TL MM

HI–RANGER
TL SERIES
MAINTENANCE MANUAL
This Maintenance Manual MUST BE READ prior to adjusting and repairing your
TL SERIES Non-Overcenter Telescoping Articulating Aerial Device.
PRINTED IN THE USA

Original Instructions in English
463209 08/2018
TL SERIES
7HUH[6RXWK'DNRWD,QF
2DNZRRG5RDG
:DWHUWRZQ6'
&$/,)251,$352326,7,21
WARNING Operating, servicing and maintaining this equipment can expose you to chemicals
including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other reproductive harm. These chemicals can be emitted
from or contained in other various parts and systems, fluids and some component wear by-products. To
minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your
equipment and vehicle in a well-ventilated area and wear gloves or wash your hands frequently when
servicing your equipment or vehicle and after operation. For more information go to
www.P65Warnings.ca.gov/passenger-vehicle.
Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause
cancer and birth defects or other reproductive harm.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
46 320 9 - 08 / 18 T e r e x S o u th D ako ta , In c. T L Se r i es
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TABLE OF CONTENTS
QUICK REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .QREF - 1
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .QREF - 1
MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .QREF - 1
PRESSURES/FLOWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .QREF - 1
HOLDING VALVE SETTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .QREF - 1
BOOM SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .QREF - 1
TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .QREF - 2
FORMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FORMS - 1
SECTION 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 1
OWNERS, USERS AND OPERATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 1
PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 1
INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 2
BULLETIN DISTRIBUTION AND COMPLIANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 2
CONTACTING THE MANUFACTURER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 2
TRANSFER OF MACHINE OWNERSHIP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 - 2
SECTION 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 1
HAZARD CLASSIFICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 1
PROPERTY DAMAGE MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 1
GENERAL SAFETY GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 3
BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 4
DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 5
ELECTRICAL HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 6
ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 7
MATERIAL HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 8
TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 8
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 9
OVERVIEW OF POTENTIAL HAZARDS AND SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 - 10
SECTION 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 - 1
SAFETY RELATED DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 - 1
SECTION 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 - 1
NOMENCLATURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 - 1
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 - 2
SECTION 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 1
MAINTENANCE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 1
PREVENTATIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 1
MAINTENANCE PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 1
ADJUSTMENTS AND REPAIRS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 1
LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 2
FREQUENT AND PERIODIC INSPECTION INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 3
DAILY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 3
90 DAYS (360 HOURS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 3
180 DAYS (720 HOURS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 3
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12 MONTHS (1,050 HOURS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 3

OPERATIONAL TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 4
SPEED TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 4
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 4
ELECTRICAL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 4
POST EVENT INSPECTION AND TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 4
LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 5
WINCH ROPE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 6
DAILY ROPE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 7
HOOK INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 7
STORAGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 8
SECTION 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 1
GENERAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 1
ROTATION BEARING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 1
ROTATION BEARING BOLT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 2
BOOM MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 3
ROTATION BEARING DEFLECTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 4
FASTENERS AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 6
BOLT TIGHTENING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 6
CRITICAL FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 6
BOLT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 7
SOCKET HEAD SCREWS TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 8
GRESEN VALVE TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 8
JIC SWIVEL NUT (37 DEGREE SEAT) TORQUE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 9
SAE O-RING BOSS FITTING TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 9
CYLINDER PISTON LOCKNUT TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 10
WELD SEAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 10
STEEL/FIBERGLASS JOINT CAULKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 10
CRITICAL WELDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 11
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 - 13
SECTION 130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 - 1
ROTATION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 - 1
BOOM ROTATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 - 1
TURNTABLE GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 - 1
TURNTABLE BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 - 1
COLLECTOR BLOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 - 1
CHECKING OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 - 1
OIL CHANGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 - 1
DISTORTED WORM GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 - 1
INSPECT BREATHER PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 - 1
WORM SHAFT END PLAY MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 - 2
MEASURING TOOTH CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 - 2
ROTATION SPEED REDUCER PINION ADJUSTMENT (OPTIONAL) . . . . . . . . . . . . . . . . . . . . .130 - 3
SECTION 135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 - 1
MAINTENANCE AND REPAIR OF FIBERGLASS BOOMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 - 1
RESURFACING EPOXY RESIN BASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 - 2
DETERMINING TYPE AND DEGREE OF DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 - 3
LIMITS OF MINOR BOOM DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 - 4
LIMITS OF MAJOR BOOM DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 - 5
SECTION 140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 1
MAINTENANCE OF BEARINGS AND BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 1
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BEARINGS AND BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 1

SELF-ALIGNING TYPE BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 1
BALL AND ROLLER BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 1
PLAIN STEEL BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 1
PLAIN BRONZE AND BABBIT BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 2
PRELUBRICATED COMPOSITE BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 2
SELF-LUBRICATING BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 3
SELF-LUBRICATING BUSHINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 4
BEARING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 5
CLEANING OF BEARINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 5
SECTION 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 - 1
LEVELING AND LIFT MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 - 1
PLATFORM LEVELING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 - 1
PURGING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 - 1
BLEEDING THE HYDRAULIC LEVELING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160 - 2
SECTION 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 1
INTRODUCTION TO THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 1
HYDRAULIC PUMP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 1
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 1
SLUGGISH OIL IN COLD WEATHER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 2
HYDRAULIC OIL FILTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 2
DIRECTIONAL CONTROL VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 3
COLLECTOR BLOCK ASSEMBLY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 4
HYDRAULIC ROTARY MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 4
HYDRAULIC SHUT OFF VALVES (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 4
HOLDING VALVES OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 5
HYDRAULIC CYLINDER OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 6
USE OF OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 - 7
SECTION 205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 1
GENERAL HYDRAULIC SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 1
RETURN LINE FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 2
TANK, BREATHER, FILLER AND OUTLET SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 3
CLEANLINESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 3
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 3
BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 3
HYDRAULIC TANK FILLER SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 4
MAGNETIC DRAIN PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 4
HYDRAULIC TANK OUTLET SUCTION SCREEN FOR PUMP . . . . . . . . . . . . . . . . . . . . . . . . .205 - 4
HYDRAULIC OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 5
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 5
OIL TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 5
OPERATING TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 6
VISCOSITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 6
VISCOSITY INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 6
ADDITIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 6
POUR POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 6
DIELECTRIC STRENGTH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 6
OIL STORAGE AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 7
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 7
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 7
HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 7
toc-3
TL SERIES
FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 7
CONCLUSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205 - 7
SECTION 210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 1
HYDRAULIC PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 1
TURNTABLE ROTATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 1
UPPER BOOM CYLINDER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 1
LOWER BOOM CYLINDER CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 1
OUTRIGGER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 2
INTEGRAL SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 2
WATER IN THE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 2
TAKING AN OIL SAMPLE FOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 2
CHANGING THE HYDRAULIC OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 3
CHECKING FOR HYDRAULIC LEAKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210 - 4
SECTION 230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 - 1
HYDRAULIC CYLINDER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 - 1
OUTRIGGER CYLINDER LOCK VALVE CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 - 3
SUN HOLDING VALVE CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 - 3
HOLDING VALVE SETTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 - 4
HOLDING VALVE ADJUSTMENT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 - 4
RELIEF METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 - 4
LOWER BOOM CYLINDER LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 - 5
UPPER BOOM CYLINDER LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 - 6
EXTENSION CYLINDER LEAKAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 - 7
OUTRIGGER CYLINDER LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 - 8
A-FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230 - 8
SECTION 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 1
SYSTEM HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 1
GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 1
GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 2
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 4
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 4
PUMP START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 7
RECOMMENDED TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 7
VANE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 8
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 8
ASSEMBLY AND CONSTRUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 8
APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 8
PUMPING CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 9
VANE PRESSURE FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 9
HYDRAULIC BALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 9
FLEX SIDE PLATE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 10
INLET BODIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 11
MOUNTING AND DRIVE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 12
SHAFT ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 12
START - UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 13
SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 13
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 13
toc-4
TL SERIES
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 13
LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 13
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 14
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 16
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 16
INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 18
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 18
TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 23
BUSHING INSTALLATION TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 23
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 25
HYDRAULIC PUMPS - AVOIDING FAILURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 26
CAVITATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 26
CAVITATION EFFECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 26
CAUSES OF PUMP CAVITATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 26
AERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 27
CAUSES OF AERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 27
DAMAGE TO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 27
AVOIDING AERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 - 27
SECTION 260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 1
CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 1
LOWER CONTROL VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 1
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 1
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 1
LOWER CONTROL VALVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 2
CONTROL VALVE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 2
REPLACING, ADDING OR REMOVING VALVE SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 3
WORK SECTION HOUSINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 4
SPOOL CLEVIS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 5
REPLACING SECTION SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 6
REPLACING BACK-UP RINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 7
REPLACING SPOOL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 7
PLUGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 9
SPOOL POSITIONERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 10
SINGLE STICK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 13
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 13
LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 14
CONTROL HEAD ASSEMBLY/DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 15
INDIVIDUAL LEVER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 16
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260 - 16
INDIVIDUAL LEVER CONTROL DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .260 - 17
SECTION 312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 1
WIRED RITE SST-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 1
SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 1
OPERATIONAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 2
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 2
INSTALLATION AND POWER-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 4
PROGRAMMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 5
PROGRAMMING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 6
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 7
toc-5
TL SERIES
TROUBLESHOOTING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 7

TROUBLESHOOTING QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 8
TEST MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 9
APPENDIX I WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 11
WIRING DIAGRAM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 12
WIRING DIAGRAM 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 13
WIRING DIAGRAM 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 14
APPENDIX II CONNECTION TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 15
J1 CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 16
TB1 CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 16
T1 & T2 CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 16
APPENDIX III REPLACEABLE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 17
APPENDIX IV TRUCK MANUFACTURER TECH SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 17
APPENDIX V AUTO STOP ON LOSS OF PRESSURE MODE . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 17
SECTION 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 - 1
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 - 1
TRUCK COMPUTER PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 - 1
OUTRIGGER MOVING ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 - 2
BOOM INTERLOCK SYSTEM (ELECTRIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 - 3
BOOM INTERLOCK SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 - 3
BOOM INTERLOCK LIMIT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 - 3
BOOM INTERLOCK SYSTEM (HYDRAULIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 - 4
BOOM INTERLOCK SYSTEM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 - 4
TESTING BOOM INTERLOCK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 - 4
SECTION 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350 - 1
WHAT IS INSULATED AND WHAT IS NOT INSULATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350 - 1
ELECTRICAL INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350 - 3
PREVENTION OF ELECTROCUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350 - 4
OPERATION ON OR NEAR ENERGIZED CONDUCTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350 - 4
SECTION 370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 1
DIELECTRIC TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 1
DIELECTRIC TESTS (INSULATED UNITS ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 1
UPPER BOOM RATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 1
VOLTAGE RATINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 1
QUALIFICATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 2
PERIODIC MAINTENANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 2
UPPER BOOM INSULATION CATEGORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 3
GRADIENT CONTROL DEVICE OR CORONA RING INSTALLATION . . . . . . . . . . . . . . . . . . .370 - 3
CATEGORY C TEST PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 3
LEAKAGE MONITORING CIRCUIT - (CAT A OR B ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 4
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 4
LEAKAGE TEST METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 4
LEAKAGE MONITORING CONTINUITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 5
LOWER BOOM INSERT TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 5
PLATFORM LINER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 5
VACUUM PREVENTION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 6
FOOT VALVE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 6
VENT VALVE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 6
HIGH RESISTANCE CONTROL HANDLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370 - 6
SECTION 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 - 1
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 - 1
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TL SERIES
HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 - 1

HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 - 1
TROUBLESHOOTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 - 2
CHECKING FOR HYDRAULIC LEAKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 - 3
TROUBLE SHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 - 4
SECTION 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 1
MECHANICAL COMPONENT MAINTENANCE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 1
INTRODUCTION TO THE MECHANICAL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 1
LOWER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 1
UPPER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 1
ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 1
PIN RETAINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 1
LOWER BOOM CYLINDER REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 2
UPPER BOOM CYLINDER REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 3
UPPER CONTROL VALVE REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 4
PLATFORM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 5
JIB / JIB CYLINDER REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 6
WINCH REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 7
LEVELING LINK REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 8
ELBOW REMOVAL / ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 9
UPPER BOOM REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 10
BOOM TIP REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 11
SIDE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 11
END MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 12
INNER BOOM REMOVAL / ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 13
LOWER BOOM REMOVAL / ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 14
MASTER CYLINDER REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 15
EXTENSION CYLINDER REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 16
BOOMS ASSEMBLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 16
SLAVE CYLINDER REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 17
WEAR PAD REMOVAL / ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 18
UPPER WEAR PAD REMOVAL (INNER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 18
ROLLER AND WEAR PAD REMOVAL (OUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 18
ROTATION BEARING REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 19
ROTATION SPEED REDUCER REMOVAL / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 - 20
SECTION 550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .550 - 1
ROTATION SPEED REDUCER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .550 - 1
DISASSEMBLY/ASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .550 - 2
SECTION 640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 1
COLLECTOR BLOCK ASSEMBLY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 1
COLLECTOR BLOCK ASSEMBLY (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 1
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 2
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 2
REMOVAL OF ELECTRIC COLLECTOR RING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 2
CLEANING, INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 2
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 4
CHECK VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 5
COLLECTOR RING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 6
COLLECTOR RING BRUSH AND ARM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 8
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TL SERIES
INSTALLATION OF COLLECTOR RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 9

SECTION 650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650 - 1
ROTARY ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650 - 1
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650 - 1
DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650 - 2
ASSEMBLY AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650 - 2
TESTING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650 - 3
HYDRAULIC LINE ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650 - 3
SECTION 660 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 1
WINCH GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 1
MAINTENANCE OF WORM GEAR WINCH (TULSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 1
CHECKING OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 1
OIL CHANGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 1
DISTORTED WORM GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 1
INSPECT BREATHER PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 1
INSPECT WINCH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 1
WINCH SPEED REDUCER REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 2
ASSEMBLY DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 2
ORBIT MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 3
BEFORE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 4
DISASSEMBLY & INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 4
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 7
ROTOR SET COMPONENT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660 - 10
SECTION 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 - 1
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 - 1
BASIC HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 - 1
OUTRIGGER SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 - 2
PLATFORM LEVELING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 - 3
BOOM INTERLOCK SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 - 4
HYDRAULIC TOOL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 - 5
UPPER BOOM STOW RELIEF (TL60 ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 - 5
SECTION 710 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .710 - 1
ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .710 - 1
OUTRIGGER SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .710 - 1
SECTION 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 - 1
OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 - 1
ELECTRIC AUXILIARY LETDOWN HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 - 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 - 1
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 - 1
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 - 1
RELIEF VALVE ADJUSTMENT (ON PUMPS EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 - 2
ELECTRICAL SCHEMATIC AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 - 3
MASTER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 - 5
BOOM STOW INTERLOCK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 - 6
BOOM STOW PROTECTION SYSTEM (OPTIONAL EXCEPT ON TL60) . . . . . . . . . . . . . . . . . . .800 - 7
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 - 7
OUTRIGGERS (DEPENDENT ON INSTALLATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 - 8
APPENDIX - A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1
STANDARDS AND REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 1
OSHA EXCERPTS: (CLEARANCE DISTANCE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 2
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STANDARD HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 4

APPENDIX - B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1
RESPONSIBILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1
ANSI A92.2-2015 (PARTIAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1
SURVEY OF JOB SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 13
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QUICK REFERENCE
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QUICK REFERENCE
LUBRICANTS
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Iso 15 or equivalent
Rotation speed reducer, worm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EP023
Ring gear and pinion lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EP #2 Grease
Winch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GL-5 EP Gearlube 85W140
MEASUREMENTS
Turntable gear backlash allowable. . . . . . . . . . . . . . . . . . . . . . . . . . . 0.004–0.007 in. (0.102-0.178 mm)
Turntable deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0076 in. per in. (0.0076 mm per mm)
from center-line
Bearing Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.144 at 11.5 in. (292.1 mm)
PRESSURES/FLOWS
System pressure
37-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 PSI @ 8 GPM (17.24 MPa @
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.28 LPM)
55 and up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 PSI @ 8 GPM (20.69 MPa @
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30.28 LPM)
Hydraulic tool pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2250 PSI @ 5–8 GPM (15.51 MPa @
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.93-30.28 LPM)
Boom / Outrigger circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 GPM (high idle) (30.28 LPM)
Upper boom stow valve (TL60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500 PSI (10.34 MPa)
HOLDING VALVE SETTINGS
Extension cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 PSI (17.24 MPa)
Jib
Extend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 PSI (13.79 MPa)
Tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 PSI (20.69 MPa)
Lower boom and upper boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . 3600 PSI (24.82 MPa)
Master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 PSI (17.24 MPa)
Slave cylinder & platform rotate cylinder . . . . . . . . . . . . . . . . . . . . . . 2000 PSI (13.79 MPa)
Unit Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 PSI (20.69 MPa)
BOOM SPEEDS
2nd section
Extend
37-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–18 seconds
50 and up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12–24 seconds
Retract
37-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14–22 seconds
50 and up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18–28 seconds
Lower boom, down and up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22–27 seconds
Rotation, 360º. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66–76 seconds
Upper boom
Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27–38 seconds
Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24–35 seconds
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QUICK REFERENCE
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TORQUES
Extension cylinder piston nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 ft. lbs. (339 N-m)
Leveling master cylinder piston nut . . . . . . . . . . . . . . . . . . . . . . . . . . 360 ft. lbs. w/oil (488 N-m)
Lower boom cylinder piston nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650 ft. lbs. w/oil (881 N-m)
Outrigger cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check repair parts manual
Pedestal to rotation bearing bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 ft. lbs. w/anti-seize (231 N-m)
Platform attachment nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ft. lbs. w/anti-seize (34 N-m)
Rotation speed reducer bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 ft. lbs. w/anti-seize (136 N-m)
Rotation speed reducer motor mounting bolts . . . . . . . . . . . . . . . . . . 55 ft. lbs. w/anti-seize (75 N-m)
Slave cylinder (Platform) side mount piston nut . . . . . . . . . . . . . . . . . 360 ft. lbs. w/oil (488 N-m)
Turntable table to rotation bearing bolts. . . . . . . . . . . . . . . . . . . . . . . 170 ft. lbs. w/anti-seize (231 N-m)
Upper boom cylinder piston nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200 ft. lbs. w/oil (1627 N-m)
End mount rotary actuator to platform basket
3/8 capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 ft-lbs w/blue loctite (53 N-m)
1/2 capscrews . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 ft-lbs w/blue loctite (68 N-m)
1” center bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 ft. lbs. w/anti-seize (461 N-m)
End mount rotary actuator to pivot weldment. . . . . . . . . . . . . . . . . . . 110 ft. lbs. w/anti-seize (149 N-m)
safety wire
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FORMS
The following pages have general forms that you may use for your inspection process. Depending on your
specific needs you may need to add inspection items to the list. The Dielectric test forms include Periodic
test forms and Qualification test forms.
ANSI A92.2 requires a written record of inspections and repairs following accidents, overload incidents, and
Periodic Inspections. Frequent inspections do not need to be recorded but if a safety hazard is found it must
be reported in writing as well as the corrective action. ANSI requires reports and records are maintained for
5 years or by applicable regulations, but it is recommended to keep them for the life of the machine.
forms-1
FORMS
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Aerial Platform Annual Inspection

In Accordance with ANSI A92.2
Immediate Repairs Required (______Yes) (_______No)

Owner/User is responsible to have repairs performed before use.
All other items marked can be addressed at the next maintenance interval.
Shop Order_____________ Test Date _____________________

Customer_____________________________________________
Location _____________________________________________
Inspector____________________ Inspector Number _________
Chassis and Unit Information
Chassis Year ___________ Chassis Model __________________

VIN Number __________________________________________
License ______________________________________________
Odometer ________________ Eng. HR/Meter ______________
Unit Manufacturer _____________________________________
Model Number ________________________________________
Serial Number ________________________________________
Unit Number ___________________ PTO HR/Meter _________
1 TUFM1067 Rev D
09-02-14
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Aerial Annual Inspection Unit Number_____________________________

Symbols: 3 = OK N/A = Not Applicable A = Adjusted/Repaired
X = See corresponding number on summary page
A. Chassis / Body Status 3. Outrigger / Torsion Bar System Status

1. Cab Controls Welds, Metal Structure, and Mounting
Master Switch Panel Anchor Bolts
Strobe Lights / Beacons Hydraulic Cylinders - Leaks
PTO Shift Control (cable, air, electric) Cylinder Pins and Keepers
PTO Indicator Light Foot Assembly and Pins
PTO Warning Label Present Holding Valves / Locks (Drift Test)
Stowed Height Placard Cylinder Lock - Out Valves
Start / Stop, Throttle Controls Torsion Bar Structure
Auxiliary Brake Control Torsion Bar Bushings
Back Up Alarm Hose Condition, Routing Under Chassis
Operators Manual With Truck Control Valves
Boom Interlock System-Jan. 2005 On
2. Body / Flatbed Outrigger Motion Alarm-Feb. 2000 On
Headlights, Stop, Tail, Turn, Hazard Relief Valve Setting
Fire Extinguisher Auxiliary Let Down System
Wheel Chocks Chassis Level Indicator-Jan. 2003 On
Outrigger Pads Chassis Tire Pressures
Unit Grounding Equipment
Cab Guard / Headache Rack 4. Pedestal and Turntable
Steps / Accessibility Welds - Metal Structure and Mounting
All Safety Decals - Legible and Elevator - Welds and Metal Structure
Proper Location Elevator Cylinders and Holding Valves
Elevator Pins, Bushings, and Keepers
B. Aerial Unit Collector Block / Hoses / Fittings
1. Basic Hydraulics Rotation Bearing and Fasteners
Reservoir - Oil Amount and Condition Rotation Gearbox
Filters, Breather Cap Lower Control Valve / Shut-off Valve
Gate Valves, Hoses, and Fittings Relief Valve Setting
Auxiliary Let Down System
2. PTO / Pump Accumulator Operation
PTO / Pump Mounting Nitrogen Setting / Charge
PTO / Pump Noises and Leaks Unloading Valve / Unit Cycling
PTO / Pump Hoses and Fittings
5. Booms and Platform
All Fiberglass for Damage and Finish
Booms - Cleanliness Inside and Out
Boom Metal Sections
Inspector Initials ________________
2 TUFM1067 Rev D
09-02-14
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Aerial Annual Inspection Unit Number_____________________________

Symbols: 3 = OK N/A = Not Applicable A = Adjusted/Repaired
X = See corresponding number on summary page
Booms and Platform (cont.) Status 8. Extension System Status

Hoses and Hose Protection Catrac, Hoses, and Wire Harness
Boom Pins, Bushings, and Nuts Hose / Wire Routing, and Protection
Boom Cylinders All Wear Pads and Rollers
Boom Lift Rod and Lift Cable All Cable Sheaves and Pulleys
Compensation System All Extension Cylinders
Boom Cylinder Holding Valves All Pins and Retainers
Boom Rest and Hold Down System Cylinder Holding Valves
Platform - Mounting, Liner, and Cover All Limit Switches
Lanyard Anchor - Belt or Fixed
Safety Harness and Lanyard C. General
Non - Skid Platform Step 1. General Lubrication
Gearboxes - Pinion Gears, Oil Level
6. Platform Controls Rotation Brake - Oil Level
Control and Safety Decals / Placards Rotation Bearing
All Upper Control Operations Control Linkages
Start / Stop and/or Throttle Control Cables Sheaves and Pulleys
Auxiliary Let Down System Hinge Points
Hydraulic Tool Valve / GFI Outlet Outriggers - Slip Plate
Control Guards / Covers
Winch Gearbox 2. Auxiliary Equipment
Winch Rope and Safety Hook Capstan
Jib and Jib Tilt Cylinder Auxiliary Winch
Load Chart, Boom Angle Indicator Pony Motor Hydraulics
Control Valve - Leaks Chipper Body Dump
Control Valve - Vacuum Vent Valves Hose Reels
Platform Rotator, Level, or Dump Hydraulic Tools
7. Platform Leveling System 3. Misc. Powered Equipment

Leveling Cables and Chains Generator - Condition
Cable Pulleys and Chain Sprockets Battery - Condition
Cable Sheaves and Clamps Hose and/or Wire Condition
Anchor Brackets
Turnbuckles and Tie Wire or Lock Nut
Hinge Points
Leveling Cylinders and Shocks
Cylinder Holding Valves
Leveling Hoses
Platform Drift
Inspector Initials___________
3 TUFM1067 Rev D
09-02-14
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Model / Serial# ______________________ Summary Page Unit Number____________
Number R/C/I Description
Legend:
(R) Repair required, Inspection Decal will be placed on the unit and marked as Immediate Repairs Required.
Once repairs have been completed, the Owner/User shall date and sign the Decal before returning to service.
(C) Check and repair as necessary on scheduled routine maintenance. Inspection decal will be placed on the unit.
(I) For Information only, no corrective action required at this time. Inspection decal will be placed on the unit.
Note:
x Owner/User is responsible to have repairs performed before use.
x Manufacturer’s recommendations as to frequent and/or periodic inspection maintenance schedules must be
followed for safe operation of this unit.
x Immediate repairs required (______ Yes) (______ No).
x Customer declined torque check of critical fasteners (______Yes) (______No) If checked, Work Order # __________
x Do not consider this a pre-purchase inspection.
Customer Signature___________________________________ Print Name ___________________________
Inspector Signature ____________________________________Date____________________
4 TUFM1067 Rev D
09-02-14
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PERIODIC/MAINTENANCE DIELECTRIC TEST ANSI/SIA A92.2 AND A10.31
Aerials Category C and Digger Derricks Work Order No.

Customer: ______________________________________ Date: _______________
Unit No.: _______________________________________ License No: __________
Equipment Identification:
Manufacturer: _________ Model: S/N:
Upper Boom Test: Chassis Insulating Test: Air Temp. °F

Upper Boom Angle ____ ° Upper Boom Angle ___ ° Humidity __________ %
Lower Boom Angle ____ ° Lower Boom Angle ___ ° Time ______________am pm
Telescopic/Digger Derrick: Fully Extended Fully Retracted To Minimum Extension Label
Test Equipment: Model-S/N: Calibration Date:
Note: μA = Micro amp
1. CATEGORY C INSULATING AERIAL DEVICE & DIGGER DERRICK (without lower test electrode system)
Unit Qualification AC TEST - 1 Minute DC TEST - 3 Minutes Initials
Voltage TEST VOLTAGE Time Leakage TEST VOLTAGE Time Leakage Accept Reject
Start µA Start µA
46 KV & Below 40KV Finish µA 56 KV Finish µA
Max. Leakage 400 µA Max. Leakage 56 µA
Start µA Start µA
KV KV Finish µA KV Finish µA
Max. Leakage µA Max. Leakage µA
2. CHASSIS INSULATING SYSTEM (lower boom insert)
AC TEST - 1 Minute DC TEST - 3 Minutes Initials
TEST VOLTAGE Time Leakage TEST VOLTAGE Time Leakage Accept Reject
Start µA Start µA
35 KV Finish µA 50 KV Finish µA
3. COMPONENT TEST
AC TEST - 1 Minute DC TEST - 3 Minutes Initials
DESCRIPTION
TEST VOLTAGE KV KV KV KV Accept Reject
Start µA µA µA µA
__________________
S/N _______________ Finish µA µA µA µA
Max. Leakage µA µA µA µA
Tested by: ______________________ Location: ___________________________
Comments:_____________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
FM5101
01/06
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FORMS
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PERIODIC/MAINTENANCE DIELECTRIC TEST ANSI/SIA A92.2

Aerial – Category A and B Work Order No.
Customer: Date:
Unit No.: License No.:
Equipment Identification:
Manufacturer: Model: S/N:
Upper Boom Test: Chassis Insulating Test: Air Temp. °F
Upper Boom Angle ____ ° Upper Boom Angle ____ ° Humidity %
Lower Boom Angle ° Lower Boom Angle ° Time am pm
Telescopic Booms: Fully Extended Fully Retracted To Minimum Extension Label
Test Equipment: Model-S/N _____________________________ Calibration Date: _______
1. CATEGORY A & B INSULATING AERIAL DEVICE (with lower test electrode system) Note: µA = Micro amp
Unit Qualification AC TEST - 1 Minute DC TEST - 3 Minutes Initial
Voltage TEST VOLTAGE Time Leakage TEST VOLTAGE Time Leakage Accept Reject
Start µA Start µA
46KV & Below 40KV Finish µA 56KV Finish µA
Start µA Start µA
69KV 60KV Finish µA 84KV Finish µA
2. LOWER TEST ELECTRODE SYSTEM:
Test for “Electrical Continuity” between the center core of the test terminal and the following:
Outer Test Band Less than 100 OHMS Inner Test Band Less than 100 OHMS
Hose Assembly Bulkhead Less than 100 OHMS Leveling Rod Bands Less than 100 OHMS
PVC Tube Bands Less than 100 OHMS Other ____________ Less than 100 OHMS
Test for “Electrical Insulation” between the center core of the test terminal and steel elbow:
More than 10,000 OHMS
3. CHASSIS INSULATING SYSTEM (lower boom insert)
AC TEST - 1 Minute DC TEST - 3 Minutes Initial
TEST VOLTAGE Time Leakage TEST VOLTAGE Time Leakage Accept Reject
Start µA Start µA
35KV Finish µA 50KV Finish µA
4. COMPONENT TEST
AC TEST – 1 Minute DC TEST – 3 Minutes Initial
DESCRIPTION
Test Voltage KV KV KV KV Accept Reject
_________________
S/N ______________ Finish µA µA µA µA
Max. Leakage µA µA µA µA
Tested by: ____________________________ Location: _____________________________
Comments: __________________________________________________________________
___________________________________________________________________________
FM5100
01/06
forms-7
FORMS
TL SERIES
TEREX TELELECT Aerial - Upper control Handle Test

Periodic Maintenance Test
Customer:_____________________________ Ack No.__________________ S/N:
Description:_____________________________________________________ P/N:
Control handle electrical test: The single stick control will be tested to determine it has insulating properties
This test does not certify the handle is capable of any voltage while in use because of limited
clearance, cleanliness, and contamination. Connect test equipment as shown.
Single Stick Control Test:
Test time: AM / PM AC test DC Test
Leakage Leakage Accept Reject
3 minutes (40KVAC) 56KVDC
Start µA µA
Finish µA µA
Allowable 400 µA Allowable 56 µA
Verify all valve control handles are non-conductive materials:
Individual levers:
Hydraulic Stop, Start/Stop, Two Speed
Note: Microampere = µA
Connect as shown for AC:

Meter can be in power
line for DC tests.
Procedure
1. Elevate boom tip so there is no contact to ground except through boom.
2. Wrap a metal spring around the handle of the single stick.
3. Attach the High Voltage lead to the spring with the clamp and cable upward.
4. Attach the return test lead to the platform bracket or mounting bracket.
If mounted on platform attach to bracket attaching to basket.
5. To test: a. Gradually increase the voltage to 40KVAC or 56KVDC, Hold at voltage for 3 minutes.
b. If flashover occurs or the leakage rate exceeds allowable it is a failure.
6. Record the results and file report.
Tested By: Date:
Comments:
Note: Do not depend on covers or plastic control handles to provide electrical protection for the operator.
Primary protection can only be provided by tested and rated protective equipment such as rubber gloves, rubber sleeves,
cover-up, or proper clearance distance from all conductive components of the boom tip. Plastic, fiberglass, and rubber
covers or handles may provide some limited insulation protection depending on condition and cleanliness.
However, covers are not tested, and handles and covers are not certified or maintained as insulating.
FM5099 03/01/10
TEREX TELELECT
forms-8
FORMS
TL SERIES
QUALIFICATION DIELECTRIC TEST

ANSI/SIA A92.2 AND A10.31
Customer:___________________________Ack No.:________________ S/N:_______________________

Product Code:________________Description:_____________________ P/N:_______________________
Overcenter/Non-Overcenter Unit Qualification Voltage:______kv Test Date:
Upper Boom Test: Insert Test: Test Performed: Inside
Upper Boom Angle:_______deg Upper Boom Angle:_______deg Outside
Lower Boom Angle:_______deg Lower Boom Angle:_______deg Temperature: deg F
Telescopic/Digger Derrick Humidity: %
Main Boom Angle:_______deg Fully Extended Fully Retracted To Minimum Extension Label
1. CATEGORY A & B INSULATING AERIAL DEVICE WITH LOWER TEST ELECTRODE SYSTEM
1 MINUTE AC TEST VOLTAGE 10 Sec. Momentary Withstand
UNIT QUALIFICATION TEST TIME Rated Double Rated Voltage Test(No Flashover Allowed) INITIAL
VOLTAGE AC AM/PM 27 kv 40 kv 54 kv 80 kv 80 kv 120 kv Accept Reject
46 kv & below Start µA µA µA
Finish µA µA µA
S/N_______________ Max Leakage 27 µA 54 µA 80 µA
69kv Start µA µA µA
Finish µA µA µA
S/N_______________ Max Leakage 40 µA 80 µA 120 µA
2. CATEGORY C INSULATING AERIAL DEVICE AND DIGGER DERRICK

UNIT QUALIFICATION TEST TIME 3 MINUTE AC TEST VOLTAGE INITIAL
VOLTAGE AC AM/PM 100 kv Accept Reject
46 kv & below Start µA
Finish µA
S/N_______________ Max Leakage 1000 µA
3. CHASSIS INSULATING SYSTEM (Lower Boom Inserts)

TEST TIME 3 MINUTE AC TEST VOLTAGE INITIAL
AM/PM 50 kv Accept Reject
Start µA
Finish µA
S/N_______________ Max Leakage 3000 µA
4. COMPONENT TEST
DESCRIPTION TEST TIME 3 MINUTE AC TEST VOLTAGE 3 MINUTE AC TEST VOLTAGE INITIAL
AND SERIAL NO. AM/PM 50 kv 100 kv 75 kv 150 kv Accept Reject
Finish µA µA µA µA
Max Leakage 1000 µA 1000 µA 100 µA 100 µA
Finish µA µA µA µA
Max Leakage 1000 µA 1000 µA 100 µA 100 µA
NOTES: µA=Micro amp
Comments:
Tested By:______________________
Reviewed By:___________________
FMPN352136 Rev B 2/01/06
forms-9
FORMS
TL SERIES
TEREX TELELECT Aerial - Upper control Handle Test

Qualification Test
Customer:_____________________________Ack No.__________________S/N:
Description:____________________________________________________ P/N:
Control handle electrical test: The single stick control will be tested to determine it has insulating properties
in new clean condition. This test does not certify the handle is capable of any voltage while in use because
of limited clearance, cleanliness, and contamination. Connect test equipment as shown.
Single Stick Control Test:
3 min Test Micro Amps Accept
40KVAC Test time: AM / PM Reject
Voltage A or B leakage (<400 µA)
Start KV µA
No Flashover <400 µA
Finish KV µA
Verify all valve control handles are non-conductive materials:
Individual levers: (Qty)
Hydraulic Stop, Start/Stop, Two Speed
Note: Microampere = µA
Connect as shown:
Procedure
1. Elevate boom tip so there is no contact to ground except through boom.
2. Wrap a metal spring around the handle of the single stick.
3. Attach the High Voltage lead to the spring with the clamp and cable upward.
4. Attach the return test lead to the platform bracket or mounting bracket.
If mounted on platform attach to bracket attaching to basket.
5. To test:
a. Gradually increase the voltage to 40KVAC, Hold at voltage for 3 minutes.
b. If flashover occurs or the leakage rate exceeds 400µA it is a failure.
6. Record the results and file report in machine test folder.
Tested By:___________________ Date: Reviewed:___________________ Date:

Comments:
Failure cause: KV Voltage of flashover exceeds 400 µA
Note: Do not depend on covers or plastic control handles to provide electrical protection for the operator. Primary
Primary protection can only be provided by tested and rated protective equipment such as rubber gloves, rubber sleeves,
cover-up, or proper clearance distance from all conductive components of the boom tip. Plastic fiberglass and rubber
covers or handles may provide some limited insulation protection depending on condition and cleanliness.
However, covers are not tested, and handles and covers are not certified or maintained as insulating.
FMPN352192 Rev D
TEREX TELELECT 03/01/10
forms-10
INTRODUCTION
TL SERIES
SECTION 10
INTRODUCTION
OWNERS, USERS AND OPERATORS
Thank you for choosing Terex South Dakota, Inc. equipment for your application. User safety is our number
one priority and this is best achieved by our joint efforts.
As equipment users and operators, you make a major contribution to safety if you:
1. Comply with OSHA, federal, state, ANSI, local and your company regulations.
2. Read, understand and follow the instructions in this manual and other manuals supplied with this
vehicle.
3. Only allow trained operators, directed by informed and knowledgeable supervision, to run the unit.
If there is anything in this manual that is not clear or you believe should be added, please send your
comments to:
Manager of Publications
Terex South Dakota, Inc.
500 Oakwood Road
Watertown, South Dakota 57201
You may also contact us by phone at: (605) 882-4000
This is the safety alert symbol. It is used in this manual to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid possible injury
or death.
This manual contains important information on the safe use of your Terex South Dakota, Inc. equipment.
Your failure to read, understand and follow all safety rules, warnings and instructions will unnecessarily
expose you and others to dangerous situations. For your safety and the safety of those around you, you
must operate your Terex South Dakota, Inc. equipment as instructed in this manual.
This manual shall be stored on the vehicle for access by the operator. The Operators manual is required to
be stored on the vehicle by ANSI and OSHA regulations.This manual, along with the AEM Aerial Devices
Safety Manual and ANSI A92.2 Manual of Responsibilities for Dealers, Owners, Users, Operators, Lessors
and Lessees should be considered a permanent part of your machine and should remain with the machine
at all times.
PRODUCT IDENTIFICATION
The serial number is located on the ID plaque. It may be located on the turntable, pedestal or lower boom,
depending on options and features. The serial number of the vehicle (VIN) will be different than the serial
number for the Aerial Device. Please refer to the Aerial Device serial number when contacting Terex South
Dakota, Inc. for service and parts information. Refer to the ID plaque for capacity and dielectric information.
Serial Number
10-1
INTRODUCTION
TL SERIES
INTENDED USE
This machine is intended to be used to lift personnel, along with tools to an aerial work site within the rated
platform capacity. If equipped with material handling features it may be used to lift material only within its
rated capacity. Use of this product in any other way is prohibited and contrary to its intended use.
BULLETIN DISTRIBUTION AND COMPLIANCE
It is the owners responsibility to comply with all bulletins issued by Terex South Dakota, Inc. or the vehicle
manufacturer. Safety of product users is of paramount importance to Terex South Dakota, Inc. Various
bulletins are used by Terex South Dakota, Inc. to communicate important safety and product information to
dealers and machine owners. The information contained in bulletins is tied to specific machines using the
machine model number and serial number. Distribution of these bulletins is based on the most current owner
on record along with their associated dealer, so it is important to register your machine and keep your
contact information up to date and changes in ownership. To ensure safety of personnel and the reliable
continued operation of your machine, compliance with the information and actions in the bulletins are
mandatory.
CONTACTING THE MANUFACTURER
If it is necessary to contact the manufacturer of the machine, supply the unit model number, serial number
and your name and contact information. At minimum, the manufacturer should be contacted for:
• Accident Reporting
• Questions regarding product applications and safety
• Standards and regulations compliance information
• Questions regarding product modifications
• Current owner updates, such as changes in machine ownership or changes in your contact
information (See Transfer of Machine Ownership below)
TRANSFER OF MACHINE OWNERSHIP
If you are not the original owner of this machine, use the following form to provide information on the
ownership change.
This information will ensure that you are the owner on record for this machine and you will receive applicable
notices and advisories in a timely manner.
You can mail information on changes in ownership to Terex South Dakota, Inc., 500 Oakwood Road, PO Box
1050, Watertown, SD 57201 or email the information to: utilities.warranty@terex.com.
REGISTRATION CARD
Terex South Dakota, Inc. Model __________________________ Serial # __________________________
Owner’s Name
Address
City State Zip
Signed Title
Email : Ph #: Mobile #:
VIN # Customer Truck #
Check: ( ) Operation & Maintenance Manual Received.
Date Placed in Service:
Previous Owner
Address
Note: If Operation & Maintenance Manual was not received, contact Terex South Dakota for copies.
10-2
SAFETY
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SECTION 20
SAFETY
The operator is the single most important factor for safety when using any piece of equipment. Learn to
operate your Terex South Dakota, Inc. equipment in a safe manner.
NOTE: The best method to protect yourself and others from injury or death is to use common
sense. If you are unsure of any operation, do not continue until you are satisfied that it is
safe to proceed.
HAZARD CLASSIFICATION SYSTEM
This machine contains safety signs to assist in hazard recognition and prevention. The hazard
classification system is a multi-tier system used to alert you to potential personal injury hazards. Signal
words used with the safety alert symbol indicate a specific level of severity of the potential hazard. To
help you recognize important safety information, we have identified warnings and instructions that
directly impact safety.
This is the safety alert symbol. It is used in this manual to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid possible injury
or death.
Danger is always used with the safety alert symbol and white letter on red background.
DANGER
Indicates a hazardous situation that, if not avoided, will result
in death or serious injury.
Warning is always used with the safety alert symbol and black letters on orange background.
WARNING
Indicates a hazardous situation that, if not avoided, could
result in death or serious injury.
Caution is used with the safety alert symbol and black letters on yellow background.
CAUTION
Indicates a hazardous situation that, if not avoided, could
result in minor or moderate injury.
PROPERTY DAMAGE MESSAGES

The signal word NOTICE, shown without the safety alert symbol, is used to address specific practices or
draw attention to supplemental information that is not related to personal injury.
Notice does not use the safety alert symbol and text is white italic letters on blue background.
NOTICE
Indicates information considered important, but not hazard
related (e.g., messages related to property damage).
20-1
SAFETY
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In addition to maintenance and operating instructions in this manual, the operator must
read and understand all the instructions in the following safety guidelines.
1. Study all safety messages and apply them on the job.

2. Modifications to this Terex South Dakota, Inc. equipment from the original design specifications without
written permission from Terex South Dakota, Inc. are strictly forbidden. A modification may compromise
the safety of the Terex South Dakota, Inc. equipment, subjecting users to serious injury or death. Any
such modification will void any remaining warranty.
3. Terex South Dakota, Inc. reserves the right to change, improve, modify or expand features of its
equipment at any time. Specifications, model or equipment are subject to change without notice and
without incurring any obligations to change, improve, modify or expand features of previously delivered
equipment.
4. Comply with manufacturer’s instructions and requirements of current OSHA regulations and ANSI
standards.
20-2
SAFETY
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GENERAL SAFETY GUIDELINES
1. The use of this Aerial Device is subject to certain potential dangers that cannot be protected against by
mechanical means. Only the exercise of intelligence, care, and common sense can eliminate these
dangers. It is essential to have competent, careful operators who are physically and mentally fit, and
thoroughly trained in the safe operation of this Aerial Device. Learn, understand and practice safe use of
all equipment and controls - before operating this Aerial Device.
2. Never exceed the rated load capacity. Know the total weight - including the operator, platform liner, tools,
and equipment, and/or other items before entering platform.
3. Conduct a thorough pre-operation of the machine and test all functions through their complete cycle
before each work shift. Immediately tag and remove from service a damaged or malfunctioning
machine.
4. Do not operate this Aerial Device if any interlock or safety device is malfunctioning.
5. Do not bypass or remove any interlock or safety device.
6. Never operate with damaged leveling chain or components.
7. Stop in position if you become aware of any dangerous conditions or hear any unusual noise (such as
grinding, cracking or grating) while operating the Aerial Device. Do not move the Aerial Device until the
problem has been resolved.
8. Do not operate the Aerial Device if it is not functioning properly or a leak is detected. Repair, document
repairs performed and inspect the unit before returning to service.
9. Never operate from the ground controls with personnel in the platform. Operation must be controlled by
the platform operator, except in case of an emergency.
10. Keep the vehicle free of obstructions that may interfere with the controls or personnel who may have to
operate them in an emergency.
11. All ground personnel must be trained in the proper procedure to follow in case of emergency.
12. Do not operate the Aerial Device in an electrical storm.
13. The hydraulic fluid is petroleum based and will burn.
20-3
SAFETY
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BEFORE OPERATION
1. Survey the conditions of the work area. Identify situations such as; soft ground, ditches, drop-offs, holes,
debris, overhead obstructions, electrical conductors, and underground utilities.
2. Plan the job (tailgate session) and clear the area of bystanders.
3. Set the vehicle parking brake and chock the wheels.
4. Make certain tire pressures are proper for operation.
5. Visually inspect condition of tires, truck suspension, and torsion bars (if equipped) for any damage.
6. The vehicle must be securely parked and stabilized before any operation is performed. If equipped with
outriggers, set all outriggers.
7. If not equipped with outriggers, or only one set of outriggers, the truck tires must equally support the
weight of the truck. One tire cannot be in a hole or depression.
8. Do not lower outriggers unless you can see that all ground personnel and bystanders are clear of the
outrigger path of movement and its ground contact point. Lower all outriggers onto solid footing.
9. Do not place outriggers on ice as slippage may occur regardless of solid footing. Operation on snow or
slippery surfaces requires extra care during set up to ensure Aerial Device and vehicle have sufficient
traction to prevent sliding.
10. The Aerial Device has been tested per the stability requirements of ANSI A92.2 and may be operated on
firm, flat, non-level surfaces up to a 5 degree slope.
11. Ground and/or barricade the vehicle per OSHA and your company rules.
12. Raise and lower booms through a complete cycle using the lower controls daily, before entering
platform, looking for any malfunction or problems. If found, shut down immediately.
13. Perform controls inspection before beginning operation. Do not operate with malfunctioning controls.
14. Barricade or cover any overhead electrical lines that may be a potential contact during operation.
15. Inspect and maintain personal protective equipment.
16. Perform inspections and maintenance as specified in the Maintenance Guidelines.
17. If this Aerial Device is equipped with platform tilt, an inspection must be made before entering the
platform, to insure all locks and pins are properly in place.
18. Be sure Operator’s Manual is on the vehicle.
20-4
SAFETY
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DURING OPERATION
1. Never operate the Aerial Device unless you know the location, function, and operation of all the controls,
including emergency and accessory operation.
2. Avoid abrupt starts, stops and reversal of direction. Operate all controls slowly for smooth motion.
3. Keep hands off all moving parts to avoid injury.
4. Operator(s) must wear an OSHA approved fall arrest system with a lanyard attached to an anchor
provided.
5. Wear personal protective equipment such as: Insulated hard hat, rubber gloves with leather protectors,
and rubber sleeves. Hearing and eye protection, proper boots and suitable clothing may also be
required.
6. Do not place the boom in open traffic lanes, stop traffic or barricade lanes to divert traffic from area.
7. Do not allow boom, platform, or any part of the Aerial Device to contact fixed objects.
8. Do not tie off to an adjacent structure, pole, or other equipment.
9. Never exceed rated capacity of platform for men, tools, and liner if equipped.
10. Do not pass tools, equipment, or other objects between the occupant of the platform and other
personnel on poles or other platforms.
11. Do not sit or climb onto edge of platform or use planks, ladders, or other devices for a work position.
Always stand with both feet on floor of the platform.
12. Do not wear climbers while in the platform.
13. Do not allow ground personnel under the platform work area.
14. Do not operate with platform leveling malfunctioning.
15. Do not move the vehicle with personnel in the platform.
16. Never tie loads to the platform or booms. Always use lifting attachment when it is necessary to lift or
lower an object.
17. Do not lift loads with the Aerial Device if it is not equipped with a lifting attachment.
18. High speed should only be used when moving the platform to an aerial job site. Low speed should be
used to move into, or within the aerial job site.
19. Low engine speed, if available, should be used when an extended period of time is going to be spent at
an aerial job site.
20. Do not use the platform for lifting material. The platform was designed for lifting personnel only.
21. If, when operating the Aerial Device, you become aware of any dangerous condition, unusual operation,
or hear any unusual noise, such as grinding, cracking, or grating sounds-STOP-in position. Do not move
the Aerial Device until the problem has been diagnosed and resolved with your safety in mind. No matter
how long it may take to get help, waiting is better than a serious or fatal accident.
22. Do not adjust outriggers while platform or booms are raised.
23. Do not operate controls while standing on the ground or other structures.
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ELECTRICAL HAZARDS
ELECTRICITY OBEYS NO LAW, BUT ITS OWN.

1. Electricity is an ever-present danger when using an Aerial Device. Follow all OSHA, ANSI, state, federal
and company rules and regulations when working on or near energized power lines.
2. Always maintain proper clearance from energized power lines. This Aerial Device cannot protect you
from phase-to-phase or phase-to-ground contact, which occurs above the insulating boom section.
• Allow for platform sag, sway or rocking.
• If any part of boom-tip, everything beyond band of arrows on boom, contacts an energized conductor,
the entire boom-tip, including the control handle(s), must be considered energized.
• If any part of the boom-tip, everything beyond band of arrows on boom, contacts a grounded object,
the entire boom-tip, including the control handle(s), must be considered grounded.
3. The booms and boom operators shall be properly insulated from any contact with electrical conductors;
including neutral or ground lines, poles, cross arms and guy wires. Utilize proper insulation such as line
covers, rubber blankets and hot line tools.
4. The covers and guards on the boom tip components may provide limited electrical protection. DO NOT
contact energized conductors and DO NOT operate without covers. Even if covers are plastic or
fiberglass, they are not tested or maintained for dielectric protection. Always cover conductors with line
hose and maintain distance from conductive items.
5. Never place booms, platforms, or personnel between energized conductors or between an energized
conductor and a grounded conductor without proper cover up.
6. Do not wear clothing that when exposed to flames or electric arcs could increase the extent of injury
from such exposure.
7. Never operate the Aerial Device in an electrical environment if the fiberglass boom components are
damaged, contaminated by moisture or dirt, or otherwise maintained improperly. A daily inspection and
an annual dielectric testing of all fiberglass boom components are necessary to maintain the integrity of
the insulation.
8. Never allow ground personnel to come in contact with the Aerial Device, vehicle, or vehicle attachments
while in operation near energized power lines.
9. When working on or near energized power lines or equipment, the vehicle must be grounded and/or
barricaded and considered as energized.
10. Never rely on the fiberglass platform insulation when in the platform. It may contain small unseen cracks
that will allow an electrical path into the platform. Always use a platform liner.
11. Never touch the controls or boom tip area when in the platform without using proper protection (wear
rubber gloves) while holding any conductors, neutrals, grounds, or other structures.
12. Ground and neutral conductors are current carrying conductors and must be treated as energized (wear
rubber gloves).
13. Wear rubber gloves when handling duplex and triplex wires.
14. All tools, accessories and other objects must be contained within the platform when working on or near
energized power lines.
15. Check the boom tip area for any exposed conductive material and do not allow boom tip to come in
contact with an energized phase or ground.
16. Do not carry or allow a conductor to touch your body. Handle conductors only with rubber gloves even if
grounded.
17. All metal components at the boom tip beyond the band of arrows are interconnected. Contact of any part
to an energized conductor will energize the entire boom tip, including the controls.
18. Do not attach any metal objects from outside the platform to the inside of the platform. This defeats the
purpose of the platform liner.
19. Do not hang metal objects from the platform. It increases the chances of accidental contact.
20-6
SAFETY
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20. Use only non-metallic tool holders and tool trays.

21. Never use leather work gloves or bare hands on grounded conductors when energized conductors are
on the same structure. Wear insulating rubber gloves with leather protectors.
22. Extend upper boom to MINIMUM EXTENSION label on side of boom before using near energized lines
for rated boom insulation.
23. Do not lift conductors with the boom tip or platform. Use lifting device with appropriate attachments.
24. Do not bring any conductive object from outside the platform to the inside of the platform. This includes
extension cords, guy wires, or conductors. They will eliminate all insulation the machine offers the
operator.
25. Do not operate controls while standing on the ground or other structure with booms elevated from stored
position. Operating the machine while standing on the ground or other structure could result in
electrocution.
ACCESSORIES
1. When working from the platform, only use hydraulic tools equipped with orange hoses marked NON-
CONDUCTIVE. The hoses must be kept clean and dry and must be inspected periodically.
2. All accessories must be inspected, maintained and operated with the same care and safety rules that
apply to the Aerial Device.
3. Do not use hoses having less than 2500 PSI (17.24 MPa) working pressure ratings.
4. Tools selected for use with this Aerial Device should be open-center type and operate satisfactorily at
2250 PSI (15.51 MPa) and 5 GPM (18.93 LPM) at idle.
5. If this Aerial Device is equipped with a boom lifting eye, the boom position and lifting capacity must not
be exceeded.
6. Personnel or load shall not be allowed in the platform when utilizing the boom lifting eye.
7. If this Aerial Device is equipped with platform tilt, an inspection must be made before entering the
platform, to insure all locks and pins are properly in place.
8. Do not place booms or platform under trees or limbs while trimming to avoid possible damage or
overloading.
9. Do not operate hydraulic hand tools on high speed for an extended period of time without stopping.
Continuous operation can cause overheating and possible damage to the hydraulic system.
10. Do not use lower hydraulic tools when platform or booms are near energized lines.
20-7
SAFETY
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MATERIAL HANDLING
1. Use only a synthetic rope for the winch line. Do not use a wire rope.
2. Do not permit personnel to be under loads being lifted.
3. Do not use winch or load line to raise personnel off the ground.
4. Do not allow rope to contact energized power lines. Do not rely on the rope being non-conductive.
5. Keep the winch rope clean and dry.
6. Inspect the winch rope daily. Do not operate with a damaged or frayed rope.
7. Use a sling. Do not use the winch rope as a sling.
8. Use only hooks with a safety latch.
9. Do not overload. The load chart supplied with each Aerial Device gives the machine capacity.
10. Know the weight of the load you are lifting. Do not guess.
11. The jib and winch are designed for vertical loads only. Center the load line directly above the load before
lifting.
12. Do not use the jib and winch to pull or string line.
13. Do not pull poles or objects embedded in the ground. It is impossible to know the force applied and will
overload the unit.
14. Lifting the load will cause deflection in the Aerial Device. Allow adequate clearance when applying and
removing the load.
15. When using the jib as a line lifter, remove the rope from the sheave.
16. Use only approved and tested hot line tools for lifting energized conductors. Clean and inspect all
fiberglass on the conductor lifter before use. Dirty or damaged fiberglass may be conductive.
17. If this Aerial Device is equipped with a boom lifting eye, the boom position and lifting capacity must not
be exceeded.
18. Personnel or load shall not be allowed in the platform when utilizing the boom lifting eye.
TRAVELING
1. Never travel with personnel in the platform.

2. Never travel with the booms raised.
3. Store booms properly in the boom rest. Lower the lower boom fully before lowering upper boom into the
rest.
4. Lock boom(s) in place with hold down system.
5. Keep all tools or other items properly stored on the vehicle while traveling. Otherwise, they may fall onto
the roadway.
6. Fully retract the outriggers, store outrigger pads, and wheel chocks.
7. Disengage the power take-off to prevent damage.
8. Ensure platform liner is retained during travel with platform cover or clips to prevent loss.
9. Follow the vehicle manufacturer's instructions for operating the vehicle.
Drive Carefully!
20-8
SAFETY
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MAINTENANCE
1. Inspect, maintain, and repair this Aerial Device in accordance with the maintenance manual for this
device and the maintenance section of this manual.
2. Only authorized and qualified personnel with complete knowledge of this Aerial Device shall be allowed
to perform maintenance on this Aerial Device.
3. Never drill holes in the platform.
4. Replace all illegible decals.
5. Do not alter the insulated portion of this Aerial Device. Altering this Aerial Device in any way could
reduce its insulating value.
6. Do not search for hydraulic leaks with your hands or any other part of your body.
7. All hoses must meet or exceed the working pressure as stated in the maintenance manual.
8. Only use orange hoses marked NON-CONDUCTIVE for tool hoses, at the boom tip, and areas that
bridge the insulation gap.
9. Do not use replacement components that are not equal to the original components.
10. Before doing any work on the hydraulic system, secure the booms and outriggers. Release any
hydraulic pressure before attempting repairs or disassembly of hoses, valves, cylinders or any other
hydraulic components.
11. Fuel or oil spills may require notification of appropriate Federal, State, or Local officials.
12. Do not operate the Aerial Device after adjustments or repairs until all guards and covers have been
reinstalled, trapped air removed from the hydraulic system, safety devices reactivated, and maintenance
equipment removed.
13. The subframe, outriggers, and mounting to the vehicle must be inspected following the frequent and
periodic inspection intervals for fastener tighteners, damaged components and weld inspections.
14. Inspect, maintain, and operate the vehicle and components following the manufacturer’s guidelines.
OVERVIEW OF POTENTIAL HAZARDS AND SYMBOLS

The Aerial Device is a heavy moving machine capable of extending its reach vertically and horizontally.
There are potential hazards associated with the use of this Aerial Device. These hazards will be minimized if
the machine is properly inspected, maintained and operated. The operators shall read and understand this
manual and be trained to use the machine in an appropriate and safe manner. Should any questions arise
concerning the maintenance or operation of the machine contact Terex South Dakota, Inc.
SYMBOL HAZARD DESCRIPTION
Alert Symbol DANGER: Failure to follow will Your safety is involved.
cause serious injury.
Operators DANGER: Failure to follow will Read and follow operator’s manual for safe operation.
Manual cause serious injury.
20-9
SAFETY
TL SERIES
Maintenance DANGER: Failure to follow will Follow all inspection and maintenance to prevent failure.
Manual cause serious injury.
Electrical DANGER: Will cause Serious Maintain minimum clearance from overhead high
Contact Injury Maintain minimum voltage power lines. Refer to "Minimum Clearance for
clearance from or Death. High Voltage Lines" chart in Appendix A. Maintain
minimum approach distance as appropriate for your
qualifications.
Do not dig near underground power lines.
Use machine only within its electrical rating. Consult the
ID Placard for dielectric rating.
Unit Overturn WARNING: Can Cause Serious Do not travel on steep inclines or crosswise to grades.
Injury or Death. Do not travel on soft or unstable ground or close to
unsupported excavations.
All tires must remain on the ground.
Set outriggers (if equipped) so indicator remains in
green area.
Crushing WARNING: Will Cause Serious Do not operate outriggers unless you can verify all
Crushing Injury. personnel and obstructions are clear. Operator must
watch the outrigger while in motion.
High Pressure WARNING: Can Cause Serious Relieve pressure on hydraulic and pneumatic systems
Air or Fluid Injury or Death. before loosening hoses or connections. Do not check for
leaks with your hand.
Lanyard Attach. WARNING: Failure to Attach Attach lanyard to the anchor provided.
Can Cause Serious Injury or
X1 Death.
Lanyard Attach. WARNING: Failure to Attach

Can Cause Serious Injury or
X2 Death. Attach lanyard(s) to the anchor provided.
Fall DANGER: Will cause Serious Always wear an OSHA approved fall arrest system with
Injury or Death. lanyard attached to anchor provided.
20-10
SAFETY
TL SERIES
20-11
SAFETY
TL SERIES
20-12
SAFETY RELATED DECALS
TL SERIES
SECTION 90
Safety signs are designed and fitted to the product to warn of possible dangers, and MUST be replaced
immediately if they become unreadable or lost. If the product is repaired and parts have been replaced on
which safety signs were fixed, be sure new safety signs are fitted before the product is put into service. Use
mild soap and water to clean safety signs - DO NOT use solvent based cleaners, as they may damage the
safety sign material.
Operating this equipment without all safety and control decals in place can be hazardous.
1,7,9,11, 5,8,10,20
21,22,26 19 3,4
3 2 3,4
WARNING WARNING
FAILURE TO FOLLOW
PROPER PROCEDURES
Could Result In
DEATH OR SERIOUS INJURY
If YOU sell, install, offer for use, use,
operate or maintain this Aerial Device
You MUST COMPLY with the requirements of:
American National Standards Institute A92.2,
Escaping fluid under pressureNational
can Electric Safety Code, and OSHA 468476A
penetrate skin causing serious
injury.
Relieve pressure before disconnecting
hydraulic lines. Keep away from leaks
and pin holes. Use a piece of
cardboard or paper to search for leaks.
Do not use your hand.
Fluid injected into skin must be
surgically removed within a few hours
by a doctor familiar with this type
injury or gangrene willH23877A
result.
1,6,9,11,17,18
UPPER LOWER UPPER PLATFORM
23,28
ROTATION WINCH CONTROLS
BOOM BOOM BOOM LEVELING
CCW UNFOLD UNFOLD EXTEND UP CCW UPPER
EMERGENCY
STOP
CW FOLD FOLD RETRACT DOWN CW LOWER

20,24,25,26,27
10
15,13,16

12 12
NOTE: *Use decal 419265 and 465703 when Aerial Device is not certified in accordance with
latest ANSI A92.2 revision or booms are not insulated.
ITEM # DECALS QTY PART #
1. EXTEND TO MINIMUM 1 79238
2. MINIMUM EXTENSION 2 79691
3. ARROWS 13’ H21503
4. NOT INSULATED BEYOND ARROWS 8 402236
5. READ CAREFULLY 1 414590
6. FAILURE TO OBEY 1 419262
7. ELECTROCUTION HAZARD 3 419263
8. FALLING FROM PLATFORM 1 419264
9. * ELECTROCUTION HAZARD-NOT INSULATED 2 419265
10. ELECTROCUTION HAZARD 3 419266
11. UNTRAINED OPERATOR 2 419267
12. OUTRIGGER-CRUSHING-DO NOT OPERATE 2 419268
13. OUTRIGGER-CRUSHING-STAND CLEAR 2 419269
14. CONDUCTIVE HOSE 1 419270
15. OVERTURNING HAZARD 1 458696
16. SLOPE INDICATOR 2 486277
17. CONTROLS NOT INSULATED 1 463602
18. * NOT INSULATED 4 465703
19. ANSI WARNING 1 468476
20. MAINTENANCE RECORD 1 489119
21. LANYARD ATTACHMENT, X2 (depending on boom tip option) 1 495440
90-1
TL SERIES
22. LANYARD ATTACHMENT, X1 (depending on boom tip option) 1 495441

23. TRUCK COMPUTER 1 495845
24. FALL HAZARD 1 495892
25. ESCAPING FLUID UNDER PRESSURE 1 H23877
26. PROP 65 OPERATING STATION 2 622232
27. CAUTION DECAL 1 70191
28. PROP 65 DRIVER SIDE WINDOW 1 622233
1. 2.
MINIMUM EXTENSION
79691
3. & 4. 5.
90-2
TL SERIES
6.
7.
90-3
TL SERIES
8.
9.
10.
90-4
TL SERIES
11. 12.
13. 14.
90-5
TL SERIES
15.
16.
17.
18.
NOT INSULATED 465703
90-6
TL SERIES
19. 20.
INSPECTION DATE RECORD

Follow the Frequent and Periodic Inspection Intervals as required in the Operators
and Maintenance Manuals. Maintain a record of all inspections.
Stamp or engrave below when and who performed inspections.
Follow component replacement intervals shown in your Maintenance Manual.
CRITICAL FASTENER DIELECTRIC ANNUAL
INSPECTION TEST INSPECTION
DATE INITIALS DATE INITIALS DATE INITIALS
489119A
21. 22.
X2 X1
495440
495441
23.
CRUSHING HAZARD
Changes to the vehicle computer settings
could affect equipment operation and
could result in crushing or tip over that
could cause Death or Serious Injury.
Do not alter computer settings without

full knowledge of affect of changes
See information supplied with truck manuals

or contact final stage manufacturer for
required settings
495845
90-7
TL SERIES
24. 25.
26. 27.
:$51,1*Cancer and Reproductive Harm -

www.P65Warnings.ca.gov.
622232B
TO PREVENT POSSIBLE INTERFERENCE
AND AVOID DAMAGE:
1. ROTATE BASKET CAREFULLY

TOWARDS BOOM AND CENTER
BASKET BEFORE FOLDING OR
UNFOLDING BOOM.
2. POSITION JIB PARALLEL TO

UPPER BOOM BEFORE STORING
IN BOOM REST.
70191C
90-8
TL SERIES
28.
2SHUDWLQJVHUYLFLQJDQGPDLQWDLQLQJWKLV
equipment, passenger vehicle or off-highway motor vehicle can
expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the state of
California to cause cancer and birth defects or other reproductive
harm. These chemicals can be emitted from or contained in other
various parts and systems, fluids and some component wear by-
products.To minimize exposure, avoid breathing exhaust, do not
idle the engine except as necessary, service your equipment and
vehicle in a well- ventilated area and wear gloves or wash your
hands frequently when servicing your equipment or vehicle and
after operation. For more information go to
www.P65Warnings.ca.gov/passenger-vehicle.
Breathing diesel engine exhaust exposes you to chemicals known

to the state of California to cause cancer and birth defects or other
reproductive harm.
Always start and operate the engine in a well-ventilated area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to
www.P65Warnings.ca.gov/diesel.
622233A
90-9
TL SERIES
90-10
NOMENCLATURE
TL SERIES
SECTION 100
NOMENCLATURE
Upper Controls
Slave Leveling Cylinder (inside boom)
Platform
2nd Section
Boom
Tip
Jib & Winch
Assembly Upper Boom
Upper Boom Cylinder
Master Leveling Cylinder

Knuckle
Lower Boom
Lower Boom Lift Cylinder

Lower Boom Link
Turntable
Lower Controls
Pedestal
Outrigger
Controls
Outrigger
100-1
NOMENCLATURE
TL SERIES
SPECIFICATIONS
The following specifications are for common units. Each installation can be custom to purchasers
requirements. They are reference only.
OAL
UL
O
OAH
FH
CH
H
CA
WB
TL37 - TL50 TL55 - TL60
Measurements TL37 TL41 TL45 TL50 TL55 TL60

TL37P TL37M TL41P TL41M TL45P TL45M TL50P TL50M TL55P TL55M TL60P TL60M
Typical Frame Height (FH) 32 in. 32 in. 40 in. 40 in. 40 in. 40 in.
(81.3 cm) (81.3 cm) (101.6 cm) (101.6 cm) (101.6 cm) (101.6 cm)
Typical Cab Height (CH) 104 in. 104 in. 104 in. 104 in. 104 in. 104 in.
(264 cm) (264 cm) (264 cm) (264 cm) (264 cm) (264 cm)
Offset (O) 72.5 in. 84.5 in. 114.6 in. 114.6 in. 161 in. 200 in.
(184.2 cm) (214.6 cm) (291.1 cm) (291.1 cm) (408.9 cm) (508 cm)
Overall Height (OAH) 10’ 7” 10’ 7” 11’ 3” 11’ 3” 11’ 3” 11’ 3”

(3.2 m) (3.2 m) (3.4 m) (3.4 m) (3.4 m) (3.4 m)
Overall Length (OAL) 23’ 5” 23’ 1” 23’ 8” 23’ 4” 20’ 5” 20’ 9” 25’ 4” 24’ 10” 26’ 5” 25’ 11” 27’ 3” 26’ 9”
(7.1 m) (7.0 m) (7.2 m) (7.1 m) (6.2 m) (6.3 m) (7.7 m) (7.6 m) (8.1 m) (7.6 m) (8.3 m) (8.2 m)
Unit Length (UL) 17’ 9” 19’ 0” 19’ 0” 23’ 10” 25’ 6” 25’ 0” 27’ 3” 26’ 9”
(5.4 m) (5.8 m) (5.8 m) (7.3 m) (8.1 m) (7.6 m) (8.3 m) (8.2 m)
Center of Rotation (H) 62.5 in. 62.5 in. 62.5 in. 82.25 in. 56 in. 37 in.
(158.8 cm) (158.8 cm) (158.8 cm) (208.9 cm) (142.2 cm) (94 cm)
Cab to Axle (CA) 84 in. 84 in. 84 in. 102 in. 120 in. 120 in.
(213.4 cm) (213.4 cm) (213.4 cm) (259.1 cm) (304.8 cm) (304.8 cm)
Wheel Base (WB) 158 in. 158 in. 158 in. 176 in. 187 in. 187 in.
(401.3 cm) (401.3 cm) (401.3 cm) (447.0 cm) (475 cm) (475 cm)
Front Axle (GAWR) 6,500 lb. 6,500 lb. 7,000 lb. 8,000 lb. 10,000 lb. 10,000 lb. 10,000 lb. 12,000 lb. 14,000 lb. 14,000 lb.
(2,948 kg) (2,948 kg) (3,175 kg) (3,629 kg) (4,536 kg) (4,536 kg) (4,536 kg) (5,443 kg) (6,350 kg) (6,350 kg)
Rear Axle (GAWR) 13,500 lb. 13,500 lb. 13,500 lb. 13,000 lb. 15,500 lb. 17,000 lb. 15,500 lb. 17,000 lb. 19,000 lb. 19,000 lb.
Gross Vehicle 17,500 lb. 19,500 lb. 19,500 lb. 21,000 lb. 25,500 lb. 25,500 lb. 25,500 lb. 29,000 lb. 33,000 lb. 33,000 lb.
Weight Rating (GVWR)
Recommended Weight 15,000 lb. 16,250 lb. 20,000 lb. 21,000 lb. 21,500 lb. 23,000 lb.
(7,081 kg) (7,371 kg) (9,072 kg) (9,525.4 kg) (9,752 kg) (10,433 kg)
For Stability
Frame Section Modulus 10.5 in 3 10.5 in 3 15.9 in / 17.2 in
3 15.9 in / 17.2 in
3 3 15.9 in / 17.2 in
3 15.9 in3 / 17.2 in3
3 3
Frame Yield Strength 36,000 psi 36,000 psi 110,000 psi / 50,000 psi 110,000 psi / 50,000 psi 110,000 psi / 50,000 psi 110,000 psi / 50,000 psi
Frame RBM 378,000 in-lbs 378,000 in-lbs 900,000 in-lbs 900,000 in-lbs 900,000 in-lbs 900,000 in-lbs
100-2
NOMENCLATURE
TL SERIES
CAPACITIES & DIMENSIONAL DATA

TL37 TL41 TL45 TL50 TL55 TL60
Bottom of Platform Height (A) 38.0 ft. 42.0 ft. 44.8 ft. 49.5 ft. 55.1 ft. 60.1 ft.
(11.6 m) (12.8 m) (13.6 m) (15.1 m) (16.8 m) (18.3 m)
Working Height (B) 43.0 ft. 47.0 ft. 49.8 ft. 54.5 ft. 60.1 ft. 65.1 ft.
(13.1 m) (14.3 m) (15.2 m) (16.6 m) (18.3 m) (19.8 m)
Horizontal Reach at 87°(C) 28.6 ft. 31.1 ft. 31.1 ft. 36.0 ft.
(8.7 m) (9.5 m) (9.5 m) (11.0 m)
N/A N/A
Horizontal Reach at 82° 28.3 ft. 30.8 ft. 30.4 ft. 35.1 ft.
(8.6 m) (9.4 m) (9.3 m) (10.7 m) N/A N/A
Horizontal Reach at 93° 29.6 ft. 32.2 ft. 32.3 ft. 37.0 ft. 38.3 ft. 40.1 ft.
(9.0 m) (9.8 m) (9.9 m) (11.2 m) (11.7 m) (12.2 m)
Lower Boom Articulation 0 to 87° 0 to 87° 0 to 87° 0 to 87° 0 to 93° 0 to 93°
Upper Boom Travel -40 to 76° -40 to 76° -40 to 76° -40 to 76° -35 to 85° -35 to 85°
Upper Boom Extension 100 in. 116 in. 116 in. 145 in. 140 in. 140 in.
(254 cm) (295 cm) (295 cm) (368.3 cm) (355.6 cm) (355.6 cm)
Platform Capacity 400 lbs. 400 lbs. 400 lbs. 600 lbs. 600 lbs. 600 lbs.
(182.5 kg) (182.5 kg) (182.5 kg) (272.2 kg) (272.2 kg) (272.2 kg)
The above TL37-TL50 data is based on a 40” frame height and 58” pedestal.
100-3
NOMENCLATURE
TL SERIES
OAL
UL
O
OAH
CH
FH
H
CA
WB
Measurements LTM40
BC
Typical Frame Height (FH) 32 in. (81.3 cm)
Typical Cab Height (CH) 78 in. (198.1 cm)
Offset (O) 63 in. (160 cm)
Overall Height (OAH) 10’ 4” (3.1 m)
Overall Length (OAL) 25’ 4” (7.7 m)
Unit Length (UL) 19’ 4” (5.9 m)
Center of Rotation (H) 68 in. (172.7 cm)
Cab to Axle (CA) 84 in. (213.4 cm)
Wheel Base (WB) 165 in. (419.0 cm)
Front Axle (FA) 7,000 lb. (3,175 kg)
Rear Axle (RA) 13,500 lb. (6,124 kg)
Gross Vehicle Weight Rating (GVWR) 19,500 lb. (8,845 kg)
Recommended Weight for Stability (With Torsion Bars) 15,000 lb. (6,803 kg)
Frame Section Modulus 9.75 in3
Frame Yield Strength 36,000 psi
Frame RBM 360,000 in-lbs
100-4
NOMENCLATURE
TL SERIES
CAPACITIES & DIMENSIONAL DATA (Based on a 40 Inch Frame Height)
MODEL Bottom of Platform Working Height Horizontal Reach Boom Travel

Height (A) (B) (C) Lower Boom Upper Boom
LTM40 39.5 ft 44.5 ft 30.7 ft -5° to 90° -20° to 80°

(12.0 m) (13.6 m) (9.4 m)
Effective Date: September, 2011. Product specifications and prices are subject to change without notice or
obligation. The photographs and/or drawings in this document are for illustrative purposes only. Refer to the
appropriate Operator’s Manual for instructions on the proper use of this equipment. Failure to follow the
appropriate Operator’s Manual when using our equipment or to otherwise act irresponsibly may result in
serious injury or death. The only warranty applicable to our equipment is the standard written warranty
applicable to the particular product and sale and Terex makes no other warranty, express or implied.
Products and services listed may be trademarks, service marks or trade-names of Terex Corporation and/or
its subsidiaries in the USA and other countries. All rights are reserved. Terex® is a registered trademark of
Terex Corporation in the USA and many other countries. Copyright 2010 Terex Corporation.
100-5
NOMENCLATURE
TL SERIES
100-6
MAINTENANCE GUIDELINES
TL SERIES
SECTION 101
PREVENTATIVE MAINTENANCE
A preventative maintenance program based on the manufacturer's recommendations shall be established.
Dated and detailed inspection and repair records shall be maintained.
The modification, rework, replacement, or substitution of any part of the Aerial Device
with a means not equal to the original equipment provided by the manufacturer may
cause serious personal injury.
It is recommended that the replacement parts for your Aerial Device be obtained from a Terex South Dakota,
Inc. distributor or Terex South Dakota, Inc.
MAINTENANCE PROCEDURE
Before maintenance, adjustments, and repairs are started the following precautions shall be taken as
applicable:
• You must be authorized by owner to operate unit.
• Place vehicle where it will cause the least interference with other equipment or operations in the area.
• All controls at the off position.
• Starting means rendered inoperative.
• Warning or “OUT OF ORDER” signs placed on the vehicle.
• Power plant stopped or disconnected at power takeoff.
• Relax all hydraulic cylinders used for boom lift and articulation.
• Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic
components.
After adjustments and repairs have been made, the Aerial Device shall not be operated until all guards have
been reinstalled, trapped air removed from hydraulic system, safety devices reactivated, and maintenance
equipment removed.
Warning or “OUT OF ORDER” signs shall be placed and removed by authorized personnel only.
ADJUSTMENTS AND REPAIRS
Any unsafe conditions disclosed by the inspection requirements of this section shall be corrected before
operation of the Aerial Device is resumed. Adjustments and repairs shall be done only by qualified
personnel.
Adjustments shall be maintained to assure correct functioning of components. The following are examples:
• All functional operating mechanisms.
• Safety devices.
• Control systems.
• Power plants.
Repairs or replacements shall be provided promptly as needed for safe operation. The following are
examples:
• All critical parts of functional operating mechanisms which are cracked, broken, corroded, bent or
excessively worn. This is for all parts of the Aerial Device, pedestal, subframe, outrigger, and
attachments to the vehicle.
• All critical parts of the vehicle structure which are cracked, bent, broken or excessively corroded.
• Hooks showing defects disclosed by “Frequent Inspection” requirements in the maintenance manual
shall be discarded. Field repairs by welding or re-shaping shall not be permitted.
101-1
TL SERIES
All replacement parts or repairs shall have at least the original safety factor. Do not alter, modify, remove or
replace any part of the Aerial Device without the approval of the manufacturer.
NOTE: Do not use hoses having less than 2500 PSI (17.24 MPa) working pressure. Only use
orange hoses marked "Non-Conductive" for hydraulic tools, at the boom tip and in areas
that bridge the insulation gap.
LUBRICATION
All moving parts of the Aerial Device and vehicle, for which lubrication is specified, shall be regularly
lubricated. Lubricating systems shall be checked for proper delivery of lubricant. Particular care should be
taken to follow manufacturer’s recommendations as to points and frequency of lubrication, maintenance of
lubricant levels and types of lubricant to be used.
The preferred lubes are listed in the lube chart. The following are acceptable for the Aerial Device:
1. Gun Grease: Lithium, Sodium, or Calcium base with EP additives, with no more than 5% molybdenum
or graphite filled white grease. Do not use fluorocarbon based lubricants or zinc oxide filled white
grease.
2. Gear Grease: If Mobil EP023 is not available, EP85W-140 can be used. More seal leakage may result
because of thinner consistency.
Machinery shall be stationary while lubricants are being applied and protection provided as called for in
“Maintenance Procedure”.
The modification, rework, replacement, or substitution of any part of the Aerial Device
with a means not equal to the original equipment provided by the manufacturer may
cause serious personal injury.
GENERAL INFORMATION
1. Keep inspection records up-to-date.
2. Record and report all discrepancies to your supervisor.
a. Records of frequent inspections do not need to be retained unless a discrepancy is found. In that
case, a record of the discrepancy and the corrective action must be retained for five (5) years.
b. Periodic inspections must be dated, signed and kept for five (5) years.
3. A dirty Aerial Device and vehicle cannot be properly inspected. Keep your Aerial Device and vehicle
clean!
4. Follow vehicle manufacturer’s requirements for inspection, maintenance, and repairs.
5. Only qualified personnel shall do repairs and inspections.
6. Oil spills may require notifying Local, State, or Federal Authorities.
7. A post event inspection or test is required if the unit has been overloaded, shock loaded, overturned, in
an accident, experienced electrical contact or applications of unintended external force.
The following checklists must be used daily, 90 days (360 hours), 180 days (720 hours),
and 12 months (1,050 hours). Failure to do so could endanger the life of the operator.
Always remember, scheduled maintenance can save much more than it costs.
NOTE: The following check points listed are the minimum recommended by Terex South Dakota,
Inc. They are subject to supplementation to conform with your own company regulations.
NOTE: Remember that the safety of all personnel and the operational efficiency of the Aerial
Device are dependent upon thorough inspections and maintenance practices.
NOTE: Dirty or dusty conditions or unusual weather conditions may require more frequent
maintenance.
Changes to the vehicle computer settings could affect equipment operation and could
result in crushing or tip over that could cause death or serious injury.
• Do not alter computer settings without full knowledge of affect of changes.
• See information supplied with truck manuals and contact final stage manufacturer
for required settings.
101-2
TL SERIES
FREQUENT AND PERIODIC INSPECTION INTERVALS

DAILY
1. Check all controls and interlock for proper operation.
2. Inspect fall arrest equipment and attachments.
3. Inspect visual and audible devices.
4. Check cleanliness and dryness of fiberglass components.
5. Visually check for missing, damaged, or loose covers and guards.
6. Check for missing and illegible warning, operational, or instructional markings.
7. Visually check oil level in hydraulic reservoir.
8. Visually inspect for leaks in hydraulic system and hose condition.
9. Visually check all cylinders for leaks.
10. Visually inspect leveling system. (Chains and Insulator Assemblies)
11. Visually inspect all pins, retainers, and fasteners for tightness.
12. Visual inspection of all structural members for cracks and permanent deformation.
13. Check for rotational obstructions.
14. Visual inspection of all visible electrical wires.
15. Operational test of all boom functions and drift.
16. Inspect load line, hook, and slings.
17. Tires for damage and proper inflation.
18. Parking brake for proper operation.
19. Vehicle inspection and load securement.
90 DAYS (360 HOURS)
1. Visually inspect all sprockets, chains, pulleys, and pins.
2. Lubricate all points per lubrication chart recommendations.
3. Apply lubricant to rotation gearbox pinion and turntable bearing.
4. Repair or replace items found to be worn or damaged.
5. Verify interlock and enable operation.
6. Daily inspections.
180 DAYS (720 HOURS)
1. Replace return filter.
2. Inspect exposed hoses.
3. Clean hydraulic tank breather.
4. Check tightness of rotation bearing bolts, turntable to bearing, and bearing to pedestal for proper torque.
5. Daily and 90 days (360 hours) inspections.
12 MONTHS (1,050 HOURS)
1. Inspect and lubricate PTO drive shaft to pump.
2. Take samples of hydraulic oil and test.
3. Check all system pressure adjustments for proper setting.
4. Perform cylinder drift tests.
5. Perform structural and critical weld inspections.
6. Perform dielectric tests.
7. Visually inspect any vacuum prevention system and verify proper operation.
8. Daily, 90 days (360 hours) and 180 days (720 hours) inspections.
101-3
TL SERIES
OPERATIONAL TESTS
Perform all of the tests and checks that follow. Cycle times must be within limits. Repair the problem that is
evident in the component.
SPEED TESTS
Speed tests should be taken with one man in platform and hydraulic fluid at normal operating temperature.
Check that all times are within the limits specified in the Quick Reference Guide.
1. Check that boom(s) operate smoothly over full travel, without squeaking or other noise.
2. Check that all moveable hydraulic and control hoses operate over full range of boom and turntable
movements without stretching, kinking or rubbing on sharp corners.
CONTROL SYSTEM
1. Check that all moveable hydraulic and control hoses operate over full range of boom and turntable
movements without stretching, kinking or rubbing on sharp corners.
2. Check that control handle returns to neutral when released from any position.
3. Check that all movements can be made to start smoothly, without jerking or sudden motion when control
handle is moved slowly.
4. Check that control head trigger energizes and de-energizes system so no movement of the booms
occurs if not actuated.
ELECTRICAL TESTS
Dielectric integrity of the booms must be tested every year or 1,050 hours of operation, whichever occurs
first, or if insulating components are replaced or if the insulation value is in question.
Platform insulation must never be depended upon when operating in an electrical

environment, and platform must be considered as having no insulation value without a
tested and certified liner installed.
Follow electrical test specifications as prescribed by ANSI A92.2 for proper test procedure for the
classification of unit being tested. See Section 370 in the Maintenance Manual for proper dielectric testing.
POST EVENT INSPECTION AND TEST
After any event where the aerial is subject to excessive loading or stress such as; overturning, unintended
external mechanical or electrical forces, shock loading or overload, the aerial device shall be removed from
service and a periodic inspection performed. In addition to the periodic inspection other non-destructive
inspection procedures may be required to detect possible structural damage. All damaged items shall be
replace or repaired before the unit is returned to service. Return to service shall be approved by a qualified
person and the inspection and repair information recorded and retained.
101-4
TL SERIES
LUBRICATION CHART
TLM SERIES
21 8
13
7 7 13
16
7 7
5
15
6 13
7
9
12
7 15
1 6
14
20 5
20 10 11
19
4
2,3
16
TRADEMARKS:
IsoControl 18,19
LUBRICANT SERVICE
ITEM LUBRICATION POINT RECOMMENDED INTERVAL METHOD
1 ROTATION SPEED REDUCER MOBILUX EP 023 FILL IF LOW
2 ROTATION BEARING
3 ROTATION GEAR TEETH ** 90 DAYS
4 PINION GEAR TEETH
LITHIUM-BASE OR GREASE
5 LIFT CYL BEARING
EP #2 GREASE 360 HOURS GUN
6 LEVELING CYLINDER BEARING
7 CYLINDER BEARINGS
8 INNER BOOM WEAR PAD
9 PLATFORM ROTATE BUSHINGS
10 JIB BUSHING
11 LINK ARM BEARING
12 LINK ARM BUSHING
LUBRICATING OIL YEARLY SPRAY
13 BOOM PIVOT PINS
14 BASKET SHAFT FOR MAINTENANCE OR OR
GREASE PINS AT
15 LIFT CYLINDER BUSHINGS REASSEMBLY. A/R GREASE GUN
16 LEVELING CYLINDER BUSHINGS
17 INNER BOOM GLASS CLEAN & WAX YEARLY OR A/R WIPE
18 RETURN LINE FILTER SEE MAINTENANCE MANUAL
PREMIUM ISO 15
19 HYDRAULIC RESERVE TANK * DAILY FILL IF LOW
HYDRAULIC FLUID
20 VALVE LINKAGE LUBRICATING OIL A/R SPRAY
GL-5 EP GEAR- 90 DAYS
21 WINCH GEARBOX FILL IF LOW
LUBE 85W-140 360 HRS
USE THE ABOVE PRODUCTS OR EQUIVALENT: * DRAIN & FILL WHEN CONTAMINATED.
ALWAYS DRAIN AND REFILL WHEN * * LUBRICATE SPARINGLY EVERY 1/8
DISASSEMBLED OR REBUILT. REVOLUTION, FOR TWO REVOLUTIONS
NOTE: ALL MOVING PARTS NOT EQUIPPED WITH GREASE IF UNIT HAS CONTINUOUS ROTATION.
FITTINGS SHOULD BE LUBRICATED WITH A PENETRATING FOR COLD WEATHER APPLICATIONS:
TYPE LUBRICANT AS REQUIRED.
USE AIRCRAFT HYDRAULIC FLUID
DUSTY AND DIRTY CONDITIONS WILL REQUIRE MIL-5606A - SEE MANUAL FOR
MORE FREQUENT LUBRICATION. PROPER FLUID SELECTION.
460072C
101-5
TL SERIES
WINCH ROPE INSPECTION

All stable braid ropes in continuous service should be visually inspected once every working day. A thorough
inspection of all ropes in use should be made at least once a month and a full written, dated and signed
report of rope condition kept on file where readily available. All inspection should be performed by an
authorized person.
All stable braid ropes installed on a machine which has been idle for a period of one week or more due to
shut down or storage should be given a thorough inspection before being placed in service. This inspection
should be performed by an authorized person whose approval should be required for further use of the rope.
A written and dated report of the rope condition should be filed.
Continued use and normal wear on rope gradually diminishes the ultimate breaking strength and lowers the
factor of safety. In determining the proper discard time of stable braid rope, the following guides are
suggested:
1. If as many as one half of the cover strands are cut at a given point, this damaged section should be cut
out and the rope rejoined with a standard end-for-end splice. If within 10 ft. of the eye, put in a new eye
splice. It can then be used normally. If a few damaged strands spaced out along the rope at intervals is
evident, the rope should be periodically examined.
Eye splices at the end of the winch line should be done in strict accordance with the
steps and procedures outlined by the rope manufacturer.
2. If the individual cover strands have been worn down after extended use to within 50 percent of their
original bulk over an extended area of the line, then the line should be discarded (or assigned to a less
critical task). This can best be determined by examination and comparison of the bulk of an individual
strand which is exposed and subject to wear with that same strand where it crosses under other strands
and is protected (and therefore is full size).
It should be kept in mind that the rope can be cut and damaged by sharp edges. Therefore, it should not be
exposed to sharp edges and surfaces such as metal burrs on winch drums, sheaves, etc. When installing
rope on older machines, great care must be exercised to assure that the rope does not come in contact with
hardware that has been scored and chewed by previously used wire rope lines.
Winch rope has its best dielectric properties when it is new and clean. Dirt, grease, other foreign matter and
moisture -humidity- will alter these dielectric properties, thus the rope should be kept clean and dry. The rope
can be cleaned by washing in a mild detergent and warm water, rinsed and air dried. Water can be trapped
between the fibers and should be squeezed out by placing the line under tension and air-dried.
The insulating factors of a fiberglass boom or jib can be affected by dirty, wet or
contaminated rope.
The first layer of wraps around the winch drum should be applied closely and tightly with some tension. This
will prevent subsequent wraps from slipping down between the turns when tension is applied.
Certain chemicals will break down the fibers of the rope. Chemicals to avoid are sulfuric acids, alkalis, or
chlorinated hydrocarbons over 160 degrees F (71 degrees C). Strong cleaning agents or bleaches may also
be harmful.
When replacing rope, make sure the correct rope type is installed. All ropes are not
constructed the same and have different ratings.
101-6
TL SERIES
DAILY ROPE INSPECTION

The synthetic rope must be inspected daily for any deterioration, resulting in appreciable loss of strength,
such as described below.
1. Excessive external roughness.
2. Glossy or glazed areas, which indicates heat damage.
3. Look for flat areas, bumps, or lumps, which indicates core or internal damage.
4. Cut or badly frayed strands.
5. Areas of discoloration, which could be caused by chemical contamination.
6. Stiffness, which would indicate excessive dirt or grit embedded or shock load damage.
7. Open the strands and look for powdered fibers, which means there is internal wear.
8. Inspect eye connection for proper weaving and damage.
If any of the above conditions are found it should be reported to a qualified person to determine if the
synthetic rope should remain in service. Further information can be found in the maintenance manual for
determining the replacement of the synthetic rope.
If there is any doubt or question about the condition of the synthetic rope -replace it!
HOOK INSPECTION
The load line hook and safety latch must be inspected daily. Any hooks showing defects shall be discarded.
Field repairs by welding or re-shaping shall not be permitted.
• Any damaged hook safety latch shall be replaced immediately.
• Any hook or fitting with a crack or distortion shall be removed from service immediately.
• Hook nut (if equipped) should be checked for corrosion or deformation.
• Refer to hook manufacturer for more specific inspection instructions.
Hook latches are to be used only as retention devices to retain loose rigging under slack
conditions. They are not intended to be anti-fouling devices and caution must be
exercised to prevent a latch from supporting any portion of a load. Periodic inspection of
the latch must be made to insure it’s proper operating condition. If damage to the latch
occurs, the latch must be replaced immediately.
101-7
TL SERIES
STORAGE PROCEDURE
When a unit will not be used for a period of time, it should be prepared for storage to reduce the deteriorating
effects of the environment. This includes the following:
• Wash and clean to remove accumulated road grime. It can discolor the paint if left on for long periods
of time.
• Clean and wax the fiberglass components. If storage is in the sun, cover the booms.
• Clean and coat the exposed cylinder rods with grease, preservative spray or heavy preservative oil.
• Clean and grease the exposed valve spools and linkage.
• Lubricate the entire Aerial Device following the lube chart.
• Check the oil for pH level and water content. Acidic oil or water in the oil may settle out during storage
and can rust the interior of the hydraulic system.
• Cover the platform to prevent water from accumulating. A platform full of water can weigh over 900
lbs. (408 kg) and exceed the capacity of the platform.
• Ensure the hydraulic tank filler-breather filter is intact to prevent dirt entering the tank when the
temperature changes.
• Grease all sliding surfaces where there is metal contact to prevent rust.
• Touch up any bare metal and where the paint is chipped or cracked.
• Spray the electric collector commutators with LPS 1 or CRC 5-56 to prevent corrosion of the surface.
• Service the truck as recommended by the manufacturer.
NOTE: The period of time between uses when the unit should be prepared for storage varies with
the location. If the climate is temperate and dry it may be 4 months. If it is in a humid area
next to the ocean with the salt air it may be only 2 weeks.
101-8
GENERAL MAINTENANCE
TL SERIES
SECTION 102
GENERAL MAINTENANCE
ROTATION BEARING MAINTENANCE
6 1
5 4
3 2
1. Unloading Plug 3. Spacers 5. Outer Ring

2. Bearings 4. Inner Ring 6. Seal
During normal inspections the seal (6) should be checked for proper retention to keep dirt and moisture from
entering the bearing. If the bearing seals have come out of place they may be visible through the rotation
bearing bolt access hole's located in the pedestal and turntable.
Bearing lubrication intervals should be done per Lubrication Chart. Lubricate in eight places around its
circumference by repositioning boom rotation after lubrication is performed at each location; repeat for two
rotations. Lubricate sparingly as seals can be pushed out by over lubrication.
Do not lubricate while moving boom.
Refer to the Quick Reference Guide for the bearing bolt torque and lubricant to use. Check the bearing bolt
torque per maintenance schedule.
NOTE: During cold weather, do not apply excessive pressure, during lubrication of the rotation
bearing, or this may result in the damage to the seals.
NOTE: The rotation bearing seals are the only serviceable items.
102-1
GENERAL MAINTENANCE
TL SERIES
ROTATION BEARING BOLT MAINTENANCE

Rotation Gearbox
Mounting Bolts Refer to Quick Ref. Guide
Refer to Quick for turntable to bearing bolts.
Ref. Guide.
Rotation Bearing
Rotation Motor
Mounting Bolts
Refer to Quick Ref. Guide
for Pedestal to bearing bolts.
The fasteners connecting the upper rotating structure to the turntable bearing and the turntable bearing to
the pedestal are very important fasteners that must be inspected and maintained periodically as specified in
the Operators and Maintenance Manuals. If one or more bolts loosen or stretch, the loading is transferred to
the adjacent bolts making them support more than their share of the load. Should the unit be allowed to
operate in this manner the fasteners will eventually fatigue and failure occur.
Improperly torqued or improper bearing bolts can cause death or serious injury.
Failure to properly inspect and maintain fasteners can result in failure of the fasteners
and the booms falling.
To prevent failure of the turntable bearing fasteners they must be inspected at intervals specified in the
Operator’s and Maintenance Manuals for the unit.
This requires:
• Daily visual inspection for loose or missing fasteners.
• Periodically verify the torque of all turntable bearing bolts.
Daily visual inspection is looking for:
• Missing or broken fasteners.
• Loose washers or gaps under fastener heads.
• Indications of looseness such as shiny areas on washer or mounting surfaces.
If any of the above are observed do not continue operation. Notify the appropriate people in your company
and have the machine repaired, it is not safe to use. Check the torque on all bearing fasteners and correct
as required.
The daily and periodic inspection also must include a visual inspection of all pins, retainers and other
fasteners in addition to the turntable bearing fasteners.
102-2
GENERAL MAINTENANCE
TL SERIES
Verify the torque of the turntable bearing fasteners at 180 day intervals, (or by hour of operation), to the
torque shown in the Quick Reference Guide.
• Use a calibrated torque wrench. It can be a clicker or dial type.
• Use extensions, socket, or crowfoot wrenches as required.
• Determine the proper torque from the Quick Reference Guide.
• Check ALL bearing fasteners, turntable to bearing and bearing to pedestal. If items prevent access to
the bolt head with a socket it will require using a crow foot wrench or removing the item that interferes.
When a crow foot wrench is used the torque setting of the wrench must be adjusted to account for the
variation in leverage. See the information supplied with your torque wrench to determine adjustment.
• Apply the torque to the head of the fastener, slowly increase the torque on the fastener until the torque
wrench clicks or shows you have reached the required torque. Do not exceed the torque value in the
Quick Reference Guide. Do not jerk the wrench. If the fastener does not move continue to next
fastener.
• If the fastener is loose it must be removed and replaced. If the fastener is a bolt using a nut, both must
be replaced. We recommend using only Terex South Dakota, Inc. supplied fasteners to ensure the
proper grade and reduce the chance of counterfeit fasteners. There are several finishes used on
fasteners that cause the tension to vary. Replace fasteners only with the same grade and finish.
• The bolting surfaces, holes and threads must be cleaned thoroughly before installing a new fastener.
• Lubricate fastener with appropriate lube shown in the Quick Reference Guide.
• Washers, if used with bearing fasteners, are only hardened flat washers. Do not use lock washers.
Replace the washer if damaged.
• Replace all covers and items moved or removed and verify operation before returning to service.
• Document the service performed as required by ANSI A92.2 and A10.31.
The information above is related to the turntable bearing fasteners. The daily visual inspection, continuous
observation for unusual noise or operation, and following the maintenance Frequent and Periodic Inspection
Intervals apply to all fasteners, pins and pin retainers of all units.
NOTE: Torque values are based on torquing the bolt head in all applications with the proper
washer. Lubricate the washer under the bolt head and the threads with the indicated
lubricant.
NOTE: If the rotation bearing is removed, ensure the mounting surfaces are smooth and clean to
ensure full contact between the bearing and mounting surface. Apply RTV (room
temperature vulcanizing) in bolt holes as indicated in the illustration above.
NOTE: There are three different finishes used on turntable bearing bolts. They are black oxide,
yellow zinc, and bright zinc. The bolts must be the same for one bearing race. There are
slight torque tension differences that would not evenly load the bolts if they are mixed on
one bearing race.
BOOM MAINTENANCE
The inner boom and wear pads require periodic cleaning and lubrication. Wash the boom to clean the
surface. Smooth any rough spots with fine scotchbrite pads. If dirt and grit is embedded in the wear pad,
clean or replace. Wax the boom or apply spray with lubricants containing silicone or teflon.
102-3
GENERAL MAINTENANCE
TL SERIES
ROTATION BEARING DEFLECTION CHECK

1. Position truck in suitable working area, extend outriggers.
2. Place lower boom in a horizontal position with upper boom fully up.
3. Retract boom extension.
4. Attach dial indicator tip at the dimension specified in the Quick Reference Guide.
5. Set the dial indicator at zero. Verify that you have at least .25 movement on the dial indicator both ways
when zeroing.
Approximate
Rotation
CL
Dial
Indicator
Magnetic Base
Measuring The
Axial Movement
6. Raise the lower boom to 90 degrees with the upper boom horizontal, then fully extend the upper boom.
7. Read the dial indicator for total deflection. Record the reading. When the total axial movement exceeds
the recommendation in the quick reference section, it is generally an indication that ball and ball path
wear is occurring. It is recommended the bearing be monitored for further wear. If a significant axial
movement increase occurs in a short time frame it indicates ball path deterioration is occurring. The
bearing should be replaced.
NOTE: The axial movement can be monitored and if no increase in axial movement occurs the
rotation bearing can be left in service.
NOTE: Consult Quick Reference Guide for maximum bearing deflection.
102-4
GENERAL MAINTENANCE
TL SERIES
START AND ENDING POSITIONS
102-5
GENERAL MAINTENANCE
TL SERIES
FASTENERS AND TORQUE VALUES

BOLT TIGHTENING DATA
The Aerial Device utilizes fasteners of different grades, sizes, and types. Each fastener is selected, installed,
and tightened to perform a specific function.
NOTE: Some fasteners used on the Aerial Device require special torque values. Check particular
sections for the values. See Quick Reference Guide or Parts Breakdown for specific
torques.
1. Use the torque charts following for all other threaded fasteners.
2. Torque chart values, when applied, must not distort components being fastened beyond their
usefulness.
3. Sheet metal screws and placard screws are not subject to torque chart values and need not be
monitored for proper tightening. For all other applications, where the fastener performs a structural
function and where holding of the joined members is ESSENTIAL, torque chart values must be applied.
4. SAE Grade 2 fasteners are soft and have no marking on the head. SAE Grade 5 fasteners have three
equally spaced hash marks on the head. SAE Grade 8 fasteners have six equally spaced hash marks on
the head (See illustration on following page).
5. The chart values for lubricated fasteners use oil unless otherwise specified.
At least annually inspect all fasteners for tightness or damage. This includes but not limited to: pins and pin
retainers, wear pad fasteners, all mounting hardware, tie down bolts, and torsion bar fasteners.
NOTE: The turntable bearing fasteners require more frequent inspection.
CRITICAL FASTENERS
Many fasteners on an Aerial Device are critical for operation. If the daily visual inspection finds any suspect
fasteners that may be loose, damaged or missing further inspection will be required. The Rotation bearing
bolts, both turntable to bearing and pedestal to bearing also require a torque check every 6 months. A more
thorough inspection of all fasteners is to be done at the annual inspection.
The daily visual inspection for loose, missing or damaged fasteners shall include:
1. Rotation bearing bolts, both turntable to bearing and pedestal to bearing.
2. Gearbox and winch fasteners
3. Platform rotation fasteners
4. All pivot pins
5. All pin retainers
6. All cylinder attaching fasteners
7. Cover and guard attaching fasteners
8. Subframe to truck mounting bolts and fasteners
9. Outrigger pins and retainers
102-6
T L S e ri es
TL SERIES
ASSEMBLY TORQUE ASSEMBLY TORQUE ASSEMBLY TORQUE

SIZE DRY LUBRICATED DRY LUBRICATED DRY LUBRICATED
1/4 - 20 66 in. lbs. (7 N-m) 49 in. lbs. (6 N-m) 8 ft. lbs. (11 N-m) 75 in. lbs. (8 N-m) 12 ft. lbs. (16 N-m) 9 ft. lbs. (12 N-m)
BOLT TORQUE CHART
1/4 - 28 76 in. lbs. (9 N-m) 56 in. lbs. (6 N-m) 10 ft. lbs. (14N-m) 86 in. lbs. (10 N-m) 14 ft. lbs. (19 N-m) 10 ft. lbs. (14 N-m)
5/16 - 18 11 ft. lbs. (15 N-m) 8 ft. lbs. (11 N-m) 17 ft. lbs. (23 N-m) 13 ft. lbs. (18 N-m) 25 ft. lbs. (34 N-m) 18 ft. lbs. (24 N-m)
Te r e x S o u th Da ko ta , In c.
7/8- 14 155 ft. lbs. (210 N-m) 120 ft. lbs. (163 N-m) 440 ft. lbs. (597 N-m) 320 ft. lbs. (434 N-m) 660 ft. lbs. (895 N-m) 500 ft. lbs. (678 N-m)
1-8 220 ft. lbs. (298 N-m) 160 ft. lbs. (217 N-m) 580 ft. lbs. (786 N-m) 440 ft. lbs. (597 N-m) 900 ft. lbs. (1220 N-m) 680 ft. lbs. (922 N-m)
1 - 12 240 ft. lbs. (325 N-m) 170 ft. lbs. (231 N-m) 640 ft. lbs. (868 N-m) 480 ft. lbs. (651 N-m) 1000 ft. lbs. (1356 N-m) 740 ft. lbs. (1003 N-m)
1 1/8 - 7 300 ft. lbs. (407 N-m) 220 ft. lbs. (298 N-m) 800 ft. lbs. (1085 N-m) 600 ft. lbs. (814 N-m) 1280 ft. lbs. (1736 N-m) 960 ft. lbs. (1302 N-m)
the Quick Reference Guide or the appropriate section for torque values.
NOTE: The above is for reference, some fasteners will require special torque values. Consult
102-7
4 63 20 9 - 8/ 1 8
GENERAL MAINTENANCE
GENERAL MAINTENANCE
TL SERIES
SOCKET HEAD SCREWS TORQUE CHART

Bolt head identification marks as per
grade. SOCKET HEAD SHOULDER
SOCKET HEAD SCREWS
SCREWS
NOTE: Manufacturing marks will TORQUE
TORQUE
vary.
BOLT SIZE
FT. LBS. N-M FT. LBS. N-M
INCHES & MILLIMETERS
1/4..................................................6.35 14 19 9 12.2
5/16................................................7.94 30 40.7 20 27.7
3/8..................................................9.53 50 68 33 44.9
7/16...............................................11.11 80 108.8
1/2................................................12.70 120 163.2 83 112.9
9/16..............................................14.29 170 231.2
5/8................................................15.88 240 326.4 165
3/4................................................19.05 400 544 290 394.4
7/8................................................22.23 630 856.8 465 632.4
1...................................................25.40 960 1305.6
1-1/8................................................25.58
1-1/4.............................................31.93 2120 2883.2
1-3/8.............................................34.93
1-/12.............................................38.10 3000 4080
GRESEN VALVE TORQUE CHART

MODEL TIE RODS RELIEF & PLUGS CLEVIS & BONNET
V10 Torque 144–160 in. lbs. (16-18 N-m) Torque 18–22 ft. lbs. (24-30 N-m) Finger tight w/loctite
V20 Torque 32 ft. lbs. + / - 1 (43 N-m +/-1) Torque 18–22 ft. lbs. (24-30 N-m) Finger tight w/loctite
V40 Torque 24–26 ft. lbs. (33-35 N-m) Torque 18–22 ft. lbs. (24-30 N-m) Finger tight w/loctite
102-8
GENERAL MAINTENANCE
TL SERIES
JIC SWIVEL NUT (37 DEGREE SEAT) TORQUE CHART

THREAD SIZE SIZE OD TUBE TORQUE FT. LBS. (N-M)
7/16 - 20 4 1/4 9 (12)
1/2 - 20 5 5/16 17 (23)
9/16 -18 6 3/8 20 (27)
3/4 - 16 8 1/2 30 (41)
7/8 - 14 10 5/8 40 (54)
1 1/16 - 12 12 3/4 85 (115)
1 3/16 - 12 14 7/8 100 (136)
1 5/16 - 12 16 1 110 (149)
1 5/8 -12 20 1-1/4 150 (203)
1 7/8 - 12 24 1-1/2 170 (231)
2 1/2 - 12 32 2 300 (407)
40 2-1/2 400 (542)
48 3 500 (678)
The torque required to seal swivel female fittings or hose couplings to a male connector depends on many
variables such as fluid medium, surface finish, etc.
The above values are intended only as a guide for the maximum values the fittings may be subjected to.
These values are the recommended torque values for JIC (37 degree Seat) Swivel nuts either swaged or
brazed type. The swivel nuts will normally withstand this torque for a minimum of 15 repeated assemblies.
SAE O-RING BOSS FITTING TORQUE CHART
O-RING
SAE # TUBE SIZE ARP # T.T. P/N TORQUE IN-LBS (N-M)
4 1/4 in. 904 55638 107 (12) +/- 10 (1)
5 5/16 in. 905 79994 145 (16)+/- 20 (2)
6 3/8 in. 906 55639 225 (25)+/- 25 (3)
8 1/2 in. 908 15690 420 (47)+/- 50 (6)
10 5/8 in. 910 438594 660 (75)+/- 50 (6)
12 3/4 in. 912 55641 900 (102)+/- 50 (6)
16 1 in. 916 18586 1200 (136)+/- 80 (9)
20 1-1/4 in. 920 415240 1600 (181)+/- 80 (9)
24 1-1/2 in. 924 438595 2000 (226)+/- 80 (9)
32 2 in. 932 421348 2800 (316)+/- 120 (14)
102-9
GENERAL MAINTENANCE
TL SERIES
CYLINDER PISTON LOCKNUT TORQUE CHART

Holding Valve Cartridge
Base Rod
End End
NOTE: See Quick Reference Guide or parts section for torques.

WELD SEAM
For design reasons some welds are intermittent or not welded at all seams. These areas are caulked and
also need to be inspected to insure a seal to keep water out and prevent rust.
STEEL/FIBERGLASS JOINT CAULKING
The joint at the fiberglass and steel sections of the upper boom and the lower boom insert must be sealed
with a bead of urethane or silicone caulk to prevent moisture entering the joint. Clean the area and apply a
bead all around. Smooth so it bonds to both the steel and the fiberglass.
Fiberglass
Insert
Steel
Boom
Silicone or
Urethane
Caulk
102-10
GENERAL MAINTENANCE
TL SERIES
CRITICAL WELDS
Verify the structural integrity of the aerial device. Structural components of the aerial lift, which support the
platform are termed critical. These items should be visually inspected for signs of deformation, cracks,
electrical contact marks, fatigue or impending failure. Any suspected item should be further inspected using
an acceptable non-destructive test procedure such as magnetic particle or dye penetrant. Repair or replace
defective items found.
The following diagrams are specific areas that must be inspected in addition any welds, at all boss locations,
weldment assemblies which pivot, and side plated attached to boom tubes, turntable weldments, cylinder
attachments, elbow weldments, cylinder case and rod weldments must be inspected. Also inspect the
pedestal to subframe, subframe to outrigger weldments, and outrigger components and outrigger pads.
If during operation excessive motion is detected or during the annual inspection remove covers as
necessary to examine the supporting structures thoroughly.
Keep unit clean to properly inspect structural components. Components cannot be inspected properly when
covered in grease and dirt.
102-11
GENERAL MAINTENANCE
TL SERIES
Contact the manufacturer before any weld repair for the proper procedure. The welder
must know the material involved and joint preparation required before proceeding to
perform an adequate repair.
102-12
GENERAL MAINTENANCE
TL SERIES
SYMBOLS
Line, pressure or tank Spring
Line, sense (Pilot Control)
Component encloser Rotary method of operation
Hydraulic flow of direction Push button method of operation

Pneumatic flow of direction
Line crossing Pedal or treddle method of
operation
Line crossing Mechanical method of operation
Lines crossing 2 position detent
Line with fixed restriction 3 position detent
Adjustable flow control, Solenoid, single winding method

non-compensated of operation
Adjustable flow control pressure Pilot pressure
compensated with reverse flow
check
Station testing, measurement, Vented reservoir

power take-off or plugged port
Single acting cylinder Pressurized reservoir
Double acting cylinder Line to reservoir above fluid level
Uni-directional hydraulic motor Line to reservoir below fluid level

(fixed displacement)
Hydraulic motor (bi-directional) Atmospheric check valve

Electric motor
M
Uni-directional hydraulic pump

Uni-directional hydraulic pump

(variable displacement)
102-13
GENERAL MAINTENANCE
TL SERIES
Check valve Shuttle valve
Counterbalance valve Filter with adjustable bypass
Filter strainer
Pressure relief valve Heater
Cooler
Pressure reducing valve Variable flow pressure

compensated flow control
2 position, 2 way valve Direction of shaft rotation
2 position, 3 way valve Pressure switch
2 position, 4 way valve Pressure gauge
3 position, 4 way valve Temperature gauge
2 position, in transition 4 way Quick disconnect

valve
Valves capable of infinite Manual shut-off valve

positioning
102-14
ROTATION MAINTENANCE
TL SERIES
SECTION 130
BOOM ROTATION SYSTEM
The turntable rotation assembly consists of turntable, turntable bearing, gearbox, hydraulic motor and the
collector block assembly. The hydraulic components are described in various sections of this manual.
TURNTABLE GEARBOX
The gearbox has a worm gear set which rotates on tapered roller bearings. Gears and bearing are given
lubricant by the grease in the gearbox. The gearbox drives a pinion, which in turn drives the ring gear.
TURNTABLE BEARING
Using the “Shear Ball” principal, the turntable bearing consists of inner and outer steel raceways, with a
continuous row of steel balls and spacers in machined races between the two sections. The bearing race is
sealed against dirt and weather and is provided with a lubrication fitting.
COLLECTOR BLOCK ASSEMBLY
The multiple port collector block assembly permits unrestricted continuous rotation of the turntable.
CHECKING OIL LEVEL
Maintain oil level to dissipate heat, too much or too little oil in the gearbox may cause trouble. Fill to the oil
level plug. Check oil level every 360 hours operation or 90 days.
OIL CHANGE INFORMATION
1. Oil should be drained after the first 2 months of operation.
2. Fill with clean kerosene and run for 1–5 minutes in each direction, Drain kerosene and add oil to full
level. Oil should be changed every 1,050 hours or 12 months. Adherence to a regular schedule of oil
change will help to assure proper gearbox operation.
3. See Quick Reference Guide for gear lube.
DISTORTED WORM GEAR
The worm gear requires no service or adjustment unless extreme overloads have been applied which might
have distorted the worm gear teeth.
If the tooth has been severely worn, they will appear to be leaning in one direction. Dismantle the worm gear
assembly, thoroughly clean the housing, inspect the worm for damage and replace all damaged parts.
INSPECT BREATHER PLUG
The rotation speed reducer is equipped with a breather plug which is located on top of the gear housing. The
purpose of the plug is to release the gases which form from oil heating when the gearbox is in operation. If
the plug is clogged, pressure will build up within the housing and cause excessive heating and oil leakage.
Ensure unit is in stored position or the boom assembly is supported so the boom
assembly will not rotate when the rotation speed reducer is removed. Failure to do so
could result in possible damage to equipment and/or personnel.
130-1
TL SERIES
WORM SHAFT END PLAY MEASUREMENT

Worm shaft end play should be checked whenever the speed reducer has been disassembled for any
reason or if excessive rotation of the pinion shaft is experienced while the gearbox is at rest.
1. Remove the hydraulic motor.
2. Attach a dial indicator to the gear housing, placing the probe squarely against the end of the worm shaft.
3. Firmly rotate the pinion shaft in one direction and hold constant tension. Zero the dial indicator and
rotate the pinion shaft in the other direction, again holding constant tension. Read the shaft end play on
the dial indicator. Proper end play is 0.000–0.002 inches (0.00-0.05 mm).
To check worm shaft end play with the gearbox installed, place dial indicator on motor end of worm shaft and
rotate the opposite end of the worm shaft with a socket until it stops. Zero the dial indicator while maintaining
tension on the worm shaft. Rotate the worm shaft in the opposite direction until it again stops and read shaft
end play on the dial indicator.
MEASURING TOOTH CLEARANCE

1. Remove the pinion guard.
2. Rotate the turntable so the position of the boom is located in the work area most often used. This is
generally the rear of the vehicle or the curb side of vehicle.
3. Using a strip of solid solder approximately 12 inches (304.8 mm) in length, insert the solder as indicated
in the illustration below. Do not use acid or rosin core solder.
4. Place the strip of solder between the pinion gear and rotation bearing ring gear.
5. Very carefully, rotate the boom allowing the solder to feed into the gear teeth until the compressed solder
exits from opposite side.
6. Measure the solder thickness as indicated at points A and B in the illustration below. Add these two
dimensions. The total value (A + B) should not be exceeded. See Quick Reference Guide for turntable
gear backlash measurement.
7. Repeat steps 2–6 with booms rotated in non-working area. Compare measurements from working and
non-working areas.
8. When tolerance exceeds .015 of an inch (.38 mm), it will generally indicate a need for adjustment or
possible ring and or pinion gear replacement.
A B Solder strip compressed as it exits from ring
and pinon gear
Pinion Gear
Solder strip about to

enter ring and pinon gear
Ring Gear
130-2
TL SERIES
ROTATION SPEED REDUCER PINION ADJUSTMENT (OPTIONAL)

The speed reducer pinion operates against the rotation bearing ring gear to rotate the boom. It is necessary
for the pinion gear to have a slight clearance when operation on the ring gear. However, excessive
clearance can cause too much backlash in the boom. The gear backlash must be set on the unit with the
lower boom horizontal and the upper boom fully articulated.
To adjust the rotation speed reducer pinion, proceed as follows.
1. Position the unit as indicated in the above paragraph.
2. Remove any protective covers which may interfere with adjustment.
3. Loosen the four mounting bolts which secure the gearbox to the pedestal.
4. Loosen the set screw which locks the eccentric ring.
5. Rotate the eccentric ring either clockwise or counterclockwise to establish the required backlash.
NOTE: Do not become confused with clearance that exists within the speed reducer (worm and
worm gear clearance).
6. When the required backlash is established, tighten the four rotation speed reducer mounting bolts.
Lubricate washer and threads and torque per Quick Reference Guide.
7. Tighten eccentric ring set screw.
Torque Rotation Gearbox

Mounting Bolts per (1) Torque Rotation
Quick Ref. Guide. Bearing Bolts per
Quick Ref. Guide.
Eccentric Ring
and Set Screw
130-3
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130-4
MAINTENANCE AND REPAIR OF FIBERGLASS BOOMS
TL SERIES
SECTION 135
The following preventative maintenance program is recommended for fiberglass booms.
1. The boom should be inspected for damage at the end of each day of use. Inspect for scratches, surface
cracks and other abrasions which may lead to further deterioration. A log should be maintained of any
damage found.
2. Wipe boom frequently with a lint free cloth. This will keep electrical leakages to a minimum and will
permit ease of visual inspection for damages.
Steam heat should not be used because of the extreme heat that could develop in a
concentrated area, thus affecting the integrity of the fiberglass.
3. Where the damage observed is limited to surface damage (minor damage), clean the boom surface by
washing with Amway Industro-Clean (made by Amway Corp., Ada, Michigan) or Simple Green
(Sunshine Makers, Inc.), rinse clean, dry thoroughly and sand the damaged area to remove foreign
material. Resurface the damaged area with polyester resin. If the unit was originally coated with a high
dielectric acrylic paint or an epoxy paint, thoroughly clean as described above and resurface damaged
area with the same material.
The following are materials proven acceptable for use in repairing fiberglass boom surfaces:
• Spiral Wound Fiberglass with Epoxy Resin Base
• Epoxy resin used in original boom fabrication
• White NPG (NeoPentyl Glycol) gelcoat with wax - available from Glidden, PPG and Cooks paints
• Silicone spray
4. Fiberglass boom surfaces can be effectively maintained against weathering by the use of silicone spray.
Clean the boom surfaces (inside and outside) by washing with Industro-Clean or Simple Green. Rinse
clean and dry thoroughly. Spray the inner and outer surfaces of the boom with a thin coating of silicone
material and rub down the sprayed surface with a lint free cloth to remove excess material. Perform the
silicone spray treatment once every 2–6 months, depending upon the climatic and atmospheric
operating conditions.
NOTE: Whenever the boom is cleaned with a cleaner which will remove the silicone, the boom
should be resurfaced with the silicone spray.
5. Test the fiberglass insulating components on a regular schedule for excessive leakage current in
accordance with ANSI (American National Standard Institute) A92.2. The components should be tested
each day when used in live line bare hand work. If a significant change (increase) in the leakage current
is detected when comparing with the previous test results, or if the leakage current is approaching full
length boom leakage, examine boom surfaces thoroughly for evidence of deterioration. Where surface
damage is observed, proceed with Step 1 and 3 above; where surface weathering is the apparent
cause, proceed with Step 4 above.
6. If it is determined during the routine or special inspection and/or electrical insulation testing operation on
the boom that there is a delamination or fracture in the basic fiberglass structure, or the current leakage
cannot be brought within the specification limits through implementation of Steps 1–4, the boom should
be replaced with a new boom. THE REPAIRABILITY OF THE DEFECTIVE BOOM SHOULD ONLY BE
DETERMINED BY THE FACTORY AND IF REPAIRABLE, SHOULD BE REPAIRED ONLY BY THE
FACTORY.
Proper care and maintenance of your fiberglass components will assure you of an electrically and
structurally safe component throughout the life of your equipment.
135-1
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RESURFACING EPOXY RESIN BASE

Fiberglass booms which have been subjected to a prolonged period of weathering without adequate field
maintenance and preservation might develop a deteriorated surface which is humidity sensitive. When this
condition is reached the fiberglass boom may no longer pass the electrical insulation test, which in
accordance with OSHA 1926.556 and ANSI (American National Standards Institute) A92.2 - latest edition
limits current leakage. Fiberglass booms and tubes manufactured with an epoxy base resin which have
surface deterioration to the extent resulting in electrical insulation failure can be reclaimed in accordance
with the following process and procedure.
1. Clean the boom surfaces thoroughly with a cleaner that is not abrasive and does not leave a residue on
the surface such as; Amway Industro-Clean (Amway Corp., Ada, Michigan), (dilute 4 to 1) or Simple
Green (Sunshine Makers, Inc.), (dilute 2 to 1) or equivalent.
2. Dry the boom out for 24 hours in an environment of less than 25 percent relative humidity (at
recommended temperatures between 100–140 degrees F (38-60 degrees C)).
3. Test the boom for electrical insulation as specified in ANSI (American National Standards Institute)
A92.2. IF THE LEAKAGE CURRENT IS LESS THAN SPECIFIED, THE BOOM MAY BE
REPROCESSED. If the leakage current is more than specified, it should be subjected to a second 24
hour drying out period. IF THE TEST LEAKAGE IS BROUGHT DOWN BELOW SPECIFICATION, THE
BOOM CAN BE REPROCESSED. If the leakage current appears to be coming down significantly (by at
least 25 percent) with each drying out cycle, this process can be continued until the boom leakage
current is below allowable specification as indicated in ANSI (American National Standards Institute)
A92.2 - latest edition, at which point it can be reprocessed. If the leakage current remains out of
specifications after the third drying out cycle and has not shown at least a 25 percent reduction in
leakage with each drying cycle, the boom shall be considered permanently defective and should be
replaced or returned to the factory for final evaluation.
4. Sand thoroughly the outside surfaces of the boom only long enough to remove the outer surface
material (not more than .015 inches (.38 mm)).
NOTE: Do not handle the sanded boom with bare hands since the oils and salts from the skin will
contaminate the boom surface and will prevent adherence of the coating. HANDLE THE
BOOMS IN THIS CONDITION ONLY WITH CLEAN GLOVES.
NOTE: Do not subject sanded booms that have not been resurfaced to humidity conditions
above 40 percent humidity. Booms should be moved as quickly as possible from
unfinished to refinished.
5. Resurface the boom with the white NPG gelcoat activated by the addition of the catalyst. The application
should be made with regular industrial spray equipment where pressure pots are included. This is
important since this is spraying with 100 percent solids. A minimum coat thickness of .010 in (.25 mm).
to a maximum of .020 in (.51 mm). shall be applied. Up to .012 in (.31 mm). of coating can be made in
one application. However, it is acceptable to coat with more than one application of lesser thicknesses if
desired. The material requires 12–24 hours at 77 degrees F (25 degrees C) for complete drying. Don’t
apply gelcoat in high humidity conditions (40 percent or above). Air dry only.
NOTE: Obtain detail application instructions and supply from manufacturer of acceptable resins.
NOTE: Any surfaces of the fiberglass boom which have been broken after coating, such as holes
drilled through glass, etc., shall have the surfaces sealed with original formula resin
material or a material equivalent in surface sealing characteristics.
6. After the boom has thoroughly dried (at least 12 hours) retest the boom for adequate electrical insulation
- as specified in ANSI A92.2. To simulate adverse weather conditions if humidity is under 60 percent,
spray the boom inside and outside surfaces with clear tap water, tip the boom to 45 degrees angle from
horizontal and allow water to drain off for 30 minutes, then test as specified in accordance with ANSI
A92.2. If the humidity is over 60 percent wipe the boom dry, inside and outside. After water spray let
surface condition dry for 15 minutes and then test full length.
7. If the leakage current in Step 6 tests (above) is over, wipe the boom dry and allow it to stand for one hour
in a 40 percent or less humidity condition and retest. If the leakage current has dropped below, it
indicates the surface finish is not of a sufficient gloss and is still humidity sensitive. The method of
applying a new surface coating should be evaluated to determine the cause for the resultant
unsatisfactory finish. When the cause is determined and eliminated the boom can be resurfaced again
with Steps 2–6. Should the boom still fail the surface condition test, return the boom to the factory for
analysis and evaluation.
135-2
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DETERMINING TYPE AND DEGREE OF DAMAGE

Structural damage can be generally classified as resulting from cuts, bruises or overloads. They are caused
and recognized as follows:
• Cuts are usually caused by tools or collision with sharp edges. These are easily seen as holes or
grooves and often with broken and exposed glass fibers.
• Bruises are caused by a blunt force impact; tree branches, poles, etc. They are recognized as
lightened craze marks that are not always obvious. Careful inspection is necessary.
• Loads in excess of the design limit will tend to make the boom buckle near the base end on the side
opposite from the applied force (or load). Cracks, swelling or creasing will be found at or near the steel
attachment and usually on the bottom.
Damage from these sources can be classed as minor, major and critical in terms of their location and extent.
CRITICAL DAMAGE MUST BE CONSIDERED NON-REPAIRABLE AND REFERRED TO THE FACTORY
FOR REPLACEMENT.
The following conditions are considered to be critical damage:
• Any overload damage,
• Through penetration of the wall anywhere,
• Major damage within 24 inches (609.6 mm) of previously repaired major damage and
• Bruises or cuts that fall beyond the limits for major damage.
Damage not already diagnosed as critical may be identified as either a bruise or a cut and classified as
described below.
First, identify the quadrant in which the damage has been done - top, bottom or side. If the damage is on a
line between quadrants, classify it as being in the closer of either quadrant top or bottom.
Second, identify in which of ten equal segments along its length the damage has occurred. Divide the
fiberglass boom in ten equal segments with segment number one at the platform or free end of the boom
and segment number ten at the base or mounting end.
Third, define the size or depth of the damage by:
• Measuring the smallest diameter circle that will contain all of the visible damage from a bruise.
• By estimating the percentage of the wall thickness that has been penetrated. This is determined by
dividing the depth of a cut by the wall thickness and multiplying by 100. (Ergo: 1/8 in. (3.18 mm) deep
cut / 5/8 in. (15.88 mm) thick wall x 100 = 20 percent). The wall thickness should be measured at the
closest end of the fiberglass to the damaged area.
Fourth, classify the damage by using the appropriate charts. These are based on the fact that the top and
bottom quadrants of a boom are more highly stressed than either side and the bending stress in the boom
increases from a minimum at the free end (bucket end) to a maximum at the base.
On either Illustration, draw a vertical line at the segment in which the damage has been located. Depending
on the percentage of penetration or the minimum diameter of the bruise, draw a horizontal line through the
vertical line at that value. If the point of intersection is on or below the appropriate line, the damage can be
classified. If the point falls above the line, it is not minor damage. If the same point is not above the
corresponding line, it may be classified as major damage. Points falling above the proper line are critical
damage.
NOTE: Minor damage can be reduced by using factory recommended guidelines.
NOTE: Major and critical damaged booms must be reported to the factory for analysis.
135-3
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LIMITS OF MINOR BOOM DAMAGE

DEPTH OF CUT OR GOUGE
MINIMUM DIAMETER AROUND BRUISE
3.5 35
(88.9)
Quad 1
SQUARE
AND Quad 4 Quad 2
DIAMETER OF MINIMUM CIRCLE AROUND BRUISE - INCHES (MM)
3.0 30 RECTANGULAR
(76.2)
Quad 3
PERCENT DEPTH OF CUT OF WALL THICKNESS
2.5 25
(63.5)
2.0 20
(50.8) Quads 2 & 4
1.5 15
(38.1)
1.0 10
(25.4)
Quads 1 & 3
.5 5
(12.7)
0 0
0 1 2 3 4 5 6 7 8 9 10
Free End Base End
Basket End
EQUAL SEGMENTS OF BOOM LENGTH
135-4
TL SERIES
LIMITS OF MAJOR BOOM DAMAGE

DEPTH OF CUT OR GOUGE
MINIMUM DIAMETER AROUND BRUISE
7.0 70
(177.8)
Quad 1
SQUARE
DIAMETER OF MINIMUM CIRCLE AROUND BRUISE - INCHES (MM)
6.0 60 AND Quad 4 Quad 2

(152.4) RECTANGULAR
Quad 3
PERCENT DEPTH OF CUT OF WALL THICKNESS
5.0 50
(127.0)
4.0 40
(101.6)
Quads 2 & 4
3.0 30
(76.2)
2.0 20
(50.8)
1.0 10
(25.4)
Quads 1 & 3
0 0
0 1 2 3 4 5 6 7 8 9 10
Free End Base End
Basket End
EQUAL SEGMENTS OF BOOM LENGTH
135-5
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135-6
MAINTENANCE OF BEARINGS AND BUSHINGS
TL SERIES
SECTION 140
BEARINGS AND BUSHINGS
The correct fitting of the various hinge pins and bearings is of extreme importance for continued trouble-free
operation of the Aerial Device. The following data will explain the various hinge pins and bearings.
Proper maintenance is essential if maximum life and performance is to be obtained from bearings.
Regular schedules for inspection and lubrication of bearings should be established and maintained. The
frequency of the inspection and lubrication periods will depend on the type and design of the unit and the
operating conditions. Refer to the lubrication chart in this manual for lubrication frequency and type of
lubricant.
Where the bearings are designed to last as long as the machine or gears, the maintenance is simple as the
bearings are well sealed and lubricated. In these cases the bearings are usually inspected only when the
unit is torn down for repair or replacement of some part or when it is down for general overhaul. It is
recommended that about once a year they be flushed out with kerosene or light oil to clean out any dirt or
foreign material that may have collected. Likewise if the machine is to be shut down for any length of time
the old lubricant should be removed and replaced with fresh oil or grease. This will eliminate the possibility of
moisture or foreign matter, which might have been in the old lubricant, settling out and causing pitting or
corrosion.
SELF-ALIGNING TYPE BEARINGS
The spherical ball bushings are used in two different functions:
A. Where loads are relatively light, the bushing is allowed to turn on a hardened hinge pin. In this case, the
pin made .001–.002 in (.03-.05 mm). smaller than the bushing bore, to allow a free fit on the pin.
B. On more heavily loaded bearings, rotation on the pin tends to wear the pin excessively. To avoid this, the
bushing is locked to the pin to cause relative rotation only between the two sections of the spherical
bushing. Two methods of locking the bushing to the pin are used:
a. Ends of the bushing hub are clamped between two sliding sleeves on each end of the pin. The
spherical bushing and sleeves may be a free sliding fit on the pin - the pin nut is drawn up tightly to
prevent rotation of the pin and inner section of bushing.
b. The bushing is made a press fit on an accurately ground hinge pin to prevent rotation of the hub. The
aim is to obtain an interference fit of .0008 in. (.020 mm) or a little less than .001 inch. However,
because of necessary tolerances in both parts, this fit may vary from about .0003–.0013 in. (.008-.033
mm) interference. With interference at maximum, difficulty may be experienced in assembly, due to
restricted space around the bearing. In this case, the bore of the bushing may be polished out to
reduce interference (difference between O.D. of pin and I.D. of bushing) to .0005 inch (.013 mm). DO
NOT fit the parts to a sliding fit, or light tap fit, as the bushing will rotate on the pin, causing premature
wear.
BALL AND ROLLER BEARINGS
Ball and roller bearings require the most exacting fit of all types. The thin races of these bearings will shrink
or expand along with the interference fits in housing and shaft, causing binding of the balls or rollers, with
resulting rapid failure. Bearings should always be a sliding, or push fit in the housing, if positive retaining
methods such as lock rings are provided.
In applications where the bearing is held in place only by a press fit, an interference fit of about .0005 in
(.0127 mm). is required. DO NOT guess at fit - measure I.D. of housing and O.D. of bearing. When driving or
pressing a bearing into a housing ALWAYS use a machined sleeve as a tool, to prevent damage to the
bearing. NEVER drive a ball bearing over a shaft with a tool on outer race, or into the housing with a tool on
inner race, as Brinelling (pitting) of the races will cause rapid wear.
PLAIN STEEL BUSHINGS
This type, consisting of a soft steel outer surface on a hardened steel pin, is used only on the blind end of
hydraulic cylinders, where the very slow movement keeps wear within acceptable limits. Since binding due
to misalignment will cause seizing of this type bearing, fits are made 1/64 in. (.40 mm), or .015/.020 in. (.38/
.51 mm) loose. DO NOT assemble this type if hinge pin must be forced through the cylinder eye.
140-1
TL SERIES
PLAIN BRONZE AND BABBIT BUSHINGS

These bushings are fitted much closer than steel bushings. However, sufficient clearance must be left for
entry of lubricant from pressure fittings, or rapid wear and seizing will result. DO NOT assemble pins that
must be twisted through the bushing - ream or hone bushing to give diametric clearance of .001–.004
in.(.03-.10 mm), with .002 in. (.05 mm) the ideal clearance. Bronze bushings must be a press fit of .002–.003
in. (.05-.08 mm) interference in the housing. DO NOT center punch or peen a bushing to fit an oversize
housing.
PRELUBRICATED COMPOSITE BEARINGS
This bearing features a new dimension in performance capabilities. In slow speed, oscillatory applications,
or wherever conditions of intermittent operation or boundary lubrication exist. The composition of this
bearing includes three layers: steel, porous bronze, and a modified acetal resin polymer.
During operation, the bearing exhibits extremely low friction and is highly resistant to wear. The composite
bearing is used extensively through out the Aerial Device at various pivot locations. See lubrication chart for
specific location and lubricating instructions.
LUBRICATION
Because of being "prelubricated" this bearing requires only a trace of lubricant to operate satisfactorily and
will, therefore, run for very long periods by drawing only upon the lubricant introduced on initial assembly.
Grease zerks are provided at the bearing locations to provide lubrication if needed to extend the life of the
bearing. When the bearing is lubricated per instructions, it will aid in the prevention of dirt and any other
foreign material from contaminating the bearing.
INSTALLATION
Bearings are usually installed by means of a shouldered arbor plug inserted in an arbor press. A chamfer in
the housing bore is necessary to serve as a lead for the bearing. An un-chamfered edge might shear fiber
from the bearing O.D., seriously reducing the press fit. The O.D. chamfer on the lead end of the bearing acts
as a pilot. Likewise, the I.D. chamfer in the bearings serves as a lead when the shaft is inserted.
Nominal bearing length

Arbor dia = Housing dia minus 1/32 inch (.79 mm)
minus 0.010 – 0.015 inch
(.25-.38 mm) Arbor
Housing
Bearing edges
supplied as cut
15°
1/2 inch
(12.7 mm)
Pilot dia = Nominal bearing bore

dia minus 0.008 – 0.010 inch (.20-.25mm)
Extreme care must be taken when installing pins to ensure they have no burrs or sharp
corners which will catch and gouge the bearing at installation.
140-2
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SELF-LUBRICATING BEARINGS
Your Aerial Device uses a self-lubricating bearing at various pivot locations. This bearing features a
combination fiber surface liner which comprises a controlled filament wound pattern of both PTFE and high
strength fibers.
The unique combination of properties of these bearings-including high load capacity, impact resistance,
dimensional and thermal stability, and corrosion and abrasion resistance-makes them suitable for your
application.
LUBRICATION
These bearings are almost always used dry, however grease can be used to reduce wear and/or to purge
the bearing zone of contaminants. Liquid lubricants and greases attract contaminating particles which may
migrate into the bearing. To minimize bearing contamination, lubricate these bearings sparingly at the time of
installation.
INSTALLATION
the housing bore is necessary to serve as a lead for the bearing. An un-chamfered edge might shear fiber
as a pilot. Likewise, the I.D. chamfer in the bearings serves as a lead when the shaft is inserted.
Nominal bearing length

Arbor dia = Housing dia minus 1/32 inch
minus 0.01 – 0.02 inch (.79 mm)
(.25-.51 mm) Arbor Housing
Bearing edges
supplied as cut
15°
1/16 inch
(1.59 mm)
Pilot dia = Nominal bearing bore

dia minus 0.015 – 0.025 inch (.38-.64 mm)
Extreme care must be taken when installing pins to ensure they have no burrs or sharp
corners which will catch and gouge the bearing at installation.
140-3
TL SERIES
SELF-LUBRICATING BUSHINGS
These bushings provide lifetime lubrication, making them ideal in applications where proper lubrication
maintenance is uncertain, difficult or sometimes impossible. They are vacuum impregnated with oil during
manufacturing to approximately 18 percent (by volume). The oil is supplied to the shaft through thousands of
interconnected, oil impregnated pores. Due to capillary action present in the material, the shaft is always wet
with oil, whether in motion or not.
the housing bore is necessary to serve as a lead for the bearing. An un-chamfered edge might shear metal
as a pilot. Likewise, the I.D. chamfer in the bearings serves as a lead when the shaft is inserted. Out-of-
roundness is corrected when the bearing is pressed into the housing.
The I.D. size is controlled by the method selected. The several methods commonly employed are:
1. No Tool Contacting I.D.
This method allows the I.D. to close-in without restraint. The approximate amount of close-in may be
determined in advance.
2. Combination Insertion and Sizing Plug
The amount of close-in may be controlled by use of a combination insertion and sizing tool. The plug
diameter should be approximately .0003 in. (.0076 mm) greater than the desired final bearing I.D.
Bearing must be such that the plug fits freely in the bearing before installation. When the bearing is
pressed into the housing, its I.D. will close-in on the plug. Oilite bearings generate their own oil film so
there is no difficulty in extracting the plug. Upon its withdrawal, the bearing I.D. will spring back
approximately .0003 inches (.0076 mm) in most cases but the exact amount must be determined by trial.
Springback data are impractical in nature and can only be used as a guide; springback is not calculated.
3. Drill Rod, Steel Ball, etc.
Efficient accurate and economical sizing in small quantities can be accomplished by the use of a piece
of drill rod, shaft, a ball, mandrel or an arbor.
4. Roller-Type Burnisher
Roller-type burnishing tools are desirable for high production work, especially where I.D. tolerances are
to be held within .0005 inch (.013 mm).
140-4
TL SERIES
BEARING REMOVAL
Care should be taken in removing bearings so that the bearings, shafts and housings are not damaged. This
can best be done by using a bearing puller. Standard types of pullers for both bearing cups and cones are
made by a number of manufacturers. Hot oil or steam heat can sometimes be used along with pullers or
wedges to help get bearings off the shafts. When the puller has been put on and pressure applied, steam or
hot oil in the bearing will cause it to expand and if pressure is applied before heat gets to the shaft, the
bearing will come off readily.
Where it is necessary to drive out cups or drive off cones, extreme care should be exercised in preventing
damage to parts, cup, cone seats, shoulders, or in raising burrs which will prevent proper seating of parts
when bearings are reassembled.
CLEANING OF BEARINGS
After bearings are removed they should be thoroughly cleaned, dried and then inspected. If they are in good
condition and are to be used again, they should be dipped in oil or covered with soft grease to prevent
rusting. This is very important as dry bearings will rust very quickly when exposed to the atmosphere. If
bearings are not to be used for some time they should be wrapped in oiled paper and boxed to keep them
dry and clean. Steam or water should never be used to clean bearings, as bearings usually rust in a very
short time when cleaned in this manner.
When only a few bearings are to be cleaned or if bearings are small, they can be cleaned in "Mineral Spirits"
which is a high grade kerosene, or ordinary kerosene may be used. For larger bearings or large quantities of
bearings, "Neutral Oil" is a very good washing compound. It has a viscosity of 100 SUS at 100 degrees F (38
degrees C). This should be heated to 300 degrees F (149 degrees C). Bearings should be cleaned in this
and then washed in hot soluble oil, a 5 percent solution heated to 190–200 degrees F (88-93 degrees C).
Other compounds that can be used as cleaners are known as "Alkali Cleaners". Some of these are:
Trisodium Phosphate, Soda Ash and Metasilicate. These should be used in a solution with two or three
ounces of compound to the gallon. The solution should be hot.
After washing bearings in any of above solutions, the bearings should be dried thoroughly and then dipped
in oil or thoroughly coated with grease or some rust preventatives. Bearings should then be wrapped in oiled
paper and stored in a clean, dry place.
When drying bearings with air, never spin bearings at high speed as this can seriously
damage the bearing.
140-5
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140-6
LEVELING AND LIFT MECHANISM
TL SERIES
SECTION 160
NOTE: Refer to hydraulic schematic in Section 700.
PLATFORM LEVELING
The hydraulic leveling system is a closed, master-slave design isolated from the rest of the hydraulic circuit
by a double holding valve. In normal operation, upper boom movement forces oil out of the master cylinder
into the slave cylinder to automatically level the platform. The master cylinder is located at the lower end of
the upper boom. It goes between the upper boom and the knuckle. The slave cylinder is located at the boom
tip and is between the 2nd section (inner boom) and the boom tip bracket. The slave cylinder will be
equipped with holding valve to lock the cylinder in place in case of hose failure.The platform can also be
hydraulically tilted from the upper control.
Since the hydraulic leveling is a closed loop system, the oil is never heated to tank temperature as is the
remainder of the hydraulic system. A maximum oil viscosity must be maintained regardless of seasonal
temperature changes. The viscosity of the oil should never be lower than the hydraulic system
recommendation and must be consistent with the maximum shown on the hydraulic oil requirements. When
changing oil, the oil must be completely purged from the leveling system by bleeding at both ends of both
cylinders.
Air must not be allowed to enter the leveling system for satisfactory leveling performance. This normally can
be accomplished by completely cycling the slave cylinder from either the upper or lower controls. If cycling
the slave cylinder does not purge the air from the system see “PURGING AIR”.
It is recommended that before using the machine at the start of each day, the platform be tilted through its
full travel several times by the actuating leveling valve. This charges the leveling system with oil.
Do not operate the boom lift cylinder unless platform is in its normal vertical operating
position.
Never disconnect any hydraulic lines from holding valves until boom or booms are fully
supported from falling.
PURGING AIR
The system may become sluggish and lag when air enters the system. Air can enter if the booms are moved
before the platform is returned to level position. In cold weather air may enter the system if the unit is stored
in warm areas then taken out into the cold, or after extended use from air in the oil. In such cases purge the
air from the system before operation by tilting the platform through its full travel.
Operate from the lower controls as follows:
1. No one shall be in the platform while performing this operation.
2. Ensure the platform is rotated to its stowed position, and platform is level.
3. Raise the upper boom fully.
4. Tilt the platform through its full travel by actuating the leveling control both tilt and level direction.
5. Return the platform to the level position.
6. Move upper boom as close to the ground with out hitting any obstructions or the ground.
7. Tilt the platform through its full travel by actuating the leveling control in both the tilt and level direction.
8. Return the platform to the level position.
9. If purging fails to remove all air see “BLEEDING THE HYDRAULIC LEVELING SYSTEM”.
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BLEEDING THE HYDRAULIC LEVELING SYSTEM

Bleeding the leveling cylinder will remove the majority of the air in the leveling system. Air is compressible
and will cause the leveling to lag. Following is a process to remove the air from the hoses between the two
leveling cylinders.
1. Locate boom in suitable position to access platform leveling control and access covers on upper boom.
2. Remove any access covers to the cylinders.
3. Place suitable container to collect purged oil under cylinder farthest from level control.
Use caution when removing cracking hose ends, high pressure oil may be present.
4. Loosen hose fitting at cylinder (rod end).

5. Operate leveling control valve to pressurize that hose. Hold valve in this position and monitor drain fluid
from loosened bleeder fittings. When fluid coming from fitting is free of air, tighten.
6. Loosen other fitting on the same cylinder.
7. Operate leveling control valve to pressurize that hose. Hold vale in this position and monitor drain fluid
from loosened bleeder fittings. When fluid coming form fitting is free of air, tighten.
8. Return platform to level position and cycle boom full up to full down.
9. If leveling performance is not satisfactory repeat the bleeding process. If unit has controls at both upper
and lower controls repeat from other control.
10. If condition persist: remove each cylinder and manually fill with oil and reinstall and repeat bleed
process.
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INTRODUCTION TO THE HYDRAULIC SYSTEM
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SECTION 200
All Aerial Devices are truck-mounted, hydraulically powered, mechanical devices. The truck must have
adequate stability, strength and mobility.
The Aerial Device uses a hydraulic system, which is powered by the truck engine or auxiliary engine, which
drives a hydraulic pump by means of a power take off (PTO) connected to the truck transmission or output
shaft.
The hydraulic system is open center. When a control is actuated, the pump output is directed to the motor or
cylinder dictated by the control, which in turn, increases the pressure as needed to operate the functions. All
control valves are open center, four-way, with spring return to the neutral position.
HYDRAULIC PUMP OPERATION

The hydraulic system may be equipped with a vane type pump, a simple gear pump, or piston pump. When
troubleshooting a hydraulic circuit, it is helpful to remember that a pump does not produce pressure. It only
produces fluid flow; resistance to fluid flow is what produces pressure.
HYDRAULIC RESERVOIR
The oil tank has two important functions, storage and cooling. The first function is to supply the hydraulic
system with clean oil to operate the Aerial Device safely and efficiently as the volume of oil to fill the
cylinders changes. The oil level should be checked daily to maintain an expansion space of about 3 1/2
inches (88.9 mm) from the top. While the pump is operating, oil will surge over the top of the center tank
baffle. This automatically purges the system of any trapped air and vents it out the breather in the tank cover.
The tank may be an external tank separate from the pedestal or may be incorporated in the pedestal. The
normal tank is 35 gallon (132 L) capacity. It may be larger if options like bumper winch are used.
Cooling is the second function of the oil tank. Under severe working conditions the contents of the tank
cycles about once in three minutes. This action generates heat which is continually dissipated through the
tank walls. 150 degrees F (66 degrees C). should be the maximum oil temperature for working hard on a
warm day. It is important to keep the tank and the area around the tank clean to allow air circulation.
Fluid level should be checked with outriggers and booms stored.
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SLUGGISH OIL IN COLD WEATHER

During cold weather, the pump should be operated at idling speed to allow the oil to warm up gradually.
Cold, thick, sluggish oil may not move fast enough and will starve the pump, thus causing severe damage.
The tank baffle diffuses the flow and hastens the warm up. (Otherwise, the warm oil would tend to bypass
most of the cold, stiff oil and simply burrow a narrow passageway of overheated oil through it.)
A small hole in the baffle near the bottom permits some oil to bypass the baffle and equalize the liquid level
on both sides. This assures proper pump priming when starting even if the oil supply is a bit low. Even if the
oil level is lower than it should be, the operating momentum still circulates oil over the baffle. However, it is
recommended to have all oil levels filled to specification.
HYDRAULIC OIL FILTER OPERATION

This Aerial Device is equipped with a return line filter between the tank and the collector block assembly.
This filter provides maximum protection for the hydraulic system by removing harmful particles and other
foreign material.
The unfiltered oil enters the filter inlet side, flows downward, around and through the filter element. As the oil
passes through the element, particles of dirt and other materials as small as 10 microns are trapped. The
clean oil enters the center passage and is returned to the reservoir. Each filter element has an operating
temperature from -65 degrees to 300 degrees F (-54 to 149 degrees C). and an operating pressure of 100
PSI (.69 MPa) maximum.
The return line filter is equipped with a bypass valve to prevent blocking the system flow, should the filter
screen become clogged, or at cold start-up when the oil is too thick to pass through the element.
All new or recently worked on Aerial Devices should be run at idle speed for 30 minutes with a NEW FILTER
CARTRIDGE, to thoroughly filter the oil. It’s a good idea to purge all cylinders and motors at the same time.
Next remove the filter cartridge and throw it away. Replace with a new filter cartridge.
Before changing filter, close shutoff valve (optional) to prevent loss of hydraulic oil. Also,
remove keys from truck so engine cannot accidentally be started, thus damaging
hydraulic system.
The return line filter filters 100 percent of the system oil flow when at operating temperature and not in
bypass mode.
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DIRECTIONAL CONTROL VALVE OPERATION

The accompanying illustrations shows an open center valve with only one spool for simplicity. In the
illustration below, the control lever is in neutral, the center ports are open and no work is done. (The oil flows
freely through the valve from pump to tank.)
CONTROL LEVER IN NEUTRAL

When the control lever is moved inward (as in the illustration below), the oil flows through the only open
passage (to operate the outrigger). By the same lever action, the return outlet is opened to allow the return
flow to go to the hydraulic tank.
OIL FLOWS THROUGH OPEN PASSAGE

CHECKS at the inlet port of both the boom and outrigger valves prevent the load from dropping. (This is
done by checking any back flow from the cylinders.)
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COLLECTOR BLOCK ASSEMBLY OPERATION

The collector block assembly consists of a continuous 360 degrees rotating fluid transfer manifold and
electric collector components. This device makes it possible to operate any or all functions of the Aerial
Devices, even while rotating - without twisting or abrading the hoses or wires.
HYDRAULIC ROTARY MANIFOLD
The inner core is fastened to the turntable with hydraulic lines connecting to the core. The surrounding
ported housing is mounted to the pedestal. O-rings in the top and bottom channels prevent external leakage.
Glass reinforced teflon rings with a backup o-rings are used as seals between channels.
All input and output ports are numbered on the inner block and the outer housing for quick, easy channel
identification.
The drain port is intended to return any seepage past the seals back to tank. It must be connected or
leakage will occur.
INPUT AND OUTPUT PORTS
HYDRAULIC SHUT OFF VALVES (OPTIONAL)

A shut off valve can be provided in the hydraulic system adjacent to the hydraulic tank to allow replacement
or servicing of the filter or pump without draining the reservoir. This valve is hand operated and will totally
block off the hydraulic lines for servicing the filters or pump.
If one or both of these valves are left closed and the system is placed in operation,
serious accident and damage to the hydraulic components will result.
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HOLDING VALVES OPERATION

Cartridge type holding valves are integral components in the cylinder. Holding valves provide two important
safety features. First, holding valves make the smooth operation of the booms possible.
Secondly, if a hydraulic line is accidentally damaged, causing a rupture, the holding valves prevent the
booms from coming down.
The holding valves have an additional feature of being adjustable to match the operating pressure and have
relief valve capabilities which respond to thermal expansion. In operation, oil going to the pilot port opens the
holding valve, allowing oil to flow out of the cylinder to the tank.
Prior to the removal of any holding valve, be certain the component or assembly is
properly supported. Removing the holding valves will cause the load of the cylinder to
free-fall unless supported.
Before holding valves are removed be sure to relieve as much trapped pressure inside
the cylinder as possible. This will prevent damage to the holding valve seals. Always
stow the booms, disengage the PTO so the hydraulic pump is not operating. Moving the
valve function (retract, up, down) back and forth several times to relieve the pressure in
the lines to the cylinder. Pressure may still be trapped in the cylinder.
Locknut
Adjust
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HYDRAULIC CYLINDER OPERATION

The function of a hydraulic cylinder is the opposite of a hydraulic pump. It converts the hydraulic pressure
into mechanical force. A cylinder performs its work in a straight line, is attached directly to the load and is
actuated by the fluid in the hydraulic system.
Standard cylinders consist of an outer case, a piston rod with an eye at one end and a piston on the other
and use seals and packings to maintain proper pressure contact and prevent oil leakage.
Rod Seal Wiper O-ring Back-up

Washer
Head Gland
Back-up
Washer
Rod
Wear Ring
Piston Seal
& O-ring
Case
Wear Ring
Piston
Holding Valve Block (Typical)
Locknut Bushing/Bearing
Cylinder cases used on Terex South Dakota, Inc. Aerial Device’s are made of steel tubing machined to a
smooth finish for long wear of the hydraulic sealing components. Piston rods are of alloy steel with high
tensile strength and a high yield strength. Piston rods are polished and chrome plated. Various types of
seals, o-rings and oil wipers are used in the cylinders.
Among the seals used in cylinders, the most common are: U-cup, Teflon piston rings, o-rings and wear rings.
The pistons and head glands are made of steel, cast iron or aluminum. The piston rod wiper is used only to
keep dirt out of the cylinder. It does not seal oil in the cylinder. The seal inside the cylinder head gland forms
the pressure seal against the sliding piston rod to keep oil in. In most cases, seal rings are used in
conjunction with nylon or phenolic wear rings.
Typical application of seal ring with wear rings is shown below.
O-Ring
Phenolic Seal Phenolic

Wear Ring Wear
Ring Ring
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USE OF OIL SEALS

Throughout any hydraulic system numerous oil seals are used to prevent seepage in control valves,
hydraulic cylinders and fittings.
The most commonly used are o-rings, quad rings, poly pacs and t-seals. These types and how they react to
various pressures are illustrated below. Backup washers are often used to prevent damage to seals as
shown.
Extrusion of O-ring Back-up ring
expands to fill gap
and save the o-ring
Neutral Pressure Excessive Excessive

Pressure Pressure Pressure
with back up
O-RING ring added
Damage caused
by leakage
Back-up ring
Extrusion of Quad ring expands to fill gap
and save the o-ring
Neutral Pressure Excessive Excessive

Pressure Pressure Pressure
with back up
ring added
QUAD RING
No Pressure High Pressure

POLY PACS
Back-up Back-up Extrusion Gap Pressure

Ring Ring
No Pressure High Pressure

T-SEALS
High Pressure
Moderate Pressure
Low Pressure
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200-8
GENERAL HYDRAULIC SYSTEM MAINTENANCE
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SECTION 205
The maintenance and inspection of certain items are the responsibility of a competent operator. Being alert
for evidence of a problem is essential in providing satisfactory service. Items deserving daily attention are
given in the operator’s manual. Included are visual inspection guidelines, lubrication instructions, hydraulic
oil and filter maintenance, and field adjustments. Any failure or malfunction should be reported to authorized
service personnel for corrective action.
Dirt is responsible for more hydraulic system failures than any other single factor. It is vitally important that
every precaution be taken when filling the reservoir tank, when removing or replacing filters or components
and when connecting quick couplers, that no dirt or impurities are allowed to enter the system. Large
particles of dirt are detrimental, but the most costly and severe damage to hydraulic components is caused
by microscopic abrasive particles.
Therefore, it is extremely important that you avoid allowing contaminants to enter your hydraulic system and
even more important that you maintain the schedule of filter element change. Failure to do so will result in
premature failure of pumps and motors and the subsequent loss of cylinders and valves.
Be sure that you don’t introduce water or contaminants into the system when you change or add oil. Filter
new oil to help prevent entry of contaminants into the system. Also, be sure that the system has the
recommended amount of oil for proper operation at all times.
When a hydraulic system is opened, cap or plug all ports to keep out dirt and moisture-laden air. Reservoir
openings should always be sealed immediately following a cleaning.
Examine pipe fittings, hoses and tubing to be certain there are no nicks, burrs, scale or dirt present. Use an
air hose to clean fittings. Hoses and tubes should be capped when stored.
Refer to “TROUBLESHOOTING” in this manual for hydraulic troubleshooting.
Remember that the safety of all personnel and the operational efficiency of the unit are
dependent upon good inspection checks and maintenance practices.
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RETURN LINE FILTER REPLACEMENT

The return line filter element must be changed using the following guidelines.
1. After the first 30 days or 120 hours of operation, whichever occurs first. Change more frequently if
working in dusty or dirty environments.
2. After six months of operation or 720 hours, whichever occurs first.
3. Whenever the filter indicator (if available) indicates replacement.
4. Whenever changing the hydraulic oil.
5. When there is a major hydraulic component failure.
When installing the new filter element, first apply a film of oil to the gasket, then hand tighten the cartridge.
Place the appropriate filter wrench onto the filter and tighten additional 1/4 of a turn. Operate hydraulic
system and check for leaks at filter cartridge.
Before changing filter, close shutoff valve (optional) to prevent loss of hydraulic oil. Also,
remove keys from truck so engine cannot accidentally be started, thus damaging
hydraulic system.
When a Inspection is performed, ensure the bypass valve is functioning properly. See your repair parts
manual for a complete breakdown of the bypass valve.
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TANK, BREATHER, FILLER AND OUTLET SCREENS

CLEANLINESS
Dirt is responsible for more hydraulic system failures than any other single factor. It is vitally important that
every precaution be taken to insure cleanliness. Continuing filtration is required to remove sludge and
products of wear and corrosion throughout the life of the hydraulic system.
When removing or replacing filters, components and quick couplers, take care to see that no dirt or
impurities enter the system.
HYDRAULIC TANK
The oil level in the hydraulic tank should be checked daily to maintain an expansion space. While the pump
is operating, oil will surge over the top of the center tank baffle. This automatically purges the system of any
trapped air and vents it out the breather cap located on the tank.
BREATHER
Clean the breather every 720 hours of operation. Clean more frequently if working in dusty or dirty
environment. Clean with solvent and use low pressure air to blow dry. Cleaning allows system to breathe
without taking in added dirt from a clogged breather.
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HYDRAULIC TANK FILLER SCREEN

The 100 mesh screen under the breather cap should always be used to assure that no large particles will
enter the system.
Clean the filler screen every 1,050 hours or 12 months of service, whichever comes sooner. Remove the
filler screen (located under breather cap) from the tank and wash it out with solvent and use high pressure
air to blow it dry. Replace screen in filler inlet and secure breather cap.
Replace the gaskets on each side when you re-assemble the filler screen, to eliminate the possibility of any
moisture seeping into the tank.
MAGNETIC DRAIN PLUG

The hydraulic tank is equipped with a magnet in the drain plug to attract and hold any metallic particles.
Remove and clean whenever the oil is changed or whenever a failure occurs in the system.
HYDRAULIC TANK OUTLET SUCTION SCREEN FOR PUMP
NOTE: When removing the screen, use a wrench on the hex. Do not turn by the wire mesh.
The one piece 30-mesh screen, located in the hydraulic tank at the outlet, is a further protection against
large particles circulating in the system. Remove tank cover and reach down into the oil and turn the one
piece screen counterclockwise to remove. Clean by washing with solvent and dry using high pressure air.
Replace by reversing above steps.
Turn with wrench

at this end.
205-4
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HYDRAULIC OIL SPECIFICATIONS

HYDRAULIC SYSTEM
Your hydraulic system has been engineered to give many years of useful service. A few simple rules and
maintenance procedures are necessary to insure efficient operation.
Hydraulic oil for your Aerial Device must meet the following requirements listed below.
1. A petroleum based oil (see list).
2. Anti-wear additives to ensure the long life of the hydraulic components.
3. Anti-foam additives to minimize air entrapment.
4. Good chemical stability at anticipated operating temperatures.
5. A flash point above anticipated operating temperatures.
6. Good demulsibility or water separation characteristics.
7. Dielectric strength.
OIL TYPE
Oil used in the hydraulic system performs the dual function of lubrication and transmission of power. Oil
must be selected with care and with the assistance of a reputable supplier.
Terex South Dakota, Inc. does not guarantee the quality or characteristics of any hydraulic oil for usage. A
reputable distributor or supplier should be consulted in any hydraulic oil application. Mixing different oils or
additives must be done only by the supplier. Serious damage to a hydraulic system can result from mixing
incompatible hydraulic oils or additives.
Contaminated fluid may cause damage to the pump and/or control valve. Before adding
fluid to the system, be sure the fluid has been filtered through a 10-micron (absolute) or
less filter.
The following chart is a list of suitable hydraulic oils with their respective properties. This information will be
helpful in the selection of a hydraulic oil or an equivalent oil for a particular application.
AMBIENT TEMPERATURE RANGE RECOMMENDED ISO VISCOSITY GRADE
-20º F To 100º F (-29º C To 38º C) 15
VISCOSITY POUR FLASH

ISO VISCO-
BRAND NAME SUS CST SITY POINT POINT
GRADE
100ºF 210ºF 40ºC 100ºC INDEX Fº Cº Fº Cº
EXXON UNIVIS J-13* 15 75.1 43.5 14.1 5.2 374 -75 -59 200 93
TEXACO RANDO 15 77 40 15.9 4.1 170 -50 -46 300 149
KENDALL GLACIAL 15 90 42 17 4.5 200 -50 -46 300 149
SHELL TELLUS T-22 22 110 43 22.5 5.1 167 -50 -46 320 160
SHELL TELLUS T-23 23 110 43 22.5 5.1 167 -50 -46 320 160
MOBIL DTE 11 M 15 80 43 15 4.1 140 -40 -40 330 166
MOBIL AERO HFA * 15 79 45 14 5.6 199 -75 -59 200 93
AMERICAN SYNTHOL 15 77.4 38.6 15 3.8 151 -51 50 370 188
PGHD 15**
PLANET GREEN
** BIODEGRADABLE HYDRAULIC OIL
* MEETS MIL-H-5606 SPECIFICATIONS
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Hydraulic oil is flammable and will burn.
OPERATING TEMPERATURES
These temperature ranges for each grade of oil are satisfactory if suitable procedures are followed for low
temperature start-up conditions and if sustained operation is avoided at the upper temperature limits.
Operation in excess of these temperatures results in increased wear of the system components and causes
more rapid deterioration of the oil. The recommended maximum operating temperature for the units
hydraulic system is 150 degrees F (66 degrees C).
Quality oils are the most economical. Specifications can be set up which will indicate, to a limited degree, the
characteristics essential in a good hydraulic oil. These are listed herein and should be checked with the oil
manufacturer prior to the use of his product.
VISCOSITY
Viscosity is the measure of fluidity. The oil must have sufficient body to provide adequate sealing effect
between working parts of the pump, valving, cylinders, etc., but not enough to cause pump intake cavitation
or sluggish valve action. Viscosity recommendations must take into consideration the working temperature
range. Refer to table of oil viscosity recommendations.
VISCOSITY INDEX
The viscosity index is a measure of the rate at which temperature changes cause a change in oil viscosity. It
is very desirable that the oil viscosity remain as nearly constant as possible under the wide range of
temperature conditions encountered in operating mobile and construction machinery. The viscosity index
(V.I.) of hydraulic oil should not be less than 140 for this type of service.
ADDITIVES
Research has developed a number of additive agents that materially improve various characteristics of oils
for hydraulic systems. They may be selected for compounding with a view toward reducing wear, increasing
chemical stability, inhibiting corrosion, depressing pour point and improving the anti-foam characteristics.
Proper use of additive agents requires specialized knowledge, and they should be incorporated by the oil
manufacturer only, as serious trouble may result otherwise.
POUR POINT
Ensure the hydraulic oil being used will have a pour point below the minimum anticipated temperature or the
hydraulic oil will not flow to the pump and will cause damage to the pump. If pour point specifications are not
met, an auxiliary heating method will be required.
DIELECTRIC STRENGTH
The dielectric strength of the oil in new condition shall be higher than 25 KV when measured per ASTM
D877 (kv/0.1).
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OIL STORAGE AND HANDLING

GENERAL
Refiners of hydraulic oils take particular care to prevent contamination of any sort from entering the oil up to
the time of delivery. It is just as important to exercise care in preventing contaminants from entering after its
delivery, and during storage and handling.
STORAGE
Care must be taken from the minute oil is delivered to keep it clean. The first step is to select a clean, dry
spot for storage. Store the drums on their sides and cover them to prevent dust accumulation.
To avoid condensation in storage, drums must be protected against sudden temperature changes and
should be kept full. Water collecting on the top of a drum will seep through the plug and into the oil. Water in
oil will reduce reliability and service life.
HANDLING
Before opening a drum, wipe the top carefully so that dirt will not fall into the oil. If, by chance, dirt does get
into the oil, make sure the oil is cleaned before using. Most large particles can be removed by straining
through a 100-mesh screen. Remove the remaining dirt by allowing it to settle in the oil.
Using only the clean oil from the top of the container may waste some oil, but it could prove to be very
worthwhile in keeping the system clean.
If equipment is available, filter or centrifuge the oil. Remember, however, that active earth types of filters
(such as Fullers Earth) remove oil additives. Consult your oil company representative or filter manufacturer if
you’re not sure.
When drawing oil out of storage, make certain it is carried from storage point to use in clean, covered
containers. If the oil drawn out of storage is not used immediately, make sure it is kept tightly covered.
Ensure the suction pipe on pumps used to transfer hydraulic oil from a drum is clean prior to the transfer of
hydraulic oil.
FILLING
Before removing filler cap to add oil to a system, wipe off the fill plug and the filler nozzle with a clean, lint-
free cloth. The safest way to pour oil from a container into a reservoir is to use a 10-micron filter on the filler
nozzle. It is especially important at this point to watch for metallic chips, bits of waste and other contaminants
that may cause damage to the system. The reservoir should be tightly closed after filling the system.
The conditions listed in the previous paragraph all contribute to inducing air into the hydraulic system or what
is commonly known as aeration. Excessive aeration can cause pump damage, resulting in immediate failure
or contribution to later failures. The two causes of damage to components by aeration is lack of lubricity and
overheating. In addition, aeration can cause jerky and uneven movement in pumps or motors which, in
combination with the causes previously mentioned, will cause failure.
CONCLUSION
Dust, water, lint or contaminants of any kind can seriously impair the operation of a system. Following the
simple rules outlined in this section can prevent such material from contaminating oil. A PREVENTATIVE
MAINTENANCE PROGRAM AIMED AT KEEPING OIL CLEAN CAN PAY OFF.
Terex South Dakota, Inc. equipment is designed to prevent dirt from entering the system during operation.
Nevertheless, it is to your advantage to study your own operating conditions and initiate practices to insure
contamination-free system operation.
NOTE: Hydraulic oil spills may require notification of local, state or federal agencies. Be aware of
the requirements in your area.
205-7
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205-8
HYDRAULIC PROCEDURES
TL SERIES
SECTION 210
TURNTABLE ROTATION CIRCUIT
The turntable rotation circuit includes a hydraulic motor, gearbox, collector block assembly, main control
valve, and the necessary hydraulic lines and fittings.
OPERATION
Right Rotation (CW): The hydraulic oil is sent to the top port of the hydraulic motor. Hydraulic oil under
pressure at the motor will permit the clockwise rotation of the turntable. Hydraulic oil from the opposite port
on the motor will return to the control valve section and to the tank.
Left Rotation (CCW): After the control valve is actuated in the opposite direction, the hydraulic oil is sent to
bottom port of the hydraulic motor. Hydraulic oil under pressure at the motor will permit the counter
clockwise rotation of the turntable. Hydraulic oil from the opposite port on the motor will return to the control
valve section and to the tank.
UPPER BOOM CYLINDER CIRCUIT

The hydraulic, upper boom cylinder circuit includes the upper boom cylinder, holding valves, flow control
valve, control valves and the necessary hydraulic lines and fittings.
OPERATION
Upper Boom Up: Hydraulic oil is sent to the base end of the upper boom cylinder form the control valve.
The hydraulic oil passes through the holding valve cartridge at the base end of the cylinder. The incoming
hydraulic oil forces the cylinder rod to extend, raising the boom. Pilot pressure releases the holding valve
cartridge at the rod end of the cylinder allowing the oil to return through the lower control valve and to the
tank.
Lower Boom Down: Hydraulic oil is sent through a flow control valve, to the rod end of the upper boom
cylinder from the control valve through the holding valve. The incoming oil forces the cylinder rod to retract,
lowering the upper boom. Pilot pressure will release the holding valve at the base end of the cylinder
allowing the oil to flow through the lower control valve and to the tank.
LOWER BOOM CYLINDER CIRCUIT

The hydraulic, lower boom cylinder circuit includes the lower boom cylinder, holding valves, control valve,
flow control valves, and the necessary hydraulic lines and fittings.
OPERATION
Lower Boom Up: Hydraulic oil is sent through a flow control valve to the base end of the lower boom
cylinder from the control valve. The hydraulic oil passes through the holding valve cartridge at the base end
of the cylinder. The incoming hydraulic oil forces the cylinder rod to extend, raising the boom. Pilot pressure
releases the holding valve cartridge at the rod end of the cylinder allowing the oil to return through the lower
control valve and to the tank.
Lower Boom Down: Hydraulic oil is sent through a flow control valve to the rod end of the lower boom
cylinder from the control valve through the holding valve.
The incoming oil forces the cylinder rod to retract, lowering the upper boom. Pilot pressure will release the
holding valve at the base end of the cylinder allowing the oil to flow through the lower control valve and to
the tank.
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OUTRIGGER CIRCUIT
The outrigger circuit includes the outrigger cylinders each with an internal check valve, two control valves,
selector (directional) valve and the necessary hydraulic lines and fittings.
OPERATION
Hydraulic oil under system pressure is made available to the inlet of the outrigger control valve. The
outrigger control valve is a open-center-type. To operate outriggers move selector to O/R position. By
actuating the outrigger valve, hydraulic oil will flow to the outrigger cylinder.
Outriggers Down: Hydraulic oil is sent to the base of the cylinder. The hydraulic oil flows freely through the
pilot check valve into the cylinder base in the lowering direction.
Hydraulic oil pilots the check valve open on the rod side of the cylinders and returns to tank through the
outriggers control valve.
Outriggers Up: Hydraulic oil is sent to the rod side of the cylinders. When pressure is sufficient to overcome
the load on the cylinders and open the pilot check valves, hydraulic oil is released from the cylinder base
and the outrigger retracts. Loss of pilot pressure from the rod side of the cylinder closes the check valve and
holds the hydraulic oil in the cylinder base, preventing further retraction of the cylinder.
INTEGRAL SELECTOR
The integral selector is located in the outrigger control valve. It selects between the unit and the outriggers.
The selector section is the first section as standard. If the unit is equipped with lower tool circuit the tool
circuit will be between the valve inlet and the selector section. When the outriggers are selected, no oil flows
to the unit and the outriggers will operate. If the unit is selected, it stops all oil from going to the outrigger
valve sections and sends all the oil to the unit. A relief valve is required in the inlet to the outrigger valve if
the pump is fixed displacement pump (vane).
WATER IN THE OIL

Water in the oil will reduce the lubrication capabilities of the oil. The dielectric properties of the oil will be lost.
The pump and components will corrode and life of the hydraulic system will be reduced.
Water in the oil will make the hydraulic oil conductive and death or serious injury may
result.
TAKING AN OIL SAMPLE FOR INSPECTION

A sample of hydraulic oil should be taken and inspected after every year or 1050 hours of operation,
whichever occurs first, or whenever it is suspected the hydraulic oil is contaminated.
The fluid must be taken at operating temperature and the sample taken while the system is operating or
shortly thereafter while contaminants are still in suspension. In no case should the fluid sample be taken at
the bottom of the reservoir, which could introduce water and heavy contaminants or near the top surface,
which could sample fluid that is not representative of what is passing through the system.
Follow the procedure below.
1. Remove breather vent from reservoir.
2. Using a hand vacuum pump and clean nylon tubing, extract a hydraulic oil sample from the reservoir
approximately half the fluid depth of the pump inlet side.
3. Have a hydraulic oil sample tested for contamination. If the sample shows contamination greater than
ISO 18/15, change the hydraulic oil or perform an off-line filtration.
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CHANGING THE HYDRAULIC OIL

The hydraulic oil must be changed if it is known to be contaminated and cannot be filtered off-line, or when a
major component fails, such as a hydraulic pump.
Before draining the fluid, the system is run until the fluid reaches operating temperature and all actuators are
cycled to put contaminants in suspension. The oil must then be drained before the system cools to prevent
contaminants from settling out of the fluid.
Relieve system pressure, including accumulators and relieve any pressure in the reservoir. Block any
machine members that might fall. Remove the reservoir inlet strainer (filler/breather) access to the fluid. Use
a portable filtration unit to transfer the fluid from the reservoir to a clean oil drum. Place a clean container
under the reservoir and drain the remaining fluid from the bottom of the reservoir.
Remove the clean out plate on the reservoir and wipe out the sludge and foreign material that has settled
out in the bottom of the reservoir with lint-free shop towels. Continuing wiping out the reservoir until it is
clean. Replace the inspection plate and drain plug.
Drain and clean replaceable filter housings and replace filter elements in the system. Fill the system with
clean flushing fluid by pumping it into the reservoir through a filter. Some authorities recommend using the
specified operating fluid as flushing oil. Start the pump. It may have to be primed. Check the outlet pressure
to be sure there is flow and that it is low (less than 1000 PSI (6.90 MPa)). Warm up the system and cycle the
actuators changing directions often. Monitor the condition of all filters and change those elements that
become loaded. If fluid samples are being taken and tested, continue flushing until the samples indicate the
specified ISO level of cleanliness has been achieved.
Shut off the system, relieve system pressure and replace all filter elements. If the specified fluid for the
machine was used to flush the system, it is neither necessary nor desirable to change the fluid. New fluid will
not meet the ISO cleanliness level achieved during the flushing process.
Cycle the clean fluid through the system several times and recheck the fluid level. The system may have to
be vented at high places to remove all the air. Finally, check the system for leakage. Enter the fluid drain,
flush and fluid change in the machine record.
Do not ride the platform while the hydraulic system is being flushed or charged. Serious
personal injury or death could result.
Using the lower/ground controls, operate each hydraulic cylinder circuit for approximately 2 minutes to flush
and charge the hydraulic system. Check the hydraulic oil level several times during this procedure. If low, fill
to FULL mark.
IMPORTANT: Tool lines, when equipped, must be full of hydraulic oil to retain their non-
conductive integrity. Therefore, a jumper hose should be connected to the tool outlets at the
platform and all shut-off valves opened during flushing and charging.
Return the pump to the proper system pressure setting.
Check for hydraulic leaks and correct, if necessary.
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CHECKING FOR HYDRAULIC LEAKS

The hydraulic system must be checked daily for hydraulic leaks.
Check hydraulic system for leaks using a piece of cardboard only. NEVER use your hands.
When checking the hydraulic system for leaks, observe only, NEVER use your hands to
locate a leak. Hydraulic oil from a pin-hole leak can puncture your skin and cause serious
injury requiring immediate medical attention.
If a component or fitting is leaking, repair or replace it as soon as possible.
IMPORTANT: Never operate the unit when leaks are present.
Pipe sealant may be used on pipe fittings. Be careful not to allow pipe sealant into the hydraulic system.
210-4
HYDRAULIC CYLINDER REPAIR
TL SERIES
SECTION 230
All hydraulic cylinders should be periodically tested for internal leakage. Refer to “LEAKAGE TEST” in this
section for testing procedure.
Check cylinders for external leakage daily. If leakage is detected, check cylinder head. If head is tight and
the cylinder still leaks, the seals must be replaced.
Shut down the hydraulic system before removing any cylinder. Remove lines to cylinder and plug or cap
them to prevent loss of fluid. Also plug cylinder ports to prevent loss of fluid. Tag or mark lines to prevent
reversing connection when reassembling.
See the appropriate section in this manual for the removal of cylinders.
Outrigger cylinders should be repaired when they tend to drift down during road travel or up when extended
in working position and the holding valves are not at fault. This downward drift indicates leaking cylinder
seals. Immediate attention should be given to any outrigger cylinder that drifts. Damage could result if an
outrigger should drift down during road travel.
Care should be exercised when removing cylinders, as they are heavy. Cylinders should
be removed by means of a hoist, if available. Do not scratch or mar surface. Use rope
slings or other soft material. Never allow chains or wire rope to contact any parts that they
could damaged. Support structure before removing cylinder.
1. Position the cylinder on a rail (if available) or a work bench and place the open port over a container in
order to catch the hydraulic fluid. Release (pressure) holding valves and extend the piston to the end of
its stroke to purge the hydraulic fluid into the container. This can be done by using the rail (if available) or
by manually pulling out the piston rod. Next, push piston rod approximately one-half way back in.
Do not use air pressure to disassemble hydraulic cylinders. Air is very compressive and
serious injury could result.
When cylinder is disassembled, check cylinder rod bearings/bushings for possible wear
and replace if necessary.
2. Remove gland nut or thread ring and plate on end of cylinder. Remove entire internal assembly from
cylinder case by pulling on the piston rod. Pull out carefully to avoid scratching the inner finish. Inspect
the inside of the case for gouges that would make an overhaul useless.
3. Remove all components from rod. Examine all components for wear, rust or other signs of deterioration.
Clean all components of rust, especially inside the cylinder case. Make sure that all components are free
of dirt or other contamination. After cleaning, coat all components with light grease before installing new
seals, packing, or other parts.
4. Install new seals, packing or other parts as needed. Reassemble the cylinder assembly. Torque hex nut.
Line inside of cylinder case and packings and threads with light grease. Insert the assembly into the
cylinder case, making sure that cylinder wall is not scratched. Also, make sure that no dirt is introduced
into the cylinder case.
5. Cycle cylinder on work bench or on a test stand to purge air from cylinder and test for possible leakage.
6. Reset or replace holding valves.
7. Install cylinder on machine.
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Rod Seal Wiper O-ring Back-up

Washer
Head Gland
Back-up
Washer
Rod
Wear Ring
Piston Seal
& O-ring
Case
Wear Ring
Piston
Holding Valve Block (Typical)
Locknut Bushing/Bearing
The cylinder will be empty of oil and full of air after repair which may make initial
operation dangerous. Thus, the cylinder should be purged of air. After purging, fill the
hydraulic reservoir to the full level, if needed, with all cylinders retracted. Do not ride the
platform while air is being purged. Serious injury or death could result.
DO NOT weld or cut anywhere on the cylinder, as it may weaken it structurally causing a
later failure.
When inspecting the threads in the gland area and rust is found, do not attempt to clean
the threads. The part must be replaced. Cleaning the threads may structurally weaken
them causing a later failure.
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OUTRIGGER CYLINDER LOCK VALVE CARTRIDGE

1. O-ring 7 1 2
2. O-ring
3. Backup Ring
4. Plug
5. O-Ring
6. Poppet (Inside Cartridge) 4
7. Cartridge Body
5 3 6
To remove and inspect valve cartridge, proceed as follows:
1. Remove all load from cylinder.
2. If external leakage exits around the cartridge body (7), replace thread seal, and see if leak stops.
3. Remove valve cartridge with socket and wrench (7/8 in. hex).
4. Inspect o-rings and backup ring (1, 2 and 3). Replace as necessary.
5. To inspect internal components of cartridge, place valve cartridge in a soft jawed vise and remove plug
(9/16 in. hex). Inspect o-ring (5) on plug (4) and replace if necessary.
6. Remove both springs and poppet from inside of cartridge. Inspect the round end of poppet. If end has
groove worn in it, replace valve cartridge.
7. Inspect seat in cartridge body where poppet (6) rests in body. If seat doesn’t have a good square edge,
replace valve cartridge.
NOTE: Do not repair poppet or cartridge body. Replace valve cartridge if repair is required to
these items. Replace o-ring and backup as necessary.
SUN HOLDING VALVE CARTRIDGE

V P 2
Holding
C Valve
Cavity
1
OIL FLOW TO
CYLINDER
NOTE: DO NOT attempt to make any repair to the holding valve cartridge other than replacement
of o-rings and back-up rings. Always replace the complete holding valve with new o-rings
and back-up rings when found to be defective.
1. Place boom on boom rest or otherwise remove weight from cylinder.
a. Place a container near the holding valve that will contain the hydraulic fluid.
b. Relieve the pressure from the cartridge by loosening the locknut (1) and turning the adjustment (2)
clockwise.
2. Remove valve from cylinder.
3. Inspect body to cylinder o-ring and replace if necessary.
4. Inspect seat. If seat is faulty, complete valve should be replaced.
5. Inspect o-rings and replace as required.
6. Assemble valve and replace on cylinder.
7. Reset holding valve cracking pressure per appropriate procedure. Holding valves must be bench "set/
tested" using a "test block".
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HOLDING VALVE SETTINGS

See Quick Reference Guide.
HOLDING VALVE ADJUSTMENT PROCEDURE

RELIEF METHOD
The valve cartridge may be removed from the cylinder and adjusted in a test block using the “RELIEF”
method of adjustment.
Boom must be supported and cylinder pressure relieved prior to removing holding valve
cartridge or boom can fall or inject fluid.
Follow the procedure below to adjust holding valve cartridge.

1. Connect the hydraulic power source along with a good quality pressure test gauge to port number one
(1) of the test block.
NOTE: A hydraulic source capable of producing up to 4000 PSI (27.58 MPa) will be required to
set the relief setting using this method.
2. Install a straight adapter fitting in port number two (2) of the test block. The fitting will aid in observing
more closely the oil flow from port two (2) during the set procedure. Leave port number three (3) open.
3. Gradually increase the pressure in port one (1) and watch for drops of oil to appear at port two (2).
4. The “holding valve relief setting” is the point where the individual drops form into a fine stream of oil.
Turn adjusting screw clockwise to decrease relief setting or counter-clockwise to increase relief setting.
5. Repeat the procedure several times to remove any residual twist in the counter balance main spring and
to assure an accurate setting. Tighten jam nut.
NOTE: To lower booms without hydraulic power, loosen jam nut, turn in adjustment screw
(clockwise), then move lift control to the "down" or "lower" position. The holding valve
relief pressure must be reset following this procedure.
Adjusting Screw Install cartridge in
unmarked port.
Jam Nut Lubricate o-rings on
installation.
Control
Valve
Pilot
Cylinder
Port #1 is the port normally connected to the cylinder.

Port #2 is the port normally connected to the control valve.
Port #3 is the pilot port.
HOLDING VALVE TEST BLOCK
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LOWER BOOM CYLINDER LEAKAGE TEST
Never remove holding valves or disconnect any hydraulic lines from holding valves until
boom or booms are fully supported from falling.
NOTE: All hydraulic cylinders should be tested annually.

NOTE: To check settings on holding valves, follow the procedure in this manual.
NOTE: When placing a weight at platform, ALWAYS refer to your ID Placard to determine the
proper weight allowance.
1. Place the hydraulic system into operation.
2. Place the upper boom and inner boom in a convenient position near horizontal.
3. Raise the lower boom approximately 5 degrees from horizontal and extend upper boom fully.
4. Place the predetermined load on a stable braid rope as shown. The unit's identification placard
determines the capacity. Platform capacity does not include the weight of the platform liner. Keep the
load close to the ground during testing.
NOTE: Valve manufacturers provide permissible leakage rates for holding valves.
Acceptable leakage rates are typically less than 5 drops per minute, which would not allow a boom to drift
any appreciable distance within 5–10 minutes. Extended test periods may not be representative of the
condition of a holding valve.
5. If the boom moves downward:
a. Remove the suspended load.
b. Properly support the upper and lower booms from falling.
c. Either replace the valve with new or test the holding valve as described in “SUN VALVE CARTRIDGE”
inspection procedure in this section.
6. If the boom still moves downward:
a. The cylinder is leaking internally and requires resealing or replacing.
TYPICAL CYLINDER
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UPPER BOOM CYLINDER LEAKAGE TEST
NOTE: All hydraulic cylinders should be tested annually.

NOTE: To check settings on holding valve cartridges, follow the procedure listed in this manual.
NOTE: When placing a weight at platform, ALWAYS refer to your ID Placard to determine the
proper weight allowance.
1. Place the hydraulic system in operation.
2. Extend the inner boom.
3. Raise the upper boom approximately 5 degrees from horizontal. Lower the lower boom fully.
4. Place the pre-determined load on a stable braid rope as shown. The unit's identification placard
determines the capacity. Platform capacity does not include the weight of the platform liner. Keep the
load close to the ground during testing.
5. If the boom moves downward:
a. Remove the suspended load.
b. Properly support the upper and lower booms from falling.
c. Either replace the valve with new or test the holding valve as described in “SUN VALVE CARTRIDGE”
inspection procedure in this section.
TYPICAL CYLINDER
400 lbs. (182 kg) weight in platform

400 lbs. (182 kg) on jib.
Check your platform capacities decal or ID Placard.
230-6
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EXTENSION CYLINDER LEAKAGE TEST

2. Raise the upper boom fully.
3. Place the load, stated on placard, on stable braid rope as shown with the inner boom retracted 2–3 ft
(609.6-914.4 mm).
4. Extend inner boom.
5. If the inner boom moves downward:
a. Shut down hydraulic system.
b. Properly support the upper boom from falling.
c. Disconnect and cap hydraulic lines from (supporting) holding valve.
d. Remove supports from boom and check for movement.
6. If movement no loner occurs, replace or repair holding valve.
Rod End View Holding Valve Holding Valve
Extension Cylinder
EXTENSION CYLINDER
230-7
TL SERIES
OUTRIGGER CYLINDER LEAKAGE TEST
A-FRAME
2. Place outriggers firmly on the ground.
3. Unfold the lower boom approximately 15 degrees from horizontal.
4. Place a predetermined load on stable braid rope.
5. Unfold upper boom approximately 15 degrees, to horizontal and place directly over either outrigger.
6. If outrigger cylinder creeps in or retracts, proceed as follows:
a. Remove load on outrigger leg. (Rotate turntable so the booms are horizontal to truck).
b. Shut down hydraulic system.
c. Disconnect and cap hydraulic lines leading to lock valve.
d. Replace load on outrigger leg. (Rotate turntable so boom is over outrigger.)
7. If movement no longer occurs, or if oil leaks from lock valve ports, replace or repair lock valve.
8. If movement inward still occurs, cylinder seals are leaking.
230-8
SYSTEM HYDRAULIC PUMP
TL SERIES
SECTION 250
NOTE: See Quick Reference Guide for specifications.
GENERAL INSTRUCTIONS
The hydraulic pump is a vane pump. These service instructions will familiarize you with single and multiple
pumps, their component parts, the relative position of each part, proper methods for assembly or
disassembly of the units, care and use of these oil hydraulic power units - so that best performance and
longer working life will result for our benefit.
To facilitate the repair of these unit and before any work is done, we suggest that you first read all of the
steps used in disassembly and all of the steps used In building up the unit.
Dirt is the enemy of any hydraulic system. The best way to fight dirt is to prevent its entry into the system.
Make sure the pump is disassembled and assembled in clean surroundings. It is important to air blast all
parts and wipe them with a clean cloth before assembly.
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GEAR PUMP
The hydraulic system is equipped with a positive displacement pump that is connected to the PTO.
The figure below shows a cross-sectional view of how the pump operates. Oil (hydraulic) is fed to one side
of the gears through the inlet port and rotated around the other side of the gears and out the outlet port.
Drive
Gear
OUT IN IN OUT
CCW CW
ROTATION ROTATION
LH DRIVE Driven RH DRIVE
MANUAL TRANSMISSION Gear AUTOMATIC TRANSMISSION
Oil Travels Around the Gears
NOTE: Consult your power transmission maintenance manual
for clarification of rotation
The oil pressure acts upon the pressure plates to seal them to the gears for fluid motor operation. The
pressure oil is bled to the back side of the pressure plates and the dams control the extent of pressure
distribution needed to provide an even, positive seal of the pressure plate at the gear sides.
Use caution in gripping all parts in the vise to avoid damaging machined surfaces.
For assured quality of material and workmanship and for compatibility in assembly, use only genuine parts
from Terex South Dakota, Inc. or your Terex South Dakota, Inc. dealer.
Check all replacement parts before installing them to be certain they were not damaged in shipment.
250-2
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1. Snap Ring 7. Roller Brgs 12A. Dowel Pins

2. Outboard Brg 8. Pocket Seals 13. Port End Cover
3. Seal 9. Thrust Plates 14. Washers
4. Shaft End Cover 10. Integral Drive Shaft 15. Studs or Capscrews
5. Check Ass’y or Plug 11. Gasket Seals 16. Nuts
6. Ring Seals 12. Gear Housing
NOTE: Plug 5 in position B gives clockwise rotation.
Plug 5 in position A gives counterclockwise rotation.
Check values in both positions, give bidirectional rotation.
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DISASSEMBLY
(Re: exploded view)
• If prying off sections becomes necessary, take extreme care not to mar or damage machined
surfaces. Excessive force while prying can result in misalignment and seriously damage parts.
• If parts are difficult to fit during assembly, tap gently with a soft hammer (never use an iron hammer.)
• Gears are closely matched, therefore they must be kept together as sets when removed from a unit.
Handle with care to avoid damage to the journals or teeth. Avoid touching gear journals.
• Never hammer bearings into bores, use an arbor press.
• Do not grip on or near any machined surfaces during assembly or disassembly.
• Match-mark all sections. Be sure to align these marks when reassembling.
Place the pump in a vise with the drive shaft pointing down. Proceed as follows:
1. Use a socket wrench to remove the 4 cap screws (14, 15, and 16) on single units or the 4 hex nuts,
studs and washers of multiple units.
2. Lift off the port end cover (13). If prying is necessary, be careful not to damage the machined surfaces.
Dowel pins will remain in either port end cover (13) or gear housing (12). Do not remove.
3. Remove the thrust plate (9). Examine and replace if necessary. See wear guide instructions.
4. Remove the thrust plate (9). Examine and replace if necessary. Remove the driven gear and the integral
gear and drive shaft (10). Keep these together as they are matched set. Examine and replace if
necessary. Be careful not to damage the machined surfaces of the gears.
5. Lift or pry off the first section gear housing. Be careful not to damage machined surfaces. Examine and
replace if necessary.
6. Inspect all bearings (7) for scoring or discoloration and replace if necessary. Use a bushing puller as
shown in the tool list to remove bushings.
7. If the pump is equipped with an outboard bearing (2). Place the shaft end cover (4) In the vise with the
mounting face up. Remove the snap ring (1) with snap ring pliers. If unit is equipped with a spiral lock
retaining ring. Remove with a small screwdriver or awl.
8. Use a bearing puller to remove the out-board bearing.
9. Grip the shaft end cover (4) in a vise with the mounting facedown. Remove double lip seal (3) by
inserting the special seal removal tool (see “TOOL LIST”) into the notch between the double lip seal and
the shaft end cover. Tap the seal out and discard. Remove and discard all rubber and polymer seals.
ASSEMBLY
(Re: exploded view)
Stone all machined surfaces with a medium grit carborundum stone.
1. If roller bearings (7) have been removed, deburr the bearing bores with emery cloth; Rinse parts in a
solvent. Air blast all parts and wipe with a clean lintIess cloth before starting assembly.
2. Grip shaft end cover (4) in vise with mounting face down. Examine plug (5a and 5b) or plugs to be sure
they are tightly in place. Replacement is necessary only if parts are damaged. Remove with screwdriver.
3. New plugs (5a and 5b) should be screwed in tightly. Stake plug with prick punch at both ends of
screwdriver slot and around edges. Peen edge of hole 1/32–1/16 in. with 1 1/2 in. diameter steel ball.
4. If new plug or plugs are being installed coat threads with Loctite thread sealant.
Assembly steps 5, 6, 7 and 8 apply to shaft end cover, bearing carriers and port end cover.
5. Any bearings (7) removed from the shaft end cover (4), port end cover (13) or bearing carrier should be
assembled in drive bores with groove to the top of unit (12 o'clock). Assemble bearings in driven bores
with the groove to bottom of unit (6 o'clock).
6. Bearings should be pressed into the bores, one at a time using the special installation tool and an arbor
press. Be sure the grooves are positioned as stated in Step #5. Bearings must be pressed into the bores
flush with the casting face. Be sure to support the castings so they are square and level.
7. Repeat Steps 1 and 2. Stone and rinse parts.
250-4
TL SERIES
8. See that dowel pins (11) are in place in any new castings. Examine all dowels. Before inserting make
certain the hole is clean and free from burrs. Gently start pin straight Into hole and tap lightly with a soft
hammer.
9. Before inserting a new lip seal in the shaft end cover, coat the outer edge of the lip seal and its recess
with Permatex Aviation Form-A-Gasket No. 3 non-hardening sealant or equivalent. With the metal side
of the lip seal up. Press it into the mounting flange side of the shaft end cover with an arbor press and
bar. Be careful not to damage the lip of the seal. Press In until flush with the recess. Wipe off excess
sealant.
10. If the unit is equipped with an outboard bearing, guide the bearing into its recess in the shaft end cover.
This is a light press fit. It may be necessary to lightly tap the bearing into the bore.
11. If the pump is equipped with an outboard bearing, place the shaft end cover in the vise with the
mounting face up. Remove the snap ring with snap ring pliers. If unit is equipped with a spiral lock
retaining ring, remove with a small screwdriver or awl.
12. Install the snap ring in the groove to retain the outboard bearing.
13. Grease the new gasket seals and insert them into the grooves in both sides of all gear housings.
Position the first gear housing over the shaft end cover and dowels. Tap it with soft hammer until it rests
tightly against the shaft end cover. Be careful not to pinch the gasket seal. Also be sure the large
rounded core is on the inlet side.
14. Assemble the channel seals into the grooves in the thrust plates with the flat side of the seal facing away
from the thrust plate as shown below.
Flat Side Thrust

Of Seal Plate
15. Gently slip the thrust plate through the gear housing and into place on the shaft end cover. The channel
seal from Step # 13 should face the shaft end cover. The relief groove in the plate should face the outlet
side of the pump.
16. Slide the driven gear through the housing and into the bushing in the shaft end cover. Coat the steel
sleeve tool with grease, Place the lightly greased drive shaft inside the sleeve and slide both through the
shaft end cover with a twisting motion until the integral gear rests against the thrust plate. Avoid
damaging the double lip seal. Remove the steel sleeve. Squirt clean oil over the gears.
17. Slip thrust plate with seal over gear journals and into housing bore. The flat side of the seal should face
up with the relief groove facing the outlet side.
18. Place the port end cover over the gear journals. Align the dowels with the holes in the mating casting.
Being careful not to pinch the gasket seal. Tap the port end cover lightly in the center between bearing
bores to engage the dowels and to move parts together in final seating.
19. Thread the 4 fasteners (cap screw and washers, or studs washers, and nuts) Into the shaft end cover
and tighten alternately or cross-corner. Rotate the drive shaft with a 6 in. wrench to make certain there Is
no binding in the pump. After the fasteners are tight and you are sure there is no internal binding, torque
the diagonally opposite fasteners to 200 ft. Ibs. (271 N-m).
250-5
TL SERIES
*As a guide in answering the question, "How much wear is allowed before the part should
be replaced?" - We offer the following suggestions...
GEAR HOUSINGS:
Wear in excess of .005 in. (.13mm) cut-out necessitates replacement of the gear housing.
Place a straight-edge across bore. If you can slip a .005 in. (.13 mm) feeler gage under
the straight-edge in the cut-out area, replace the gear housing.
Pressure pushes the gears against the housing on the low pressure side. As the hubs and
bushings wear, the cut-out becomes more pronounced. Excessive cut-out in a short
period of time indicates excessive pressure or oil contamination. If the relief valve settings
are within prescribed limits. Check for shock pressures or tampering. Withdraw oil sample
and check it and tan. for dirt. Where cut-out is moderate,.005 in. (.13 mm) or less, gear
housing is in good condition and may be re-used.
GEARS:
Any scoring on gear hubs necessitates replacement. Scoring, grooving, or burring of
outside diameter of teeth requires replacement. Nicking, grooving, or fretting of teeth
surfaces also necessitates replacement.
DRIVE SHAFTS:
Replace if there is any wear detectable by touch in the seal area or at the drive coupling
.002 in. (.05 mm) wear is the maximum allowable. Wear in the shaft seal area indicates oil
contamination. Wear or damage to splines, keys, or keyways necessitates replacement.
THRUST PLATES:
The thrust plates seal the gear section at the sides of the gears. Wear here will allow
internal slippage, that is, oil will bypass within the pump. A maximum of .002 in. (.051 mm)
wear is allowable. Replace thrust plates if they are scored, eroded or pitted. Check center
of thrust plates where the gears mesh. Erosion here indicates oil contamination. Pitted
thrust plates indicate cavitation or oil aeration. Discolored thrust plates indicate
overheating, probably insufficient oil.
DOWEL PINS:
If either the dowel or dowel hole is damaged, the dowel or machined casting, or both,
must be replaced. If more than reasonable force is required to seat dowels, the cause
may be poorly de burred or dirty parts; cocking of dowel in the hole; or improper pin-to-
hole fit.
BUSHINGS:
If gears are replaced, bushings must be replaced Bushings should fit into bore with a
heavy press fit.
SEALS AND GASKETS:

Replace all rubber and polymer seals. Including all o-rings, thrust plate channel seals,
shaft seal and gasket seals.
PLUGS:
Examine the plugs in the shaft end and port end cover to make sure they are in the proper
position and tight. The P330 should have two plugs in both the shaft end and port end.
The P350 and P365 have one plug in their shaft and port ends high pressure side only.
250-6
TL SERIES
PUMP START-UP
Before installing a new or rebuilt pump, back off the main relief valve until the spring tension on the adjusting
screw is relieved. This will avoid the possibility of immediate damage to the replacement unit in the event
that the relief valve setting had been increased beyond the recommended operation pressure prior to
removing the old unit.
Before connecting any lines to the pump, fill all ports with clean oil to provide initial lubrication. This is
particularly important if the unit is located above the oil reservoir.
After connecting the lines and mounting the replacement unit, operate the pump at least two minutes at no
load and at low RPM (400 RPM minimum). During this break-in period, the unit should run free and not
develop an excessive amount of heat. If the unit operates properly, speed and pressure can then be
increased to normal operating settings.
Reset the main relief valve to its proper setting while the pump is running at maximum operating engine
(motor) speed for the vehicle.
Always use an accurate gauge when adjusting any pressure settings.
RECOMMENDED TEST PROCEDURE

Be sure there is an adequate supply of oil for the pump.
The oil should be a good quality hydraulic oil. (Test procedures are described in detail in SAE handbooks;
see “Hydraulic Power Pump Test Procedure, SAE J745c”).
Feeding hot oil into a cold pump may cause the pump to seize. Jog the pump by momentarily starting the
driving engine or motor to gradually equalize pump and oil temperatures.
Run the pump at least two minutes at no load and moderate speed (not over 1500 RPM). If the pump
becomes excessively hot, shut down immediately and locate the problem source.
Gradually increase pressure on pump, in 500 PSI (3.45 MPa) increments until the desired test pressure has
been reached. This should take about five minutes.
Delivery should run close to rated catalog performance figures which are averaged from testing several
pumps. Something like a 5 percent lower reading may be used as a rated minimum if new or relatively new
parts have been used. When rebuilding the pump with parts from the original pump, which, while worn,
appear satisfactory for re-use, a 10 percent or 15 percent lower reading may be permitted, depending on the
performance expected from the equipment. One's own experience will prove the best guide here.
Many repairmen measure the output at normal operating speed and at zero pressure, then again at 1000
PSI (6.90 MPa) (or the operating pressure of the equipment) and allow a volume decrease approximating
the listing below. It is a suggested reference only which makes allowance for re-used parts.
GPM DELIVERY AT 1800 GPM DROP OFF AT…
RPM 100 PSI (.69 MPA) 1000 PSI/70 BAR 2000 PSI/70 BAR 3000 PSI/70 BAR
10-30 1 1/2 - 3 2 - 3 1/2 2 1/2 - 4
30-50 2-3 2 1/2 - 4 3 - 4 1/2
50-70 2 1/2 - 3 1/2 3-5 3 1/2 - 5 1/2
At test speeds other than 1800 RPM, GPM delivery will vary almost proportionately, but the same (drop-off)
figures should be used.
Be sure to run the pump in the direction for which it was designed and built. Driving pump in the wrong
direction will build up pressure behind shaft seal, damaging it and necessitating replacement.
After completing testing procedures, pump is ready for installation and immediate duty operation on
equipment. Again, it must re remembered that to prevent seizure, hot oil must not be fed into a cold pump.
250-7
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VANE PUMP
GENERAL
Pumps in this series are used to develop hydraulic fluid flow for the operation of industrial and mobile
equipment. The positive displacement pumping cartridges are of the rotary vane type with shaft side loads
hydraulically balanced. The flow rate depends on the pump size and the speed at which it is driven.
All units are designed so that the direction of rotation, pumping capacity and port positions can be readily
changed to suit particular applications.
ASSEMBLY AND CONSTRUCTION
The basic pump illustrated is representative of all single pumps in this series. The unit consist principally of
an inlet cover, outlet body, driveshaft and pumping cartridge. The principle components of the cartridge are
an elliptical cam ring, a slotted rotor splined to the driveshaft and inlet, and outlet support plate fitted with
four special seal packs, two flex side plates, and ten vanes and inserts fitted to the rotor slots. Fluid enters
the cartridge through the inlet port in the cover and is discharged through the outlet flex side plate and
support plate to the outlet port in the body.
APPLICATION
Pump ratings in GPM are at 1200 RPM and 100 PSI (.69 MPa). For ratings at other speeds and pressures,
methods of installation or other application information, refer to the installation manual.
250-8
TL SERIES
PUMPING CARTRIDGE
Fluid flow is developed in the pumping cartridge. The action of the cartridge is illustrated in the figure below.
The rotor is driven within the ring by the driveshaft, which is coupled to a power source. As the rotor turns,
centrifugal force on the vanes, aided by under-vane pressure fed from the outlet port, causes the vanes to
follow the elliptical inner surface of the ring.
Radial movement of the vanes and turning of the rotor causes the chamber volume between the vanes to
increase as the vanes pass the inlet sections of the ring. This results in a low pressure condition which
allows atmospheric pressure to force fluid into the chambers.
An additional inlet fluid path exists through a drilled hole in the cam ring. This hole connects the inlet port
directly to the inlet areas of the cam ring and provides an additional flow path for fluid to get into the
cartridge.
Fluid is trapped between the vanes and carried past a sealing land to the outlet section of the ring. As the
outlet section is approached, the chamber volume decreases and the fluid is forced out into the system.
System pressure is fed under the vanes, assuring their sealing contact against the ring during normal
operation.
VANE PRESSURE FEED

The intra-vane design provides a means of controlling the outward thrust of the vane against the ring and
maintains tip loads within reasonable limits. In the intra-vane cartridge, full system pressure is continuously
applied to the area between the vane and insert. This area is small and thrust is correspondingly light.
During vane travel through pressure areas, full system pressure is applied against the bottom area of the
outer vane. The valving of pressure to and from the bottom area of the vane is through holes drilled in the
rotor. This selective application of pressure maintains the vane in substantially constant radial hydraulic
balance in all positions.
Vane tip wear is compensated for automatically. As the vane wears, pressure moves the vane farther out in
the rotor slot holding the vane tip against the cam ring.
HYDRAULIC BALANCE
The pump ring is shaped so the two pumping chambers are formed 180 degrees apart. Thus, opposing
hydraulic forces which develop side loads on the shaft cancel out.
250-9
TL SERIES
FLEX SIDE PLATE OPERATION

The flex side plates for both inlet an outlet are symmetrical. Pressure is fed behind each side plate into two
kidney shaped cavities which are sealed by special seal packs. The two flex side plates and their associated
kidney shaped cavities function in the following manner. As pressure builds up in the outlet, pressure also
builds up in the cavities. The pressure in the cavities hold the flex side plates in hydrostatic balance against
the rotor and provide optimum running clearances for minimum internal leakage and minimum friction.
The flex side plates also provide passages for feeding under vane pressure to the space between the vane
and insert. The bronze faces of the flex side plates ride next to the rotor and provide excellent wear and cold
start characteristics.
The inlet and outlet support plates hold the flex side plates in position and contain passages which allow
fluid to pass from the inlet to the pumping cartridge and from the cartridge to the outlet port.
The simplified cross section of the pump above shows one pressure plate and one wear plate at each end of
the pump rotor cartridge, which contain the vanes. The pressure plate bends inward under force exerted by
the oil under the system back pressure to maintain an efficient seal with the rotor and its pump vanes.
250-10
TL SERIES
INLET BODIES
Two inlet body configurations and two shaft seal arrangements are available in this pump series.
When a single shaft seal is used, a steel ball is pressed into the body.
Double shaft seal models require a different shaft that may or may not be interchangeable with previous
designs. This is due to an increase in shaft shoulder length to accommodate the second shaft seal. The
overall shaft length of both models are the same as previous designs.
250-11
TL SERIES
MOUNTING AND DRIVE CONNECTIONS

NOTE: High performance vane pumps are designed for foot or flange mounting.
1. Direct Drive - A pilot on the pump mounting flange assures correct mounting and shaft alignment,
provided the pilot is firmly seated in the accessory pad of the power source. Care should be exercised in
tightening all flange mounting screws to prevent misalignment.
If gaskets are used between flanges, they should be installed carefully so as to lie flat and should not be
the type that will take a set. Shaft keys and couplings must be properly seated to avoid slipping and
possible shearing.
Proper coupling alignment is essential to prolong pump life.
Pump shafts are designed to be installed in couplings with a slip fit or very light press.
Pounding the coupling end on the shaft can ruin the bearings.
2. Indirect Drive - Indirect drive is not recommended for these pumps.

Pilot
Diameter
Shaft
SHAFT ROTATION
To reverse cartridge kit rotation, remove two screws and reverse the location of inlet and outlet support
plates. Reinstall two screws hand tight. Use pump cover to align all sections of cartridge. Carefully remove
the cover and tighten the screws.
NOTE: Pumps are normally assembled for right-hand (clockwise) rotation as viewed from the
shaft end. A pump made for left-hand rotation is identified by an “L”.
NOTE: If it is desired to reverse the direction of drive rotation, it is necessary to disassemble the
pump and reverse the location of the cartridge inlet and outlet support plates.
Never drive a pump in the wrong direction of rotation. Seizure may result, necessitating
extensive repairs.
250-12
TL SERIES
START - UP
Whenever it is possible to do so, fill the pump ports with system hydraulic fluid. This will make it easier for
the pump to prime when it is first started.
Self-Priming - With a minimum drive speed of 600 RPM, a pump should prime almost immediately. Failure to
prime within a reasonable length of time may result in damage due to lack of lubrication. Inlet lines must be
tight and free from air leaks. It may be necessary to crack a fitting on the outlet side of the pump to purge
entrapped air.
No-Load Starting - These pumps are designed to start up with no load on the pressure ports. They should
never be started against a load or a closed center valve.
SERVICE TOOLS
Two special tools are required to service these pumps. A driver should be used to assure installation of the
primary shaft seal without damage and a “bullet” should be placed over the end of the shaft, to avoid
damaging the seal lip when the shaft is installed. Installation of the secondary seal does not require a driver.
The driver can be made from tubular stock. The tool applies a uniform pressure to the recessed area of the
seal, rather than to the lip of the seal. The inside diameter of the tool will not interfere with the garter spring
located around the lip of the seal.
D C
INSPECTION
Periodic inspection of the fluid condition and tube or piping connections can save time-consuming
breakdowns and unnecessary parts replacement. The following should be checked regularly.
1. All hydraulic connections must be kept tight. A loose connection in a pressure line will permit the fluid to
leak out. If the fluid level becomes so low as to uncover the inlet pipe opening in the reservoir, extensive
damage to the pump can result. In suction or return lines, loose connections permit air to be drawn into
the system, resulting in noisy and/or erratic operation.
2. Clean fluid is the best insurance for long service life. Therefore, the reservoir should be checked
periodically for dirt or other contaminants. If the fluid becomes contaminated the system should be
thoroughly drained and the reservoir cleaned before new fluid is added.
3. Filter elements also should be checked and replaced periodically. A clogged filter element results in a
higher pressure drop. This can force particles through the filter which would ordinarily be trapped, or can
cause the bypass to open, resulting in a partial or complete loss of filtration.
4. Air bubbles in the reservoir can ruin the pump and other components. If bubbles are seen, locate the
source of the air and seal the leak.
5. A pump which is running excessively hot or noisy is a potential failure. Should a pump become noisy or
overheated, the machine should be shut down immediately and the cause of improper operations
corrected.
ADJUSTMENTS
No periodic adjustments are required, other than to maintain proper shaft alignment with the driving medium.
LUBRICATION
Internal lubrication is provided by the fluid in the system. Lubrication of the shaft couplings should be as
specified by their manufacturers.
250-13
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TROUBLESHOOTING
The table lists the common difficulties experienced with vane pumps and hydraulic systems. It also indicates
the probable causes and remedies for each of the troubles listed.
It should always be remembered that many apparent pump failures are actually the failures of other parts of
the system. The cause of improper operation is best diagnosed with adequate testing equipment and a
thorough understanding of the complete hydraulic system.
250-14
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TROUBLE PROBABLE CAUSE REMEDY

Pump Not Delivering Fluid Driven in the wrong direction of The drive direction must be changed
rotation. immediately to prevent seizure.
Coupling or shaft sheared or Disassemble the pump and check the
disengaged. shaft and cartridge for damage. Replace
the necessary parts.
Fluid intake pipe in reservoir Check all strainers and filters for dirt and
restricted. sludge. Clean if necessary
Fluid viscosity too heavy to pick up Completely drain the system. Add new
prime filtered fluid of the proper viscosity.
Air leaks at the intake. Pump not Check the inlet connections to determine
priming. where air is being drawn in. Tighten any
loose connections. See that the fluid in the
reservoir is above the intake pipe opening.
Check the minimum drive speed which
may be too slow to prime the pump.
Relief valve stuck open. (Models Disassemble the pump and wash the
with integral relief valve only.) valve in clean solvent. Return the valve to
its bore and check for any stickiness. A
gritty feeling on the valve periphery can be
polished with crocus cloth. Do not remove
excess material, round off the edges of the
lands or attempt to polish the bore. Wash
all parts and reassemble the pump.
Vane(s) stuck in the rotor slot(s). Disassemble the pump. Check for dirt or
metal chips. Clean the parts thoroughly
and replace any damaged pieces. If
necessary, flush the system and refill it
with clean fluid.
Insufficient Pressure Build- System relief valve set too low. Use a pressure gage to correctly adjust
up the valve.
Pump Making Noise Pump intake partially blocked. Service the intake strainers. Check the
fluid condition and, if necessary, drain and
flush the system. Refill with clean fluid.
Air leaks at the intake or shaft seal. Check the inlet connections and seal to
(Oil in reservoir would probably be determine where air is being drawn in.
foamy). Tighten any loose connections and replace
the seal if necessary. See that the fluid in
the reservoir is above the intake pipe
opening
Pump drive speed too slow or too Operate the pump at the recommended
fast. speed
Coupling misalignment. Check if the shaft seal bearing or other
parts have been damaged. Replace any
damaged parts. Realign the coupled
shafts.
Before breaking a circuit connection, be certain that power is off and the system pressure
has been relieved. Lower all vertical cylinders, discharge all accumulators and block any
load whose movement could generate pressure. Plug all units and cap all lines to prevent
entry of dirt into the unit or system.
250-15
TL SERIES
GENERAL
Plug all removed units and cap all lines to prevent the entry of dirt into the system. During disassembly, pay
particular attention to identification of the parts, especially the cartridges, for correct assembly. Various steps
in the overhaul process are shown.
DISASSEMBLY
1. Basic Pump - Remove the foot mounting and shaft key, if used. Support the pump on blocks or clamp
the body in a vise as shown. If a vise is used, use protective jaws to avoid damage to the body and its
machined surfaces. Mark the pump body and cover for correct reassembly. Remove four cover screws
and lift the cover off the pump.
Cover Screw
Index Marks For

Assembly
Reference
If Vise Is Used
Clamp Here
250-16
TL SERIES
Remove the cover o-ring. Pull and/or pry out the cartridge as shown.
Remove the large spirolox ring and pull the shaft and bearing from the body. Drive the shaft seals out of
the body. If it is necessary to remove the shaft bearing, first remove the small snap ring and then press
the shaft out of the bearing while supporting the bearing inner race.
2. Cartridge Disassembly
a. Remove the o-ring, back-up ring and square sealing ring from the outlet support plate.
b. Scribe a line across the outer surface of the cartridge kit. The scribe marking will provide a reference
for parts during assembly.
c. Place the cartridge on a flat surface (outlet support plate down) and remove the two socket head
screws.
Do not slide flex side plates across the ring and rotor. Burrs on the ring or rotor can cause
deep scratches in the soft brass surface.
d. Slide the inlet support plate and seal packs off the cartridge. DO NOT allow the flex side plate to slide
with the support plate.
Move the flex side plate off center just enough to grab the edge and lift up and away without sliding.
If a small flat piece of wood is available, place it over the ring and rotor and reverse the cartridge to have the
outlet support plate pointing up. Slide the outlet support plate and seal packs off the cartridge, do not allow
the flex side plate to slide with the support plate.
Move the flex side plate off center just enough to lift up and away without sliding.
Remove the cam ring form the rotor and vanes. Locate the arrow stamped into the rotor periphery. Remove
the vanes and inserts in order, starting at the arrow. Keep them in order for inspection.
NOTE: Do not remove cartridge locating pins from the inlet support plate unless they are
damaged. The pins are of a drive-loc type and can be difficult to remove.
250-17
TL SERIES
INSPECTION AND REPAIR

CLEANING: All parts must be thoroughly cleaned and kept clean during inspection and assembly. The close
tolerance of the parts makes this requirement very important. Clean all removed parts, using a commercial
solvent that is compatible with the system fluid. Compressed air may be used in cleaning, but it must be
filtered to remove water contamination.
1. Discard the shaft seal(s), o-rings, back-up rings and seal packs. Use a new seal kit for reassembly.
Wash the metal parts, blow them dry with air and place on a clean surface for inspection.
2. Check the cartridge wear surfaces for pickup, scoring and excessive wear. Slight heat discoloration of
the flex side plate bronze surface is normal. Score marks deeper than .001 inch (.025 mm) and
scratches deeper than .002 inch (.051 mm) indicate a new part is needed. Slight scoring and/or
scratches can be removed with an oiled Arkansas stone.
DO NOT use a dry stone on the bronze surface or scratches will result.
3. Inspect both sides of each vane and insert in order. If pickup, heavy wear or scoring is found, inspect the
appropriate rotor slot. Replace scored parts.
4. Inspect the cam ring for vane chatter marks, wear and/or scratches. Replace if scoring is evident.
Replacement ring width must be identical to the ring being replaced or reduced life and/or
output flow will result. The minimum ring to rotor clearance limits are noted below.
MODEL MIN. CLEARANCE LIMIT IN INCHES

**20VQ 0.0007 (.018 mm)
NOTE: All cartridge kit parts must be free of burrs. Stone the mating surfaces of each part with
an oiled Arkansas stone prior to assembly.
NOTE: Pre-assemble replacement cartridge kits are available. If the old cartridge is worn
extensively, a new kit should be used.
5. Vane and rotor wear can be checked by inserting the vane in the rotor slot and checking for excessive
play. Replace the rotor and vanes if wear is evident.
6. Rotate the bearing while applying pressure to check for wear, looseness and pitted or cracked races.
7. Inspect the seal and bushing mating surfaces on the shaft for scoring or wear. Replace the shaft if marks
cannot be removed by light polishing.
ASSEMBLY
NOTE: Coat all parts except seals and back-up rings with clean hydraulic fluid to facilitate
assembly and provide initial lubrication. Use small amounts of petroleum jelly to hold the
o-ring in place during assembly.
IMPORTANT: During handling and shipping of the precision machined cartridge parts, it is
possible to raise burrs on the sharp edges. All sharp edges on the part of a new cartridge kit
should be stoned prior to installation.
NOTE: To reverse direction of a new cartridge kit, simply reverse location of the inlet and outlet
support plates and realign the cartridge with the cover.
1. Cartridge - The direction of rotation is as viewed from the shaft end; right-hand rotation is clockwise; left-
hand counterclockwise.
NOTE: If locating pins were removed from the inlet support plate, install new pins with locking
flutes located within the inlet support plate. Drive the new pins into the support plate,
with a soft tip hammer.
a. Place the inlet and outlet support plates on a flat surface as shown. Install seal packs into cavities with
seal retainer surface up. (O-rings facing downward into the cavities.)
b. Place a flex side plate over each of the support plates with bronze wear surface facing up. Align
scribe marks to make sure the correct flex side plate is used with the correct support plate.
250-18
TL SERIES
NOTE: Flex side plates develop a wear pattern with the rotor and vanes and should not be
interchanged.
c. For right-hand rotation units, set the rotor on the flat wooden board with the arrow pointing right. (For
left-hand rotation the arrow should point left.) Assemble the vanes and inserts into the rotor in reverse
order. Make sure the sharp chamfer edge of each vane leads in the direction of rotation. All vanes
must move freely in the rotor slots with no evidence of bind.
d. Assemble the cam ring over the rotor and vanes with the arrow pointing in the same direction as the
rotor. Lubricate the top surface of the rotor and vanes liberally with system fluid.
e. Locate the scribe mark on the cam ring, the outlet support plate and the flex side plate.
Hold the outlet support plate and flex side plate together and assemble over the cam ring and rotor with the
scribe marks in-line.
f. Hold the cartridge together to prevent movement and turn the assembly over so the outlet support
plate rests on a flat surface and the flat wooden board is up. Remove the flat wooden board.
g. Lubricate the exposed surface of the rotor and vanes with system fluid. Locate the scribe mark on the
inlet support plate and flex side plate. Hold the inlet support plate and flex side plate together and
assemble over the cam ring and rotor with scribe marks in-line.
NOTE: The cast-in arrows located next to the socket head screws, indicate cartridge direction of
rotation.
h. Thread the two socket head screws into the cartridge until snug (hand tight).
NOTE: The O.D. of all component parts of the cartridge kit must be in-line with each other or the
cover cannot be installed. Align the cartridge as follows:
i. Install the cover over the cartridge. Tap lightly on the cover with your hand until each part centers.
Remove the cover gently so as not to disturb alignment. Torque socket head screws to the torque
noted and recheck kit alignment with the cover. Repeat until cartridge kit is aligned.
j. Check the rotor for bind by inserting the index finger through the shaft opening of the inlet support
plate. Hold the cartridge kit in a horizontal shaft position and lift the rotor with the finger. The rotor
should move freely back and forth within the cartridge. If the rotor binds, open the kit, clean and stone
all possible areas of bind, then reassemble using the aforementioned procedure. The rotor MUST
move freely within the cartridge when assembled.
2. Basic Pump - Clamp the body in a vise or place on 2x4 wooden blocks to facilitate assembly.
a. Lubricate the primary shaft seal with petroleum jelly and place in position within the body, garter
spring up.
b. Use the seal installation tool to prevent damage to the seal. Press the seal into the body until it
bottoms out.
NOTE: Two shaft seal arrangements are available in the VQ pump series. If a secondary seal is
required, perform the following step.
c. Lubricate the secondary seal with petroleum jelly and place the seal in position against the shaft end
of the body. Use a small hardwood block to drive the seal evenly into the body. Installation is complete
when the seal face is flush with the front of the body. DO NOT drive the seal past flush as it can block
the body drain opening.
NOTE: If the shaft bearing was defective, install a new bearing as follows:
d. Press the shaft into the new bearing with an arbor press while supporting the bearing inner race.
Install a small snap ring behind the bearing.
e. Place the bearing spacer washer over the shaft, against the front of the bearing. Use a “bullet” over
the shaft end to prevent damage to the seal(s). Lubricate the “bullet” with petroleum jelly and carefully
push the shaft through the seals until the bearing and spacer is in location within the body. Install the
large spirolox ring into the body snap ring groove behind the bearing.
f. Install the square sealing ring into the body.
g. Install the o-ring and back-up ring on the cartridge, outlet support plate hub.
h. Carefully install the cartridge into the body so one of the chamfers on the cam ring aligns with the
cover inlet port.
250-19
TL SERIES
i. Lubricate and install the large cover to body o-ring in place.

j. Install the cover in position; move back and forth until the cartridge pins drop into the cover holes.
k.Oil and install the cover to body bolts (4 required).
l. Turn the pump shaft by hand to verify freedom of the cartridge.
SCRIBING THE CARTRIDGE INLET SUPPORT PLATE REMOVAL
INLET FLEX PLATE REMOVAL REVERSE CARTRIDGE, USE A PIECE OF WOOD

TO HOLD RING, ROTOR, AND VANES
250-20
TL SERIES
Seal Packs
OUTLET SUPPORT PLATE REMOVAL OULET FLEX SIDE PLATE REMOVAL
ROTOR
Seal Packs
1 2 3 4 5
6 7 8 9 10
VANES
AND INSERTS
SEQUENTIAL REMOVAL OF VANES FROM ASSEMBLY OF FLEX SIDE PLATES OVER SEAL
ROTOR STARTING AT ARROW ON ROTOR PACKS ONTO THE INLET AND OUTLET
SUPPORTS PLATES
250-21
TL SERIES
OUTLET SUPPORT PLATE AND FLEX SIDE CARTRIDGE READY FOR INSTALLATION OF
PLATE ASSEMBLED TO CARTRIDGE. READY SOCKET HEAD SCREWS.
FOR INSTALLATION OF INLET SUPPORT PLATE
ADN FLEX SIDE PLATE.
ALIGNING CARTRIDGE KIT WITH COVER
250-22
TL SERIES
TOOL LIST
1. Arbor Press 9. Soft Hammer 17. Scale (1/32 in. Or 1/64 in.
Graduations)
2. Awl 10. Permatex Aviation Form-a-
3. 1 1/2 in. Dia. Steel Ball gasket No. 3 Non-hardening 18. Small Screw Driver
Sealant Or Equivalent
4. Bearing Puller (Owatonna 19. Torque Wrench
Tool Co. MD-981 Or
11. Medium Grit Carborundum 20. Vise With 6 in. Minimum Open
Equivalent)
Stone Spread
5. Bushing Removal Tool (See 12. Seal Removal Tool (See 21. Bar For Lip Seal Installation
Drawing) Drawing) Note: For P330 Use 1 3/4 in.
Dia. By 2 in. Bar
6. Clean Lintless Cloths 13. Oil And Grease
For P350 Use 2 3/2 in. Dia. By
7. Deburring Tool (An old file 14. Snap Ring Pliers
with the cutting teeth ground 2 in. Bar
15. Prick Punch
off.) For P365 Use 2 3/2 in. Dia. By
16. Bushing Installation Tool (See 2 in. Bar
Drawing)
8. Machinist’s Hammer 22. Special Steel Sleeve (See
Drawing)
SEAL REMOVAL TOOL
Seal Removal Tool can be easily made from an old screwdriver. Heat the tip and bend as shown. Grind off
the tip to fit the notch behind the shaft seal.
1/4”
BUSHING INSTALLATION TOOL

Bearing quality steel heat treated.
A
B
.06 .06
C D
30°
30°
Grind Relief Allowable
A B C DIA D DIA
3.00 1.47 1.054 +.000 1.250
P330
.002
3.00 1.47 1.282 +.000 1.625
P350
.002
3.25 1.73 1.492 +.000 1.750
P365
.002
250-23
TL SERIES
STEEL SLEEVE
The special steel sleeve is used to insert the drive shaft through the lip seal without damage and can be
made from bar stock. For the P330 use a 1 1/8 in. or 1 1/4 in. diameter x 4 5/8 in. bar. For the P350 use a 1
3/8 in.diameter x 4 5/8 in. bar. For the P365 use a 1 3/2 in. diameter x 4 5/8 in. bar. The drawing and chart
give details for making this tool.
B
A
E D
A B C RADIUS D DIA E DIA F CHAMFER

3 3/8” 4 1/2” 9/16” 1.065 +.000 1.002 +.000 .015” x 45 deg
P330
-.002 -.002
3 3/8” 4 1/2” 9/16” 1.290 +.000 1.250 +.000 .15” x 60 deg
P350
-.002 -.002
3 3/8” 4 1/2” 9/16” 1.377 +.000 1.250 +.000 .63” x 60 deg
P365
-.002 -.002
MAKE FROM OTC
PUMP MODIFY COLLET AS SHOWN DIMENSIONS
COLLET
P330 A= +.980” 33863
C
-.970”
B= +.875”
-.(Ref)
A C= +.100”
B
-.090”
P350 A= +.980” 33864

C
-.970”
B= +.875”
-.(Ref)
C= +.100”
A B
-.090”
P365 A= +.980” 33865

C
-.970”
B= +.875”
-.(Ref)
C= +.100”
A B
-.090”
The bushing in P330, P350, and P365, pumps may be removed from their bores using blind hole collet-type
bushing pullers similar to those manufactured by Owatonna Tool Co. The table illustrates the modification
necessary to adapt the OTC collets to this task. Equivalent pullers from other suppliers may be modified in
similar fashion.
250-24
TL SERIES
RELIEF VALVE
Relief valves are required with gear or vane pumps to limit the maximum pressure. They may be located in
the upper and lower tool circuits and at the lower outrigger controls as the main system relief.
If the unit is equipped with a vane or gear pump adjust the relief valve to the system pressure. See Quick
Reference Guide for pressures.
Adjust the system relief by:
1. Connecting a gage to the inlet of the outrigger valve.
2. Start the unit and engage the hydraulic pump at rated speed.
3. Select the outrigger function and operate UP to deadhead the flow.
4. Read the pressure.
5. Adjust by loosening the lock nut and turning the screw in to increase or out to decrease.
6. Re-test to verify setting after tightening the lock nut.
Death or personal injury could result if system pressure is set above the recommended
setting. Do not adjust pressure higher than recommended.
PUMP ADJUSTMENTS
No periodic adjustments are required, other than to maintain proper shaft alignment with the driving medium.
If the pump is a pressure conpensated piston pump the componsation setting determins the system
pressure. See Quick Reference Guide for proper setting.
LUBRICATION
Internal lubrication is provided by the fluid in the system. Lubrication of the shaft couplings should be as
specified by their manufacturers.
250-25
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HYDRAULIC PUMPS - AVOIDING FAILURES

Many things can happen to a hydraulic system that will cause pump failure. By practicing preventive
maintenance procedures, frequency of pump failures can be cut down. Pump failure can be avoided if tell-
tale symptoms are discovered and checked out when they occur.
The main symptoms to watch for are excessive system temperatures and noise. These usually indicate a
defective pump. Also watch the overall performance of the system. If the equipment operates a little slower,
less powerfully, or is less responsive, it is time to check the system for flow rate and pressure.
Any excessive or unusual pump noise should be investigated immediately. Pump noise generally indicates
cavitation.
If a pump stops suddenly, it is almost certain that a major internal pump part has failed. The only solution for
this, of course, is to examine the pump and rebuild or replace it as necessary.
After the pump has been repaired or replaced, don’t operate the system until it has been
drained, flushed, new filters installed, and refilled with new fluid. This should do away
with most particles from the failed part that could damage the newly repaired system.
Some other items that can cause poor performance and eventual pump failure are listed here. These should
be checked periodically.
• Reservoir - Check the fluid level daily to be sure it is in the operating range. If the level is going down
faster than usual, there’s probably a leak somewhere in the system.
• Inlet Line - A bit of debris may have plugged the inlet pipe preventing sufficient fluid from reaching the
pump. Frays and kinks in the inlet line can also restrict the fluid supply. Be sure the inlet line is secure
and leak proof.
• Filters - The filter should be checked frequently and cleaned or replaced as necessary. This is
especially true when the vehicle is operated in dusty work locations.
• Oil viscosity - Be careful not to use fluid that is too thick. Fluid may thicken through oxidation or
contamination.
• Shut offs - Not fully open.
• A vacuum leak in the pump suction line.
CAVITATION
Cavitation is a vacuum in the fluid. Cavities occur when the components are not completely filled. It can also
occur in motors or cylinders where the load overruns the delivery from the pump. Cavitation is prevalent in
the pump when the inlet conditions are critical. The characteristic sound of cavitation is a high pitched
“scream” and this noise increases with the degree of cavitation and with increased operating pressure. This
is caused by the implosion of the cavities or voids in the fluid.
CAVITATION EFFECTS
Typical effects of cavitation are eroded end plates (as shown by pitting between the inlet and outlet port).
Cavitation effects are much the same as aeration.
CAUSES OF PUMP CAVITATION
Pump cavitation may be caused by a restricted inlet line, by sharp bends in the inlet line, by a clogged inlet
filter, by fluid that is too high in viscosity, and by excessively long inlet lines. Also, if the pump inlet is too high
above the fluid level in the reservoir, the “lift” required may be too much to allow the pump to fill. One other
possible cause of cavitation is a vacuum in a non-vented reservoir caused by the fluid shrinking in volume as
it cools without the breather, allowing air back into the reservoir. This can be checked by momentarily
cracking the reservoir cover when the machine is started up cold. Cavitation from fluid that is too thick
sometimes is avoided by operating at reduced pump speed until the fluid is warmed up and becomes less
viscous.
Remember that heat, high pressures and contamination all speed up oxidation. This results in gum, sludge,
plugged valves and excessive wear on the pump, cylinder and valve parts. The answer is to always use the
proper grade and amount of fluid and to perform regular preventative maintenance. Whenever cavitation is
detected, it should be corrected or the life of the pump will be shortened. When cavitation is suspected, a
vacuum gauge should be installed at the pump inlet to determine if corrective action is required.
250-26
TL SERIES
AERATION
All hydraulic fluid contains some dissolved air, usually about 10 percent by volume. Under increased
pressure, the fluid will absorb much more air. Aeration in a hydraulic circuit is the presence of free air in
places where there should be only fluid. Usually the air will be in the form of bubbles dispersed through the
fluid.
Difficulties with aeration will occur more frequently as flow velocities increase in hydraulic components. The
section below covers some of the causes of air being introduced into a system and suggested practices to
effectively reduce and eliminate this problem.
CAUSES OF AERATION
The most common places for air to be introduced into a hydraulic system or for aeration to occur are as
follows:
• Damaged inlet line - loose or defective fittings or seals at any component.
• Damaged return line - loose or defective fittings or seals at any component.
• Damaged or worn cylinder rod, packing or seals.
• Cracked junction blocks, tees or piping.
NOTE: Fluid acts as a sealant at atmospheric pressure. When system drops below atmospheric
pressure, air may be drawn in where fluid will not necessarily leak out.
• Fluid level too low. This can cause vortexing at pump inlet in reservoir, thus drawing in air.
• Air trapped in filter with no means of bleed off.
• Air trapped in system during original filling, or when adding fluid for make-up.
DAMAGE TO SYSTEM
Excessive aeration can cause pump damage, resulting in immediate failure or contribution to later failures.
The two causes of damage to components by aeration is lack of lubricity and overheating. In addition,
aeration can cause jerky and uneven movement in pumps or motors which, in combination with the causes
previously mentioned, will cause failure.
Loss of lubricity in a hydraulic component will eventually result in seizure and subsequent pump failure.
Overheating is caused by a breakdown of hydraulic fluid as a result of oxidation. Oxidation of fluid leads to
sludging and varnish formation. Operating a system with aeration can oxidize the whole charge of fluid and
eventually sludge and varnish will cause the motor or pump to overheat excessively and cause failure.
AVOIDING AERATION
Regular inspection and regular maintenance are the best ways to prevent air from being introduced into a
hydraulic system. Keeping all connections and fittings tight is the easiest way to avoid the introduction of air.
Return fluid entering the reservoir will create aeration if it is discharged above the main body of the fluid in
the tank. To prevent this condition, maintain sufficient fluid in the tank to keep the return line submerged. The
pump intake line should always be below the fluid surface for the same reason.
In starting a new system or after a system has been completely drained and flushed, a tendency for the fluid
to aerate may exist until all the air is purged from all lines and components. To correct this condition, a
thorough purging of the entire system should be performed.
250-27
TL SERIES
250-28
CONTROL VALVES
TL SERIES
SECTION 260
CONTROL VALVES
THIS SECTION CONTAINS EXCERPTS FROM GRESEN.
LOWER CONTROL VALVE ASSEMBLY

DESCRIPTION
The lower control valve is a 7 spool sectional, directional control valve. The first section is a two position
selector. In neutral position, oil is allowed on to the rest of the lower control valve. When activated it directs
oil to the upper controls only. The lower controls will not operate. When in neutral, the pressure and return
lines to the upper controls are blocked to allow override. The standard lower control then has 5 (4 way - 3
position) valve sections. They control the upper boom, rotation, and lower boom.
SERVICE
NOTE: Each valve housing with spool is a matched set. When ordering replacement parts, they
must be ordered as a matched set. Terex South Dakota, Inc. will not replace only a spool
or housing as individual components.
V-10
Other than replacement of seals, repairs to the control valve are seldom required. Always check all other
possible causes of an operation malfunction before dismantling the control valve. If the unit operates
normally when you use the manual control handles, but fails to operate from the platform, the trouble is
probably in the control head assembly or associated hydraulic lines, not the control valve.
260-1
CONTROL VALVES
TL SERIES
LOWER CONTROL VALVE REMOVAL

1. Place booms in the stowed position. Stop the engine and disengage PTO.
2. Clean the control valve assembly and surrounding area to keep contaminates out of the hydraulic
system.
3. Tag, disconnect, and cap hydraulic lines and other connections which may be present at the control
valve assembly for correct installation. This includes hydraulic lines from boom cylinders and rotation
motor.
4. Remove fasteners securing valve assembly to the turntable, and place valve assembly in a suitable
work area.
CONTROL VALVE DISASSEMBLY
The following instructions are used to disassemble the control valve section ONLY to the
point of replacing the required seals and/or o-rings. ALWAYS DISASSEMBLE CONTROL
VALVE SECTION IN A CLEAN WORK AREA.
1. After removing valve assembly from machine, place in a clean, suitable work area.
2. Remove hydraulic fittings from ports of valve section where o-rings are to be replaced.
NOTE: Remove all hydraulic fittings from entire valve assembly if all o-rings are to be replaced.
3. Remove nuts and tie rods.
4. Valve spool (4) and housing (6) must be replaced as a matched set.
NOTE: Remember cleanliness is extremely important.
8 7 3 7
“A” “B”
9
2
Optional Clevis
Used With Extended
Handle Assemblies
TYPICAL SCHEMATIC
5 1 6 4
TYPICAL WORK SECTION
Work Section as Viewed from the Downstream Side
1. Spool Seal 4. 4-Way Spool 7. No Relief Cavity Plug

2. Spring Return 5. Spool Clevis (optional)
Positioner Kit
6. Valve Housing 8. Clevis Pin
3. Load Check Kit 9. Cotter Pin
260-2
CONTROL VALVES
TL SERIES
REPLACING, ADDING OR REMOVING VALVE SECTIONS
For clarification, the inlet cover (cover containing the main relief cartridge) will be called the left end of the
valve assembly.
1. Before disassembly, it is suggested that each work section be marked numerically to avoid incorrect
reassembly.
2. Remove the four hex nuts and lock washers from the tie rods at the right (outlet cover) end of the valve
assembly.
3. Remove the outlet cover and each section by sliding from the tie rods.
Do not pre-lube the o-ring section seals prior to installation. Compression of lubricants
can distort the valve body causing spool bind.
4. If work sections are to be added or subtracted from the valve assembly. Select the proper stud kit.
NOTE: Refer to “REPLACING SECTION SEALS” for proper procedures on section seal
installation.
5. Torque stud nuts evenly to specifications.
If the stud nuts are not tightened to the proper torque, valve spools may bind or stick, or
cause o-ring seals to extrude.
260-3
CONTROL VALVES
TL SERIES
WORK SECTION HOUSINGS

The sectional control valve had a casting and spool change in June, 1999.
Old Style - New Style -
Wide Radius Small Radius
Upstream Face
(No O-Ring C’Bores)
OLD STYLE HOUSING NEW STYLE HOUSING

(No. 23592) (No. 24990)
Housing Identification No.

(Located Here - In The Down-
Stream Face Of Both Housings)
There is a visual similarity between the 23592 and the 24990 work section housings. Many of the positioner
components that will work with one type housing will NOT work with the other. For assistance in determining
which housing you are servicing, refer to the above drawing.
260-4
CONTROL VALVES
TL SERIES
SPOOL CLEVIS IDENTIFICATION

The sectional control valve had a casting and spool change in June, 1999. The earlier model V10 used 3/8 -
24 UNF-2A thread on spool end. Later models use 5/16 -24 UNF-2A thread on spool end. Replacement
parts will be 5/16 thread.
5/16 5/16
Thread Thread
479730 = .745 455806 = 1.05
479729 = .665 455810 = .97
3/8 3/8
Thread Thread
3/16” Pin Hole 5/16” Pin Hole
CLEVIS NO. 479730 & 479729 CLEVIS NO. 455806 & 455810
For Use With Standard Enclosed Handles For Use With Universal Handles
Also Accepts Spool Boots
5/16 5/16
Thread Thread
455804 = .676 455805 = 1.80
455812 = .593 455811 = 1.72
3/8 3/8
Thread Thread
3/16” Pin Hole 5/16” Pin Hole
CLEVIS NO. 455804 & 455812 CLEVIS NO. 455805 & 455811
Also Accepts Spool Boot For Use With Standard Extended
Enclosed Handles
5/16 5/16
Thread Thread
465514 = 2.595 483529 =
455813 = 2.515 2.685
3/8 3/8
Thread Thread
3/16” Pin Hole
CLEVIS NO. 465514 & 465513 CLEVIS NO. 483529

For Use With Standard Extended Required For HRH and SOL-IH Actuation
Enclosed Handles For Use In 24990 Section Only
NOTE: Do not tighten clevis or bonnet end bolts into spools with wrenches. Coat with blue
loctite and hand tighten only (60 in. lbs. max.).
260-5
CONTROL VALVES
TL SERIES
REPLACING SECTION SEALS

Section Seals are located on the Inlet Cover and on the downstream side of all work sections.
2
Section Seal Kit
T 1
1. O-ring seal (Open
center and Exhaust Cores)
2. O-ring seal (Power Core)

T
IMPORTANT:
Do not prelube section seals
1. Disassemble valve as described.
2. Remove the old o-ring section seals. Be careful not to scratch or otherwise damage sealing surface
areas.
3. Thoroughly clean the o-ring counter bores and surfaces of each valve section.
4. Place valve assembly on a flat surface for reassembly.
5. Replace the four o-ring section seals.
Do not pre-lube the o-ring section seals prior to installation. Compression of lubricants
can distort the valve body causing spool bind.
6. Replace work sections on assembly studs in the reverse order in which they were removed. The o-ring
counter bores (with o-rings in place) should be to your right (downstream side of section) with the inlet
cover on your left.
Use care when sliding the work sections on the tie rods to avoid dislodging the o-rings.
7. When all work sections and the outlet cover are positioned on the assembly studs, replace the lock
washers and nuts.
8. Torque the nuts evenly per Quick Reference Guide.
If the stud nuts are not tightened to the proper torque, valve spools may bind or stick, or
cause o-ring seals to extrude.
260-6
CONTROL VALVES
TL SERIES
REPLACING BACK-UP RINGS

NOTE: Only replace continuous back-up rings if they have been damaged.
If the continuous back-up ring should need replacing, follow these simple procedures:
1. Using a single edge razor blade, carefully cut through the back-up ring in an angle as shown below.
NOTE: Make only one diagonal cut through the back-up ring. Do not separate the ring into two
pieces.
2. Slip the back-up ring over the cartridge and into place.
REPLACING SPOOL SEALS
SPOOL SEAL REMOVAL (MANUAL HANDLE)
1. Remove the handle assembly and clevis pin from the spool.
2. Remove the bonnet and spool positioner assembly from the rear of the work section.
3. Carefully slide the spool out of the valve housing.
4. Remove the old spool seals. Be careful not to scratch or otherwise damage the spool bore and sealing
surface areas.
5. Thoroughly clean both seal grooves.
260-7
CONTROL VALVES
TL SERIES
SPOOL SEAL INSTALLATION (MANUAL HANDLE)
1. Lightly oil and insert one of the new spool seals in the handle end seal groove of the valve housing.
Verify seal fit by carefully running your finger around the exposed edge of the seal. You should have a
smooth, perfect ridge with no kinks or twists.
DO NOT insert the seal on the positioner end at this time or it may be damaged when the
spool is re-introduced into the valve housing.
2. Lightly oil the valve spool and re-introduce the spool into the valve housing, starting from the positioner
end (opposite the end with the seal installed).
3. Slowly push the spool past the seal with a twisting motion to assist the movement. Stop when the seal
groove is exposed on the positioner end.
DO NOT pull the spool too far, as this will allow the seal in the front groove to enter a
spool groove. If it does, the seal may be cut when the spool is pushed back.
4. Lightly oil and insert the remaining spool seal in the bonnet end seal groove. Verify seal fit in the same
manner as in step 1.
5. Return the spool to the center position with a twisting motion to assist movement.
6. Reattach the spool positioner, slide the bonnet in place and replace the bonnet screws.
7. Replace the spool clevis pin and handle assembly.
260-8
CONTROL VALVES
TL SERIES
PLUGS
O-Ring Seal
O-Ring Seal
Back-Up Seal
O-Ring Seal
SAE 10 PLUG CLOSED CENTER PLUG

(Required for Turn Around) (Required for Closed Center or
Torque Option Cavity Cartridge To: END Power Beyond)
18 -20 ft. lbs. (24 - 27 Nm) Torque Option Cavity Cartridge To:
18 - 20 ft. lbs. (24 - 27 Nm)
O-Ring Seal
O-Ring Seal
Back-Up Seal
Back-Up Seal
O-Ring Seal
O-Ring Seal
POWER BEYOND SLEEVES WORK PORT RELIEF CAVITY PLUG
(Required for TOP Power Beyond) (No Relief)
Torque Option Cavity Cartridge To: Torque Relief Cavity Plug To:
18 - 20 ft. lbs. (24 - 27 NM) 18 - 20 ft. lbs. (24 - 27 NM)
NOTE: Only replace continuous back-up rings if they have been damaged.
260-9
CONTROL VALVES
TL SERIES
SPOOL POSITIONERS
NOTE: Clean threads and apply loctite No. 242 (blue) thread locking adhesive prior to
installation.
NOTE: Unless otherwise specified, mount bonnet with drain slot down toward valve mounting
feet.
SPRING RETURN "SC" TO NEUTRAL
(Item 6 = Used in
23592 Housing Only)
5 Torque to: 4 3 Torque to: 1 2 1 6

5-6 ft. lbs. 4-5 ft. lbs.
(7-8 Nm) (6-7 Nm)
1. Spring Collar 3. Spool Screw 5. Bonnet Screw

2. Centering Spring 4. Bonnet 6. Seal Plate
3-POSITION "D" DETENTED
(Item 7 = Used
in 23592
Torque to: Torque to: Housing Only)
6 (7-8 Nm) 5 1 3 (6-7 Nm) 4 8 7
Apply NLGI #2 heavy

duty General Purpose
Grease to surfaces of
2 Ref. #’s 1, 2 & 4 prior to
installation.
1. 3-Position Detent Sleeve 4. Detent Spring 7. Seal Plate

2. Detent Ball 5. Bonnet 8. Spacer
3. Detent Ball Holder 6. Bonnet Screw
260-10
CONTROL VALVES
TL SERIES
2-POSITION "D" DETENTED

Locate here for Locate here for
Neutral and Spool Neutral and
Out Detents 8 Spool In Detents
Torque to: Neutral and
Torque to: Spool In
6 (7-8 Nm) 5 1 3 (6-7 Nm) 4 9
Neutral and
Spool Out
Apply NLGI #2 heavy duty
General Purpose Grease
7 to surfaces of Ref. #’s 1, 2
(Item 7 = Used & 4 prior to installation.
2
in 23592 Housing Only)
1. 3-Position Detent Sleeve 4. Detent Spring 7. Seal Plate

2. Detent Ball 5. Bonnet 8. Spacer
3. Detent Ball Holder 6. Bonnet Screw 9. Spacer
NOTE: The location of this spacer will convert the assembly to Detent "Neutral" and "Spool In"
or "Neutral" and "Spool Out".
3-POSITION, SPRING EXTENDED
Torque to: Torque to:

5 (7-8 Nm) 4 3 2 (6-7 Nm) 1
For use in 24990 Housings
1. 3-Position Detent Sleeve 3. Spring 5. Bonnet Screw

2. Spool Screw 4. Bonnet
260-11
CONTROL VALVES
TL SERIES
NEUTRAL SWITCH - 24990 HOUSINGS

MATING CONNECTOR
Top view of 21930001 Packard weather pack
Switch Connector No. 12015792
10
Apply a NLGI #2
heavy duty General Purpose
Grease prior to installation.
5 1 4 2 3 2
9
8
7 Torque to: 6 Clean threads and apply Type II. Grade N
5-6 ft. lbs. (Ref: Loctite 242) prior to installation
(7-8 Nm) Torque to 4-5 ft. lbs. (5-7 Nm)
1. Positioner Spacer Spring In 5. Jam Nut

2. Spring Collar Switch Plate 6. Interlock Switch
3. Spring Screw
4. Switch Positioner Spud Switch Body
NOTE: Properly align the positioner spacer with the switch body prior to installing the dowel pin.
SWITCH SETTING INSTRUCTION

1. Apply type III, Grade R between the locknut and switch prior to installation.
2. Attach continuity tester to switch terminals.
3. Make certain that the valve spool is shifted.
4. Screw switch to body until continuity tester indicates switch contacts have closed.
5. Turn switch in and additional full turn.
6. Place valve in neutral and verify continuity tester indicated switch contacts have opened.
7. Tighten locknut to 5–10 ft. lbs. (7-14 N-m) taking care not to change the switch adjustment.
260-12
CONTROL VALVES
TL SERIES
SINGLE STICK ASSEMBLY
T
P 23 P 21 P19 P17 P15 P13 P 11 P9 P7 P5 P3
P 25 P1
P
P 26 P 24 P 22 P 20 P18 P16 P14 P12 P10 P8 P6 P4
P2
T
DUMP TOOLS JIB EXT WINCH JIBTILT PLAT ROT PLAT LEV ENABLE LB ROT UB
REMOVAL
1. Tag all hoses prior to removal. Place caps on hoses and fittings to prevent contamination.
2. Remove fasteners securing valve assembly to platform weldment.
3. Place the control head with linkage and valve in a suitable work area.
MAINTENANCE
1. Remove spring from the boot. Remove boot by carefully sliding it over the cap and handle.
2. Inspect the following for wear and replace if worn when the control assembly is disassembled:
forks rods
ball sockets links
shafts pins
bushings enabling shaft
arms clevis
handle boot
NOTE: Lubricate bearing surfaces, ball sockets and all other moving parts prior to reassembly.
NOTE: Linkage adjustment must be performed when the control head assembly is mounted to
the valve assembly.
NOTE: After control head assembly has been installed on valve assembly, all functions must be
able to function independently with no linkage interference or binding. All functions in
neutral should have slight free travel.
260-13
CONTROL VALVES
TL SERIES
LUBRICATION
Control head linkage should be lubricated after every 90 days of operation or 500 hours, which ever occurs
first. Use Lubriplate #130AA, or equivalent, on ball joints.
NOTE: Arrows indicate lubrication points.
V-10 APPLICATION
Use of excessive oil or grease lubricant in control head assembly could allow dirt and
dust to collect on fiberglass parts. This may allow an arch path for electric current. Clean
up excess lubricant that could contaminate the fiberglass components.
260-14
CONTROL VALVES
TL SERIES
CONTROL HEAD ASSEMBLY/DISASSEMBLY

Cap Pivot Cap
Point
Upper Boom
Rod Pivot Point
(8) (10) Handle Enabling

Rotation Upper Boom Rod Lever
Pivot Arm Adjustment Location
(adjust so cap is
parallel with base)
(7)
Pins Upper
Boom Rod
Fork Pivot (6) (5)

Point Upper Lower
Boom Arm Enable Arm
(1,2) (3,4) (A) (1,2)

Base
1. Position control head assembly onto valve assembly. Align hole in base ("A" above) with rotation valve
section spool clevis. Install hex head capscrews and washers (1–4) using loctite. Torque #10 screws to
2.5 ft. lbs. (3 N-m), 5/16 screws to 13 ft. lbs (18 N-m).
2. For proper alignment of lower enable arm (5), install arm as shown, align arm by positioning link parallel
with valve spool (when valve spool is pushed in), and tighten fasteners. Verify alignment by checking
that the ball joint pivot is in line with the clevis pin for rotation clevis in the enabled position.
3. For proper alignment of upper boom arm (6), install as shown, align arm by positioning link parallel with
valve spool when spool is in neutral. Verify alignment by checking that the distance from the upper boom
rod pinning points are the same distance at the top to the cap pivot (pinning point) and the bottom to the
fork pivot.
4. Press pins (7) into rotation pivot arm (8). Install arm minimizing the back and forth movement of arm.
5. After control head has been installed on the valve assembly, the enabling rod must be adjusted to shift
valve spool fully and maintain slight free travel of trigger in all positions when released.
6. With control head assembly mounted on valve assembly, all functions should be able to function
independently with no linkage interference or binding. All functions in neutral should have slight free
travel.
7. Disassembly in reverse.
Use of excessive oil or grease lubricant in control head assembly could allow dirt and
dust to collect on fiberglass parts. This may allow arch path for electric current.
260-15
CONTROL VALVES
TL SERIES
INDIVIDUAL LEVER CONTROL

REMOVAL
To remove the valve assembly, proceed as follows:
1. Tag, disconnect, and cap all hydraulic lines to the valve assembly.
2. Remove the 3 mounting fasteners (5) that secure the valve assembly to the mounting bracket weldment
(6).
3. Remove the valve assembly and place in a suitable work area.
MAINTENANCE
The following items should be checked whenever performing maintenance on the valve assembly.
1. Spring return (1), check for proper spring tension. It must retain constant pressure on the handle (2).
Replace if spring no longer holds tension.
2. Check the pins for wear (3), which secure the handle (2) to the working section (4). Replace any worn
parts at this time.
3. Check for leakage between the work sections, inlet, and outlet valve bodies. If evidence of leakage exits,
be sure to disassemble the complete valve assembly and replace all the o-rings between all valve
sections. See your repair parts manual for seal kit information.
260-16
CONTROL VALVES
TL SERIES
INDIVIDUAL LEVER CONTROL DISASSEMBLY/ASSEMBLY

To disassemble the control handle, proceed as follows:
1. Remove key (1) and pin (2).
2. Remove key (3) and pin (4).
3. Remove spring (5).
4. Remove handle (6).
5. Inspect for wear at this time. Replace any worn parts at this time.
6. Re-assemble in reverse. Check for smooth movement following method of operation shown below. If
lever or levers appear to bind, check for proper installation. Handle must not actuate the valve without
lifting the lever. When the handle is released it must return to lock.
260-17
CONTROL VALVES
TL SERIES
260-18
WIRED RITE SST-4
TL SERIES
SECTION 312
WIRED RITE SST-4
& OPERATION GUIDE
INFORMATION IN THIS SECTION IS FROM WIRED RITE SYSTEMS, INC. (Docsst-4-01.8 Rev 0)
SAFETY SUMMARY
The following general safety precautions must be observed during all phases of operation, service, and
repair of this instrument. Failure to comply with these precautions or with specific warnings elsewhere in this
manual violates safety standards of design, manufacture and intended use of the instrument. Wired Rite
Systems assumes no liability of the customer’s failure to comply with these requirements.
1. SST-4 installation must be performed by appropriate qualified personnel trained for the installation of
vehicle electrical equipment and controls for engine functions.
2. Vehicle safety interlocks installed in vehicles must never be bypassed.
3. Verify that the vehicle is disabled before performing installation or maintenance procedures with the
SST-4. The battery should be disconnected to ensure that the vehicle is disabled during installation.
4. Whenever performing maintenance, use only factory specified parts and replacement parts.
5. Always use appropriate gauge wire for the expected current and power ratings.
6. DO NOT SUBSTITUTE PARTS OR MODIFY circuitry. Because of the danger of introducing additional
hazards, do not install substitute parts or perform any unauthorized modification.
7. Equipment that appears damaged or defective should be made inoperative and secured against
unintended operation until they can be repaired by qualified service personnel.
312-1
WIRED RITE SST-4
TL SERIES
OPERATIONAL FEATURES
Ability to remotely operate engine controls, including Start/Stop, Throttle and E-Power.
Active and Inactive modes. Active mode when Master enable signal is provided to the SST-4.
Auto Stop On Loss Of Pressure Mode allows the monitoring of engine or PTO functions and automatic fail-
over to preset emergency power settings.
Inputs triggers include: MASTER, Start/Stop (SS), Auxiliary (AUX), Throttle (TH), Pressure Sensor
(PRESSURE). Triggers are provided by supplying either a positive signal (+12V) or ground signal.
Three replaceable on-board relays enable switching for Ignition, Start/Stop, and E-Power.
Circuit breakers provide protection for Ignition, Start/Stop, and E-Power circuits.
Dual Throttle relays allow for multiple throttle settings (engine speeds).
Emergency Power (E-Power) source can be triggered independently.
Four character display showing faults, programming parameters and hour meter readout.
LED status indicators provide additional information, such as status of relay positions.
Programmable via 3-Push button switches for choosing menu and entering/modifying parameters. No
computer is required for programming.
Timer delays can be set for the following: (Delay values are shown in Table 4)
• E-Power Delay Timer
• Throttle Delay Timer
• Glow Plug Timer
• Start Duration Timer (max cranking time of the vehicle’s starter)
• Loss of engine oil/hydraulic fluid pressure sensor delay
Maximum time for the E-Power circuit to be engaged can be set. Time values are shown in Table 4.
Test mode allows bench testing of the inputs and outputs using built-in display.
On-board self-diagnostic tests display faults, and system “remembers” any faults that have occurred, even if
the faults no longer exist.
Connector kits are included for control and throttle connectors.
Pre-wired harnesses are available (optional).
CONNECTIONS
Detailed wiring diagrams and notes are found in Appendix I. Please refer to that section for information and
suggestions for your specific requirements. This manual assumes that the installation was completed using
these suggestions.
Figure 2 shows the SST-4 board layout, highlighting key components.
Figure 3 shows the terminal connections for the wiring to the SST-4.
WIRING DIAGRAMS
Wiring diagrams for common configurations of the SST-4 board are shown in Appendix I Wiring Diagrams.
312-2
WIRED RITE SST-4
TL SERIES
CONNECTION TABLES
Tables showing the function of each connection to the SST-4 are shown in Appendix II Connection Tables.
MOUNTING
SCREWS
D2
START/STOP
THROTTLE
INDICATOR 4 DIGIT
PROC-
DISPLAY
ESSOR
PUSH BUTTONS
RELAY INDICATORS MENU UP DOWN
D3 D4
D5 D6 D7
T1 T2
STARTER AUX IGNITION RELAY RELAY
RELAY RELAY RELAY
MOUNTING
SCREWS
J4 J3 J7 J6 J5 J8 J9
J4-J3 J7-J6 (or J6-J5) J8-J9
RESET RESET RESET THROTTLE RELAY
CONTROLS
CIRCUIT BREAKERS
J1 20 AMP
CONTROL
TB1 TERMINAL BLOCK T1 T2
FIGURE 2 SST-4 SIMPLIFIED BOARD LAYOUT SHOWING KEY COMPONENTS
TB1
T1 T2
J1 2 1 2 1
3 1 1 2 3 4 5 6 7
6 4
4 3 4 3
J1 INPUTS TB1 T1 T2
PIN FUNCTION TSP FUNCTION PIN FUNCTION PIN FUNCTION
1 Pressure 1 Ground 1 RLY1 Norm.closed 1 RLY2 Norm.closed
2 Aux Trig 2 Start Out 2 RLY1 Norm.open 2 RLY2 Norm.open
3 Master 3 Main Power (VBAT) 3 RLY1 Norm.closed 3 RLY2 Norm.closed
4 Throttle 4 Aux In 4 RLY1 Norm.open 4 RLY2 Norm.open
5 Start/Stop 5 Aux Out
6 Ground 6 Ignition In
7 Ignition Out
FIGURE 3 SST-4 TERMINAL CONNECTIONS
312-3
WIRED RITE SST-4
TL SERIES
INSTALLATION AND POWER-UP

After all of the connections have been made, and the unit has been mounted securely, the SST-4 is ready to
be powered up. The following procedure describes the power up and initial checkout.
1. With the ignition switch in the ON position, turn on the “Master” switch to power up the SST-4. On initial
power up the SST-4 will perform a self-diagnostic test to verify that all of the functions are operating
correctly. If a flashing “SP” is reported, the Master switch was turned on with the ignition switch in the off
position. Turn on the Ignition switch, and then hold down the UP and DOWN buttons simultaneously for
5 seconds to clear the fault.
2. If no faults are detected, the SST-4 will go into “Run Mode” and the hour meter readout will be visible on
the display (refer to Table 1).
3. If a fault is detected on power up, a code will be flashing on the display indicating in which circuit the
fault has occurred. For assistance in troubleshooting, please refer to the trouble shooting section.
4. After all of the faults have been cleared and the SST-4 is operating in normal mode, apply signals to test
the proper function of the SST-4. Table 1 outlines the different display codes and the operations which
they indicate. Apply signals as available to ensure proper operation of each function. When checking
signals, verify the status of various signals on the board by using the green display indicators, shown in
and detailed in Table 2.
DISPLAY FLASHING DESCRIPTION
Yes Board power only, Master switch is off.
No Run Mode (Hour Meter Display).

NOTE: If Hour Meter is counting, the decimal flashes. If not
counting, decimal does not flash.
No Stop Mode.
No Start signal active, glow plugs on.
No Start signal active, starter on.
No Throttle Plunger input active.
No Emergency Power input active.
TABLE 1 DISPLAY DURING NORMAL OPERATIONS
LED DESCRIPTION ON INDICATES

D2 Start/Stop or Throttle input An input trigger is applied to Start/Stop or Throttle.
D3 Throttle relay #1 Relay is enabled.
D4 Throttle relay #2 Relay is enabled.
D5 Start relay Relay in enabled, power at START OUT on TB1.
D6 AUX relay (E-Pump) Relay in enabled, power at AUX OUT on TB1.
D7 Ignition Relay is enabled, power at IGN OUT on TB1.
TABLE 2 SST-4 GREEN LED INDICATORS
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PROGRAMMING
PARAMETER VALUE DESCRIPTION
“A” 1 Single plunger (Start/Stop only)
Plunger Mode
2* Dual plunger (Start/Stop/Throttle)
“B” 1* Throttle relays latch ON and OFF (maintained)
Throttle Mode
2 Throttle relays are momentary (on-demand)
(Only if A is set to 2)
3 T1 latches on, T2 momentary, STOP turns both OFF
4 T1 & T2 latch ON, T2 OFF, STOP turns both OFF
5 Timed operation (see ”E”)
6 T1 latches ON, T1 OFF & T2 latches ON, T1 & T2 OFF
7 T1 momentary ON, T2 momentary ON, repeat
8 No Throttle Mode
9 As soon as Master Power is applied, T1 latches ON, T2
momentary, STOP turns both OFF
“C” 1* AUX (Emergency Power) from the J1 Pin 4 input (Throttle)
AUX (Emergency Power) Mode
2 AUX (Emergency Power) from the J1 Pin 5 input (Start/Stop)
3 Reserved
4 AUX (Emergency Power) from J1 Pin 2 (Aux Trig)
5 Auto Stop On Loss Of Pressure Mode (see Appendix V)
“D” AUX (Emergency Power) Time 0-9, 3* Time delay for Emergency Power relay actuation
“E” Throttle Mode Timer 0-9, 5* Time delay for Throttle timed operation
“F” Glow Plug Timer 0-9, 0* Delay time for starter activation
“H” Start Duration Timer 0-9, 5* Maximum time for starter cranking
“J” Emergency Power Duration Time 0-d, 8* Maximum time for Emergency Power operation
“L” 0* Diagnostic display OFF
Diagnostic Display ON/OFF
1 Diagnostic display ON
“O” Auto Stop Pressure Delay Timer 3-d, 7* Pressure sender delay time out when in Auto Stop Mode
“P” 0* Normally open and ground signal indicates pressure present
Pressure Switch Descriptor
1 Normally closed and ground signal indicates NO pressure
2 Normally open and positive signal indicates pressure present
3 Normally closed and positive signal indicates NO pressure
TABLE 3 PROGRAMMABLE PARAMETERS AND SETTING
NOTE: *DENOTES FACTORY SETTING
VALUE DELAY TIME VALUE DELAY TIME VALUE DELAY TIME

0 No Delay/Time Out 5 10 Seconds A 1 Minute
1 1 Second 6 15 Seconds B 2 Minutes
2 2 Seconds 7 20 Seconds C 3 Minutes
3 3 Seconds 8 30 Seconds D 4 Minutes
4 5 Seconds 9 45 Seconds
TABLE 4 PROGRAMMABLE DELAY TIMER VALUES
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PROGRAMMING PROCEDURE
The following procedure describes how to view and change settings for SST-4 operation. These procedures
require the user to access the push buttons on the SST-4 circuit board: “MENU”, “UP”, and “DOWN”.
1. Press the “MENU” button on the SST-4 board. The display will show the board’s current operating
configuration, starting with “A2”, that is, the system is set for Dual Plunger Mode.
2. Press “MENU” again, and the next parameter is displayed. Repeat pressing “MENU” to view all the
settings, until the system returns to “A2”.
3. If changes are desired, press “MENU” until the target parameter is displayed. Use the “UP” and “DOWN”
keys to change the parameter to the desired value. The available choices are those shown in Table 5.
4. To save changes, press and hold the “MENU” key for 5 seconds. The display flashes “SA” to confirm
that the configuration change has been saved.
If the configuration has been changed mistakenly, restore the SST-4 to its previous configuration by holding
the “MENU” and “DOWN” keys for three seconds. This will reload the last saved settings. You can page
through the configurations and see that it is as expected, then the settings must be saved, by holding the
“MENU” key for 5 seconds. The display will flash “SA” for confirmation of the save. The SST-4 is preloaded
with a factory default configuration. The default settings are displayed on Table 3 with an asterisk (*). To
recall these setting hold the “MENU” and “UP” keys down together for 3 seconds. You can page through the
configurations and see that it is as expected, then the settings must be saved, by pressing and holding the
“MENU” key for 5 seconds. The display will flash “SA” as confirmation of the save. The table below shows a
summary of the push button controls.
It is important to note that changes are not saved automatically, but must be written to memory by holding
down the “MENU” key for 5 seconds. This includes any of the recall functions described above. The values
that were recalled are not made active until the user has saved them.
FUNCTION SUMMARY FUNCTION DESCRIPTION PROCEDURE
Choose Parameter Choose which parameter will be Press “MENU” until the desired parameter is
modified. displayed.
Choose Value Choose the value of the selected Press “UP” and “DOWN” until the desired
parameter parameter value is displayed.
Save Changes Save the changes made to one Press and hold “MENU” for 5 seconds. “SA” is
or more parameter values flashed to confirm save.
Recall Previous Recall previously saved Press and hold both “MENU” and “DOWN” for
configuration and cancel last three seconds. “SA” is flashed to confirm save.
save command
Recall Factory Recall factory settings for all Press and hold both “MENU” and “UP” for
parameters three seconds. “SA” is flashed to confirm save.
TABLE 5 MENU/UP/DOWN PUSHBUTTON FUNCTIONS
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TROUBLESHOOTING
If a problem is encountered, the following procedure can be used to troubleshoot the system, and identify
and fix some of the more common problems. If the problem is not easily identified, please contact Wired Rite
for assistance at 1-800-538-7483. Before beginning the troubleshooting, please check these five items:
1. System Lock-up. The processor on the SST-4 board can go into a locked-up situation if the power is
toggled on and off at a rapid rate. If this occurs the processor must be reset by disconnecting the power
to the board for several seconds and then reconnecting it.
2. Ground. The ground wire of the SST-4 must NOT be connected to the chassis, but routed directly to the
negative side of the battery.
3. On-board LED indicators. An additional troubleshooting resource is the on-board LED indicators.
These functions are described in TABLE 2 SST-4 GREEN LED INDICATORS.
4. Diagnostic Display. If an error is detected by the SST-4, and parameter “L” is set to 1, the display will
flash to identify the problem circuit. Refer to Table 6 for locating the cause of the fault.
5. Storing And Clearing Faults. If a fault occurs, the SST-4’s on board diagnostics will record in which
circuit the fault occurred and save the fault into memory. To clear all of the recorded faults, press and
hold the “UP” and “DOWN” buttons on the board for three seconds or remove board power. This will
erase the volatile memory and place the system back in the “Run Mode”.
TROUBLESHOOTING PROCEDURE
1. Begin with all inputs to the board OFF. Remove the enclosure lid if present to allow visual inspection of
the 4-character display and the relay status indicators.
2. Supply power to the SST-4 board. The 4-character displays should be active, for example with two
blinking decimal points. Check for board power on TB1 Pin 3 (GND is available on TB1 Pin 1.) If there is
no power, check the circuit breaker.
3. Turn the ignition ON. This should illuminate the relay indicators D5 (Starter relay), D6 (AUX relay), and
D7 (Ignition relay). If one or more indicators are not illuminated, then that circuit may not be receiving
power from the ignition splice. Check the associated wiring path to ensure that the circuit is enabled. You
may need to manually reset the manual circuit breakers near each relay by pressing the yellow tab.
NOTE: The AUX relay manual circuit breaker can be placed in two positions, depending on
whether the system incorporates a separate E-Power battery. If there is a separate E-
Power battery, then the circuit breaker should be connected between J5 and J6;
otherwise it should be connected between J6 and J7.
4. Turn ON the SST-4 Master switch. This is sometimes labeled “MACHINE” or “PTO” or “AERIAL
ENABLE” to indicate non-truck functions. This should activate the hour meter on the 4-character display.
If not, check that the signal from the SST-4 Master signal is being applied to J1 Pin 3.
5. Apply Start signal from the aerial switch. Indicator D2 should be illuminated. If not, verify that the Start
signal is being applied to J1 Pin 5. Remove the Start signal.
6. Apply Throttle signal from the aerial switch. Indicator D2 should be illuminated. If not verify that the
Throttle signal is being applied to J1 Pin 4. Remove the Throttle signal.
7. Apply signal to activate the Start, Stop, and E-Power functions as defined in the programming settings.
Verify that the 4-character display shows “St”, “SP”, and “EP” as expected. If not, check programming
settings (see Programming Section). Set parameter “L” to 1 and if the display is flashing “St”, “SP”, or
“EP”, then there has been a fault in that circuit. Check the manual circuit breakers and reset if necessary
by pressing the yellow tab on the circuit breaker.
8. Apply signal to activate the Throttle functions as defined in the programming settings. Verify that the
Throttle relay Indicators D3 and D4 are activated. If not, check programming settings (see Programming
Section).
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TROUBLESHOOTING QUICK REFERENCE

The following table shows common problems and possible solutions when operating the SST-4. If the
problem is not easily identified, please contact Wired Rite for assistance at 1-800-538-7483.
PROBLEM POSSIBLE SOLUTION
Nothing is displayed on 4-character display. Check board power available at TB1 Pin 3. If power is applied
and board is unresponsive, try resetting processor by
removing system power for at least three seconds. Then
reapply power.
Relay indicators D5, D6, D7 off with ignition Check ignition splice. Check manual circuit breakers. Check
on. position of AUX relay circuit breaker. With separate E-Power
battery, circuit breaker should be between J5 and J6.
Otherwise it should be J6 and J7.
No Hour Meter is displayed on 4-character Check board power and SST-4 MASTER input at J1 Pin 3.
display.
Hour Meter is not counting (decimal not Check SST-4 MASTER input at J1 Pin 3. Check programming
flashing). parameter “O” for Hour Meter Input Mode (Master or Spare).
Start/Stop or Throttle inputs do not activate Check signal path for trigger signals Start/Stop (J1 Pin 5) and
D2 indicator. Throttle (J1 Pin 4).
Displayed state of “St, “SP” or “EP” are not Check programming parameters C and D and timer durations.
as expected.
Throttle relay not triggering and relay Check signal path for Throttle signals into T1 and T2. Check
indicators D3 and D4 are not illuminated. programming parameters A, B, and E.
FLASHING DISPLAY DESCRIPTION

Fault detected in Stop circuit
Fault detected in Start circuit
Fault detected in Emergency Power circuit
TABLE 6 FAULT DISPLAY
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TEST MODE OPERATION

Test Mode is used to verify the wiring and operation of the system.
CAUTION: When in Test Mode, the vehicle or emergency pump may start unexpectedly.
Whenever possible, Test Mode should be used for bench testing. If used when installed, two
mechanics should be present, and extra care is strongly advised.
To enter Test Mode, press and hold all three buttons: “MENU”, “UP”, and “DOWN” for five seconds until all of
the segments flash in the middle two 7-segment displays.
To verify each of the items shown in the table below, perform the user action, and verify the resulting display.
VERIFICATION OF
USER ACTION RESULTING DISPLAY
RELAY FUNCTIONS
Ignition Relay & T1 With ignition ON press MENU button on SST-4 board
Throttle Relay (Warning: Vehicle may start).
Starter Relay & T2 With ignition ON press Up button on SST-4 board

Throttle Relay (Warning: vehicle may start).
Emergency Pump Relay With ignition ON press Down button on SST-4 board
(Warning: E-Pump may start).
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VERIFICATION OF
USER ACTION RESULTING DISPLAY
INSTALLATION WIRING
Board Power (TB1, Apply power to board.
Position 3)
Ignition Power (TB1, Turn ignition key ON.

Position 6)
Power From Master Turn ON Master switch.

Switch (J1, Pin 3)
Remote E-Power Input Activate remote E-Power switch.

(J1, Pin 2)
Remote Start/Stop Input Activate remote Start/Stop switch.

(J1, Pin 5)
Remote Throttle Input (J1, Activate remote Throttle switch.

Pin 4)
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APPENDIX I WIRING DIAGRAMS

The SST-4 can be wired in various ways for a variety of engine control applications. This section includes
wiring diagram for three common configurations:
• AUX E-Power Battery. Emergency Power is provided from an Auxiliary Battery. Programming state
would include “C4”.
• No AUX E-Power Battery. Emergency Power is provided from normal battery (there is no Auxiliary
Battery) and E-power control is from Start/Stop or Throttle signals. Programming state would include
“C1” or “C2”.
• No Aux E-Power Battery, simplified. Fully ignition supplied. Emergency Power is provided from
normal battery (there is no Auxiliary Battery) and E-Power control is from Start/Stop or Throttle
signals. Programming state would include “C1” or “C2”.
TB1
T1 T2
J1 2 1 2 1
3 1 1 2 3 4 5 6 7
6 4
4 3 4 3
J1 INPUTS TB1 T1 T2
7 Ignition Out
CONNECTION NOTES
1. The Auxiliary (AUX), Throttle (TH), and Start/Stop (SS) are input triggers that are provided by supplying
either a positive signal (+12V) or ground signal.
2. Emergency Power operation: If using a separate E-Power Battery, the circuit breaker for the AUX relay
on the SST-4 must be connected between the J6 and J5 female push-on connectors. If a separate E-
Power battery is NOT being used, the circuit breaker must be connected between the J6 and J7
connectors. See Figure 2 for connection locations.
312-11
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WIRING DIAGRAM 1
• AUX E-Power Battery. Emergency Power is provided from Auxiliary Battery. Note center Circuit
Breaker is positioned in the J6-J5 location.
EMERGENCY
HYDRAULIC PUMP
SOLINOID
D2
MENU UP DOWN
STARTER AUX. IGNITION D3 D4
D5 D6 D7
THROTTLE START/STOP E-POWER
AUX.
STARTER E-PUMP IGNITION AIR CYLINDER AIR CYLINDER AIR CYLINDER
J1 T1 T2
20A 20A 20A
1 TB1 7 CIRCUIT
BREAKER
RED/WHT (J1 PIN-3)
PRESSURE SWITCHES
MASTER
PUR/GRN-AUX OUT
ORG/RED-IGN OUT
ORG/BLK- STARTER
RED/GRN-AUX BAT
SWITCH AUXILIARY
BATTERY
ORG-IGN IN
WHT- GND
RED-VBAT
REFER TO ENGINE ECM

BATTERY +12 VOLTS
DOCUMENTATION FOR
WIRING INSTRUCTIONS
WHT/YEL (J1 PIN-4)

WHT/BLU (J1 PIN-5)
WHT/GRN (J1 PIN-2)
WRS PART# CBW 1081 IGNITION

INSTALLER MUST CUT ELECTRONIC
EXISTING IGNITION
WIRE HERE CONTROL
MODULE
80 AMP EXISTING
BREAKER ACC
BATTERY
EXISTING ON
START
EXISTING
+
STARTER
STARTER
VEHICLE
SOLENOID
BATTERY
TB1
T1 T2
J1 2 1 2 1
3 1 1 2 3 4 5 6 7
6 4
4 3 4 3
J1 INPUTS TB1 T1 T2
7 Ignition Out
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WIRING DIAGRAM 2
• No AUX E-Power Battery. Power supplied from main battery through waterproof circuit breaker.
Emergency Power is provided from normal battery (there is no Auxiliary Battery) and E-Power control
is from Start/Stop or Throttle signals. Programming state would include “C1” or “C2”.
EMERGENCY
HYDRAULIC PUMP
SOLINOID
D2
MENU UP DOWN
D5 D6 D7
THROTTLE START/STOP
AUX.
STARTER E-PUMP IGNITION AIR CYLINDER AIR CYLINDER
J1 T1 T2
20A 20A 20A
1 TB1 7
RED/WHT (J1 PIN-3)
PRESSURE SWITCHES
MASTER
PUR/GRN-AUX OUT
ORG/RED-IGN OUT
ORG/BLK- STARTER
SWITCH
ORG-IGN IN
WHT- GND
RED-VBAT
REFER TO ENGINE ECM

BATTERY +12 VOLTS
DOCUMENTATION FOR
WIRING INSTRUCTIONS
WHT/YEL (J1 PIN-4)

WHT/BLU (J1 PIN-5)
WRS PART# CBW 1081 IGNITION

EXISTING IGNITION
WIRE HERE CONTROL
MODULE
80 AMP EXISTING
BREAKER ACC
BATTERY
EXISTING ON
START
EXISTING
+
STARTER
STARTER
VEHICLE
SOLENOID
BATTERY
TB1
T1 T2
J1 2 1 2 1
3 1 1 2 3 4 5 6 7
6 4
4 3 4 3
J1 INPUTS TB1 T1 T2
7 Ignition Out
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WIRING DIAGRAM 3
• No AUX E-Power Battery, simplified. Power supplied from main battery through ignition switch
circuit. Please note that this circuit puts extra demand on the ignition circuit. Wire of sufficient gauge
must be used. Check your vehicle electrical specifications to be certain that his circuit will not damage
the ignition system. Emergency Power is provided from normal battery (there is no Auxiliary Battery)
and E-Power control is from Start/Stop or Throttle signals. Programming state would include “C1” or
“C2”.
EMERGENCY
HYDRAULIC PUMP
SOLINOID
D2
MENU UP DOWN
D5 D6 D7
THROTTLE START/STOP
AUX.
STARTER E-PUMP IGNITION AIR CYLINDER AIR CYLINDER
J1 T1 T2
20A 20A 20A
1 TB1 7
RED/WHT (J1 PIN-3)
PRESSURE SWITCHES
INSTALLER SUPPLIED WIRE
MASTER
PUR/GRN-AUX OUT
ORG/RED-IGN OUT
ORG/BLK- STARTER
SWITCH
ORG-IGN IN
WHT- GND
REFER TO ENGINE ECM

BATTERY +12 VOLTS
DOCUMENTATION FOR
WIRING INSTRUCTIONS
WHT/YEL (J1 PIN-4)

WHT/BLU (J1 PIN-5)
IGNITION
EXISTING IGNITION
WIRE HERE CONTROL
MODULE
EXISTING
ACC
BATTERY
EXISTING ON
START
EXISTING
+
STARTER
STARTER
VEHICLE
SOLENOID
BATTERY
TB1
T1 T2
J1 2 1 2 1
3 1 1 2 3 4 5 6 7
6 4
4 3 4 3
J1 INPUTS TB1 T1 T2
7 Ignition Out
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APPENDIX II CONNECTION TABLES

1. Ignition relay on SST-4 is “Normally Closed”. If power is not supplied to the board, the ignition circuit will
be closed and the ignition function will not be interrupted.
2. The SST-4 hour meter can be triggered either by the Master signal or the Spare signal on J1 Pin 1. This
is user-programmable, as described in Section 5 PROGRAMMING.
3. T1 and T2 are identical, except T1 controls relay T1 and T2 controls relay 2.
TB1
T1 T2
J1 2 1 2 1
3 1 1 2 3 4 5 6 7
6 4
4 3 4 3
J1 INPUTS TB1 T1 T2
7 Ignition Out
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J1 CONNECTIONS
J1# LABEL FUNCTION VEHICLE WIRE LABEL
1 Pressure Pressure sensor trigger input. Engine Oil or PTO Pressure
Hydraulic Fluid sensor
2 Aux Trigger Triggers auxiliary circuitry used for E-Power. E-Pump switch Aux Trig
3 Master Enables SST-4 operation and triggers on- Master Enable switch Master Pos
board hour meter.
4 Throttle Triggers throttle circuitry on SST-4 board. Bucket Throttle switch Throttle
5 Start/Stop Triggers Start/Stop circuitry on SST-4 board. Bucket Start/Stop Start Trig
switch
6 Ground Ground (Use negative battery connection, not Battery (-) Gnd
vehicle chassis.).
TB1 CONNECTIONS
TB1# LABEL FUNCTION VEHICLE WIRE LABEL
1 Gnd Ground (Use negative battery connection, not Battery (-) Gnd
vehicle chassis.).
2 Start Out Supplies power to starter when relay is Output From Key Starter
enabled. “Start”
3 Vbat Supplies +12V to board in normal operation. Battery (+) Vbat
4 Aux In Auxiliary input. May be used for emergency E-Power Battery Aux Bat
power or other user defined function.
5 Aux Out Auxiliary output supplies high current output E-Pump Aux Out
to E-Pump or other function when relay is
enabled.
6 Ign In Ignition input signal. Key Side of Ignition Ign In
Splice
7 Ign Out Ignition output. ECM Side of Ignition Ign Out
Splice
T1 & T2 CONNECTIONS
T1 WIRE
LABEL FUNCTION VEHICLE
PIN LABEL
1 RLY1 N.C. Common to throttle control relay one, normally closed. Throttle Circuit RLY1 NC
2 RLY1 N.O. Common to throttle control relay one, normally open. Throttle Circuit RLY1 NO
3 RLY1 N.C. Output from throttle control relay one, normally closed. Throttle Circuit RLY1 NC
4 RLY1 N.O. Output from throttle control relay one, normally open. Throttle Circuit RLY1 NO
T1 WIRE
LABEL FUNCTION VEHICLE
PIN LABEL
1 RLY2 N.C. Common to throttle control relay two, normally closed. Throttle Circuit RLY2 NC
2 RLY2 N.O. Common to throttle control relay two, normally open. Throttle Circuit RLY2 NO
3 RLY2 N.C. Output from throttle control relay two, normally closed. Throttle Circuit RLY2 NC
4 RLY2 N.O. Output from throttle control relay two, normally open. Throttle Circuit RLY2 NO
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APPENDIX III REPLACEABLE PARTS

The following are replaceable parts on the SST-4. To order please see website at http://store.wiredrite.com/
store.
PART # DESCRIPTION AMP# QTY
65303421 Circuit Breaker 3
65303422 Relay 3
65303423 Amp, Mini Mate N’loc 6 Pos. Plug 172168-1 1
65303424 Amp, Mini Mate N’loc 4 Pos. Plug 172167-1 2
65303425 Amp, Mini Mate N’loc Socket 711639-1 14
APPENDIX IV TRUCK MANUFACTURER TECH SUPPORT

Additional information from the truck manufacturers is provided in the references below:
GENERAL MOTORS:
www.gmupfitter.com
• Hotline 800-875-4742
FORD MOTOR COMPANY:
www.fleet.ford.com
CUMMINS:
www.cummins.com
• Customer Assistance 1-800-DIESELS (1-800-343-7357)
INTERNATIONAL:
www.internationaldelivers.com
• Tech Central Help Line 1-800-448-7825
FREIGHTLINER:
www.freightlinertrucks.com
APPENDIX V AUTO STOP ON LOSS OF PRESSURE MODE

This mode will force the SST-4 into STOP mode if loss of pressure is detected on a user-installed circuit.
This will then allow the user-specified stop mode settings to control. This mode is especially useful in the
situation where the vehicle stalls and the E-Pump must be used to control the Aerial Device. Setting the
SST-4 and supplying a pressure switch to monitor either the engine oil or the PTO hydraulic pressure will
permit an automatic fail-over to the E-Pump without operator intervention.
Two inputs are used: the MASTER (J1 Pin 3) input, usually connected to a switch controlled by the operator
to activate the SST-4, and the PRESSURE (J1 Pin 1) input, which should be connected to a pressure switch
that senses either engine oil or hydraulic fluid pressure. When in this mode, and pressure is lost, the SST-4
will be forced into STOP mode after the delay specified in parameter “O”.
Since there are many different types of pressure switches available in the market, parameter “P” is used to
describe how your particular switch functions.
When the system is in this mode, the hour meter counts only when both the MASTER input and the
PRESSURE input are true.
The pressure switch may be installed to measure either engine oil pressure or PTO hydraulic fluid pressure.
If the switch is on the PTO, it is possible that the truck will be stopped automatically if the operator-controlled
Master switch is turned on, but the operator does not engage the PTO before the time out interval specified
in parameter “O”. For this reason, it is strongly suggested that the MASTER and PTO function be combined
onto one switch.
Be certain to specify a delay interval in parameter “O” of sufficient duration to allow any other timers to
complete. This is especially true if you are utilizing parameter “F” (Glow Plug Delay) as it is possible to set up
a situation where the vehicle can never be restarted if “F” is set to a period longer than “O”.
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312-18
ELECTRICAL COMPONENTS
TL SERIES
SECTION 325
TRUCK COMPUTER PROGRAMMING
Many of the following electrical systems are programmed into the truck computer system. The idle speed
settings, neutral interlock, parking brake interlock and boom interlock may use inputs and outputs through
the truck computer system. The computer programming information is included with the truck manual and
also available from Terex South Dakota, Inc. service people if needed. When a truck technician performs
trouble shooting or service involving the truck computer do not change to default settings. That may create
an unsafe system.
CRUSHING HAZARD
Changes to the vehicle computer settings
could affect equipment operation and
could result in crushing or tip over that
could cause Death or Serious Injury.
Do not alter computer settings without

full knowledge of affect of changes
See information supplied with truck manuals

or contact final stage manufacturer for
required settings
495845
325-1
TL SERIES
OUTRIGGER MOVING ALARM SYSTEM

The outrigger moving alarm system is designed to sound an alarm while outriggers are being lowered or
raised. This is achieved by placing a switch at each outrigger control. These outrigger switches are wired in
parallel to an alarm. The alarm will sound when the outrigger handle is moved.
The outrigger moving alarm must be operational at all times when the Master power is “ON” and the
hydraulic system is operational. The alarm may be live at all times.
325-2
TL SERIES
BOOM INTERLOCK SYSTEM (ELECTRIC)

The boom interlock system is designed to keep the boom assembly from lifting out of the boom rest until all
outriggers are extended. The inter lock does not ensure stability, only that the operator has to move the
outriggers. The operator is entirely responsible for proper set up. Outrigger switches, one on each outrigger,
are wired in series to operate a solenoid valve. The solenoid valve will block oil or reduce pressure to the
aerial unit functions until all outrigger switches are closed. When the outriggers are set, the lower boom can
be raised out of rest.
BOOM INTERLOCK SYSTEM CHECK
If the main hydraulic system checks out after troubleshooting and the unit will not function, the problem could
be a malfunctioning limit switch or a loose connection.
1. Check for loose connections in all wiring from each limit switch to the interlock solenoid valve.
2. Lower all outriggers, then disengage the PTO and shut off the engine. Check each limit switch in the
circuit, connect an ohmmeter to the wires and perform a continuity check of the limit switch. If the limit
switch shows no continuity exists, the limit switch is malfunctioning.
BOOM INTERLOCK LIMIT SWITCH
The boom interlock limit switch (one each) is mounted on the outer cylinder tube on a bracket with a cover
enclosing the switch. To gain access to the limit switch, remove the cover.
The boom interlock limit switch must show continuity when the outrigger is extended past switch. If no
continuity exits, the limit switch must be replaced. Always check for freedom of movement in the limit switch
arm. If it is sticky or feels rough, replace the limit switch.
NOTE: Continuity MUST NOT show when limit switch tested is in open position (retracted
position).
NOTE: Continuity MUST show when limit switch tested is in closed position (outriggers
extended).
NOTE: After the removal and installation of any assembly or component, always cycle unit and
inspect for proper operation.
The switch height adjustment must be set so when the inner leg is under the switch the switch is open.
325-3
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BOOM INTERLOCK SYSTEM (HYDRAULIC)

The boom interlock system is designed to keep the boom assembly from lifting out of the boom rest until all
outriggers are extended. Interlock valves, one on each outrigger, are connected in parallel to a tank port.
The valve will divert oil to tank for the aerial unit functions until all outrigger valves are closed. When the
outriggers are set, the outrigger valves will block flow to the tank and allow the lower boom to be raised out
of rest.
BOOM INTERLOCK SYSTEM CHECK
If the main hydraulic system checks out after troubleshooting and the unit will not function, the problem could
be a malfunctioning valve that does not block flow to tank. See hydraulic schematic in SECTION 700.
TESTING BOOM INTERLOCK SYSTEM

1. Set all outriggers - booms should operate.
2. Retract one outrigger - booms must not operate.
3. Reset outrigger and repeat individually of each outrigger.
325-4
WHAT IS INSULATED AND WHAT IS NOT INSULATED
TL SERIES
SECTION 350
The term insulated means separated from other conductive surfaces by a dielectric substance (including air
space) offering a high resistance to the passage of current (from OSHA 1926.960).
D
D
A
C
B
C
E B
E
Area A. Upper Boom Insulation, provides an insulating area between area D and earth ground when clean,
in a properly maintained condition, and extended to MINIMUM EXTENSION label.
Area B. Lower Boom Insert, provides an insulating area between area C and the vehicle when in properly
maintained condition.
Area C. Elbow, does not provide insulation. This area contains conductive materials such as cylinders, pins,
boom structure, and other metal components. The operator shall not allow any portion of this area to come
in contact with an energized phase, ground conductor, or grounded objects. Proper protective devices shall
be used on all conductors. Any contact with a phase line, a ground and phase line or between two-phase
conductors will create a hazard.
Area D. Boom Tip, does not provide insulation. This area contains conductive materials such as control
levers, un-insulated platform(s), platform support shaft, boom-tip structure and other metal components.
These objects must be considered connected. The operator shall not allow any portion of this area to come
in contact with an energized phase, ground conductor or grounded objects. Proper protective devices shall
be used on all conductors. The operator shall not make contact with any portion of this area when working
on or near an energized phase, ground or grounded objects, unless wearing proper protective clothing such
as rubber gloves and sleeves rated at the voltage of the lines. Any contact with a ground and phase or
between two-phase conductors will create a hazard. Accidental contact of any portion of area D to an
energized conductor will energize the entire area D. The jib and winch rope will be conductive if wet or dirty.
NOTE: A properly maintained platform liner will only provide protection for those portions of the
body or materials entirely within the liner and not in contact with any part of area D.
Area E. Does not provide insulation. This area contains conductive materials such as cylinders, pins, boom
structure, turntable, pedestal and other metal components. The operator shall not allow any portion of this
area to come in contact with an energized phase, ground, or grounded objects. Proper protective devices
shall be used on all conductors. This area is attached to the vehicle and connected trailers, which must be
barricaded and/or grounded through an approved ground system when working in the vicinity of energized
conductors. Any contact with a phase or between two-phase conductors will create a hazard.
350-1
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The insulating boom section only prevents

current from passing from the band of arrows at the boom
tip to the lower band of arrows. All components above and
below that area must be considered conductive.
The boom tip is everything past the upper band

of arrows. All boom tip components are structurally and
electrically connected. Contact with any part of the boom
tip will energize the entire boom tip including, controls, jib,
winch, and platform support structure.
Death or serious injury to the operator or ground

personnel can occur if any part of the boom or boom tip
contacts an energized conductor, ground line, grounded
line, or OBJECTS. Proper clearance must be maintained.
You must always cover the line and wear rubber

gloves with rubber sleeves and an approved hard hat
when any part of the Aerial Device is working on or near
energized lines or conductors even when working on a
grounded line, neutral line, or ground line.
Neutral, static and ground lines are current

carrying conductors and require proper handling. Treat
them as energized.
You must read the operators manual to fully

understand the protection the Aerial Device will give you.
Anytime the platform occupant(s) contact two items at different potential without proper
personnel protective equipment, their body may become a path for electric current, and
they may be electrocuted. This includes touching the controls, any tools, or items on the
boom tip while also contacting a line or ground.
350-2
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ELECTRICAL INSULATION
Operation on or near energized lines is extremely hazardous unless proper OSHA and ANSI work rules are
followed. The operation of this Aerial Device in proximity to high voltage electrical lines involves several
hazards to the operator of the Aerial Device, ground personnel and bystanders on the ground. These
hazards are as follows:
1. Contact of the operator with a single energized line will allow current to pass through the operator's body
to ground by means of an all-metal boom structure, unless the operator is insulated from ground.
2. Contact of the operator with two energized lines or one energized line and a grounded conductor will
cause electrocution, even if the operator is insulated from ground by the Aerial Device.
The fiberglass upper boom, fiberglass lower boom insert and fiberglass platform,
including its components, do not protect the platform operator from injury in case of
contact between two energized lines, or between an energized line and a grounded
conductor.
Working around electrical power lines is covered by ANSI and OSHA Regulations. To
reduce danger to the operator and ground personnel or bystanders on the ground,
understand and follow all rules.
IMPORTANT: Only caution and proper work practice on the part of the occupant(s) will protect
the occupant(s).
3. Contact of a metal section of the boom with a wire, below the insulation of the boom, will energize the
Aerial Device and the vehicle causing electrocution to ground personnel and bystanders standing on the
ground and touching the vehicle.
Ground personnel should never touch the Aerial Device, the vehicle or an attached trailer
while the Aerial Device is in operation near electrical power lines even though the Aerial
Device has an insulated boom and lower boom insert.
Avoid contact of any metal part or equipment below the insulated section of the lower
boom with an electrical power line. Serious injury or death could result.
4. Contact of the boom with a wire may break the wire or burn the wire in two, which will cause a hazard to
ground personnel and bystanders below.
Some protection against Hazard No.1 is furnished by the fiberglass upper boom. When PROPERLY
MAINTAINED, the insulated boom protects platform personnel in case they were to contact a SINGLE
energized power line within the qualification voltage limit stamped on the nameplate. However, this
protection can be nullified by accumulation of dirt and moisture on or in the boom. Operator safety requires a
regular electrical testing program.
Some protection against interphase contact, Hazard No. 2, is offered by the platform liner. The platform liner
is used for interphase protection of the lower half of the body only. Only caution on the part of platform
personnel and use of proper protective equipment will protect the upper half of their body from this hazard.
Any conductive object in the platform liner, which protrudes above the liner, will eliminate any protection the
liner may offer.
Limited protection of ground personnel against contact of the steel elbow area or lower boom with an
energized line, Hazard No. 3, is offered by the insulated lower boom and a proper grounding system. The
lower boom insert, like the insulated upper boom, must be regularly tested and cleaned to ensure continued
safety. Contact with an energized line below the lower boom insert will energize the vehicle and the ground
around the vehicle. Anyone close to the vehicle may be injured. A ground cable to a suitable ground may
prevent damage and injury. Ensure ground cables are making good contact with the vehicle and ground rod
or neutral and are not coiled on reel or storage hooks. A properly grounded vehicle does not guarantee
protection for people on the ground. It’s purpose is to engage the line protection, fuse or breakers as quick
as possible to limit damage. A lethal voltage may still exist between the vehicle and ground.
There is no protection against Hazard No. 4. Caution must be exercised continually to avoid making contact
with an energized line, which, if broken or burned, may drop to the ground and cause injury to ground
personnel and any bystanders.
350-3
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PREVENTION OF ELECTROCUTION
1. NEVER rely on fiberglass dielectric properties around power lines with moisture present on the
platform(s) and booms. If the Aerial Device is stored outdoors, protect the platform(s) and booms from
the weather with a cover when not in use. To preserve dielectric properties, fiberglass must be kept
clean and dry.
2. REMEMBER, auxiliary equipment, such as electrical cords, communication lines, and conductive tools,
that bridge the insulation between the operator and ground, render the insulation useless.
3. REMEMBER your Aerial Device cannot protect you against contact between two-phases, between one
phase and a pole or a grounded conductor. Never work between electrical lines unless the proper
precautions are observed.
4. DO NOT allow any ground personnel or bystanders to touch the Aerial Device, the vehicle, or an
attached trailer while the Aerial Device is in operation near electrical power lines, even if the Aerial
Device has an insulated lower boom.
5. Have boom insulation TESTED annually, in accordance with established rules and regulations.
6. CONTROLS are not insulated and are interconnected to all other conductive components at the boom
tip. DO NOT contact any conductor or wire while touching controls, unless wearing insulating rubber
gloves rated for the voltage.
7. DO NOT depend on plastic covers, fiberglass covers, or guards installed on the Aerial Device for
dielectric protection from contact with a line or ground. The covers may provide some protection, but
they are not tested to guarantee dielectric strength. Hidden damage, dirt and contamination will make
them conductive. Use line covers or blankets when closer than the minimum approach distance.
OPERATION ON OR NEAR ENERGIZED CONDUCTOR

When working ON OR NEAR ENERGIZED CONDUCTORS (either known or suspected), special conditions
arise. While the fiberglass upper boom provides a high degree of electrical insulation between the platform
and the vehicle, there are several things it WILL NOT DO:
• IT WILL NOT PROVIDE PHASE TO PHASE PROTECTION.
• IT WILL NOT PROVIDE PHASE TO GROUND PROTECTION THROUGH STATIC LINES OR GUY
WIRES.
• IT WILL NOT PROTECT THE VEHICLE FROM BEING ENERGIZED IF STEEL BOOMS CONTACT A
LOWER LEVEL SECONDARY POWER SOURCE.
The fiberglass boom must be kept clean and dry for this type of work.
350-4
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The fiberglass boom and platform liners must be dielectrically tested periodically to
insure the insulating properties are being maintained.
Do not assume that it is so.
Ground personnel must be warned to stay away from vehicle in case of accidental boom
contact between conductor and metallic portion of boom, which will cause serious injury
or death.
The fiberglass upper boom, fiberglass lower boom insert and fiberglass platform,
including its components, do not protect the platform operator from injury in case of
contact between two energized lines or between an energized line and a grounded
conductor.
Upper Controls can become energized if any part of the boom-tip past the band of arrows
on the boom contacts a conductor. The Aerial Device upper control station has metal
parts that are necessary to provide the structural support for the components. These
metal parts at the boom-tip are interconnected. The main shaft that supports the
platform(s) and controls also support other load carrying options that can be added to the
boom-tip.
Do not depend on Aerial Device covers for insulation. Plastic or fiberglass covers offer
limited electrical insulation. Covers are not tested, certified or maintained as insulation.
All conductors including grounds and neutral lines are current carrying conductors and
must be treated as energized unless properly grounded and tested.
The fiberglass upper and lower boom, in a well maintained condition, provides electrical
insulation between the upper boom-tip and the vehicle to ground. This fiberglass will not
protect the platform operator if any portion of the boom tip or upper arm control station,
including options is brought into contact with an energized or non-energized conductor
and the operator is in contact with a different potential, such as grounded non-energized
conductor. This type of contact can energize or ground the controls because all
components of the upper control station are interconnected. The fiberglass will not
provide protection for the operator in phase to phase contact or a phase to ground wire
contact above the upper boom insulation. Nor will it protect the vehicle from becoming
energized if the steel boom section below the lower boom insert, if so equipped, is
brought into contact with an energized conductor. Serious injury or death could result.
350-5
TL SERIES
350-6
DIELECTRIC TESTS
TL SERIES
SECTION 370
DIELECTRIC TESTS
DIELECTRIC TESTS (INSULATED UNITS ONLY)
Dielectric tests are performed to verify the insulation on insulated parts of the machine provide the insulation
expected. The ambient conditions and cleanliness and condition of the insulating parts will vary the test
results. The dielectric test consists of applying a voltage to metal components at one end or side of an
insulating section and measuring the leakage current that will go through the insulating part to metal at the
other end or side as the current travels to ground. There are two different types of dielectric tests. The
Qualification test will qualify a machine for the specific insulating rating, the Maintenance test will determine
if the boom continues to provide the expected insulation. The test procedures are established by ANSI
A92.2 to provide consistent methods to measure the leakage current at specific voltages determined by the
voltage rating of the unit. The upper boom insulation determines what the voltage rating of the machine will
be. The platform liner and the lower boom insert will be tested only; they do not have a rating. The high
resistance single stick controls are tested only and do not have a rating and are not considered part of the
insulating system.
UPPER BOOM RATING
The ID plate on your aerial device will indicate if the unit is insulated and the voltage the insulation has been
designed and tested to withstand. The manuals also indicate what areas of the machine will provide
insulation. Look on the ID plate for the QUALIFICATION VOLTAGE. The number in this area is the voltage
rating the unit was tested and qualified per ANSI standards. The date of the Manufacturing Qualification test
is indicated on the ID plate as the TEST DATE.
Not Insulated or Insulated ANSI Category

If the Insulated box is checked, Indicates what work unit
it indicates the booms will provide is capable of performing.
electrical insulation. If the Not
Insulated box is checked, the unit
will not provide any dielectric
protection.
Qualification Voltage Date of Manufacturer Test

Maximum Phase to Phase
voltage machine can be
used on with proper PPE
and work procedures.
ID PLATE
VOLTAGE RATINGS
There are two Voltages stamped on the ID Plate near the lower controls of the Aerial Device and shown in
the front of this manual.
Design Voltage - This is the maximum voltage that this machine can be rated if it is properly equipped
and tested. The machine cannot be used at this voltage unless the Qualification Voltage indicates the
same voltage on the ID Plate or there is an alternate re-rating tag that indicates; the company doing the
qualification test, date of test, and new rating.
Qualification Voltage - The qualification voltage is the maximum voltage for which the upper boom
insulation has been tested and is rated. The aerial can be use to work on or near electrical system lines
up to this phase to phase voltage if the proper personnel protective equipment and procedures are used.
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DIELECTRIC TESTS
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NOTE: If the unit is used on structures containing energized components at a higher voltage
than the Qualification voltage the machine is considered not insulating.
NOTE: All voltage ratings are for the phase to phase voltage rating of the system. It is not the
phase to ground voltage.
There are several reasons to perform a dielectric test, to assure the aerial device is providing the insulation
expected. They include:
• When new the unit is tested and qualified to the rating shown on the ID Plate.
• Annually at a minimum a Periodic maintenance test is performed to ensure the dielectric properties
are maintained.
• A maintenance test should be performed when there is a question of the dielectric properties or when
components in the insulating sections of the boom are repaired or replaced.
• If the Upper boom is replaced the unit must have a qualification test performed.
To properly perform a dielectric test the technician must understand several important electric concepts,
understand the procedure, and be considered qualified by their employer to perform the tests.
There are several areas of the machine that provide electrical protection. These include the Upper Boom
insulation section the lower boom insulating section, and the Platform liner, (if equipped). The manuals will
show the specific insulating areas of the machine. The single stick controls at the boom tip may be equipped
with high resistance control levers which may provide the operator some limited protection, depending on
cleanliness and condition, and should also be tested at the same frequency as the booms.
A record of leakage current test results are valuable to show deterioration of the insulating properties of the
boom, indicating the need to refinish the fiberglass booms or inspect the boom and hoses carefully.
The hydraulic oil should be examined and have a dielectric test performed at the same time the booms are
tested. The dielectric strength of new oil should exceed25 KV and used oil remain above 15 KV when tested
per ASTM D877 (kv/0.1).
NOTE: See “Section 350, WHAT IS INSULATED AND WHAT IS NOT INSULATED” for components
providing insulation.
QUALIFICATION TEST
The unit will have the original Qualification Test performed prior to shipment from the factory up to a rating of
69kV. Qualification tests above 69 KV will be performed by test firms with capability of the high voltages
required. Documentation of the higher voltage testing will be on the test firm’s certificates.
If the upper boom or lower boom insert is replace or modified the Qualification test must be repeated. The
original test is no longer valid. Maintain a written, dated and signed record of any Qualification tests
performed and send a copy to the manufacturer for their machine record.
The Qualification Test must use AC test equipment following the procedures to the voltages shown in Table
1 of ANSI A92.2.
Record the boom positions when performing any dielectric test. The position can vary the readings obtained.
PERIODIC MAINTENANCE TEST

At least annually the insulation of the unit shall be verified by performing a maintenance test on the unit at
voltages shown in Table 2 of ANSI A92.2 according to the Qualification voltage shown on the ID Plate.
Record the boom positions when performing the dielectric test. The position can vary the readings obtained.
Testing the boom in the same position each time will give more consistent readings.
When the hoses or leveling rods, which pass through the insulating sections, are replaced the maintenance
test is required to verify insulation properties. Maintain a written, dated and signed record of all periodic
maintenance test performed in a readily available location. By comparing the test results from year to year
any trend upward in leakage current may aid to determine if the fiberglass boom insulating properties are
deteriorating and the fiberglass needs to be refinished.
The Periodic Test can be done with AC or DC test equipment. Refer to ANSI 92.2 for the test procedures for
AC or DC test equipment.
NOTE: For complete electrical test procedures, read, understand, and follow the information in
the latest edition of ANSI A92.2.
370-2
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UPPER BOOM INSULATION CATEGORY

The insulation properties of aerials are broken into three categories, by method of measuring the leakage
current and the work practice used. The test procedure used will depend on the Category.
Category C is the most common type of insulating boom in use, the boom is not considered primary
insulation for the operator, but is secondary insulation to insulating rubber gloves and proper work practice.
The unit does not have a monitoring circuit (lower test electrode system) for measuring the upper boom
leakage current. It can be rated to a maximum of 46kV. The leakage test involves positioning the vehicle on
insulating pads and measure return current from the entire body. During use all the metal components at the
boom tip must be considered connected, but are not electrically bonded together. During the test only, all
metal at the boom tip must be bonded with jumper cables.
Category B has the same insulating characteristics as Category C because the boom is not considered
primary insulation for the operator, but is secondary insulation to insulating rubber gloves and proper work
practice. The unit has a monitoring circuit to measure the upper boom leakage current. The unit may be
equipped with a corona ring (gradient control device) depending on the voltage rating. It may also have, but
it is not required by standard, a shield over the test bands on the boom. During use all the metal components
at the boom tip must be considered connected, but are not electrically bonded together. During the test only,
all metal at the boom tip must be bonded with jumper cables. Category B units can not be used as a
Category A bare hand unit and can not be converted without contacting the manufacturer.
Category A Units are known as bare hand units. The protection provided by the Upper boom, when using
proper bare hand procedures only, are the primary protection of the platform occupants. If bare hand
procedures are not followed the boom will not provide primary protection, but secondary protection only, and
the platform occupants must depend on their insulating rubber gloves as their primary protection. The metal
components at the boom tip are required to be bonded. A decal at the boom tip must indicate the bonding.
When rated above 138KV a corona ring and shield will be installed. The hydraulic system will be equipped
with foot valves (check valves) and vent valves to prevent vacuum formation in lines that pass through the
insulated upper boom. As part of the bare hand procedure the boom insulation must be tested daily before
use. When using a Category A unit for rubber glove or hot stick work the boom tip bonding should be
disconnected and reconnected when doing bare hand work.
GRADIENT CONTROL DEVICE OR CORONA RING INSTALLATION
When the gradient control device is removed it must be replaced in the same location and using the same
fasteners as originally installed. Use the parts manual for details. There are two types, the ring style or the
ultra style. The corona ring in all cases must be the closest to the elbow of all the metal components at the
boom tip and have good electrical contact with the other metal at the boom tip.
The Ring style is a round metal tube in round or oval configuration around the boom. The ring must not have
any sharp edges toward the elbow. The screws used to connect the two halves must be flush to the surface
and only round heads protrude.
The Ultra corona ring uses a sharp edge toward the elbow to concentrate the electrical energy. The inner
surface toward the boom should have a smooth radius and the outer edge being sharp and angled toward
the elbow. The ring may be held off the boom with rubber or plastic spacers. The side toward the boom tip
should not have any sharp points.
CATEGORY C TEST PROCEDURE

The aerial device is driven onto insulating pads and the outriggers set on insulating pad. These can be
plastic or dry wood outrigger pads. The metal at the boom tip is bonded together so all metal is connected to
the power lead from the tester. Follow the procedure in ANSI A92.2 for set up and connections.
370-3
DIELECTRIC TESTS
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LEAKAGE MONITORING CIRCUIT - (CAT A OR B ONLY)

Leakage monitoring circuits are used on Category A & B units only and provides a circuit for measurement
of leakage current traveling;
• Over the inner and outer surfaces of the fiberglass upper boom
• All hydraulic hoses and oil passing through the insulating span of the upper boom.
• Leveling rods passing through the upper boom.
The components being monitored will lead to a terminal strip where a coax cable will go down the upper
boom and terminate above the lower boom insert at a Amphenol connector. To measure the leakage a meter
is connected at that point. Category C units do not use a monitoring circuit and must have the unit insulated
from ground to perform the dielectric test. Other leakage monitoring instruments are available that require
special wiring, for those refer to information provided with the system.
DESCRIPTION
The monitoring system consists of:
a. Two 1 in. (25.4 mm) wide metallic bands, encircling the inner and outer surfaces of the fiberglass upper
boom near the elbow end. They are approximately 2 in. (50.8 mm) away from the steel boom.
b. Metallic bulkhead fittings in all hydraulic lines across dielectric area fastened to a metal plate.
c. Metal clamps on leveling rods.
d. Amphenol connector typically installed in the lower boom in front of the lower boom insert. The test bands,
leveling rods and tube couplings are electrically connected to the connector with coaxial cable.
Note to measure the leakage properly the components of the monitoring circuit must not touch or have
continuity to the metal boom structure. This ensures the current traveling down the booms and components
will go to the meter and be accurately measured.
LEAKAGE TEST METHOD
1. For operation and testing of the Aerial Device, the requirements of ANSI A92.2 must be followed. The
assembled Aerial Device must be tested on a grounded test stand or vehicle. Aerial device must be
mounted on vehicle chassis during maintenance test.
2. The upper and lower booms are raised in accordance with ANSI A92.2. The metal boom tip components
supporting the platform, the control head and any other metallic object attached to the platform, are
connected to the “hot” electrode of the test set, in order to apply the test voltage. The “ground” electrode
is connected to the boom metal. The test unit return lead or a suitable microamp meter is connected to
the Amphenol connector above the lower boom fiberglass insert with a shielded cable. For maximum
flexibility, a dual range meter with scales of 0–200 microamp and 0-200 milliamps is recommended.
3. Tests consist of voltage applications, based on the line-to-ground voltage of the system on or near which
the Aerial Device will be operated. See tables in the latest edition of ANSI A92.2 standard for the level of
voltage to be applied.
4. Test above must not yield leakage current readings in excess of the values listed in the table in ANSI
A92.2.
370-4
DIELECTRIC TESTS
TL SERIES
LEAKAGE MONITORING CONTINUITY TEST

Equipment Required: Multimeter
1. Set Multimeter to the ohms (resistance) scale.
2. Attach the black lead to the center pin of the Amphenol connector.
3. Touch the red lead to the metal outside of the Amphenol connector. Meter should remain at infinite
resistance.
4. Touch the red lead to the metal on the upper boom stub weldment. Meter should remain at infinite
resistance.
5. If either step 3 or 4 show low resistance, or continuity, check for an electrical short.
6. Touch the red lead to the test band on the outside of the fiberglass boom. Meter should read low
resistance, or continuity.
7. Touch the red lead to the test band on the inside of the fiberglass boom. Meter should read low
resistance, or continuity.
8. Touch the red lead to the metal fittings on the bulkhead bracket inside the fiberglass boom near the test
bands. Meter should read low resistance, or continuity.
9. Touch the red lead to the metal clamp on the upper leveling rod inside the fiberglass boom. Meter should
read low resistance, or continuity.
10. Touch the red lead to the metal clamp on the lower leveling rod in the fiberglass boom. Meter should
read low resistance, or continuity.
11. If any of steps 6 through 10 do not show continuity, check for a loose or broken wire.
12. Disconnect the Multimeter lead from the Amphenol connector and continue and perform the high voltage
electrical tests per latest edition of ANSI A92.2
Periodic testing of the upper boom is absolutely necessary to ensure the integrity of its insulation. Always
maintain an appropriate ledger for documenting the test results. Inconsistent test results would indicate a
need for maintenance and or/repair.
Areas to inspect when test results are not consistent:
a. Insure booms are clean (inside and outside).
b. Inspect entire unit for evidence of any hydraulic oil leakage or hose wear.
c. Inspect fiberglass for damage, contamination, and rust tracks (inside and outside), check fiberglass for
cracks.
d. Inspect entire unit for loose, damaged, worn and missing fasteners.
e. Check all hoses for wear and leakage.
f. Check hydraulic oil for contamination, if color is milky, the hydraulic fluid is probably contaminated with
water. Oil sampling may be necessary to identify hydraulic oil contamination.
LOWER BOOM INSERT TEST
The lower boom insert will be tested similar to a category C unit upper boom, see the ANSI A92.2
procedure. The vehicle is driven on insulating pads with insulating pads under outriggers so the unit is not
connected to ground. The elbow is energized and the return current from the vehicle is measured. DC
testing allows the meter to be in the input power line for maintenance tests only.
PLATFORM LINER TEST
The platform liner is typically tested in a fiberglass tank of water with a small amount of salt to make it
conductive. Water level is within 6 inches from the top of the liner. The power is applied to the inside of the
liner and meter return from the outside. There are other methods and equipment to perform liner tests. See
the manuals with the equipment and ANSI A92.2 standard for proper test. DC testing allows the meter to be
in the input power line for maintenance tests only.
370-5
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VACUUM PREVENTION SYSTEM TESTING

Aerial devices with platform heights greater than 50 ft. (15.2 m) above the oil tank require a means to
prevent vacuum forming in the hydraulic lines. This is accomplished on all units with foot valves to hold oil in
the line. Category A units have vent valves at the platform in addition to the foot valves. If the foot valves
should fail to hold oil in the line the vent valves will let air in the line and prevent a high vacuum from forming.
FOOT VALVE TESTS
Connect a loop hose with a test gauge to the upper tool couplers. Position the unit in the rest and run the tool
with the pressure gauge in the line. Run the unit and watch the gauge. It should read the back pressure from
the platform controls. Shut the vehicle off and watch the gauge. When the pump stops the gauge should
drop but not return to zero. Typical readings will be 25 PSI (.17 MPa) for units up to 70 ft. (21.3 m) and 40
PSI (.28 MPa) for taller units. If the gauge returns to zero the foot valve must be removed, cleaned and
retested or possibly replaced and retested to verify function.
VENT VALVE TESTS
To test the vent valves will require a vacuum pump and connectors, p/n 488180, to test each line. The unit is
run and then shut down. The tester is connected to each coupler at the boom tip in turn. The vacuum pump
is slowly pumped to increase the vacuum on the vent. The vent should open about 2.46 PSI (.02 MPa)
reading.
HIGH RESISTANCE CONTROL HANDLES
The single stick control will be tested to determine it has high resistance properties in new clean condition.
This test does not certify the handle is insulating, isolating or capable of any voltage while in use because of
limited clearance and contamination.
The test procedure is explained on the test sheet. The new test and the maintenance test are both the same
value. The only difference is the maintenance test can also be done with DC test equipment. For all plastic
handle single sticks the test on the bench of only the single stick itself is 40KV with no more than 400
microamps leakage.
Units built before 3/1/10, see ID plate test date, or units with replacement plastic single sticks will be tested
when installed on the unit to 30KVAC with no more than 400 microamps leakage or 42KVDC with no more
than 42 microamps leakage.
370-6
TROUBLESHOOTING
TL SERIES
SECTION 400
TROUBLESHOOTING
A hydraulic system is a means of transferring force using a contained liquid as a medium. Any force on a
confined fluid is applied equally to any point in the system that the fluid reaches. Oil is normally used as the
fluid for the components of the system.
Two terms used in reference to hydraulic systems are flow and pressure. FLOW is the movement of the oil
through the system. PRESSURE is the result of resistance to the flow of oil in the system. It is important to
remember that pressure is not directly created by the pump, but results when the flow from the pump meets
resistance in the system. This resistance can be either external (load) or internal (restriction of lines and
components). Flow and pressure work closely together. Flow controls the speed of operation, while pressure
determines the force available to do work. In this manual, flow will be measured in gallons per minute (GPM)
or liters per minute (LPM. Pressure will be measured in pounds per square inch (PSI) or megapascals
(MPa).
HYDRAULIC COMPONENTS
The following is a brief description of the basic components found in the hydraulic system.
Pump: The heart of the hydraulic system. The pump causes movement of the hydraulic oil within the
system. The pump changes mechanical energy into hydraulic energy (generated by engine or motor). The
pump does not generate pressure.
Relief Valve: The first valve in the circuit after the pump must be a relief valve. This prevents damage to the
pump and hoses unless the pump is pressure compensated.
Valves: Various types and designs used to control flow and pressure in the hydraulic system.
Cylinders and Motors: The working tools of the hydraulic system. Cylinders and motors convert the
hydraulic energy back to mechanical energy, in either linear or rotary motion.
Hydraulic Tank: Provides cooling and storage for oil in the system and assures a full supply of oil to the
pump. Because piston rods take up space in the cylinders, the oil level in the tank will be higher when all
cylinders are retracted.
Filters: Collect and remove particles of dirt and contamination from the hydraulic system.
Hydraulic Lines and Fittings: The roadways of the system. All lines and connections must be air-tight to
prevent loss of fluid and keep air out of the system. Entrapped air can cause erratic operation and serious
damage to the hydraulic system components. Only the hydraulic tank is under atmospheric pressure. All
lines and fittings must be closed to atmosphere.
Check Valves: One way checks are installed in the pressure and return lines to maintain hydraulic oil in the
lines that pass through the booms to the platform. This prevents a vacuum from forming in the hydraulic
lines, which would degrade the dielectric integrity when a no flow condition occurs. (i.e. Pump failure, engine
shutdown, etc.)
Use only orange, non-conductive hoses for tool, platform area and insulated sections.
Failure to do so may cause death or serious injury.
HYDRAULIC SCHEMATICS
A schematic drawing of the hydraulic system is included in SECTION 700. The schematic shows the
complete arrangement of the system, with its various circuits and components, eliminating the need to
physically trace out each circuit on the machine.
The hydraulic schematic is helpful in isolating circuit problems. By analyzing the symptom and its location,
you can easily trace back through the circuit to the source of the trouble. Troubles that are common to more
than one circuit can be traced back to the components that are common to the system (example: pump,
filter, hydraulic tank, control valve, etc.). Problems that exist in only one circuit/function can be immediately
determined to be caused by a component malfunction in that particular circuit.
400-1
TROUBLESHOOTING
TL SERIES
TROUBLESHOOTING PROCEDURES
Experience with hydraulic equipment of this type is usually of greatest advantage in troubleshooting.
1. Talk to the Operator - What are the symptoms? Has the machine lost speed or power? Does the
problem exist in all circuits, or is it particular to only one circuit?
2. Check the Schematic - Locate the problem circuit or circuits. Ask yourself, what component could
possibly cause a problem with these symptoms? List the components possibly causing the problem in
the order of probability.
Death or personal injury could result if system pressure is set above the recommended
setting per Quick Reference Guide. Do not adjust pressure higher than recommended.
3. Go to the Machine - Make a visual and operational inspection. Look for damage or restriction of lines,
bent tubes, kinked hoses, leakage, etc. Isolate the component or circuit which is possibly causing the
problem. Use a flowmeter to check the flow and possible leakage (bypass) within the circuit. Follow the
pressure in the circuit. In the order of probability, eliminate each possible cause until the trouble is found.
4. Troubleshooting Guide - For your reference, a troubleshooting guide is included in this section. The
guide lists some common problems and possible causes of hydraulic system troubles.
Serious personal injury could result when performing maintenance on the hydraulic
system of this Aerial Device if proper care is not used. Secure boom and outriggers first,
then release system hydraulic pressure before attempting any repairs or disassembly of
hoses, valves, cylinders, and all other hydraulic components.
Only authorized and skilled personnel, with complete knowledge of this Aerial Device,
should be allowed to perform maintenance on this hydraulic system.
400-2
TROUBLESHOOTING
TL SERIES
CHECKING FOR HYDRAULIC LEAKS

The hydraulic system must be checked daily for hydraulic leaks.
When checking the hydraulic system for leaks, observe only, NEVER use your hands to
locate a leak. Hydraulic oil from a pin-hole leak can puncture your skin and cause serious
injury requiring immediate medical attention.
Check hydraulic system for leaks using a piece of cardboard only. NEVER use your hands. If a component
or fitting is leaking, repair or replace it as soon as possible.
IMPORTANT: Never operate the unit when leaks are present.
Pipe sealant may be used on pipe fittings. Be careful not to allow pipe sealant into the hydraulic system.
400-3
TROUBLESHOOTING
TL SERIES
TROUBLE SHOOTING GUIDE

Operation Is Erratic - Low fluid supply. Fill reservoir to proper level with all
Hydraulic Pump Noisy. cylinders retracted.
Suction line kinked or collapsed. Re-route hose to remove kinks or sharp
bends.
Cavitation. See "Hydraulic Pump Cavitates" under
"TROUBLE" column.
Air trapped in relief valve. Any or all of the following:
a. Bleed air from relief valve.
b. Tighten leaky connections.
c. Fill reservoir to proper level.
d. Clean reservoir breather vent.
e. Change system fluid.
Pump worn or damaged. Replace or repair. See "HYDRAULIC
PUMP REPAIR" in this manual.
Oil viscosity too heavy. Use lower viscosity oil. See “OIL
SPECIFICATIONS” in this manual.
Hydraulic Motor Noisy. Low fluid supply. Motor worn or Replace or repair. See "HYDRAULIC
damaged. MOTOR REPAIR" in this manual.
Relief Valve Noisy. Damaged relief valve. Replace valve.
Worn poppet and seat. Replace or repair.
Rubber or trash in valve. Remove rubber or trash.
PTO Noisy. PTO gears too tight. Increase gear backlash. See Installation
Manual.
PTO gears too loose. Reduce gear backlash. See Installation
Manual.
PTO bearing caps too tight. Add gaskets to end caps.
Nicked or damaged PTO gears. Replace gears or replace PTO as
necessary.
Worn PTO bearing. Replace bearing.
Hydraulic Pump Not warming up system on a cold day. Warm up system by retracting a cylinder
Cavitates. and thus forcing the hydraulic oil to
bypass.
Clogged hydraulic tank outlet screen. Remove and clean strainer. See “TANK,
BREATHER, AND FILLER" in this
manual.
Shutoff valve(s) closed. Open valve(s).
Oil viscosity too heavy. Use lower viscosity oil. See "OIL
SPECIFICATIONS" in this manual.
Low oil supply. Fill reservoir to proper level with all
cylinders retracted.
Leaky connections. Tighten connections.
Dirty reservoir breather vent. Clean breather vent.
Dirty oil. Change to clean oil.
400-4
TROUBLESHOOTING
TL SERIES

Hydraulic Pump Fluid overheats. See "Fluid Overheats" under
Overheats. "TROUBLE" column.
Cavitation. See "Hydraulic Pump Cavitates" under
"TROUBLE" column.
Air in fluid. Any or all of the following:
a. Tighten leaky inlet connections.
b. Fill reservoir to proper level.
c. Clean reservoir breather vent.
Relief valve set too high or too low. Install pressure gauge and adjust to
correct pressure.
System pressure setting too high or too Install pressure gauge and adjust to
low. correct pressure.
Worn or damaged pump. Replace or repair. See "HYDRAULIC
Control valve malfunctions. Check control valve to make sure one
spool is not in detent.
Low oil supply. Fill reservoir to proper level with all
Hydraulic Motor Fluid overheats. See "Fluid Overheats" under
Overheats. "TROUBLE" column.
System pressure setting too high. Install pressure gauge and adjust to
correct pressure.
Motor worn or damaged. Replace or repair. See "HYDRAULIC
MOTOR REPAIR" in this manual.
Fluid Overheats. Pump overheats. See "Hydraulic Pump Overheats" under
"TROUBLE" column.
System pressure setting too high or too Install pressure gauge and adjust to
low. correct pressure.
Fluid dirty or low supply. Change fluid and filter. Fill reservoir to
proper level with all cylinders retracted.
Incorrect fluid viscosity. Change to fluid of proper viscosity. See
"OIL SPECIFICATIONS" in this manual.
Worn pump, valve, motor, cylinder or Replace or repair.
other component.
Hydraulic line undersized. Use correct size line.
Hydraulic tank not getting sufficient air. Move all loose or excess items away
from tank.
Hydraulic tools on or used for long Shut off. If needed to run for long
periods of time. periods, increase oil capacity and add
cooler.
Operating on HI engine speed. Should only be used when operating
tools when 5 GPM is required.
Pump sized to large. Unit operates at 2 GPM at idle and 5
GPM at high speed for tools.
400-5
TROUBLESHOOTING
TL SERIES

No oil flow. PTO not engaged. Engage PTO.
(No Response To Any Low oil supply. Fill reservoir to proper level with all
Control.) cylinders retracted.
Shut off valve(s) closed. Open valve(s).
Loose or broken hydraulic line or fitting. Inspect for leaks. Tighten loose
connections or replace defective
components.
Pinched or kinked hydraulic line. Locate pinch or kink and correct.
Electric system not engaged. Turn on master power.
Pump not receiving fluid. Any or all of the following:
a. Replace dirty filter.
b. Clean clogged inlet line.
d. Fill reservoir to proper level.
Defective pump. Replace or repair. See "HYDRAULIC
Pump to PTO coupling sheared. Check for damaged pump or pump
drive. Replace and align coupling.
The relief valve setting not high enough. Adjust relief valve. See "HYDRAULIC
Spring in relief valve broken. Replace relief valve and re-adjust.
Pump turning in wrong direction. Reverse rotation. See "REVERSING
PUMP ROTATION" in this manual.
Defective control valve. Replace or repair.
Tool system on. Turn off.
Check valve in collector block assembly Install in correct direction.
blocking flow.
Enable lever of upper control not Readjust.
shifting.
Low Oil Pressure. Leak in system. Tighten leaky connections or replace
(Slow Or Erratic defective components.
Response To Any Worn pump, valve, motor, cylinder or Repair or replace.
Control.) other component.
Hydraulic fluid low. Fill reservoir to proper level with all
Pump not operating at proper speed. If Repair or replace. See "HYDRAULIC
pressure decreases with pump RPM, PUMP REPAIR" in this manual.
this indicates pump efficiency has
dropped.
Excessive load. Lighten to rated load. Refer to load chart
mounted on crane.
Relief valve setting too low. Adjust relief valve. See "HYDRAULIC
Pinched or kinked hydraulic line. Locate pinch or kink and correct.
Broken hydraulic line or loose fitting. Replace, repair or tighten as required.
Defective hydraulic cylinder. Replace or repair. See "HYDRAULIC
CYLINDER REPAIR" in this manual.
400-6
TROUBLESHOOTING
TL SERIES

Low Oil Pressure. Defective hydraulic pump. Replace or repair. See "HYDRAULIC
(Slow Or Erratic PUMP REPAIR" in this manual.
Response To Any Defective hydraulic motor. Replace or repair. See "HYDRAULIC
Control.) Cont’d MOTOR REPAIR" in this manual.
Defective control valve. Replace or repair. Make sure that the
mounting bolts on control valve are
torqued properly.
Cavitation. See "Hydraulic Pump Cavitates" in
"TROUBLE" column.
Air in fluid. Any or all of the following:
a. Tighten leaky connections.
b. Fill reservoir to proper level.
d. Change system fluid.
Upper boom is slow or erratic. Contamination in flow control. Flush or
replace.
Collector block assembly internal leak. Repair.
Auxiliary power check not seating. Remove and flush, or replace.
Control Valve Will Not Defective control valve due to being Warm up valve, clean valve, replace
Move To Activating frozen because of weather, dirt or rubber valve, or re-install valve as necessary. If
Position. in spool, bent spool, or binding due to re-installing or replacing, make sure that
faulty installation. mounting bolts are torqued properly and
tie bolts are torqued properly.
Screw holding valve centering spring Tighten screw.
loose.
Cylinder Retracts Seals in cylinder worn. Replace. See "HYDRAULIC
Under Load. CYLINDERS REPAIR" in this manual.
Defective holding valve. Replace holding valve.
Lift Cylinder Will Not Possibly overloaded. Unless there is some malfunction as
Lift Load. listed under "No Oil Flow" or "Low Oil
Flow" in the "TROUBLE" column, then
the unit is overloaded. Reduce to rated
load as given on load chart that is
mounted on unit.
Low Pressure. Set to system pressure.
Boom Creeps Down Leaking by the lift cylinder piston seals. After placing boom in rest:
Slowly When Left In An
Disconnect pilot line and plug both the
Elevated Position. fitting and the line.
If the boom still creeps down the
problem is in the holding valve or lift
cylinders.
If the boom does not creep down the
problem is in the pilot piston area and
most likely the pilot piston o-rings.
Leakage in the holding valve. Replace or repair.
400-7
TROUBLESHOOTING
TL SERIES

Pump Not Delivering Driven in the wrong direction of rotation. The drive direction must be changed
Fluid. immediately to prevent seizure. (See
The Pump Section of this manual.)
Coupling or shaft sheared or Disassemble the pump and check the
disengaged. shaft and cartridge for damage. (See
Pump Section in this manual). Replace
the necessary parts.
Fluid intake pipe in reservoir restricted. Check all strainers and filters for dirt and
sludge. Clean if necessary.
Fluid viscosity too heavy to pick up Completely drain the system. Add new
prime. filtered fluid of the proper viscosity.
Air leaks at the intake. Check the inlet connections to determine
where air is being drawn in.
Pump not priming. Tighten any loose connections. See that
the fluid in the reservoir is above the
intake pipe opening. Check the minimum
drive speed which may be too slow to
prime the pump.
Relief valve stuck open. Disassemble the pump and wash the
valve in clean solvent. Return the valve
to its bore and check for any stickiness.
A gritty feeling on the valve periphery
can be polished with crocus cloth. Do
not remove excess material, round off
the edges of the lands or attempt to
polish the bore. Wash all parts and
reassemble the pump.
Gears possibly locked. Disassemble the pump. Check for dirt or
metal chips. Clean the parts thoroughly
and replace any damaged pieces. If
necessary flush the system and refill it
with clean fluid.
Insufficient Pressure Relief valve set too low. Use a pressure gage to correctly adjust
Build-up. the relief valve.
Complete loss of flow from pump. A valve is stuck open permitting free flow
to tank. Broken inlet or pressure line.
Actuator bypassing the full flow.
Pump making noise. Pump intake partially blocked. Service the intake strainers. Check the
fluid condition and, if necessary, drain
and flush the system. Refill with clean
fluid.
Air leaks at the intake or shaft seal. (Oil Check the inlet connections and seal to
in reservoir would probably be foamy). determine where air is being drawn in.
Tighten any loose connections and
replace the seal if necessary. See that
the fluid in the reservoir is above the
intake pipe opening.
Pump drive speed too slow or too fast. Operate the pump at the recommended
speed.
Coupling misalignment. Check if the shaft seal bearing or other
parts have been damaged.
Replace any damaged parts. Realign the
coupled shafts.
400-8
TROUBLESHOOTING
TL SERIES

Outriggers will not Outrigger leg wedged in housing. Operate opposite side outrigger to make
retract (if equipped). only firm contact with ground. Place
boom over opposite side of truck from
stuck outrigger. This should remove
weight on stuck outrigger, allowing it to
retract.
Defective outrigger cylinder, check valve Replace or repair.
or control valve.
No Rotation. Broken gear or shaft in gear reducer. Repair or replace.
Motor malfunctioning. Replace hydraulic motor.
Damage seal in collector block Replace seals in collector block
assembly. assembly.
Difficult or slow Lack of lubrication in turntable bearing or Lubricate, see “LUBRICATION CHART”
rotation. ring gear. in this manual.
Control valve not fully actuated. See “UPPER CONTROLS ASSEMBLY”.
Motor malfunctioning. Replace hydraulic motor.
Rotation Drift. Control head or lever not centered. Center control head or lever.
Worn gears or shafts in rotation gear Replace or repair.
reducer.
400-9
TROUBLESHOOTING
TL SERIES
400-10
MECHANICAL COMPONENT MAINTENANCE AND REPAIRS
TL SERIES
SECTION 500
INTRODUCTION TO THE MECHANICAL SYSTEM
LOWER BOOM
The lower boom pivots about a horizontal centerline on the turntable, and operates as part of a
parallelogram with a leveling link to keep the elbow parallel to the turntable.
UPPER BOOM
The upper boom pivots about a horizontal centerline. The upper boom pivots at the elbow weldment and
articulates from 40 degrees below horizontal to 75 degrees above horizontal (some units are -35 to 85),
relative to the turntable. The inner boom extends on rear wear pads and on front rollers with rollers on the
sides. The extension cylinder, located inside the boom, is a double acting, regenerating cylinder. The hoses
are inside a hose carrier.
ROTATION
The turntable, booms, and platform rotate about a vertical centerline on the pedestal supported by a shear-
ball bearing. This bearing consists of two concentric rings. The inner ring is attached to the pedestal and has
a ball path around the outer diameter. The outer ring is attached to the turntable and has a ball path around
the inner diameter. Spherical balls are trapped in between the two rings in the ball path. The balls allow
rotation of the inner ring and the motion is controlled by a gear train that is driven by a hydraulic motor. Gear
teeth on the outside diameter of the outer bearing ring engage a drive gear supported on the turntable. As
the drive gear rotates, the turntable rotates relative to the outer bearing ring. This drive gear is actuated by
the hydraulic motor through a self–locking worm gear speed reducer. Smooth and controlled rotational
movements of the turntable, booms, and platform are provided.
PIN RETAINERS
Some pins use a high strength bolt to attach the pins to the structure and prevent turning. Install with the
spacer under the nut. Threads of bolt must be outside retainer. Tighten nut until seated. Do not torque.
NOTE: Verify pin retainer. If not equipped with spacer see PA 1005.
500-1
TL SERIES
LOWER BOOM CYLINDER REMOVAL / ASSEMBLY

• The boom assembly, including the platform, will have to be supported with a
suitable lifting device prior to removal of cylinders.
• Do not scratch or mar surface of fiberglass. Use rope slings or other soft material -
never use chains or wire rope directly on fiberglass.
• Care should be exercised when removing cylinders, as they are heavy. Cylinders
should be removed by means of a hoist, if available.
1. Place lower boom in the position as shown.
2. Shut the hydraulic system down.
3. Support cylinder which is going to be removed with a suitable lifting device.
4. Tag, disconnect and cap hydraulic lines leading to cylinder.
5. Remove fasteners (1) securing pin (2) at the rod end of the cylinder.
6. Remove pin (2) from rod end of cylinder.
7. Carefully lower the cylinder.
8. With lifting device in place, remove fasteners (3) securing base cylinder pin (4).
9. With lifting device in place, remove cylinder pin (4) and carefully lower the cylinder and place in a
suitable work area.
10. Reassemble in reverse order.
NOTE: Prior to installation of cylinder pins, check for any nicks or burrs and remove if found.
Damage to the bearings/bushing will result if not repaired at this time.
NOTE: Check bearings for wear whenever maintenance or repair is being performed at cylinders
or linkage. Replace any worn components. Always lubricate prior to assembly. See your
lubrication chart.
3,4
Fasteners securing
cylinder base end to boom.
1,2
Fasteners
securing rod eye
pin to elbow
bracket.
Use caution when positioning hydraulic hoses. Sharp bends will create kinks and cause
unnecessary repairs later.
operation dangerous. Thus, the cylinder should be purged of air. Extend and retract
cylinder fully with no load in the platform three times to purge. After purging, fill the
hydraulic reservoir to the full level, if needed, with all cylinders retracted. Do not ride the
platform while air is being purged, serious injury or death could result.
500-2
TL SERIES
UPPER BOOM CYLINDER REMOVAL / ASSEMBLY

2. Support cylinder which is going to be removed with a suitable lifting device.
4. Remove nut and fastener (1) securing pin (2) at the rod end of the cylinder.
5. Remove pin from rod end of cylinder.
6. Carefully lower the cylinder.
7. With lifting device in place, remove nut and fastener (3) securing base pin (4).
8. With lifting device in place, remove pin (4) and carefully lower the cylinder and place in a suitable work
area.
9. The bushings in the cylinder base end and cylinder rod eye should be checked for wear. Replace any
worn components.
NOTE: Prior to installation of cylinder pins, check for any nicks or burrs and remove if found.
lubrication chart.
3,4
Fasteners securing
1,2 cylinder base end to boom.
Fasteners
securing rod eye
pin to elbow
bracket.
operation dangerous. Thus, the cylinder should be purged of air. Purge cylinder of air on
the bench before installation on the unit. Air in the system will cause the leveling to "lag".
500-3
TL SERIES
UPPER CONTROL VALVE REMOVAL / ASSEMBLY

1. Ensure platform is supported with a suitable lifting device.
2. Tag, disconnect and cap all hydraulic lines and air lines to the control valve assembly.
3. Remove the fasteners (1) securing the control valve assembly to the bracket. Carefully remove the
control valve assembly and place in a suitable work area.
NOTE: Do not forget to tag hydraulic lines for reassembly.
500-4
TL SERIES
PLATFORM REMOVAL / ASSEMBLY

1. Ensure platform is supported by suitable lifting device.
2. Remove covers.
3. Remove nuts (1) holding platform to bracket.
4. Slowly remove platform and place in work area.
NOTE: See Quick Reference Guide for torque.
500-5
TL SERIES
JIB / JIB CYLINDER REMOVAL / ASSEMBLY

• Never disconnect any hydraulic lines until boom assembly is fully supported from
falling by a suitable lifting device.
1. Remove winch line from jib sheave head roller.
2. Tag, disconnect and cap hydraulic lines to jib cylinder.
3. Remove snap rings (1) and pins (2) from the jib cylinder, place jib cylinder in a suitable work area.
4. Remove Detent pin (3), pull jib assembly (4) through the jib bracket.
500-6
TL SERIES
WINCH REMOVAL / ASSEMBLY

1. Follow procedure for “JIB REMOVAL”.
2. Tag, disconnect and cap hydraulic lines at the motor.
3. Remove the roll pin (1) and the collar (2).
4. Prior to removing the winch gearbox assembly, support the winch drum and winch weldment with a
suitable lifting device. Remove the winch by sliding the winch assembly away from the upper boom.
Removal of top mounted jib is done by pulling the jib rotation pin and lifting the jib/winch assembly up. A
storage tube is provided with the unit for stowing the jib once it is removed.
500-7
TL SERIES
LEVELING LINK REMOVAL / ASSEMBLY
Never disconnect any hydraulic lines until boom assembly is fully supported from falling
by a suitable lifting device.
• Ensure upper and lower boom assembly is supported by a suitable lifting device.
1. Jog main boom cylinder in or out slightly to remove force on leveling link.
2. Remove fasteners (1) securing the link pivot pin (2) at the elbow. Remove the pivot pin and lower the
end of the link.
3. Remove fasteners (3) securing the link pivot pin (4) at the turntable. Remove the pivot pin (4) and place
link in a suitable work area. Inspect all assemblies for evidence of any wear at this time. Replace or
repair as necessary.
4. Reassembly in reverse order.
500-8
TL SERIES
ELBOW REMOVAL / ASSEMBLY

1. Shut down hydraulic system.
2. Mark and disconnect hose at the control valve, plug all hoses and cap all fittings.
3. Tag, disconnect any air lines if present at this time. Mark and disconnect all wires going into the boom.
4. Follow procedure for “PLATFORM REMOVAL”.
5. Follow procedure for “UPPER BOOM REMOVAL”.
6. Remove fasteners (1) securing the link to elbow pivot pin (2). Remove the link to elbow pivot pin (2) and
lower the elbow end of the link.
7. Remove fasteners (3) securing the lift boom to elbow pivot pin (4). Remove the lower boom to elbow
pivot pin (4) and place elbow weldment in a suitable work area. Inspect all assemblies for evidence of
any wear at this time. Replace or repair as necessary.
or linkage. Always lubricate prior to assembly. See your lubrication chart.
3, 4
1, 2
500-9
TL SERIES
UPPER BOOM REMOVAL / ASSEMBLY

1. Shut down the hydraulic system.
2. Ensure booms are supported properly.
NOTE: It is easier to work on the upper boom if the entire boom assembly is removed from the
truck, but the upper boom can be removed alone if there are platforms to work from at the
height of the elbow.
4. Tag, disconnect any air lines if present at this time. Mark and disconnect all wires going into the boom.
6. Follow procedure for “UPPER BOOM CYLINDER REMOVAL”.
7. Remove fasteners (1) securing the boom pivot pin (2) at the turntable weldment at this time. Remove
boom pivot pin (2) and place boom assembly in a suitable work area. Inspect all assemblies for
evidence of any wear at this time. Replace or repair as necessary.
NOTE: See Quick Reference Guide for torques.
NOTE: Prior to installation of cylinder pins, inspect for any nicks or burrs and remove if found.
lubrication chart.
500-10
TL SERIES
BOOM TIP REMOVAL / ASSEMBLY

SIDE MOUNT
2. Tag, disconnect any hydraulic or air lines if present.
3. Remove snap ring (1) and leveling crank bolt (2).
4. Remove platform shaft.
5. Check for wear at the mounting bolt and all pivot points.
6. Examine for cracks and worn areas.
7. Check the bearing, if worn replace. Always apply a light coat of grease to bearing prior to installation of
pin weldment.
8. Reassemble in reverse order and follow leveling assemble procedure to properly adjust the leveling
system.
500-11
TL SERIES
END MOUNT
2. Tag, disconnect any hydraulic or air lines if present.
3. Remove snap ring (1) and leveling crank lynch pin (2).
4. Remove platform shaft.
5. Check for wear at the mounting bolt and all pivot points.
6. Examine for cracks and worn areas.
7. Check the bearing, if worn replace. Always apply a light coat of grease to bearing prior to installation of
pin weldment.
8. Reassemble in reverse order and follow leveling assemble procedure to properly adjust the leveling
system.
500-12
TL SERIES
INNER BOOM REMOVAL / ASSEMBLY

1. Follow procedure for “BOOM TIP REMOVAL”.
2. Follow procedure for “EXTENSION CYLINDER REMOVAL”.
3. Disconnect catrac from inner boom. Pull the hoses out of the boom at the elbow.
4. Remove rollers.
5. Slide the boom out slowly using a suitable lifting device. Let the hose carrier unfold until it is entirely in
the boom. Then feed the hoses in until boom is out.
6. Reassemble in reverse order. See kitsheet or reassembly instructions for roller assembly.
lubrication chart.
500-13
TL SERIES
LOWER BOOM REMOVAL / ASSEMBLY

1. Shut down the hydraulic system.
2. Ensure booms are supported properly.
4. Tag, disconnect any air lines if present. Mark and disconnect all wires going into the boom.
5. Follow procedure for “ELBOW REMOVAL”.
6. Follow procedure for “LOWER BOOM CYLINDER REMOVAL”.
7. Remove fasteners (1) securing the boom pivot pin (2) at the turntable weldment. Remove boom pivot pin
(2) and place boom assembly in a suitable work area. Inspect all assemblies for evidence of any wear at
this time. Replace or repair as necessary.
1, 2
500-14
TL SERIES
MASTER CYLINDER REMOVAL / ASSEMBLY

1. Tag, disconnect and cap hydraulic lines at cylinder.
2. Remove fastener securing rod eye pin (1) and remove the rod eye cylinder pin.
3. Remove fasteners at the cylinder base end (2). Remove cylinder and place in a suitable work area.
4. The ball bushings in the cylinder base and cylinder rod eye should be checked for wear. Replace any
worn components.
The cylinder will be empty of oil and full of air after repair, which may make initial
hydraulic reservoir to the full level, if needed, with all cylinders retracted. From the lower
controls, cycle the boom fully three (3) times before operating from the platform. Do not
ride the platform while air is being purger - SERIOUS INJURY OR DEATH COULD
RESULT.
500-15
TL SERIES
EXTENSION CYLINDER REMOVAL / ASSEMBLY

BOOMS ASSEMBLED
1. Position the upper boom horizontal with no load in the platform.
2. Remove the extension cylinder cover.
3. Extend boom to access the opening. Remove the cylinder end support (1).
4. Remove cylinder pin (2) by first removing set screw (3).
5. Tag, disconnect and cap hydraulic lines at the base end cylinder.
6. Remove four fasteners (4) holding extension cylinder to inner boom.
7. Remove the cylinder pin (2) and slide the cylinder slowly out of the rear of the boom. Support the
cylinder as it is removed with a suitable lifting device.
8. Inspect and replace worn bushings at this time.
9. Reassemble in reverse order. Loctite the four screws securing the rod to the inner boom.
lubrication chart.
The cylinder will be empty of oil and full of air after repair, which may make initial
hydraulic reservoir to the full level, if needed, with all cylinders retracted. From the lower
controls, cycle the boom fully three (3) times before operating from the platform. Do not
ride the platform while air is being purger - SERIOUS INJURY OR DEATH COULD
RESULT.
500-16
TL SERIES
SLAVE CYLINDER REMOVAL / ASSEMBLY

1. Position the upper boom in a comfortable working position. Ensure the platform is supported with a
suitable lifting device.
4. Remove fasteners securing rod end (1).
5. Remove fasteners securing base (2) and remove cylinder.
6. Inspect the rod eye and base bushings for wear. Replace worn bushings at this time.
operation dangerous. Thus, the cylinder should be purged of air. Purge cylinders on the
bench before re-assembling on the unit.
500-17
TL SERIES
WEAR PAD REMOVAL / ASSEMBLY

UPPER WEAR PAD REMOVAL (INNER)

1. Follow procedure for “INNER BOOM REMOVAL”.
2. Remove the two fasteners holding each wear pad.
3. Replace wear pads.
4. Apply Loctite to the wear pad screws before reinstalling them.
ROLLER AND WEAR PAD REMOVAL (OUTER)
The rollers & wear pads that guide the upper telescoping boom must be adjusted or replaced when they
become worn. This is evident when there is excessive play in the upper boom. Generally, clearance of 1/16”
or more is considered excessive. Wear pads and rollers must also be replaced if they become contaminated
with embedded grit and are damaging the boom.
1. Ensure inner boom is supported properly.
2. Remove upper wear pad, two nuts, and the side rollers and roller assembly.
3. Lift up on inner boom until it is just touching the top of outer boom.
4. Replace wear pads.
5. Adjust rollers by shifting shims from below roller shaft evenly so the boom is centered in outer boom.
See kitsheet for more details.
500-18
TL SERIES
ROTATION BEARING REMOVAL / ASSEMBLY

The turntable, lower boom cylinder, lower boom, upper boom with boom tip must be removed prior to
removing the rotation bearing.
1. Tag and remove any hydraulic lines and air lines which pass through the turntable to the pedestal.
Ensure the unit is supported properly prior to the next step. Failure to do so could result
in possible damage to equipment and / or personnel.
2. Loosen the mounting bolts securing the rotation gear box to the turntable assembly.
3. Ensure all the required hydraulic lines have been disconnected, remove the mounting bolts which
secure the rotation speed reducer to the turntable.
4. Remove hex head rotation bearing bolts and washers (1 and 2) which secure the inner rotation bearing
to the turntable.
5. After the turntable is removed, the remaining hex head bolts and washers (3 and 4) that secure the outer
bearing to the pedestal may be removed.
6. Carefully remove the rotation bearing and place in a suitable work area.
NOTE: The seal is the only serviceable item on the bearing.
Turntable
1,2
Rotation
Bearing
3,4
Pedestal
500-19
TL SERIES
ROTATION SPEED REDUCER REMOVAL / ASSEMBLY

Ensure unit is in stored position or the boom assembly is supported so the boom
assembly will not rotate when the rotation speed reducer is removed. Failure to do so
could result in possible damage to equipment and/or personnel.
1. Tag, disconnect, and cap hydraulic lines to orbital motor.
2. Remove the bolts and flat washers (1 and 2).
3. To remove the speed reducer with motor, use a suitable lifting device. Remove by lifting the assembly up
and away from the turntable ring gear. Place in a suitable work area.
1, 2
500-20
ROTATION SPEED REDUCER REPAIR
TL SERIES
SECTION 550
3 7 1,15 13 9 23 10 6 11 6 33 4
11
27 A W
S I
N
L
12
TU
16
FILL WITH
GREASE TULS
14 31 2
19
28 5
5 24
24
33 4 20 21 18 8 17,25 21 22
26,29,30
1. Bearing Cup 12. Bushing 23. Lockwasher

2. Oil Seal 13. Thrust Washer 24. Capscrew
3. Output Shaft 14. Key 25. Bearing Cup
4. Housing 15. Bearing Cone 26. Shim
5. Protector 16. 90 Degree Grease Fitting 27. Locknut
6. Cover 17. Bearing Cone 28. Oil Seal
7. Oil Seal 18. Bushing & Breather Kit 29. Shim
8. S.L. Worm 19. Socket Head Capscrew 30. Shim
9. S.L. Gear 20. End Cap 31. Capscrew
10. O-ring 21. O-Ring 32.
11. Capscrew 22. Motor End Cap 33. Pipe Plug
550-1
TL SERIES
DISASSEMBLY/ASSEMBLY PROCEDURE
Properly support the gearbox with the output pinion shaft facing down.
1. Remove six capscrews and washers (23 and 25) and remove the cover (2).
2. Remove eight capscrews and washers (22, 26, 20 and 24) and remove the bearing retainer (8) and
bearing retainer/motor adapter (9).
3. Move the worm (4) in either direction until it disengages the worm gear (3).
During the next step, the pinion shaft should be supported to prevent it from dropping
when the retaining ring is removed.
4. Remove spacer (10) and retaining ring (13). Remove the output pinion shaft (5). It is likely that the pinion
shaft will have to be tapped out of the housing. Be careful not to damage bearing and sealing surfaces.
5. Remove the worm gear (3) and other spacer (10).
6. The worm (4) and bearings (6 and 7) can now be removed.
When reassembling the gearbox, be sure the bearing cups (6) are loose enough to allow
the worm to move low in the housing until the worm gear (3) and spacer (10) are installed
onto the output pinion (5). The bearing retainers (8 and 9) can then be installed which will
bring the worm into mesh with the worm gear.
550-2
COLLECTOR BLOCK ASSEMBLY MAINTENANCE
TL SERIES
SECTION 640
COLLECTOR BLOCK ASSEMBLY (STANDARD)
The collector block assembly has three hydraulic ports and up to six electrical connections. It serves as a
link for the hydraulic and electrical lines between the fixed pedestal and the rotating boom.
Because of the slow movement of the collector block assembly, replacement of the o-ring seals or other
maintenance will be infrequent. If however, internal or external leakage should occur, indicating worn seals,
dismantle the collector block assembly and replace the o-rings and seals.
Core
Mounting Plate
Turntable
Port 1 is Pedestal
return port. Top Plate
Port 2
carries high
pressure oil. Port D carries
drain oil from
swivel to reservoir.
Port 3
is not used.
Brush
Assembly
Collector Rings
Case
640-1
TL SERIES
TROUBLESHOOTING
To determine if the collector block assembly is the problem when trouble develops in the hydraulic system, it
is important to know the flow paths inside the collector block assembly. If internal leakage develops between
a passage carrying high pressure oil and one that is carrying low pressure oil, the oil will bypass within the
system and do no useful work. Remember, oil will always follow the path of least resistance.
REMOVAL
1. Stop the engine and disengage PTO.
2. Clean the collector block assembly area thoroughly to keep dirt out of the hydraulic system.
3. Mark top of manifold with turntable for correct installation.
4. Below the turntable, disconnect hydraulic lines from elbows in the ports of the sleeve. Be prepared to
collect the oil remaining in the collector block assembly and in the hydraulic lines between the main
control valve and the collector block assembly. Put plugs in the lines to keep dirt out of the system.
5. Disconnect electrical wire(s) from terminal(s) at the side of the collector block assembly.
6. At top of collector block assembly, disconnect hydraulic lines from fittings in ports of manifold. Put plugs
in the lines to prevent dirt from entering the system. Remove all fittings from top ports of collector block
assembly.
NOTE: The fittings in the top of the manifold are check fittings and must be installed in the same
locations.
7. The electrical wire(s) on top of the collector block assembly are sealed into the manifold with silicone
sealant. Disconnect the electrical wires at the pressure switch and accessory(s).
8. The collector block assembly can be removed from the top if the boom is removed or dropped down
through the bottom or out the access hole in the side of the pedestal. To pull up, remove the 4 bolts
holding the mounting plate to the turntable. To lower down, remove bolts holding collector block
assembly to the adapter plate.
DISASSEMBLY
(See Figure 1.)
1. Remove lock ring (14), cover (15) and second lock ring (14).
2. Remove lock ring (6).
3. Loosen each insulator assembly (A).
4. Pull manifold (1) out of sleeve (2).
5. Remove and discard o-rings (4) and wear rings (3) from each of four grooves in manifold. Remove two
seals from remaining grooves. Discard all seals and replace with seal kit.
REMOVAL OF ELECTRIC COLLECTOR RING ASSEMBLY
1. Remove silicone from top of manifold.
2. Remove two hex head screws (13) and flat washers (12).
3. Remove each collector ring assembly. Tag and record the color code for ease of assembly. Collector
ring assemblies must be installed in proper order, each assembly has a different color wire.
CLEANING, INSPECTION AND REPAIR
1. Clean manifold and sleeve using a non-flammable solvent. Dry with compressed air. Use compressed
air to blow into each inner passage in manifold and to clean the threads in the ports. Remove all burrs
and rough edges.
Compressed air for cleaning purposes should not exceed 30 PSI (.21 MPa). User should
use normal precautions, wear safety goggles and should not direct the stream of air
toward himself or other persons to prevent injury to personnel.
2. Inspect bore of sleeve for gouging, pitting or damage. Surface should be completely smooth.
3. Inspect for cracks or other defects. Check for visible wear at outer edge of each o-ring groove and each
porting groove.
4. Replace all o-rings and any part which shows evidence of damage or wear.
640-2
TL SERIES
FIGURE 1
1. Manifold 7. Pipe Plug 11. Collector Ring 16. Brush
2. Sleeve 8. Silicone Sealant Insulator 17. Spring
3. Wear Ring (4) 9. Collector Ring 12. Flat Washer (2) 18. Brush Insulator
Insulator
4. O-ring (4) 13. Hex Head Screw (2) 19. Hex Nut (2)
5. Seal (2) 10. Collector Ring 14. Snap Ring (2)
Assembly
6. Snap Ring 15. End Cover
640-3
TL SERIES
ASSEMBLY
(See Figure 1.)
COLLECTOR RING ASSEMBLY
1. Orientate each collector ring in their proper order.
2. Thread wires through manifold.
3. Secure collector rings to manifold with hex head screws (13) and flat washers (12).
4. Inject silicone into opening in manifold. Keep wires separated to allow silicone to flow between wires.
Depth of silicone must not be less than 1 inch.
COMPLETE COLLECTOR BLOCK ASSEMBLY
1. Install new o-rings (4) and wear rings (3) on manifold. A thin metal sleeve or heavy aluminum foil
wrapped around the manifold will be helpful in installing the o-rings. Assemble the o-rings dry. Use care
that you do not stretch, cut, or roll the o-rings as you install them. Carefully slip each o-ring over the
sleeve, then slide it down the manifold and into its groove. Start at the top (shoulder part) of the manifold
and move groove by groove towards the bottom (snap ring end) of the manifold. Install two seals (5) in
remaining grooves.
2. After all o-rings and wear rings are installed on the manifold, apply a liberal amount of Lubriplate
#130AA over the o-rings and outer diameter of manifold and the bore of the sleeve. Carefully install the
manifold into the sleeve, snap ring end first. Rotate the manifold by hand as you lower it straight into the
sleeve. Make sure the o-rings do not twist, roll, or get cut as you insert the manifold into the sleeve.
3. Install snap ring (6). Rotate the manifold in the sleeve to check for binding or restriction. Install lock ring
(14), cover (15) and first lock ring (14).
4. Tighten each insulator assembly (A) against the collector ring assemblies.
5. Pressure test collector block assembly before installation. Plug one end of each passage and apply
hydraulic pressure to opposite end. Check for leakage or loss of pressure. Each passage should be
tested at 2000 PSI (13.79 MPa). Check the ports adjacent to the port being tested for leakage. If leakage
occurs, rotate several turns and retest. If leakage persists, disassemble and inspect o-ring and wear ring
installation.
INSTALLATION
1. Position collector block assembly in turntable, engaging stop with tabs on lower pedestal plate. Install
mounting bolts and lock washers to fasten collector block assembly to its mounting plate at top of
turntable, in the same position as it was removed.
2. Install electrical wire(s) to terminal(s) at side of collector block assembly.
3. Connect hydraulic lines to respective elbows on side of sleeve, under the turntable. Be sure they are
connected properly. Release vacuum.
4. Before you install the hydraulic lines to ports at top of collector block assembly, pour clean hydraulic oil,
of the type used in the system, into each of the open ports of the manifold. This will fill the lower lines
and provide initial lubrication of the o-rings in the collector block assembly.
5. Install fittings in manifold ports. Connect hydraulic lines to respective ports. Ensure checks are pointing
in direction of flow.
6. Connect electrical wire(s) to proper functions and accessories).
7. Run system and check for leaks. Do not rotate turntable until hydraulic oil has filled all of the passages of
the collector block assembly.
Do not operate Aerial Device with platform controls until air is removed from the Aerial
Device hydraulic system. Lower and raise outriggers several times until all air is removed
from circuits. Using lower controls, operate each function (upper boom, lower boom and
turntable) until all air is removed from each circuit.
640-4
TL SERIES
CHECK VALVES
There are two check valves located on the top of the collector block assembly on units over 50 feet (15.2 m).
Their function is to hold oil in the hoses when the hydraulic pump is not running. The hoses must be full of oil
to maintain dielectric strength of the boom insulation. A vacuum or partial vacuum can allow flashover at
lower voltages. The checks are located on top of the collector block assembly. They look like hydraulic
fittings. Arrows on the side indicate direction of flow. The return flow must point towards the collector block
assembly and the pressure must point away from the collector block assembly.
Checks located on top of collector block assembly.
RETURN - PORT 1
NOTE: Fitting
check flow direction.
PRESSURE - PORT 2
640-5
TL SERIES
COLLECTOR RING MAINTENANCE

Located on the center of rotation, collector rings maintain full electrical contact at all times between a rotating
member with continuous 360 degrees rotation, and a stationary member. Without the collector ring, the wire
harness would twist off and electrical contact would be lost.
The collector ring is designed for maximum efficiency with a minimum of maintenance. The self-cleaning
brushes will provide long life. On all circuits from 10–0 Amp capacity, the brushes ride on a 3/16 in. (4.76
mm) wide brass ring. One brush pair per circuit is used on 10–20 Amp circuits. For circuits requiring up to 30
Amp capacity, two pair of brushes per circuit are used. For 45 Amp capacity, a 3/8 in. (9.53 mm) wide brass
ring and a single pair of wide brushes is used. Two pair of wide brushes are used on 75 Amp capacity. The
special 7 1/2 Amp capacity circuits ride on a 3/32 in. (2.38 mm) brass ring. (See note in this section
concerning service and replacement of these). The brushes are fastened to the brush arms to allow pivoting
of the brushes. This assures complete contact at all times between the brush and the brass ring. This is
especially important if an orbiting condition develops as the equipment ages.
The brushes are normally attached to the brush harness with knife disconnect terminals. This allows for
quick disconnect of the harness, should removal of the ring be required. Terminals of this type are protected
by a plastic sleeve.
When installing the ring assembly, care should be taken to insure complete coverage of the terminals by this
sleeve. Some collector ring harnesses use multiple circuit electrical connectors or plugs These should be
disconnected and connected carefully to avoid damaging the contacts.
In the case of customer attachment, the center harness is normally connected to the core leads on the
collector ring by the set screw connectors provided with the ring. These connectors have proven to be
superior to the twist on type, especially in field installations, because they are a positive type installation.
The brass sleeve is slipped over the stripped wire ends, and the set screw tightened with a straight
screwdriver. The nylon cover is then screwed down over the sleeve for protection. Care should be taken to
keep the center leads as short a possible when connecting the center harness to prevent the wires from
catching on any moving parts.
Some collector rings are rewired during manufacture and the center core leads are permanently fastened to
the center harness with machine crimped terminals. If it becomes necessary to remove these, the set screw
type connectors should be used for replacement.
If not revolved for some time, under some conditions, the collector ring will have a tendency to collect fine
silt, or a salt atmosphere will cause corrosion. If this happens, the equipment should be rotated through
several revolutions if possible. The cleaning action of the brushes should clean the ring surfaces. If it does
not, or it is not practical to revolve the machine, it may be necessary to use a standard non-residue solvent
to clean the ring. Then lightly sand the brushes and rings with a fine grade of sandpaper and blow off with
compressed air.
640-6
TL SERIES
Expansion Plug
Collector
Block Core
(Ref)
Collector
Block Case
(Ref)
Clamp
Brush & Holder
4 Channel Collector
Ring Assembly
640-7
TL SERIES
COLLECTOR RING BRUSH AND ARM MAINTENANCE
To replace a brush and arm assembly, remove the hex nuts and washers at the top of the brush stud along
with the outboard bearing, if used. This will allow the brush assemblies to be removed.
NOTE: Some smaller rings use cap screw, or may be equipped with socket screw type set collars
instead of hex nuts.
Carefully remove the brushes without over stretching the brush springs and arrange in order of removal with
the spacers. Replace the damaged brush assembly and then reassembly the brushes and spacers in
reverse the removal order. this will ensure the correct spacing between electrical parts. Be sure that all
brushes are snapped in tight and making full contact with their corresponding brass ring. Also check that all
springs are hooked correctly through the brush arm.
NOTE: Special care should be exercised when handling or replacing the 7 1/2 Amp brush and
arm assemblies. Because of their small size, they can be broken if forced up or down. In
the correctly installed position, the possibility of breakage is minimal.
640-8
TL SERIES
If it should become necessary to remove the collector ring from the machine, do so by loosening the socket
screw at the base of the ring. This will allow the ring to be lifted off the mounting tube. When replacing it,
make sure these set screws are again tightened. If the set screws are not tight, the core can turn or be held
by the brushes, and twist off the core leads or center harness. The mounting tube should be 1.492–1.496 in.
(37.897-38.00 mm) O.D. and approximately 14 gauge thickness. This allows for proper fit along with
maximum inside clearance, while maintaining necessary strength. Care should be taken to abide by these
tolerances if mounting tube replacement is required. The grease seal or o-ring in the optional base for
inverted mounting should be lubricated with GE G322L Versilube or equivalent silicone grease before the
insertion of the mounting tube.
In most cases, collector ring assemblies should not be fastened down tightly. If they are not attached
perfectly to the center of rotation or if wear causes an orbiting condition as the equipment ages, excess
strain is applied to the collector ring assembly. Therefore, the collector ring drive pins for the collector rings
should be at least 1/8 in. (3.18 mm) smaller in diameter than the 3/4 in. (19.05 mm) diameter holes in the
base casting of the ring. The drive hole in the base of the collector ring is tapped 1/2-13 UNC. A 1/2-13 UNC
pin in this hole should be allowed to float on the opposite end. The same result is achieved by using a 7/16
in. (11.11 mm) diameter or smaller pin fastened tightly on the driven end and with a loose fit in the hole.
INSTALLATION OF COLLECTOR RING
In a typical application, a 1.492–1.496 in. (37.90-38.00 mm) O.D. mounting tube is fastened to a stationary
lower unit. the ring core (or center stack of brass rings) is secured to the mounting tube by a set screw collar
located at the base of the core. The set screw are tightened to 45–55 in. lbs. (5-6 N-m) to keep the core
stationary. If this is not done, the core can turn, twisting the center harness wires.
The center harness is attached to the core by set screw connectors, and normally runs through the center of
the core to exit at the bottom of the drive tube. This harness is connected to the electrical components in the
stationary member. Typically the brushes, base bracket, and cover will turn with the rotating member of the
equipment upon which it is located and can move continuously around the ring core, providing uninterrupted
electrical contact.
Rotating the brushes around the core is accomplished by the use of a boss in the base bracket. This is
normally tapped to 1/2-13 (UNC) thread and a threaded pin inserted. The other end of the pin must not be
fastened tightly to the rotating member, but must be allowed to float. This is very important on many
machines that may acquire an orbiting condition as the equipment ages. This type of wear will put stress on
the ring and may ultimately break the base if it is bolted tightly. If the turning pin is tightly mounted on the
rotating member, it must then be small enough on the opposite end to float within the boss.
The brush shunt wires are attached to the brush harness with mating knife disconnect terminals and are
protected by a plastic sleeve. The brush harness then exits through the base bracket and is connected to the
electrical components in the rotating member.
Do not remove cover or attempt maintenance until power is disconnected and locked.
640-9
TL SERIES
640-10
ROTARY ACTUATOR
TL SERIES
SECTION 650
ROTARY ACTUATOR
(OPTIONAL - ONLY AVAILABLE ON END MOUNT PLATFORM)
THEORY OF OPERATION
In reference to the figure below, fluid entering Port P2 under pressure will bear on the piston (4) and force
the piston sleeve (3) upwards. The left-handed splined of the piston sleeve (3) will combine with the right-
handed spline of the shaft (2A) and cause rapid counter-clockwise rotation of the shaft and flange (2B)
(looking down). Fluid entering Port P1 will reverse this rotation.
Displacement and torque are identical for clockwise and counter-clockwise rotation.
The shaft (2A) is integral with the shaft flange (2B) and bearing tube (2C). The shaft is supported radially by
the large upper radial bearing (19) and the lower radial bearing (18). Axially, the shaft is separated from the
housing by the upper and lower thrust rings (20). The end cap (5) is adjusted for axial clearance and locked
in position by cap screws (7).
650-1
ROTARY ACTUATOR
TL SERIES
DISASSEMBLY AND INSPECTION

Place on a clean workbench with room to place the internal parts as they are removed. Remove all hydraulic
fittings. Loosen cap screws (7) and unscrew locknut (6) and end cap (5). The shaft is now free to move up
and out of engagement with the piston sleeve (3). Note the orientation between the spline teeth (See figure
on following page), as this will greatly simplify actuator timing upon reassembly.
After removing the shaft, the piston sleeve and the piston assembly can now be moved down and out of the
housing. Remove all seals and bearings from their grooves, except static piston seals (9) and (11). These
seals generally do not require replacement. Clean all parts thoroughly and inspect for wear. A small amount
of wear in the spline teeth will have little effect on the actuator strength. New spline sets are manufactured
with a backlash of about .005 in. (.13 mm) per mating set. After long service, a backlash of about .015 in.
(.38 mm) per set may still be acceptable in most cases, depending on the required accuracy of the
application.
Item (1) is the integral housing and ring gear. Check the ring gear for wear and weld damage to the pins.
Inspect the cylinder bore for wear and scratches. The surface finish should be 32 RMS or better; re-hone if
necessary. The radial bearings (17) should have a maximum radial clearance of .006 inch (.15 mm). A
clearance in excess of .008 in. (.20 mm) requires replacement of the bearings. Rough and groved shaft
journals require shaft replacement.
ASSEMBLY AND TESTING
Wash all parts thoroughly in cleaning solvent and blow dry. Coat all sealing and working surfaces with a
good grade hydraulic oil. Install seals and bearings in the piston sleeve, piston, shaft, and end cap. The lips
of the exclusion seals (16) face outward, and the lips of the high pressure seals face inward.
Place the actuator in a vertical position, install the piston sleeve (3) in timed relation to the housing, applying
firm pressure as the new seals and bearings enter the housing and become compressed by the housing
chamber.
Do not mis-align the sleeve too much any one way, as it will mar the cylinder bore.
The timing marks (the small punch marks on the face of each gear), must be aligned for proper shaft
orientation (see figure on following page).
If the actuator is not equipped with grease fittings, the thrust bearings (20) are coated with good grease
before sliding on the shaft and end cap. The shaft is installed by again aligning the proper punched timing
marks (see figure on following page). Temporarily taping the threaded portion of the shaft will help
installation past the shaft seals (masking tape works well). Apply antiseize to threaded and surrounding
areas of the end caps. Also, depending on the size of the actuator (60K and larger), the end cap may need
to be installed with the actuator in a vertical position.
The end cap (5) is torqued to 60–400 ft. lbs. (81-542 N-m) depending on the actuator size, such that the
actuator begins rotation at approximately 100 PSI (.69 MPa). The shaft flange cannot be rotated by hand;
the combined backdrive efficiency and friction prevent manual rotation. If the end cap is torqued too high, the
actuator may require as much as 300 PSI (2.07 MPa) to rotate. If the end cap is not torqued high enough,
shaft axial motion and radial backlash will result. The end cap must be secured against the shaft by
tightening cap screws (7), or by installing axial set screws, depending on the model. Apply hydraulic
pressure and check for breakaway pressure and shaft axial motion.
650-2
ROTARY ACTUATOR
TL SERIES
Matched timing Matched timing

marks on piston marks on shaft
sleeve and ring gear. and piston sleeve.
1 2
To test for leakage, pressurize Port P2 to 3000 PSI (20.69 MPa). No oil should seep fro Port P1 or from
around end cap (5). Repeat test by pressurizing Port P1 and check for leakage out of Port P2, around shaft
flange (2B), and from ring gear pin welds.
TESTING AND STORAGE
All standard actuators have been tested and operated through at least twenty-five (25) full cycles at 3000
PSI (20.69 MPa). Additionally, all actuators are tested at 4500 PSI (31.03 MPa) for structural integrity.
The actuators are normally shipped filled with petroleum base hydraulic oil, and the ports are plugged with
the proper high strength steel plugs to prevent leakage during shipment.
HYDRAULIC LINE ATTACHMENT
The hydraulic lines from the control valve to the actuator should be as short as possible. If the lines hold
more oil than the actuator displaces, some of the oil is cycled back and forth, and not allowed to flow to tank
for filtering and cooling, resulting in premature actuator wear.
650-3
ROTARY ACTUATOR
TL SERIES
650-4
WINCH GEARBOX
TL SERIES
SECTION 660
WINCH GEARBOX
MAINTENANCE OF WORM GEAR WINCH (TULSA)
Breather
NOTE: Oil should be level with the bottom of the check/fill plug (A) when the winch is at the
position shown. Maximum 120 hour interval.
CHECKING OIL LEVEL
Maintain oil level to dissipate heat. Too much or too little oil in the winch may cause trouble. Fill to the oil
level plug. Check oil level every 360 hours or 90 days of operation.
OIL CHANGE INFORMATION
1. Oil should be drained after the first two months of operation.
2. Fill with clean kerosene and run for 15 minutes in each direction. Drain kerosene and add oil to full level.
Oil should be changed every 12 months or 1,050 hours. Adherence to a regular schedule of oil change
will help to assure proper winch operation.
DISTORTED WORM GEAR
The worm gear requires no service or adjustment unless extreme overloads have been applied which might
have distorted the worm gear teeth.
A distorted worm gear tooth, even though it may not be broken, warns the operator through the creeping of
the load line. If creeping of the load line is evident, inspect the worm gear teeth by removing the housing
cover.
If the tooth form has been destroyed, they will appear to be leaning in one direction. Dismantle the worm
gear assembly, thoroughly clean the housing, inspect the worm for damage and replace all damaged parts.
INSPECT BREATHER PLUG
The winch is equipped with a breather plug which is located on top of the gear housing. The purpose of the
plug is to release the gases which form from oil heating when the winch is in operation. If the plug is clogged,
pressure will build up within the housing and cause excessive heating and oil leakage.
INSPECT WINCH MOUNTING
Inspect the winch mounting bolts periodically. Replace those that are missing and tighten those which are
loose. Pay special attention to the attachment bolts which anchor the front base angle of the winch. Do not
borrow bolts from the winch base as a loose winch mounting can create a safety hazard.
Check other equipment items that are involved with the use of the winch. They are vital to safety and
property. Prevent any condition that may endanger the safety of personnel.
660-1
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TL SERIES
WINCH SPEED REDUCER REPAIR

9 10
7 12
8 11
6 22 13
5 14 15
4 16
3 17
2 18
1 19
20
21
1. Capscrew 7. Oil Seal 13. Key 18. Bushing
2. Cover 8. Housing 14. Bushing 19. O-Ring
3. Gasket 9. Breather 15. Washer 20. Cover
4. Ring Retaining 10. Bearing 16. Gear 21. Capscrew
5. Bearing 11. Ring Retaining 17. Washer 22. Plug
6. Worm 12. Gasket
To repair the winch speed reducer, proceed as follows:
1. Remove speed reducer from machine.
2. Disassemble speed reducer as shown in illustration above.
3. Thoroughly wash and clean all parts.
4. If the worm (6) or the worm gear (16) are excessively worn (too much backlash), replace them.
5. Clean or replace the bearings (5, 10 and 18) as necessary. If the bearings are to be cleaned, refer to
"MAINTENANCE OF BEARINGS" in this manual for cleaning procedure.
6. Replace the oil seals (7) and gaskets (3 and 12).
7. Replace any other parts that may be worn or damaged.
8. The worm shaft bearings (5 and 10) are a thrust type bearing and must be installed with the thick side of
the outer race supported by the bearing end caps.
When reassembling the speed reducer, be extremely careful not to let any part get dirty
or contaminated.
9. Reassemble speed reducer.

10. Refer to Quick Reference Guide for recommended lubricant, (1-1/2 pints).
11. Install speed reducer on machine.
ASSEMBLY DATA
See Quick Reference Guide.
660-2
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ORBIT MOTOR
ORBIT MOTOR EXPLODED VIEW

1. Special Bolts 8. Rotor Set 12. Coupling Shaft 17. Backup Washer
(5 or 7)
8A. Rotor 12A. Key 18. Housing
1A. Special Bolts (7) 8B. Stator or Stator 12B. Nut 18A. O-ring (2)
Half
1B. Special Bolts (7) 12C. Washer 19. Bearing/Bushing,
Outer
1C. Special Bolts (7) 8C. Vane (7) 12D. Bolt
2. End Cover 8D. Stator Half 12E. Lockwasher 20. Dirt & water Seal
3. Seal Ring 8E. Vane (7) 12F. Retaining Ring 21. Plug (2)
Commutator
9. Wear Plate 13. Bearing/Bushing, 22. O-Ring (2)
Inner
4. Seal Ring (5) 10. Drive Link 23. Spring
5. Commutator 11. Thrust Bearing 14. Thrust Washer 24. Valve (Shuttle or
Relief)
6. Commutator Ring 15. Thrust Bearing
7. Manifold 16. Seal 25. Backup Washer
660-3
WINCH GEARBOX
TL SERIES
BEFORE DISASSEMBLY
Before you disassemble the Torqmotor unit or any of its components read this section of the manual. It
provides important information on parts and procedures you will need to know to service the Torqmotor.
Determine whether the Torqmotor you are about to disassemble is the Small Frame Series MG or MF or the
Large Frame Series MB or ME so you can follow those procedures that pertain to that Series Torqmotor. The
first two letters of the "spec" number on the Torqmotor identification tag is the Series designation. Also
determine the type of end cover construction.
The Small Frame Series MG & MF Torqmotors will have a 3.66 inch (92.9 mm) main body outside diameter
and five 5/16-24 UNF 2A cover bolts. The Large Frame Series MB & ME Torqmotors will have a 5 inch (127
mm) main body outside diameter and seven 3/8 24 UNF 2A cover bolts.
Thoroughly clean off all outside dirt, especially from around fittings and hose connection, before
disconnection and removing the Torqmotor. Remove rust or corrosion from coupling shaft.
Remove coupling shaft connections and hose fittings and immediately plug port holes and fluid lines.
Remove the Torqmotor from system, drain it of fluid and take it to a clean work surface.
Clean and dry the Torqmotor before you start to disassemble the unit.
As you disassemble the Torqmotor clean all parts, except seals, in clean petroleum-based solvent, and blow
them dry.
• Solvents are flammable, be extremely careful when using any solvent. Even a
small explosion or fire could cause injury or death.
• Wear eye protection and be sure to comply with osha or other maximum air
pressure requirements.
Never steam or high pressure wash hydraulic components. Do not force or abuse closely
fitted parts.
Keep parts separate to avoid nicks and burrs.

Discard all seals and seal rings as they are removed from the Torqmotor. Replace all seals, seal rings and
any damaged or worn parts with OEM approved service parts.
DISASSEMBLY & INSPECTION
1. Place the Torqmotor in a soft jawed vice, with coupling shaft (12) pointed down and the vise jaws
clamping firmly on the sides of the housing (18) mounting flange or port bosses. Remove manifold port
o-rings (18A) if applicable.
If the Torqmotor is not firmly held in the vise, it could be dislodged during the service
procedures, causing injury.
2. Scribe an alignment mark down and across the Torqmotor components from end cover (2) to housing
(18) to facilitate reassembly orientation where required. Loosen two shuttle or relief valve plugs (21) for
disassembly later if included in end cover. 3/16 or 3/8 inch allen wrench or 1 inch hex socket required.
3. Remove the five or seven special ring head bolts using an appropriate 1/2 or 9/16 inch size socket.
Inspect bolts for damaged threads, or sealing rings, under the bolt head. Replace damaged bolts.
4. Remove end cover assembly (2) and seal ring (4). Discard seal ring.
NOTE: Refer to the appropriate "ALTERNATE COVER CONSTRUCTION" in your service parts
section of this manual to determine the end cover construction being serviced.
5. If the end cover (2) is equipped with shuttle valve or relief valve (24) components, remove the two
previously loosened plugs (21) and o-rings (22).
Be ready to catch the shuttle valve or relief valve components that will fall out of the end
cover valve cavity when the plugs are removed.
NOTE: O-ring (22) is not included in seal kits but serviced separately if required.
660-4
WINCH GEARBOX
TL SERIES
The insert and if included the orifice plug in the end cover (2) must not be removed as they are serviced as
an integral part of the end cover.
6. Thoroughly wash end cover (2) in proper solvent and blow dry. Be sure the end cover valve apertures,
including the internal orifice plug, are free of contamination. Inspect end cover for cracks and the bolt
head recesses for good bolt head sealing surfaces. Replace end cover as necessary.
NOTE: A polished pattern (not scratches) on the cover from rotation of the commutator (5) is
normal. Discoloration would indicate excess fluid temperature, thermal shock, or excess
speed and require system investigation for cause and close inspection of end cover,
commutator, manifold, and rotor set.
7. Remove commutator ring (6). Inspect commutator ring for cracks, or burrs.
8. Remove commutator (5) and seal ring (3). Remove seal ring from commutator, using an air hose to blow
air into ring groove until seal ring is lifted out and discard seal ring. Inspect commutator for cracks or
burrs, wear, scoring, spalling or brinelling. If any of these conditions exist, replace commutator and
commutator ring as a matched set.
9. Remove manifold (7) and inspect for cracks surface scoring, brinelling or spalling. Replace manifold if
any of these conditions exist. A polished pattern on the ground surfaces from commutator or rotor
rotation is normal. Remove and discard the seal rings (4) that are on both sides of the manifold.
NOTE: The manifold is constructed of plates bonded together to form an integral component not
subject to further disassembly for service. Compare configuration of both sides of the
manifold to ensure that same surface is reassembled against the rotor set.
10. Remove rotor set (8) and wearplate (9) together to retain the rotor set in its assembled form, maintaining
the same rotor vane to vane (8C) to stator contact surfaces. The drive link (10) may come away from the
coupling shaft (12) with the rotor set, and wearplate. You may have to shift the rotor set on the wearplate
to work the drive link out of the rotor (8A) and wearplate. Inspect the rotor set in its assembled form for
nicks scoring, or spalling on any surface and for broken or worn splines. If the rotor set component
requires replacement, the complete rotor set must be replaced as it is a matched set. Inspect the
wearplate for cracks, brinelling, or scoring. Discard seal ring (4) that is between the rotor set and
wearplate.
NOTE: The rotor set (8) components may become disassembled during service procedures.
Marking the surface of the rotor and stator that is facing UP, with etching ink or grease
pencil before removal from Torqmotor will ensure correct reassembly of rotor into stator
and rotor set into Torqmotor. Marking all rotor and rotor set into Torqmotor. Marking all
rotor components and mating spline components for exact repositioning at assembly will
ensure maximum wear life and performance of rotor set and Torqmotor.
NOTE: Series ME Torqmotors may have a rotor set with two stator half's (8B & 8D) with a seal
ring between them and two sets of seven vanes (8C & 8E). Discard seal ring only if stator
half's become disassembled during the service procedures.
NOTE: A polished pattern on the wear plate from rotor rotation is normal.
11. Place rotor set (8) and wear plate (9) on a flat surface and center rotor in stator such that two rotor lobes
(180 degrees apart) and a roller vane centerline are on the same stator center line. Check the rotor lobe
to roller vane clearance with a feeler gage at this common centerline. If there is more than .005 inches
(0.13 mm) of clearance, replace rotor set.
NOTE: If rotor set (8) has two stator half's (8B & 8D) and two sets of seven vanes (8C & 8D) as
shown in the alternate construction ME rotor set assembly view, check the rotor lobe to
roller vane clearance at both ends of rotor.
12. Remove drive link (10) from coupling shaft (12) if it was not removed with rotor set and wear plate.
Inspect drive link for cracks and worn or damaged splines. No perceptible lash (play) should be noted
between mating spline parts. Remove and discard seal ring (4) from housing (18).
13. Remove thrust bearing (11) from top of coupling shaft (12) Torqmotor is a Series MB or ME. Inspect for
wear, brinelling, corrosion and a full complement of retained rollers.
14. Check exposed portion of coupling shaft (12) to be sure you have removed all signs of rust and
corrosion which might prevent its withdrawal through the seal and bearing. Crocus cloth or fine emery
paper may be used. Remove any key (12A), nut (12B), washer (12C), bolt (12D), lock washer (12E), or
retaining ring (12F).
660-5
WINCH GEARBOX
TL SERIES
15. Remove coupling shaft (12) by bushing on the output shaft. Inspect coupling shaft bearing and seal
surfaces for spalling, nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or
worn internal and external splines or keyway. Replace coupling shaft if any of these conditions exist.
NOTE: Minor shaft wear in seal area is permissible. If wear exceeds .020 inches (0.51 mm)
diametrically, replace coupling shaft.
A slight "polish" is permissible in the shaft bearing areas. Anything more would require coupling shaft
replacement.
16. Remove and discard seal ring (4) from housing (18).
17. Remove thrust bearing (15) and thrust washer (14) if the unit is a Series MG or MF. Inspect for wear,
brinelling, corrosion and a full complement of retained rollers.
NOTE: Large frame Series MB & ME Torqmotors have a thrust bearing (15) sandwiched between
two thrust washers (14) that cannot be removed from housing (18) unless bearing (13) is
removed for replacement.
18. Remove seal (16) and back up washer (17) from Small Frame, MG & MF housing (18). Discard both.
Remove seal (16), backup washer (17), and backup washer (25) from Large Frame, Series MB & ME
Torqmotor housing by working them around unseated thrust washers (14) and thrust bearing (15) and
out of the housing. Discard seal and washers.
NOTE: The original design units of Large Frame, Series MB & ME Torqmotors did not include
backup washer (25), but must include backup washer (25) when reassembled for service.
19. Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal
puller required.
20. Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs, brinelling or corrosion.
Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes
for thread damage. If the housing is defective in these areas, discard the housing assembly.
21. If the housing (18) assembly has passed inspection to this point, inspect the housing bearings/bushings
(19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust
bearing (15). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit
freely. All rollers and thrust washers must be free of brinelling and corrosion. The MG Series bushing
(19) or (13) to coupling shaft diametral clearance must not exceed .010 inch (.025 mm). A bearing,
bushing, or thrust washer that does not pass inspection must be replaced. If the housing has passed this
inspection the disassembly of the Torqmotor is completed.
NOTE: The depth or location of bearing/bushing (13) in relation to the housing wear plate
surface and the depth or location of bearing/bushing (19) in relation to the beginning of
bearing/bushing counter bore should be measured and noted before removing the
bearings/bushings. This will facilitate the correct reassembly of new bearings/bushings.
22. If the bearings, bushing or thrust washers must be replaced use a suitable size bearing puller to remove
bearing/bushings (19) and (13) from housing (18) without damaging the housing. Remove thrust
washers (14) and thrust bearing (15) if they were previously retained in the housing by bearing (13).
THE DISASSEMBLY OF TORQMOTOR IS COMPLETED
660-6
WINCH GEARBOX
TL SERIES
ASSEMBLY
Replace all seals and seal rings with new ones each time you reassemble the Torqmotor unit. Lubricate all
seals and seal rings with SAE 10W40 oil or clean grease before assembly.
NOTE: Individual seals and seal rings as well as a complete seal kit are available. The parts are
available through Terex South Dakota, Inc. distributors, or Terex South Dakota, Inc..
Unless otherwise indicated, do not oil or grease parts before assembly.
Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air.
Remove any paint chips from mating surfaces of the end cover, commutator set, manifold rotor set, wear
plate and housing and from port and sealing areas.
Since they are flammable, be extremely careful when using any solvent. even a small
explosion or fire could cause injury or death.
Wear eye protection and be sure to comply with OSHA or other maximum air pressure requirements.
1. If the housing (18) bearing components were removed for replacement, thoroughly coat and pack a new
outer bearing/bushing (19) with clean corrosion resistant grease. Press the new bearing/bushing into the
counterbore at the mounting flange end of the housing, using the appropriate sized bearing mandrel
which will control the bearing/bushing depth.
Small Frame Series MG and MF Torqmotor housings require the use of bearing mandrel to press
bearing/bushing (19) into the housing to a required depth of .151/.161 inches (3.84/4.09 mm) from the
end of the bearing counterbore.
Large Frame Series MB and ME Torqmotor housings require the use of the bearing mandrel to press
bearing (19) into the housing to a required depth of .290/.310 inches (7.37/7.87 mm) from the outside
end of the bearing counterbore.
NOTE: Bearing mandrel must be pressed against the lettered end of bearing shell. Take care that
the housing bore is square with the press base and the bearing/bushing is not cocked
when pressing a bearing/bushing into the housing.
If the bearing mandrel specified is not available and alternate methods are used to press
in bearing/bushing (13) and (19) the bearing/bushing depths specified must be achieved
to insure adequate bearing support and correct relationship to adjacent components
when assembled.
Because the bearing/bushings (13) and (19) have a press fit into the housing they must be discarded when
removed. They must not be reused.
2. The Small Frame Series MG and MF Torqmotor inner housing bearing/bushing (13) can now be pressed
into its counterbore in housing (18) flush to .03 inch (.76 mm) below the housing wear plate contact face.
Use the opposite end of the bearing mandrel that was used to press in the outer bearing/bushing (19).
The Large Frame Series MB and ME Torqmotor housing (18) requires that you assemble a new backup
washer (17), new backup washer (25), new seal (16), with the lip facing out, new thrust washer (14),
new thrust bearing (15) and a new second thrust washer (14) in that order before pressing in the inner
housing bearing (13). When these components are in place, press new bearing (13) into the housing
(18) to a depth of .105/.125 inches (2.67/3.18 mm) below the housing wear plate contact face. Use the
opposite end of the bearing mandrel used to press in outer bearing (19).
3. Apply a small amount of clean grease to a new dirt and water seal (20) and press it into the housing (18)
outer bearing counterbore.
The Small Frame Series MG and MF Torqmotor dirt and water seal (20) must be pressed in until its'
flange is flush against the housing.
The Large Frame Series MB and ME Torqmotor dirt and water seal (20) must be pressed in with the lip
facing out and until the seal is flush to .020 inches (.51 mm) below the end of housing.
4. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against
the mounting flange.
660-7
WINCH GEARBOX
TL SERIES
5. On Small Frame, Series MG & MF Torqmotors assemble a new backup washer (17) and new seal (16)
with the seal lip facing out, into their respective counterbores in housing (18) if they were not assembled
in procedure 2.
Large Frame, Series MB and ME Torqmotor housing (18) that did not require replacement of the bearing
package will require that the two "captured" thrust washers (14) and thrust bearing (15) be unseated and
vertical to the counterbore and the new backup washer (17), new backup washer (25), and new seal
(16) be worked around the thrust bearing package and placed into their respective counterbores. The
seal lip must face out of the seal counterbore. Be sure the thrust bearing package is reseated correctly
after assembly of the seal and a backup washer.
Original design Large Frame, MB & ME Torqmotors that do not have backup washer (25)
when disassembled must be assembled with a new backup washer (17), new backup
washer (25), and new seal (16).
6. Assemble thrust washer (14) then thrust bearing (15) that was removed from the Series MG or MF
Torqmotor.
NOTE: Small Frame Series MG and MF Torqmotors require one thrust washer (14) with thrust
bearing (15). The coupling shaft will be seated directly against the thrust bearing.
7. Apply masking tape around splines or keyway on shaft (12) to prevent damage to seal.
8. Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower
(outer) housing bearing/bushing (19). Install the coupling shaft (12) into housing (18), seating it against
the thrust bearing (15) in MG and MF Series housings and against the second thrust washer (14) in MB
and ME Series housing.
The outer bearing (19) is not lubricated by the system's hydraulic fluid. Be sure it is
thoroughly packed with the recommended grease.
NOTE: The coupling shaft (12) will be flush or just below the housing wear plate surface on Small
Frame, Series MG and MF Torqmotors when properly seated while the coupling shaft (12)
on Large Frame, Series MB and ME Torqmotors will be approximately .10 inch (2.54 mm)
below the housing wear plate surface to allow the assembly of thrust bearing (11). The
coupling shaft must rotate smoothly on the thrust bearing package.
9. Install thrust bearing (11) onto the end of coupling shaft (12) only if you are servicing an MB or ME
Series Torqmotor.
10. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring
groove.
NOTE: One or two alignment studs screwed finger tight into housing (18) bolt holes,
approximately 180 degrees apart, will facilitate the assembly and alignment of
components as required in the following procedures. The studs can be made by cutting
off the heads of either 3/8-24 UNF 2A or 5/16-24 UNF 2A bolts as required that are over .5
inch (12.7 mm) longer than the bolts used in the Torqmotor.
11. Install drive link (10) the long splined end down into the coupling shaft (12) and engage the drive link
splines into mesh with the coupling shaft splines.
NOTE: Use any alignment marks put on the coupling shaft and drive link before disassembly to
assemble the drive link splines in their original position in the mating coupling shaft
splines.
12. Assemble wear plate (9) over the drive link (10) and alignment studs onto the housing (18).
13. Apply a small amount of clean grease to a new seal ring (4) and assemble it into the seal ring groove on
the wear plate side of the rotor set stator (8B).
660-8
WINCH GEARBOX
TL SERIES
14. Install the assembled rotor set (8) onto wear plate (9) with rotor (8A) counterbore and seal ring side
down and the splines into mesh with the drive link splines.
NOTE: It may be necessary to turn one alignment stud out of the housing (18) temporarily to
assemble rotor set (8) or manifold (7) over the drive link.
If necessary, go to the appropriate, "ROTOR SET COMPONENT ASSEMBLY," in this section.
The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain
the original rotor drive link spline contact. A rotor set without a counterbore and that was not etched before
disassembly can be reinstalled using the drive link spline pattern on the rotor splines if apparent, to
determine which side was down. The rotor set has a seal ring groove on the wear plate contact side of the
stator (8B).
15. Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact
side of manifold (7).
NOTE: The manifold (7) is made up of several plates bonded together permanently to form an
integral component. The manifold surface that must contact the rotor set has it's series of
irregular shaped cavities on the largest circumference or circle around the inside
diameter. The polished impression left on the manifold by the rotor set is another
indication of which surface must contact the rotor set.
16. Assemble the manifold (7) over the alignment studs and drive link (10) and onto the rotor set. Be sure
the correct manifold surface is against the rotor set.
17. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold.
18. Assemble the commutator ring (6) over alignment studs onto the manifold.
19. Assemble a new seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of
drive link (10) onto manifold (7) with seal ring side up.
20. If shuttle valve components items (21, 22, 23, 24) were removed from the end cover (2) turn a plug (21)
with a new o-ring (22), loosely into one end of the valve cavity in the end cover. Insert a spring (23) into
the other end of the valve cavity. Turn the second plug (21) with a new o-ring (22) loosely into the end
cover valve cavity. 3/16 inch Allen wrench required.
21. If relief valve components items (21, 22, 24) were removed from the end cover (2) assemble a new o-
ring (22) on the two plugs (21). Assemble a two piece relief valve (24) in each of the plugs, with the large
end of the conical spring into the plug first and the small end of the conical spring. Turn each of the plug
and relief valve assemblies into the end cover loosely to be torqued later. 3/8 inch Allen or 1 inch Hex
socket required.
22. Assemble a new seal ring (4) into end cover (2) and assemble end cover over the alignment studs and
onto the commutator set. If the end cover has only 5 bolt holes be sure the cover holes are aligned with
the 5 threaded holes in housing (18).
NOTE: If the end cover has a valve (24) or has five bolt holes, use the line you previously scribed
on the cover to radially align the end cover into its original position.
23. Assemble the 5 or 7 special bolts and screw in finger tight. Remove and replace the two alignment studs
with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end
cover and other components into place with a final torque of 22–26 ft. lbs. (30–35 N m) for the five MG &
MF Series 5/16 24 threaded bolts or 45–55 ft. lbs. (61-75 N m) for the seven MB & ME Series 3/8-24
threaded bolts.
NOTE: The special bolts required for use with the relief or shuttle valve (24) end cover assembly
(2) are longer than the bolts required with standard end cover assembly. Refer to the
individual service parts lists if replacement is required.
24. Torque the two shuttle valve plug assemblies (21) in end cover assembly to 9–12 ft. lbs. (12–16 Nm) if
cover is so equipped.
Torque the two relief valve plug assemblies (21) in end cover assembly to 45–55 ft. lbs. (61–75 Nm) if
cover is so equipped.
THE ASSEMBLY OF TORQMOTOR IS COMPLETED
660-9
WINCH GEARBOX
TL SERIES
ROTOR SET COMPONENT ASSEMBLY

ONE PIECE STATOR CONSTRUCTION
A disassembled rotor (8A) stator (8B) and vanes (8C) that cannot be readily assembled by hand can be
assembled by the following procedures.
1. Place stator (8B) and vanes (8C) onto wear plate (9) with seal ring (4) side down, after following
Torqmotor assembly procedures 1–13. Be sure the seal ring is in place.
2. If assembly alignment studs are not being utilized, align stator bolt holes with wear plate and housing
bolt holes and turn two bolts (1) finger tight into bolt holes approximately 180 degrees apart to retain
stator and wear plate stationary.
3. Assemble the rotor (8A), counterbore down if applicable, into stator (8B), and onto wear plate (9) with
rotor splines into mesh with drive link (10) splines.
NOTE: If the manifold side of the rotor was etched during Torqmotor disassembly, this side
should be up. If the rotor is not etched and does not have a counterbore, use the drive
link spline contact pattern apparent on the rotor splines to determine the rotor side that
must be against the wear plate.
4. Assemble six vanes (8C), or as many vanes that will readily assemble into the stator vane pockets.
Excessive force used to push the rotor vanes into place could shear off the coating
applied to the stator vane pockets.
5. Grasp the output end of coupling shaft (12) with locking pliers or other appropriate turning device and
rotate coupling shaft, drive link and rotor to seat the rotor and the assembled vanes (8C) into stator (8B),
creating the necessary clearance to assemble the seventh or full complement of seven vanes.
Assemble the seven vanes using minimum force.
6. Remove the two assembled bolts (1) if used to retain stator and wear plate. Go to Torqmotor assembly
procedure #15, to continue Torqmotor assembly
660-10
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TL SERIES
TWO PIECE STATOR CONSTRUCTION

A disassembled rotor set (8) that cannot be readily assembled by hand and has a two piece stator can be
assembled by the following procedures.
1. Place stator half (8B) onto wear plate (9) with seal ring (4) side down, after following Torqmotor
assembly procedures 1–13. Be sure the seal ring is in place.
2. Align stator bolt holes with wear plate and housing bolt holes and turn two alignment studs finger tight
into bolt holes approximately 180 degrees apart to retain stator half and wear plate stationary.
3. Assemble the rotor (8A), counterbore down if applicable, into stator (8B), and onto wear plate (9) with
rotor splines into mesh with drive link (10) splines.
NOTE: Use any marking you applied to rotor set components to reassemble the components in
their original relationship to ensure ultimate wear life and performance.
Excessive force used to push the rotor vanes into place could shear off the coating
applied to the stator vane pockets.
6. Place second stator half (8D) on a flat surface with seal ring groove up. Apply a small amount of grease
to a new seal ring (4) and assemble it into stator half ring groove.
7. Assemble the second stator half (8D) over the two alignment studs and rotor (8A) with seal ring side
down onto the first stator half (8B) aligning any timing marks applied for this purpose.
If the stator half (8B) is a different height (thickness) than stator half (8D) the stator vanes
(8C) or (8E) of the same length (height) as the stator half must be reassembled in their
respective stator half for the rotor set to function properly.
NOTE: Use any marking you applied to rotor set components to reassemble the components in
their original relationship to ensure ultimate wear life and performance.
Go to Torqmotor assembly procedure #15 to continue Torqmotor assembly.
660-11
WINCH GEARBOX
TL SERIES
660-12
T L S e ri es
7
7
33 C 33
V1 V2
C1 C2 PLAT LIFT
22 22
PLAT
16
ROT
3
TL SERIES
3
42 42 42
JIB EXT JIB TILT
BSKT LIFT CYL
X X X X X X X X X X X X X X X X X X
X X X X X
BASIC HYDRAULICS
JIB UB
PLAT PLAT PLAT JIB WINCH EXTEND OUT
IN DUMP TOOLS LEV LIFT ROT EXT TILT UB ROT LB
ENABLE
C1
AUX C 18
FUNCTIONS V1 2
C2 V2 WINCH
SLAVE 2
LEVELING C 18
LEVELING
MASTER
C
16 3 C UB
3 LIFT
16
22 22 14 14
SECTION 700
C1 C2 15
Te r e x S o u th Da ko ta , In c.
ATTACH C
AS SHOWN 18 LB LIFT
BELOW 4 15
9 UB EXT C
23 V1 V2
24
PRESET AT 26
7 7
2500 PSI
18 15
16
16
21
21
SEE AUX CNTRL
19 ROTATE
3
INSTALL DWG's VIEW OF BACK OF 3
TURNTABLE 2
C C 2
21
C
20
2 1 3
HYD. MANIFOLD
O/R 1 2 3 D PRESET
700
PSI
X
PB
IN SELECT BSKT LEV WINCH UB EXT LB LIFT UB LIFT ROT OUT

M
O/R
O/R
SELECTOR
12V POWER
(OPT)
700-1
4 63 20 9 - 8/ 1 8
700-2
46 320 9 - 8/1 8
OUTRIGGER SCHEMATIC
HYD SWIVEL
1 2 3 D
X
SEE NOTE 2
O/R STREETSIDE O/R CURBSIDE
TOOL TOOL
RETURN PRESSURE
SUCTION
O/R O/R STRAINER
ENG. PTO
RESERVOIR
RETURN
INLET INLET
Te re x So uth Da kota , Inc.

FILTER
P.B.
T T SHUT OFF OPTION
SUPPLIED BY INSTALLER
O/R O/R O/R O/R SEL. TOOL CAPSTAN ADJUST TO SYSTEM
(SPECIAL) PRESSURE
STREETSIDE VALVE CURBSIDE VALVE
1
TL SERIES
T L Se ri es
TL SERIES
PLATFORM LEVELING CIRCUIT
700-3
700-4
46 320 9 - 8/1 8
HYDRAULIC SCHEMATIC
TO UNIT
SYSTEM
PUMP
2 1
UNIT SELECTOR
VALVE BOOM SOLENOID
SWITCH MOUNTING BRACKET
VALVE
ASSEMBLY DATUM: DO NOT ASSEMBLE FACE OF SWITCH PAST FACE OF
MOUNTING BRACKET
TANK
.81 FREE
MAX CURRENT THRU SWITCH:
.68 SWITCH 5 AMP RESISTIVE/3 AMP INDUCTIVE
W/INTEGRAL SELECTOR CLOSED SCALE 1:2
CLOSED CENTER AND OPEN CENTER SYSTEMS
GO DIRECTLY FROM THE PUMP TO THE O/R VALVE
TO UNIT
MAX CURRENT THRU SWITCH:
0.5 AMP
SYSTEM 2
BOOM SOLENOID (NO)
PUMP
BOOM INTERLOCK SCHEMATIC
- SELECTOR SECTION
- O/R SECTION
T
PB TO TANK
NOTE: FOR UNITS WITH RADIAL JACKS, A RELAY MUST BE WIRED FOR JACK SWITCH
PROTECTION (RED DASHED LINES) INSTEAD OF STANDARD WIRING DIAGRAM (SOLID LINES)
STANDARD HYDRAULIC DUMP INTERLOCK DIAGRAM

87 30
20A RELAY PTO LIGHT

(IN DASH)
85 86
BLK
R MOUNT ON FIREWALL
BLK
TRUCK
NC NC NC NC BATTERY
BOOM SOLENOID
VALVE (NO)
SWITCHES ON OUTRIGGERS PTO IGNITION
(2 OR 4 SWITCH OPTIONAL) SWITCH SWITCH
+12V DC
USE APPROPRIATE ELECTRIC DIAGRAM FOR WIRING AND

PIN SELECTION
4 87 30
5 20A RELAY
85 86
6
SWITCHES ON OUTRIGGERS BLK

+12V DC
(2 OR 4 SWITCH OPTIONAL)
OPTIONAL ELECTRIC INTERLOCK DIAGRAM

TL SERIES
T L Se ri es
TL SERIES
HYDRAULIC TOOL SCHEMATIC
UPPER BOOM STOW RELIEF (TL60 ONLY)

9 12 3 2 1
5
TO SYSTEM RETURN 3
OUTLET INLET
10 11
TO UPPER BOOM DOWN 4
700-5
TL SERIES
700-6
ELECTRICAL SCHEMATICS
TL SERIES
SECTION 710
OUTRIGGER SCHEMATIC
ALARM
IGN. POWER
10 A (ON WHEN KEY ON)
SHOWN WITH TWO SETS OF O/R'S
710-1
TL SERIES
710-2
OPTIONAL EQUIPMENT
TL SERIES
SECTION 800
OPTIONAL EQUIPMENT
ELECTRIC AUXILIARY LETDOWN HYDRAULIC PUMP
DO NOT USE the auxiliary pump for an extended period. Use the pump only to lower the
booms and/or raise the outriggers when the main pump or truck engine malfunctions.
Using the auxiliary pump to raise the booms may cause damage to the auxiliary pump
motor.
This accessory provides auxiliary power in the event of main hydraulic pump or truck engine failure. The
auxiliary pump will engage when the two-speed control is pushed and held for 10 seconds.
The auxiliary pumps at 2500 PSI (17.24 MPa) will produce approximately 1.6 GPM (6.1 LPM) of flow for
folding the booms and/or raising the outriggers.
NOTE: The auxiliary pump will not operate on a depleted truck battery.
Operate the auxiliary pump only as needed to store the unit. The installation consists of the following
components:
1. A 12 Volt DC pump.
2. A normally-open pressure switch and air plunger at platform.
3. A normally-open relay with coil activated by the mini box.
4. Mini-box.
OPERATION
When the main pump is in operation and the engine is running, the auxiliary pump will not operate.
Actuation of the air plunger at the boom tip or the toggle switch at the lower controls will start the auxiliary
pump if the engine is off, allowing operation under normal control at reduced speed.
LIMITATIONS
The auxiliary pump will not provide protection against an empty hydraulic oil reservoir or dead battery.
Hydraulic oil level and battery condition must be checked regularly to ensure dependability.
Both boom fold and outrigger up functions may be operated under normal control, but at reduced speed.
Operation of the Aerial Device by the auxiliary pump should be restricted to a minimum because of heavy
battery drain imposed by the auxiliary pump unit.
MAINTENANCE
Normal hydraulic system maintenance and battery maintenance is required on the auxiliary pump. Failure of
the auxiliary pump to operate most likely indicates an open electrical circuit or defective pressure switch.
800-1
OPTIONAL EQUIPMENT
TL SERIES
RELIEF VALVE ADJUSTMENT (ON PUMPS EQUIPPED)

NOTE: Relief valve setting of the auxiliary pump may be preset at 1300 PSI (8.96 MPa).
When installing a new auxiliary pump, the internal relief valve must be set to the unit’s rated system
pressure. (Refer to Quick Reference Guide.)
1. Install a hydraulic pressure gauge and a shut-off valve in the pressure line from the auxiliary pump.
2. Locate the relief valve cap on the auxiliary pump. Remove the cap to expose the slotted adjustment
plug.
3. Close the shut-off valve in the hydraulic supply line (valve installed in step 1 above).
4. Actuate pump by pressing and holding two-speed control for 10 seconds. This will enable you to take
and record a reading from the pressure gauge.
Do not allow the auxiliary pump to run continuously while relief valve adjustment is being
made. If the auxiliary pump is allowed to run continuously with the shut-off valve closed,
which was installed in step 1), the pump motor may overheat or deplete the truck’s
battery.
5. Open the shut-off valve which was installed in step 1.
6. To increase auxiliary pump relief valve setting, turn slotted plug clockwise. To decrease pressure setting,
turn slotted plug counter-clockwise.
7. Repeat steps 5–7 until the pressure gauge indicates system pressure.
8. Remove hydraulic test gauge and shut-off valve.
800-2
OPTIONAL EQUIPMENT
TL SERIES
ELECTRICAL SCHEMATIC AND INSTALLATION

(AUXILIARY LET DOWN HYDRAULIC PUMP)
Relief Valve Motor
Solenoid
Hydraulic Pump
800-3
OPTIONAL EQUIPMENT
800-4
46 320 9 - 8/1 8
TO SYSTEM
3
SYSTEM PUMP
IGNITION IGNITION
EXT. OUTPUTS GND +12V 12 V D C SPLICE SPLICE
SYSTEM OR (GAS)
INPUT 12VDC 12VDC
START INPUT INPUT
TEST INDICATOR (DIESEL)
PUSH TO START THROTTLE STOP
TEST
START THROTTLE STOP

1
RELAY RELAY RELAY
HYDRAULIC SCHEMATIC
TO STARTER TO THROTTLE RUN (NC) SUCTION LINE
SOLENOID SOLENOID
IGNITION FROM TANK
SPLICE
(GAS)
FUEL
FAULT OUTPUT
POS
NEG
POS
NEG
SHUTOFF OIL PRESSURE
(DIESEL)
SWITCH ON
ENGINE
AIR PRESSURE

SWITCH FOR NC
2 SPEED/ 14 GA. +
POWER UNIT
14 GA.
POWER
NO M UNIT
"00" AWG
TO THROTTLE
MOMENTARY COLLECTOR ACTUATOR +
PUSHBUTTON BLOCK
TO 12VDC
SWITCH AT POWER
LOWER CONTROL SOURCE _
(OPTIONAL) ELECTRICAL SCHEMATIC
TL SERIES
T L Se ri es
OPTIONAL EQUIPMENT
TL SERIES
MASTER CONTROL
TRUCK IGNITION SWITCH
The key must be in the ignition and turned to either the accessory position or the “ON” position before
current is available to operate the aerial lift, stop/start, or two speed functions.
TOGGLE SWITCH
The toggle switch is a single-pole, two-position switch mounted on the truck dash board. When on it
energizes the mini-box allowing remote operation. When off the truck will operate normally for highway
operation.
RED DASH LIGHT
The red dash light is a 12 volt lamp which indicates whether or not the mini-box is “ON”. When the lamp is lit,
the remote system is active.
DASH PUSH BUTTON CONTROL
This is a spring-loaded, push button control that can be used by ground personnel to stop or start the truck
engine when the master control system is “ON”.
Toggle Switch
Dash Light
Stop/Start
Push Button
PRESSURE SWITCH AND AIR CYLINDER

The pressure switch is mounted in the turntable and the air cylinder is mounted at the platform. A small air
line connects the two components. When the air cylinder is operated, it acts as a pump and compresses the
air in the air line. When adequate air pressure is produced, the electrical contacts in the pressure switch
close and the signal goes to the mini-box. The mini-box will then change state.
800-5
OPTIONAL EQUIPMENT
TL SERIES
BOOM STOW INTERLOCK SYSTEM
800-6
OPTIONAL EQUIPMENT
TL SERIES
BOOM STOW PROTECTION SYSTEM (OPTIONAL EXCEPT ON TL60)

The boom stow protection system is designed to limit the down force of the boom while storing the boom.
This is done with a boom rest switch wired to a solenoid dump valve which will dump the boom down oil to
tank when the boom is in the rest.
1
2
Relief Valve
See Quick Ref.
Guide
DESCRIPTION
As boom is lowered into the rest it contacts the micro switch, thus completing the circuit and energizing the
solenoid dump valve. The dump valve dumps boom down line through the relief, limiting the amount of down
pressure on the boom. Boom lift circuit remains the same so boom can be raised out of rest.
BOOM CYLINDER
RELIEF, SOLENOID VLV SOL. VALVE
GRD VALVE
1
2
SECTION
5
PRESS.
4
3
(BOOM REST)
12 VDC
MASTER POWER
MICRO SWITCH
NOTE:
5 ADJUST RELIEF SO WHEN LOWER BOOM IS FOUR FEET OUT OF REST IT WILL TAKE
OVER 5 SECONDS TO REACH REST WHILE HOLDING LOWER BOOM DOWN CONTROL.
POSITION OF LIMIT SWITCH ARM SHOWN WHEN THE BOOM IS IN THE STORED POSITION.
NOTE: The limit switch shown above is in the normally closed position. Continuity must show
when tested in this position.
800-7
OPTIONAL EQUIPMENT
TL SERIES
OUTRIGGERS (DEPENDENT ON INSTALLATION)

The two or more outriggers consist of rectangular tubes, one tube inside the other tube. The outer tube is
attached to the pedestal. A double acting hydraulic cylinder is housed within the outriggers attached to the
larger tube near the top and to the smaller tube near the bottom.
When the hydraulic cylinder is retracted, the inner tube is wholly within the outer tube providing the
necessary clearance from the ground and minimal width for road travel. As the hydraulic cylinder is
extended the inner tube telescopes down and away from the center of the aerial lift to contact the ground
and elevate the chassis slightly. The outriggers greatly increase the vehicles resistance to overturning since
the tipping point is moved further away from the center of gravity.
800-8
APPENDIX - A
APPENDIX A
APPENDIX - A
STANDARDS AND REGULATIONS
In addition to the operational instructions provided herein, various standards and governmental regulations
must be followed in the use and operation of your Terex South Dakota, Inc. unit.
ANSI STANDARDS
ANSI standards that are applicable to the operation and maintenance of your unit:
1. ANSI A92.2 (latest revision) Vehicle Mounted Elevating and Rotating Aerial Devices,
2. ANSI A10.31 (latest revision) Digger Derricks - Safety Requirements, Definitions and Specifications (A
partial extraction is included in this appendix),
3. ANSI C2, Part 4 (latest revision) (National Electric Safety Code®) Rules for the Operation of Electric
Supply and Communication Lines and Equipment,
4. ANSI Z133.1 (latest revision) Safety Requirements for Tree Pruning, Trimming, Repairing, or Removal.
For complete, current copies of ANSI standards, you must annually write to the following:
American National Standards Institute
11 West 42nd Street
New York, NY 10036
Copies of the standards can also be found on the Internet at:
www.ansi.org
OSHA REGULATIONS
OSHA regulations that are applicable to the operation and maintenance of your unit:
1. OSHA Subpart V, Power Transmission and Distribution,
2. OSHA 1910.67, Vehicle Mounted Elevating and Rotating Cable Placers,
3. OSHA 1910.268, Telecommunications,
4. OSHA 1910.269, Electrical Power Generation, Transmission and Distribution,
5. OSHA Subpart M, Fall ,
6. OSHA 1910.147, The Control Of Hazardous Energy (Lockout/Tagout),
7. OSHA Subpart S, Electrical,
8. OSHA 1910.333, Selection and use of work practices.
9. OSHA Subpart CC, - Cranes and Derricks in Construction
For complete, current copies of OSHA regulations, you must annually write to the following or contact your
OSHA Regional Office.
Technical Data Center
Frances Perkins Department Of Labor Building
Room N2439
200 Constitution Avenue
Washington, DC 20210
Copies of the standards can also be found on the Internet at:
www.osha.gov.
These are not all inclusive of the applicable codes, standards, or regulations. It is your responsibility and
your employer's responsibility to identify and comply with applicable codes, standards and regulations.
The information provided herein is accurate as of the date your Terex South Dakota, Inc. unit was
manufactured. You must comply with the codes, standards and regulations as they are updated over time. It
is your employer's responsibility to obtain copies and comply with all standards and regulations.
Appendix A Te re x S o u t h D a k o t a , I n c . A- 1
APPENDIX - A
APPENDIX A
OSHA EXCERPTS: (CLEARANCE DISTANCE)

The following are excerpts from OSHA Standards. They are not complete and do not cover all safety work
rules. Refer to the most current version of OSHA regulations available at www.osha.gov for any changes
since this manual was printed.
PARTIAL EXCERPT FROM SUBPART S - ELECTRICAL: (02-01-1998 EDITION)
1910.333 Selection and use of work practices.
(c), (i) Unqualified person.
(A) When an unqualified person is working in an elevated position near overhead lines, the location shall be
such that the person and the longest conductive object he or she may contact cannot come closer to any
unguarded, energized overhead line than the following distances:
1. For voltages to ground 50kV or below - 10 feet (3.05 m);
2. For voltages to ground over 50kV - 10 feet (3.05 m) plus four inches (101.6 mm) for every 10kV over
50kV.
(B) When an unqualified person is working on the ground in the vicinity of overhead lines, the person may
not bring any conductive object closer to unguarded, energized overhead lines than the distances given in
paragraph (c)(3)(i)(A) of this section.
NOTE: For voltages normally encountered with overhead power line, objects which do not have
an insulating rating for the voltage involved are considered to be conductive.
EXCERPT FROM OSHA SUBPART V - POWER TRANSMISSION AND DISTRIBUTION (11-14-
1990 EDITION)
1926.950 General Requirements (c) Clearances. The provisions of paragraph© (1) or (2) of this section shall
be observed.
(1) No employee shall be permitted to approach or take any conductive object without an approved
insulating handle closer to exposed energized parts than shown in Table R-6, unless:
(i) The employee is insulated or guarded from the energized part (gloves or gloves with sleeves rated for the
voltage involved shall be considered insulation of the employee from the energized part), or
(ii) The energized part is insulated or guarded from him and any other conductive object at different
potential, or
(iii) The employee is isolated, insulated, or guarded from any other conductive object(s), as during live-line
bare-hand work.
(2)(i) The minimum working distance and minimum clear hot stick distances stated in Table R-6 shall not be
violated. The minimum clear hot stick distance is that for the use of line-line tools held by lineman when
performing live-line work.(e)(15) The minimum clearance distances for live-line bare-hand work shall be as
specified in Table R-7. These minimum clearance distances shall be maintained from all grounded objects
and from lines and equipment at a different potential than that to which the insulated Cable Placer is bonded
unless such grounded objects or other lines and equipment are covered by insulated guards. These
distances shall be maintained when approaching, leaving and when bonded to the energized circuit.
1926.960(c)(1)(i)
The employer shall establish minimum approach distances no less than the distances computed by Table V-
2 for ac systems or Table V-7 for dc systems.
1926.960(G)(2)
Estimate of available heat energy. For each employee exposed to hazards from electric arcs, the employer
shall make a reasonable estimate of the incident heat energy to which the employee would be exposed.
1926.960(G)(3)
Prohibited clothing. The employer shall ensure that each employee who is exposed to hazards from flames
or electric arcs does not wear clothing that could melt onto his or her skin or that could ignite and continue to
burn when exposed to flames or the heat energy estimated under paragraph (g)(2) of this section.
A-2 Te r e x S o u th Da ko ta , In c. A pp end i x A
APPENDIX - A
APPENDIX A
DISTANCE
NOMINAL VOLTAGE (KV) PHASE-TO-GROUND PHASE-TO-PHASE
(PHASE TO PHASE) EXPOSURE EXPOSURE
M FT M FT
0.050 TO 0.300² AVOID CONTACT AVOID CONTACT
0.301 TO 0.750² 0.33 1.09 0.33 1.09
0.751 TO 5.0 0.63 2.07 0.63 2.07
5.1 TO 15.0 0.65 2.14 0.68 2.24
15.1 TO 36.0 0.77 2.53 0.89 2.92
36.1 TO 46.0 0.84 2.76 0.98 3.22
46.1 TO 72.5 1.00 3.29 1.20 3.94
1. Employers may use the minimum approach distances in this table provided the
worksite is at an elevation of 900 meters (3,000 feet) or less. If employees will be
working at elevations greater than 900 meters (3,000 feet) above mean sea level, the
employer shall determine minimum approach distances by multiplying the
distances in this table by the correction factor in Table R-5 corresponding to the
altitude of the work.
2. For single-phase systems, use voltage-to-ground.
TABLE R-6 - ALTERNATIVE MINIMUM APPROACH DISTANCES FOR VOLTAGES OF 72.5 KV AND
LESS
PHASE-TO-GROUND PHASE-TO-PHASE
VOLTAGE RANGE PHASE EXPOSURE EXPOSURE
TO PHASE (KV)
M FT M FT
72.6 TO 121.0 1.13 3.71 1.42 4.66
121.1 TO 145.0 1.30 4.27 1.64 5.38
145.1 TO 169.0 1.46 4.79 1.94 6.36
169.1 TO 242.0 2.01 6.59 3.08 10.10
242.1 TO 362.0 3.41 11.19 5.52 18.11
362.1 TO 420.0 4.25 13.94 6.81 22.34
420.1 TO 550.0 5.07 16.63 8.24 27.03
550.1 TO 800.0 6.88 22.57 11.38 37.34
1. Employers may use the minimum approach distances in this table provided the
worksite is at an elevation of 900 meters (3,000 ft) or less. If employees will be
working at elevations greater than 900 meters (3,000 feet) above mean sea level, the
employer shall determine minimum approach distances by multiplying the
distances in this table by the correction factor in Table R-5 corresponding to the
altitude of the work.
2. Employers may use the phase-to-phase minimum approach distances in this table
provided that no insulated tool spans the gap and no large conductive object is in
the gap.
3. The clear live-line tool distance shall equal or exceed the values for the indicated
voltage ranges.
TABLE R-7 ALTERNATIVE MINIMUM APPROACH DISTANCES FOR VOLTAGES OF MORE THAN 72.5
KV
Appendix A Te re x S o u t h D a k o t a , I n c . A- 3
APPENDIX - A
APPENDIX A
STANDARD HAND SIGNALS
STOP. With arm extended EMERGENCY STOP. With both arms extended HOIST. With upper arm RAISE BOOM. With arm
horizontally to the side, horizontally to the side, palms down, arms are swung back extended to the side, extended horizontally to the
palm down, arm is swung and forth. forearm and index finger side, thumb points up with
back and forth. pointing straight up, hand other fingers closed.
and finger make small
circles.
SWING. With arm RETRACT TELESCOPING RAISE THE BOOM AND DOG EVERYTHING. LOWER. With arm and
extended horizontally, index BOOM. With hands to the LOWER THE LOAD. With Hands held together at index finger pointing down,
finger points in direction front at waist level, thumbs arm extended horizontally waist level. hand and finger make small
that boom is to swing. point at each other with to the side and thumb circles.
other fingers closed. pointing up, fingers open
and close while load
movement is desired.
LOWER BOOM. With arm EXTEND TELESCOPING TRAVEL/TOWER LOWER THE BOOM AND MOVE SLOWLY. A hand
extended horizontally to the BOOM. With hands to the TRAVEL. With all fingers RAISE THE LOAD. With is placed in front of the
side, thumb points down front at waist level, thumbs pointing up, arm is arm extended horizontally hand that is giving the
with other fingers closed. point outward with other extended horizontally out to the side and thumb action signal.
fingers closed. and back to make a pointing down, fingers open
pushing motion in the and close while load
direction of travel. movement is desired.
USE AUXILIARY HOIST CRAWLER CRANE USE MAIN HOIST. A hand CRAWLER CRANE TROLLEY TRAVEL. With
(WHIPLINE). With arm TRAVEL, BOTH TRACKS. taps on top of the head. TRAVEL, ONE TRACK. palm up, fingers closed and
bent at elbow and forearm Rotate fists around each Then regular signal is given Indicate track to be locked thumb pointing in direction
vertical, elbow is tapped other in front of body; to indicate desired action. by raising fist on that side. of motion, hand is jerked
with other hand. Then direction of rotation away Rotate other fist in front of horizontally in direction
regular signal is used to from body indicates travel body in direction that other trolley is to travel.
indicate desired action. forward; rotation toward track is to travel.
body indicates travel
backward.
NOTE: Not all signals can be used on Digger Derricks or Aerial Devices. Method of signaling
must be agreed upon by ground person and operator before work begins.
A-4 Te r e x S o u th Da ko ta , In c. A pp end i x A
APPENDIX - B
APPENDIX B
APPENDIX - B
RESPONSIBILITIES
ANSI A92.2-2015 became effective June 2016. It became the responsibilities of Dealers and Installers,
Owners, Users, Operators, Lessors or Lessees, and Brokers to follow the requirements of this standard after
June 2016, regardless of the date of manufacture.
ANSI A92.2-2015 (PARTIAL)
Table of Contents:
7. Responsibilities of Dealers and Installers. B-1
8. Responsibilities of Owners. B-2
9. Responsibility of Users. B-5
10. Responsibilities of Operators. B-7
11. Responsibilities of Lessors or Lessees. B-9
12. Responsibilities of Brokers. B - 10
7. RESPONSIBILITIES OF DEALERS AND INSTALLERS.

7.1 General Responsibilities. Each dealer or installer as applicable shall comply with the requirements of
this section.
7.2 Vehicle Specifications. Each dealer or installer, or both, who sells an aerial device shall inform the
owner or user, or both, of the manufacturer’s minimum vehicle specifications.
7.3 Vehicle Weight Distribution. The installer shall be responsible for the weight distribution of the
completed mobile unit (MEWP) in accordance with the requirements of the aerial device and the applicable
regulations. Allowance shall be made for the weight of readily removable tools and material specified by the
user.
7.4 Manuals. Upon delivery of the equipment to the owner or user, the dealer or installer shall provide the
manuals as required by Paragraph 6.4 of this standard and manuals for auxiliary equipment added by the
installer.
7.5 Installations. The installer shall comply with Sections 5 and 6 of this standard relating to proper
installation and shall follow the instructions of the manufacturer. In the event the original manufacturer no
longer exists, an equivalent entity may provide these instructions. The installer shall maintain access to the
lower controls as described in section 4.3.3. The installer of the aerial device shall, before the mobile unit
(MEWP) is placed in operation, perform stability tests in accordance with the requirements of 4.5.1 and
4.5.2, the operational and visual tests in accordance with the requirements of 6.6.1 and 6.6.2, and the
appropriate electrical tests required in 5.4 of this standard. For insulating aerial devices, the installer shall
assure conformance to the Qualification test requirements of 5.3.2 by either obtaining a certification of the
test and performing a periodic test after installation, or by performing the Qualification test. The installer
shall, when installing an aerial device on a chassis which is a highway vehicle, comply with all requirements
of the applicable Federal Motor Vehicle Safety Standards in effect at the time of installation. Certification as
a manufacturer (alteration, intermediate or final) of a motor vehicle under the Federal Motor Vehicle Safety
Standards is required. The travel height of the mobile unit (MEWP) shall be posted in a location that is
readily visible to the vehicle operator.
7.5.1 Locking Pins. Any locking pins shall be secured against unintentional disengagement and loss.
7.5.2 Unauthorized Use. Mobile Units (MEWPs) shall be equipped with a device to prevent unauthorized
use.
7.6 Ingress/Egress
7.6.1 Steps/Ladders. Distance between the ground or lower platform surface to the top surface of the first
step should not exceed 27 inches where possible. Distance between the top surface of steps or rungs
should not exceed 16 inches where possible. Each step or rung should have a minimum width of 6 inches for
placement of one foot or 12 inches for placement of two feet and minimum rung diameter of 1 inch.
Appendix B Te re x S o u t h D a k o t a , I n c . B-1
APPENDIX - B
APPENDIX B
7.6.2 Access Opening/Passage. Access opening/passage should have a minimum width of 18 inches and
minimum opening height of 30 inches.
7.6.3 Three Point Support. Steps or ladders whose inclined angle from horizontal is greater than 50
degrees should incorporate supports that would permit a person to use simultaneously two hands and one
foot or two feet and one hand for support while ascending or descending.
7.7 Quality Assurance. The installer shall have a documented quality assurance program that will ensure
compliance with this standard.
7.8 Weldings. All welds made by the installer, whose failure could result in motion of the platform(s) shall
meet the Structural Welding Code AWS D1.1-2006 and AWS Dl.2-2003. The installer shall establish
applicable welding quality assurance procedures for all weldments.
7.9 Training. The dealer or installer shall offer training or training materials that aid owners, users, lessors
and lessees in the operation, inspection, testing and maintenance of the aerial device. This training shall be
offered initially and subsequently on request.
7.9.1 Dealer or Installer as User. Whenever a dealer or installer directs personnel to operate an aerial
device (inspecting, sales demonstrations, or any form of use), the dealer or installer shall assume the
responsibilities of users as specified in Section 9 of this standard. All personnel authorized to operate the
aerial device shall have been trained in a program that meets the requirements of this standard.
7.10 Maintenance Training. Dealer maintenance personnel shall be trained in inspection, testing and
maintenance of the aerial device in accordance with the manufacturer’s recommendations.
8. Responsibilities of Owners.
8.1 General Responsibilities. Each owner shall comply with the requirements of this section. The following
responsibilities pertain to the owner’s inspection, testing, maintenance, modification, training and transfer of
ownership. These activities shall be performed by qualified person(s).
8.2 Inspection and Testing Classifications.
8.2.1 Initial Inspection and Test. Prior to initial use, all new or modified mobile units (MEWP) shall be
inspected and tested to ensure compliance with the provisions of this standard. Certification by the
manufacturer, dealer, final installer or an equivalent entity(s), meets this requirement.
8.2.2 Regular Inspection and Tests. The inspection procedure for mobile units (MEWP) is divided into two
classifications based upon the intervals at which inspections and tests shall be performed. Intervals shall be
set by the owner in accordance with the manufacturer’s recommendations. Such intervals are dependent
upon component function and exposure to wear, deterioration and other agents which adversely affect
component life. Two classifications are designated:
(1) Frequent Inspection and Test: Daily to monthly intervals.
(2) Periodic Inspection and Test: One to twelve month intervals.
8.2.3 Frequent Inspection and Test. Items determined by the owner in accordance with the manufacturer’s
recommendations for each specific aerial device shall be inspected. The following inspections and tests
shall be performed by the operator prior to first use at the beginning of each shift:
(1) Conduct walk around visual inspection looking for damaged components, cracks or corrosion, excessive
wear and any loose, deformed or missing bolts, pins, fasteners, locking devices and covers.
(2) Check all controls and associated mechanisms for proper operation to include, but not limited to, the
following:
(a) Proper operation of interlocks.
(b) Controls return to neutral when released and not sticking.
(c) Control functions and operation clearly marked.
(3) Check visual and audible safety devices for proper operation.
(4) Visually inspect fiberglass and insulating components for visible damage or contamination.
(5) Check for missing or illegible operational and instructional markings.
(6) Check hydraulic and pneumatic systems for observable deterioration and excessive leakage.
(7) Check electrical systems related to the aerial device for malfunctions, signs of excessive deterioration,
dirt and moisture accumulation.
B-2 Terex South Dakota, Inc. A pp e n d i x B

APPENDIX - B
APPENDIX B
(8) Perform functional test to include, but not limited to, the following:
(a) Set-up the aerial device for operation, including stabilizers.
(b) Cycle the aerial device functions through the complete range of motion from the lower controls,
except where operation through the complete range of motion would create a hazard.
(c) Check functionality of emergency controls.
Any suspected items shall be carefully examined or tested and a determination made by a qualified person
as to whether they constitute a safety hazard. All unsafe items shall be replaced or repaired before use.
8.2.4 Periodic Inspection or Test. An inspection of the mobile unit (MEWP) shall be performed at the
intervals defined in 8.2.2 depending upon its activity, severity of service, and environment, or as specifically
indicated below. (These inspections shall include the requirements of 8.2.3):
(1) Structural members for deformation, cracks or corrosion.
(2) Parts, such as pins, bearings, shafts, gears, rollers, locking devices, chains, chain sprockets, wire and
synthetic ropes and sheaves for wear, cracks or distortion.
(3) Hydraulic and pneumatic relief valve settings.
(4) Hydraulic system for proper oil level.
(5) Hydraulic and pneumatic fittings, hoses and tubing for evidence of leakage, abnormal deformation or
excessive abrasion.
(6) Compressors, pumps, motors and generators for loose fasteners, leaks, unusual noises or vibrations,
loss of operating speed and excessive heating.
(7) Hydraulic and pneumatic valves for malfunction and visible cracks in the external valve housing, leaks
and sticking spools.
(8) Visually inspect any vacuum prevention systems and verify function of such systems.
(9) Hydraulic and pneumatic cylinders and holding valves for malfunction and visible damage.
(10) Hydraulic and pneumatic filters for cleanliness and the presence of foreign material in the system
indicating other component deterioration.
(11) Electrical systems and components for deterioration or wear including those not readily visible on a
frequent inspection.
(12) Performance test of all boom movements.
(13) Condition and tightness of bolts and other fasteners in accordance with the manufacturer’s
recommendation.
(14) Welds, as specified by the manufacturer.
(15) Legible and proper identification, operational and instructional markings.
(16) If the aerial device is rated as an insulating device, the electrical insulating components and system(s)
shall be thoroughly inspected for lack of cleanliness and other conditions that compromise insulation. Then
these components and system(s) shall be tested for compliance with the rating of the aerial device in
accordance with one of the applicable methods and procedures as outlined in Section 5.4.3 of this standard:
(a) If the aerial device is used for AC bare-hand work, the before use tests outlined in 5.4.3.1 (11) (c) may
be relied upon when performed quarterly, however the unit shall undergo an AC voltage test at lest every
three years in accordance with Table 2 criteria;
(b) If the aerial device is used for DC bare-hand work, the “in the field” tests outlined in 5.4.3.1 (11) (c)
may be relied upon when performed quarterly, however the unit shall undergo an appropriate DC over
voltage test at least every three years;
(c) After repair or replacement of any component that crosses the insulating system(s), or the repair or
replacement of an insulating component(s),(e.g., hoses, leveling rods, boom coating, etc.), the unit shall
be dielectrically tested in accordance with Section 5.4.3;
(d) An insulated replacement boom shall be tested to ensure conformance to 5.3.3 by the supplier;
(e) Bare-hand work units shall be tested for the applicable unit rating in accordance with Table l (or
appropriate DC test for units used on direct current lines, see Appendix B) after any major repair to the
insulating boom or any insulating boom replacement. Major repair to the insulating boom shall include
resurfacing or repainting of the exterior or interior boom surfaces. The removal and subsequent
reinstallation of a gradient control device is not considered a “major repair” provided proper reinstallation
APPENDIX - B
APPENDIX B
of the gradient control device is performed by a qualified person in accordance with the manufacturer’s
instructions.
(17) If the aerial device has upper controls equipped with high electrical resistance components and the
manufacturer so indicates, they shall be maintained as high electrical resistance components and should be
electrically tested per 5.4.3.6.
8.2.5 Post Event Inspection or Test. After any event during which structural members of an aerial device
or mobile unit (MEWP) are suspected of being subjected to excessive loading or stress such as overturning
of the mobile unit (MEWP) or application of unintended external mechanical or electrical forces to the aerial
device, the aerial device shall be removed from service and subjected to the applicable periodic inspection
requirements in 8.2.4. In addition to the periodic inspection, supplemental non-destructive examination
procedures or other tests to assist in detecting possible structural damage to the aerial device may be
required. All damaged items shall be replaced or repaired before the unit is returned to service. Return to
service shall be approved by a qualified person.
8.3 Inspection and Test Records.
8.3.1 Frequent. Items to be inspected shall be designated to the operator or other authorized person
making frequent inspections. Records of frequent inspections need not be made. However, where a safety
hazard is found, it shall be reported in writing to a person responsible for the corrective action and that report
and a record of the correction shall be maintained for five years, or as required by applicable regulations.
(Appropriately archived electronic, dated and signed records meet this requirement.)
8.3.2 Periodic. Written, or appropriately archived electronic, dated and signed reports and records shall be
made of periodic inspections and tests and retained for a period of five years or as required by applicable
regulations. The Periodic Electrical Test required under Section 5.3.4 shall be documented by the entity
performing such, with a report provided to the owner and a placard indicating proof of test applied to the
MEWP.
8.4 Maintenance. Maintenance and frequency of maintenance shall be determined by the owner in
accordance with the manufacturer’s recommendations.
8.4.1 Maintenance Training. The owner shall train their maintenance personnel in inspection and
maintenance of the aerial device in accordance with the manufacturer’s recommendations and Section 8 of
this standard.
8.4.2 Welds. Welding repairs of components or welds, designated as critical in the manufacturer’s manual
shall be made in accordance with the manufacturer’s recommendations and shall meet the Structural
Welding Code AWS D1.1-2006 or AWS D1.2-2003. Should the original manufacturer no longer exist, and
equivalent entity may determine the required procedure.
8.5 Modifications. No modifications or additions which affect the stability, mechanical, hydraulic, or
electrical integrity or the safe operation of the aerial device shall be made without the written approval of the
manufacturer. If such modifications or changes are made, the capacity, operation and maintenance
instruction markings shall be changed accordingly. In no case shall the safety factors be reduced below
those specified in this standard or below the manufacturers design safety factors, whichever are greater.
Should the original manufacturer no longer exist, an equivalent entity may approve required modification.
8.5.1 Alterations. Altering or disabling the function of safety devices, guards, or interlocks, if so equipped, is
prohibited.
8.5.2 Overriding Safety Devices. Overriding of safety devices is prohibited, whether during normal
operation or rescue, except in accordance with the manufacturer’s prescribed safety override procedures.
The overriding of safety devices during the testing, repair, or maintenance of an aerial device shall be carried
out in accordance with the manufacturer’s recommendations and procedures. Procedures for overriding
safety devices shall be designed to minimize the possibility that an unsafe condition could exist.
8.6 Weight Distribution. Changes in loading or additions made to the mobile unit (MEWP) after the final
acceptance that affect weight distribution shall meet applicable regulations by governmental agencies. In no
case shall axle loads of the fully loaded vehicle exceed the Gross Axle Weight Ratings (GAWR) assigned by
the manufacturer. Note: Any change in weight distribution may adversely affect stability.

APPENDIX - B
APPENDIX B
8.7 Transfer of Ownership. When a change in ownership of an aerial device occurs, it shall be the
responsibility of the seller to provide the manufacturer's manual(s) for that aerial device to the purchaser. It is
the responsibility of the purchaser to notify the manufacturer of the unit model and serial number and the
name and address of the new owner within 60 days. If the owner uses other entities as agents (e.g.,
Brokers) for the sale or the arrangement of a sale of an aerial device(s) their responsibilities under this
section continue.
8.8 Markings. The markings on the aerial device shall not be removed, defaced, or altered. All missing or
illegible markings shall be promptly replaced.
8.9 Parts. When parts or components are replaced they shall be identical in specification and function to the
original aerial device parts or components or shall provide an equal or greater factor of safety.
8.10 Safety Bulletins. Owners shall comply with safety related bulletins as received from the manufacturer,
dealer or installer.
8.11 Manuals. The owner shall ensure that the operating manual(s) is stored on the mobile unit (MEWP).
8.12 Training, Retraining and Familiarization of Operators.
8.12.1 General Training. Only personnel who have received general instructions regarding the inspection,
application and operation of aerial devices, including recognition and avoidance of hazards associated with
their operation, shall operate an aerial device. Such items covered shall include, but not necessarily be
limited to, the following issues and requirements:
(1) The purpose and use of manuals.
(2) That operating manuals are an integral part of the aerial device and must be properly stored on the
vehicle when not in use.
(3) A pre-start inspection.
(4) Responsibilities associated with problems or malfunctions affecting the operation of the aerial device.
(5) Prohibition of overriding safety devices except as approved by the manufacturer (see 8.5.2).
(6) That secondary operating systems shall not be used for purposes other than test or recovering the work
platform.
(7) Factors affecting stability.
(8) The purpose of placards and decals.
(9) Workplace inspection.
(10) Applicable safety rules and regulations, such as Part 4, ANSI C2-2007, National Electrical Safety Code
(applies to utility workers as defined in ANSI C2). The above standard is an example; other industries using
aerial devices have safety rules pertinent to that industry.
(11) Authorization to operate.
(12) Securing the aerial device and mobile unit (MEWP) from unauthorized use.
(13) Operator warnings and instructions.
(14) Proper use of personal fall equipment. Fall systems criteria and practices are covered in 29 CFR
1926.502.
(15) Actual operation of the Aerial Device. Under the direction of a qualified person, the trainee shall operate
the aerial device for a sufficient period of time to demonstrate proficiency in the operation of all control
functions of the aerial device and safe use at operating height and reach.
(16) Stowing the aerial device for transport and precautions related to moving the mobile unit (MEWP).
8.12.2 Retraining. The operator shall be retrained, when so directed by the user, based on the following:
(1) The user’s observation and evaluation of the operator. This evaluation of the operator shall include
evaluating the operator’s proficiency of operating the aerial device in a safe manner.
(2) After an accident or near miss while operating an aerial device.
8.12.3 Familiarization. When an operator is directed to operate an aerial device they are not familiar with,
the operator, prior to operating, shall be instructed regarding the following items:
(1) The location of the manuals.
(2) The manufacturer’s warnings and instructions.
APPENDIX - B
APPENDIX B
(3) The purpose and function of all controls.

(4) Safety devices and operating characteristics specific to the aerial device.
The operator shall operate the aerial device for a sufficient period of time to achieve proficiency in the actual
operation of the aerial device.
Where authorized bye the user, a qualified person may self-familiarize if the items above are completed.
8.13 Owner as a Lessor. When owners function as lessors, they shall have the same responsibilities as
specified under Section 11 of this standard.
9. Responsibility of Users.
9.1 General Responsibilities. Each User shall comply with the requirements of this section.
9.2 Personnel. Only trained and authorized personnel shall be permitted to operate the aerial device.
platform.
1926.502.
(15) Actual operation of the Aerial Device. Under the direction of a qualified person, the trainee shall operate
the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial
device and safe use at operating height and reach.
9.3.3 Familiarization. When an operator is directed to operate an aerial device with which they are not
familiar, they shall receive prior instruction regarding the following items:

APPENDIX - B
APPENDIX B

operation of the aerial device. Where authorized by the user, a qualified person may self-familiarize if the
items above are completed.
9.3.4 Proof of Training. Users providing training should provide successful trainees a means to evidence
their training and should provide such proof if requested by the trainee. The document evidencing training
shall include the following information:
(1) Name of trainee.
(2) Name of entity providing training or retraining.
(3) Name of trainer(s).
(4) Clear identification of the make(s) and model(s) of the mobile unit (MEWP)(s) on which the operator has
been trained.
(5) The date of training.
(6) The specific period of time the training is valid.
9.3.5 Record Keeping. Records of the person(s) trained in the operation of an aerial device should be
retained by the training entity. These records should be retained for at least the period of time the training is
valid.
9.4 Application. The employer and authorized operator(s) shall ensure that the aerial device is used only
for intended applications as defined in the operating manual and that all recognized safety practices are
observed. The aerial device shall not be operated while the mobile unit is positioned on trucks, trailers,
railway cars, floating vessels, scaffolds, or similar equipment unless the application is approved in writing by
the manufacturer or a qualified person.
NOTE: The User is directed to Appendix C for guidance as to appropriate applications.
9.5 Electrical Hazard. All applicable safety related work practices intended to protect from electrical
hazards shall be defined and explained to the operator by a qualified person. The operator shall maintain the
appropriate Minimum Approach Distance (MAD) from energized conductors and apparatus commensurate
with the operator’s qualification. See Appendix F for the information on the Minimum Approach Distances
and other precautions.
9.6 Bare-Hand Work. For bare-hand work, a Category A aerial device shall be used.
9.7 Lower Controls. The lower controls of aerial devices shall not be used with personnel in the platform
except for operator rescue or platform recovery.
9.8 Manufacturer’s Safety Bulletins. The user shall comply with the applicable safety-related bulletins as
received from the manufacturer, installer, dealer or owner.
10. Responsibilities of Operators.

10.1 General Responsibilities. Each operator shall comply with the requirements of this section.
10.2 Personnel. Only trained, familiarized, and authorized personnel shall be permitted to operate the aerial
device.
10.3 Operation. During operation of the aerial device.
(1) The operator shall make decisions on the use and operation of the aerial device with due consideration
for the fact that their own safety as well as the safety of others is dependent on those decisions.
(2) The operator shall immediately report to an authorized person (or supervisor) any safety related
problem(s) or malfunction(s) that become evident. The operator shall ensure all problems and malfunctions
that affect the safety of operations are repaired prior to continued use.
(3) All platform occupants shall use appropriate fall connected to the aerial device anchorage(s).
10.4 Work Platform. Personnel shall maintain a firm footing on the platform floor while working thereon.
Climbing by occupants on the mid-rail or top-rail of the work platform is prohibited. The occupant shall not
use railings, planks, ladders, or any other device in or on the work platform for achieving additional working
height or reach.
APPENDIX - B
APPENDIX B
10.5 Brakes. The vehicle parking brake(s) shall be set at all times that the boom is elevated except when
the aerial device is being used in accordance with 10.11.
10.6 Loading.
(1) Any loading which includes a horizontal load shall be avoided unless the mobile unit is designed for that
application.
(2) Adding material or personnel loads at height may be done provided the manufacturer of the aerial device
being used does not prohibit such activities. The addition of such loads shall not exceed the rated capacity
for the configuration being used. Note: Load sensing systems may not provide in these situations.
10.6.1 Vacating or Entering an Elevated Aerial Device. Personnel shall only vacate or enter a raised
aerial platform if not prohibited by the manufacturer and by complying with current OSHA regulations and
IEEE 1307 standard for transferring from an elevated platform to a structure.
10.6.2 Carrying Materials Larger than the Platform. The operator shall ensure that only properly secured
and distributed tools and materials which can be handled by a person(s) working from the platform, shall be
moved. Such operations shall be performed in accordance with the manufacturer’s instructions and limits.
10.7 Alterations. Altering or disabling the function of safety devices, guards, or interlocks if so equipped, is
prohibited.
10.7.1 Overriding Safety Devices. Overriding of safety devices is prohibited, whether during normal
operation or rescue, except in accordance with the manufacturer’s prescribed safety override procedures.
The overriding of safety devices during the testing, repair, or maintenance of an aerial device shall be carried
out in accordance with the manufacturer’s recommendations and procedures. Procedures for overriding
safety devices shall be designed to minimize the possibility that an unsafe condition could exist.
10.8 Observations. Observations during operation for any malfunctions shall be conducted on an ongoing
basis.
10.8.1 Pre-start Inspection. Items determined by the owner in accordance with the manufacturer’s
recommendations for each specific aerial device shall be inspected prior to each day’s operation. The
following tests and inspections shall be performed by the operator once daily, prior to first use:
(1) Conduct walk around visual inspection, looking for damaged components, cracks or corrosion, excessive
wear and any loose, deformed or missing bolts, pins, fasteners, locking devices and covers.
(2) Check all controls and associated mechanisms for proper operation to include, but not limited to, the
following:
(a) Proper operation of interlocks.
(b) Controls return to neutral when released and not sticking.
(c) Control functions and operation clearly marked.
(3) Check visual and audible safety devices for proper operation per the manufacturer’s requirements.
(4) Visually inspect fiberglass and other insulating components for visible damage and contamination.
(5) Check for missing or illegible operational and instructional markings.
(6) Check hydraulic or pneumatic systems for observable deterioration and excessive leakage.
(7) Check electrical systems related to the aerial device for malfunction, signs of excessive deterioration, dirt
and moisture accumulation.
(8) Perform functional test to include, but not limited, to the following:
(a) Set-up aerial device for operation, including stabilizers.
(b) Cycle each aerial device boom function through its complete range of motion from the lower controls,
except where operation through the complete range of motion would create a hazard.
(c) Check functionality of emergency controls.
10.8.2 Transporting. The aerial device, including its stabilizers, if so equipped, shall be in the
manufacturer’s recommended configuration when being transported.

APPENDIX - B
APPENDIX B
10.9 Worksite. Before the aerial device is used the worksite shall be surveyed for hazards such as:
(1) Insufficient supporting surfaces such as soft ground or tamped earth fills.
(2) Ditches.
(3) Excessive slopes, drop-offs, curbs, and floor obstructions.
(4) Debris.
(5) Overhead obstructions and electrical conductors.
(6) Weather conditions.
(7) Presence of unauthorized persons.
(8) Road or worksite traffic.
(9) Subsurface chambers such as underground utility components or septic systems.
(10) Hazardous locations and environments.
10.10 Precautions. Before and during each use the operator shall:
(1) Check for overhead obstructions and electrical conductors.
(2) Maintain adequate clearance from obstructions and electrical apparatus.
(3) Ensure that the load and its distribution on the platform and/or load lifting device is in accordance with the
manufacturer's requirements.
(4) Ensure that outriggers and stabilizers are used if the manufacturer's instructions require their use.
(5) Ensure that guardrails are properly installed, and the gates are closed.
(6) Use outrigger pads when necessary to provide firm footing.
(7) Cease operation of the aerial device and request further information from the user should the operator
encounter any suspected malfunction of the aerial device or any hazard or potentially unsafe condition.
(8) If the platform or elevating assembly becomes caught, snagged, or otherwise prevented from normal
motion by external obstacles such that control reversal does not free the platform, all personnel should be
removed from the platform before attempts are made to free the platform or elevating assembly.
10.11 Mobile Operation. Before engaging in mobile operation the operator shall determine that the aerial
device is specifically designed for mobile operation.
10.11.1 Driver Precautions. Before and during driving, the driver shall:
(1) Avoid traveling on any surface that adversely affects vehicle stability.
(2) Maintain a safe distance from obstacles and overhead lines.
(3) Maintain communications between driver and operator.
(4) Under all travel conditions, the driver shall limit travel speed in accordance with condition of the ground
surface, congestion and slope.
(5) Prohibition of overriding safety devices except as approved by the manufacturer. (see 8.5.2).
platform.
APPENDIX - B
APPENDIX B

1926.502.
(15) Actual operation of the aerial device. Under the direction of a qualified person, the trainee shall operate
functions of the aerial device and safe use at operating height and reach.
(1) The user’s observation and evaluation or the operator. This evaluation of the operator shall include
the operator, prior to operating, shall be instructed by a qualified person regarding the following items:
10.13 Electrical Hazard. All applicable safety related work practices intended to protect personnel from
electrical hazards shall be defined and explained to the operator by a qualified person. The operator shall
maintain the appropriate Minimum Approach Distance (MAD) from energized conductors and apparatus
commensurate with the operator’s qualification. Aerial device or apparatus used to lift energized lines
require use of an insulating device; that has been rated, tested and maintained for the appropriate line
voltage to prevent energizing the boom tip. See Appendix F for information on the Minimum Approach
Distance, handling energized apparatus and other precautions.
11. Responsibilities of Lessors or Lessees.

11.1 General Responsibilities. Each renter or lessor or lessee shall comply with the requirements of the
applicable section or sections below.
11.1.1 Lessor or Lessee as Dealer or Installer. When a lessor or lessee uses the aerial device as a dealer
or installer they shall have the same responsibilities as specified under Section 7 of this standard.
11.1.2 Lessor or Lessee as Owner. When a lessor or lessee uses the aerial device as an owner they shall
have the same responsibilities as specified under Section 8 of this standard.
11.1.3 Lessor or Lessee as User. When a lessor or lessee uses the aerial device as a user they shall have
the same responsibilities as specified under Section 9 of this standard.
11.1.4 Lessor or Lessee as Operator. When a lessor or lessee uses the aerial device as an operator they
shall have the same responsibilities as specified under Section 10 of this standard.
11.2 Ownership Responsibilities. The lessor shall carry out the responsibilities of ownership specified in
this standard which are not assigned to the lessee as the user.

APPENDIX - B
APPENDIX B
11.3 Obligations. Upon delivery each lessor of an aerial device shall provide the operators manual and the
ANSI/SIA A92.2-2009 Manual of Responsibilities for dealers, owners, users, operators, lessors, lessees and
brokers of Vehicle Mounted Elevating and Rotating Aerial Devices. These manuals shall be stored on the
mobile unit (MEWP).
11.3.1 Inspection and Test. Prior to delivery, the lessor of an aerial device shall perform a frequent
inspection as specified in Section 8.2.3 of this standard.
11.3.2 Responsibilities. Upon delivery, each lessor of an aerial device shall inform the lessee of their
responsibilities in accordance with Section 8 as to inspection, testing and maintenance requirements;
Section 9 as to user’s responsibilities; and Section 10 as to operator’s responsibilities.
11.4 Training. The lessor shall offer training or training materials that aid the lessee in the operation,
inspection, testing and maintenance of the aerial device. This training shall be offered initially and
subsequently on request.
11.4.1 General training. Only personnel who have received general instructions regarding the inspection,
platform.
Aerial Devices have safety rules pertinent to that industry.
1926.502.
(15) Actual operation of the aerial device. Under the direction of a qualified person, the trainee shall operate
functions of the aerial device and safe at operating height and reach.
11.4.2 Retraining. The operator shall be retrained when so directed by the user, based on the following:
the operator, prior to operating, shall be instructed by a qualified person regarding the following items:
APPENDIX - B
APPENDIX B
11.5 Communications. In the event the manufacturer or installer provides the lessor manuals, bulletins, or
other materials for the information of the user of an aerial device, the lessor shall pass them on to the user
without delay.
11.6 Use of Brokers. If Brokers are employed in leasing, the responsibility of lessors and lessees as
specified in this Section continue even though a Broker may be involved in the transaction.
12. RESPONSIBILITIES OF BROKERS.

12.1 Broker Involved In a Sale. A broker involved in a sale shall:
(1) Assure that the entity actually transferring ownership knows the proper location and identification of
proper of the purchasing entity.
(2) Confirm that operations and maintenance manuals are provided to the new owner.
(3) Confirm that all parties are aware of their responsibilities under Section 8.7 of this standard.
12.2 Broker Involved In a Lease. A broker involved in a lease shall:
(1) Assure that the entity actually transferring possession know the proper location and identification of the
proper personnel of the lessee or user of the aerial device.
(2) Confirm that the operators’ manual, maintenance manual, and Manual of Responsibilities are provided to
the lessee.
(3) Confirm that all parties are aware of their responsibilities under Section 11.4 of this standard.

APPENDIX - B
APPENDIX B
SURVEY OF JOB SITE

Appendix (This Appendix is not part of American National Standard A92.2-2009 - but is included for
information only.)
Construction and electrical workers are subject to certain hazards that cannot be eliminated by mechanical
means and must be controlled by care, common sense and intelligence. Terex South Dakota, Inc. realizes
the importance of safety and strongly recommends that prior to commencing any operation, the employer
make a survey of the conditions of the site to determine the hazards and the kind and number of safeguards
that the employer will install.
The survey should include, but not be limited to, the following:
(1) Safe access and movement
(a) Work areas
(b) Walkways, runways and passageways
(c) Ladders, stairways and elevators
(d) for floor and roof openings
(e) Illumination
(2) Vehicles
(a) Roads
(1) Turn space
(2) Parking area
(3) Mud areas
(b) Materials storage areas and dump areas
(c) Signs and signals to route vehicles on the job
(d) Maintenance and repairs of vehicles
(3) Utilities and service
(a) Location of temporary buildings
(b) Location and identification of high-voltage lines (identify by signs; move, de-energize or erect barrier
to prevent contact)
(c) Location of sanitary facilities and drinking water
(4) Scheduling work for safety
(a) Providing hard hats, life belts, goggles, work vests and the like on the job
(b) Establishing liaison among contractors to prevent congestion among trades
(c) Providing temporary flooring, safety nets and scaffolding where required
(5) Work Procedures
(a) Space
(b) Equipment such as cranes, hoists, elevators and trucks
(c) Rigging procedures
(d) Personal protective equipment
(6) Tools and equipment
(a) Repair, maintenance and care
(b) Inspection
(c) Supplies of tools for each job
(7) Workers and foremen
(a) Job assignment
(b) Training and supervision
APPENDIX - B
APPENDIX B
(c) Number of workers

(d) Plans for maintaining interest in safety:
(1) Safety bulletins, record charts and posters
(2) Recognition for groups or individuals
(3) Investigation and reporting on reportable accidents
(4) Knowledge of safety orders
(5) Safety meetings
(6) Specific safety instructions for new employees
(e) Establishment of provisions to take immediate action to correct unsafe conditions or acts
(f) First aid and medical treatment of injuries

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HI–RANGER

PRINTED IN THE USA

12 MONTHS (1,050 HOURS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 - 3

BEARINGS AND BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 - 1

TROUBLESHOOTING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 - 7

HYDRAULIC COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400 - 1

INSTALLATION OF COLLECTOR RING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640 - 9

STANDARD HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 4

Aerial Platform Annual Inspection

Immediate Repairs Required (______Yes) (_______No)

Shop Order_____________ Test Date _____________________

Chassis and Unit Information

Chassis Year ___________ Chassis Model __________________

Aerial Annual Inspection Unit Number_____________________________

A. Chassis / Body Status 3. Outrigger / Torsion Bar System Status

Inspector Initials ________________

Aerial Annual Inspection Unit Number_____________________________

Booms and Platform (cont.) Status 8. Extension System Status

7. Platform Leveling System 3. Misc. Powered Equipment

Model / Serial# ______________________ Summary Page Unit Number____________

Number R/C/I Description

Customer Signature___________________________________ Print Name ___________________________

Inspector Signature ____________________________________Date____________________

PERIODIC/MAINTENANCE DIELECTRIC TEST ANSI/SIA A92.2 AND A10.31

Aerials Category C and Digger Derricks Work Order No.

Upper Boom Test: Chassis Insulating Test: Air Temp. °F

Tested by: ______________________ Location: ___________________________

PERIODIC/MAINTENANCE DIELECTRIC TEST ANSI/SIA A92.2

Tested by: ____________________________ Location: _____________________________

TEREX TELELECT Aerial - Upper control Handle Test

Connect as shown for AC:

QUALIFICATION DIELECTRIC TEST

Customer:___________________________Ack No.:________________ S/N:_______________________

2. CATEGORY C INSULATING AERIAL DEVICE AND DIGGER DERRICK

3. CHASSIS INSULATING SYSTEM (Lower Boom Inserts)

FMPN352136 Rev B 2/01/06

TEREX TELELECT Aerial - Upper control Handle Test

Tested By:___________________ Date: Reviewed:___________________ Date:

PROPERTY DAMAGE MESSAGES

1. Study all safety messages and apply them on the job.

GENERAL SAFETY GUIDELINES

ELECTRICITY OBEYS NO LAW, BUT ITS OWN.

20. Use only non-metallic tool holders and tool trays.

1. Never travel with personnel in the platform.

OVERVIEW OF POTENTIAL HAZARDS AND SYMBOLS

Lanyard Attach. WARNING: Failure to Attach

22. LANYARD ATTACHMENT, X1 (depending on boom tip option) 1 495441

NOT INSULATED 465703

INSPECTION DATE RECORD

Do not alter computer settings without

See information supplied with truck manuals

:$51,1*Cancer and Reproductive Harm -

1. ROTATE BASKET CAREFULLY

2. POSITION JIB PARALLEL TO

Breathing diesel engine exhaust exposes you to chemicals known

Upper Boom Cylinder

Master Leveling Cylinder

Lower Boom Lift Cylinder

Measurements TL37 TL41 TL45 TL50 TL55 TL60

Overall Height (OAH) 10’ 7” 10’ 7” 11’ 3” 11’ 3” 11’ 3” 11’ 3”

CAPACITIES & DIMENSIONAL DATA

Typical Frame Height (FH) 32 in. (81.3 cm)

Typical Cab Height (CH) 78 in. (198.1 cm)

Immediate Repairs Required (Yes) (_No)

Shop Order_ Test Date _________

Chassis Year _ Chassis Model ________

Model / Serial# __________ Summary Page Unit Number

Customer Signature_________ Print Name _

Inspector Signature ________________Date

Tested by: Location: _____

Tested by: Location: _

Customer:_____Ack No.: S/N:_

Tested By:_ Date: Reviewed:_ Date: