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Copyright2005 by Altec Industries, Inc.

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

database or retrieval system, without prior written permission of the publisher. Making copies of any part

of this publication for any purpose other than personal use is a violation of United States copyright laws.

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

Operators Manual

749-20143August 2005

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Electrical Continuity Hazard

Always wear insulated protective equipment, use conductor cover-ups, and maintain required clearanceswhen in the vicinity of energized conductors.

Aerial devices and digger derricks with insulated 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 insulated 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 devices1 and digger derricks are neverconsidered primary protection for the

operator from electrical contact. An operators primary protection comes through use of protective equip-

ment (insulated gloves, insulated sleeves, conductor cover-ups) 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 conduc-

tor 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.

1Except ANSI Category A units

Altec Industries, Inc.

Midwest DivisionSt. Joseph, Missouri

Safety Bulletin

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Warranty

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Unit Registration

Important Unit Warranty Information

To insure the proper registration of your new Altec unit, send in the registration card when

the unit has been delivered or placed inservice. Please note that the 12 month warranty

period on your new ALTEC unit begins at the unit delivery/in-service date at your facility if

you mail this card.

If the card is not mailed within 60 days of the delivery of the unit, the unit invoice datewill be understood to be the in-service date.

In order to insure the correct processing of any warranty claim it is important that the at-

tached card be filled out and returned to the central processing center.

Place the proper postage on the card and place it in the mailbox.

Altec Unit Registration Card

Altec Model Number _____________________________

Altec Serial Number _____________________________

Company Name _______________________________________________

Address ______________________________________________________

City ____________________________ State ________ Zip _________

Contact Name _________________________________________________

Phone Number ________________________________________________

Email Address _________________________________________________

Date Placed in Service _______________ Customer Truck No. ________

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Altec Industries, Inc.Sales Registration Administrator2106 South Riverside RoadSt. Joseph, MO 64507

FIRST CLASSPOSTAGEREQUIRED

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2nd Owner Unit Registration Card

Altec Model Number _____________________________


Company Name _______________________________________________

Address ______________________________________________________

City ____________________________ State ________ Zip _________

Contact Name _________________________________________________

Phone Number ________________________________________________

Email Address _________________________________________________


Previous Owner ________________________________________________

Address ______________________________________________________

City ____________________________ State ________ Zip _________

3rd Owner Altec Unit Registration CarAltec Model Number _____________________________


Company Name _______________________________________________

Address ______________________________________________________

City ____________________________ State ________ Zip _________

Contact Name _________________________________________________

Phone Number ________________________________________________

Email Address _________________________________________________


Previous Owner ________________________________________________

Address ______________________________________________________

City ____________________________ State ________ Zip _________


Unit Registration

The attached registration card(s) are provided to assist a future purchaser to notify Altec of the change of

ownership This notification is part of the ANSI standard under Responsibilities of Owners - Transfer of

Ownership.

The ANSI Standard states When a change in ownership of a digger derrick or aerial device occurs, it

shall be the responsibility of the seller to provide the manufacturers manual(s) for the digger derrick or

aerial device to the purchaser. It is the responsibility of the purchaser to notify the manufacturer of the unit

model and serial number and the name and address of the new owner within 60 days.

Please complete the information on the appropriate card, attach a stamp and mail to Altec. This allows

Altec to update the customer mailing list so that necessary manufacturer/user communications can be sent

to the new owner.

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Preface

This unit is the result of Altecs advanced technology and quality awareness in design,engineering, and manufacturing. At the time of delivery from the factory, this unit met orexceeded all applicable requirements of the American National Standards Institute. Allinformation, illustrations, and specifications contained within this manual are based on thelatest product information available at the time of publication. It is essential that all personnelinvolved in the use and/or care of this unit read and understand the Operators Manual.

Given reasonable care and operation, according to the guidelines set forth in the manualsprovided, this unit will provide many years of excellent service before requiring majormaintenance.

Impacts to and excessive forces on the hydraulic utility equipment, through vehicularaccidents, rollovers, excessive loading, and the like, may result in structural damage notobvious during a visual inspection. If the hydraulic utility equipment is subjected to suchimpacts or forces, a qualified person may need to perform additional testing such as acousticemissions, magnuflux or ultrasonic testing as applicable. If structural damage is suspectedor found, contact Altec for additional instructions.

Warning

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

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

Danger

Death or serious injury will result from unprotected contact with energized conductors.

Non-insulated units have no dielectric rating. Maintain safe clearances, as defined byfederal, state, and local authorities, and your employer, from energized conductors.

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

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

7-04

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Section 1 IntroductionAbout This Manual ..................................................................................................... 1

Section 2 Unit Specifications

Purpose of the Unit ........................................................................................................ 3General Specifications ................................................................................................... 3Component Identification ............................................................................................... 5Reach Diagrams ............................................................................................................ 6

Section 3 SafetySafety Instructions ....................................................................................................... 11Capacity ....................................................................................................................... 11Accident Prevention Signs ........................................................................................... 11

Accident Prevention Signs Diagram ...................................................................... 12

Section 4 Before You Operate

Capacity and Stability .................................................................................................. 19

Operation Near Energized Conductors ......................................................................... 20Daily Preoperational Inspection ................................................................................... 21

Inspection Diagram ............................................................................................... 22Preparing for Operation ................................................................................................ 24Cold Weather Start-Up ................................................................................................. 25

Section 5 OperationGround Level Controls ................................................................................................. 27

Machine/Outriggers Selector ................................................................................. 27Outriggers .............................................................................................................. 27Interlock System ................................................................................................... 28Motion Alarm ......................................................................................................... 28

Lower Controls ............................................................................................................. 28

Upper Controls ............................................................................................................. 28Emergency Stop .................................................................................................... 29Single Handle Control ............................................................................................ 29

Booms ......................................................................................................................... 30Lower Boom .......................................................................................................... 30Upper Boom .......................................................................................................... 31Boom Storage ....................................................................................................... 31

Rotation ....................................................................................................................... 31Personnel Platform ...................................................................................................... 32

Platform Rotation .................................................................................................. 32Platform Leveling System ..................................................................................... 33Platform Tilt ........................................................................................................... 33Lanyard Anchor ..................................................................................................... 33

Material Handling System ............................................................................................ 33Telescopic Jib (Hydraulic Extend) ......................................................................... 34Telescopic Jib (Manual Extend) ............................................................................ 35Jib Adapter ............................................................................................................ 35Winch .................................................................................................................... 35Phase Lifter ........................................................................................................... 36Lower Boom Lifting Eye ........................................................................................ 36

Tool System ................................................................................................................ 37Remote Start/Stop System .......................................................................................... 38

Toggle Switch ........................................................................................................ 38Captive Air Cylinder ............................................................................................... 38

Table of Contents

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Other Methods of Lowering/Stowing the Unit ............................................................... 38Secondary Stowage DC Pump ..................................................................................... 39Manually Lowering/Stowing the Unit ............................................................................ 39Auxiliary Power Sources .............................................................................................. 42

Section 6 Care of the Unit

Hydraulic System ........................................................................................................ 45

Fiberglass .................................................................................................................... 45Single Handle Control and Control Handle Covers ....................................................... 45Structures and Mechanical Systems ........................................................................... 45

AppendixGlossaryMaterial Handling Capacity ChartsTroubleshooting Chart

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Section 1 Introduction 1

Section 1 Introduction

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

This symbol is used throughout this manual to

indicate danger, warning, and caution instruc-tions. These instructions must be followed toreduce the likelihood of personal injury and/or propertydamage.

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

Danger

Indicates an imminently 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.

WarningIndicates a potentially hazardous situation which,

if not avoided, could result in death or seriousinjury.

CautionIndicates a potentially hazardous situation which,

if not avoided, may result in minor or moderateinjury. It may also be used to alert against unsafe

practices.

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

About This Manual

This manual provides instruction for the operation of theunit. The operator must be familiar with the unit and itscapabilities before using the unit on the job. This manualis written to provide an understanding of the unit, safety,proper set-up, and operation.

Charts and figures are provided to support the text.Because options vary from one model to another, somefigures may only be a representation of what is actually onthe unit.

Contact the following organizations for additional informa-tion.

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

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

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

(OSHA)

Dealers, installers, owners, users, operators, rentors,lessors, and lessees must comply with the appropriate

sections of the applicable ANSI standard.

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

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2 Section 1 Introduction

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Section 2 Unit Specifications 3

Section 2 Unit Specifications

Purpose of the Unit

This unit has been designed and built to function as aninsulated aerial work platform. It can be used to raisepersonnel and material to the workstation.

General SpecificationsThis unit uses a side-by-side boom design. Unit heightspecifications are based on 40-inch (101.6 centimeters)frame height, but common frame heights vary from 36inches (91.44 centimeters) to 44 inches (111.76 centime-ters). Figure 2.1 provides general unit specifications.

Insulation or isolation capabilities depend on proper maintenance and dielectric testing of the fiberglass components. As with any insulated unit, there are limits toprotection that can be provided by the unit. Some of thoselimitations are presented in this manual in Section 4 undeOperation Near Energized Conductors.

This unit may be ANSI rated for insulated aerial devices asCategory A, B, or C. This ANSI rating is stamped on theserial number placard located on the pedestal. Dielectrictesting of the insulating components and proper maintenance are necessary to maintain optimum dielectric protection.

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4 Section 2 Unit Specifications

Item

AM50

AM55

AM5

0E

AM55E

Maximumgroundtobottomofpla

tformheight

50.3

(15.3m)

55.3

(16.9m)

51.4

(15.7m)

56.0

(17.1m)

Workingheight

55.3

(16.8m)

60.3

(18.4m)

56.4

(17.2m)

61.0

(18.6m)

Maximumsidereachupperboomovercenter,lowerboomat0

42.3

(12.9m)

47.3

(14.4m)

44.1

(13.5m)

48.8

(14.9m)

Maximumsidereachupperboomnon-overcenter

31.5

(9

.6m)1

34.4

(10.5m)1

39.7

(12.1m)2

43.4

(13.2m)2

Travelheight

11.3

(3

.4m)

11.3

(3.4m)

11.3

(3

.4m)

11.3

(3.4m)

Maximumhydraulicpressuresetting

3,0

00psi(207bar)

3,0

00psi(207bar)

3,0

00psi(207bar)

3,0

00psi(207bar)

Rotation

Continuous

Continuous

Contin

uous

Continuous

Lowerboomarticulation

0

to1

00

0

to100

0

to124

0

to124

Lowerboomisolation

24

(610mm)

24

(610mm)

12

(305mm)

24

(610mm)

Upperboomarticulation

0

to2

10

0

to210

0

to200

0

to200

Upperboomisolation

120(3048mm)

150(3810mm)

120(3048mm)

150(3810mm)

Winchcapacity(fulldrum)

2,0

00lb(9

07.2

kg)

2,0

00lb(907.2

kg)

2,0

00lb(9

07.2

kg)

2,0

00lb(907.2

kg)

Jibarticulation

-30to

90

-30

to90

-30to

90

-30

to90

Maximumjibcapacity(extended)3

750lb(340.2

kg)

750lb(340.2

kg)

750lb(340.2

kg)

750lb(340.2

kg)

Maximumjibcapacity(retracted)3

2,0

00lb(9

07.2

kg)

2,0

00lb(907.2

kg)

2,0

00lb(9

07.2

kg)

2,0

00lb(907.2

kg)

Maximummaterialhandlingcapacity3

2,0

00lb(9

07.2

kg)

2,0

00lb(907.2

kg)

2,0

00lb(9

07.2

kg)

2,0

00lb(907.2

kg)

Maximumlowerboomliftingeyecapacity3

2,0

00lb(9

07.2

kg)

2,0

00lb(907.2

kg)

2,0

00lb(9

07.2

kg)

2,0

00lb(907.2

kg)

Syntheticwinchline

80

80

80

80

Maximumtoolpressure

2,0

00psi(138bar)

2,0

00psi(138bar)

2,0

00psi(138bar)

2,0

00psi(138bar)

Maximumtoolflow

8gpm(30

.3l/min)

8gpm(30.3

l/min)

8gpm(30

.3l/min)

8gpm(30.3

l/min)

Maximumplatformcapacityon

eman3

400lb(181.4

kg)

400lb(181.4

kg)

400lb(181.4

kg)

400lb(181.4

kg)

Maximumplatformcapacitytw

oman3

800lb(362.9

kg)

800lb(362.9

kg)

800lb(362.9

kg)

800lb(362.9

kg)

Maximumtotalplatformcapacitydualoneman,singlecontrol3

800lb(362.9

kg)

800lb(362.9

kg)

800lb(362.9

kg)

800lb(362.9

kg)

Maximumtotalplatformcapacitydualoneman,

dualcontrols3

800lb(362.9

kg)

700lb(317.5

kg)

800lb(362.9

kg)

700lb(317.5

kg)

Platformrotation

90

90

90

90

1Lowerboomat100

2Lowerboomat124

3Refertocapacityplacards

Figure2.1UnitSpecifications

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Component Identification

Upper Boom

Outriggers

Outrigger

Controls

Lower BoomCylinderPedestal

Turntable

LowerControls

Boom Pin

Upper Controls

Lower Boom

UpperBoom DriveMechanism

Upper BoomCylinders Elbow

Winch

Jib

UpperBoom Tip

Lower BoomInsulator

Platform

Platform TiltCylinder

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Reach Diagrams

AM50

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Section 3 Safety 7

AM55

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AM50E

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AM55E

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Section 3 Safety 11

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 inwhich accidents can occur. Pay special attention to allsafety alerts.

Danger

Death or serious injury will result from careless orimproper use of the unit. Do not operate the unitwithout proper training.

Warning

Death or serious injury can result from careless orimproper use of the unit. The operator bears ultimateresponsibility 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 trainedto act quickly and responsibly in an emergency, knowingthe location of the controls and how they operate. Keepany tools or equipment needed to perform manual opera-tions in a well-marked, designated area.

Danger

Death or serious injury will result from unprotectedcontact with energized conductors. Maintain safe

clearances from electrical power lines and apparatus.

Allow for platform or line sway, rock, or sag.

Death or serious injury will result from unprotectedcontact with energized conductors. This unit does not

provide protection from contact with or proximity toan electrically charged conductor when you are in

contact with or proximity to another conductor or anygrounded device, material, or equipment. Maintain

safe clearances from energized conductors.

Death or serious injury will result from unprotected

contact with energized conductors. Operators mustread and understand the contents of Section 4 in this

manual before operating the unit near energized con-ductors.

Knowledge of the information in this manual and propertraining provide a basis for safely operating the unit. Follow

your employers safe work practices and the procedures inthis 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 accor-

dance with the manufacturers and governmentsrequirements.

Use the personal fall protection system. 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 boomsfrom the rest.

Operate the controls smoothly, avoiding suddenstarts and stops.

Never exceed the rated capacity values. Follow all of your employers work rules and applicable

government regulations.

Capacity

Platform capacity of the unit is the total weight of thepersonnel, tools, material, and liner that may be lifted bythe platform without overloading the unit. The platformcapacity can be found on the serial number placard locatedon the pedestal. Before lifting a load, determine the totaweight to be lifted by the unit, including personnel, tools

material, and liner. Compare that total weight to thecapacity listed on the serial number placard.

Capacity information for the material handling system canbe found in Section 5.

Accident Prevention Signs

This unit was equipped with accident prevention signs athe time of manufacture. If any of these are lost or becomeillegible, obtain replacements from your Altec representative.

The location, part numbers, and descriptions of all placards are listed in the Parts Manual. Refer to the AccidenPrevention Signs and Diagram for examples of the placards and their locations.

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12 Section 3 Safety

Accident Prevention Signs Diagram

2*

16* 10*

2

16* 10*

11 6 7 22

14 9

18 All placards on top andbottom of boom tip cover

2 12

12

15

* Located on both sides of unit

21 19

8*

1

9

6

17Single 2-manPlatform Only

Single 2-man

Platform Only 4

3

Top only

13

5

20

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Section 3 Safety 13

1

2

43

4-06

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14 Section 3 Safety

6

75

8

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Section 3 Safety 15

9 10

13

12

11

4-06

DANGER

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16 Section 3 Safety

16

18

1514

17

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Section 3 Safety 17

19

2122

20

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18 Section 3 Safety

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Section 4 Before You Operate 19

Section 4 Before You Operate

All operators involved in the use and/or care of this unitmust know the location and understand the operation ofeach control on the unit. Control locations are pointed outin Component Identification. Operation of the controls isexplained in Section 5.

Capacity and StabilityMaximum capacity of the platform(s) is stated on the serialnumber placard. This placard is mounted on the side of thepedestal. Capacity values indicate the lift capacity of theunit.

Warning

Death or serious injury can result from overloading

the unit. Do not exceed the rated capacity values.

An upper boom angle indicator and a placard indicatingmaterial handling lift capacities are located at the boom tip.Sample material handling placards are shown in Figure4.1. The values on the jib capacity placard indicatemaximum structural capacity of the jib only. The values onthe lift capacity placard indicate the maximum load whichcan be lifted at various boom angles and configurations.Refer to the material handling capacity chart, platformmounted placards, and angle indicators for specific liftinformation.

Warning

Park on a firm surface before operating the unit. Use

wheel chocks and parking brakes. On units equippedwith outriggers, use of outriggers is mandatory. On

such units, outriggers must be extended as instructed

under Outriggers. Use outrigger pads on all unpavedsurfaces, asphalt pavement, and other soft surfaces

It is impossible to foresee all situations and combinationsfor set up of the unit. Establish criteria for stable operationof the unit based on actual conditions, work procedures

and experience. The owner and operator bear ultimateresponsibility for insuring that the unit is properly set up

Warning

Death or serious injury can result if the unit becomesunstable. Properly set the outriggers before moving

the booms from the rest.

Understand the stability characteristics of this unit beforeusing it. As delivered, this unit will meet or exceed therequirements for stability as set forth in ANSI publications

Determine the weight of the material before moving it. Usethe placards on the unit and in the Operators Manual todetermine the available rated lifting capacities. Do notexceed rated lift capacities.

Using the unit in an unsafe manner or overloading the unitcan cause weld fatigue and eventual failure.

Stability, or resistance to tipping, is determined by manyfactors including the size and weight of the chassis and thelocation of the unit mounting on the chassis. The unit isequipped with outriggers to help stabilize the unit while i

is in use.

Figure 4.1 Sample Material Handling Capacity Charts

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20 Section 4 Before You Operate

Operation NearEnergized Conductors

Warning

Death or serious injury can result from careless orimproper use of the unit. The operator bears ultimate

responsibility for following all regulations and safetyrules of their employer and/or any state or federal law.

This unit is manufactured with an insulated upper boomand lower boom insert. When these components areproperly used and maintained, the unit will provide second-ary insulation so that the unit will perform its function as aninsulated aerial work platform. The unit is manufactured tomeet ANSI dielectric requirements in effect at the time ofits manufacture. The classification and dielectric rating ofthe unit must be known and understood by its users.Category B and C aerial devices are designed and manu-factured for work in which the boom is not considered asprimary insulation, but secondary to other protectiveequipment such as insulating (rubber) gloves, sleeves,and hot sticks.

This unit is equipped with an insulated single handlecontrol(s). The control, which is green in color, may offerlimited secondary dielectric protection. To maintain thislimited secondary protection it must be kept clean, dry,and in good condition with periodic tests of its dielectricproperties.Never rely on the insulating feature of the singlehandle control as a substitute for primary protection fromelectrical contact.

Rubber control covers, used on upper control valve handles,do not insulate the controls, but may provide limiteddielectric protection in certain circumstances. Never relyon the rubber control covers as protection from electrical

hazards.

Danger

Death or serious injury will result from careless orimproper use of the unit. Do not operate the unit

without proper training.

All personnel using this unit must understand the hazardsof contact with energized conductors, for the protection ofthemselves, their coworkers, and the public.

Electricity seeks earth ground by any means avail-able. Non-insulated units, or insulated units not knownto be in good condition, must not be taken close toenergized conductors. OSHA regulations prescribeminimum clearances required for such equipment.

An operators primary protection from electrical con-tact comes through the use of protective equipment

(insulated gloves, insulated sleeves, hot sticks) andmaintenance of appropriate clearance. The unit itselfonly provides secondary protection for the operator byinsulating the operator from grounding through theboom and vehicle.

DangerDeath or serious injury will result from contact with or

proximity to an energized conductor. Maintain thedielectric characteristics of the insulating compo-

nents.

The fiberglass boom and internal upper boom compo-nents are intended to provide the platform occupantsecondary protection from current flow to groundpotential through the boom and vehicle. This protec-tion is provided only when they are clean, dry, freefrom tracking, and in good condition, as establishedby dielectric testing. Utility poles, cross arms, hard-ware, etc., must be considered to be grounded. Thisunit cannot protect platform occupants against elec-trocution from body contact with two energized con-ductors or a single energized conductor and anygrounded equipment, including neutral wires.

The fiberglass platform and other fiberglass or plasticcomponents (including covers) will not provide protec-tion against electrical current. Properly fitted with aliner, designed, tested, and maintained for the dielec-tric rating, the platform will offer some protection forthe lower extremities of the occupants body when

they are entirely within the liner and not in contact withother objects including the boom tip area. It cannotprotect against contact between an occupant, directlyor through the boom tip, and either two conductors ora single conductor and grounded equipment. Neverrely on fiberglass or plastic components at the boomtip as protection from electrical hazards.

The upper and lower boom insulated portions aredefined by placards on the booms (refer to Figure 4.2).These insulated portions are intended to provide theplatform occupant secondary protection from currentflow to ground potential through the boom and vehicle.

The placard on the upper boom farthest away from theelbow also defines the boom tip area as all compo-nents beyond the placard (refer to Figure 4.2). Theboom tip area should be considered conductive anddoes not provide any protection from contact withenergized conductors or contact with an energizedconductor and any grounded equipment on or incontact with the pole, including neutral wires. Occu-pants of the platform must consider the boom tip aconductive object subject to minimum approach dis-tance rules (refer to the placard in the AccidentPrevention Signs Diagram and on the unit).

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Danger

Death or serious injury will result from failure to followsafe electrical work practices. The OSHA minimum

approach distances for qualified electrical workersand line clearance tree trimmers must be maintained.

All other workers must stay at least 10 feet fromenergized conductors.

Only qualified electrical workers using appropriatepersonal protective equipment (rubber gloves/sleeves)

may come closer than the minimum approach dis-tance to an unguarded energized conductor. When

using rubber gloves/sleeves to work on an energizedconductor, the minimum approach distance must be

maintained between the operator/aerial device andany other unguarded energized conductors.

Occupants of a fiberglass platform must not touch twoenergized conductors, or an energized conductor anda grounded wire or components without using personalprotective equipment for primary protection. The boomtip area should be considered conductive and at thesame electrical potential as objects it is in contact withor near.

Contact by conductive components, or even anynonconductive component, with an energized con-ductor may energize the entire vehicle. If the vehiclebecomes energized, it is an extreme hazard to anyonewho might touch the vehicle or unit. All personnel mustremain clear of the vehicle or unit any time booms areelevated 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 con-ductor and a ground.

Contact by any part of the boom tip with an energizedconductor while the boom tip is also in contact withanother energized source or a grounded object cancause the hydraulic oil at the boom tip to burn oexplode.

Tools, supplies, and metal components of the unitincluding the boom tip and controls, may be conductive and should be used with care.

Hydraulic oil must be kept free of water and othecontaminants to maintain its dielectric properties

Sample and test the hydraulic oil periodically.

In addition to these hazards, other hazardous situationsmay endanger personnel. Personnel must be aware of andpractice all regulations and safety rules of their employeand/or any state or federal law.

Daily Preoperational Inspection

Inspect the unit at the beginning of each work day beforegoing out on the job to detect potential service and safetyproblems. Check the following items during the dailypreoperational inspection (refer to Inspection Diagram). Iany problem is found, including oil leaks or improperoperation, stop and have the problem corrected beforeplacing the unit in service.

1. Position the unit on a level surface. With the boomsand outriggers stowed, check the oil level in thehydraulic reservoir. The oil level must be between theAdd and Full marks on the dipstick. If necessary, addoil as described in the Maintenance Manual. The needto add oil regularly indicates a leak in the hydraulicsystem that should be corrected.

Figure 4.2 Insulated Portion of Booms and Conductive Boom Tip Area

Insulated Portion

Elbow ConductiveBoom Tip Area

Band of Arrows Placards

Insulated Portion

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Warning

Death or serious injury can result from hydraulic oil

being injected into the flesh. Do not use hands or otherbody parts to check hydraulic lines and fittings for

leaks.

Seek medical attention if injured by escaping hydrau-lic oil. Serious infection or reaction can result ifmedical treatment is not given immediately.

Spilled hydraulic oil creates slick surfaces and cancause 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.

Inspection Diagram

This diagram is for representational purposes only.The operator bears ultimate responsibility for properly inspecting all components.

CounterbalanceValves

Pins

Weldments

Cylinders

Outriggers

MaterialHandling Jib

Winch Line

Reservoir

Oil LevelSteel Tubes

SecondaryStowage System

PlatformMounting Bracket

Platform/

Liner

Lower Controls

Lower/Upper BoomFiberglass Sections

Hoses

Upper Controls

Secondary StowageDC Pump

Fasteners/Cap Screws

Pins/Fasteners

Covers

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2. Visually inspect the unit for hydraulic leaks. Continueto look for hydraulic leaks while performing the inspec-tion.

3. Throughout the inspection, pay particular attention tothe following components, looking for proper operationand any damage, cracks or corrosion, missing or

loose fasteners, cracked or broken inspection marks,and excessive wear.

Rotation bearing Rotation gearbox Lower boom pin Lower boom cylinder mounting pins Both upper boom cylinder mounting pins Upper boom drive mechanism mounting pins Elbow area Leveling system Platform tilt cylinder pins Platform pin

Platform mounting bracket Platform mounting fasteners Winch gearbox Winch line and material handling attachment Personal fall protection system Covers

4. Inspect all covers to make sure they are in place,secure, and in good condition.

5. Check visual and audible safety devices for properoperation. Replace missing and/or illegible placards.

Danger

Death or serious injury will result from unprotectedcontact with energized conductors. The platform and

covers carry no dielectric rating. They cannot protectagainst contact between an operator and either twoconductors or a single conductor and grounded ele-

ments of the pole. The fiberglass platform, properlyfitted with a platform liner, designed, tested, and

maintained for the dielectric rating, will offer someprotection for the lower extremities of the occupant.

6. Inspect the fiberglass booms, single handle control,control handle covers, boom tip covers, and platform(s)for any conditions that could reduce the limited dielec-tric properties, including the following items.

a. Dirt and foreign objects.

b. Damage, including chipped or scratched surfaces.

c. Holes in the platform, liner, and control handlecovers.

d. Moisture and/or oil.

Warning

Death or serious injury can result from falling from theplatform. All platform occupants must properly use anappropriate 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 ofconductive material.

7. Apply the parking brake, chock the wheels, start theengine, and engage the power take-off (PTO).

AttentionDo not put the unit in service and run the pump atnormal operating speeds until the hydraulic oil reser

voir feels warm to the touch.

8. If the temperature outside is below 32 degrees Fahrenheit (0 degrees Celsius), warm the hydraulic oibefore operating the unit. The procedure for warmingthe oil is described in this section under Cold WeatheStart-Up. Do not operate the pump or engine at morethan a fast idle until the hydraulic oil has warmed up

9. Unlatch the manual upper boom restraint, if so equippedWith the outriggers stowed, test the outrigger interlocksystem, if so equipped, by placing the upper boom

control in the Unfold position. If boom movemenoccurs, the outrigger interlock system is not functioning properly.

10. Move the machine/outrigger selector switch to Outriggers. Properly set the outriggers as described inSection 5 under Outriggers. Check for proper opera-tion and audible alarms.

Danger

Death or serious injury will result from unprotectedcontact with energized conductors. Maintain safe

clearance from electrical power lines and apparatusAllow for platform or line sway, rock, or sag.

Caution

Injury and property damage can result from contact of

the booms or platform with fixed objects. Make surethere is sufficient clearance before operating the unit

Injury and property damage can result from abruptreversals in direction, starts, or stops. Operate the

controls smoothly.

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11. Move the machine/outrigger selector to the Machineposition.

a. Unlatch the manual upper boom restraint, if soequipped.

b. The automatic upper boom restraint, if so equipped,

should disengage when the station selector is inLower Controls. The automatic restraint will openas the upper boom is raised.

12. Test the operation of the lower controls with nopersonnel in the platform.

a. Operate each control with the control selector in theEmergency Stop position. If movement occurs, theemergency stop is not functioning properly.

b. Operate each function through the full range ofmotion. All functions must operate smoothly, con-

sistently, and the controls must return to neutralafter being released. While the unit is operating,look for malfunctioning components and oil leaks.

c. When the control selector is in the lower controlposition, all upper controls, except platform tilt,should not function. The lower controls must overridethe upper controls.

Caution

Injury and property damage can result from abrupt

reversals in direction, starts, or stops. Fully engagethe interlock trigger before moving the control. Centerthe control before releasing the trigger.

AttentionWhen testing the operation of the interlock system,position the platform and booms to prevent damage

from unexpected movement.

13. Test the operation of the upper controls.

a. Operate a control with the emergency stop pushed in.If movement occurs, the emergency stop is not

functioning properly.

b. Operate the single handle control without engagingthe interlock trigger. If boom movement occurs, theinterlock system is not functioning properly.

c. Engage the single handle control interlock trigger.The vehicle engine should throttle up.

d. Operate each function. While the unit is operating,look for oil leaks.

14. Test the interlock blocking valve.

a. Operate the unit from the upper controls.

b. Return to the lower controls.

c. With the control selector still in the Upper Controls

position, move a control handle of one of the lowercontrols. If boom movement occurs, the interlocksystem is not functioning properly.

AttentionThe DC pump is for secondary stowage use only.

Damage to the pump and motor can result if the DCpump is operated more than three minutes continu-ously.

15. Check the secondary stowage DC pump system forproper operation.

Warning

Death or serious injury can result if the unit becomesunstable. Properly stow the booms before raising the

outriggers.

16. Stow the booms, raise the outriggers, disengage thePTO, and turn off the engine.

Preparing for Operation

Before using this unit each day, perform the daily preop-erational inspection. This unit may be operated in accor-dance with the following procedure on firm surfaces.Consider the reach of the unit and the work to be done whenpositioning the unit.

1. Place the transmission in neutral and apply theparking brake. Apply the supplemental holding brake,if so equipped, and chock the wheels.

Warning

Park on a firm surface before operating the unit. Use

wheel chocks and parking brakes. On units equippedwith outriggers, use of outriggers is mandatory. On

such units, outriggers must be extended as instructedunder Outriggers. Use outrigger pads on all unpaved

surfaces, asphalt pavement, and other soft surfaces.

It is impossible to foresee all situations and combinationsfor set up of the unit. Establish criteria for stable operationof the unit based on actual conditions, work procedures,and experience. The owner and operator bear ultimateresponsibility for insuring that the unit is properly set up.

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HydraulicHose

Needle Valve

Quick Coupler

2. Engage the PTO according to the manufacturersoperating instructions.

3. If so equipped, move the truck/machine selectorswitch in the cab to the Machine position.

CautionInjury can result from slipping and falling. Use careand the handles and steps provided.

AttentionDo not put the unit in service and run the pump atnormal operating speeds until the hydraulic oil reser-voir feels warm to the touch.

4. If the temperature outside is below 32 degrees Fahr-enheit (0 degrees Celsius), warm the hydraulic oilbefore operating the unit. The procedure for warmingthe oil is described in this section under Cold WeatherStart-Up. Do not operate the pump or engine at morethan a fast idle until the hydraulic oil has warmed up.

5. Move the machine/outrigger selector to Outriggers.

6. Properly set the outriggers as described in Section 5under Outriggers.

7. Unlatch the manual upper boom restraint, if so equipped.

Cold Weather Start-Up

When operating the unit in temperatures of 32 degreesFahrenheit (0 degrees Celsius) or below, use a coldweather hydraulic oil in the hydraulic system. Refer to theMaintenance Manual for oil recommendations.

Warning

Death or serious injury can result if the recommendedhydraulic oil is not used. Other fluids added to the

hydraulic system can affect the insulating capability ofthe unit.

Attention

Only use hydraulic oil as recommended. Other fluidsadded to the hydraulic system can increase compo-

nent wear and affect the lubricating characteristics o

the oil.

Do not put the unit in service and run the pump atnormal operating speeds until the hydraulic oil reservoir feels warm to the touch.

Cold, thick oil does not flow well and may cause delays inresponse to control movement, as well as cavitation andconsequent pump damage.

If the unit is equipped with a tool circuit, the hydraulic oican be warmed up quickly using the following procedure

1. Attach a 1/16(1.60 millimeters) orifice or needle valveto a hydraulic hose that is 2to 3(60 to 100 centimeters) long.

2. Attach a quick disconnect coupler to each end of thehose. An oil warming kit (refer to Figure 4.3) containing

all necessary parts for this assembly can be foundunder Service Tools and Supplies in the MaintenanceManual Appendix.

Figure 4.3 Oil Warming Kit

3. Connect each end of the hose to the units lower oupper tool circuit.

4. Turn the tool function on. If the hose is equipped witha needle valve, turn the needle valve clockwise (inuntil the engine throttles up.

5. After the hydraulic oil has warmed up, turn the toofunction off and disconnect the oil warming kit.

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Section 5 Operation 27

Section 5 Operation

Caution

Injury and property damage can result from abruptreversals in direction, starts, or stops. Operate the

controls smoothly.

Outriggers help stabilize the unit while it is in use. Before

operating the unit, follow the procedure in Section 4 underPreparing for Operation. Properly set the outriggers asdescribed in the following section.

Warning

Park on a firm surface before operating the unit. Usewheel chocks and parking brakes. On units equipped

with outriggers, use of outriggers is mandatory. Onsuch units, outriggers must be extended as instructed

under Outriggers. Use outrigger pads on all unpavedsurfaces, asphalt pavement, and other soft surfaces.

It is impossible to foresee all situations and combinationsfor set up of the unit. Establish criteria for stable operationof the unit based on actual conditions, work procedures,and experience. The owner and operator bear ultimateresponsibility for insuring that the unit is properly set up.

Ground Level Controls

Machine/Outriggers SelectorThe machine/outriggers selector handle operates a hy-draulic valve to make the outriggers or the unit functionsoperational. This control is located on the tailshelf of the

unit (refer to Figure 5.1).

Figure 5.1 Ground Level Controls

OutriggersThe controls for the outriggers are located at the tailshelf

Warning

Park on a firm surface before operating the unit. Usewheel chocks and parking brakes. On units equipped

with outriggers, use of outriggers is mandatory. Onsuch units, outriggers must be extended as instructed

under Outriggers. Use outrigger pads on all unpavedsurfaces, asphalt pavement, and other soft surfaces

It is impossible to foresee all situations and combinationsfor set up of the unit. Establish criteria for stable operationof the unit based on actual conditions, work proceduresand experience. The owner and operator bear ultimateresponsibility for insuring that the unit is properly set up

Warning

Death or serious injury can result if the unit becomesunstable. Properly set the outriggers before moving

the booms from the rest.

Death or serious injury can result from contact with amoving outrigger. Clear the area around the outrig

gers before operating the unit.

Death or serious injury can result if the unit becomesunstable. Properly stow the booms before raising theoutriggers.

The surface that the outrigger shoe will rest on must be firmand capable of supporting a substantial load in a concentrated area. If necessary, place outrigger pad supportsbeneath each outrigger shoe to increase the support areaand load holding capability.

Downward movement on the outrigger control lowers theoutrigger and upward movement raises the outrigger. Thecontrol returns to neutral when released.

Properly Setting on a Level SurfaceWith the booms stowed, lower the outriggers to a firmfooting.

Lower the outriggers as far as possible, while allowing thevehicle to be level, with all tires maintaining contact withthe ground surface. Although the tire-to-surface contacpressure may vary, extend the outriggers to remove thebulge from the tires. Lower the outriggers approximately 3inches (7.5 centimeters) after reaching ground level. Thiswill usually be enough to remove the bulge and still be ableto see some tire-to-surface contact at each tire.

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28 Section 5 Operation

To insure proper outrigger spread when using outriggerpads or blocks, extend the outriggers approximately 3inches (7.5 cm) after reaching ground level (not padsurface level). This may result in tires coming off theground.

Properly Setting on a Sloping Surface

With the booms stowed, lower the low side outriggers to afirm footing.

Lower the high side outriggers only after a firm footing hasbeen reached with the low side outriggers. Lower the highside outriggers approximately 3 inches (7.5 cm) afterreaching the ground level. Adjust outrigger extension toestablish a level vehicle.

Lower the outriggers as far as possible, while allowing thevehicle to be level, with all tires on the high side maintain-ing contact with the ground surface. Tires on the low sideof the slope may not remain in contact with the ground,

depending on how much slope is present.

To insure proper outrigger spread when using outriggerpads or blocks, extend the outriggers approximately 3inches (7.5 cm) after reaching ground level (not padsurface level). This may result in tires coming off theground.

Interlock SystemThe unit may be equipped with an outrigger interlocksystem. This system requires the outriggers to be de-ployed before the booms can be moved from the boom

rest. Operation of the turntable and boom functions isprevented until the outriggers are deployed. The interlocksystem does not assure full stability. The unit may alsohave an outrigger interlock override control in the vehiclecab. This control overrides the interlocks until the PTO isdisengaged. The next time the PTO is engaged theoutrigger interlocks are reactivated.

Motion AlarmThe unit is equipped with an outrigger motion alarm. Anaudible alarm alerts personnel in or near the work area thatthe outriggers are in motion.

When an outrigger control handle is moved from neutral,the warning is sounded. Returning the handle to neutralturns the alarm off.

Lower Controls

Warning

Death or serious injury can result from unit operationby someone other than the platform occupant. Whenthe 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 op-erator.

The lower control station is located on the turntable and isshown in Figure 5.2. This station has controls for thefollowing functions.

Boom function controls Emergency stop control Auxiliary winch control Platform stow control for units with single two-man

platform Control selector

The following functions can be selected by the controlselector valve.

Upper controls Lower controls Emergency stop

Place the control selector in the Upper Controls position tooperate the unit from the upper controls at the platform.

Trapped air may lead to hesitancy in the control system orpoor metering of the control functions. When the selectorhandle is in the Upper Controls position, it will automati-cally purge the system until the interlock trigger on thesingle handle control is engaged.

Caution

Injury and property damage to the unit can result fromuncontrolled movement. Move the control selector tothe Upper Controls position when the lower controls

are not in use.

Place the control selector in the Lower Controls position tooperate the unit from the lower controls at the turntable.The upper controls at the platform, except platform tilt, arenot operational while the selector is in the Lower Controlsposition. After operating the unit from the lower controlsmove the control selector to the Upper Controls position.This prevents movement of the unit from accidentalmovement of the lower control handles.

Place the control selector in the Emergency Stop positionto stop all functions from the lower controls.

Upper Controls

Various controls are used to operate unit functions fromthe upper control station (refer to Figure 5.3). Refer to theappropriate section for operation of the secondary stow-age pump, start/stop system, platform, jib, winch, and toolfunctions.

3-06

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Figure 5.2 Lower Controls

The following functions can be operated from the uppercontrols.

Lower boom raise/lower Upper boom fold/unfold Turntable rotate Platform rotate Platform tilt Jib extend/retract Jib tilt Winch pay in/out Tools on/off Emergency stop Remote start/stop Secondary stowage DC pump

Emergency StopAn emergency stop valve is located at the upper controlstation(s) (refer to Figure 5.3). This valve blocks hydraulicoil flow to stop all functions at the upper controls.

When the knob is pushed down, the following functions willnot operate.

Lower boom raise/lower Upper boom fold/unfold Turntable rotate

Platform rotate Platform tilt Jib extend/retract

Jib tilt Winch pay in/out Tools on/off

Single Handle ControlOne or more functions may be operated at a time. Thespeed of movement is relative to the movement of thecontrol.

As the upper boom unfolds overcenter, platform movement changes from raising to lowering with respect to theground.

The following functions can be operated with the singlehandle control.

Lower boom raise/lower Upper boom fold/unfold Turntable rotate

Interlock

The interlock system is intended to prevent unintentionaboom movement that might result from accidental bump-ing of the single handle control.

Full Pressure

Pilot Pressure

3-06

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Figure 5.3 Upper Controls

Outside, Below Hole

Outside, Above Hole

Caution

Injury and property damage can result from abrupt

reversals in direction, starts, or stops. Fully engagethe interlock trigger before moving the control. Center

the control before releasing the trigger.

The interlock trigger can be engaged as a natural part ofgrasping the single handle control.

Booms

This unit is an overcenter type design with articulating side-by-side booms. The booms may be positioned individuallyor in coordination with one another. The boom functions maybe controlled from the lower or upper controls.

The booms are made of steel and fiberglass.

Warning

Death or serious injury can result from improper useof the boom(s) or platform(s). Do not use the boom(s)or platform(s) to push or support objects such as

poles, conductors, etc.

Lower BoomOperate the lower boom from the upper controls with the

single handle control for normal operation. Engage theinterlock trigger and move the control in the desireddirection. Operate the lower boom from the lower controlswhen using the lower boom lifting eye, when testing, orduring an emergency.

A double-acting cylinder is used to raise and lower thelower boom. The cylinder is held in position by twocounterbalance holding valve cartridges in a block near thebase end of the cylinder. The holding valves are intendedto prevent oil from escaping from the cylinder if a hydraulicline fails.

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Upper BoomOperate the articulating upper boom from the upper con-trols with the single handle control for normal operation.Engage the interlock trigger and move the control in thedesired direction. Operate the upper boom from the lowercontrols when using the lower boom lifting eye, whentesting, or during an emergency.

Single-acting cylinders are used to raise and lower theupper boom. The cylinders are held in position by counter-balance holding valve cartridges in a block near the baseend of the cylinders. The holding valve is intended toprevent oil from escaping from the cylinder if a hydraulicline fails.

The unit will have either a manual or automatic upper boomrestraint to hold the boom in the rest.

The automatic restraint (refer to Figure 5.4), if so equipped,requires no action by the operator. The restraint locking

mechanism is automatically actuated by the followingactions.

When the PTO is disengaged When the machine/outrigger selector is in the

Outrigger position When the control selector is in the Upper Controls

position and the upper control interlock is notengaged

Figure 5.4 Upper Boom Restraint

The automatic restraint may be connected to a light in thevehicle cab, which indicates when the upper boom is notproperly stowed.

Boom StorageIf the booms bounce while the vehicle is in motion, damagemay be caused to the booms, cylinders, turntable, and/orthe platform. Excessive downward force after the booms

are in the rest may also damage the booms and/or boomrest.

The unit is equipped with a valve to limit the force appliedto the lower boom rest while stowing the lower boomDownward force is limited by a mechanically activatedswitch connected to a solenoid valve that reduces the

pressure to the retract side of the cylinder as the loweboom nears its rest.

Warning

Death or serious injury can result if the unit becomes

unstable. Properly stow the booms before raising theoutriggers.

AttentionFollow the stowing procedure to prevent damage tothe unit.

Tilt the jib parallel to the upper boom before stowingthe boom.

When stowing the booms, use the following procedure.

1. Position the platform in its stowed position at the sideof the boom tip.

2. Position the jib parallel to the upper boom.

3. Rotate the turntable to position the lower boom ovethe boom rest.

4. Stow the lower boom.

5. Stow the upper boom. Make sure the platform and jibclear any obstacles as the upper boom is placed in therest.

6. Fasten the upper boom strap, if so equipped.

Rotation

The turntable can be rotated through 360 degrees continuously after the booms are elevated.

The rotation system is self-locking, intending to assurethat the turntable will remain in position when hydraulicpressure is not applied to the motor. The system iscapable of holding the turntable in position without the useof a brake.

At the upper controls, engage the interlock trigger, raisethe booms to clear any obstacles, and move the singlehandle control in the appropriate direction to rotate theturntable. Return the control to neutral to stop rotation.

Restraint

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At the lower controls, raise the booms to clear anyobstacles, and move the control handle in the appropriatedirection to rotate the turntable. Return the control toneutral to stop rotation.

An extension shaft is provided on the gearbox to allow formanual rotation. Other Methods of Lowering/Stowing the

Unit in this section describes this procedure.

Personnel Platform

The unit is equipped with one of the following options.

Single 1-man, side-mounted Single 2-man, side-mounted Dual 1-man, side-mounted

Danger


contact with energized conductors. Operators mustread and understand the contents of Section 4 in thismanual before operating the unit near energized con-

ductors.

Death or serious injury will result from unprotectedcontact with energized conductors. The platform is

not considered insulated and carries no dielectricrating. The fiberglass platform cannot protect against

contact between an operator and either two conduc-tors or a single conductor and grounded elements ofthe pole. The fiberglass platform, properly fitted with

a platform liner designed, tested, and maintained forthe dielectric rating, will offer some protection for the

lower extremities of the occupant.

Warning

Death or serious injury can result from careless orimproper use of the unit. The operator bears ultimate

responsibility for following all regulations and safetyrules of their employer and/or any state or federal law.

Death or serious injury can result from contact with

energized conductors. Do not operate the unit with a

hole in the platform or liner.

Death or serious injury can result from falling from theplatform. Do not use a ladder or other means to extend

reach from the platform.

Death or serious injury can result from falling from theplatform. Do not sit or stand on the platform rim.

Death or serious injury can result from improper useof the unit. Do not operate the unit or occupy the

platform while the vehicle is in motion.

Death or serious injury can result from improper use

of the boom(s) or platform(s). Do not use the boom(s)or platform(s) surfaces to push or support objects

such as poles, conductors, etc.

Death or serious injury can result from falling from theplatform. All platform occupants must properly use an

appropriate OSHA approved personal fall protectionsystem.

Keep the lanyard used with the OSHA approved per-sonal fall protection system in place and in good

condition. Never replace it with a lanyard made ofconductive material.

Death or serious injury can result from overloadingthe unit. Do not exceed the capacity values.

Caution

Injury can result from slipping and falling. Use careand the handles and steps provided.

Platform capacity of the unit is the total weight of thepersonnel, material, and liner that may be lifted by the unitwithout overloading it.

Platform RotationPlatform rotators are used to position the platform from theside of the boom to the boom tip. This allows increasedreach and better access to the jib and winch. Whenstowing the unit, rotate the platform to its stowed position

before stowing the upper boom.

A control handle at the upper controls (refer to Figure 5.3)is used to rotate the platform. Raise the control interlockand move the control to rotate the platform. The singlehandle control interlock does not have to be engaged.

The side-mounted platforms rotate 90 degrees toward theboom tip.

Caution

Injury and property damage can result from the plat-

form contacting the boom. Rotate the platform to theside of the boom before moving the boom to an

overcenter position. Do not rotate the platform past thestop when the boom is overcenter.

Two-man, side-mounted platforms have a platform rota-tion stop (refer to Figure 5.3). The stop keeps the platformfrom being rotated into a position where it might contact theboom as the upper boom goes overcenter. Release thestop to rotate the platform to the end of the boom when theupper boom is not overcenter. Do not rotate the plat-formpast the stop when the upper boom is overcenter.

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The two-man platform can be rotated to the stow positionfrom the lower controls (refer to Figure 5.2).

Stow the platform in the side-mounted position.

Platform Leveling SystemThe platform leveling system continually adjusts the

position of the platform to keep the platform floor parallelto the turntable base as the booms move.

Warning

Death or serious injury can result from a damaged

platform leveling system. Avoid contact of the boomsor platform with fixed objects such as tree limbs,poles, buildings, etc.

Platform TiltPlatform tilt may be used to remove injured personnel in anemergency, to remove water or debris from the platform,

or to tilt the platform as desired by the operator. Alloperators should become familiar with this procedure.

Warning

Death or serious injury can result from falling from the

platform. Do not operate the platform tilt when theboom functions are being operated.

AttentionDamage to the leveling system can result if the unit is

transported while the platform is tilted.

Engage the upper control interlock, lift up on the platformtilt control interlock, and move the platform tilt control(refer to Figure 5.3) in the direction desired. The platformmay also be tilted by moving the control selector on theturntable to the Lower Controls position, lifting up on theplatform tilt control interlock, and moving the tilt control inthe desired direction.

On dual platform units, both platforms are tilted by the tiltcontrol.

Return the platform to a vertical position before operating

the unit.

Lanyard AnchorThe lanyard anchor (refer to Figure 5.5) is part of thepersonal fall protection system. The lanyard must beproperly attached to the anchor. Occupants of the two-man platform can use separate anchors.

Figure 5.5 Lanyard Anchor

Material Handling System

The material handling systems provide mechanical poweto lift materials such as transformers and conductors.

The following material handling options are available.

Hydraulic extend jib Jib adapter 1-ton hook Phase lifter

Lower boom lifting eye

Danger


contact with energized conductors. This unit does notprovide protection from contact with or proximity toan electrically charged conductor when you are in

contact with or proximity to another conductor or anygrounded device, material, or equipment. Maintain

safe clearances from energized conductors.

WarningDeath or serious injury can result when the jib con-tacts two energized conductors or an energized con

ductor and a ground. Do not allow the jib to contact anenergized conductor. Use a phase lifter or other

insulated tool to handle energized conductors.

Death or serious injury can result if the winch linebreaks. Stay clear of a load that is being moved orlifted.

Anchor Two-ManPlatform Anchor

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Death or serious injury can result from improper use

of the jib or winch. Never use a jib or winch to liftpersonnel.



Refer to Figure 2.1 for material handling capacities. Neverlift an unknown load. Determine the weight of the materialbefore moving it. Use the placards on the unit and thismanual to determine the available rated lift capacities. Donot exceed rated lift capacities.

Always move material slowly and deliberately. Smooth,steady operation while handling heavy material will resultin precise and efficient work methods.

Caution

Damage to the unit can result from side loading. Use

the material handling system for vertical lifting only.

Injury and property damage can result from loss of

load control. Use tools specifically designed for andproperly attached to the lifting device when lifting

materials.

Do not attempt to physically assist the lifting device.

AttentionPlan work procedures and mentally walk throughthem before moving or lifting any load.

The jib, winch, and tool functions are not operational fromthe upper controls when the interlock trigger on the singlehandle control is engaged or when the control selector isin the Lower Controls position.

The winch may be operated from the lower controls whenthe control selector is in the Lower Controls position.

Telescopic Jib (Hydraulic Extend)The jib is a 4x 4(102 mm x 102 mm), fiberglass squareand is anchored to the support bracket with a detent pin.The jib may be tilted hydraulically through 120 degrees,

+90 degrees to -30 degrees with respect to the upperboom.

Warning


the jib. Do not exceed the values on the jib capacitychart.

AttentionProperty damage can result from failure to pay out the

winch line when extending or lengthening the jib.

A removable double sheave head is attached to the end ofthe jib for use with the winch line. The sheave head willwork either in the overcenter or non-overcenter positionsof the upper boom. Several lifting attachments are avail-able to lift insulator strings, conductors, or multiple con-ductors.

Hydraulic ExtensionMove the jib extend control in the appropriate direction toextend the jib. The jib may be extended with or without aload.

The extension cylinder assembly may be pinned to the jibin two positions. In either position, 18 inches of travel isavailable to hydraulically extend or retract the load.

Caution

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

AttentionDamage to the jib, extension cylinder, or the support

bracket can result from failure to remove the secondpin when extending or retracting the jib. When the jib

is under load, one of the pins must always be in place.The second pin must only be in place for the shorten-ing and lengthening procedures.

Use the following procedures to move the extensioncylinder from one jib pinning position to another under load.

Shortening the Jib 1. Retract the jib to near full cylinder extension. Extend-ing the cylinder retracts the jib.

2. Extend or retract the jib to line up a transfer pin holewith the hole in the jib support bracket.

3. Insert the transfer pin stored on the platform bracketcover through the support bracket and the jib.

4. Extend or retract the jib slowly to remove any loadfrom the cylinder and onto the jib support bracket.

5. Remove the pin that is through the extension guide.Operate the jib extend function to line up the extensionguide pin hole with the next jib pin hole. Install the pinthrough the extension guide pin hole and the jib.

6. Extend or retract the jib slowly to remove any loadfrom the transfer pin. Remove the transfer pin andreturn it to the holding bracket on the platform bracketcover.

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Lengthening the Jib 1. Extend the jib to near full cylinder retraction. Retract-

ing the cylinder extends the jib.

2. Extend or retract the jib to line up a transfer pin holewith the hole in the jib support bracket.

3. Insert the transfer pin stored on the platform bracketcover through the support bracket and the jib.

4. Extend or retract the jib slowly to remove any loadfrom the cylinder and onto the jib support bracket.

5. Remove the pin that is through the extension guide.Operate the jib retract function to line up the extensionguide pin hole with the next jib pin hole. Install the pinthrough the extension guide pin hole and the jib.

6. Extend or retract the jib slowly to remove any loadfrom the transfer pin. Remove the transfer pin and

return it to the holding bracket on the platform bracketcover.

AttentionFollow the stowing procedure to prevent damage to

the unit.

Tilt the jib parallel to the upper boom before stowing theboom. The jib must be tilted parallel to the upper boom soit does not contact the turntable or the lower boom whenstowing the upper boom.

Stowing the Jib 1. Tilt the jib parallel to the upper boom.

2. Shorten the jib.

3. Fully retract the jib.

Telescopic Jib (Manual Extend)The jib is a 4x 4(102 mm x 102 mm), fiberglass squarethat has two pinning positions and is anchored to the jibsupport bracket with a detent pin. The jib may be tiltedhydraulically through 120 degrees, +90 degrees to -30degrees with respect to the upper boom.

Warning


the jib. Do not exceed the values on the jib capacitychart.

AttentionProperty damage can result from failure to pay out the

winch line when extending or lengthening the jib.

A removable double sheave head is attached to the end othe jib for use with the winch line. The sheave head wilwork either in the overcenter or non-overcenter positionsof the upper boom. Several lifting attachments are available to lift insulator strings, conductors, or multiple conductors.

The jib has three pinning positions for extension.

AttentionFollow the stowing procedure to prevent damage to

the unit.

Tilt the jib parallel to the upper boom before stowing theboom. The jib must be tilted parallel to the upper boom soit does not contact the turntable or the lower boom whenstowing the upper boom.

Stowing the Jib 1. Tilt the jib parallel to the upper boom.

2. Remove the detent pin from the support bracket.

3. Slide the jib back into the support bracket.

4. Align the pin hole and install the detent pin in thesupport bracket.

Jib AdapterAn adapter may be fastened to the jib to accept hot linetools.

WinchThe hydraulic powered winch can be operated by the winchcontrol handle at the upper or the lower controls.

The lower control station winch control is for emergencyoperation of the winch or stability testing only.

The upper control station is equipped with a winch controvalve. To operate the winch line from the upper controlsmove the winch control handle in the desired direction.

The winch is equipped with a mechanical brake intendedto prevent unintentional movement of the load. The winch

has an average line speed of 40 feet/minute (12.2 m/min)

Warning

Death or serious injury can result from falling loadsWinch cable anchors are not designed to hold rated

capacity. Keep a minimum of four wraps on the drum

The standard winch line is 1/2(12.7 m) diameter line and80(24.4 m) long.

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It is impossible to foresee all situations and combinationsfor attaching the winch line to the load. The operator bearsultimate responsibility for assuring that the line is properlyattached to the load.

Warning

Death or serious injury can result if the syntheticwinch line contacts an energized conductor and a

ground. Do not allow the winch line to contact anenergized conductor.

The synthetic winch line is not considered an insulator.Contact between an energized conductor and the groundcan result when the winch line is extended to the ground.

Warning

Death or serious injury can result from overloadingthe jib. Do not exceed the values on the jib capacity

chart.

Death or serious injury can result from overloadingthe unit. Do not attempt to lift or pull loads that are

attached to the ground or structures.

Phase LifterThe phase lifter is a jib attachment for raising a singleconductor using the hydraulic jib. The load applied to thephase lifter must not exceed the least of the applicablevalues of the phase holder capacity, the jib structuralcapacity, or the material handling capacity of the unit.

Warning

Death or serious injury can result when the jib con-tacts two energized conductors or an energized con-ductor and a ground. Do not allow the jib to contact an

energized conductor. Use a phase lifter or otherinsulated tool to handle energized conductors.

Lower Boom Lifting EyeThe lower boom lifting eye (refer to Figure 5.7) adapts thelower boom for light duty material handling. This attach-ment provides a secure mounting for a shackle on the endof the lower boom.

Warning



The lower boom lifting eye capacity placard is located nearthe base end of the lower boom. Do not exceed thecapacity values indicated on the capacity placard.

Warning


the unit. Do not occupy or leave tools in the platformwhen using the lifting eye.

The platform must not be occupied when using the lowerboom lifting eye.

Figure 5.6 Phase Lifter

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Figure 5.7 Lifting Eye

Lower Boom AngleTo Lift a Load of Must be at Least

800 pounds (362.9 kg) 0 degrees (horizontal)

1,000 pounds (453.6 kg) 30 degrees



Keep the upper boom as near to the rest position aspossible. Do not strike the unit or other obstacles with theplatform.

Tool System

Hydraulic tool connections may be available at groundlevel and at the platform. The tool circuits are factory setat 8 gpm (30.3 l/min) and 2,000 psi (138 bar).

The pressure and flow of the tool circuits are adjustable toaccommodate hydraulic tools with various pressure andflow requirements. Pressure and flow adjustments of thetool circuits are covered in the Maintenance Manual.

The lower tool circuit quick disconnects may be mountedstationary on the tailshelf or on a hose reel. The upper toocircuit quick disconnects are located at the platform. Thetool circuit will accommodate open or closed center toolssuch as impact wrenches, saws, or other hydraulic tools

HTMA quick disconnect fittings allow for easy attachmenand removal of the tool.

To use the tool circuit, connect the tool and place the toolscontrol handle in the On position.

Danger

Death or serious injury will result from hydraulic oi

burning or exploding. Avoid contact of the boom tipwith two energized conductors or an energized con-

ductor and a ground.

2,000 Lb

1,500 Lb

1,000 Lb

800 Lb

60

45

30

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Caution

Injury can result from hydraulic oil being injected intothe flesh when loosening or disconnecting hydraulic

components. Remove the pressure before looseningor disconnecting hydraulic components.

Seek immediate medical attention if injured by escap-ing hydraulic oil. Serious infection or reaction can

result if medical treatment is not given immediately.

Spilled hydraulic oil creates slick surfaces and cancause personnel to slip and/or fall. Keep the unit andwork areas clean.

Return the tool control handle to the Off position when thetool circu

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