outriggers, the rotation in-
terlock system, if so equipped, prevents the booms from
being rotated to a side of the vehicle (street or curb side)
that does not have the horizontal outrigger legs fully
extended. This system also disables the boom functions
until all vertical outrigger legs have been lowered.
This system allows the unit to be operated in narrow open-
ings since the outriggers on the side (street or curb side)
opposite the load do not have to be extended out, though
they must be lowered. If the operator attempts to rotate to
the side that the horizontal outrigger legs have not been
extended, the rotation interlock will stop rotation in that
direction. The turntable may then be rotated back to the
side of the vehicle that has the horizontal outrigger legs
fully extended. Alternatively, the booms may be stowed
and the outriggers may be extended on the side (street
or curb side) to which the work is to be done.
Winch
The unit may be equipped with a boom tip winch or a
turntable winch. The winch can be controlled from the
lower control panel, the upper control panel, or the radio
control transmitter.
The winch remains operational when the outriggers and
tools/derrick selector switch is in the Outriggers and Tools
position. This facilitates certain lower tools operations
which are aided by use of the winch.
Shifting the winch hand control in the Raise position pays
in the winch line. Shifting the winch hand control in the
Lower position pays out the winch line. Meter the winch
hand control when starting, stopping, or reversing direc-
tions to minimize shock loads on the unit.
When operating the winch from the lower control panel
or radio control transmitter, the foot throttle or engine
speed switch must be used as described in the Foot
Throttle, Engine Speed, or Throttle section to obtain full
function speed.
Warning
Death or serious injury can result from falling loads.
Winch cable anchors are not designed to hold rated
capacity. Keep a minimum of fve wraps on the drum.
Keep a minimum of fve wraps of winch line on the winch
drum at all times.
The winch raise circuit is equipped with a holding valve to
hold the position of the load after the control is returned
to neutral.
Warning
Never lift an unknown load. Determine the weight of the
material before moving it. Use the placards, charts, and
gauges provided on the unit to determine the available
load capacities.
Warning
breaks. Stay clear of a load that is being moved or
lifted.
Do not attempt to physically assist the lifting device.
Caution
Injury and property damage can result from loss of
load control. Use tools specifcally designed for and
properly attached to the lifting device when lifting
materials.
Notice
Plan work procedures and mentally walk through
them before moving or lifting any load.
Before using the winch raise function to lift a load, use
the capacity chart to determine if the load is within the
load capacity of the unit. The boom raise capacity test
may be used to determine if the load is within the rated
hydraulic capacity of the unit. In some boom positions, the
rated capacity of the winch will be greater than the load
capacity of the unit. The capacity of the winch is stated
on the capacity placard near the lower controls.
Warning
fail and load/hook block to fall. Do not allow the
hook block to contact the boom tip by hoisting up,
extending, or lowering the boom.
As the booms extend (upper boom on boom tip winch
models, intermediate and upper boom on turntable winch
models), pay out the winch line to compensate for the
increased rope length required between the winch drum
and the boom tip sheave. Also as the boom is lowered
on a turntable winch unit, pay out the winch line to com-
pensate for the increased rope length required between
the winch drum and the boom tip sheave. If the winch
line is not payed out suffciently during boom lowering,
the winch line hook will catch on the boom tip. If the hook
catches on the boom tip, damage to the unit or breaking
of the winch line could result.
When raising the winch line with a load, do not use the
HOP system to determine the load the unit will lift. The
HOP is intended to prevent overloading of the unit due
to operator error when lifting a load. Each time the HOP
system operates, the unit is subjected to an overload.
Repeated overloads could cause component failure.
Section 5 under Hydraulic Overload Protection (HOP)
describes the HOP system.
When lifting a load with the winch, operate the winch in a
manner that avoids side loading the booms. Always rotate
the booms to the load before lifting it. If the rotation system
does not have enough power to rotate the load around,
do not attempt to winch the load in from the side.
Notice
Do not rely on the side load protection system to prevent
side loading of the booms. The protection system is
intended to prevent side loading due to operator error.
Each time this protection system operates, the unit is
overloaded. Repeated overloads may cause component
failure. This system is described in Section 5 under Side
Load Protection.
Notice
When the hydraulic side load protection system operates,
the booms will sideslip, or rotate, toward the load. Never
attempt to counteract this sideslip by shifting the rotation
hand control in the opposite direction of the sideslip.
Notice
Notice
When the electronic side load protection system engages,
remove the side load from the booms before operating
any function that would cause increased loading of the
booms.
Notice
Property damage can result from using the winch to
pull a pole that is frmly set in the ground.
Do not use the winch to pull a pole that is frmly set in
the ground. Attempting to pull a pole that is frmly set in
the ground could overload the unit.
Use the pole puller to break the pole loose from the
ground before using the winch to pull the pole out of the
ground. The pole puller is described under Pole Puller
in this section.
Warning
breaks. Stay clear of a load that is being moved or
lifted.
Death or serious injury can result from improper use
of the jib or winch. Never use a material handling jib
or winch to lift personnel.
Never stand or walk on or beneath a load that is being
moved or lifted. Never use a material handling jib or
winch to lift personnel.
Use caution and common sense when lifting a load with
the winch. Ground personnel must stay in clear view of
the operator and clear of the load and winch line.
Warning
a moving winch hook. Maintain a safe distance from
the winch hook after removing it from a load.
Before removing the load hook from a load, always relieve
all of the tension on the winch line. Releasing the load
hook before all of the tension on the line is relieved may
cause uncontrolled movement of the load hook.
Warning
Death or serious injury can result from using a winch
hook that is overloaded. Make sure that the hook is
marked with the rated load.
Death or serious injury can result from an improperly
secured load. Use a winch hook with an operational
throat latch mechanism.
Death or serious injury can result from an improperly
secured load. Never wrap the winch line around the
load or use it as a sling to secure the load.
Winch Line
Warning
contacts an energized conductor and a ground. Do
not allow the winch line to contact an energized
conductor.
The winch drum is designed to accommodate either wire
rope or synthetic rope. The rated working load of the
winch line may limit the loads lifted by the unit.
The winch line rated working load is stated on the ca-
pacity placard near the lower control station. Winch line
rated working load is the average breaking strength of
the winch line (as specifed by the line manufacturer) di-
vided by the appropriate design factor. The design factor
for synthetic-type ropes and rotation-resistant-type steel
ropes shall not be less than fve. The design factor for
standard-type steel ropes shall not be less than 3
1
/2. The
rated working load of the line will vary depending on the
type and size of the line. If the winch line was provided
by Altec Industries, contact your Altec representative
for information concerning the rated working load of the
winch line. If the winch line was provided by an alternate
source, contact the winch line manufacturer concerning
the rated working load of the winch line.
Depending on the rated working load of the winch line,
a multiple part load line may be required to fully utilize
the load capacity of the unit.
ANSI requires the use of a multiple part winch line for
loads that exceed the winch line rated working load. The
winch line rated working load must be greater than or
equal to the load weight divided by the number of parts
of winch line.
The unit is equipped with a multiple part winch line anchor
point at the end of the intermediate boom. Figure 6.12
illustrates a multiple part winch line. A snatch block and
clevis are needed to utilize a multiple part winch line.
Figure 6.12 Multiple Part Winch Line
Warning
Death or serious injury can result if the snatch block
or clevis break loose and load control is lost. Use a
snatch block with a rated working load greater than
or equal to the maximum load weight which will be
lifted. Use a clevis with a rated working load greater
than or equal to the maximum load weight which will
be lifted divided by the number of parts of line.
Snatch blocks and clevises vary depending on capac-
ity. Be sure to use a snatch block with a capacity that
meets or exceeds the maximum load weight which will
be lifted. Be sure to use a clevis with a capacity that
meets or exceeds the maximum load weight which will
be lifted divided by the number of parts of line. Snatch
blocks and clevises of various capacities are available
from your Altec representative.
When using a multiple part winch line, the upper boom
must be fully retracted if the anchor point is on the end
of the intermediate boom. A statement referring to this
can be found on the placard near the capacity placard
at the lower control station.
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.
Warning
a moving winch hook. Maintain a safe distance from
the winch hook after removing it from a load.
Use a swivel hook with wire rope. If wire rope becomes
twisted, it can store great amounts of energy that is
released when the load is unhooked from the winch
line. This energy can cause the load hook to bounce
around, resulting in serious injury. Utilizing a swivel hook
on the end of the winch line helps prevent the line from
twisting. If a swivel hook is used, it must have a load
hook rating greater than or equal to the winch line rated
working load.
Warning
breaks. Replace a worn or damaged winch line.
Inspect the winch line daily as described in Section 4
under Daily Preoperational Inspection. If the line shows
any sign of wear, a thorough inspection of the entire winch
line (as described in the Maintenance Manual) is required.
Winch line replacement criteria must be consistent with
the winch line manufacturers recommendations.
Snatch Block
Clevis
Digger
The unit may be equipped with one of two types of dig-
gers: a two-speed digger that is mechanically shifted by a
hydraulic cylinder or a two-speed digger with a hydraulic
two-speed motor. The digger may be mounted on either
side of the boom.
To determine the type of two-speed digger mounted on
the unit, look inside the access hole on the digger bail
(refer to Figure 6.13). If a small hydraulic cylinder is
seen, the unit is equipped with a two-speed digger that
is mechanically shifted by this hydraulic shift cylinder. If
the unit does not have a shift cylinder, it is equipped with
a two-speed digger that is hydraulically shifted by a two-
speed motor. Units equipped with a shift cylinder have
a placard located near the lower control panel warning
the operator against shifting the digger while it is turning.
The digger controls may be operated from the lower
control panel or the radio control transmitter. They are
the digger shift switch, digger hand control, auger release
switch, and the digger shake switch.
The digger hand control rotates the auger in the dig or
clean direction. The dig direction, as viewed from above
the auger, is clockwise. The clean direction, as viewed
from above the auger, is counterclockwise.
When operating the digger from the lower control panel
or radio control transmitter, the foot throttle or engine
speed switch must be used as described in the Foot
Throttle, Engine Speed, or Throttle section to obtain full
function speed.
The auger release switch is used to retract the auger
latch when stowing and unstowing the auger.
The digger shake switch is used to remove dirt from the
auger. The digger shake switch causes rapid reversal of
auger motion, causing dirt to fall off the auger fighting.
The digger hanger bracket is equipped with a digger
transfer mechanism. The digger transfer mechanism
consists of a latch weldment on the digger hanger bracket
and a latch keeper welded to the lower boom. When the
digger is stowed, the digger transfer mechanism locks
the digger hanger bracket to the lower boom. When the
digger is unstowed, the mechanism automatically trans-
fers the bracket from the lower boom to the intermediate
boom. In order for the digger transfer mechanism to work
properly, 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 operator
extends the intermediate boom to position the auger for
digging, the digger will be left behind. If this happens, the
intermediate boom may be retracted without frst stowing
the digger. This allows the lug on the digger hanger bracket
latch to enter the slot in the intermediate boom.
Auger Stow Bracket
Auger Windup Sling
Auger Tube
Auger Latch
Section A-A
Digger Bail
Digger
Shift Cylinder
Auger
Lug
Cable Guide
Dish
Auger Extension Shaft
Cap
Screw
Auger Tube
Digger Link
Digger Bail
Figure 6.13 Digger and Related Components
Digger Hanger Bracket
Warning
Death or serious injury can result if the auger sling
breaks. Replace a worn or damaged auger sling.
Notice
system.
If a wire rope auger windup sling shows signs of wear
and/or four or more broken wires, replace it immediately.
If a synthetic auger windup sling has cut strands and/or
external wear, replace it immediately. A worn auger windup
sling could fail causing a free swinging auger. Section 4
under Daily Preoperational Inspection describes how to
inspect the auger windup sling.
When the digger is stowed, the digger holdback latch
holds the hanger bracket against the lower boom as the
intermediate boom is extended (refer to Figure 6.14).
Any binding or other problem that could cause enough
force to make the hanger bracket jump past the holdback
latch must be corrected immediately. If the digger hanger
bracket jumps past the digger holdback latch, it could
cause damage to the digger link and other components.
Unstowing
1. Position the unit on a level surface, apply the parking
brake, and chock the wheels. Engage the PTO and
properly set the outriggers.
2. Raise and rotate the booms high enough so that
when the digger is lowered, it will clear the vehicle,
obstacles, and all personnel.
Warning
Death or serious injury can result from being hit by a
swinging auger. Never walk or stand near the boom
when using the auger.
All personnel must be clear of the area before stowing
or unstowing the auger.
3. Make sure the intermediate boom is fully retracted.
If the intermediate boom is not fully retracted, the
digger transfer mechanism will not attach the digger
hanger bracket to the intermediate boom.
Warning
swinging auger. Select low digger speed and meter
the digger control when stowing or unstowing the
auger.
A two-speed digger should be in low digger speed when
unstowing the auger.
4. Make sure the digger is in low speed.
5. Shift the digger hand control slightly in the Dig position.
Do this until the auger rolls up enough to remove any
slack in the auger windup sling and take the weight
off the auger latch (refer to Figure 6.13).
6. On some chassis, it may be necessary to use the foot
throttle or engine speed switch to increase the engine
speed to maintain pressure to operate the digger
and latch at the same time. Press the auger release
switch. The latch will retract from under the auger
tube. Continue to hold the auger release switch.
7. Shift the digger hand control slightly in the Clean posi-
tion until the auger begins to unroll from the windup
sling. When the auger clears the latch, release the
auger release switch.
Figure 6.14 Digger Link in Stowed Position
Section A-A
Digger Link
Digger Hanger
Bracket
Intermediate Boom
Lug
Latch
Keeper
Digger Holdback
Bracket
Digger Hanger
Bracket Unlatched
From Latch Keeper
A
A
8. Continue operating the digger slowly in the Clean
position until the auger windup sling swings free of
the auger.
Operation
The use of the digger will vary depending on the particu-
lar job that is being performed and the soil conditions.
However, there are general operational practices that
should be followed when digging holes. The following
paragraphs describe practices that will enhance digger
operation and allow for safe operation.
Once the digger is unstowed, the intermediate boom and
rotation controls may be used to position the digger.
Notice
age the unit.
Digging is most effcient when a relatively steady down-
ward force is kept on the auger. Do this by metering the
boom hand control to the Lower position while operating
the digger hand control. Coordinate the boom and digger
controls to exert various amounts of force and speed as
needed for soil conditions.
Too much downward force with the boom lower function
may cause the auger to corkscrew into the ground. This
means the auger acts like a screw, rather than cutting
the soil loose for the fighting to pick up. If the auger
begins to corkscrew, shift the digger hand control to
the Clean position. Back the auger out of the hole until
normal digging can be resumed. Avoid corkscrewing the
auger because it creates great stress on the booms. It
is especially important to avoid corkscrewing the auger
when it is positioned at a side angle to the boom. This
may cause side loading to develop on the booms.
Use the boom lower, rotation, and intermediate boom
extend functions to follow the auger as it advances into
the ground. This is especially important when digging
with the auger positioned at a side angle to the boom. An
angled auger creates a greater possibility of developing
side load. Do not rely on the side load protection system
to prevent side loads from developing on the booms.
The side load protection system is intended to protect
the unit from excessive side load due to operator error
when digging or winching. Each time the side load protec-
tion system operates, the unit is overloaded. Repeated
overloads may cause component failure.
Notice
Notice
When the electronic side load protection system has
engaged the HOP system, remove the side load from
the booms before operating any function that would
cause increased loading of the booms.
remove the side load from the booms before operating any
function that would cause increased loading of the booms.
Use the intermediate boom extend function to maintain
alignment between the hole and auger shaft. If alignment
is not maintained, the auger or auger extension shaft could
bend. If the auger or auger extension shaft bends, stop
the operation of the auger immediately. A bent auger or
auger extension shaft must be straightened or replaced
immediately.
Notice
Do not operate the unit with a bent auger or auger
extension shaft.
Use caution when stowing an auger with a bent auger
or auger extension shaft. The auger may not enter the
stow bracket during stowing, causing the windup sling
or the clevis shear pin to fail.
If the unit is equipped with a two-speed digger that is
shifted mechanically by a hydraulic cylinder, use the
digger shift switch to shift between low and high digging
speeds. Place the digger hand control in neutral and wait
for the digger to stop turning. Move the digger shift switch
in the desired direction. Move the digger shift switch to
the High position and release it to shift the digger to high.
A red indicator light comes on when the digger speed is
in high. Move the digger shift switch to the High position
again and release it to shift the digger speed to low. The
digger control must be in neutral for the digger to shift
speeds. Operating the digger shift switch with the control
in any other position will not shift the digger.
Notice
If the unit is equipped with a two-speed digger that is
shifted mechanically by a hydraulic cylinder, do not change
digging speeds until the digger has completely stopped.
Shifting a mechanical two-speed digger while it is turning
may severely damage the diggers internal gears. This
type of digger has an electrical interlock circuit to help
prevent shifting while the digger control is operated.
If the unit is equipped with a digger that has a hydrauli-
cally shifted two-speed motor, use the digger shift switch
to shift between low and high digging speeds. The switch
may be operated with the digger hand control in any
position. This type of digger is designed to be shifted
while it is turning.
If the unit is equipped with a two-speed digger, always
return the digger speed to low when not using the high
speed. If the unit is equipped with dual controls, always
return the digger speed to low on the control panel in use
before leaving that panel to work from the other panel.
Notice
Excessive engine speeds can result in accelerated
component wear.
Use the foot throttle or engine speed switch just enough
to allow for maximum function speeds.
When digging in hard soil conditions, it may be necessary
to continually operate the digger control in the Dig position.
If this occurs, do not allow the hydraulic oil temperature
to exceed 195 degrees Fahrenheit (91 degrees Celsius)
for summer weight oil and 160 degrees Fahrenheit (71
degrees Celsius) for winter weight oil. At these high tem-
peratures and above, there is accelerated wear on the
pump and motor. Also, seals in the hydraulic system begin
to wear more rapidly and the hydraulic oil deteriorates.
When the auger fighting is loaded with soil, raise the
auger above the ground with the auger turning slowly.
Move the digger shake switch back and forth. This will
normally remove the soil from the auger fighting. The
operator may also move the digger shift switch to the
High position and operate the throttle at high speed to
increase the auger speed to remove the soil.
Caution
Injury can result from being pinched or trapped be-
tween moving components. Keep hands clear.
Keep hands and fngers clear when positioning the au-
ger on the extension shaft and aligning the holes for the
retaining cap screw.
The depth of a hole may be increased by repositioning the
bolt at the top of the auger tube. Remove the cap screw
at the top of the auger tube (refer to Figure 6.13). Shift
the boom hand control in the Raise position and pull the
auger extension shaft up. Replace the cap screw in one
of the lower holes in the auger extension shaft.
Warning
Always return the auger to its original top position on the
auger extension shaft before stowing the auger. Attempt-
ing to stow the auger with the auger extension shaft bolt
in a lower position may cause failure of the auger windup
sling and damage to the turntable. A failed windup sling
could cause a free swinging auger.
Different sizes of augers are available. Use caution when
removing or installing an auger.
Warning
Death or serious injury can result from being hit
by a falling auger. Properly support the auger to
prevent it from falling or rolling during removal or
installation.
Death or serious injury can result from uncontrolled
movement. Properly support the auger before remov-
ing the retaining cap screw.
Death or serious injury can result from accidental
movement. Make sure the auger control is disengaged
while removing and installing the auger.
Caution
Injury can result from slipping and falling. Use a
stable work platform when removing or installing
the auger.
Injury can result from being pinched or trapped be-
tween moving components. Keep hands clear.
Keep hands and fngers clear when positioning the au-
ger on the extension shaft and aligning the holes for the
retaining cap screw.
Setting Anchors
The digger assembly is ideally suited for installing screw
anchors by using special driving tools supplied by the
anchor manufacturer.
Notice
age the unit.
Since screw anchors are designed to corkscrew into the
soil, they can exert tremendous amounts of down pull and
side load on the unit. The unit is equipped with protection
systems to prevent excessive side loads and down pulls
from damaging the unit. However, the life of the unit will
be prolonged if the operator will use the boom, rotation,
and intermediate boom functions to follow the anchor as
it advances into the ground.
Notice
Notice
remove the side load from the booms before operating any
function that would cause increased loading of the booms.
Notice
Side loads may be caused by a variety of operations. One
of those operations is failing to follow the movement of a
screw anchor with the boom, rotation, and intermediate
boom controls. Side loads can also be caused by lower-
ing the boom against an auger or screw anchor that is
angled to the side of the boom.
Rotation Float System
The rotation foat system operates with the side load
protection system to help the operator prevent damage
to the unit when a side load is developed on the booms
while operating the digger.
Operate the rotation foat system by holding the rotation
foat switch while operating the digger control. A horn will
sound to alert the operator that the rotation foat system
has been activated.
Warning
movement of the unit. Do not engage the rotation
foat system if the unit is on a slope and the screw
anchor is not engaged in the soil.
The rotation foat system allows hydraulic oil to fow be-
tween the work ports of the rotation motor. This allows
the turntable to rotate slowly to follow the installation of
a screw anchor. If the switch for the rotation foat system
is not activated, the unit will operate using the side load
protection system to help prevent damage to the unit.
Warning
movement. Do not operate the unit if the rotation foat
system is not operating properly.
The rotation foat system should only operate when the
switch is pushed and the digger control is operated. If
the indicator light and the audible alarm remain on all the
time, the system may be energized. When the system is
energized, the turntable may rotate.
Use the following procedure to temporarily disable the
system.
1. Locate the rotation foat system solenoids (refer to
Figure 6.15) on the rotation gearbox motor valve
blocks at the rear of the turntable.
Figure 6.15
Rotation Gearbox Motor Valve Blocks
2. Disconnect the solenoid wiring connectors from both
solenoids.
Stowing
Augers that are up to 36 (91.44 cm) in diameter may
be stowed on the standard unit. The auger stow bracket
is equipped with a feature that alerts the operator if the
auger windup sling is becoming overloaded. This feature
consists of a windup sling clevis held in position by a
clevis shear pin.
Warning
Solenoid
If the clevis shear pin fails during stowing, use caution
while continuing to stow the auger. The auger windup sling
may fail, which could result in a free swinging auger.
As shown in Figure 6.16, the shear pin normally holds
the windup sling clevis in a horizontal position. If the
windup sling is overloaded during stowing of the auger,
the clevis shear pin will fail before the sling is damaged.
When the clevis shear pin fails, the windup sling clevis
tilts to a vertical position. When the clevis tilts vertically,
the auger will drop a few inches with a jolt. This action
will alert the operator that the windup sling is overloaded.
Determine the cause of the clevis shear pin failure and
replace the clevis shear pin immediately.
Use the following procedure to stow the digger.
1. Fully retract the intermediate boom. Stowing the
digger with the intermediate boom partially extended
may cause the auger fighting to hit and damage the
auger stow bracket.
Warning
swinging auger. Select low digger speed and meter
the digger control when stowing or unstowing the
auger.
A two-speed digger should be in low digger speed when
stowing the auger. If the digger is not in low speed, the
auger will roll up too rapidly. Rolling the auger up too
rapidly may cause shock loading, resulting in failure of
the windup sling or clevis shear pin.
2. Move the digger shift switch to the Low position.
3. Rotate the boom to a position that will allow the boom
and auger to clear all obstacles when the digger is
stowed.
4. Shift the boom hand control to lower the point of the
auger to the ground.
5. Hook the loop at the end of the auger windup sling
on the lug on the auger (refer to Figure 6.13).
6. Operate the digger hand control slightly in the Dig
position and raise the booms. Make certain the sling
continues to wrap around the auger tube below the
cable guide dish (refer to Figure 6.13).
Warning
The digger hand control must be metered as the auger
enters the stow bracket. Failure to meter the hand control
may cause the auger to roll up too rapidly. Rolling the
auger up too rapidly could cause shock loading, resulting
in failure of the windup sling or clevis shear pin. A failed
windup sling may result in a free swinging auger.
7. Continue rolling the auger up slowly using the digger
control. On some chassis, it may be necessary to use
the foot throttle or engine speed switch to increase
the engine speed to maintain pressure to operate
the digger and latch at the same time. When the
auger tube is close to the auger stow bracket, use
the auger release switch to retract the latch as the
auger tube enters the auger stow bracket.
Clevis Shear Pin Failed
Auger Stow
Bracket
Auger Windup Sling
Clevis Clevis Shear Pin Intact
Figure 6.16 Windup Sling Clevis and Clevis Shear Pin
The controls for the pole guide are on the lower control
panel and the radio control transmitter. The pole guide
forward/back control tilts the pole guide through its range
of motion. The pole guide open/close control operates
the motion of the pole guide tongs.
Notice
to the unit.
mediate boom.
The transferable boom fares and pole guide assembly
must be pinned to the upper boom before using the pole
guide. Transferring this assembly is described under Boom
Flares in this section. Transferable Upper Controls in this
section describes how to properly pin the transferable
upper controls.
Interlock System
There are three electrical switches that sense the posi-
tion of the pole guide and detent pin. This system helps
prevent damage to the pole guide, boom tip, and upper
boom.
The pole guide interlock system will not allow the upper
boom to extend when the pole guide and transferable
fares assembly are pinned to the intermediate boom un-
less the pole guide is fully stowed. The interlock will not
allow the pole guide to be tilted down if the transferable
fare assembly is pinned to the intermediate boom and
the upper boom is extended. This prevents damage to
the pole guide, boom tip, and upper boom.
Boom Flares
The unit is equipped with boom fares that are transfer-
able. The boom fares are designed to take the majority
of the poles weight when handling a pole. The fares also
prevent the pole from contacting the fberglass boom tip,
thus preventing damage to the boom tip.
Transferable boom fares allow the fares to be pinned
to the end of the intermediate or upper boom. The trans-
ferable boom fares and the pole guide are mounted on
the same weldment, allowing them to be transferred as
one assembly.
When working near energized conductors, the boom
fares may be pinned to the end of the intermediate
Warning
Immediately shift the digger hand control to neutral after
the latch closes under the auger tube. If the hand control
is not immediately returned to neutral and the auger stow
protection system is improperly adjusted or malfunctions,
the windup sling or the clevis shear pin could fail. A failed
windup sling may result in a free swinging auger.
8. When the auger tube is just above the top of the
latch, return the auger release switch to neutral to
close the latch under the auger tube. Immediately
shift the digger hand control to neutral.
Pole Guide
The pole guide is part of a transferable assembly. The
boom fares and pole guide are transferable between the
intermediate and upper booms.
Caution
Injury and property damage can result from improper
use of the pole guide tongs. Do not grasp the pole
tightly with the pole guide tongs.
Do not use the pole guide to clamp the pole tightly or to
lift any of the pole weight. The pole guide may be used,
along with the winch and boom fares, to set a pole. The
pole guide tongs open to encircle the pole and close
around the pole to keep it in position. The pole guide can
be tilted forward and back to maintain the tongs horizontal
to the midsection of the pole. Figure 6.17 shows the pole
guide assembly.
Figure 6.17 Pole Guide Assembly
The pole guide tongs are intended to be used as a guide
only. When handling a pole, let the boom fares take most
of the pressure of the pole and use the winch line to do
the lifting. Do not use the pole guide to clamp the pole
tightly or to lift any of the pole weight.
Transferable Upper Controls in this section describes how
to properly pin the transferable upper controls.
Pole Puller
The pole puller may be used to break a pole loose from
the ground. After the pole is loose in the ground, use the
winch raise and boom raise functions to pull the pole out
of the ground. Using the pole puller will avoid placing
excessive loads on the unit.
Use the following procedure to use the pole puller and
minimize the risk of serious injury and damage to the
pole puller or chain.
1. Do not pull a pole that is not within the units load
capacity. It may be necessary to reposition the booms
so the load is within the units load capacity.
Danger
The booms must not be elevated near energized con-
ductors when operating the lower tool system. The lower
tool system hoses may be wire braid reinforced. Wire
reinforced hoses are conductive to any electrical charge
on the unit.
2. Before using the pole puller, make sure the booms
are not elevated near unprotected energized lines.
3. Make sure the ground around the pole is level. If
the ground is not level, use a shovel to make a level
area. If the ground cannot be made level or if it is
soft, block up the base of the pole puller, until it is
level. Do this by placing suitable material, such as
wood or outrigger pads, under the base of the pole
puller. The entire base of the pole puller must be
frmly supported to prevent bending of the pole puller
base.
4. Position the base of the pole puller on the ground,
next to the base of the pole. Position the round bar
on top of the base next to the pole (refer to Figure
6.19).
5. Position the pole puller cylinder on the base with the
curved bracket at the bottom of the cylinder over the
round bar.
6. Place the D-ring on the pole puller chain over the lug
on the rod end of the cylinder.
boom to minimize the amount of steel at the boom tip
and to provide a smaller boom tip profle. When handling
poles, the transferable fares must be pinned to the up-
per boom. This places the steel fares and pole guide at
the boom tip when the upper boom is extended. It also
protects the fberglass boom tip from damage due to
contact with a pole.
Transferring the Boom
Flares and Pole Guide Assembly
A retaining pin holds the transferable boom fares and
pole guide assembly at the end of the intermediate or
upper boom. There are two retaining pin hole locations
in the transferable boom fares weldment (refer to Figure
6.18). The transferable boom fares and pole guide as-
sembly are pinned to the intermediate boom by insert-
ing the retaining pin in the upper hole (Location A). The
assembly is pinned to the upper boom by inserting the
retaining pin in the lower hole (Location B).
Figure 6.18 Transferable Boom Flares
and Pole Guide Assembly Pinning Locations
To transfer the boom fares and pole guide assembly from
the intermediate to the upper boom or vice versa, retract
the upper boom fully. Lower the boom to a point where
the transferable fares retaining pin can be reached. Pull
the retaining pin out and insert it into the opposite hole.
When the pin is fully inserted, a detent ball will snap into
a groove to hold it in place.
Notice
to the unit.
mediate boom.
Location A
Location B
12. When the pole is loose from the ground, tighten the
winch line. Remove the chain from the pole and move
the pole puller away from the pole.
13. Use the winch raise and boom up functions to lift the
pole out of the ground.
Lower Tools
The tools outlets will accommodate hydraulic tool acces-
sories such as a wrench, drill, or pole puller. The tools
outlets are equipped with quick disconnect fttings for
easy attachment of the tools. The tools circuit will ac-
commodate open or closed center tools.
Two styles of lower tools circuits are available. One style
has a retractable reel with hoses that allow for tool opera-
tion at some distance from the vehicle. The other style
has stationary outlets mounted on the vehicle.
The tools control handle for the lower tools circuit is
normally located in the pedestal or on the tailshelf of
the unit. It is next to the outrigger control handles and is
labeled Tools (refer to Figure 6.20).
Before a tool is connected or disconnected from the outlets,
bleed off the pressure trapped in the lines. This is done
by shifting the outriggers and tools/derrick switch to Der-
rick and shifting the tools control handle back and forth.
Danger
The booms must not be elevated near energized con-
ductors when operating the lower tool system. The lower
tool system hoses may be wire braid reinforced. Wire
reinforced hoses are conductive to any electrical charge
on the unit.
To use the tools circuit, the outriggers and tools/derrick
selector switch must be in the Outriggers and Tools
position. Move the tools control handle to the Tools On
detent position. This provides hydraulic pressure for the
tools circuit. Use the control on the tool itself to operate
the tool. If the tool has no built in control, such as a pole
puller, use the tools control handle on the vehicle to
operate the tool.
Notice
Always turn off the tools circuit when it is not in use.
Leaving a closed center tool connected with the
Figure 6.19 Pole Puller Use
Warning
Death or serious injury can result if the chain breaks
or slips off the pole. Do not use a choke chain or more
than one wrap of chain around the pole.
7. Wrap the chain tightly around the pole one time.
Insert a link from the free end of the chain in the slot
of the lug.
8. Attach the hydraulic tool circuit hoses to the cylinder.
Make sure the quick disconnect couplers are frmly
attached.
9. Attach the winch line at the top of the pole. Use the
winch line to support the pole once it is pulled loose
from the ground by the pole puller.
Warning
Death or serious injury can result from a falling pole.
Secure the pole with a winch line and clear all person-
nel from the area before operating the pole puller.
10. To use the tools circuit, the outriggers and tools/der-
rick selector switch must be in the Outriggers and
Tools position. Shift the tools control handle to the
Tools On detent position. This will extend the pole
puller cylinder. As the cylinder extends, the chain will
tighten and start to lift the pole out of the ground.
11. Fully extend the pole puller cylinder. If the pole is
loose from the ground, proceed to step 12. If the pole
is still set in the ground, retract the cylinder. Tighten
the winch line. Reposition the cylinder and chain
against the pole and fully extend the cylinder.
Chain Link in Slot
D-Ring Over Lug
Tools
Return Hose
Tools
Pressure Hose
Round Bar
Base
The derrick winch is operational with the outriggers and
tools/derrick selector switch in the Outriggers and Tools
position. This facilitates certain lower tools operations
which are aided by use of the winch.
Upper Tools
Units may be equipped with a tools circuit at the boom
tip. The tools circuit accommodates open or closed
center tools.
The upper tool circuit uses dedicated hydraulic lines for
this purpose. Two quick disconnect fttings for power tools
are provided at the boom tip.
On units with upper controls, the tools circuit is controlled
by the control labeled Start/Stop Tools on the upper control
panel. To provide hydraulic oil fow to the tools circuit,
move the controls switch on the lower control panel to
the Upper/Radio position and move the upper controls
on/off control to the On position. Then push and release
the tools control in the Tools direction.
On units with no upper controls, and no radio controls,
the tools circuit is controlled by the air operated cylinder
labeled Tools at the boom tip. To provide hydraulic oil
fow to the tools circuit, push and release the control in
the Tools direction.
On units with the radio control system, push the toggle
switch forward on the transmitter once to turn the tool
on.
tools circuit turned on and the tool not in use will
keep full tools system pressure applied to the tool.
Leaving an open center tool connected with the tools
circuit turned on and the tool not in use will cause
heat generation.
When the tools circuit is not being used, the tools control
handle should be returned to the Tools Off position. This
shuts off hydraulic fow from the tools circuit. Before a
tool is connected or disconnected from the lower tools
outlets, bleed off the pressure trapped in the lines as
previously stated in this section.
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.
The pressure and fow of the lower tools circuit are adjust-
able to accommodate hydraulic tools with various pressure
and fow requirements. Unless otherwise requested, the
pressure is factory set at 2,000 psi (137.90 bar) and the
fow is factory set at 8 gpm (30.28 lpm). Adjustment of the
tools circuit is covered in the Maintenance Manual.
Selector
Switch
Figure 6.20 Ground Level Controls

Figure 6.21 Upper Tool Controls
Notice
Always turn off the tools circuit when it is not in use.
Leaving a closed center tool connected with the
tools circuit turned on and the tool not in use will
keep full tools system pressure applied to the tool.
Leaving an open center tool connected with the tools
circuit turned on and the tool not in use will cause
heat generation.
When the tools circuit is not being used, it should be
turned off. This shuts off hydraulic fow from the tools
circuit. At the boom tip, push and release the control to
turn the tools circuit off. From the radio control transmit-
ter, push the toggle switch forward once to turn the tools
circuit off. The tool pressure line and the tool itself are
drained when the tools circuit is turned off. This prevents
pressure from becoming trapped in the hose and allows
the tool to be easily disconnected.
Danger
Death or serious injury will result from hydraulic oil
burning or exploding. Avoid contact of the boom
tip with two energized conductors or an energized
conductor and a ground.
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.
The pressure and fow of the upper tools circuit are adjust-
able to accommodate hydraulic tools with various pressure
and fow requirements. Unless otherwise requested, the
pressure is factory set at 2,000 psi (137.90 bar) and the
fow is factory set at 8 gpm (30.28 lpm). Adjustment of the
tools circuit is covered in the Maintenance Manual.
Personnel Platform
The unit may be equipped with a fberglass personnel
platform mounted at the upper boom tip for use in aerial
operations. The platform is gravity leveled and equipped
with a mechanical platform brake to lock it in all positions.
A polyethylene platform liner is available.
Platform capacity of the unit [300 lb (136.08 kg)] is the
total weight of the personnel, tools, and material, not
including the liner.
The platform capacity must not exceed the lesser of the
rated capacity or load capacity as determined by the use
of the platform at the boom tip (refer to Load Capacity
Chart for Platform and Combined Derrick/Platform Use)
or use on the personnel jib (refer to Rated Capacity
Placard for Personnel Jib).
Warning
Death or serious injury can result from improper
use of the platform(s). Do not use the platform(s)
surfaces to push or support objects such as poles,
conductors, etc.
Unstowing
When the platform is needed, it may be unlocked from
its stowed position, which is parallel to the boom. This is
done by unlocking the platform brake and disengaging
the spring-loaded detent pin from the brake disc. Use the
following procedure to unstow the platform.
1. Unlock the platform brake by rotating the handle
away from the bottom of the platform (refer to Figure
6.22).
2. Lift up on the bottom of the platform to remove its
weight from the detent pin.
3. Locate the T-handle detent pin on the boom side
of the platform support bracket. The detent pin is
spring loaded. Pull out and rotate the T-handle until
the short arm of the T-handle engages the notched
tab to hold the pin out (refer to Figure 6.23).
Quick Disconnects
Figure 6.22 Platform Brake
Figure 6.23 T-Handle Detent Pin
4. Carefully lower the platform to the vertical position.
Operation
When using the platform, use caution and common sense.
The following paragraphs describe safety practices that
should be followed when operating from the platform.
The operator has full, metered control from the upper
controls. Slow, smooth operation of the upper controls
is important. Smooth operation of the controls minimizes
the swinging of the gravity leveled platform.
Danger
contact with energized conductors. The platform
and covers carry no dielectric rating. They cannot
protect against contact between an operator and
either two conductors or a single conductor and
grounded elements of the pole. The fberglass plat-
form, properly ftted with a platform liner, designed,
tested, and maintained for the dielectric rating, will
offer some protection for the lower extremities of
the occupant.
Warning
or federal law.
energized conductors. Do not operate the unit with
a hole in the platform or liner.
the platform. Do not use a ladder or other means to
extend reach from the platform.
Death or serious injury can result from falling from the
platform. Do not sit or stand on the platform rim.
Death or serious injury can result from improper use
of the unit. Do not operate the unit or occupy the
platform while the vehicle is in motion.
the platform. All platform occupants must properly
use an appropriate OSHA approved personal fall
protection system.
Keep the lanyard used with the OSHA approved
personal fall protection system in place and in good
condition. Never replace it with a lanyard made of
conductive material.
Death or serious injury can result from unit opera-
tion by someone other than the platform occupant.
When the platform is occupied, only use the lower
controls to position the platform in an emergency
or when the platform occupant is guiding the lower
controls operator.
Death or serious injury can result from improper
use of the platform(s). Do not use the platform(s)
surfaces to push or support objects such as poles,
conductors, etc.
Platform
Mounting
Bracket
Platform
Mounting Pin
Detent Pin
Engaged
in Notched
Tab
Brake
Disc
Detent Pin
Engaged in
Brake Disc
Platform
Retaining
Pin
Unstowed Stowed
Unlocked Locked
Caution
For operator safety, follow OSHA and company rules
about platform operation and minimum clearances.
Warning
the platform. Release the locking assembly on a
gravity-leveled platform before raising or lowering
the booms.
Before positioning the boom from the platform, unlock
the platform brake completely. This is done by rotating
the handle away from the bottom of the platform (refer
to Figure 6.22). The brake must be unlocked to allow
gravity leveling of the platform.
Warning
the platform. Secure the platform brake after arriving
at the work position.
Use the platform brake in the locked position to keep the
platform from swinging when the boom is in position and
aerial work is being performed. Figure 6.22 illustrates
the platform brake in the unlocked and locked position.
The brake is locked by rotating the handle downward.
When properly adjusted, the brake will support 300 pounds
(136.08 kg) at the platform lip. If slippage occurs under
this condition, the brake needs to be adjusted. Adjustment
of the brake is described in the Maintenance Manual.
Stowing
When not in use, the platform may be stowed at the
boom tip. It is locked in a position parallel to the boom
by the platform brake and the spring-loaded detent pin
engaged in the brake disc. Use the following procedures
to stow the platform.
1. Unlock the platform brake by rotating the handle
away from the bottom of the platform (refer to Figure
6.22).
2. Locate the T-handle detent pin on the boom side of
the platform support bracket (refer to Figure 6.23).
The detent pin is spring loaded. Disengage the detent
pin. To do this, pull out the detent pin. Then turn it 90
degrees so the T-handle will clear the notched tab
and allow the spring to pull the pin in.
3. Normally, the stowed platform is positioned with the
bottom of the platform toward the pedestal of the unit.
However, if the platform is mounted on the same side
of the boom as the auger stow bracket, the platform
is stowed with the bottom of the platform away from
the pedestal. Swing the platform in the appropriate
direction and lift it up until the detent pin snaps into
the hole in the brake disc.
Notice
Follow the stowing procedure to prevent damage
to the unit.
Always lock the platform brake before road travel. Lock-
ing the platform brake gives maximum support to the
platform. Failure to lock the brake may result in damage
to, or failure of, the detent pin.
Lock the platform brake by rotating the handle toward
the platform (refer to Figure 6.22).
Removal
The platform assembly may be completely removed.
Unstow the platform as described in this section. Remove
the platform retaining pin (refer to Figure 6.23) that goes
through the mounting socket on the boom tip. Pull the
entire assembly out of the platform mounting socket. To
aid in reinstalling the platform later, lubricate the inside of
the platform mounting socket with anti-seize compound.
Lanyard Anchor
The lanyard anchor (refer to Figure 6.24), is part of the
personal fall protection system. The lanyard must be
properly attached to the anchor.
Figure 6.24 Lanyard Anchor
Transferable Upper Controls
Transferable upper controls are available to operate
the boom and winch functions from the personnel plat-
form.
Lanyard
Anchor
Notice
Property damage can result if the upper controls
are pinned improperly. Do not pin the pullout upper
controls to the personnel jib when the outer housing
of the upper controls is pinned to the transferable
boom fares.
Do not pin the pullout upper controls to the personnel jib
when the outer housing of the upper controls is pinned to
the transferable boom fares. This pinning arrangement
will cause over extension of the pullout upper controls
when the upper boom is extended. Damage to the upper
controls assembly will result.

Pinning Confgurations With Boom
Flares Pinned to the Upper Boom
When the transferable boom fares are pinned to the upper
boom, the following upper control panel confgurations
are available (refer to Figure 6.25).
Option One The upper controls may be pinned to
the transferable fares by positioning the detent pin in
Pin Location D. This pinning arrangement allows the
upper controls to extend with the transferable boom
fares as the upper boom is extended. The controls are
available to the occupant of the personnel platform.
Option Two The transferable controls may be
pinned to the upper boom by positioning the detent
pin in Pin Location E. This allows the upper controls
to extend as the upper boom is extended. This posi-
tions the upper controls at the upper boom tip. The
controls are available to the occupant of the personnel
platform.
Option Three If the unit is equipped with pullout
upper controls and a personnel jib, the pullout upper
controls may be pinned to the personnel jib only when
the outer housing of the upper controls is pinned to
the upper boom. This allows the upper controls to be
available to the platform occupant when the platform
is pinned to the personnel jib.
Notice
Property damage can result if the upper controls
are pinned improperly. Do not pin the pullout upper
controls to the personnel jib when the outer housing
of the upper controls is pinned to the transferable
boom fares.
Do not pin the pullout upper controls to the personnel jib
when the outer housing of the upper controls is pinned to
the transferable boom fares. This pinning arrangement
will cause over extension of the pullout upper controls
When the upper controls are not desired at the boom
tip, the upper control outer housing can be pinned to the
transferable fares, with the transferable fares pinned to
the intermediate boom. This keeps the controls at the
end of the intermediate boom when the upper boom is
extended.
If the unit is equipped with a personnel jib, it should also
have the pullout style of upper controls. With this style of
transferable upper controls, the upper panel is mounted
on a sliding fberglass tube that may be extended from
a separate outer housing.
The upper control panel has four control handles that pro-
vide full metered control of the boom and winch functions.
The control handles operate the rotation, extension, boom
and winch functions. There is also an upper controls on/
off selector handle and a tools on/off control handle. The
quick disconnects for hydraulic tool hook up are located
under the upper control panel. The upper controls are
described under Upper Controls in this section.
Before transferring the upper controls, retract the upper
boom. Rotate and lower the boom until the upper controls
assembly can be easily reached from the ground.
Pinning Confgurations With Boom
Flares Pinned to the Intermediate Boom
When the transferable boom fares are pinned to the
intermediate boom, the following upper control panel
confgurations are available (refer to Figure 6.25).
Option One The upper controls may be pinned to
the transferable boom fares by positioning the detent
pin in Pin Location A. This allows the upper controls
to remain at the end of the intermediate boom when
the upper boom is extended. This pinning arrange-
ment minimizes the number of components at the
boom tip when lifting a load.
Option Two The transferable controls may be
pinned to the upper boom by positioning the detent
pin in Pin Location B. This allows the upper controls
to extend as the upper boom is extended. This posi-
tions the upper controls at the upper boom tip. The
upper controls will be available to the occupant of
the personnel platform.
Option Three If the unit is equipped with pullout
upper controls and a personnel jib, the pullout up-
per controls may be pinned to the personnel jib only
when the outer housing of the controls is pinned to
the upper boom.
Figure 6.25 Pinning Confgurations
Pin Location A
Upper controls pinned to boom fares
Boom fares pinned to
intermediate boom (pin enters
from opposite side of boom)
Pin Location B
Upper controls pinned
to upper boom
Personnel Jib
Control Mounting Bracket
Pin Location C
Detent Pin
T-Handle Retaining Pin
Boom fares pinned to upper boom
(pin enters from opposite side of boom)
Pin Location D
Upper controls pinned to
transferable boom fares
Pin Location E
Upper controls pinned
to upper boom
Boom fares pinned to
intermediate boom (pin enters
from opposite side of boom)
when the upper boom is extended. Damage to the upper
controls assembly will result.
Pin the outer housing of the upper controls to the
upper boom as described under Option Two. Pin the
control mounting bracket to the jib with the T-handle
retaining pin and remove the detent pin that secures
the pullout upper control panel to the outer housing.
Pull the upper control panel out of the outer housing.
Align the upper control panel pinning hole with the
pinning hole in the bracket of the personnel jib. Insert
the detent pin through the aligned holes (refer to Pin
Location C).
ROACS Remote Start/Stop System
The ROACS is a remote control engine start/stop system
with additional auxiliary functions. The ROACS system
has an Operators Manual that explains how to operate
this system.
Press the Enable Remote button to turn on the transmitter.
One button is provided on the ROACS transmitter for
engine start/stop. To start the engine, press the button
until the engine is running and then release. If the en-
gine does not start, press the button and release. Then
repeat the procedure. To turn off the engine, press the
button and release.
Other buttons may provide operation of various functions
such as DC pumps, warning horns, engine rpm, power
tools solenoid valves, etc.
A light on the transmitter indicates that a signal is being
sent to the ROACS receiver in the vehicle cab.
Fiberglass Jibs
Fiberglass jibs are available for personnel or material
handling. Material handling jibs are available in different
styles. The personnel jib is available in one style.
All jibs will have a rated jib capacity placard (refer to Figure
6.26) mounted on the jib bracket or jib boom. In some
material handling jib positions, the rated capacity of the
winch will be greater than the rated capacity of the jib.
Warning
the jib. Do not exceed the values on the jib capacity
chart.
Death or serious injury can result from damaging
the jib. Remove the jib before operating the pole
guide.
Refer to the capacity placards before using a jib.
Before lifting a load with the jib, refer to Section 3 under
Capacity.
Material Handling Jibs
Material handling jibs are available in three different styles
a 4.2 (1.28 m) one piece jib, a 4.8 (1.46 m) two piece
telescopic jib, and an 8 (2.44 m) one piece jib.
The jibs may be pinned to the boom tip when needed.
The jib may be manually tilted up and down by using one
of the different pinning positions.
The 4.8 (1.46 m) two piece jib is a manual telescopic
jib. It may be extended from 3.6 (1.10 m) to 4.8 (1.46
m). To extend the jib, remove the detent pin and pull the
jib extension out of the base of the jib. Line up the holes
and replace the detent pin.
Personnel Jib
Warning
the unit. Do not lift loads with the winch line when
the personnel jib is in use.
The 8 (2.44 m) personnel jib boom has one pinning
position. One or two platforms may be pinned to the jibs
platform mounting socket.
The transferable pullout upper controls may be pinned to
the jib for operation of the unit from the platform. Trans-
ferable Upper Controls in this section describes how to
pin the pullout upper controls to the jib.
Read and understand the information under Personnel
Platform in this section before operating the unit from the
platform. This section contains important platform safety
and operational information.
Other Methods of
Lowering/Stowing the Unit
Use the lower controls to lower the platform and/or stow
the boom if the upper controls are not operational.
Danger
equipment that has become electrically charged. De-
termine that the unit is not energized before making
contact with the unit.
Figure 6.26 Fiberglass Jibs
Note Sample placards shown. Refer to
the jib capacity chart mounted on the jib
for specifc jib lifting capacity information
Personnel Jib
Platform
Mounting Socket
Pinning Position
Turntable Winch With Material Handling Jib
Pinning Positions
Detent Pin
Boom Tip Winch With Material Handling Jib
Warning
or two-blocking the unit. The HOP, load moment
limiter, ATB, and side load protection systems are
not operational when stowing the unit with the lower
control valve manual override handles.
Remove a load that could overload the unit. Do not ap-
ply a side load to the unit while stowing with the manual
override handles.
Before the manual override control handles may be used,
the derrick blocking valve (DS1) on the selector valve
must be opened. The DS1 solenoid valve may be opened
one of two ways, depending upon whether the electrical
control system is operational or not. If the electrical control
system, including the lower control panel, is working, use
the procedure under option one to stow the unit. If the
electrical control system is not working but power is still
available to the wiring harness in the pedestal, follow the
procedure under option two to stow the unit.
Option One
Use the following procedure to close the unloader valve
and lower or stow the unit.
1. Operate the hand control for the defective function
or move the digger shift switch to the High position
to open the DS1 solenoid valve.
2. Use the manual override control handles to lower
or stow the unit. Operate the functions slowly and
cautiously. Only use the manual override control
handles to lower or stow the unit. Do not use them
to operate the unit for normal operation. Return the
digger shift switch to low if it was in high.
Option Two
Use the following procedure to open the DS1 solenoid
valve and lower or stow the unit.
1. Turn off the engine and disengage the PTO.
2. Remove an access cover from the pedestal. Locate
the selector valve which is mounted inside the ped-
estal (refer to Figure 6.28).

3. Unplug the electrical harness connectors from the
DS1, DS2, and DS4 solenoids.
4. Plug the connector from the DS4 solenoid into the
DS1 solenoid.
5. Turn on the engine and engage the PTO. Move the
outriggers and tools/derrick selector to the Outriggers
and Tools position.
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.
After determining that it is safe to touch the vehicle, use
the lower controls for boom and platform movement.
The lower controls will override the upper controls by
moving the controls switch on the lower control panel to
the Lower position. Then use the lower controls to care-
fully lower the platform to the ground. If possible, retract
the intermediate and upper booms before lowering the
platform to the ground.
If the unit cannot be operated from the lower or upper
controls, it may be stowed using the manual operation
of lower control valve procedure.
Manual Operation of Lower Control Valve
The lower control valve is equipped with manual override
control handles. The handles may be used to manually
operate the valves if the electrical system or pulsars mal-
function. This enables the unit to be stowed for travel.
The lower control valve is located on the side of the
turntable behind the turntable cover. Figure 6.27 shows
each manual override control handle on the valve.
Figure 6.27 Lower Control Valve
Manual Override
Control Handles
Upper Boom
Intermediate
Boom
Lower Boom
Rotate
Digger
Winch
Figure 6.28 Selector Valve
6. Use the manual override control handles to lower
or stow the unit. Operate the functions slowly and
cautiously. Only use the manual override control
handles to lower or stow the unit. Do not use them
to operate the unit for normal operation.
7. Turn off the engine and disengage the PTO.
8. Unplug the DS4 connector from the DS1 solenoid.
9. Plug the DS1, DS2, and DS4 connectors back into
the DS1, DS2, and DS4 solenoids.
10. Stow the outriggers. Take the unit out of service until
the problem is corrected.
Manual Operation of Lower
Control Valve (Units With Radio
Controls Only as Lower Controls)
The lower control valve is equipped with manual override
control handles. The manual override control handles
may be used to manually operate the valves if the Radio
Controls become inoperable. This enables the unit to be
stowed for travel.
The lower control valve is located on the side of the turn-
table behind an opening in the turntable cover. Figure 6.29
shows each manual override control handle on the valve.
Warning
or two-blocking the unit. The HOP, load moment
limiter, ATB, and side load protection systems are
not operational when stowing the unit with the lower
control valve manual override handles.
Figure 6.29 Manual Operation Switches
Remove a load that could overload the unit. Do not ap-
ply a side load to the unit while stowing with the manual
override handles.
Before the manual override control handles may be used,
the DS1 solenoid valve on the selector valve must be
opened. The DS1 solenoid valve may be opened by us-
ing the switch on the turntable. If the electrical system
is working, use the switches on the turntable and the
manual override control handles to stow the unit.
Move the enable switch (refer to Figure 6.29) to the On
position to open the DS1 solenoid valve. Use the manual
override control handles to operate the boom and dig-
ger/winch functions and the switches to operate the pole
guide functions. After the unit has been stowed, return
the enable switch to the Off position.
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 6.30). One of the
Pedestal
Side Plate
Outrigger/Tool Sense
Dump Valve Cartridge
and Solenoid (DS4)
Outrigger/Tool Blocking Valve
Cartridge and Solenoid (DS2)
Derrick Blocking Valve
Manual
Override
Control Handles
Upper Boom
Intermediate
Boom
Lower Boom
Rotate
Digger
Winch
Switches
Radial
Holding Valve
Base End
Rod End
A-Frame
Holding Valve
Base End
Rod End
Holding Valve
Figure 6.30 Outriggers
Rod End
Base End
Holding Valves
Out and Down
Hex
Head Screw
Rod End
Holding Valves
Base End
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.
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.
Section 7 Troubleshooting 77
Section 7 Troubleshooting
Circuit Breakers
Circuit breakers protect certain electrical circuits on the
unit. When a particular electrical circuit is overloaded,
the breaker for that circuit will trip.
Thermal Self-Resetting Circuit Breakers
The unit has a 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 (PDM) box, which is located
in the vehicle cab. These breakers are the thermal self-
resetting type.
If the main power supply circuit breaker trips, all functions
above rotation will stop working. Also, the lower control
panel lights will be dead. The breaker will reset within
a few minutes if the cause of the electrical overload is
removed. If the breaker continues to trip and the cause
cannot be determined, use the manual controls to stow the
unit. Section 6 under Manual Operation of Lower Control
Valve describes how to use the manual controls. Take the
unit out of service and have the problem corrected.
Pulsars and Hand Controls
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 upper
boom, digger, and winch functions are considered major
functions.
The procedures in this section allow a function to be
temporarily restored. This will allow the unit to be stowed.
The unit should then be transported back to a service
facility for permanent repairs.
1. Remove the right hand side cover from the turntable
(as viewed from the boom tip looking toward the
turntable).
2. Locate the pulsar for the disabled function.
3. Each pulsar has two electrical wires connected to
the electrical harness by a two pin connector. Each
harness connector attached to a pulsar connector
is labeled (refer to Figure 7.1). The label identifes
the pulsar connected to that harness connector. The
label is found next to the connector on the electri-
cal harness. Disconnect the pulsar for the defective
function from the electrical harness.
Figure 7.1 Lower Control Valve
4. Locate the two pin connectors for the pulsar of a
working function. Unplug the two pin connector.
5. Plug the two pin harness connector of the working
function into the pulsar connector of the disabled
function. The hand control or joystick movement for
this function will become the alternate control for the
disabled function.
Labels
Connectors
Pulsars
78 Section 7 Troubleshooting
6. Attempt to operate the function with the alternate
control. If the disabled function will now operate, the
problem is likely in the electrical portion of the func-
tion (possibly the hand control or joystick). Proceed
to step 8. If the function will not operate, proceed to
step 9.
7. Use the alternate control to stow the unit. Return the
pulsar electrical wires to the correct connections at
the harness. Take the unit out of service until the
problem is corrected.
8. If the disabled function will not operate with an alter-
nate control, then the electrical portion of the valve
(possibly the pulsar) is defective. Return the electrical
wires to their original connections at the harness. Use
the manual override controls to operate the defective
function (refer to Section 6 under Manual Operation
of Lower Control Valve). Stow the unit. Take the unit
out of service until the problem is corrected.
Outrigger/Tool Blocking
and Sense Dump Valves
If the outriggers and lower tools circuit will not operate,
the problem may be a defective outrigger/tool blocking
valve or outrigger/tool sense dump valve, or a fault in
the electrical circuit which operates one or both of these
valves. When the outriggers and tools/derrick selector
switch at the rear of the vehicle is in the Outriggers and
Tools position, the outrigger/tool blocking valve should
open and the outrigger/tool sense dump valve should
close. This directs hydraulic oil fow to the outrigger and
tools valves and causes the pump sense line to build to
the proper pressure. If either one of these valves does
not operate properly, the outriggers and tools circuit will
not operate.
If the outrigger/tool blocking valve is not opening or the
outrigger/tool sense dump valve is not closing due to a
fault in the electrical system, use the following procedure
to temporarily restore operation. This will allow the outrig-
gers to be raised. The unit should then be transported
back to a service facility for permanent repairs.
The following supplies are necessary to complete this
procedure.

Jumper wires
12 volt power source
1. Remove an access cover from the pedestal. Locate
the selector valve which is mounted inside the ped-
estal (refer to Figure 7.2).
Figure 7.2 Selector Valve
2. Unplug the electrical harness connectors from the
DS2 and DS4 solenoids.
3. Use jumper wires to connect one pin on each of
these solenoids to a 12 volt power source and the
other pin on each of these solenoids to ground.

4. Attempt to operate the outriggers. If the outriggers
operate, the outrigger/tool blocking valve is now
open and the outrigger/tool sense dump valve is now
closed.
5. Operate the outrigger control handles to raise the
outriggers.
6. Remove the jumper wires from the DS2 and DS4
solenoids, and plug the DS2 and DS4 connectors
back into the DS2 and DS4 solenoids.
7. Take the unit out of service until the problem is cor-
rected.
If no functions above rotation will operate, the problem
may be a defective derrick blocking valve or a fault in
the electrical circuit which operates the derrick blocking
valve. Whenever a function other than lower tools or
outriggers operates, the derrick blocking valve should
open. When the derrick blocking valve opens, hydraulic
oil fow is directed to the lower control valve. If the der-
rick blocking valve does not open properly, no functions
above rotation will operate.
If no functions above rotation operate, use the following
procedure to temporarily restore operation. This will allow
Pedestal
Side Plate
Outrigger/Tool Sense
Dump Valve Cartridge
and Solenoid (DS4)
Outrigger/Tool Blocking Valve
Section 8 Care of the Unit 79
the unit to be stowed. The unit should then be transported
back to a service facility for permanent repairs.
1. If the lower control panel lights are dead, the prob-
lem may be a tripped circuit breaker. Refer to Circuit
Breakers in this section.
2. If the lower control lights are on, determine if the
derrick blocking valve will close electrically. Refer to
Section 6 under Manual Operation of Lower Control
Valve.
3. Slowly and cautiously attempt to operate a function.
If the function operates, the derrick blocking valve is
now open.
4. Stow the unit with the lower controls. Take the unit
out of service until the problem is corrected.
80 Section 8 Care of the Unit
Section 8 Care of the Unit 81
Section 8 Care of the Unit
An alert operator can contribute to the proper care of the
unit. The observation and correction of minor maintenance
problems, as they occur, may prevent costly repairs,
lengthy downtime, and improve safety.
At no time should an Altec unit be altered or modifed
without specifc written approval from Altec Industries,
Inc.
Hydraulic System
The condition of the hydraulic oil is a major factor in ob-
taining long life and trouble-free service from the hydraulic
system components. The oil temperature, oil level and
oil cleanliness must be properly maintained.
Notice
The minimum temperature at which oil will fow to the
pump varies with the type of oil in the reservoir. Regardless
of the hydraulic oil used, improper start-up can quickly
damage the pump. Always allow the oil to warm up before
putting the unit in service. Section 4 under Cold Weather
Start-Up describes this procedure.
The maximum temperature that the hydraulic system can
operate at depends upon the hydraulic oil used. Cold
weather oil should not exceed 160 degrees Fahrenheit
(71 degrees Celsius) and warm weather oil should not
exceed 195 degrees Fahrenheit (91 degrees Celsius).
If overheating occurs during normal use, identify the
cause and have it corrected immediately.
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.
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.
Check the oil level in the hydraulic reservoir daily. When
checking the oil level, the vehicle should be on level
ground, booms and outriggers stowed. The oil level
must be between the Add and Full marks on the fller
cap dipstick. If oil must be added, use the proper type
as described in the Maintenance Manual.
A cold oil/change flter light is located on the lower control
panel. This light alerts the operator when the return line
flter cartridge needs to be replaced or when the hydraulic
oil is cold. If the oil is warm and the light continues to be
on, the return line flter cartridge needs to be replaced.
Replacing the return line flter is described in the Main-
tenance Manual.
Immediately report any unusual hydraulic system noise
observed during operation so that the cause can be
determined and corrected.
Fiberglass
Keep the fberglass upper boom clean to maintain the
nonconductive properties of the fberglass. Keep the fber-
glass clean by periodically washing it with mild detergent
in warm water. Do not scratch the boom surface.
If the unit is equipped with a platform, do not allow it
to contact fxed objects such as poles and trees. Keep
the platform clean by periodically washing it with mild
detergent in warm water.
Structures and Mechanical Systems
Report any loose fasteners, lockwires, pins, pin retainers,
etc., so the cause can be determined and corrected.
Warning
work areas clean.
Proper lubrication on a regular basis will increase the life
of the unit and help to prevent maintenance problems.
Report any sign of lubricant leaking from the gearbox so
the cause can be determined and corrected.
Avoid shock loads and overloading. These conditions
can present hazards to the unit and personnel. Start and
stop all operations as smoothly as possible. Do not allow
debris, tools, etc., to accumulate on the unit. The unit must
be free to extend and retract without obstruction.
Notice
system.
Inspect the auger windup sling each day before operat-
ing the unit. If a wire rope auger windup sling shows
82 Section 8 Care of the Unit
signs of wear and/or four or more broken wires, replace
it immediately. If a synthetic auger windup sling has cut
strands and/or external wear, replace it immediately. A
worn auger windup sling could fail causing a free swing-
ing auger. A free swinging auger could cause death or
serious injury.
Inspection of the auger windup sling daily is described in
Section 4 under Daily Preoperational Inspection.
When cleaning with high pressure washers or steam
cleaning equipment, do not directly spray the electrical
components or control panels. All electrical connections
are sealed and designed for outside use. However, high
pressure fuids can sometime force their way past the
seals and cause corrosion to start.
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.
Altec Derrick Preoperational Checklist
Vehicle No. _____________________ Location _____________________________ Date _________________
Model No. _______________ Serial No. ____________________ Odometer __________ Hour Meter __________
Refer to the Altec Operators Manual for detailed instructions on the preoperational inspection and operation of this
equipment.
Prior to each shift, perform a visual and/or functional inspection consistent with the requirements in the Operators
Manual of each area listed below, as equipped. Confrm that there are no apparent defciencies or damage that
constitute a safety hazard prior to use.
On a monthly basis, complete, sign, date, and fle this checklist in accordance with OSHA requirements.
Symbols
/O = Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
______ Tires (condition, proper infation)
______ Hydraulic reservoir (cleanliness, oil level)
______ Hydraulic hoses, tubes, cylinders, gearboxes (condition, no leaks)
______ Pins, pin retainers, fasteners, welds (condition, no cracks, lubrication)
______ Covers (in place, condition)
______ Audible and visual safety and warning devices and placards (operation, condition)
______ Ground drive controls (operation, return to neutral, E-stop)
______ Apply parking brake, set wheel chocks, start engine, and engage PTO
______ Outrigger interlock system (operation)
______ Outriggers, motion alarm, selector (operation, no drift once deployed)
______ Chassis-mounted winch and/or capstan (operation, return to neutral, E-stop)
______ HOP with boom stowed (operation)
______ Anti-two-block and ATB override (battery, operation)
______ Pole guide interlock (operation)
______ Lower controls (operation, return to neutral, E-stop)
______ Lower controls enable pedal (operation, return to neutral)
______ Boom (no drift with controls in neutral)
______ Upper controls (operation, return to neutral, E-stop, interlock)
______ Radio controls (operation, return to neutral, E-stop, tilt shutdown)
______ Radio controls used as upper controls in platform docking station (operation, interlocks)
______ Fiberglass boom, boom tip, jib (condition, cleanliness)
______ Platform(s), liner(s), fall protection equipment (condition, cleanliness)
______ Winch line (condition, reeving, drum spooling)
______ Load hook and latch and/or other lifting attachments (condition)
______ Auger windup sling, digger storage and transfer systems, extension shaft (condition, retention)
______ Outriggers (no drift during preoperational inspection)
______ Ground conditions (adequate for proper support)
______ Unit level with outriggers deployed (within specifcations)
Comments _________________________________________________________________________________
__________________________________________________________________________________________
__________________________________________________________________________________________
Name (printed) ________________________________ Signature _____________________________________
749-50083B
Appendix Derrick Preoperational Checklist
SWING: Arm extended, point with
finger in direction of swing of
boom.
STOP: Arm extended, palm down,
move arm back and forth horizon-
tally.
EMERGENCY STOP: Both arms ex-
tended, palms down, move back
and forth horizontally.
HOIST: With forearm vertical,
forefinger pointing up, move
hand in small horizontal circle.
USE MAIN HOIST: Tap fist on head;
then use regular signals.
TRAVEL: Arm extended forward,
hand open and slightly raised, mak-
ing pushing motion in direction of
travel.
DOG EVERYTHING: Clasp hands in
front of body.
TRAVEL (Both Tracks): Use Both fists
in front of body, making a circular
motion about each other, indicat-
ing direction of travel, forward or
backward. (For land cranes only.)
USE WHIP LINE (Auxiliary Hoist):
Tap elbow with one hand; then
use regular signals.
RAISE BOOM: Arm extended, fin-
gers closed, thumb pointing up-
ward.
LOWER BOOM: Arm extended, fin-
gers closed, thumb pointing down-
ward.
TRAVEL (One Track): Lock the track
on side indicated by raised fist.
Travel opposite track in direction in-
dicated by circular motion of other
fist, rotated vertically in front of
body. (For land cranes only.)
RETRACT BOOM: (Telescoping
Booms). Both fists in front of body
with thumbs pointing toward each
other.
EXTEND BOOM: (Telescoping
Booms). Both fists in front of body
with thumbs pointing
outward.
MOVE SLOWLY: Use one hand to
give any motion signal and place
other hand motionless in front of
hand giving the motion signal.
(Hoist slowly shown as example.)
RAISE THE BOOM AND LOWER THE
LOAD: With arm extended, thumb
pointing up, flex fingers in and out
as long as load movement is de-
sired.
LOWER THE BOOM AND RAISE THE
LOAD: With arm extended, thumb
pointing down, flex fingers in and
out as long as load movement is
desired.
Extracted From ANSI Standard
ASME B30.5 - 2000
This Complies With OSHA Standards
Standard Hand Signals for
Controlling Crane Operations
9700-13539
LOWER: With arm extended
downward, forefinger pointing
down, move hand in small
horizontal circle.
Appendix Standard Hand Signals for Controlling Crane Operations
Troubleshooting Chart
Appendix Troubleshooting Chart
Symptom
All functions above rotation
stop working. Lower control
panel lights are on.
All functions stop working.
Lower control panel lights do
not operate.
One major function (boom,
rotation, intermediate boom
or upper boom, digger or
winch) stops working.
Outriggers and lower tool
circuit do not work with selec-
tor switch in Outriggers and
Tools position.
One major function drifts with
control in neutral.
Boom lower, intermediate and
upper boom extend, digger
dig, and winch raise all stop
operating. Booms are not
overloaded. Boom stow switch
is not actuated.
Upper control panel stops
working.
Upper boom will not extend.
Test Procedure/Corrective Action
Properly extend outriggers.
Disengage emergency stop.
Apply 12 volts to the derrick blocking valve solenoid (DS1)
using the outrigger/tool sense dump (DS4) connector. Stow
the unit by manual operation of the lower control valve.
The circuit breaker is the thermal type and will self-reset
upon cooling.
Stow the unit by manual operation of the lower control valve.
Switch the pulsar leads at the electrical harness to use an
alternate control. If the function is operable, stow the unit with
the lower controls. If the trouble stays with the original function,
stow the unit by manual operation of the lower control valve.
Apply 12 volts to the outrigger/tool blocking valve solenoid
(DS2) and the outrigger/tool sense dump valve solenoid (DS4).
Stow the unit by operating the outrigger valves.
Unplug pulsars and stow the unit by manual operation of the
lower control valve.
Retract boom or lower winch line to release ATB switch.
Replace ATB switch battery.
Use the lower controls to bring the platform to the ground.
Tilt pole guide back.
Possible Cause
Outrigger interlock engaged.
Emergency stop engaged.
Derrick blocking valve
malfunction.
Main power supply circuit
breaker is tripped.
Electrical system failure.
Hand control or pulsar
malfunction.
Outrigger blocking valve
malfunction.
Electrical system failure.
Defective boom stow switch,
lift cylinder pressure sensor,
electronic side load, or cable
leading to one of these com-
ponents.
ATB switch is actuated.
ATB switch battery is dead.
Upper controls electrical
system failure.
Pole guide interlock engaged.
Appendix Troubleshooting Chart

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