SIL-3125

Customer Outreach
PO Box 8338
Saint Joseph, MO 64508
[email protected]
connect.altec.com/login
Phone 1-877-GO ALTEC
This campaign applies to your vehicle. Refer to the provided list.
Dear Altec Owner,
Altec Industries, Inc. has issued a customer satisfaction campaign as described in the included Service Information Letter (SIL). According to our records, you own one or more units this applies to.
Refer to the included letter for the items covered under the Altec Warranty Policy. If you had this repair performed
before you received this letter, you may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this letter.
Compare your unit’s identifying information with the provided list to verify your unit is affected. You may also
contact Altec or view your fleet through Altec Connect to determine if there are any other outstanding notices.
If you have sold or retired the unit, update the records through Altec Connect. If you have leased this equipment
to another person or company, you are required by Federal Law to forward a copy of this notice to the lessee by
first class mail within ten (10) days of the receipt of this notice.
We regret this inconvenience; however, we are taking this action in the interest of your safety and continued satisfaction with Altec products.
Thank you for your immediate attention on this important matter.
Service Information Letter SIL- 3125-A
A Class & A Class Elevator Platform Retention
Units Affected: Certain A Class and A Class Elevator model units built from June 1997 to November
2023. Verify your unit is affected by reviewing the attached list or accessing Altec Connect.
Background: Altec has updated the preventive maintenance procedures for the boom tip pin retaining
plate on affected units.
Customer Action: Add the included manual addendum to the Maintenance Manual. This addendum includes all updated manual procedures. Make sure the boom tip pin retaining plate cap screws are inspected
at the next regularly scheduled maintenance interval according to the updated Preventative Maintenance
and Inspection Checklist.
The addendum includes a Preventive Maintenance and Inspection Checklist to replace the one currently in
the manual. There are two checklists included with this mailing: one for elevator units and one for non-elevator units. Select the correct checklist for your unit and discard the other.
Subsequent damage due to failure to perform the required action(s) in the time period
allowed will not be covered by warranty.
Requirements: Every affected unit requires the manual addendum be added to the
unit's Maintenance Manual. If you would like an updated copy of the entire Maintenance Manual at no charge, scan the QR code to order one. This option is only valid
until February 29, 2024.
Completion and Warranty: This notice will be marked complete upon mailing. No further action is
required. There is no inspection or repair labor for this notice.
If you would like a new manual at no cost to you, scan the QR code to place an order before February 1,
2024.
Altec Contact Info:
Altec Connect: connect.altec.com/login
Phone: 1-877-GO ALTEC (1-877-462-5832) | Options: 1 - Parts; 2 - Shop Service; 3 - Mobile Service;
4 - Technical Support; 5 - Global Rental Service Request; 6 - Chassis Repair
Inspection labor
Repair labor
Account #
Travel
NHTSA code
Prime fail P/N
Doc ref
Page 1 of 3
Altec Use Only
0.0 hr
0.0 hr
010.1093.43156.000.9350.000
Not included
90
NA
NA
Altec Use Only
Description
Part No.
Unit specific maintenance manual
Varies
Qty Warranty
1
Until 2-1-24
Released: January 17, 2024
SIL-3125-A
Manual Addendum — Boom Tip Retaining Plates
Section 4 — Preventive Maintenance and Inspection
Pins and Pin Retainers
Boom Tip Pin Retaining Plates
Both ends of the boom tip pin are secured by a retaining
plate and two cap screws. When inspecting the boom
tip pin, make sure the cap screws installed through the
retaining plate are secure.
Retaining
Plate
Retaining
Plate
Boom Tip Pin
Removal
1. Position the unit on a level surface, apply
the parking brake, and chock the wheels.
2. Release the pressure from each circuit in
the hydraulic system by shifting the lower control handle for each function in both
directions several times. Also, shift the
control handles at the platform for the upper tool circuit functions in both directions
several times.
3. Remove the covers at the platform.
Figure 4.XX — Retaining Plate and Cap Screws
Check the retaining plate cap screws to be sure they are
torqued to 32 foot-pounds (43 N•m) or 90 percent of the
normal installation torque of 35 foot-pounds (47 N•m)
as recommended by the Preventive Maintenance and
Inspection Checklist.
Foot-Pounds (N•m)
Boom tip pin retaining plate cap screws
Figure 4.XX — Torque Value
35 (47)
Section 6 — Mechanical Systems
Platform and Leveling System
CAUTION
Injury and property damage can result
from unexpected platform movement. Tilt
the platform to a nearly level position before moving the platform leveling control
to Auto.
Injury and property damage can result
from unexpected platform movement. Allow room for platform movement when the
leveling control is moved to Auto.
NOTICE
Damage to the unit can result if hoses are not
connected properly. Mark the platform leveling hoses before they are disconnected.
4. Support the platform so that it may be removed after it is disconnected from the
boom tip.
5. Remove the access covers near the boom
tip.
6. Disconnect the hoses from the leveling
system.
7. Disconnect the hoses and air lines that are
routed from the boom tip to the platform
assembly.
8. Remove the jib/winch assembly cover.
9. Disconnect the hoses that are connected to
the jib/winch assembly.
10. Remove and discard the cap screws that
secure the retaining plate on the end of the
boom tip pin on the platform side (refer to
Figure 6.XX). When servicing the boom tip
pin or retaining plates, do not reuse the retaining plate cap screws. Once a cap screw
is removed, the nylon patch on the threads
will be distorted. This distortion may not
allow the cap screw to tighten properly if
reused. Use new cap screws of the proper
length with nylon patch when reinstalling
the retaining plate.
Page 2 of 3
SIL-3125-A
Retaining
Plate
Boom Tip Pin
Retaining
Plate
Figure 6.XX — Retaining Plate and Cap Screws
11. While supporting the platform, slide the
platform pivot arm, mounting bracket, platform, and all of the components connected
to them off the shaft.
12. Disconnect and remove the jib tilt cylinder.
13. Remove and discard the cap screws that secure the retaining plate on the end of the jib/
winch side of the boom tip pin (refer to Figure 6.XX).
14. Support and remove the jib/winch assembly.
15. Remove the cap screws that secure the leveling system to the end of the fiberglass.
16. Support and remove the leveling system
from the end of the fiberglass.
Installation
1. Insert the leveling system into the end of the
fiberglass and secure it with the cap screws,
washers, and self-locking nuts. Torque the
cap screws to 75 foot-pounds (95 N•m).
2. Install the jib/winch assembly on the boom
tip pin with the shims, retaining plate, and
new cap screws. Torque the cap screws to 35
foot-pounds (47 N•m).
3. Install the jib tilt cylinder.
4. Install the platform assembly on the boom
tip pin with the shims, retaining plate, and
new cap screws. Torque the cap screws to 35
foot-pounds (47 N•m).
5. Connect the hoses and air lines to the jib/
winch assembly, platform assembly, and the
leveling system.
Page 3 of 3
6. If any fluid leaked from the leveling
valve, measure the fluid for the proper
level (refer to Section 5 under leveling
valve) and add if necessary.
7. Replace the covers.
8. Move the platform leveling control to
Manual. Operate the tilt control and
check for proper operation.
9. Carefully move the leveling control to
Auto and check for proper operation.
10. Operate the unit through all boom angles and rotation from the lower controls
while checking for leaks and proper operation. Operate the winch while checking
for leaks and proper operation.
11. Operate the unit through all boom angles and rotation from the upper controls
while checking for leaks and proper operation. Operate the jib and winch while
checking for leaks and proper operation.
12. Perform a structural test as described in
Section 9.
Appendix —
Preventive Maintenance and Inspection Checklist
Refer to the attached checklists: one for elevator
units and one for non-elevator units. Retain the
correct checklist for your unit and discard the other.
A Class elevator
Preventive Maintenance and Inspection Checklist
Vehicle No. ________________________ Location __________________________ Date _________________
Service Request # ____________________  Model # ____________________  Serial # ______________________
Odometer ________________ Hours Meter ________________ Inspector ______________________________
Open Altec Product Notices ____________________________________________________________________
Check for Altec Product Notices or other applicable documents provided by Altec for servicing the unit by calling
1-877-GO ALTEC (1-877-462-5832) or by contacting [email protected].
Perform all inspections, adjustments, repairs, and lubrication according to the specifications in all unit maintenance
and/or service manuals. If tracking PTO hours using an approved method or device, follow the recommended hourly
maintenance intervals. If performing maintenance based upon a calendar based schedule, follow the recommended
monthly intervals. The required items apply to both tracking methods.
Intervals
o Prior to placing the unit in service
o Required maintenance
o 4,000 PTO hours/4 years
Symbols
3/O = Okay or completed
U = Unsafe to operate
o 85 PTO hours/1 month
o 1,000 PTO hours/1 year
o Major structural inspection
C = Corrected by inspector
N/A = Not applicable
o 500 PTO hours/6 months
o 2,000 PTO hours/2 years
R = Repair or replacement required
Prior to Placing the Unit in Service
Rotation Bearing
Perform the Preoperational Inspection
(refer to the Operator’s Manual)
Turntable tilt measurement2: ___________
Hydraulic Reservoir and System
Check oil and collect oil sample for analysis1
85 PTO Hours/1 Month
Lubrication
Perform the Preoperational Inspection
(refer to the Operator’s Manual)
Rotation bearing ball race
Covers/Placards
Lower boom cylinder spherical bearings
Condition, in place
Upper boom cylinder spherical bearings
Hydraulic Reservoir
Elevator base and pedestal cylinder pivot bearings
Oil level
Elevator arm link pivot pins
Manuals
Gearbox (if applicable)
Operator’s Manual present
Rotation bearing gear teeth and pinion gear teeth
Safety and Sentry documents present
500 PTO Hours/6 Months
All Electrical
Perform the 85 hour/1 month inspection
Hydraulic Reservoir/Pump/PTO
Components and wiring (clearances, tightness, support,
Mounting (cap screws secure, welds intact, no cracks)
Shutoff valve fully open
No leaks
Battery
Mounting (vertically and horizontally secure)
no insulation damage)
Connections (secure, no corrosion)
Unit Mounting
Subbase mounting (fasteners secure, welds intact,
no cracks)
Electrical connection (secure, no corrosion)
Subbase structure (welds intact, no cracks)
Routing (cables do not cross, fuses secure)
Pedestal mounting (fasteners secure, welds intact,
no cracks)
074960201B-01
Appendix — Preventive Maintenance and Inspection Checklist
A Class elevator
Filters
Rotation Bearing and Gearbox
Change return line filter
Motor mounting cap screws secure
Outriggers
Eccentric ring lock in place and secure
Mounting (welds intact, no deformation or cracks)
No leaks
Aerial device/outriggers selector operation
Operation (smoothness and noise level)
Outrigger interlock system operation
Pinion gear teeth
Operation (holding without drift)
Rotation bearing gear teeth
Structures (welds intact, no deformation or cracks)
Gearbox internal lost motion
Pins and retainers secure
Rotation bearing inspection and measurement [after
No leaks
0.050″ (1.27 mm) increased wear from initial
Lower Tools Circuit
		measurement]2
Operation
Rotation bearing cap screw visual inspection
No leaks
Quick disconnect couplers (condition, operation,
Rotation gearbox mounting cap screw visual inspection
Lower Boom Cylinder
dust caps)
Pivot bearings secure within cylinder eyes
Hydraulic System
Pin retainers secure
Pump compensator _________
Operation
Pilot pressure _________
No leaks
Standby pressure _________
Chromed rod (condition)
Tool system pressure _________
Lower Boom
Lower Controls
Structure (welds intact, no deformation or cracks)
Operation (metering, proper direction)
Fasteners secure
Engine start/stop switch operation
Insulator fasteners secure
Lower/upper control operation
Insulator (condition, clean, undamaged)
Elevator control valve (operation, no leaks)
Covers
Elevator Lift Cylinder
No leaks
Self-aligning pivot bearings secure within cylinder eyes Elbow
Operation
Lower scissor link anchor pin (retainer condition,
No leaks
cap screws secure)
Chromed rod condition
Elbow pivot pin (retainer condition, cap screw secure)
Barrel condition
Eccentric bushings (cap screws and rollpins in place)
Pedestal
Upper boom drive mechanism anchor pins
Structure (welds intact, no deformation or cracks)
No leaks
		 (retainer condition, cap screws secure)
Upper Boom Cylinder
Covers
Pin retainers secure
Rotary joint mounting cap screws (secure),
Operation
restraint bracket secure
No leaks
Slip ring mounting cap screws (secure)
Turntable
Chromed rod (condition)
Upper Boom
Structure (welds intact, no deformation or cracks)
Fiberglass cap screws (secure)
Boom pin and retainers secure
Fiberglass (condition, clean, undamaged)
Lower boom cylinder pivot pin and retainers secure
Hose carrier
Covers
Covers
No leaks
No leaks
Appendix — Preventive Maintenance and Inspection Checklist
074960201B-01
A Class elevator
Extension Cylinder
Lanyard attachment cap screws secure
Upper boom extension cylinder trunnion pins secure
Material Handling Package
Pins and retaining rings secure
Jib/sheave (condition, turns freely)
Operation
Jib/sheave pins (condition, operation)
No leaks
Jib tilt/extension cylinder (leaks, chromed rod, retainers)
Chromed rod (condition)
Jib tilt cylinder mounting bracket cap screws torque
Upper Boom Tip
Jib/winch structures (welds intact, no deformation
Structure (welds intact, no deformation or cracks)
or cracks)
Boom tip pin retaining plate cap screws secure
Mounting pins, fasteners and retainers secure
Upper Controls
Winch mounting (cap screws secure, welds intact,
Operation (metering, proper direction)
deformation or cracks)
Interlock (operation)
Winch motor mounting cap screws (secure)
Platform leveling control (operation)
Winch brake (operation)
Emergency hydraulic shutdown (operation)
Gearbox outboard bearing secure
Upper controls cable (routing, wire ties)
No leaks
Tools quick disconnect couplers (condition, operation,
Winch line (condition)
dust caps)
Cover
Lubrication
No operation in Lower Controls position
No leaks
Outrigger inner leg outer surface
Platform
Extendible upper boom
Mounting secure (bracket, pins, and fasteners)
Valve spools
Platform (condition, clean)
Rotation gearbox, output shaft upper bearing
Mounting structures (welds intact, no deformation
(if applicable)
or cracks)
Single handle control linkage pivots only
Required Maintenance (Regardless of Hours)
Annual Testing
Dielectric test platform liner(s)
Vehicle inspection is up to date
Confirmation test of single handle control
Dielectric test unit
Atmospheric vents (visually inspect all, verify operation)
1,000 PTO Hours/1 Year
Perform the 500 hour/6 month inspection
Rotation bearing inspection and measurement [before
Unit Plumbing Below Rotation
		0.050″ (1.27 mm) increased wear from initial
Hoses and tubes (routing, condition, no leaks)
		measurement]2
Extension Cylinder
Exhaust shields
Pump/PTO
Hoses (routing, condition)
Lower Boom
Shaft condition
Mounting cap screws secure
Insulator fasteners torque
Hydraulic Reservoir and System
Upper Boom
Drain water from bottom of reservoir
Upper boom weldment fasteners torque
Collect oil sample for analysis
Slide pad bearings and fasteners
1
Upper Boom Tip
Clean suction filter element
Reservoir cover gasket condition
Boom tip pin retaining plate cap screw torque inspection
Rotation Bearing and Gearbox
Mounting to upper boom secure
Rotation bearing cap screw annual torque inspection
Rotation gearbox mounting cap screws annual
torque inspection
074960201B-01
Winch
Line anchor point secure
Winch load stopping/holding
Appendix — Preventive Maintenance and Inspection Checklist
A Class elevator
Fiberglass
Structures
Seal between insulator and steel tubes
All structures and welds included on 500 hour/6 month
Insulator is clean and waxed
checklist (no significant corrosion)
Lubrication
Insulator bond
Seal between upper boom and steel tube
Rotation gearbox oil level
Winch gearbox oil level
2,000 PTO Hours/2 Years
Perform the 1,000 hour/1 year inspection
Rotation Bearing and Gearbox
Hydraulic Reservoir and System
Pinion to rotation bearing gear backlash
Lubrication
Change hydraulic oil
Clean or change filler hole strainer
Pump input shaft splines
Change filler/breather cap
4,000 PTO Hours/4 Years
Perform the 2,000 hour/2 year inspection
Lubrication
Hydraulic Reservoir and System
Change winch gearbox oil
Flush hydraulic system
Change rotation gearbox oil
Major Structural Inspection (Regardless of Hours)
Perform this inspection after the first 15 years of service,
Cylinder eye structure (welds intact, no deformation
and at every 10-year interval thereafter
or cracks)
Perform 1,000 hour/1 year inspection
Load Test
Bushing bearings at rod eye and cylinder eye3
Extension Cylinder
Perform major structural load test
Cylinder eye structure (welds intact, no deformation
Cycle Times
or cracks)
Check all aerial functions for any operation faster than Lower Boom
specified cycle times
Upper Boom
Self-lubricating bearings in lower boom for boom pivot pin3
Lower Boom Cylinder
Self-lubricating bearings in upper boom, drive link, and
Rod eye structure (welds intact, no deformation or cracks)
idler link3
Cylinder eye structure (welds intact, no deformation
Upper Boom Cylinder
or cracks)
Rod eye structure (welds intact, no deformation or cracks)
Cylinder eye structure (welds intact, no deformation
Spherical bearings at rod eye and cylinder eye3
Upper Boom Tip
or cracks)
Spherical bearing at rod eye and cylinder eye3
Self-lubricating bearings for platform leveling sprocket3
Outrigger Cylinder
Platform Leveling Cylinders
Rod eye structure (welds intact, no deformation or cracks)
Rod eye structure (welds intact, no deformation or cracks)
1
2
3
Periodic laboratory analysis is the most accurate method of determining the condition of the hydraulic oil and when it should be changed.
If laboratory analysis is used, take a baseline sample. Compare future lab tests on subsequent samples to the original to establish a trend.
Initially measure turntable tilt as a baseline. Check rotation bearing wear every year until it measures 0.050″ (1.27 mm) increased wear from
initial measurements. After reaching 0.050″ (1.27 mm) increased wear, measure every 6 months. Refer to the Maintenance Manual for the
proper procedure. Record measurements in the Rotation Bearing Maintenance Log.
Perform bearing inspection test as described in Section 9 of the Maintenance Manual.
Comments __________________________________________________________________________________
___________________________________________________________________________________________
Appendix — Preventive Maintenance and Inspection Checklist
074960201B-01
A Class - non-elevator
Preventive Maintenance and Inspection Checklist
Vehicle No. ________________________ Location __________________________ Date _________________
Service Request # ____________________  Model # ____________________  Serial # ______________________
Odometer ________________ Hours Meter ________________ Inspector ______________________________
Open Altec Product Notices ____________________________________________________________________
Check for Altec Product Notices or other applicable documents provided by Altec for servicing the unit by calling
1-877-GO ALTEC (1-877-462-5832) or by contacting [email protected].
Perform all inspections, adjustments, repairs, and lubrication according to the specifications in all unit maintenance
and/or service manuals. If tracking PTO hours using an approved method or device, follow the recommended hourly
maintenance intervals. If performing maintenance based upon a calendar based schedule, follow the recommended
monthly intervals. The required items apply to both tracking methods.
Intervals
o Prior to placing the unit in service
o Required maintenance
o 4,000 PTO hours/4 years
Symbols
3/O = Okay or completed
U = Unsafe to operate
o 85 PTO hours/1 month
o 1,000 PTO hours/1 year
o Major structural inspection
C = Corrected by inspector
N/A = Not applicable
o 500 PTO hours/6 months
o 2,000 PTO hours/2 years
R = Repair or replacement required
Prior to Placing the Unit in Service
Rotation Bearing
Perform the Preoperational Inspection
(refer to the Operator’s Manual)
Turntable tilt measurement2: ___________
Hydraulic Reservoir and System
Check oil and collect oil sample for analysis1
85 PTO Hours/1 Month
Perform the Preoperational Inspection
Safety and Sentry documents present
Lubrication
(refer to the Operator’s Manual)
Covers/Placards
Rotation bearing ball race
Condition, in place
Lower boom cylinder spherical bearings
Hydraulic Reservoir
Upper boom cylinder spherical bearings
Oil level
Gearbox (if applicable)
Manuals
Rotation bearing gear teeth and pinion gear teeth
Operator’s Manual present
500 PTO Hours/6 Months
All Electrical
Perform the 85 hour/1 month inspection
Hydraulic Reservoir/Pump/PTO
Components and wiring (clearances, tightness, support,
Mounting (cap screws secure, welds intact, no cracks)
Shutoff valve fully open
No leaks
Battery
Mounting (vertically and horizontally secure)
no insulation damage)
Connections (secure, no corrosion)
Unit Mounting
Subbase mounting (fasteners secure, welds intact,
no cracks)
Electrical connection (secure, no corrosion)
Subbase structure (welds intact, no cracks)
Routing (cables do not cross, fuses secure)
Pedestal mounting (fasteners secure, welds intact,
no cracks)
074960202E
Appendix — Preventive Maintenance and Inspection Checklist
A Class - non-elevator
Filters
Rotation bearing inspection and measurement [after
Change return line filter
0.050″ (1.27 mm) increased wear from initial
Outriggers
		measurement]2
Mounting (welds intact, no deformation or cracks)
Rotation bearing cap screw visual inspection
Aerial device/outriggers selector operation
Outrigger interlock system operation
Rotation gearbox mounting cap screw visual inspection
Lower Boom Cylinder
Operation (holding without drift)
Pivot bearings secure within cylinder eyes
Structures (welds intact, no deformation or cracks)
Pin retainers secure
Pins and retainers secure
Operation
No leaks
No leaks
Lower Tools Circuit
Operation
Chromed rod (condition)
Lower Boom
No leaks
Structure (welds intact, no deformation or cracks)
Quick disconnect couplers (condition, operation,
Fasteners secure
dust caps)
Insulator fasteners secure
Hydraulic System
Insulator (condition, clean, undamaged)
Pump compensator _________
Covers
Pilot pressure _________
No leaks
Standby pressure _________
Elbow
Tool system pressure _________
Lower scissor link anchor pin (retainer condition,
Lower Controls
cap screws secure)
Operation (metering, proper direction)
Elbow pivot pin (retainer condition, cap screw secure)
Engine start/stop switch operation
Eccentric bushings (cap screws and rollpins in place)
Lower/upper control operation
Upper boom drive mechanism anchor pins
Pedestal
		 (retainer condition, cap screws secure)
Structure (welds intact, no deformation or cracks)
Upper Boom Cylinder
No leaks
Pin retainers secure
Covers
Operation
Rotary joint mounting cap screws (secure),
No leaks
restraint bracket secure
Slip ring mounting cap screws (secure)
Chromed rod (condition)
Upper Boom
Turntable
Fiberglass cap screws (secure)
Structure (welds intact, no deformation or cracks)
Fiberglass (condition, clean, undamaged)
Boom pin and retainers secure
Hose carrier (telescopic units only)
Lower boom cylinder pivot pin and retainers secure
Covers
Covers
No leaks
No leaks
Extension Cylinder
Rotation Bearing and Gearbox
Upper boom extension cylinder trunnion pins secure
Motor mounting cap screws secure
Pins and retaining rings secure
Eccentric ring lock in place and secure
Operation
No leaks
No leaks
Operation (smoothness and noise level)
Chromed rod (condition)
Pinion gear teeth
Upper Boom Tip
Rotation bearing gear teeth
Structure (welds intact, no deformation or cracks)
Gearbox internal lost motion
Boom tip pin retaining plate cap screws secure
Appendix — Preventive Maintenance and Inspection Checklist
074960202E
A Class - non-elevator
Upper Controls
Jib tilt cylinder mounting bracket cap screws torque
Operation (metering, proper direction)
Jib/winch structures (welds intact, no deformation
Interlock (operation)
or cracks)
Platform leveling control (operation)
Mounting pins, fasteners and retainers secure
Emergency hydraulic shutdown (operation)
Winch mounting (cap screws secure, welds intact,
Upper controls cable (routing, wire ties)
deformation or cracks)
Tools quick disconnect couplers (condition, operation,
Winch motor mounting cap screws (secure)
dust caps)
Winch brake (operation)
No operation in Lower Controls position
Gearbox outboard bearing secure
No leaks
No leaks
Platform
Winch line (condition)
Mounting secure (bracket, pins, and fasteners)
Cover
Lubrication
Platform (condition, clean)
Lanyard attachment cap screws secure
Outrigger inner leg outer surface
Mounting structures (welds intact, no deformation
Extendible upper boom
or cracks)
Valve spools
Material Handling Package
Rotation gearbox, output shaft upper bearing
Jib/sheave (condition, turns freely)
(if applicable)
Jib/sheave pins (condition, operation)
Single handle control linkage pivots only
Jib tilt/extension cylinder (leaks, chromed rod, retainers)
Required Maintenance (Regardless of Hours)
Annual Testing
Dielectric test platform liner(s)
Vehicle inspection is up to date
Confirmation test of single handle control
Dielectric test unit
Atmospheric vents (visually inspect all, verify operation)
1,000 PTO Hours/1 Year
Extension Cylinder
Perform the 500 hour/6 month inspection
Unit Plumbing Below Rotation
Hoses (routing, condition)
Lower Boom
Hoses and tubes (routing, condition, no leaks)
Exhaust shields
Insulator fasteners torque
Pump/PTO
Upper Boom
Shaft condition
Upper boom weldment fasteners torque
Mounting cap screws secure
Slide pad bearings and fasteners
Hydraulic Reservoir and System
Upper Boom Tip
Drain water from bottom of reservoir
Boom tip pin retaining plate cap screw torque inspection
Collect oil sample for analysis
Mounting to upper boom secure
1
Winch
Clean suction filter element
Reservoir cover gasket condition
Line anchor point secure
Rotation Bearing and Gearbox
Winch load stopping/holding
Rotation bearing cap screw annual torque inspection
Rotation gearbox mounting cap screws annual
Fiberglass
Seal between insulator and steel tubes
torque inspection
Insulator is clean and waxed
Rotation bearing inspection and measurement [before
Insulator bond
		0.050″ (1.27 mm) increased wear from initial
Seal between upper boom and steel tube
		measurement]
074960202E
2
Appendix — Preventive Maintenance and Inspection Checklist
A Class - non-elevator
Structures
Lubrication
All structures and welds included on 500 hour/6 month
Rotation gearbox oil level
checklist (no significant corrosion)
Winch gearbox oil level
2,000 PTO Hours/2 Years
Rotation Bearing and Gearbox
Perform the 1,000 hour/1 year inspection
Hydraulic Reservoir and System
Pinion to rotation bearing gear backlash
Lubrication
Change hydraulic oil
Clean or change filler hole strainer
Pump input shaft splines
Change filler/breather cap
4,000 PTO Hours/4 Years
Lubrication
Perform the 2,000 hour/2 year inspection
Hydraulic Reservoir and System
Change winch gearbox oil
Flush hydraulic system
Change rotation gearbox oil
Major Structural Inspection (Regardless of Hours)
Perform this inspection after the first 15 years of service,
Cylinder eye structure (welds intact, no deformation
and at every 10-year interval thereafter
or cracks)
Perform 1,000 hour/1 year inspection
Bushing bearings at rod eye and cylinder eye3
Load Test
Extension Cylinder
Perform major structural load test
Cylinder eye structure (welds intact, no deformation
Cycle Times
or cracks)
Check all aerial functions for any operation faster than Lower Boom
specified cycle times
Self-lubricating bearings in lower boom for boom pivot pin3
Upper Boom
Lower Boom Cylinder
Self-lubricating bearings in upper boom, drive link, and
Rod eye structure (welds intact, no deformation or cracks)
idler link3
Cylinder eye structure (welds intact, no deformation
Upper Boom Cylinder
or cracks)
Rod eye structure (welds intact, no deformation or cracks)
Cylinder eye structure (welds intact, no deformation
Spherical bearings at rod eye and cylinder eye3
Upper Boom Tip
or cracks)
Spherical bearing at rod eye and cylinder eye
Self-lubricating bearings for platform leveling sprocket3
3
Outrigger Cylinder
Platform Leveling Cylinders
Rod eye structure (welds intact, no deformation or cracks)
Rod eye structure (welds intact, no deformation or cracks)
1
2
3
Periodic laboratory analysis is the most accurate method of determining the condition of the hydraulic oil and when it should be changed.
If laboratory analysis is used, take a baseline sample. Compare future lab tests on subsequent samples to the original to establish a trend.
Initially measure turntable tilt as a baseline. Check rotation bearing wear every year until it measures 0.050″ (1.27 mm) increased wear from
initial measurements. After reaching 0.050″ (1.27 mm) increased wear, measure every 6 months. Refer to the Maintenance Manual for the
proper procedure. Record measurements in the Rotation Bearing Maintenance Log.
Perform bearing inspection test as described in Section 9 of the Maintenance Manual.
Comments __________________________________________________________________________________
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074960202E
Appendix — Preventive Maintenance and Inspection Checklist