Final Assembly Manual PDF

AM50/55/60 Series
Including E
Final Assembly Manual
Altec Industries, Inc. reserves the right to improve models and change specifications without notice.
749-30069
2010
Copyright © 2010 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.
Table of Contents
Section 1 — Introduction
About This Manual… ..................................................................................................... 1
General Specifications ................................................................................................... 2
Disclaimer of Liability ..................................................................................................... 3
Section 2 — Planning
Planning the Installation ................................................................................................. 5
Configuration Tables ...................................................................................................... 6
Chassis ........................................................................................................................ 15
Axle, Spring, and Tire Capacity ............................................................................. 15
Payload Reserve Capacity .................................................................................... 15
Unit Weight to Maintain Stability ........................................................................... 15
Gross Vehicle Weight Rating (GVWR) .................................................................. 15
Vertical Center of Gravity (VCG) ........................................................................... 15
Horsepower ........................................................................................................... 15
Transmission ......................................................................................................... 15
Outriggers .................................................................................................................... 15
Types .................................................................................................................... 16
Shoes .................................................................................................................... 16
Primary .................................................................................................................. 16
Auxiliary ................................................................................................................ 16
Interlocks .............................................................................................................. 16
Motion Alarms ....................................................................................................... 16
Subbase ....................................................................................................................... 16
Body ............................................................................................................................ 16
Types .................................................................................................................... 16
Cross Member Height ............................................................................................ 16
Outrigger Locations ............................................................................................... 16
Floor Opening ........................................................................................................ 16
Accessories .......................................................................................................... 16
Component ................................................................................................................... 17
Weight Distribution Calculations .................................................................................. 17
Pump ........................................................................................................................... 19
Diesel Engine Speed Setting ................................................................................. 19
Gas Engine Speed Setting .................................................................................... 19
PTO ............................................................................................................................. 19
Welding and Fasteners ................................................................................................ 20
Dimensions, Weights, and Center of Gravity ............................................................... 21
AM50 ..................................................................................................................... 21
AM55 ..................................................................................................................... 22
AM60 ..................................................................................................................... 23
AM50E .................................................................................................................. 24
AM55E .................................................................................................................. 25
AM60E .................................................................................................................. 26
Components .......................................................................................................... 28
Platform ................................................................................................................. 29
Outriggers .............................................................................................................. 30
Reservoirs ............................................................................................................. 36
Throttle Actuator .................................................................................................... 38
Cargo to Platform Step .......................................................................................... 39
Cargo to Compartment Step .................................................................................. 39
Typical Configurations ................................................................................................. 40
Swing Radius Diagram ................................................................................................. 42
Reach Diagrams .......................................................................................................... 44
Section 3 — Installation
Final Assembly Installation .......................................................................................... 51
Subbase ....................................................................................................................... 53
Outriggers .................................................................................................................... 54
Outrigger Leg Extension .............................................................................................. 65
Pump ........................................................................................................................... 66
Throttle Actuator .......................................................................................................... 68
Body Mounting ............................................................................................................. 69
Pedestal/Subbase ........................................................................................................ 70
Reservoir Assembly ..................................................................................................... 71
Outrigger Interlock ....................................................................................................... 73
Boom Rest/Cab Guard ................................................................................................. 80
Step ............................................................................................................................. 81
Lifting Eye .................................................................................................................... 83
Jib Adapter ................................................................................................................... 84
Phase Lifter ................................................................................................................. 85
Platform Rest ............................................................................................................... 86
Plumbing ...................................................................................................................... 87
Throttle Actuator .................................................................................................... 87
Below Rotation, Tools and Secondary Stowage System ...................................... 88
Below Rotation, Tools ........................................................................................... 91
Below Rotation, Secondary Stowage System ....................................................... 93
Below Rotation ...................................................................................................... 96
Electrical ...................................................................................................................... 98
Ignition Splice ........................................................................................................ 98
Full Pressure, 12 and 24 VDC ............................................................................... 99
Pilot Pressure, 12 and 24 VDC ............................................................................101
Full Pressure, Engine Start/Stop, 12 and 24 VDC ................................................103
Pilot Pressure, Engine Start/Stop, 12 and 24 VDC ..............................................107
Full Pressure, Secondary Stowage System, 12 and 24 VDC ............................... 111
Pilot Pressure, Secondary Stowage System, 12 and 24 VDC .............................115
Full Pressure, Engine Start/Stop With Secondary Stowage System,
12 and 24 VDC ..............................................................................................119
Pilot Pressure, Engine Start/Stop With Secondary Stowage System,
12 and 24 VDC ..............................................................................................123
Neutral/Emergency Brake Interlock for
Automatic Transmissions With Cable Shift PTO ........................................... 127
Automatic Transmissions With Electric Shift PTO ........................................128
Placards ......................................................................................................................129
Unit Locations ...................................................................................................... 129
Final Assembly ....................................................................................................131
Final Assembly Locations ....................................................................................133
Serial Number ....................................................................................................... 135
Section 4 — Testing and Inspection

Dielectric ..................................................................................................................... 137
Insulated Single Handle Control ...........................................................................137
Stability .......................................................................................................................137
Final Stage Certification ..............................................................................................139
Appendix
Hydraulic System Schematics
Troubleshooting Chart
Preoperational Inspection Checklist
Stability Test Forms
Operational Inspection Checklist
Dielectric Test Forms
Final Inspection Checklist
Section 1 — Introduction
The terms danger, warning, caution, and notice represent

About This Manual… varying degrees of personal injury and/or property damage
This manual provides basic information to install the unit, that could result if the preventive instructions are not
body, and accessories. Since vehicle and body configura- followed. The following paragraphs from ANSI publica-
tions vary, engineer each installation using this manual as tions explain each term.
a guide. Contact Altec Engineering before deviating from
the information in this manual. Danger
Indicates an imminently hazardous situation which,
Because options vary from one model to another, some if not avoided, will result in death or serious injury.
drawings may only be a representation of what is on the This signal word is to be limited to the most
unit. extreme situations.
Knowledge of the information in this manual combined with Warning

proper skills and training in hydraulic, electrical, and Indicates a potentially hazardous situation which,
mechanical systems, provide a basis for safely installing if not avoided, could result in death or serious
the unit. Read and understand all applicable information. injury.
Contact the following organizations for additional informa- Caution

tion. Indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate
• American National Standards Institute (ANSI) injury. It may also be used to alert against unsafe
A92.2 for aerial devices; A10.31 for digger derricks practices.
• American Society for Testing and Materials (ASTM)
• American Welding Society (AWS) Notice
• European Committee for Standardization (CEN) The preferred signal word to address practices not
• Fluid Power Society (FPS) related to personal injury.
• Hydraulic Tool Manufacturer’s Association (HTMA)
• International Electrotechnical Commission (IEC) It is essential that all personnel involved in the use, care,
• International Organization for Standardization (ISO) and/or installation of this unit read and understand the
• National Highway Transportation Safety Administra- Operator’s, Maintenance, and Final Assembly Manual.
tion (NHTSA) Safety alerts throughout the manuals highlight situations
in which accidents can occur. Pay special attention to all
Dealers, installers, owners, users, operators, renters, safety alerts.
lessors, and lessees must comply with the appropriate
sections of the applicable ANSI standard. It is essential that all personnel involved in the use, care,
and/or installation of this unit read and understand the
The Appendix contains reference items to assist in the Operator’s, Maintenance, and Final Assembly Manual.
installation process. The schematics and troubleshooting Safety alerts throughout the manuals highlight situations
chart contain information about the hydraulic system and in which accidents can occur. Pay special attention to all
operational problems that may occur during installation. safety alerts.
Forms are provided to inspect and test the completed unit
before putting it into service. Use the proper forms depend- Work practices may expose personnel to hazardous
ing on the options chosen for the particular unit. materials. Before using any chemical, read and under-
stand the manufacturer’s label and the material safety
Additional copies of this manual may be ordered. Supply data sheet (MSDS). These sheets explain emergency and
the model and serial number found on the serial number first aid procedures and waste disposal methods. Properly
placard and the manual part number from the front cover dispose of oil and hazardous materials.
to assure that the correct manual will be supplied.
This symbol is used throughout this manual to Danger

indicate danger, warning, and caution instruc- Death or serious injury will result from unprotected
tions. These instructions must be followed to contact with energized conductors. This unit does not
reduce the likelihood of personal injury and/or property provide protection from contact with or proximity to
damage. an electrically charged conductor when you are in
contact with or in proximity to another conductor or
Section 1 — Introduction • 1
any grounded device, material, or equipment. Main- electrical systems. Use caution when working with
tain safe clearances from energized conductors. any electrical device.
Injury and property damage can result from contact of

Warning the booms or platforms with fixed objects. Make sure
It is impossible to foresee all situations and combina- there is sufficient clearance before operating the unit.
tions for set up of the unit. Establish criteria for stable
operation of the unit based on actual conditions, work Injury can result from airborne particles entering the
procedures, and experience. The owner and operator eyes and lungs. Wear appropriate safety equipment.
bear ultimate responsibility for insuring that the unit
is properly set up. Injury can result from handling wire rope. Wear appro-
priate safety equipment.
Death or serious injury can result from improper use
of solvents. Follow the manufacturer’s label for proper Injury can result from slipping and falling. Use care
use and disposal. and the handles and steps provided.
Death or serious injury can result if the recommended Notice

hydraulic oil is not used. Use of other fluids in the Only use hydraulic oil as recommended. Other fluids
hydraulic system can affect the insulating capability of added to the hydraulic system can increase compo-
the unit. nent wear and affect the lubricating characteristics of
the oil.
Death or serious injury can result from uncontrolled
movement. Purge the air from the actuator before Carefully load the test weight to prevent damage to the
operating the unit. platform or liner.
Death or serious injury can result if the unit becomes Only use oils meeting the viscosity rating for military
unstable. Maintain stability of the unit while perform- specification MIL-5606 in extremely cold climates.
ing a structural test by following proper procedure. These oils have fewer antiwear characteristics and are
not recommended for full time use.
Caution Do not spray water from a high pressure washer
Injury can result from hydraulic oil being injected into directly at hydraulic components.
the flesh. Properly cap or connect hydraulic lines
before operating the unit. Damage to the pump or return line filter can result if the
unit is operated with either or both of the shutoff valves
Injury can result from hydraulic oil being injected into closed. Fully open the shutoff valves before engaging
the flesh if the tool hoses burst or the tool ruptures. Do the (PTO, hydraulic system).
not adjust the pressure of the tool circuit above the
hydraulic power tools manufacturer’s rating for the
General Specifications
tool.
This unit uses a side-by-side boom design.
Injury can result from hydraulic oil being injected into
the flesh when loosening or disconnecting hydraulic Unit height specifications are based on 40″ (101.6 cm)
components. Remove the pressure before loosening frame height, but common frame heights vary from 36″
or disconnecting hydraulic components. (91.44 cm) to 44″ (111.76 cm). Figures 1.1 and 1.2 provide
unit specifications.
Seek immediate medical attention if injured by escap-
ing hydraulic oil. Serious infection or reaction can The basic structural components are the outriggers, sub-
result if medical treatment is not given immediately. base, pedestal, turntable, lower boom, and upper boom.
The steel structures are made in the form of a closed box.
Spilled hydraulic oil creates slick surfaces and can This structural style resists torsional loading, as well as
cause personnel to slip and/or fall. Keep the unit and tension, compression, and bending loads that may be
work areas clean. applied to the unit. Careful consideration has been given
to the design and manufacturing process to minimize the
Injury can result from electric shock. Severe arcing possibility of fatigue cracks.
can occur even when working with low voltage vehicle
2 • Section 1 — Introduction
The square boom structural components are made of Unauthorized alterations or modifications will void the
filament wound fiberglass. The inner fiberglass surface is warranty. However, of a greater concern is the possibility
coated with urethane. The outer surface has a smooth that unauthorized changes could adversely affect the
gelcoat finish to protect the fiberglass. unit’s operation that could endanger personnel and/or
damage property. Altec will not be responsible for unautho-
rized alterations or modifications that cause death, seri-
Disclaimer of Liability ous injury, and/or property damage.
Altec Industries, Inc. will not be liable for unauthorized
alterations or modifications of the unit. Altec Industries, Altec Industries, Inc. assumes no liability for any personal
Inc. will not be liable for improper or abusive operation of injury and/or property damage related to the use of this
the unit. manual when performing testing, operating, maintenance
and/or repair procedures on this Altec unit.
Do not alter or modify this unit in any way that might affect
its structural integrity, dielectric integrity, or operational
characteristics without specific written approval from
Altec Industries, Inc.
Item Specification
Travel height 11.3′ (3.4 m)
Maximum hydraulic pressure setting 3,000 psi (207 bar)
Rotation Continuous
Winch capacity (full drum) 2,000 lb (907.2 kg)
Jib articulation -30° to 90°
1
Maximum jib capacity (extended) 750 lb (340.2 kg)
1
Maximum jib capacity (retracted) 2,000 lb (907.2 kg)
1
Maximum material handling capacity 2,000 lb (907.2 kg)
1
Maximum lower boom lifting eye capacity 2,000 lb (907.2 kg)
Synthetic winch line 80′
Maximum tool pressure 2,000 psi (138 bar)
Maximum tool flow 8 gpm (30.3 l/min)
Platform rotation 90°
1
Refer to capacity placards
Figure 1.1 — Unit Specifications
Section 1 — Introduction • 3
Item AM50 AM55 AM50E AM55E
Maximum ground to bottom of platform height 50.3′ (15.3 m) 55.3′ (16.9 m) 51.4′ (15.7 m) 56.0′ (17.1 m)
Working height 55.3′ (16.8 m) 60.3′ (18.4 m) 56.4′ (17.2 m) 61.0′ (18.6 m)
Maximum side reach — upper boom overcenter, lower boom at 0° 42.3′ (12.9 m) 47.3′ (14.4 m) 44.1′ (13.5 m) 48.8′ (14.9 m)
1 1 2
Maximum side reach — upper boom non-overcenter 31.5′ (9.6 m) 34.4′ (10.5 m) 39.7′ (12.1 m) 43.4′ (13.2 m)2
Lower boom articulation 0° to 100° 0° to 100° 0° to 124° 0° to 124°
Lower boom isolation 24″ (61 cm) 24″ (61 cm) 12″ (30 cm) 24″ (61 cm)
4 • Section 1 — Introduction
Upper boom articulation 0° to 210° 0° to 210° 0° to 200° 0° to 200°
Upper boom isolation 120″ (305 cm) 150″ (381 cm) 120″ (305 cm) 150″ (381 cm)
3
Maximum platform capacity — one man 400 lb (181.4 kg) 400 lb (181.4 kg) 400 lb (181.4 kg) 400 lb (181.4 kg)
3
Maximum platform capacity — two man 800 lb (362.9 kg) 800 lb (362.9 kg) 800 lb (362.9 kg) 800 lb (362.9 kg)
3
Maximum total platform capacity — dual one man, single control 800 lb (362.9 kg) 800 lb (362.9 kg) 800 lb (362.9 kg) 800 lb (362.9 kg)
3
Maximum total platform capacity — dual one man, dual controls 800 lb (362.9 kg) 700 lb (317.5 kg) 800 lb (362.9 kg) 700 lb (317.5 kg)
Item AM57 AM60 AM60E

Maximum ground to bottom of platform height 57.3′ (17.5 m) 60.3′ (18.4 m) 61.0′ (18.6 m)
Working height 62.3′ (19.0 m) 65.3′ (19.9 m) 66.0′ (20.1 m)
Maximum side reach — upper boom overcenter, lower boom at 0° 49.3′ (15.0 m) 52.3′ (15.9 m) 53.8′ (16.4 m)
1 1
Maximum side reach — upper boom non-overcenter 35.4′ (10.8 m) 37.4′ (11.4 m) 47.1′ (14.4 m)2
Lower boom articulation 0° to 100° 0° to 100° 0° to 124°
Lower boom isolation 36″ (91 cm) 24″ (61 cm) 24″ (61 cm)
Upper boom articulation 0° to 210° 0° to 210° 0° to 200°
Upper boom isolation 162″ (412 cm) 180″ (457 cm) 180″ (457 cm)
3
Maximum platform capacity — one man 400 lb (181.4 kg) 400 lb (181.4 kg) 400 lb (181.4 kg)
3
Maximum platform capacity — two man 800 lb (362.9 kg) 800 lb (362.9 kg) 600 lb (272.2 kg)
3
Maximum total platform capacity — dual one man, single control 700 lb (317.5 kg) 600 lb (272.2 kg) –
3
Maximum total platform capacity — dual one man, dual controls 600 lb (272.2 kg) 600 lb (272.2 kg) –
1
Lower boom at 100°
2
Lower boom at 124°
3
Refer to capacity placards
Figure 2.2 — Unit Specifications (by Model)
Section 2 — Planning
The subbase provides bending strength and torsional

Planning the Installation stiffness to resist frame twist above that provided from the
The following areas require planning before installing the vehicle frame.
unit, chassis, outrigger, subbase, body, component, pump
and PTO. This is a general summary of the planning Body selection considerations are body type, cross mem-
required to properly install the unit. ber size, outrigger openings, unit mounting openings, body
attachment method, and body accessories.
When selecting the chassis, the axle/spring capacity,
payload capacity, unit weight to achieve stability, GVWR, Accessories such as lights, generators, inverters, storage
vertical center of gravity, engine horsepower and trans- compartments, ladder racks, capstans, winches, etc.
mission must all be considered. Weight distribution calcu- must be selected based on customer requirements.
lations must be made to determine expected axle loading
when all components are installed. These calculations, The proper pump size and type are required for unit
when cross referenced with the appropriate configuration operation. Engine operating speed and PTO ratio (if
table, provide information that is essential to chassis applicable) must be determined to produce the proper oil
selection. flow. PTO selection includes mating to the transmission,
output percentage, mounting flange requirements, duty
Outrigger selection is based on primary outrigger require- cycle, horsepower requirements, mounting location, rota-
ments, mounting locations, outrigger leg extension, outrig- tion direction, and type of engaging mechanism.
ger interlocks, and outrigger motion alarms. The
configuration tables provide information on what outrigger Use proper welding and fastener installation techniques
types are available. when installing the unit.
Section 2 — Planning • 5
Configuration Tables
Minimum Recommended
Rear Axle Unit 1 CA Range 2 Platform Curbweight 4 Chassis Specifications
4
S = Single Mounting (WB Range) Capacity Front 3 Rear 3 Jib Capacity for Stability Drivetrain Front Axle 5 Rear Axle 5 GVWR 5
Model Platform T = Tandem Location (in) (in) (lbs) Outrigger Outrigger (lbs) (lbs) With Options Rating (lbs) Rating (lbs) (lbs)
AM50 Single S -14 108-138 300 241/244 241 N/A N/A
1-Man (174-264) 243 1,450 22,700
247 N/A N/A
450 1,450 21,800
460 1,450 20,700
470 1,450 20,300
350 241/244 241 N/A N/A
6 • Section 2 — Planning
243 1,450 23,000
247 N/A N/A
450 1,450 22,100
460 1,450 21,000
470 1,450 20,600
400 241/244 241 N/A N/A
243 1,450 23,400
247 N/A N/A
450 1,450 22,500
460 1,450 21,300 4x2 12,000 21,000 33,000
470 1,450 20,900 4x2 w/winch 13,000 20,000 33,000
Dual S -14 108-138 600 241/244 241 N/A N/A 4x4 14,000 21,000 35,000
1-Man (174-264) 243 805 22,500 4x4 w/winch 16,000 21,000 37,000
Single 247 N/A N/A
Controls 450 805 21,600
460 805 20,500
470 805 20,100
700 241/244 241 N/A N/A
243 805 23,200
247 N/A N/A
450 805 22,300
460 805 21,200
470 805 20,700
800 241/244 241 N/A N/A
243 805 23,900
247 N/A N/A
450 805 23,000
460 805 21,800
470 805 21,400
Notes
1
Unit mounting location (inches) is from centerline of rotation to the center of the rear axle (single) or center of rear tandem. A negative value indicates a location rearward of the rear axle or tandem.
2
Wheelbase (WB) and cab to axle (CA) dimensions vary slightly with different vehicle manufacturers. Chassis WB and CA dimensions that fall in the recommended range are acceptable. Weight distribution will be applicable.
3
Outrigger reference codes are as follows:
Code 241 — Flat shoe A-frame with 149″ maximum spread Code 450 — Fold-up shoe A-frame with 153″ maximum spread
Code 243 — Radial with 164″ maximum spread Code 460 — Fixed shoe X-frame with 172″ maximum spread
Code 244 — Fold-up shoe A-frame with 153″ maximum spread Code 470 — Fold-up shoe X-frame with 174″ maximum spread
Code 247 — Three stage A-frame with 165″ maximum spread
4
Jib capacities taken with upper boom at zero degrees and load radius of zero to one foot.
5
Values in the table are typical minimum ratings. Due to variations in each unit’s weight distribution, the anticipated weight distribution for each particular configuration must be considered before specifying a front or rear axle
rating and GVWR.
6
This axle rating is estimated to only give an available payload of less than 10 percent of the overall axle rating with a standard configuration.
7
Unit lifting capacity may require deration in some working positions, if minimum loaded chassis weight is not maintained. Chassis weight values shown in table must be confirmed by conducting an actual stability test in
accordance with ANSI A92.2 as applicable.
8
Minimum recommended frame section modulus/yield strength (cu-in/psi): 10.31/80,000 to 14.85/120,000. The values listed are for a single frame rail including any factory installed reinforcement. The frame’s Rated Bending
Moment (RBM), in inch-pounds, may be found by multiplying the section modulus by the yield strength (i.e. 12 x 110,000 = 1,320,000).
9
Consult Altec Engineering before deviating from the configurations listed in the table.
Minimum Recommended
4
AM50 Dual S -14 108-138 600 241/244 241 N/A N/A
1-Man (174-264) 243 745 22,900
Dual 247 N/A N/A
Controls 450 745 22,000
460 745 20,100
470 745 20,500
700 241/244 241 N/A N/A
243 745 23,600
247 N/A N/A
450 745 22,700
460 745 21,500
470 745 21,100
800 241/244 241 N/A N/A
243 745 24,300
247 N/A N/A
450 745 23,400
460 745 22,200 4x2 12,000 21,000 33,000
470 745 21,700 4x2 w/winch 13,000 20,000 33,000
Single S -14 108-138 600 241/244 241 N/A N/A 4x4 14,000 21,000 35,000
2-Man (174-264) 243 1,040 21,800 4x4 w/winch 16,000 21,000 37,000
247 N/A N/A
450 1,040 21,000
460 1,040 19,900
470 1,040 19,500
700 241/244 241 N/A N/A
243 1,040 22,500
247 N/A N/A
450 1,040 21,600
460 1,040 20,500
470 1,040 20,100
800 241/244 241 N/A N/A
243 1,040 23,300
247 N/A N/A
450 1,040 22,300
460 1,040 21,200
470 1,040 20,800
Notes
1
2
3
4
5
rating and GVWR.
6
7
8
9
Minimum Recommended
4
AM55 Single S -14 108-138 300 241/244 241 N/A N/A
1-Man (174-264) 243 1,115 24,000
247 N/A N/A
450 1,115 21,900
460 1,115 20,800
470 1,115 20,400
350 241/244 241 N/A N/A
243 1,115 23,200
247 N/A N/A
450 1,115 22,300
460 1,115 21,100
470 1,115 20,700
400 241/244 241 N/A N/A
243 1,115 23,600
247 N/A N/A
450 1,115 22,600
460 1,115 21,500 4x2 12,000 21,000 33,000
470 1,115 21,100 4x2 w/winch 13,000 20,000 33,000
Dual S -14 108-138 600 241/244 241 N/A N/A 4x4 14,000 6 21,000 35,000
1-Man (174-264) 243 470 26,000 4x4 w/winch 16,000 21,000 37,000
Single 247 N/A N/A
Controls 450 470 25,000
460 470 23,700
470 470 23,300
700 241/244 241 N/A N/A
243 470 26,800
247 N/A N/A
450 470 25,700
460 470 26,000
470 470 24,000
800 241/244 241 N/A N/A
243 470 27,600
247 N/A N/A
450 470 26,500
460 470 25,200
470 470 24,700
Notes
1
2
3
4
5
rating and GVWR.
6
7
8
9
Minimum Recommended
4
AM55 Dual S -14 108-138 600 241/244 241 N/A N/A
1-Man (174-264) 243 500 26,700
Dual 247 N/A N/A
Controls 450 500 25,700
460 500 24,400
470 500 23,900
700 241/244 241 N/A N/A
243 500 27,500
247 N/A N/A
450 500 26,400
460 500 25,100
470 500 24,600
800 N/A N/A N/A N/A
Single S -14 108-138 600 241/244 241 N/A N/A 4x2 12,000 21,000 33,000
2-Man (174-264) 243 705 24,200 4x2 w/winch 13,000 20,000 33,000
247 N/A N/A 4x4 14,000 6 21,000 35,000
450 705 23,200 4x4 w/winch 16,000 21,000 37,000
460 705 22,100
470 705 21,600
700 241/244 241 N/A N/A
243 705 25,000
247 N/A N/A
450 705 24,000
460 705 22,800
470 705 22,400
800 241/244 241 N/A N/A
243 705 25,800
247 N/A N/A
450 705 24,800
460 705 23,500
470 705 23,000
Notes
1
Unit mounting location (inches) is from centerline of rotation to the center of the rear axle (single) or center of rear tandem. A negative value indicates a location rearward of the rear axle or
tandem.
2
Wheelbase (WB) and cab to axle (CA) dimensions vary slightly with different vehicle manufacturers. Chassis WB and CA dimensions that fall in the recommended range are acceptable.
Weight distribution will be applicable.
3
4
5
Values in the table are typical minimum ratings. Due to variations in each unit’s weight distribution, the anticipated weight distribution for each particular configuration must be considered
before specifying a front or rear axle rating and GVWR.
6
7
Unit lifting capacity may require deration in some working positions, if minimum loaded chassis weight is not maintained. Chassis weight values shown in table must be confirmed by conduct-
ing an actual stability test in accordance with ANSI A92.2 as applicable.
8
Minimum recommended frame section modulus/yield strength (cu-in/psi): 10.31/80,000 to 14.85/120,000. The values listed are for a single frame rail including any factory installed reinforce-
ment. The frame’s Rated Bending Moment (RBM), in inch-pounds, may be found by multiplying the section modulus by the yield strength (i.e. 12 x 110,000 = 1,320,000).
9
Minimum Recommended
4
AM60 Single S -14 108-138 300 241/244 241 N/A N/A
1-Man (174-264) 243 785 23,000
247 N/A N/A
450 785 22,200
460 785 21,000
470 785 20,600
350 241/244 241 N/A N/A
243 785 23,500
247 N/A N/A
450 785 22,600
460 785 21,500
470 785 21,000 4x2 13,000 20,000 33,000
400 241/244 241 N/A N/A 4x2 w/winch 14,000 20,000 34,000
243 785 24,000 4x4 14,000 6 21,000 35,000
247 N/A N/A 4x4 w/winch 16,000 21,000 37,000
450 785 23,000
460 785 21,900
470 785 21,500
Dual S -14 108-138 600 241/244 241 N/A N/A
1-Man (174-264) 243 325 29,900
Single 247 N/A N/A
Controls 450 325 28,800
460 325 27,400
470 325 26,800
700 N/A N/A N/A N/A
800 N/A N/A N/A N/A
Notes
1
Unit mounting location (inches) is from centerline of rotation to the center of the rear axle (single) or center of rear tandem. A negative value indicates a location rearward of the rear
axle or tandem.
2
Wheelbase (WB) and cab to axle (CA) dimensions vary slightly with different vehicle manufacturers. Chassis WB and CA dimensions that fall in the recommended range are
acceptable. Weight distribution will be applicable.
3
4
5
Values in the table are typical minimum ratings. Due to variations in each unit’s weight distribution, the anticipated weight distribution for each particular configuration must be consid-
ered before specifying a front or rear axle rating and GVWR.
6
7
Unit lifting capacity may require deration in some working positions, if minimum loaded chassis weight is not maintained. Chassis weight values shown in table must be confirmed by
conducting an actual stability test in accordance with ANSI A92.2 as applicable.
8
Minimum recommended frame section modulus/yield strength (cu-in/psi): 10.31/80,000 to 14.85/120,000. The values listed are for a single frame rail including any factory installed
reinforcement. The frame’s Rated Bending Moment (RBM), in inch-pounds, may be found by multiplying the section modulus by the yield strength (i.e. 12 x 110,000 = 1,320,000).
9
Minimum Recommended
4
AM60 Dual S -14 108-138 600 241/244 241 N/A N/A
1-Man (174-264) 243 265 29,700
Dual 247 N/A N/A
Controls 450 265 28,600
460 265 27,200
470 265 26,700
700 N/A N/A N/A N/A
800 N/A N/A N/A N/A
Single S -14 108-138 600 241/244 241 N/A N/A
2-Man (174-264) 243 370 26,100
247 N/A N/A
450 370 25,100 4x2 13,000 20,000 33,000
460 370 23,900 4x2 w/winch 14,000 20,000 34,000
470 370 23,500 4x4 14,000 6 21,000 35,000
700 241/244 241 N/A N/A 4x4 w/winch 16,000 21,000 37,000
243 370 27,000
247 N/A N/A
450 370 26,000
460 370 24,800
470 370 24,400
800 241/244 241 N/A N/A
243 370 28,000
247 N/A N/A
450 370 26,900
460 370 25,600
470 370 25,100
Notes
1
axle or tandem.
2
3
4
5
6
7
8
9
Jib Curbweight 4 Minimum Recommended
Rear Axle Unit 1 CA Range 2 Platform Capacity4 for Stability Chassis Specifications
3 3
S = Single Mounting (WB Range) Front Rear Capacity (lbs) (lbs) Drivetrain Front Axle 5 Rear Axle 5 GVWR 5
Model Platform T = Tandem Location (in) (in) Outrigger Outrigger (lbs) Max Min Max Min With Options Rating (lbs) Rating (lbs) (lbs)
AM50E Single S -14 108-138 241/244 470 300 1,380 750 30,000 24,700
1-Man (174-264) 350 1,380 750 30,500 25,100
400 1,380 750 30,900 25,500
Dual,1-Man S -14 108-138 241/244 470 600 675 300 28,800 25,800
Single (174-264) 700 675 300 29,700 26,600 4x2 12,000 21,000 33,000
Controls 800 675 300 30,600 27,400 4x2 w/winch 13,000 20,000 33,000
Dual,1-Man S -14 108-138 241/244 470 600 675 300 28,100 25,200 4x4 14,000 6 21,000 35,000
Dual (174-264) 700 675 300 28,900 26,000 4x4 w/winch 16,000 21,000 37,000
Controls 800 675 300 29,700 26,800
Single S -14 108-138 241/244 470 600 965 400 29,400 24,600
2-Man (174-264) 700 965 400 30,300 25,500
800 965 400 31,200 26,300
Notes
1
axle or tandem.
2
3
Code 241 — Flat shoe A-frame with 149″ maximum spread
Code 244 — Fold-up shoe A-frame with 153″ maximum spread
Code 470 — Fold-up shoe X-frame with 174″ maximum spread
4
5
6
7
8
9
3 3
AM55E Single S -14 108-138 241/244 470 300 1,030 500 30,400 25,600
1-Man (174-264) 350 1,030 500 30,900 26,000
400 1,030 500 31,400 26,500
Dual,1-Man S -14 108-138 241/244 470 600 380 0 29,700 26,400
Single (174-264) 700 380 0 30,600 27,300 4x2 12,000 21,000 33,000
Dual,1-Man S -14 108-138 241/244 470 600 675 300 28,800 25,500 4x4 14,000 6 21,000 6 35,000
Dual (174-264) 700 675 300 29,700 26,400 4x4 w/winch 16,000 21,000 6 37,000
Controls 800 N/A N/A N/A N/A
Single S -14 108-138 241/244 470 600 615 200 29,500 25,900
2-Man (174-264) 700 615 200 30,500 26,800
800 615 200 31,500 27,700
Single T -41 108-138 241/244 470 300 1,030 500 30,400 25,600
1-Man (174-264) 350 1,030 500 30,900 26,000
400 1,030 500 31,400 26,500
Dual,1-Man T -41 108-138 241/244 470 600 380 0 29,700 26,400
Single (174-264) 700 380 0 30,600 27,300 6x4 12,000 34,000 46,000
Dual,1-Man T -41 108-138 241/244 470 600 675 300 28,800 25,500 6x6 14,000 34,000 48,000
Dual (174-264) 700 675 300 29,700 26,400 6x6 w/winch 16,000 34,000 50,000
Controls 800 N/A N/A N/A N/A
Single T -41 108-138 241/244 470 600 615 200 29,500 25,900
2-Man (174-264) 700 615 200 30,500 26,800
800 615 200 31,500 27,700
Notes
1
axle or tandem.
2
3
4
Maximum jib capacities correspond with maximum curb weight for stability, and minimum jib capacities correspond with minimum curb weight for stability. These numbers are for
reference only. If the unit is unstable at this curb weight, the jib or platform capacity will have to be derated and/or more counterweight will need to be added.
5
6
7
8
9
3 3
AM60E Single S -14 108-138 241/244 470 300 650 400 30,000 27,500
1-Man (174-264) 350 650 400 30,400 28,000 4x2 13,000 20,000 33,000
400 650 400 30,900 28,500 4x2 w/winch 14,000 20,000 34,000
Single S -14 108-138 241/244 470 600 420 200 30,900 28,800 4x4 14,000 6 21,000 6 35,000
2-Man (174-264) 700 N/A N/A N/A N/A 4x4 w/winch 16,000 21,000 6 37,000
800 N/A N/A N/A N/A
Single T -41 108-138 241/244 470 600 650 400 30,000 27,500
1-Man (174-264) 700 650 400 30,400 28,000 6x4 13,000 34,000 47,000
800 650 400 30,900 28,500 6x4 w/winch 13,000 6 34,000 47,000
Single T -41 108-138 241/244 470 600 420 200 30,900 28,800 6x6 14,000 6 34,000 48,000
2-Man (174-264) 700 N/A N/A N/A N/A 6x6 w/winch 16,000 34,000 50,000
800 N/A N/A N/A N/A
Notes
1
axle or tandem.
2
3
4
5
6
7
8
9
Gross Vehicle Weight Rating (GVWR)
Chassis On medium duty trucks, the required GVWR is the sum of
Use the weight distribution calculations and the appropri- the front and rear axle capacities. While the configuration
ate configuration table when selecting a chassis. Weight tables show recommended GVWR, the front and rear axle
distribution calculations may have to be adjusted to capacity selection process will also determine the GVWR.
account for bare axle weights and wheelbase dimensions For example, if a 12,000 pound front axle and a 21,000
on the final chassis. There are several considerations pound rear axle is chosen, the GVWR will be 33,000
when selecting a chassis. pounds. In the axle capacity selection process, tire
selection may limit the GVWR to a value below the
Axle, Spring, and Tire Capacity manufacturer’s published GVWR.
Front and rear axle capacities are limited by the suspen-
sion component that has the least capacity. For example, Vertical Center of Gravity (VCG)
a 21,000 pound capacity rear axle may be limited to less Vehicle manufacturers typically set limits on the height of
than 21,000 pounds if the tires or springs do not allow the finished vehicle’s vertical center of gravity as mea-
21,000 pound capacity. sured relative to the ground. This information is shown in
the Vehicle Manufacturer’s Body Builder’s Book and is
While the configuration tables show minimum front and commonly 70 inches maximum for a single rear axle
rear axle capacity, the anticipated front and rear axle medium duty vehicle and 75 inches maximum for a
weights from the weight distribution calculations should be tandem rear axle vehicle.
checked to determine the actual axle capacity needed. Be
sure to include estimates for payload, passengers, and Make sure the finished vehicle, with or without payload,
fuel in the weight distribution calculations when consider- does not violate the vehicle manufacturer’s limits. Though
ing front and rear axle capacities. Also, include any higher values may be allowed by the vehicle manufactur-
counterweight that will be needed to maintain unit stability. ers, experience has shown that VCG values under 60
inches tend to reduce drivability problems such as weave
The configuration tables can give an approximate vehicle and roll.
weight to achieve stability. In cases where axles will be
loaded to near maximum capacity, it may be necessary to Horsepower
shift component mounting locations to obtain better weight Engine power requirements are, in most cases, deter-
distribution. Changes to the wheelbase length may also be mined by issues such as towing or gradeability. Consult
needed to reduce axle loads. Update the weight distribu- your chassis dealer for assistance.
tion calculations each time a change is made.
Transmission
Payload Reserve Capacity The customer usually specifies whether the transmission
Make sure adequate reserve capacity remains to carry the is automatic or manual shifting. However, be aware that
anticipated payload. The customer will specify how much some automatic transmissions do not allow for the addi-
payload reserve is needed. tion of options such as torque converter lock-up kits. A
torque converter lock-up kit may need to be added to
Unit Weight to Maintain Stability prevent slippage in the torque converter when using a PTO
The approximate total unloaded vehicle weight to meet driven pump on an automatic transmission. Some newer
ANSI stability requirements is shown in the configuration automatic transmissions do not require a torque converter
tables. Make sure all readily removable tools and acces- lock-up kit since the PTO is driven directly from the engine
sories are not included in the weight distribution calcula- instead of through the torque converter. Manual transmis-
tions when considering the total finished vehicle weight to sions do not require a lock-up kit. Consult your chassis
meet stability requirements. Also, driver and passenger dealer for assistance with transmission selection and
weight must not be included and fuel weight in excess of torque converter lock-up kits.
100 pounds should be omitted from the total vehicle weight
for stability considerations.
Outriggers
If the weight distribution calculations show a total un- Since the primary function of outriggers is to maintain unit
loaded vehicle weight less than the value shown in the stability, issues such as overall vehicle weight and stabil-
configuration tables, add the difference to the vehicle in ity are closely linked to the choice of outriggers. There are
the form of permanent counterweight. If counterweight is several considerations when selecting outriggers.
added, recheck the axle capacities and reserve payload
capacities by updating the weight distribution calcula-
tions, to be sure they are still adequate.
Types Interlocks
Determine what outrigger types are available (refer to the To ensure stability, outriggers must be properly set before
appropriate configuration table). Some customers have a a unit is operated. Outrigger interlock switches are added
preference toward either A-frame or radial outriggers. A- to prevent unit operation unless the outriggers have been
frame outriggers, due to their telescopic nature, tend to lowered.
increase their spread as penetration is increased and
decrease their spread as they are retracted. Increased Motion Alarms
outrigger spread tends to create a more stable vehicle. Warning alarms are added to outriggers to warn an operator
Radial outriggers, due to their radial nature, decrease or bystander that an outrigger is in motion.
spread as penetration is increased. A-frame outriggers
require slightly more lubrication due to the sliding action of
Subbase
the telescopic members. Radial outriggers usually offer
the least obstruction to the payload area of the vehicle. The addition of a subbase is required on all models.
Shoes
Body
Some outriggers have fixed shoes while others have
shoes that pivot. Most radial and some A-frame outriggers Body selection is an important part of the final assembly
have pivoting shoes. The pivoting shoe outriggers usually process. There are several considerations when selecting
give better ground contact pressure distribution since the a body.
pad of the shoe can sit flat on the contact surface. On most
pivoting shoe outriggers extra clearance is needed to Types
mount the outrigger to prevent the shoe from contacting Altec offers many body configurations. Consult the Altec
the body or chassis. On fixed shoe outriggers, the outrig- Body Catalog for more information or directly contact the
ger ground contact pad can generally remain below the Altec Body Plant. Custom engineering is available to meet
level of the body compartments which allows the outrigger special needs.
to fit into a smaller opening than would be possible with the
pivoting shoe outrigger. Cross Member Height
Bodies which mount on top of subbases commonly use
On extra tall chassis frames, it may be necessary to lower three inch body cross members.
the outrigger shoe to maintain critical ground clearance
dimensions. Lowering the shoe is most easily accom- Outrigger Locations
plished on fixed shoe, A-frame outriggers. In most cases Where applicable, clearance must be provided in or around
it is not possible to lower the shoe on pivoting shoe the body to allow for the addition of outriggers. Altec bodies
outriggers without converting to a fixed shoe. On extra tall commonly have boxed openings to accept outriggers. Be
chassis frames, it might be advantageous to choose a sure to plan outrigger openings with the body manufac-
fixed shoe, A-frame outrigger. turer.
Primary Floor Opening

The outrigger closest to the unit mounting location is Generally, the body floor must be removed in the area of
considered the primary outrigger. Refer to Section 3 under the pedestal to allow for unit mounting. Altec offers bodies
Outriggers and the appropriate configuration table for more which have the body floor removed in the unit mounting
information. area.
Auxiliary Accessories
Many units require two sets of outriggers to meet stability Altec offers accessories such as access ladders, ladder
requirements. The second set of outriggers is considered racks, storage boxes, platform extensions, bumpers,
the auxiliary outrigger. Refer to the appropriate configura- boom rests, cab guards, platform rests, etc., which work
tion table to determine what auxiliary outriggers are avail- well with both Altec and competitor’s bodies. A catalog is
able. available to aid in accessory selection. Contact the Altec
Body Plant for more information.
respectively. HCG values are relative to the rear axle
Component centerline and should be negative when located be-
Component requirements vary. The final customer may hind the rear axle. VCG values are relative to the
specify component requirements such as platform exten- ground. Use a VCG value of two inches higher than the
sions, special lighting or wiring, generators, inverters, frame height for the front bare axle weight and three
special storage compartments, winches, capstans, plat- inches below the frame height for the rear bare axle
form rests, special access ladders, ladder racks, bumpers, weight.
hose reels, grounding reels, special throttle controls, cab
guards, special alarms or warning devices, etc. When 4. Complete column E by multiplying the corresponding
ordering these components, be sure to obtain the weight values in columns B and C. Complete column F by
and center of gravity of the components for use in the multiplying the corresponding values in columns B
weight distribution calculations. and D.
Follow all manufacturer’s guidelines when installing the 5. Calculate the front axle reaction (column G) for each
components. Remember to provide the customer with all of the components by dividing the wheelbase dimen-
manuals and literature documenting purchased compo- sion (WB) into each of the column E values.
nents.
6. Calculate the rear axle reaction (column H) for each of
the components by subtracting column G values from
Weight Distribution Calculations column B values.
Weight distribution calculations are an essential part of the
planning process. Several of the critical design decisions 7. Total columns B, E, F, G, and H. Note that the total
of any final assembly project are based on the results of front and rear axle weights are shown by the totals of
the weight distribution calculations. Refer to Chassis in columns G and H respectively.
this section for more information on how the weight
distribution data affects the chassis selection. Weight and 8. The combined unit HCG may be found by dividing the
center of gravity for some components may be found in total of column B into the total of column E. The
this section. An example of weight distribution calcula- combined unit VCG may be found by dividing the total
tions is provided as an aid to using this important planning of column B into the total of column F. Refer to
tool. Chassis in this section to ensure that all weight related
issues have been checked.
The drawing in Figure 2.1 is only an example and is not
.
intended to represent a particular unit model. Total vehicle HCG = Total E –. Total B
1,942,400 = 86.4 inches
1. Make a layout drawing or sketch similar to the drawing 22,485
to define where all of the components will be located.
.
Total vehicle VCG = Total F –. Total B
2. Create a weight distribution table with each of the 1,256,750 = 55.9 inches
components in column A (refer to Figure 2.1). List the 22,485
corresponding weight of each component in column B.
The weights of components such as payload, person- Front axle weight = Total G = 11,035 pounds
nel, removable tools, and fuel in excess of 100 pounds
should be considered for sizing the front and rear axle Rear axle weight = Total H = 11,450 pounds
capacities but must not be considered when checking
overall vehicle weight to meet stability requirements. Total vehicle weight = Total G + Total H
11,035 + 11,450 = 22,485 pounds
3. List the horizontal (HCG) and vertical (VCG) centers
of gravity for each component in columns C and D Figure 2.2 shows the calculation results from the example.
WB=176 A B C D E F G H
Front Rear
REF Description WT HCG VCG BXC BXD E/WB B-G
1 Front bare axle 6,300 176 41 1,108,800 258,300 6,300 0
2 Rear bare axle 4,000 0 36 0 144,000 0 4,000
3 Aerial device 5,500 94 99 517,000 544,500 2,938 2,562
4 Front outrigger 1,020 102 44 104,040 44,880 591 429
5 Rear outrigger 900 -40 45 -36,000 40,500 -205 1,105
6 Body 2,225 20 46 44,500 102,350 253 1,972
7 Subbase 1,000 30 42 30,000 42,000 170 830
8 Platform step 50 -60 70 -3,000 3,500 -17 67
9 Pintle hook 60 -75 25 -4,500 1,500 -26 86
10 Rear step 40 -76 18 -3,040 720 -17 57
11 Boom stow 100 210 75 21,000 7,500 119 -19
12 Cab guard 150 155 110 23,250 16,500 132 18
13 PTO/pump 90 140 25 12,600 2,250 72 18
14 Reservoir/oil 150 85 55 12,750 8,250 72 78
*15 Personnel 500 130 60 65,000 30,000 369 131
*16 Fuel 400 125 25 50,000 10,000 284 116
*TOTALS 22,485 NA NA 1,942,400 1,256,750 11,035 11,450
Omit item 15 when checking vehicle weight for stability and limit item 16 to 100 pounds.
Figure 2.1 — Weight Distribution Table
Gas Engine Speed Setting
Due to the lower torque capabilities of most gas engines
at idle speeds, it is usually necessary to use lower PTO
ratios in conjunction with a throttle actuator to increase the
engine operating speed to 1,000 to 1,200 rpm. Use the
formula for figuring the proper PTO percentage to produce
55.90″ the recommended oil flow.
11,035 pounds 86.40″ Example — Find the PTO output percentage to produce a
11,450 pounds desired engine operating idle speed of 1,200 rpm and meet
the recommended pump speed of 1,350 rpm.
Figure 2.2 — Example Calculation Results
1,350 x 100 = 113% PTO output percentage
Pump 1,200
The pump can be supplied in right hand or left hand rotation
directions and often has an SAE B 2-bolt flange for direct PTO
mounting to a PTO. Refer to Section 3 under Pump for
A PTO application manual from a suitable PTO manufac-
more information.
turer should be used in the selection process. PTO
manufacturers and distributors often make available, upon
The recommended pumps to use are a Vickers PVE19 and
request, a copy of their application manual. The following
an Eaton 70422. The 70422 is slightly smaller than the
procedure, in conjunction with the guidelines shown in a
PVE19, but produces roughly the same flow after account-
manufacturer’s application manual, should prove helpful in
ing for pump efficiency. The non-extended version of the
selecting an appropriate PTO.
unit requires 17 gpm maximum flow from the pump. The
extended (E) version requires 21 gpm. The PVE19 and
1. Determine the make and model of the transmission on
70422 pumps should be run at approximately 1,750-1,775
which the PTO will be installed. This information will
rpm at the pump shaft for a non-extended unit, or 2,175-
be used later in the selection process.
2,200 rpm for an extended unit.
2. Determine the output horsepower requirement for the
Diesel Engine Speed Setting
PTO. Use the following formulas to determine the
The operational speed setting of a diesel engine will
estimated horsepower requirement to drive vane,
depend on the selection of the PTO output speed percent-
gear, and piston pumps. The formulas assume a 60
age. Many diesel engines use a PTO ratio which will allow
percent overall mechanical efficiency for a vane
the engine to operate at a speed of 900 to 1,100 rpm. A
pump, 75 percent for a gear pump, and 85 percent for
throttle actuator mechanism can be used to automatically
a piston pump.
increase the engine speed to the preset level when one or
more of the unit functions is operated. After a target engine
Pump Horsepower Requirement Calculations
operating speed is selected, find the required PTO output
speed percentage using the following formula.
Vane pump input horsepower = gpm x psi
1,028
Pump rpm x 100 = PTO output percentage
Engine rpm
Gear pump input horsepower = gpm x psi
1,286
Example — Find the PTO output percentage to produce a
desired engine operating idle speed of 1,000 rpm and meet
Piston pump input horsepower = gpm x psi
the recommended pump speed of 1,350 rpm.
1,457
1,350 x 100 = 135% PTO output percentage
3. Determine the PTO output shaft speed percentage.
1,000
After the desired pump and engine speed are known,
the PTO output shaft speed percentage can be
determined. Refer in this section under Pump to
determine the proper pump and engine speed. The
PTO output rpm is expressed as a percentage of the mounted so that the pump will be above or below the
engine speed. For example, at an engine speed of center of the opening. They may also provide mount-
1,000 rpm, a 120 percent PTO would produce an ing options which allow the PTO to be mounted so the
output shaft speed of 1,200 rpm while an 85 percent pump will be toward the front or rear of the vehicle.
PTO would produce only 850 rpm at the same 1,000 Look at the mounting area of the transmission to
rpm engine speed. Calculate the approximate PTO determine the best PTO mounting location to avoid
output speed percentage using the following formula. interference such as exhaust pipes or frame braces.
PTO output percent = pump shaft rpm x 100 8. Determine the rotation direction for the PTO. Consult
engine rpm a PTO application manual to determine the PTO
rotation direction for a specific transmission model
4. Determine how the pump connects to the PTO. If and mounting location. Changing the mounting loca-
possible, the pump should connect directly to the PTO tion from the rear to the front pump may reverse the
using a flange-mounted pump and PTO. However, due rotation direction. Changing from the left side of the
to interference, sometimes it is necessary to separate transmission to the right side does not commonly
the pump mount from the PTO and connect the pump reverse the direction. The direction is shown in the
input shaft to the PTO output shaft with a drive shaft. PTO application manual as either engine or opposite.
The drive shaft connection requires more installation Opposite direction PTOs rotate opposite from the
time and more maintenance than the direct flange engine rotation direction and are sometimes called
mounting. right hand PTOs. Engine direction PTOs are some-
times called left hand PTOs. A left hand PTO accepts
Most Altec supplied pumps use an SAE B 2-bolt only a right hand pump and a right hand PTO accepts
flange. Be sure to select a PTO which will accept the only a left hand pump.
flange mounting and shaft supplied with the pump to
be used. There may be several different orientation Manual transmissions commonly use opposite direc-
options for the same mounting flange. tion PTOs and the corresponding left hand pump and
automatic transmissions commonly use engine direc-
5. Determine the PTO duty cycle. Most PTO manufac- tion PTOs and the corresponding right hand pump.
turers consider operation of the PTO longer than 5
minutes every 20 minutes to be continuous duty. 9. Determine how the PTO is to be engaged. PTO
Operation less than 5 minutes every 20 minutes would manufacturers provide several different shifting mecha-
be considered intermittent duty. Select the PTO nisms for each PTO. Cable, wire, air cylinder, and
based on a continuous duty cycle. electric solenoid actuated PTOs are usually available.
6. Determine the required PTO output torque. Use the 10. Check hardware needs. Some PTOs require special
horsepower value calculated in step 2 and the pump stud kits for mounting to some transmissions. The
speed used in step 3 in the following formula to PTO application manual will indicate if a stud kit or
determine the required PTO output torque. Some PTO mounting hardware is needed.
application manuals list only the allowable intermittent
PTO torque. The allowable continuous duty torque is 11. Using the information from steps 1 to 10, consult a
about 70 percent of the allowable intermittent torque. PTO application manual to select an appropriate PTO.
PTO output torque (ft-lbs) = horsepower x 5,252

(continuous duty) pump rpm
Welding and Fasteners
Welding processes must follow Altec Manufacturing/
7. Determine the PTO mounting location. Most manual Assembly Procedure MAP-1501. Fastener procurement,
transmissions provide PTO mounting openings on use, and storage must follow Altec EOP-0006. Final
both sides of the transmission while automatic trans- Assembly Centers must maintain current revisions of both
missions provide a mounting opening only on the right MAP-1501 and EOP-0006. Contact Altec Engineering to
or curb side of the transmission. PTO manufacturers obtain the latest revisions of these procedures.
provide mounting options which allow their PTOs to be
Dimensions, Weights, and Center of Gravity
AM50
AM55
AM60
AM50E
AM55E
AM60E
AM50 AM55 AM60
Platform Weight HCG VCG Weight HCG VCG Weight HCG VCG
(lbs) (in) (in) (lbs) (in) (in) (lbs) (in) (in)
Single 1-man 7,314 60.3 63.2 7,530 73.0 63.5 7,730 85.0 63.5
Dual 1-man 7,583 55.4 63.4 7,799 67.8 63.7 7,999 79.8 63.7
Dual 1-man, dual upper controls 7,646 54.4 63.5 7,862 66.7 63.7 8,062 78.7 63.7
Single 2-man 7,345 59.7 63.2 7,561 72.3 63.5 7,761 84.3 63.5
AM50E AM55E AM60E

Platform Weight HCG VCG Weight HCG VCG Weight HCG VCG
(lbs) (in) (in) (lbs) (in) (in) (lbs) (in) (in)
Single 1-man 7,773 62.2 62.1 7,981 72.1 62.4 8,176 84.5 62.6
Dual 1-man 8,043 57.9 62.4 8,251 67.5 62.6 N/A N/A N/A
Dual 1-man, dual upper controls 8,105 57.0 62.5 8,313 66.5 62.7 N/A N/A N/A
Single 2-man 7,805 61.7 62.2 8,013 71.6 62.4 8,208 83.9 62.6
Weights do not include reservoir, platform liners, or platform covers
Component Weight Center of Gravity
Outriggers Refer to Outriggers in this section Refer to Outriggers in this section
Body Varies (contact manufacturer) Varies (contact manufacturer)
Cargo to compartment step 8 pounds Refer to Operator Access Step in this section
Compartment to platform step 18 pounds Refer to Platform Access Step in this section
Cab guard Varies (per customer specification) Varies (per customer specification)
Pintle hook Varies (contact manufacturer) Varies (contact manufacturer)
Boom rest Varies (per customer specification) Varies (per customer specification)
Rear bumper Varies (contact manufacturer) Varies (contact manufacturer)
Throttle actuator assembly 16 pounds Refer to Throttle Actuator in this section
Pump PVE19 38 pounds HCG and VCG near center of pump
Pump PVE12 26 pounds HCG and VCG near center of pump
DC pump 40 pounds HCG and VCG near center of motor
Reservoir Refer to Reservoir in this section Refer to Reservoir in this section
PTO Varies (contact manufacturer) Varies (contact manufacturer)
Platform liner, 50 kV, 24 x 30 50 pounds HCG is -60.9; VCG is 75.6
Platform liner, 50 kV, 24 x 48 85 pounds HCG is -60.9; VCG is 75.6
Components
Platform
Code 41/241
Outriggers
Code 43/243
Code 44/244
∅
Code 47/247
Code 450
Code 470
15 Gallon
Reservoirs
28 Gallon
15 Gallon
Throttle Actuator
Cargo to Platform Step
Cargo to Compartment Step
Typical Configurations
Single Axle
Tandem Axle
Swing Radius Diagram
AM50/55/60
AM50E/55E/60E
Reach Diagrams
AM50
AM55
AM50E
AM55E
AM57
AM60
AM60E
Section 3 — Installation
11. Position the pedestal through the body floor cut-out

Final Assembly Installation and weld it to the subbase. The body is often elevated
Additional information about each step may be found to allow access to weld the pedestal to the subbase.
under the appropriate heading. Alternately, an oversize body floor cut-out can be
used, and the floor can be filled in after welding the
1. Construct the subbase. pedestal to the subbase.
2. Check the body length (measure from centerline of 12. Attach the body cross members to the subbase. Fill
rear axle) to determine if chassis frame extensions will in the floor around the pedestal as necessary.
be needed, and, if so, their length. When installing
frame extensions, follow vehicle manufacturer’s guide- 13. Install the external oil reservoir if applicable.
lines for welding to the chassis frame. If it is not
possible to overlap the extension on the existing 14. Plumb the unit, outriggers, tools, winch, etc. Make
frame, doubler plates and/or beveled butt joints should sure all hoses or tubes are securely fastened to
be used to improve the weld connections. prevent leaks due to road travel or operating vibration.
Secure hoses at least every two feet of running length
3. Install the outriggers. It is common for the outriggers and around all connections.
to be welded to the subbase first and then the entire
subbase/outrigger assembly is placed on the vehicle Apply protective guards, grommets, covers, loom or
frame. conduit, as necessary, to protect hoses and tubes
from sharp edges. Apply protective shields, where
4. Install the subbase. necessary, to prevent leaking hydraulic oil from con-
tacting hot surfaces such as exhaust pipes, mufflers,
5. Install the required outrigger bracing under the chassis or manifolds.
frame.
15. Fill the reservoir with hydraulic oil, as specified in the
6. Install the pump, PTO, and throttle actuator system. Maintenance Manual. Operate the unit and check for
Plumb as necessary. leaks.
7. Install the pintle hook per the customer specifications 16. Construct and install the boom rest and cab guard.
with necessary reinforcements and bracing. Make sure the boom rest is located within the allow-
able range. Make sure the elbow, with the booms
8. Install and plumb outrigger valves and route hydraulic stowed in the rest, is approximately one inch higher
hoses to the outriggers. Outrigger valves must be than any other part of the unit. This allows the driver
located so the operator can easily see the outrigger to know whether he has adequate height clearance by
movement from the corresponding outrigger control simply watching the elbow clearance upon entering a
valve. The outrigger valve which controls the curb side low clearance situation.
outriggers is often mounted on the rear curb side
corner of the vehicle. The outrigger valve which 17. Install the rear bumper or platform extension as
controls the street side outriggers is mounted on the required.
rear street side corner of the vehicle. Make sure no
equipment or component is later added which will 18. Install the rear access ladder if applicable. Make sure
obstruct clear view of the outrigger movement from all parts of the booms and turntable will clear the
each corresponding outrigger control station. Secure access ladder during a complete rotation cycle.
hoses (every two feet) to subbase, vehicle frame, and/
or cross members as necessary. 19. Install the torque converter lockup, auxiliary brakes,
grab handles, steps, and other miscellaneous compo-
9. Check the body floor clearance hole to see if it will nents.
accept the pedestal and rear outriggers. Adjust cut-
out as necessary. 20. Install all lights, outrigger interlock switches, etc., and
wire the vehicle.
10. If an internal reservoir is used, plumb the reservoir and
install it within the pedestal. 21. Conduct the preoperational inspection. Adjust the
system pressure per the Maintenance Manual. Adjust
the engine throttle speed for proper pump flow.
Section 3 — Installation • 51
22. Conduct the operational, stability, and dielectric tests. 24. Do the final painting and placard installation.
After conducting the dielectric test, stamp the test
date on the serial placard. 25. Conduct the final inspection, and certification as a
complete vehicle. Lubricate the telescopic surfaces
23. Prime or rust proof all welds and bare metal. of A-frame outriggers after final painting.
52 • Section 3 — Installation
Subbase
73010117
Outriggers
Code 41/241
OUTRIGGERS, CODE 41/241
ITEM NO. QTY. PART NO. DESCRIPTION
1 1 273-20026 TUBE ASSEMBLY, .38 OD X 40.25

Code 43/243
Code 44/244

Code 47/247

5 2 710-00594 MOUNTING PLATE
Code 450
OUTRIGGERS, CODE 450

Code 470
Outrigger Leg Extension
The ground clearance dimensions must be maintained to achieve the required ground clearance dimension.
regardless of the chassis frame height. On taller chassis Figure 3.1 shows a method of extending an outrigger leg
frames, it may be necessary to extend the outrigger legs on a flat shoe type outrigger.
Figure 3.1 — Outrigger Leg Extension
Pump
The PVE12 or PVE19 variable displacement axial piston 3. After the pump is mounted on the PTO, but before it
pump used on this unit should operate quietly, efficiently, is operated, remove the case drain line (D) at a
and dependably throughout the life of the unit. Some connection higher than the pump (such as at the
precautions during installation and start-up are necessary reservoir). Pour a half quart of hydraulic oil or oil
to prevent damage and prolong its useful life. conditioner (such as STP) into the line. Make sure the
line is not restricted so the oil can flow into the pump.
1. Before mounting the pump, apply anti-seize com- This will ensure the moving parts of the pump have
pound to the input shaft. some lubrication during start-up.
2. Be sure the case drain port (D) is connected to the oil 4. Connect port L of the pump to the signal line.
reservoir. It must connect directly to the reservoir
(tank) without going through restrictions such as an oil 5. Fill the reservoir with oil and open the suction line gate
filter. valve before starting the pump.
PVE19
PVE12
Figure 3.2 — Pumps
Throttle Actuator
Body Mounting
Attaching the body involves welding the body cross 2. With the body sitting unfastened on the subbase, the
members to the subbase. Some body manufacturers pedestal is placed through the hole in the body floor
(such as with some fiberglass bodies) may require an and welded to the subbase. The body can be elevated
alternate mounting method. Consult the body manu- to allow access to weld the pedestal.
facturer’s recommendations.
3. Weld the pedestal to the subbase.
The following procedure and Figure 3.3 represent typical
mounting guidelines. 4. Add support members to the body floor around the
pedestal.
1. If necessary, cut out the body floor for the pedestal.
5. Checking the final position of the body. Weld the body
cross members to the subbase.
Figure 3.3 — Body Mounting
Pedestal/Subbase
73010220C
REFERENCE OR INSTALLER SUPPLIED ITEMS

ITEM NO. QTY. DESCRIPTION
A 2 708-78344 BAR, FLAT, .50 X 8.00, EMS 1-1 X 18.00 LG (AM50/55/60)

A 4 708-78344 BAR, FLAT, .50 X 8.00, EMS 1-1 X 18.00 LG (AM50E/55E/60E)
A 2 708-78344 BAR, FLAT, .50 X 8.00, EMS 1-1 X 18.00 LG (AM50E/55E60E)
B As Req’d .625 HUCK BOLT C50LR-BR20 OR .750 BOM-R24 OR .625 GRADE 8 BOLT TORQUE TP 220 FT-LBS
C 1 SUBBASE - SEE SUBBASE CONSTRUCTION DETAILS
D 2 708-50267 TIE PLATE, PEDESTAL

E 1 708-50268 TIE PLATE, PEDESTAL, FORMED, L.H.
F 1 708-50269 TIE PLATE, PEDESTAL, FORMED, R.H.
G 2 708-40270 BASE PAD, FRONT
H 2 708-50286 BASE PAD, REAR
Reservoir Assembly
71490165
RESERVOIR ASSEMBLY, 15 AND 28 GALLON
714-90165 RESERVOIR ASSEMBLY, 15 GALLON, WITH MOUNTING BRACKETS AND 8.00 DIPSTICK
714-90166 RESERVOIR ASSEMBLY, 28 GALLON, WITH MOUNTING BRACKETS AND 8.00 DIPSTICK
1 1 714-00070 RESERVOIR ASSEMBLY, 15 GALLON, WITH 8.00 DIPSTICK

1 1 714-00077 RESERVOIR ASSEMBLY, 28 GALLON, WITH 8.00 DIPSTICK
2 1 275-16002 ELBOW, 90 DEGREE STREET, 1.25 NPT, MALLEABLE IRON 150 LBS
3 1 275-06002 PIPE, CLOSE NIPPLE, 1.25, SCHED. 40
4 1 275-56001 VALVE, GATE, 1.25 NPT, BRONZE
5 1 275-51004 VALVE, SHUTOFF, DRAIN COCK, .25 NPT

6 1 275-03001 PIPE, THREADED BOTH ENDS, .50 SCHED 40 X 6.00 LG
7 1 275-23006 BELL REDUCER, .50 NPTF X .25 NPTF
8 1 353-20003 FILTER, SUCTION, 150 MICRON
9 1 274-23076 ADAPTER 90 DEGREE ELBOW 1.25 NPTF TO -20 JIC
10 1 274-23070 ADAPTER 90 DEGREE ELBOW .75 NPTF TO -12 JIC

11 4 200-31104 CAP SCREW, HEX HEAD., .313 -18 UNC, STEEL, GRADE 5, .75 LG.
12 4 204-11101 WASHER, LOCK, S/T, .313 REGULAR, STEEL, MEC PLATED,
13 4 203-11101 NUT, HEX JAM, .313 -18 UNC, STEEL,
14 2 714-00278 RESERVOIR, SUPPORT WELDMENT -26.0 MOUNTING LENGTH
15 1 353-30009 FILTER ELEMENT

+ 20 * 356-10022 FILL CAP, WITH 8.00 LG DIPSTICK AND CHAIN
21 * 203-01001 NUT, HEX .25 -20 UNC, STEEL
22 * 204-11001 WASHER, LOCK, S/T, .25 MED STEEL, MEC PLATED
23 * 706-40020 COVER, RESERVOIR
24 * 390-03005 O-RING, 6.00 ID X .25, BUNA N 70 DUROMETER -437

25 * 353-20019 STRAINER, 1.406 DIA X 8.00 LG.
26 * 275-06004 PIPE, THREADED ONE END, 1.75 X 8.00 LG.
27 * 275-14001 ELBOW, 90 DEGREE STREET, .75 NPT, MALLEABLE IRON 150 LBS
28 * 275-04002 PIPE, THREADED ONE END, .75, SCHED 40 X 10.00 LG
* INCLUDED IN RESERVOIR ASSEMBLY 714-00070 AND 714-00077

71490066
RESERVOIR ASSEMBLY, 15 OR 20 GALLON, TRIANGULAR

714-90066 RESERVOIR ASSEMBLY 15 GALLON, AND 8.00 DIPSTICK, TRIANGULAR,

970031818 RESERVOIR ASSEMBLY 20 GALLON, AND 8.00 DIPSTICK, TRIANGULAR,
(COMPLETE, LESS ITEMS 11, 12 & 13)
1 1 714-00118 RESERVOIR, TANK, 15 GALLON, TRIANGULAR

2 1 353-20008 FILTER, SUCTION, 150 MICRON
3 1 275-06002 PIPE, CLOSE NIPPLE, 1.25, SCH 40, ASTM A120
4 1 706-40021 COVER, RESERVOIR, 10 GA W/WELD ON FILL NECK
5 1 391-90009 GASKET, RESERVOIR

6 1 356-10004 FILLER BREATHER, 6" DIPSTICK
7 6 200-31004 NUT, HEX, .250-20 UNC, REG, STEEL, PLATED
8 6 390-30001 SEAL, WASHER, .25
11 1 275-03001 PIPE, THREADED BOTH ENDS, .50 SCH 40 X 6.00 LG
12 1 275-23006 BELL REDUCER, .50 NPTF TO .25 NPTF

13 1 275-51004 VALVE, SHUTOFF, DRAIN COCK, .25 NPT
14 1 353-20019 STRAINER, 1.406 DIAMETER X 8.00 LG
Outrigger Interlock
970055415C
OUTRIGGER INTERLOCK SWITCH, A-FRAME AND X-FRAME

970055687
1 2 970022750 BRACKET ASSEMBLY, PROXIMITY SENSOR; W/ STRAIN REL (WITHOUT INTERNAL SPACER)
1 2 970023580 PROXIMITY SWITCH ASSEMBLY, OUTRIGGER LEG (WITH INTERNAL SPACER)
2 8 020151016 CAP SCREW, BUTTON HEAD, STEEL, PLATED, SOCKET, 3/8 LG, .25, 20 UNC, GRADE 8
A-Frame and X-Frame
970055418
OUTRIGGER INTERLOCK SWITCH, RADIAL

970055697
1 2 970021816 SWITCH ASSEMBLY, MERCURY, OUTRIGGER INTERLOCK, W/ CONNECTOR

2 2 020031035 CAP SCREW, STEEL, HEX HEAD, .50 IN L, .25-20 UNC;GR 5, W/PATCH LOCK, MTS 16,18, 19
Radial
970053067C
ELECTRICAL DIAGRAM, OUTRIGGER INTERLOCK WITH 2 TO 4 SWITCHES
970031921
1 1 970017049 HARNESS, 10 COND., INTERFACE CABLE, OUTRIGGER INTERLOCK

3 1 970017242 CABLE ASSEMBLY, 4 COND., OUTRIGGER BYPASS (1 SET OF OUTRIGGERS)
5 1 970017244 CABLE ASSEMBLY, 6 COND., 18 GA, 30 FT, OUTRIGGER INT EXT (1 SET OF OUTRIGGERS)
5 2 970017244 CABLE ASSEMBLY, 6 COND., 18 GA, 30 FT, OUTRIGGER INT EXT (2 SETS OF OUTRIGGERS)
6 1 970016347 CONTROL MODULE, OUTRIGGER INTERLOCK, 6 INPUT
8 1 970031909 DC CONVERTER, 24 TO 12 VOLT DC, 5 AMP
Boom Rest/Cab Guard
Step
The following requirements apply to step installation on all • Any step which may be recessed into the vehicle
vehicles or mobile equipment upon which Altec installs body, such as in the rear light channel or riser, must
units offering access from the vehicle body unless other- have a vertical toe clearance of no less than four
wise specified by the customer. inches.
Refer to Figure 3.4 for step location information. • Construct step surfaces from grip-strut material or
equivalent. This will minimize accumulation of debris
• Height of first step above the ground must not exceed on the step and aid in the cleaning of debris from the
24 inches. shoe sole, which will minimize foot slippage.
• Riser height (the distance between two consecutive • Steps and railings must provide a three-point support
steps measured from the tread surface of one step to which will permit a person to simultaneously use two
the tread surface of the next step) must be a minimum hands and one foot or two feet and one hand while
of 9 inches, a maximum of 16 inches, with a preferred ascending or descending the vehicle.
height of 12 inches.
• Place a No Step decal on any oil or auxiliary fuel
• Tread depth (the distance from the leading edge to reservoir which is mounted on a vehicle in such a
back edge of the step) must be a minimum of five manner that a person might use the top surface of the
inches. reservoir as a step when walking or climbing on the
vehicle.
• Steps must be a minimum of six inches wide.
Figure 3.4 — Step
Lifting Eye
LIFTING EYE
1 1 703-01488 MOUNTING BRACKET, LIFTING LUG

2 1 703-00851 LIFTING LUG
3 4 200-31445 CAP SCREW, HEX HEAD, .500-13 UNC, STEEL, GR 5, 1.75 LG., W/ PATCH LOCK
4 4 204-01404 WASHER, FLAT, .500, TYPE A NARROW, STEEL
5 1 670-00108 PLACARD, CAPACITY CHART, LOWER BOOM LIFTING EYE
6 1 670-01003 PLACARD, BOOM ANGLE INDICATOR

7 1 702-00034 BOOM ANGLE INDICATOR
8 1 082-51027 TUBING, ROUND, .625 OD X .156 WALL, EMS 1-4 X 1.188 LG.
9 2 204-01002 WASHER, FLAT, .250, TYPE B WIDE, STEEL
10 1 200-31011 CAP SCREW, HEX HEAD, .250-20 UNC, STEEL, GR 5, 2.25 LG.
11 1 203-11001 NUT, HEX JAM, .250-20 UNC, STEEL

12 1 203-91002 NUT, HEX, NYLON TOP LOCK, .250-20 UNC, STEEL
13 1 204-01004 WASHER, FLAT, .250, TYPE A NARROW, STEEL
Jib Adapter
Phase Lifter
Platform Rest
Platform rests are recommended when the rear overhang below, has been found to perform well, to be easy to install
distance from the centerline of the rear axle (or trunnion) and to require little maintenance. It is important that the
to the center of the platform exceeds 85 inches. Rests are operator be made aware that the platform must be lifted off
also recommended on off-road vehicles or vehicles which the rest with the upper boom before raising the lower boom
often encounter rough terrain, regardless of the rear to prevent possible damage to the platform or leveling
overhang distance. If during roading, a platform bounces system. It is recommended that a decal be added, near the
enough to throw small tools from the floor of the platform, unit controls, to remind the operator of the potential
a rest should be considered. A platform rest is required by damage from improper operation.
manufacturing when the unit is equipped with a hydraulic
platform elevator. End-mounted platform rests can obstruct access to the
cargo area of a body. In these cases, a pin-on type rest
Platform rest may be constructed in many configurations. may be used to allow for quick removal.
However, a rubber compression-type rest, as shown
70490273
Plumbing
72050069
Throttle Actuator
970053382C
Below Rotation, Tools and Secondary Stowage System
BELOW ROTATION, TOOLS AND SECONDARY STOWAGE SYSTEM
070890833
1 1 035200253 HYDRAULIC VALVE, MANUAL, 2 SPOOLS

2 1 035200254 HYDRAULIC VALVE, MANUAL, 3 SPOOLS, MOTOR SPOOL IN TOOL SECTION
3 1 035200285 HYDRAULIC VALVE, MANUAL, 1 SPOOL, WITH PRESSURE REDUCING VALVE
4 2 067080052 PLACARD, ENGLISH, INFORMATION, OUTRIGGERS
5 1 067001910 PLACARD, ENGLISH, INSTRUCTION, SELECTOR VALVE, LEXAN, 1.50 IN W 2.50 IN L
7 2 027556001 HYDRAULIC VALVE, GATE, 1.25 NPT

8 1 027400051 ADAPTER, STRAIGHT, -4 SAE, -4 JIC
9 2 027405056 ADAPTER, STRAIGHT, -8 SAE, -8 SAE
10 1 035250059 HYDRAULIC VALVE, FLOW REGULATOR, 5,000 PSI, FIXED AT 8 GPM
12 2 027403202 ADAPTER, STRAIGHT BULKHEAD, -8 JIC, .38 NPT

13 2 027489056 BULKHEAD NUT, -8
14 1 027407053 ADAPTER, REDUCER, -8 JIC, -6 JIC
15 1 027487054 ADAPTER, NUT, -8 JIC FEMALE
16 2 035620132 QUICK DISCONNECT COUPLERS, COUPLER/NIPPLE SET
17 1 035620144 QUICK DISCONNECT, CAP, FITS .38 FF HTMA TYPE NIPPLE, HTMA
18 1 035620145 QUICK DISC, CAP, FITS .38 NS TYPE COUPLER/NIPPLE, FITS .38 FF HTMA TYPE COUPLER
19 1 035239004 HYDRAULIC VALVE COMPONENT, PRESSURE REDUCING, CARTRIDGE
20 1 067000008 PLACARD, ENGLISH, INFORMATION, TOOLS
22 4 020031007 CAP SCREW, STEEL, HEX HEAD, 1.25 IN L, .25 IN DIA, .25-20 UNC, GR 5, MTS 16, 18
23 4 020391002 NUT, STEEL, SELF-LOCKING, .25-20 UNC, MTS 16, 18,

24 8 020401004 WASHER, STEEL, FLAT, .25 IN SAE, PLATED
25 1 027420058 ADAPTER, 90 DEGREE ELBOW, -8 SAE, -8 JIC
26 1 027476154 ADAPTER, CAP, -8 JIC FEMALE

32 1 027111003 HOSE ASSEMBLY, -4 SAE, 15.00 IN L, 100R1, 1-4, 1-4, WIRE BRAID, CL 12.875 IN
970053385
Below Rotation, Tools
BELOW ROTATION, TOOLS
708-90834
1 1 352-00253 VALVE, MANUAL, 2 SPOOL, MOTION SWITCHES

2 1 352-00254 VALVE, MANUAL, 3 SPOOL, MOTOR SPOOL IN TOOL SECTION, MOTION SWITCHES
3 1 352-00285 VALVE, MANUAL, 1 SPOOL
4 2 670-80052 PLACARD, OUTRIGGER
5 1 670-01910 PLACARD, SELECTOR VALVE
+ 7 2 275-56001 VALVE, GATE, 1.25 IN OD, BRONZE

8 1 274-00051 ADAPTER STRAIGHT -4 SAE TO -4 JIC
9 2 274-05056 ADAPTER STRAIGHT -8 SAE, -8 SAE
10 1 352-50059 VALVE, FLOW REGULATOR, 3.0 TO 10 GPM
11 1 274-00059 ADAPTER STRAIGHT -8 SAE TO -6 JIC
12 2 274-03202 ADAPTER STRAIGHT BULKHEAD .375 NPT TO -8 JIC

13 2 274-89056 ADAPTER, NUT, BULKHEAD -8 JIC
14 1 274-07053 ADAPTER STRAIGHT TUBE REDUCER .50 TUBE TO .375 TUBE
15 1 274-87054 ADAPTER, NUT, -8 JIC FEMALE
16 1 356-20132 COUPLING, QUICK DISCONNECT, SET, HTMA FLUSH FACE, .375 NPT
17 1 356-20144 CAP, QUICK DISCONNECT, FEMALE HALF, HTMA FLUSH FACE

18 1 356-20145 CAP, QUICK DISCONNECT, MALE HALF, HTMA FLUSH FACE
19 1 352-39004 VALVE, CARTRIDGE, PRESSURE REDUCER
20 1 670-00008 PLACARD, TOOLS
32 1 271-11003 HOSE ASSEMBLY, .250 X 15.00, R1, 1-4, 1-4, N/C
33 1 274-87056 ADAPTER, NUT, -12 JIC FEMALE

34 1 274-07057 ADAPTER STRAIGHT TUBE REDUCER .75 TUBE TO .25 TUBE
970095666B
Below Rotation, Secondary Stowage System
BELOW ROTATION, SECONDARY STOWAGE SYSTEM
070890825


22 4 020031007 CAP SCREW, STEEL, HEX HEAD, 1.25 IN L, .25 IN DIAMETER, .25-20 UNC, GRADE 5
23 4 020391002 NUT, STEEL, SELF-LOCKING, .25-20 UNC,

28 1 027487153 ADAPTER, SLEEVE, .38 NPT

970095667
Below Rotation
BELOW ROTATION
070890826


Electrical
Ignition Splice is in both the Run and the Start position will be the
A critical part of start/stop systems is the ignition splice. wire(s) to cut. Before cutting the wire, measure the
With the introduction of computer diagnostic and monitor- current to be sure it does not exceed 15 amps when
ing systems, anti-lock brakes, and “smart” transmissions, the ignition switch is in either the Run or Start posi-
wiring systems on vehicle chassis have become more tion. Power module or start/stop boxes can handle 15
complex. The servicing chassis dealer can assist in amps on the main ignition wires.
determining where to safely make the required chassis
ignition system splices or taps without causing any detri- A factory Body Builders Instruction Book may show
mental effect to the existing chassis electrical system. the wires connecting to the ignition switch and be
The following procedure will aid in making connections to useful in determining which wire(s) to cut for the
the existing chassis wiring system. ignition splice.
1. Make the ignition connections as close to the vehicle Test the selection by cutting the wire(s) while the
ignition switch as possible. Shortly after leaving the engine is running. Upon cutting the wire, the engine
ignition switch, many wires split off to power various should stop. Once the proper ignition splice wire is
components. By making connections close to the located, cut the wire and connect the ends to the two
ignition switch, the number of wires that might need terminals on the power module or start/stop box
to be spliced or tapped is reduced. marked Ignition Splice.
2. Locate the ignition splice terminals on the start/stop 4. Locate the start wire. Within the same bundle of wires
or power module box. These two terminals (marked connecting to the ignition switch, find the wire that
Ignition Splice) will connect to each half of the chas- tests hot only when the vehicle ignition switch is in the
sis ignition wire(s) that will be cut. When the engine Start position. This wire typically connects to the
is started from either a remote location or the vehicle engine starter relay.
ignition, a relay within the start/stop box will recon-
nect these wires. This duplicates what normally hap- Measure the current in this wire during cranking. If the
pens, before making the splice, at the vehicle ignition current does not exceed five amps, tap into it with
when the vehicle ignition switch is moved from the Off another wire and connect the new wire to the terminal
position to the Run position. of the start/stop box marked Starter Relay. While five
amps will trip most vehicle starter relays, some
3. Locate the vehicle ignition wire(s) that should be cut. starter relays, such as those found on some GM gas
In the bundle of wires going to the vehicle ignition engines, require much more. In cases where five
switch, locate the battery wires or the wires which test amps is inadequate, a secondary relay must be
hot when the vehicle ignition switch is off. These added. On most engines with manual transmissions,
battery wires are not candidates for making the the tap must be made downstream from the clutch
ignition splice. Of the remaining wires in the bundle, pedal interlock switch for the engine to be started
the wire(s), that is hot when the vehicle ignition switch from the remote location without engaging the clutch.
970109958A
Full Pressure, 12 and 24 VDC
FULL PRESSURE, 12 AND 24 VDC
059040526
1 1 035290164 VALVE, BOOM STOW, 12 VDC

2 1 970109955 PROXIMITY SENSOR, 3 WIRE DC, NORMALLY CLOSED, PNP, CONTROL LIGHTS, 15.75 IN L
19 1 059830047 TERMINAL, RING, .3125 STUD, 18-22 GA. WIRE, HEAT SHRINK, PERMA SEAL
21 1 059470031 SWITCH, PRESSURE, SPDT, ADJUSTABLE 300-800 PSI
26 1 970108863 ELECTRICAL HARNESS, 4 COND, STRANDED, 18 GA, MULTI, BOOM STOW LIMIT, 12 VDC
27 2 020120705 MACHINE SCREW, SLOTTED, PAN HEAD, 1.50 IN L, 8-32 UNC
28 3 020400701 WASHER, FLAT, #8
29 3 020390704 NUT, STEEL, KEP, 8-32 UNC, ZINC PLATED
30 1 020120711 MACHINE SCREW, SLOTTED, PAN HEAD, .63 IN L, 8-32 UNC

970109959A
Pilot Pressure, 12 and 24 VDC

PILOT PRESSURE, 12 AND 24 VDC
059040527
1 1 035210059 HYDRAULIC VALVE, SOLENOID, 2-WAY, 1 SPOOL, 3,000 PSI, 8 GPM, 12 VDC
16 1 059837012 TERMINAL, BUTT SPLICE, 14-16 GA, INSULATED, HEAT SHRINK
19 1 059830047 TERMINAL, RING, .3125 STUD, 18-22 GA, HEAT SHRINK, PERMA SEAL

21 2 059470031 SWITCH, PRESSURE, SPDT, 300 PSI - 800 PSI ADJUSTABLE, 800 PSI PRESET

28 3 020400701 WASHER, FLAT, #8

970109960A
Full Pressure, Engine Start/Stop, 12 and 24 VDC

FULL PRESSURE, ENGINE START/STOP, 12 AND 24 VDC
059040528

3 1 060090086 SWITCH SUBASSEMBLY, ELECTRICAL, TOGGLE WITH ONE AIR SWITCH
5 1 027520001 COUPLING, .125 NPT STEEL
6 2 027429061 ADAPTER 90 DEGREE COMPRESSION .125 NPT TO .125 TUBE

7 1 008251025 TUBING, ROUND, .625 OD X .125 WALL, EMS 1-14 X .50 LG.
8 1 020031010 CAP SCREW, HEX HEAD, .25-20 UNC, STEEL, GRADE 5, X 2.00 LG.
9 2 020401004 WASHER, FLAT .25 SAE STEEL PLATED
10 1 020391002 NUT, .25 -20 UNC, STEEL, SELF-LOCKING
11 1 070660170 COVER, RUBBER, 1.188 DIAMETER, PLUNGER

12 1 023220042 KNOB, 1.188 DIAMETER, BLACK, .313-24 UNF
13 1 020311602 NUT, HEX, JAM, .625 -18 UNF, STEEL, RIGHT HAND THREADS
14 1 031010010 AIR CYLINDER, 1.125 BORE X 2.50 STROKE
15 2 067002588 PLACARD, PICTORIAL, ENGINE START/STOP
16 1 059837012 TERMINAL, BUTT SPLICE #16-14 WIRE, HEAT SHRINK

17 1 059470011 SWITCH, PRESSURE, 1.5 PSI
22 1 023111005 CLAMP, COATED, .50 ID
28 3 020400701 WASHER, FLAT, #8

970109961A
Pilot Pressure, Engine Start/Stop, 12 and 24 VDC

PILOT PRESSURE, ENGINE START/STOP, 12 AND 24 VDC
059040529
3 1 060090086 SWITCH, TOGGLE, WITH ONE AIR SWITCH
3 1 060090087 SWITCH, TOGGLE, WITH TWO AIR SWITCH (DUAL CONTROLS)
5 1 027520001 COUPLER, .13 NPT

6 2 027429061 ADAPTER, 90 DEGREE COMPRESSION, .13 NPT, .13 PLASTIC TUBE
7 1 008251025 TUBE, ROUND, .63 IN OD, .13 IN T, EMS 1-14 or EMS 5-10, .50 IN L,
8 1 020031010 CAP SCREW, STEEL, HEX HEAD, 2.00 IN L, .25-20 UNC, GRADE 5
10 1 020391002 NUT, STEEL, SELF-LOCKING, .25-20 UNC

11 1 070660170 COVER, RUBBER, PLUNGER, PLATFORM CONTROL, BLUE
13 1 020311602 NUT, STEEL, HEX JAM, .63 IN DIAMETER, .63-18 UNF
14 1 031010010 PNEUMATIC CYLINDER & PARTS, 1.13 IN BORE, 2.50 IN STROKE
15 2 067002588 PLACARD, ENGLISH, INFORMATION, PICTORIAL, ENGINE START/STOP

17 1 059470011 SWITCH, PRESSURE, SPST, NORMALLY OPEN, 5 AMP, 1.5 PSI
19 1 059830047 TERMINAL, RING, .3125 STUD, 18-22 GA, HEAT SHRINK, PERMA SEAL
21 2 059470031 SWITCH, PRESSURE, SPDT, 300-800 PSI ADJUSTABLE, 800 PSI PRESET,
22 1 023111005 CLAMP, COATED, .50 IN ID

28 3 020400701 WASHER, FLAT, #8

970109962A
Full Pressure, Secondary Stowage System, 12 and 24 VDC

FULL PRESSURE, SECONDARY STOWAGE SYSTEM, 12 AND 24 VDC
059040530



15 2 067002589 PLACARD, PICTORIAL, SECONDARY STOWAGE SYSTEM

18 1 035460100 PUMP/MOTOR UNIT, .150 CID, 12 VDC

22 1 023111005 CLAMP, COATED, .50 ID
28 3 020400701 WASHER, FLAT, #8


970109966A
Pilot Pressure, Secondary Stowage System, 12 and 24 VDC

PILOT PRESSURE, SECONDARY STOWAGE SYSTEM, 12 AND 24 VDC
059040531
3 1 060090087 SWITCH SUBASSEMBLY, ELECTRICAL, TOGGLE WITH TWO AIR SWITCH (DUAL CONTROLS)


15 2 067002589 PLACARD, PICTORIAL, SECONDARY STOWAGE SYSTEM

22 1 023111005 CLAMP, COATED, .50 ID
28 3 020400701 WASHER, FLAT, #8

970109972A
Full Pressure, Engine Start/Stop With Secondary Stowage System, 12 and 24 VDC

PILOT PRESSURE, ENGINE START/STOP WITH SECONDARY STOWAGE SYSTEM, 12 AND 24 VDC
059040532



15 2 067002587 PLACARD, PICTORIAL, ENGINE START/STOP WITH SECONDARY STOWAGE SYSTEM


22 1 023111005 CLAMP, COATED, .50 ID
28 3 020400701 WASHER, FLAT, #8


970109973A
Pilot Pressure, Engine Start/Stop With Secondary Stowage System, 12 and 24 VDC

PILOT PRESSURE, ENGINE START/STOP WITH SECONDARY STOWAGE SYSTEM, 12 AND 24 VDC
059040533
1 1 035210059 HYDRAULIC VALVE, SOLENOID, 2-WAY, 1 SPOOL, 3000 PSI, 8 GPM, 12 VDC
1 1 035210172 HYDRAULIC VALVE, SOLENOID, 2-WAY, 1 SPOOL, 3000 PSI, 8 GPM, 24 VDC
3 1 060090087 SWITCH SUBASSEMBLY, ELECTRICAL, TOGGLE WITH TWO AIR SWITCH (DUAL CONTROLS)


15 2 067002587 PLACARD, PICTORIAL, ENGINE START/STOP WITH SECONDARY STOWAGE SYSTEM

22 1 023111005 CLAMP, COATED, .50 ID
28 3 020400701 WASHER, FLAT, #8

Neutral/Emergency Brake Interlock for Automatic Transmissions With Cable Shift PTO

Automatic Transmissions With Electric Shift PTO

Placards
970045644
Unit Locations

UNIT LOCATIONS
067080910
1 3 067000454 PLACARD, ENGLISH, INFORMATION, ALTEC LARGE, KISS CUT

2 2 067000455 PLACARD, ENGLISH, INFORMATION, ALTEC SMALL, KISS CUT
3 3 067040172 PLACARD, ENGLISH, DANGER, QUALIFIED PERSONNEL ONLY
4 3 067040174 PLACARD, ENGLISH, DANGER, OPERATING INSTRUCTIONS, VERTICAL
5 4 067040179 PLACARD, ENGLISH, DANGER, ELECTRICAL HAZARDS, HORIZONTAL
6 2 067040207 PLACARD, ENGLISH, SAFETY, DANGER, FALL HAZARD

7 1 067002594 PLACARD, ENGLISH, PIC CAUTION PLAT OVERCENTER, VINYL
8 1 067040235 PLACARD, INFORMATION, NOTICE TRANSFER OF OWNERSHIP
9 1 067040272 PLACARD, SAFETY, DANGER ELECTRICAL CONTACT ALL
10 2 067040252 PLACARD, SAFETY, DANGER ELECT. CONTACT, VERT, ALL COMPONENTS AT BOOM TIP
11 2 067040290 PLACARD, SAFETY, DANGER CONDUCTIVE HOSE

12 2 067040429 PLACARD, ENGLISH, SAFETY, DANGER, NO HAND HOLD, VINYL
13 1 067001823 PLACARD, INFORMATION, PATENTS
14 2 067040294 PLACARD, SAFETY, WARNING NO RIDER
15 4 067001123 PLACARD, ENGLISH, INFORMATION, WARNING, NO STEP, 3.20″ W 4.00″ L
16 4 067040170 PLACARD, ENGLISH, DANGER, MOVING OUTRIGGER HAZARD, STAND CLEAR

17 2 067040229 PLACARD, SAFETY, DANGER, CRUSHING HAZARD, OUTRIGGER OPERATION
18 1 067040430 PLACARD, ENGLISH, INFORMATION, SAFETY CAUTION NO HAND, VINYL
19 1 067002602 PLACARD, ENGLISH, PIC CAUTION PLAT OVERCENTER, VINYL
20 2 067000232 PLACARD, INFORMATION, CAUTION, PLATFORM STOWED
21 2 067040295 PLACARD, SAFETY, WARNING KEEP CLEAR, HANDS AND CLOTHING

22 1 067040349 PLACARD, SAFETY, CAUTION JIB TURNTABLE CONTACT
24 1 067002698 PLACARD, ENGLISH, PLATFORM CAPACITY, 300 POUND MAX, VINYL
24 1 067002699 PLACARD, ENGLISH, PLATFORM CAPACITY, 350 POUND

25 1 067040453 PLACARD, ENGLISH, WARNING, ELECTROCUTION HAZARD, VINYL
26 1 067040454 PLACARD, ENGLISH, INFORMATION, DANGER ELECTRICAL HAZARD, VINYL
27 1 067001614 PLACARD, INFORMATION, PATENT APPLIED FOR

28 1 067040372 PLACARD, SAFETY, DANGER, PREOPERATIONAL CHECKLIST
29 4 067000801 PLACARD, INFORMATION, ARROWS
30 1 067001067 PLACARD, ENGLISH, JIB STRUCTURAL CAPACITY, 5′
31 1 067040345 PLACARD, SAFETY, WARNING ROTATION BEARING, BOLT TORQUE
32 1 067040465 PLACARD, ENGLISH, DANGER, MINIMUM APPROACH DISTANCE

33 1 970087136 PLACARD, DANGER, INSTABILITY

Final Assembly
A thorough review of the finished unit must be made to
ensure that all placards included with the unit order are
installed in the proper location. Besides the various
placards included with each unit order, additional safety or
instructional placards may be needed relating to specific
features on the finished unit. It is the responsibility of Final
Assembly Engineering at each facility to specify all
additional safety and instructional placards and their
respective locations. Any additional placards specified by
Final Assembly Engineering should be affixed and prop-
erly located. To provide a record of compliance with these
requirements, the Final Inspection Checklist must be
completed and signed by an inspector.
Four of the more common final assembly safety placards

are shown. Since these placards are needed for most
finished units, each Final Assembly Center should have
them. Additional placards may also be required.
No Step
A No Step placard (part number 670-01123) warns against
stepping on surfaces which should not be used as a step Figure 3.5 — No Step Placard
or supporting surface to prevent potential slips and falls.
This placard must be placed on or near any surface not No Rider
intended to be used as a step. Common mounting loca- A No Rider placard (part number 670-40294) must be
tions are as follows. placed on or near any area, outside the personnel cab,
where a person might ride while the vehicle is in motion.
• Top surface of oil reservoirs or fuel tanks Common mounting locations are as follows.
• Any protruding flat surface such as light guards, dock • Near control platforms such as on behind cab and
bumpers, outrigger shoe, etc. corner mounted derricks
• Top of exposed outriggers such as street side corner • On or near riding seat
mount outriggers, A-frame, and out and down outrig-
gers • Cargo areas
• Top of bins or boxes • Chipper fender and rear feed platform
• Top of covers such as DC pump covers or reservoir • Rear tailshelf or bumper

and accumulator covers
• Chipper fenders

Figure 3.6 — No Rider Placard Figure 3.7 —
Keep Hands and Clothing Clear Placard
Keep Hands and Clothing Clear
A Keep Hands and Clothing Clear placard (part number Overload Hazard
670-40295) must be placed near any area where a person’s An Overload Hazard placard (part number 670-40369)
extremities or clothing could become entangled between must be placed near the pintle hook at the rear of the
a rotation component such as a winch drum and the vehicle.
associated rope or cable. Common mounting locations are
as follows.
• Near the pay-out/pay-in area of a bumper or bed

mounted winch
• Near a turntable mounted winch on a derrick or cable

placer
• Near a boom tip mounted winch on a derrick or aerial

device
• On the sides of a derrick boom tip near the sheave(s)
• On the outboard side of reel lifter arms
Figure 3.8 — Overload Hazard Placard

Corner Mount Outrigger Vehicle Rear View
Reel Lifter/Cable Placer Reel Lifter
A-Frame Outrigger Out and Down Outrigger
Final Assembly Locations

Accumulator Cover Bed-Mounted Winch Riding Seat
Fuel Tank Capstan Reservoir DC Pump Cover
Aerial Device Boom Tip Digger Derrick Boom Tip

Serial Number
The serial number placard (refer to Figure 3.9) cannot be
fully completed at the time of manufacture. After conduct-
ing the dielectric test on the completed unit, the installer
must stamp the test date on the placard in the blank
marked Date Unit Tested. The serial number placard is
usually on the pedestal of the unit. There is a copy of the
unit serial number placard inside the front cover of the
Operator’s Manual. The installer must also write the
dielectric test date on this copy. The installer must then
compare the serial number placard information inside the
front cover of the Operator’s Manual with the information
shown on the unit serial number placard. Any discrepan-
cies must be corrected.
Figure 3.9 — Serial Number Placard

Section 4 — Testing and Inspection
The Appendix contains forms to use for various tests and Test Forms
inspections. The particular form to use will be determined Stability test forms are provided in the Appendix. The
by the options chosen for the unit. Choose the proper form forms designate the proper boom and jib positions and the
and fill in all the applicable information. All applicable proper test loads to be used. They show the unit loading
forms and checklists must be completed and filed with the configuration(s) that would most likely cause overturning.
unit work order information. Completed forms should be dated and signed by the test
technician after conducting the stability tests and should
be retained as part of the original unit documentation.
Dielectric
Before the mobile unit is placed in operation, perform Additional test forms may be needed to show appropriate
dielectric tests according to ANSI. Tests that can be stability tests for units equipped with special lifting fea-
performed only after installation are the responsibility of tures such as a lower boom lifting eye or a gin pole socket.
the installer, whether the installer is a dealer, owner, or If Altec Engineering determines that these special lifting
user. Understand the test procedures in ANSI publications features will always produce less tendency toward over-
and in this manual. After the completed unit is in the turning than would normal platform and jib stability test
possession of the owner or user, subsequent testing loads, stability tests using these special lifting features
becomes the responsibility of the owner or user. are not required.
Insulated Single Handle Control General Test Conditions

This unit may be equipped with an insulated single handle • Remove all tools and material including removable
control(s). This control, which is green in color, may offer boom supports, extra platforms (not attached to the
limited secondary dielectric protection. Before the mobile unit), and all removable cargo.
unit is placed in operation, perform a dielectric test of the
green insulated single handle control. • Restrict the amount of total fuel in all tanks to 20
gallons or less.
A dielectric test form can be found in the Appendix.
Complete the test, document the results, and maintain the • Only the test technician can be on the unit during the
test in a permanent file. test.
• Do not use outrigger pads.

Stability
Due to the possible affect on stability, this unit and/or • Perform the test only while operating from the lower
vehicle should never be altered or modified without the controls.
specific written approval from Altec Industries, Inc. Com-
ponent replacement with original equipment parts will not • Provide a suitable restraint during all stability tests to
affect the stability of this unit. prevent the mobile unit from overturning in the event
a condition of instability is reached. A typical restraint
ANSI A92.2 requires a level surface test and a five degree method is a loose loop of chain around each side of the
slope test when the unit mounting is complete on the rear axle (allows the axle to raise off the test surface
vehicle. These stability tests are not required to be at least 8 to 10 inches before tightening the chain),
performed again unless significant changes are made in near the wheel, which is securely anchored to the
the original vehicle and body mounting or the unit is ground. Increase the length of the chain to allow
remounted on another vehicle. further movement if there is any doubt about whether
the mobile unit has reached a condition of instability.
Raising of outriggers or tires does not necessarily
Warning indicate a condition of instability.
Death or serious injury can result from uncontrolled
movement. Do not permit anyone to occupy the plat- • Choose Test A or Test B depending on the location of
form until the unit has passed applicable tests. the weight for the test. Test B can only be used if the
jib can structurally carry both the jib load and the
Death or serious injury can result if the mobile unit platform load.
becomes unstable. Provide a suitable restraint while
the stability tests are performed. • The unit must pass the Level Surface Test before
conducting the Five Degree Slope Test.
Notice
Carefully load the test weight to prevent damage to the
platform or liner.
Section 4 — Testing and Inspection • 137

Level Surface Test tendency to overturn about one side than another,
1. Position the unit on a level, hard surface, apply the position the least stable side on the low side of the
parking brake and chock the wheels. Engage the slope. Apply the parking brake and chock the wheels.
hydraulic system. Engage the hydraulic system.
2. Properly set the outriggers. Extend the outriggers to 2. Properly set the outriggers. Extend the outriggers fully
remove the bulge from the tires while still maintaining on the low side of the slope. The mobile unit does not
at least some tire-to-surface contact at each tire. have to be level or maintain tire contact on the low side
Level the mobile unit side-to-side with the outriggers. for this test. (The mobile unit is usually the most stable
If equipped with two sets of outriggers, use the when the low side outriggers are at maximum penetra-
outriggers to level in the front to back direction. tion and the high side outriggers are at minimum
penetration.) Extend the outriggers on the high side of
3. Move the booms and jib into a position to most likely the slope, enough to complete a full cycle of rotation
cause overturning (refer to the test form). without any intermediate readjustment of any of the
outriggers. Do not extend the high side outriggers
4. Apply a load at the center of the platform(s) equal to enough to cause the front tire or outside dual rear tires
1.5 times the rated platforms load. The load can be on the high side of the slope to lose surface contact.
applied either into the platform(s) or suspended by a
load line from the center of the platform(s). The 3. Move the booms and jib into a position to most likely
platform test load may be suspended on the jib line, in cause overturning (refer to the test form).
addition to the jib test load, if the unit is equipped with
a material handling jib structurally capable of carrying 4. Apply a load at the center of the platform(s) equal to
the added load. 1.33 times the rated platform load. The load can be
applied either into the platform(s) or suspended by a
5. Apply a load to the material handling jib, if equipped, load line from the center of the platform(s). The
equal to 1.5 times its rated load. platform test load may be suspended on the jib line, in
addition to the jib test load, if the unit is equipped with
6. Rotate the turntable in a full rotation cycle, watching a material handling jib structurally capable of carrying
for any evidence of instability. Outriggers and tires the added load.
may lift off the surface during the test without indicat-
ing a condition of instability as long as the mobile unit 5. Apply a load to the material handling jib, if equipped,
does not tend to overturn. equal to 1.33 times its rated load.
7. If the initial test shows that the mobile unit is unstable, 6. Rotate the turntable in a full rotation cycle, watching
adjust the outriggers to determine any effect on for any evidence of instability. Outriggers and tires
stability. Rotate the turntable again in a full rotation may lift off the surface during the stability test without
cycle watching for any evidence of instability. indicating a condition of instability as long as the
mobile unit does not tend to overturn.
8. Add permanent counterweight if it is determined that
the mobile unit will not pass the test as originally built. 7. If the initial Five Degree Slope Test shows that the
Use temporary counterweight to determine how much mobile unit is unstable, adjust the outriggers to deter-
permanent counterweight is needed and where the mine any effect on stability. Rotate the turntable again
counterweight should be added. Rotate the unit in a full in a full rotation cycle watching for any evidence of
rotation cycle watching for any evidence of instability instability.
after adding the temporary counterweight. If the unit
passes the test with the temporary counterweight, 8. Add permanent counterweight if it is determined that
remove the temporary weight and add the permanent the mobile unit will not pass the test as originally built.
counterweight. Perform the test again. The unit must Use temporary counterweight to determine how much
pass this test before moving on to the Five Degree permanent counterweight is needed and where the
Slope Test. counterweight should be added. Rotate the unit in a full
rotation cycle watching for any evidence of instability
Five Degree Slope Test after adding the temporary counterweight. If the unit
1. Position the unit on a level, hard surface with the passes the test with the temporary counterweight,
centerline of the vehicle positioned approximately remove the temporary weight and add the permanent
perpendicular to the direction of the slope. If the Level counterweight. Perform the test again. The mobile unit
Surface Test showed the mobile unit has a greater must pass this test.
138 • Section 4 — Testing and Inspection

9. After the test has been completed, torque all acces-
sible rotation bearing cap screws to 325 foot-pounds MANUFACTURED BY:
(441 N•m) using a circular pattern (only required ALTEC INDUSTRIES, INC.
following initial stability test at the time of initial ST. JOSEPH, MO
installation of unit on chassis).
DATE OF MANUFACTURE 04 MONTH 93 YEAR
10. After the test has been completed, torque the rotation INCOMPLETE VEHICLE MANUFACTURED BY:
gearbox mounting cap screws to 225 foot-pounds (305 GMC
DATE INC. VEH. MFD 02 MONTH 93 YEAR
N•m) (only required following initial stability test at the
time of initial installation of unit on chassis).
GVWR 37000 LBS ______
GAWR FRONT 14000 LBS WITH
Final Stage Certification 12R22.5 H TIRES,
20X8 RIMS, @ 120 PSI COLD SINGLE____
Most units are mounted on chassis-cab vehicles certified GAWR INTERMEDIATE (1) NONE WITH
by the primary manufacturer (i.e. Ford, GM, etc.) as an TIRES,
incomplete vehicle. After the vehicle is completed, the
National Highway Transportation Safety Administration RIMS, @ PSI COLD__________
(NHTSA) requires that the final stage manufacturer certify GAWR INTERMEDIATE (2) NONE WITH
the vehicle as a complete vehicle. The simplified final TIRES,
stage certification label is often used (refer to Figure 4.1).
RIMS, @ PSI COLD__________
Place the final stage certification label next to the driver’s GAWR REAR 23000 LBS WITH
side of the vehicle on one of the following locations. 11R22.5 H TIRES,
20X8 RIMS, @ 120 PSI COLD DUAL_____
• Hinge pillar
• Door latch post CONFORMITY OF THE CHASSIS-CAB
• Door edge that meets the door latch post TO FEDERAL MOTOR VEHICLE SAFETY
STANDARDS, WHICH HAVE BEEN
If none of these positions are available, place the label on PREVIOUSLY FULLY CERTIFIED BY
one of the following locations. THE INCOMPLETE VEHICLE MANU-
FACTURER OR BY THE INTERMEDIATE
• Inward-facing surface of the driver’s door
VEHICLE MANUFACTURER, HAS
BEEN COMPLETED IN ACCORDANCE
• Left side of the instrument panel
WITH PRIOR MANUFACTURER’S
INSTRUCTIONS, WHERE APPLICABLE.
NHTSA may be petitioned for an alternate label location if
none of the above locations is practical. The label must be THIS VEHICLE CONFORMS TO ALL
located where it can be read without moving any part of the OTHER APPLICABLE FEDERAL MOTOR
vehicle except an outer door. VEHICLE SAFETY STANDARDS IN
EFFECT IN 02 MONTH 93 YEAR
The vehicle manufacturer is required to affix an incomplete VEHICLE IDENTIFICATION NO:
vehicle certification label to the vehicle in one of the 1HTSDH2R6PH518005 37-63769
locations shown above and must also provide an incom-
plete vehicle document. The incomplete vehicle docu- VEHICLE TYPE: TRUCK 93-053
ment is very important because you cannot legally certify
without it. The incomplete vehicle document gives a list of Figure 4.1 — Final Stage Certification Label
applicable safety standards in effect at the time of manu-
facture of the incomplete vehicle. The document also 1. Manufactured By — Fill in the company name.
includes instructions to the final assembly manufacturer
on how to complete the vehicle in order to conform to the 2. Date of Manufacture — Fill in the month and year the
standards. Some of the information from the incomplete installation was completed. Do not use the date it was
vehicle document will be used on the final assembly started.
certification label.
3. Incomplete Vehicle Manufactured By — Fill in the
Complete the final stage certification label in capital letters name of the vehicle manufacturer.
as follows.
Section 4 — Testing and Inspection • 139

4. Date Inc. Veh. Mfd. — Fill in the month and year given 7. …Standards in Effect in — Fill in the month and year
in the incomplete vehicle label or document which is the vehicle was manufactured as shown on the
supplied by the vehicle manufacturer. incomplete vehicle document. Do not use the date the
unit was completed to avoid the possibility that other
5. GVWR — Unless the vehicle’s GVWR has changed, safety standards might have come into effect be-
use the figure shown on the incomplete vehicle label tween the time the vehicle was manufactured and the
or document. time the unit was completed.
6. GAWR Front, GAWR Intermediate (1), GAWR Inter- 8. Vehicle Identification No. — Fill in the vehicle identi-
mediate (2), GAWR Rear — Fill in the gross axle fication number as shown on the incomplete vehicle
weight ratings (GAWR) for each axle. Unless the document. For future service traceability, add the final
vehicle’s GAWR values have changed, use the infor- assembly work order number beside the vehicle
mation shown on the incomplete vehicle label or identification number.
document. For each axle, fill in the load rating, tire
size, rim size, cold tire pressure, and whether single 9. Vehicle Type — Fill in the type of the vehicle which is
or dual tires per side. If the vehicle does not have any usually truck. If the vehicle was assigned a number,
one of the intermediate axles, fill in “none” where include the number.
applicable.
140 • Section 4 — Testing and Inspection

Appendix
Hydraulic System Schematics
Dual One-Man Platforms, Dual Controls, Pilot Pressure
Appendix — Hydraulic System Schematics

Dual One-Man Platforms, Pilot Pressure

"A" "B"
"A" "B"
Dual One-Man Platforms, Full Pressure

Single Platform, Pilot Pressure

"A" "B"
"A" "B"
Single Platform, Full Pressure

Outrigger Control Valve Outrigger/Tool Control Valve
Reservoir
Pump Secondary Rotary Joint Lower Tools Pressure

Stowage DC Pump Reducing Valve
Blocking Valve Relief Valve Hydraulic Interlock Valve Interlock Valve

(Pilot Pressure) Stop Valve (Full Pressure) (Pilot Pressure)
Lower Boom Stow Valve Lower Boom Stow Valve Cross-Ported Pilot Counterbalance
(Full Pressure) (Pilot Pressure) Operated Check Valve Valve

Jib/Winch Control Valve Jib/Winch Control Valve Jib/Winch Control
Hydraulic Extend Secondary Hydraulic Extend Primary Platform Valve Manual Jib
Platform (Pilot Pressure)
Machine Outrigger Pump Control Valve

Selector Valve
Upper Control Valve Upper Control Valve Lower Control Valve

(Full Pressure) (Pilot Pressure) (Pilot Pressure)

Shuttle Valve Dual Upper Controls (Pilot Pressure)
Lower Control Valve

(Full Pressure)
Tool Control Valve Tools Platform Tools Platform Rotate Control

(Full Pressure) Rotate/Tilt Control Valve Valve Secondary Platform
(Pilot Pressure)

Troubleshooting Chart
Symptom Possible Cause Test Procedure/Corrective Action
Pump is noisy. The reservoir oil level is too low. Fill the reservoir to the proper level.
Restriction in pump suction line. Fully open the suction line shutoff valve.
Check for kinked or plugged suction hose. Remove restriction.
Make sure suction hose is 11/4 minimum.
Air entering suction line. Fill the reservoir to the proper level.
Tighten loose hydraulic fittings.
PTO/pump connection misaligned. Correct misalignment.
Cavitation. Remove restriction or replace line.
Use hydraulic oil of proper viscosity.
Reduce pump speed.
Excessive heat The reservoir oil level is too low. Fill the reservoir to the proper level.
buildup (180°+).
The engine speed is set too high. Adjust the throttle cylinder.
Excessive internal system Check the outrigger power beyond plug seals for leaks.
leakage.
Make sure the relief valve settings are properly set.
Check the boom tip tool valve for leakage. Replace if necessary.
Power tools improperly sized for Change power tools or adjust the tool flow control.
gpm flow of tool circuit.
Boom functions Lower control valve spools do not Lubricate or replace as necessary.
operate slowly. fully shift.
Adjust the pilot pressure to 350 psi (24.13 bar).
Adjust the forced opening on the upper control valve to the proper
value.
Make sure the lower control valve handles are not hitting the
turntable cover, hoses, etc.
Engine rpm is set too low or the Adjust the engine rpm.
throttle does not increase engine
speed.
Improperly adjusted lower control Properly adjust the valve spool stops.
valve spool stop(s) (pilot pressure).
Low pump flow. Check the pump with a flowmeter. Replace if defective.
Low pump standby pressure. Adjust the standby pressure to 350 psi (24.13 bar).
Restriction in the pressure line. The restricted area will be warmer to the touch than the rest of the
system. Remove the restriction.
Blocking valve is not fully open Test by connecting a flowmeter at valve input and back to reservoir.
(pilot pressure). Replace the blocking valve if necessary.
One boom function Purge check not seating Operate the lower control handle to verify that function operates
operates slow. (pilot pressure). properly from that control.
Clean or replace the check valve.
Appendix — Troubleshooting Chart

Tools, jib, winch Tool signal not working. Replace the tool signal pressure reducing valve.
operate slowly or
will not work under Tool pressure is set too low. Adjust the tool pressure reducing valve.
load.
Power tools improperly sized Change power tools or adjust the tool flow control.
for gpm flow of tool circuit.
Engine throttle does not work. Adjust or replace the engine throttle control.
Pump pressure Pump standby pressure is Adjust to 350 psi (24.13 bar).
oscillates during too low.
operation.
The engine and Tool valve is on. Turn the lower or upper tool circuit valve off.
pump remain
loaded all the time. Tool blocking valve is defective. Replace the tool blocking valve cartridge.
The pump signal is not bleeding Check orifice in lower control valve and clean.
off (full pressure).
No functions from The control selector valve is in Place the control in the Upper Controls position.
the upper controls. the Lower Controls or Emergency
Stop position.
The control selector valve is Check the operation of the upper/lower control selector valve.
not fully shifted. Replace if defective.
Air in the hydraulic line. Purge all air out of the lines.
Low or no pilot pressure. Test and/or adjust standby pressure to 375 psi (25.86 bar).
Test and/or adjust pilot pressure to 375 psi (25.86 bar).
Improper upper control interlock Adjust the linkage.

valve linkage adjustment.
Blocking valve of the upper Check the operation of the blocking section of the upper control
control valve is not fully shifted. valve. If defective, replace the spool for the blocking section.
Only the outriggers Outriggers are not properly set. Properly set the outriggers. All interlock switches must be activated
and power tools for unit functions to operate.
operate.
Improper pilot pressure. Test and/or adjust the pilot pressure to 375 psi (25.86 bar).
Low system pressure. Test and/or adjust the system pressure to 3,000 psi (206.84 bar).
Malfunctioning lower control Clean or replace the blocking valve.

blocking valve (pilot pressure).
No signal at the lower control Check the relief valve in the lower control housing.
valve. Replace if necessary.
Check the blocking valve in the inlet manifold housing.

Replace if necessary.
Check the pilot pressure reducing valve at the test port

quick disconnect. If necessary, replace the valve.
No signal to the pump control The seals may be leaking in the rotary joint if the signal is reaching
manifold. the rotary joint but not the pump control manifold.
Check for blocked, plugged, or cut hydraulic lines. If necessary,

replace or repair.

All functions Tools are turned off. Turn the lower or upper tool circuit valve on.
operate except
power tools. The upper control interlock is Release the interlock trigger on the single handle control.
depressed.
The blocking valve is shifting off Remove and cap the pilot port line of the tool control valve to
or malfunctioning (pilot pressure). determine if the blocking valve is malfunctioning.
The tool system is receiving an Remove and cap TP port line of the tool control valve to determine
external signal (pilot pressure). if the system is receiving an external signal.
Pump is not receiving a signal from Check for pressure at the signal port of the tool control valve.
tool control valve (pilot pressure).
All functions Sticky outrigger valve spools. Lubricate or replace as necessary.

operate except
outriggers. Blocked or plugged hydraulic line. Remove the restriction or replace the line.
The outrigger leg Pilot operated check valve Clean the valve in solvent and blow it dry with compressed air.
does not hold contamination.
under load.
Pilot operated check valve Replace the valve.
malfunction.
Internal cylinder leakage. Replace the seals in the cylinder.
The lower boom Counterbalance valve Replace the counterbalance valve.

cylinder does not contamination.
hold under load.
Counterbalance valve Remove the valve and adjust using a test block.
malfunction — out of adjustment.
Replace the counterbalance valve.
Internal cylinder leakage. Replace the seals in the cylinder.
Nothing operates. PTO is not engaged. Check the PTO. If it is not engaged, properly engage it.
Hydraulic oil is not reaching the Open the shutoff valve in the suction line.
pump.
Fill the reservoir to the proper level.
Check for a blocked, plugged, or cut suction line. If necessary,

replace or repair.
Improperly plumbed pump. Check the Hydraulic Schematic. The signal port is port B, the drain
port is A. Check pump installation for proper shaft alignment. Side
loads on the pump drive shaft will cause complete loss of pressure.
No system pressure. If there is no pressure at the system pressure test port on the tool
control valve, check for loss of prime to pump. May be caused by a
leak in the pump suction line. Repair if necessary.
Pump is not operating properly. Connect a flowmeter to the pump and check flow.
Disassemble the pump compensator housing at the back of the

pump and check for excessive friction on the compensator spool or
contamination. Pump malfunction is usually caused by improper
installation, contamination, or lack of oil in the pump.
If the pump generates pressure when the signal line is connected

to the pump, the pump is not the problem.
Rebuild or replace the pump.
Severe hydraulic Hose, tube, fitting, seal failure, etc. Replace the defective component.
leak.

Preoperational Inspection Checklist
W.O. No. __________________ Customer ___________________________________ Date ____________________
Model Number ___________________________________ Serial Number ___________________________________
Vehicle Number ________________________________ Inspector _________________________________________
Check each item for proper installation, proper operation, damage, appearance, workmanship, welding quality, fluid level,
and/or compliance with order as applicable.
Symbols
= Okay or completed C = Corrected by inspector R = Repair or replacement N/A = Not applicable
Chassis (leaks, proper fluid level, proper operation, gauges) Outriggers

Engine oil Mounting
Brakes Pins and pin retainers
Battery Boom Rests
Cooling system Mounting
Power steering Gussets
Transmission Pin alignment
Fuel system Click pin and chain
Transfer case Tool System
Differential(s) fluid Quick disconnect couplers, dust plugs, and caps
Tire pressure Hose reel mounting
Windshield wipers/washers Hose reel brake
Lugs Manual reel hose tied together
Belts Auto return reel operation
Lubrication of Installed Equipment (per manufacturer) Hydraulic Hoses
Boom tip winch Proper size
Midship/rear winch Clamped sufficiently
Front winch Protected from wear or damage
Rotation gearbox Routing
Hydraulic reservoir at proper level and shutoff Jib
valve open Ease of installation and removal
Air compressor crank case oil Rotating or flip-over jib operation
Auxiliary engine crank case Pin alignment
Outrigger legs PTO
Mechanical Equipment Mounting
Pins and retainers Cable properly adjusted
Cylinders Linkage
Booms Linkage jam nuts, pins, and keys
Rails Lever stop
Arms Control handle and storage bracket
Pedestal Required number of gears
Control console Ease of shifting
All controls properly marked Positively positions PTO in neutral
Each outrigger visible from control location No unusual or excessive noise
Covers Governor installation and operation
Mounting Slip joints
Platform Pump
Frame Reinforcement Mounting
Installed properly Location and clearance
Appendix — Preoperational Inspection Checklist
Plumbing Rubber bumpers
No unusual or excessive noise Door seals
Drive Line Drip molding and pop rivets
Alignment Drain holes plugged
Angle and/or pitch Body and compartments for dents
Set screws and tie wire Wheel panel alignment and clearance
Grease fittings Fender crowns
U-joints Fold down or slide out step
Keys center punched Stirrup or cable step
Clearances Steps/ladders equally spaced, mounted straight
No unusual or excessive noise Grab handles mounted straight and secure
Exhaust System Possum belly enclosed in front sliding roof
Mounting Winch shaft sliding door
Drain holes Expanded metal installation
Heat shields braced and sharp edges removed Men working sign box
Clear of wiring and hoses Tamp box
Two-Speed Hangers Lamp box sheave pocket reinforced tailgate
Mounting Reflectors
Shifting rod clearance over axle Hotstick box
Shifting lever and linkage installed Hotstick rack
Linkage jam nuts, pins, and keys Ladder rack
Sprocket and chain aligned and tight Fiberglass platform storage bracket
Winch (Chassis) Pruner tube
Mounting Fiberglass jib storage bracket
Extended shaft clearance and lengths Cross-arm bracket
Guards Rope hooks
Winch dog lever and linkage Pike pole rack
CR reel mounting and clearance Tie wire tube
Lever storage pocket Crew Cab
Cab Guard Windows
Mounting Heaters
Backup plates inside compartments No leaks
Rubber bumper for hood to hit Seats
Corners of angle on boom rest rounded Seat belts
Bumpers Doors
Level Drip moulding over doors
Extension braced securely Masonite
Gussets in corners of body Kick plate
Uniform weld across rear Supplemental Holding Brake (Hydraulic)
Flag holders Components mounted properly
Body Line clamped properly
Condition and installation Lines and hoses not rubbing
Standard mounting procedures Vacuum system not leaking
Compartmentation according to order Hydraulic system not leaking
Dividers Electrical system operation
Shelves and drawers properly installed Electrical
Door alignment Wiring clamped and shielded
Door latches adjusted Color coding per specification
Chains or holdbacks properly installed Fuse panels and fuses

Overload system operation Sheave block pockets
Outrigger warning system operation Rope rack
Switches located and marked properly CR reel
Lights (to FMVSS 108) CR reel mounting bracket
Marker Water cask and mounting bracket
Clearance Cup dispenser
Beacon Radio rack
Spotlight Mud flaps
Turn signals Pintle hook or trailer hitch mounting
Stop Torsion bar mounting
Tail Spare tire carrier
Four-way flasher Spotlight
Compartment Tow hooks
Cab Brake lock
Headlights Grill guards
Parking Work Order
Reflectors All requirements met
License plate Unit is ready for stability test and operational test.
Accessories
Fire extinguisher and mounting bracket
Sheave block Test performed by Date

ANSI/CSA Stability Test Form, AM50
Platform Jib Test

Test Weight
Weight
Level Surface Stability Test Chart

Standard Test A Alternate Test B
Upper Platform Platform Test Jib Test Platform Jib Test
Platform Upper Controls Capacity (lbs) Weight (lbs) Weight at D Test Weight Weight at D
Single 300 450 730 lbs - 48″ 0 1,200 lbs - 24″
1-man Single 350 525 730 lbs - 48″ 0 1,275 lbs - 24″
400 600 730 lbs - 48″ 0 1,350 lbs - 24″
300 900 0 0 880 lbs - 24″
Single 350 1,050 0 0 1,025 lbs - 24″
Dual 400 1,200 0 0 1,175 lbs - 24″
1-man 300 900 0 0 880 lbs - 24″
Dual 350 1,050 0 0 1,025 lbs - 24″
400 1,200 0 0 1,175 lbs - 24″
Single 600 900 135 lbs - 48″ 0 1,030 lbs - 24″
2-man Single 700 1,050 135 lbs - 48″ 0 1,180 lbs - 24″
800 1,200 135 lbs - 48″ 0 1,330 lbs - 24″
Five Degree Slope Stability Test Chart

Single 300 400 650 lbs - 48″ 0 1,070 lbs - 24″
400 535 650 lbs - 48″ 0 1,200 lbs - 24″
Dual 300 800 0 0 780 lbs - 24″
1-man Single 350 935 0 0 915 lbs - 24″
400 1,065 0 0 1,040 lbs - 24″
300 800 0 0 780 lbs - 24″
Dual 350 935 0 0 915 lbs - 24″
400 1,065 0 0 1,040 lbs - 24″
Single 600 800 120 lbs - 48″ 0 915 lbs - 24″
800 1,065 120 lbs - 48″ 0 1,180 lbs - 24″
Appendix — Stability Test Forms

Procedure
1. Perform the stability test on a level surface and on a five degree slope in accordance with applicable ANSI
requirements.
2. Fill out all information on this form as a record of a completed stability test.
3. Find the model being tested in the chart for the test being performed.
4. Position the jib so the distance (D) from the center of the load line to the center of the jib pivot equals the value
designated in the stability charts.
5. Subtract the weight of liners, tools, etc., from the test weight shown in the stability charts. For platform capaci-
ties not shown, use a test weight of 1.5 times rated load for the Level Surface Stability Test and 1.33 times
rated load for the Five Degree Slope Stability Test.
6. Load the jib and the platform with the proper weight. Standard Test A or Alternate Test B may be used.
7. After the test has been completed, torque all accessible rotation bearing cap screws to 325 foot-pounds using a
circular pattern (only required following initial stability test at the time of initial installation of unit on chassis).
8. After the test has been completed, torque the rotation gearbox mounting cap screws to 225 foot-pounds (only
required following initial stability test at the time of initial installation of unit on chassis).
General Information
Model number ___________________________ Serial number _________________________________________
Platform type ______________________________ Platform capacity (lbs) __________________________________
Counterweight added to unit (lbs) _____________________________________________________________________
Location of counterweight relative to rear axle __________________________________________________________
Level Surface Test
Test conducted A _____ B _____ Platform test weight (lbs) ___________ Jib test weight (lbs) ____________
Thickness of outrigger pads (0 if not used) _________ Reason if used _____________________________________
Five Degree Slope Test
Side of vehicle on low side of slope __________ Thickness of outrigger pads (0 if not used) ____________________
Conclusion
Rotation bearing cap screws torqued ___________ Rotation gearbox mounting cap screws torqued ____________
Pass _____ Fail (reason) __________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
Signature of Technician _______________________________________ Date of test ________________________

ANSI/CSA Stability Test Form, AM55
Platform Jib Test

Test Weight
Weight

Single 300 450 240 lbs - 48″ 0 690 lbs - 24″
1-man Single 350 525 240 lbs - 48″ 0 760 lbs - 24″
400 600 240 lbs - 48″ 0 835 lbs - 24″
300 900 0 0 880 lbs - 24″
Dual Single 350 1,050 0 0 1,030 lbs - 24″
1-man 400 1,200 0 0 1,175 lbs - 24″
Dual 300 900 0 0 880 lbs - 24″
350 1,050 0 0 1,030 lbs - 24″
Single 600 900 0 0 890 lbs - 24″
2-man Single 700 1,050 0 0 1,040 lbs - 24″
800 1,200 0 0 1,190 lbs - 24″

Single 300 400 215 lbs - 48″ 0 615 lbs - 24″
1-man Single 350 470 215 lbs - 48″ 0 680 lbs - 24″
400 535 215 lbs - 48″ 0 745 lbs - 24″
300 800 0 0 785 lbs - 24″
Dual Single 350 935 0 0 915 lbs - 24″
1-man 400 1,065 0 0 1,045 lbs - 24″
Dual 300 800 0 0 785 lbs - 24″
350 935 0 0 915 lbs - 24″
Single 600 800 0 0 790 lbs - 24″
2-man Single 700 935 0 0 925 lbs - 24″
800 1,065 0 0 1,055 lbs - 24″

Procedure
requirements.
3. Find the model being tested in the chart for the test being performed.
4. Position the jib so the distance (D) from the center of the load line to the center of the jib pivot equals the value
designated in the stability charts.
General Information
Model number ___________________________ Serial number _________________________________________
Platform type ______________________________ Platform capacity (lbs) __________________________________
Level Surface Test
Conclusion
Pass _____ Fail (reason) __________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
Signature of Technician _______________________________________ Date of test ________________________

ANSI/CSA Stability Test Form, AM50E
Position 2 Jib Test

Weight
Platform
Test
Position 1 Weight
Platform
Test Weight
Jib Test
Weight
Jib Capacity

Jib Capacity Standard Test A Alternate Test B
(refer to Platform Platform Test Jib Test Platform Test Jib Test
illustration) Position Platform Capacity (lbs) Weight (lbs) Weight (lbs) Weight (lbs) Weight (lbs)
300 450 2,070 0 2,535
Single 1-man 350 525 2,070 0 2,610
400 600 2,070 0 2,690
600 900 1,015 0 1,940
Maximum 2 Dual 1-man 700 1,050 1,015 0 2,095
800 1,200 1,015 0 2,250
600 900 1,450 0 2,375
Single 2-man 700 1,050 1,450 0 2,530
800 1,200 1,450 0 2,685
600 900 795 0 1,710
1 Single 2-man 700 1,050 795 0 1,865
Medium 800 1,200 795 0 2,015
600 900 1,015 0 1,940
2 Single 2-man 700 1,050 1,015 0 2,095
800 1,200 1,015 0 2,250
300 450 945 0 1,405
Single 1-man 350 525 945 0 1,480
400 600 945 0 1,555
600 900 270 0 1,185
1 Dual 1-man 700 1,050 270 0 1,340
800 1,200 270 0 1,490
600 900 405 0 1,320
Single 2-man 700 1,050 405 0 1,475
Minimum 800 1,200 405 0 1,625
300 450 1,125 0 1,590
Single 1-man 350 525 1,125 0 1,665
400 600 1,125 0 1,745
600 900 450 0 1,375
2 Dual 1-man 700 1,050 450 0 1,530
800 1,200 450 0 1,685
600 900 600 0 1,525
Single 2-man 700 1,050 600 0 1,680
800 1,200 600 0 1,835

300 400 1,840 0 2,250
Single 1-man 350 465 1,840 0 2,320
400 535 1,840 0 2,390
600 800 900 0 1,725
Maximum 2 Dual 1-man 700 935 900 0 1,865
800 1,065 900 0 1,995
600 800 1,285 0 2,110
Single 2-man 700 935 1,285 0 2,250
800 1,065 1,285 0 2,380
600 800 705 0 1,520
1 Single 2-man 700 935 705 0 1,655
Medium 800 1,065 705 0 1,790
600 800 900 0 1,725
2 Single 2-man 700 935 900 0 1,865
800 1,065 900 0 1,995
300 400 840 0 1,245
Single 1-man 350 465 840 0 1,315
400 535 840 0 1,385
600 800 240 0 1,055
1 Dual 1-man 700 935 240 0 1,190
800 1,065 240 0 1,325
600 800 360 0 1,175
Single 2-man 700 935 360 0 1,310
Minimum 800 1,065 360 0 1,445
300 400 1,000 0 1,410
Single 1-man 350 465 1,000 0 1,480
400 535 1,000 0 1,550
600 800 400 0 1,225
2 Dual 1-man 700 935 400 0 1,365
800 1,065 400 0 1,495
600 800 535 0 1,360
Single 2-man 700 935 535 0 1,500
800 1,065 535 0 1,630

Procedure
requirements.
2. Refer to the jib capacity (max, med, min) on the capacity placard at the boom tip (refer to illustration).
3. Perform this test in the boom position designated in the chart. Maximum jib capacity requires testing in position
2. Medium and minimum jib capacity requires testing in both positions 1 and 2. For position 1 rotate the plat-
form to the side. For position 2 rotate the platform to the end.
5. Position the jib parallel to the upper boom and fully retracted. This will provide a 16″ (40.64 cm) load line
distance.
General Information
Model number ___________________________ Serial number ___________________________________________
Jib capacity: Maximum _________________ Medium _________________ Minimum _________________
Number of platform(s) ___________________________ Platform capacity (lbs) _____________________________
Level Surface Test
Test conducted: A _____ B _____
Position 1: Platform test weight (lbs) ______________________ Jib test weight (lbs) ______________________

Conclusion
Date _________________________ Test performed by __________________________________________________
Pass _____ Fail (reason) __________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________

ANSI/CSA Stability Test Form, AM55E
Position 2 Jib Test

Weight
Platform
Test
Position 1 Weight
Platform
Test Weight
Jib Test
Weight
Jib Capacity

300 450 1,545 0 2,005
Single 1-man 350 525 1,545 0 2,085
400 600 1,545 0 2,160
600 900 580 0 1,505
Maximum 2 Dual 1-man 700 1,050 580 0 1,660
800 1,200 580 0 1,815
600 900 925 0 1,850
Single 2-man 700 1,050 925 0 2,005
800 1,200 925 0 2,160
600 900 325 0 1,240
1 Single 2-man 700 1,050 325 0 1,390
Medium 800 1,200 325 0 1,545
600 900 600 0 1,525
2 Single 2-man 700 1,050 600 0 1,680
800 1,200 600 0 1,835
300 450 520 0 975
Single 1-man 350 525 520 0 1,055
400 600 520 0 1,130
600 900 0 0 915
1 Dual 1-man 700 1,050 0 0 1,065
800 1,200 0 0 1,220
600 900 45 0 960
Single 2-man 700 1,050 45 0 1,110
Minimum 800 1,200 45 0 1,265
300 450 750 0 1,210
Single 1-man 350 525 750 0 1,290
400 600 750 0 1,365
600 900 0 0 925
2 Dual 1-man 700 1,050 0 0 1,080
800 1,200 0 0 1,235
600 900 300 0 1,225
Single 2-man 700 1,050 300 0 1,380
800 1,200 300 0 1,535

300 400 1,375 0 1,785
Single 1-man 350 465 1,375 0 1,855
400 535 1,375 0 1,925
600 800 515 0 1,335
Maximum 2 Dual 1-man 700 935 515 0 1,475
800 1,065 515 0 1,610
600 800 820 0 1,640
Single 2-man 700 935 820 0 1,780
800 1,065 820 0 1,915
600 800 285 0 1,100
1 Single 2-man 700 935 285 0 1,235
Medium 800 1,065 285 0 1,370
600 800 535 0 1,355
2 Single 2-man 700 935 535 0 1,495
800 1,065 535 0 1,630
300 400 460 0 865
Single 1-man 350 465 460 0 935
400 535 460 0 1,005
600 800 0 0 815
1 Dual 1-man 700 935 0 0 950
800 1,065 0 0 1,085
600 800 40 0 855
Single 2-man 700 935 40 0 990
Minimum 800 1,065 40 0 1,125
300 400 665 0 1,075
Single 1-man 350 465 665 0 1,145
400 535 665 0 1,215
600 800 0 0 820
2 Dual 1-man 700 935 0 0 960
800 1,065 0 0 1,095
600 800 265 0 1,085
Single 2-man 700 935 265 0 1,225
800 1,065 265 0 1,360

Procedure
requirements.
2. Refer to the jib capacity (max, med, min) on the capacity placard at the boom tip (refer to illustration).
3. Perform this test in the boom position designated in the chart. Maximum jib capacity requires testing in position
2. Medium and minimum jib capacity requires testing in both positions 1 and 2. For position 1 rotate the plat-
form to the side. For position 2 rotate the platform to the end.
5. Position the jib parallel to the upper boom and fully retracted. This will provide a 16″ (40.64 cm) load line
distance.
General Information
Model number ___________________________ Serial number ___________________________________________
Jib capacity: Maximum _________________ Medium _________________ Minimum _________________
Number of platform(s) ___________________________ Platform capacity (lbs) _____________________________
Level Surface Test

Conclusion
Pass _____ Fail (reason) __________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________

ANSI/CSA Stability Test Form (With Lower Boom Lifting Eye)
Procedure
requirements.
3. Place both booms in a horizontal position with the upper boom near its rest.
4. Do not occupy or load the platform or jib.
5. Lift eye test weight is 1,200 pounds (544 kg) for the Level Surface Stability Test and 1,065 pounds (483 kg) for
the Five Degree Slope Stability Test.
6. Perform an applicable unit stability test.
General Information
Model number __________________________ Serial number ____________________________________________
Level Surface Test
Lift eye test weight (lbs) _________________ Thickness of outrigger pads (0 if not used) _____________________
Lift eye test weight (lbs) _________________ Thickness of outrigger pads (0 if not used) _____________________
Side of vehicle on low side of slope __________________________________________________________________
Conclusion
Pass _____ Fail (reason) __________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________

Operational Inspection Checklist
W.O. No. __________________ Customer ___________________________________ Date ____________________
Model Number _________________________________ Serial Number _____________________________________
Symbols
Supplemental Holding Brake Upper boom fold 29 to 41 32 to 38

Set at start of operation test — must still be holding Rotate 51 to 69 57 to 63
after two hours or at end of test, whichever is longer Operational Tests
PTO Outrigger interlocks require outriggers to be lowered
Ease of shifting within 0-6 inches of the ground before the unit can
Noise level be operated. Raising the outriggers with the unit
Pump stowed deactivates all unit controls.
Plumbing Cycle remote start/stop on/off from platform 10 times
Excessive or unusual noise Truck/machine switch on dashboard must be in
Inlet for air leaks Machine position to operate remote start from platform
Throttle (automatic or manual) Remote stop operates instantly
Properly installed and operating Secondary stowage pump will fully stow boom
Hydraulic System (warm oil to 120° before testing) Gin pole socket has rating placard, upper and lower
Upper boom holding valve boom angle indicators installed properly
Lower boom holding valve Jib tilts to all positions, can be pinned easily, and
Outrigger holding valves telescopes to storage or use positions. All rating
Components, hoses, and fittings for leaks placards are installed.
System pressure set at 3,000 psi Winch operates smoothly and proper winch gearbox
Pilot pressure set at 350-400 psi oil level
Upper Controls Unit operates smoothly and controls meter well
Controls operate according to placards Tools circuits are free of leaks — measured flow
Interlock operates properly meets customer specification
No movement when controls are in neutral Platform liners are supplier certified and fit snugly
Platform tilt inoperative when interlock is not engaged Accessories
Cycle Test Platform covers
Operate booms through full travel and rotate turntable Access ladders and steps
both directions 360° from lower controls Pruner holder
Operate lower boom full travel from platform for five Chainsaw holder
minutes Fall arrest system
Operate upper boom full travel from platform for five Other
minutes This unit has been operational tested and complies with Altec
Operate rotate turntable from platform both directions quality standards.
360° for 3 minutes each direction
Seconds
Cycle Times Full Pilot Test performed by Date
50/55/57/60 lower boom raise/lwr 38 to 52 42 to 48
50E/55E/60E lower boom raise/lwr 48 to 66 54 to 60
Upper boom unfold 29 to 41 32 to 38 Foreman signature Date
Appendix — Operational Inspection Checklist

Appendix — Operational Inspection Checklist
Dielectric Test Form for AM50/55
Category C — 46 kV and Below
Upper Boom Test – – – – –
Lower Boom Test

Bonding
Jumper
High Voltage
Test Leads
Control Leads High Voltage

Transformer
Ground/Return Controls Ground

Leads
Polyethylene Pad
Position A Position B
Procedure
1. Read and understand the dielectric test information in the Maintenance Manual and ANSI requirements.
2. Insulate the vehicle from ground by placing polyethylene pads beneath each tire and outrigger leg.
3. The preferred test is with the unit in Position A. Position B may be used for an inside facility with limited test
space. When using Position B place the bottom of the platform 15′ (2.6 m) from the ground. Electrical connec-
tions are the same for both positions.
4. Electrically bond all metal at the boom tip to ensure all possible current paths are considered. Include all
conductive brackets, air plunger switches, hydraulic valves, controls, cylinders, jib brackets, etc.
5. Attach the ground/return leads and bonding jumpers to the vehicle.
6. Attach the high voltage test lead (insulated from ground) to the lower boom for the lower boom test and to the
upper boom for the upper boom test as shown.
7. Do not use cancel (null) circuit if the tester is so equipped.
8. To test the upper boom, gradually increase the voltage to 100 kV. Hold at 100 kV (60 hertz) for 3 minutes
continuously. If flashover occurs or the leakage rate exceeds 1,000 microamps, the unit has failed the test.
Record leakage reading.
9. To test the lower boom, gradually increase the voltage to 50 kV. Hold at 50 kV (60 hertz) for 3 minutes continu-
ously. If flashover occurs or the leakage rate exceeds 3,000 microamps, the unit has failed the test. Record
leakage reading.
General Information
Model number ________________________________ Serial number ____________________________________
Test device number ____________________________ Test position _____________________________________
Conclusion
Upper boom leakage reading (microamp) ____________ Lower boom leakage reading (microamp) ______________
Pass _____ Fail (reason) __________________________________________________________________________

Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
Appendix — Dielectric Test Forms

Category B — 46 kV and Below
Lower Boom Test

Test Band
Bonding
Jumper
Meter Receptacle
High Voltage
Test Leads
Ground/Return
Leads
Transformer
Controls Ground
Ground for
Polyethylene Pad Upper Boom Test
Procedure
5. Attach the ground and test leads and bonding jumpers for the upper boom test as shown.
7. Gradually increase the voltage to 27 kV. Hold at 27 kV (60 hertz) for 1 minute continuously. If flashover occurs
or the leakage rate exceeds 27 microamps, the unit has failed the test. Record leakage reading.
8. Gradually increase the voltage to 54 kV. Record leakage when 54 kV (60 hertz) is reached. If flashover occurs
9. Hold the voltage at 54 kV (60 hertz) for 1 minute continuously. If flashover occurs or the leakage rate exceeds
54 microamps, the unit has failed the test. Record leakage reading.
10. Gradually increase the voltage to 80 kV. Hold at 80 kV (60 hertz) for 10 seconds. If flashover occurs or the
leakage rate exceeds 80 microamps, the unit has failed the test. Record leakage reading.
11. Remove the ground and test leads from the upper boom. Attach the test leads for the lower boom test as
shown.
12. Gradually increase the voltage to 50 kV. Hold at 50 kV (60 hertz) for 3 minutes continuously. If flashover occurs
or the leakage rate exceeds 3,000 microamps, the unit has failed the test. Record leakage reading.
General Information
Upper Boom Test
Leakage reading (microamp) at: 27 kV _______ 54 kV _______ 54 kV after 1 minute _______ 80 kV _______

Lower Boom Test
Leakage reading (microamp) _______________________
Conclusion
Pass _____ Fail (reason) __________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________

Category B — 69 kV
Lower Boom Test

Test Band
Bonding
Jumper
Meter Receptacle
High Voltage
Test Leads
Ground/Return
Leads
Transformer
Controls Ground
Ground for
Polyethylene Pad Upper Boom Test
Procedure
5. Attach the ground and test leads and bonding jumpers for the upper boom test as shown.
7. Gradually increase the voltage to 40 kV. Hold at 40 kV (60 hertz) for 1 minute continuously. If flashover occurs
8. Gradually increase the voltage to 80 kV. Record leakage when 80 kV (60 hertz) is reached. If flashover occurs
9. Hold the voltage at 80 kV (60 hertz) for 1 minute continuously. If flashover occurs or the leakage rate exceeds
80 microamps, the unit has failed the test. Record leakage reading.
10. Gradually increase the voltage to 120 kV. Hold at 120 kV (60 hertz) for 10 seconds. If flashover occurs or the
leakage rate exceeds 120 microamps, the unit has failed the test. Record leakage reading.
11. Remove the ground and test leads from the upper boom. Attach the test leads for the lower boom test as
shown.
12. Gradually increase the voltage to 50 kV. Hold at 50 kV (60 hertz) for 3 minutes continuously. If flashover occurs
or the leakage rate exceeds 3,000 microamps, the unit has failed the test. Record leakage reading.
General Information
Upper Boom Test
Leakage reading (microamp) at: 40 kV _______ 80 kV _______ 80 kV after 1 minute _______ 120 kV _______

Lower Boom Test
Leakage reading (microamp) _______________________
Conclusion
Pass _____ Fail (reason) __________________________________________________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________

Confirmation Test of
Upper Control Components With Electrical Resistance
Maximum
Test Microamp
High Voltage Lead Test Voltage Leakage
AC 40 kV 400
DC 56 kV 56
Tester
Control Lead
Ground/Return Lead
The purpose of this test is to verify the high electrical resistance components in the single handle control. In some cases
the high voltage test lead may short circuit to other nearby conductive components. First, verify that provided covers
in the control area are intact. Then, insulating material, such as a piece of insulated blanket or liner, may also be placed
under and to the sides of the spring which wraps the high voltage test connections, as needed during the test, to prevent
this from happening.
Procedure
3. Wrap a 0.375″ to 1.000″ diameter spring around the control handle as shown. Conductive aluminum foil may be
used in lieu of a spring.
4. Attach the high voltage lead (insulated from ground) to the spring on the control handle as shown.
5. Attach the ground/return lead to the control base or platform mounting bracket. This lead must contact a bare
metal surface. (The bellows must be in place for this test.)
6. Use the lower controls to raise or extend the upper boom the minimum distance as required on the unit dielec-
tric test form.
8. To test the control, gradually increase the voltage (refer to the chart). Hold at the appropriate voltage for three
minutes continuously. If flashover occurs or the leakage rate exceeds the appropriate microamps from the
chart, the control has failed the test. Record leakage reading.
General Information
Model number ______________________________ Serial number ____________________________________
Test device number _______________________________________________________________________________
Conclusion
Test conducted AC ___________________________________ DC ______________________________________
Curb side control leakage reading (microamp) ________ Street side control leakage reading (microamp) ________
Pass ______ Fail (reason) _________________________________________________________________________

Comments _______________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
Signature of technician ________________________________________ Date of test ________________________

Periodic Dielectric Test Form for Platform Liners
Either method may be used.
Wet Method Setup
1. Connect a ground lead to the steel tank. High Voltage Lead 6″ (15.24 cm) Maximum
2. Immerse the liner in the tank and fill with conductive fluid until
Liner
the level around both the inner and outer surfaces of the liner
is within 6″ (15.24 cm) of the top of the liner. Conductive
Fluid
3. Suspend the high voltage lead in the fluid within the liner.
Ground Tank
Dry Method Setup
1. Refer to TRS-0001 to apply conductive foil to the liner and High Voltage Lead 6″ (15.24 cm) Maximum
conduct the test. Liner
2. Connect a ground to the outer conductive foil.
3. Connect the high voltage lead to the inner conductive foil. Conductive
Foil
Testing (Wet or Dry) Ground
1. Apply the test voltage to the conductive fluid or foil. Voltage may be either 35 kV (60 hertz) for 1 minute or 100
kV DC for 3 minutes.
2. If flashover occurs, or the liner wall punctures, the liner has failed the test.
3. Turn off the test voltage (be sure the voltage meter indicates zero voltage). Remove the high voltage lead.
Remove the liner from the tank or remove the foil covering.
4. The test for more than one liner may be recorded on the same form providing the same setup is used to
eliminate external variables.
Conclusion
Unit Serial No. Liner Part No. Liner Serial No. Pass (Initials) Fail (Reason)
_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________

_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________
_____________ _____________ _____________ ___________ _____________________________________

_____________ _____________ _____________ ___________ _____________________________________
Wet/dry ___________ Test voltage __________ Test device number ______________________________________
Comments _______________________________________________________________________________________
________________________________________________________________________________________________

Final Inspection Checklist
W.O. No. __________________ Customer ___________________________________ Date _____________________
Model Number _________________________________ Serial Number _____________________________________
Symbols
Cab Capacity placards

Cab cleaned inside and out Operation and instruction placards and labels
Compartment keys in glove box Safety placards installed
Windshield condition Scotlite properly installed
Outside mirrors condition Paint
Cut-outs, booted and/or grommeted Overspray removed
Added controls, gauges, levers and brackets, general All cylinder rods and valve spools free of paint
appearance, and interferences Gearbox breathers free of paint
All controls, gauges, levers for proper ease of operation Undercoating coverage
Fuel gauge working on all tanks Tires and mud flaps free of paint
Body General appearance
Door latch Accessories
Door bumpers Platform liner
Door chains Platform cover
Door seals Saw
Sliding roof Impact
Sliding drawers, tracks and racks Drill
Dividers and shelves properly installed Tamp
General appearance and workmanship Pole puller, base, and chain
Lights (to FMVSS 108) Socket set
Marker Pruner
Clearance Hydraulic hoses
Beacon CR reel
Spotlight Capstan head
Turn signals Water cask
Stop Fire extinguisher
Tail Flare kit
Four-way flasher Floodlights
Compartment Spare tire
Cab Jack and lug wrench
Headlights Sheave block
Parking Spare filter cartridge
Reflectors Tool tray
License plate Manuals for installed equipment
ID Plates and Markings Stability Test
Weight Applicable test performed
Certification label Dielectric Tests
Controls Applicable tests performed
PTO
Appendix — Final Inspection Checklist
Road Test Operator’s and Maintenance Manuals with unit
Check for unusual noises in drive train
Check for unusual noises from mounted equipment Unit is ready for delivery.
Engine condition
General
Requirements of order met Test performed by Date
Inspection forms completed
Stability test form complete
Dielectric test form complete Foreman signature Date
Final axle weights recorded
Appendix — Final Inspection Checklist

Final Assembly Manual PDF

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AM50/55/60 Series

Final Assembly Manual

Section 4 — Testing and Inspection

The terms danger, warning, caution, and notice represent

Knowledge of the information in this manual combined with Warning

Contact the following organizations for additional informa- Caution

This symbol is used throughout this manual to Danger

Injury and property damage can result from contact of

Death or serious injury can result if the recommended Notice

Item AM57 AM60 AM60E

The subbase provides bending strength and torsional

Primary Floor Opening

Figure 2.1 — Weight Distribution Table

PTO output torque (ft-lbs) = horsepower x 5,252

AM50E AM55E AM60E

Weights do not include reservoir, platform liners, or platform covers

Cargo to Compartment Step

11. Position the pedestal through the body floor cut-out

1 1 273-20026 TUBE ASSEMBLY, .38 OD X 40.25

1 1 273-20278 TUBE ASSEMBLY, .38 OD X 55.94

1 1 273-20046 TUBE ASSEMBLY, .38 OD X 66.00

1 1 273-20278 TUBE ASSEMBLY, .38 OD X 55.94

Figure 3.1 — Outrigger Leg Extension

Figure 3.3 — Body Mounting

REFERENCE OR INSTALLER SUPPLIED ITEMS

A 2 708-78344 BAR, FLAT, .50 X 8.00, EMS 1-1 X 18.00 LG (AM50/55/60)

D 2 708-50267 TIE PLATE, PEDESTAL

1 1 714-00070 RESERVOIR ASSEMBLY, 15 GALLON, WITH 8.00 DIPSTICK

5 1 275-51004 VALVE, SHUTOFF, DRAIN COCK, .25 NPT

10 1 274-23070 ADAPTER 90 DEGREE ELBOW .75 NPTF TO -12 JIC

15 1 353-30009 FILTER ELEMENT

24 * 390-03005 O-RING, 6.00 ID X .25, BUNA N 70 DUROMETER -437

* INCLUDED IN RESERVOIR ASSEMBLY 714-00070 AND 714-00077

RESERVOIR ASSEMBLY, 15 OR 20 GALLON, TRIANGULAR

714-90066 RESERVOIR ASSEMBLY 15 GALLON, AND 8.00 DIPSTICK, TRIANGULAR,

1 1 714-00118 RESERVOIR, TANK, 15 GALLON, TRIANGULAR

5 1 391-90009 GASKET, RESERVOIR

12 1 275-23006 BELL REDUCER, .50 NPTF TO .25 NPTF

OUTRIGGER INTERLOCK SWITCH, A-FRAME AND X-FRAME

A-Frame and X-Frame

OUTRIGGER INTERLOCK SWITCH, RADIAL

1 2 970021816 SWITCH ASSEMBLY, MERCURY, OUTRIGGER INTERLOCK, W/ CONNECTOR

1 1 970017049 HARNESS, 10 COND., INTERFACE CABLE, OUTRIGGER INTERLOCK

8 1 970031909 DC CONVERTER, 24 TO 12 VOLT DC, 5 AMP

1 1 703-01488 MOUNTING BRACKET, LIFTING LUG

6 1 670-01003 PLACARD, BOOM ANGLE INDICATOR

11 1 203-11001 NUT, HEX JAM, .250-20 UNC, STEEL

Below Rotation, Tools and Secondary Stowage System

1 1 035200253 HYDRAULIC VALVE, MANUAL, 2 SPOOLS

7 2 027556001 HYDRAULIC VALVE, GATE, 1.25 NPT

12 2 027403202 ADAPTER, STRAIGHT BULKHEAD, -8 JIC, .38 NPT

23 4 020391002 NUT, STEEL, SELF-LOCKING, .25-20 UNC, MTS 16, 18,

28 1 027476153 ADAPTER, CAP, -6 JIC FEMALE

Below Rotation, Tools

1 1 352-00253 VALVE, MANUAL, 2 SPOOL, MOTION SWITCHES

+ 7 2 275-56001 VALVE, GATE, 1.25 IN OD, BRONZE

12 2 274-03202 ADAPTER STRAIGHT BULKHEAD .375 NPT TO -8 JIC

17 1 356-20144 CAP, QUICK DISCONNECT, FEMALE HALF, HTMA FLUSH FACE

33 1 274-87056 ADAPTER, NUT, -12 JIC FEMALE

1 2 035200253 HYDRAULIC VALVE, MANUAL, 2 SPOOLS

8 1 027400051 ADAPTER, STRAIGHT, -4 SAE, -4 JIC

25 1 027420058 ADAPTER, 90 DEGREE ELBOW, -8 SAE, -8 JIC

33 1 027487056 ADAPTER, NUT, -12 JIC FEMALE