Page 1
DRM 12
Operator’s, Maintenance,
and Parts Manual
www.altec.com
Altec Industries, Inc. reserves the right to improve models and change specications without notice.
Operator’s and Maintenance Manual: 970413435 Parts Manual: 970413436
2013
Copyright 2013 by Altec Industries, Inc.
All rights reserved. No part of this publication may be used or reproduced by any means, or stored in a
database or retrieval system, without prior written permission of the publisher. Making copies of any part
of this publication for any purpose other than personal use is a violation of United States copyright laws.
Page 2
Preface
This unit is the result of Altec Environmental Products, LLC’s advanced technology and
quality awareness in design, engineering, and manufacturing. At the time of delivery from
the factory, this unit met or exceeded all applicable requirements of the American National
Standards Institute. All information, illustrations, and specications contained within this
manual are based on the latest product information available at the time of publication. It is
essential that all personnel involved in the use and/or care of this unit read and understand
the Operator’s Manual. Keep this manual with the unit.
Given reasonable care and operation, according to the guidelines set forth in the manuals
provided, this unit will provide many years of excellent service before requiring major maintenance.
Impacts to and excessive forces on the equipment, through vehicular accidents, rollovers,
excessive loading, and the like, may result in structural damage not obvious during a visual
inspection. If the equipment is subjected to such impacts or forces, a qualied person may
need to perform additional testing such as magnaux or ultrasonic testing as applicable. If
structural damage is suspected or found, contact Altec Environmental Products, LLC for
additional instructions.
Warning
Death or serious injury can result from component failure. Continued use of equipment
with hidden damage could lead to component failure.
Never alter or modify this unit in any way that might affect the structural integrity or opera-
tional characteristics without the specic written approval of Altec Environmental Products,
LLC. Unauthorized alterations or modications will void the warranty. Of greater concern,
is the possibility that unauthorized modication could adversely affect the safe operation of
this unit, resulting in personal injury and/or property damage.
Danger
Death or serious injury will result from operation of a chipper while coupled to an
energized aerial device. Non-insulated aerial devices have no dielectric rating. When
coupled, chipper to aerial lift and in the proximity of energized conductors, there shall
be no operation or contact with the chipper.
No unit can provide absolute safety when in proximity to energized conductors. No unit is
designed or intended to replace or supersede any protective device or safe work practice
relating to work in proximity to energized conductors. When in proximity to energized conductors, this unit shall only be used by trained personnel using their company’s accepted
work methods, safety procedures, and protective equipment. Training manuals are available
from a variety of sources.
Set-up requirements, work procedures, and safety precautions for each particular situation
are the responsibility of the personnel involved in the use and/or care of this unit.
Page 3
Page 4
Table of Contents
Section 1 — Introduction
About This Manual…..................................................................................................... 1
Section 2 — Unit Specications
Purpose of the Unit ....................................................................................................... 3
General Specications .................................................................................................. 3
Component Identication .............................................................................................. 4
Section 3 — Safety
Safety Instructions ........................................................................................................ 5
Lock-Out Tag Out Procedure (LOTO) ..................................................................... 5
Capacity ........................................................................................................................ 5
Chipper Personnel Safety Devices ............................................................................... 6
Panic Bar Assembly ................................................................................................ 6
Chip Curtain ............................................................................................................ 6
Rotational Indicator ................................................................................................. 7
Drum Blade Change Pin ......................................................................................... 7
Guards .................................................................................................................... 7
Feed Roll Lock Pin ................................................................................................. 8
Safety Tow Chains .................................................................................................. 8
Breakaway Switch .................................................................................................. 8
Disclaimer of Liability .................................................................................................... 9
Accident Prevention Signs ............................................................................................ 9
Accident Prevention Signs Diagram ..................................................................... 10
Section 4 — Before You Operate…
Daily Preoperational Inspection .................................................................................. 19
Hitching to Tow Vehicle ............................................................................................... 20
Fueling Chipper ........................................................................................................... 21
Controls ....................................................................................................................... 21
Feed Roller Operation .......................................................................................... 21
PTO/Clutch Engagement ...................................................................................... 22
FeedSense® (Electronic Feed Control)................................................................ 23
Work Site Preparation ................................................................................................. 23
Brush Preparation ................................................................................................. 24
Starting the Engine ............................................................................................... 25
Engaging/Disengaging the Cutter Head ............................................................... 25
Feeding Brush to the Chipper ............................................................................... 26
Winch Safety and Operation (Optional Equipment) .............................................. 29
Section 5 — Clearing Feed System and Discharge Chute
Feed System ............................................................................................................... 31
Discharge Chute ......................................................................................................... 32
Section 6 — Care of the Unit
Engine Oil ................................................................................................................... 33
Engine Coolant ........................................................................................................... 33
Engine Air Filter ........................................................................................................... 33
Clutch and Power Take-Off (PTO) .............................................................................. 34
Battery ......................................................................................................................... 34
Fasteners .................................................................................................................... 34
Tires and Wheels ........................................................................................................ 34
Tongue and Hitch ........................................................................................................ 34
Chipper Electric Braking System ................................................................................ 35
Page 5
Hinge and Friction Points ............................................................................................ 35
Drum and Feed Roll Bearings ..................................................................................... 35
Section 7 — Maintenance
Equipment Storage ..................................................................................................... 38
Protective Measures ............................................................................................. 38
Extended Storage ....................................................................................................... 38
Engine Storage ..................................................................................................... 38
Chipper Storage ................................................................................................... 38
Hydraulic System ........................................................................................................ 39
Cleanliness Precautions ....................................................................................... 39
Filtration ................................................................................................................ 39
Oil Specications .................................................................................................. 40
Oil Condition ......................................................................................................... 40
Changing Oil and Flushing the System ................................................................ 41
Lubrication .................................................................................................................. 42
Lubrication Chart .................................................................................................. 43
Structures .................................................................................................................... 44
Care of Exterior Surfaces ..................................................................................... 44
Welds ................................................................................................................... 45
Fasteners .................................................................................................................... 45
System Operation ....................................................................................................... 46
Oil Reservoir ............................................................................................................... 46
Oil Pump ..................................................................................................................... 46
Hydraulic Motors ......................................................................................................... 46
Valves.......................................................................................................................... 46
Leakage ...................................................................................................................... 46
Heat Generation .......................................................................................................... 47
Hydraulic Lines ........................................................................................................... 47
Drive Belt/Pulleys ........................................................................................................ 47
Troubleshooting, Testing, and Adjustments ................................................................ 49
Synchronizing Tow Vehicle Brake Controller ........................................................ 49
Breakaway Braking System .................................................................................. 49
Mechanical ........................................................................................................... 50
Electrical ............................................................................................................... 53
Troubleshooting .................................................................................................... 54
Appendix
Glossary
Torque Values
Daily Preoperational Checklist
Preventive Maintenance and Inspection Checklist
Troubleshooting Chart
Parts
Page 6
Section 1 — Introduction
About This Manual…
This manual provides instruction for the operation and
maintenance of the unit. The operator must be familiar
with the unit and its capabilities before using the unit
on the job. This manual is written to provide an understanding of the unit, safety, proper set-up, operation,
and maintenance.
Charts and gures are provided to support the text.
Because options vary from one model to another, some
gures may only be a representation of what is actually
on the unit.
Contact the following organizations for additional information.
• American National Standards Institute (ANSI)
Z133.1 Pruning, Repairing, Maintaining, and Remov-
ing Trees, and Cutting Brush-Safety Requirements
• American Public Power Association
(Safety Manual for an Electric Utility)
• American Society for Testing and Materials
(ASTM)
• American Welding Society (AWS)
• European Committee for Standardization (CEN)
• Fluid Power Society (FPS)
• Hydraulic Tool Manufacturer’s Association (HTMA)
• International Electrotechnical Commission (IEC)
• International Organization for Standardization
(ISO)
• Occupational Safety and Health Administration
(OSHA)
• Federal Motor Carrier Safety Administration
(FMCSA)
• U.S. Department of Transportation (DOT)
• Federal Highway Administration (FHWA)
Dealers, installers, owners, users, operators, renters,
lessors, and lessees must comply with the appropriate
sections of the applicable ANSI standard.
The Appendix contains reference items to assist in unit
operation. A glossary of industry terms is provided for your
convenience. This glossary provides an understanding
of the industry terms and phrases used in Altec manuals.
Throughout the manual, the term unit is used to describe
the Altec device.
Additional copies of this manual may be ordered through
your Altec representative. Supply the model and serial
number found on the serial number placard and the
manual part number from the front cover to assure that
the correct manual will be supplied.
This symbol is used throughout this manual to
indicate danger, warning, and caution instructions. These instructions must be followed to
reduce the likelihood of personal injury and/or property
damage.
The terms danger, warning, caution, and notice represent varying degrees of personal injury and/or property
damage that could result if the preventive instructions
are not followed. The following paragraphs from ANSI
publications explain each term.
Danger
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury. This
signal word is to be limited to the most extreme
situations.
Warning
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Caution
Indicates a hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be used to alert against unsafe
practices.
Notice
The preferred signal word to address practices
not related to personal injury.
Section 1 — Introduction • 1
Page 7
2 • Section 1 — Introduction
Page 8
Section 2 — Unit Specications
Purpose of the Unit
This unit has been designed and built to reduce brush
and above ground tree components into uniformed wood
chips.
General Specications
This unit is a 12″ (30.5 cm) capacity, controlled feed drum
chipper. The chipper mechanism is permanently mounted
Item Specication
Chipping capacity 12″ (30.5 cm)
Engine horsepower 85 horsepower (63 kW)
Weight 5,310 pounds (2,408 kg)
Tongue weight (may vary) 530 pounds (240 kg)
Travel height 8’ 2″ (2.5 m)
Width 6’ 8″ (2 m)
Travel length 15’ (4.5 m)
Operational length 16’ 11″ (5.2 m)
Feed roller opening 17″ (43.18 cm) wide x 12″ (30.5 cm) high
Feed table dimensions 50″ (127 cm) wide x 30″ (76.2 cm) deep
Infeed chute opening 50″ (127 cm) wide x 30″ (76.2 cm) high
Length to feed roll nip point1 94″ (2.4 m)
Drum dimensions 20″ (50.8 cm) wide x 21″ (53.3 cm) diameter
Drum weight 520 pounds (236 kg)
Drum rpm 2,230 rpm
Feed rolls 161/2″ (41.9 cm) wide x 20″ (50.8 cm) diameter
Feed rate 111 feet per minute (34 mpm)
Feed wheel motor rating 32.2 cu in displacement (528 cu cm)
Hydraulic pressure 2,500 psi (172.4 bar)
Hydraulic tank capacity 12 gallon (45.4 l)
Fuel tank capacity 18 gallon (68.1 l)
Discharge chute rotation 360°
1
Measured from ground level at infeed chute, through the center of the feed table.
Figure 2.1 — Unit Specications
on the towable frame assembly. The chipper mechanism
is belt driven by a self contained engine. Material is fed
utilizing one horizontally mounted, hydraulically controlled
feed roll. Chip discharge is designed for 360 degree rotation for chip body and road side discharge applications.
Section 2 — Unit Specications • 3
Page 9
Component Identication
Discharge Chute
Feed Table
Control
Bar
Feed
Box
Chute
Rotation
Belt Guard
Chute Height
Adjustment
Clutch
Jack
Stand
Chute
Deector
Safety
Chains
Panic Bar
Breakaway
Switch
Tow Bar
Clearance
Lights
Hydraulic
Filter
Fender
Hydraulic
Reservoir
Infeed Chute
Engine
Fuel Tank
Pintle
Hook
Hydraulic
Motor
4 • Section 2 — Unit Specications
Fender
Page 10
Section 3 — Safety
Safety Instructions
This unit is designed and manufactured with many features intended to reduce the likelihood of an accident.
Safety alerts throughout this manual highlight situations
in which accidents can occur. Pay special attention to
all safety alerts.
Danger
Death or serious injury will result from careless or
improper use of the unit. Do not operate the unit
without proper training.
Warning
Death or serious injury can result from careless
or improper use of the unit. The operator bears
ultimate responsibility for following all regulations
and safety rules of their employer and/or any state
or federal law.
It is very important that all personnel are properly trained
to act quickly and responsibly in an emergency, knowing
the location of the controls and how they operate. Keep
any tools or equipment needed to perform manual operations in a well-marked, designated area. Keep the work
area well organized and eliminate trip hazards.
Danger
Death or serious injury can result from entanglement
with material being fed into the chipper. Always wear
the proper protective equipment for the task being
performed. Make sure all safety operational and
maintenance parameters are strictly enforced.
Death or serious injury can result from accessing
moving components such as cutter drum/disc or drive
components. Never attempt access to or attempt to
cover moving components.
Death or serious injury will result from unprotected
contact with energized conductors. Do not operate
or come in contact with a chipper while coupled to
an operational aerial device.
Knowledge of the information in this manual and proper
training provide a basis for safely operating the unit. Follow
your employer’s safe work practices and the procedures
in this manual when operating the unit.
Lock-Out Tag Out Procedure (LOTO)
Warning
Death or serious injury can result from unexpected
movement. Follow the lock-out tag out procedure
before accessing internal components of the unit.
LOTO procedures must be completed prior to performing
maintenance or clearing debris from internal components
of the chipper or engine.
Never leave the chipper unattended with the keys in the
ignition.
1. Turn Ignition key off and remove key. Secure the key
in a safe location with controlled access.
2. Make sure chipper drum or disc comes to a complete
stop.
3. Remove negative battery cable.
4. Lock and tag battery box.
5. Follow all appropriate LOTO procedures according to
OSHA Standards 29 CFR Standard 1910.147 (The
Control of Hazardous Energy).
6. Follow any additional federal, state, local, or con-
trolling agency standards or procedures that may
apply.
General Operating Information
• Do not operate the unit without proper training.
• Be sure that the unit is operating properly, and has
been inspected, maintained, and tested in accordance
with the manufacturer’s and government’s requirements.
• Use required personal protective equipment.
• Be aware of the surroundings.
• Perform the Daily Preoperational Inspection before
operating the unit each day.
• Apply the tow vehicle parking brake and chock chipper and tow vehicle wheels.
• Properly set up chipper operational area, including
vehicle and pedestrian control.
• Never exceed the rated capacity values.
• Follow all of your employer’s work rules and applicable
government regulations.
• Verify there are no loose tools or materials on the
chipper or in the infeed chute.
Capacity
This unit capacity is the maximum size material which
will pass through the feed wheel opening. Always take
Section 3 — Safety • 5
Page 11
into consideration general material shape, protrusions,
and attached limbs.
Chipper Personnel Safety Devices
Danger
Death or serious injury will result from careless or
improper use of the unit. Do not operate the unit
without proper training.
All personnel using this chipper must be trained and
qualied in all aspects of the operations, maintenance,
repair, and safety procedures dened in this manual
prior to conducting any operations or procedures. All
maintenance personnel and operators shall ensure the
proper operation of each safety device prior to starting
the engine or operating the chipper. Contact Altec Environmental Products for replacement parts.
Warning
Death or serious injury can result when operating
this unit. Safety devices are not a substitution for
proper operation. Read the entire manual and all
safety decals and placards.
Panic Bar Assembly
In the event of an unforeseen situation the panic bar
(refer to Figures 3.1 and 3.2) can be activated by pulling
down on bar A or by pulling or pushing bar B towards the
rear of the chipper. This action will stop all movement of
the feed roller.
soon as the valve handle is activated. Make sure all
operators are advised prior to your actions and that
the infeed chute is clear of all personnel and tools
before reactivation of the feed system.
Run
Valve
Figure 3.2 — Valve and Bar Linkage
The panic bar assembly consists of two bars (A and B),
the hydraulic valve and the bar linkage. When you pull
down on bar A or push towards the rear of the chipper
on bar B, the bar connecting linkage activates the handle
on the valve. This action stops all movement of the feed
rollers. To continue operation you must manually reset
the handle on the valve to the Run position.
1. Test the panic bar assembly daily and whenever new
personnel are assigned to the chipper.
Stop
Bar Linkage
B
A
Figure 3.1 — Panic Bar Assembly
Warning
Death or serious injury can result from unexpected
roller movement. Feed rollers begin movement as
6 • Section 3 — Safety
2. After completing all appropriate safety and operational
checks and with no material in the infeed chute, pull
or push the feed bar to activate the feed roller in the
forward or reverse direction. Visually verify the rotation of the feed roller.
3. Push down on bar A or move bar B.
4. Feed roller movement must stop.
5. If feed rollers do not stop, repair as necessary prior
to operating the chipper.
Chip Curtain
The kickback curtain (refer to Figure 3.3) stops or deects
chips and small debris from leaving the infeed chute
area. This also helps in decreasing the amount of clean
up around the chipper.
Page 12
Figure 3.3 — Chip Curtain
Warning
Death or serious injury can result from ying objects.
The chip curtain must be properly installed and in
good condition. Wear appropriate safety equipment.
Inspect chip curtain for damage or missing segments.
Replace the chip curtain if damaged.
Rotational Indicator
The rotational indicator (refer to Figure 3.4) is located on
the belt guard. Movement of the bolt head seen through
this guard indicates movement of the drum and drive
components.
Make sure components have come to a complete
stop before performing inspection or maintenance.
Inspect visibility of the rotational indicator. Make sure no
debris is blocking view.
Drum Blade Change Pin
Complete LOTO procedures prior to performing maintenance on the blades.
A pin (refer to Figure 3.5) is used to lock drum while
performing blade maintenance. After the drum hood has
been opened, rotate the pin, and slide it into the slot.
Engage the pin directly in front of the drum blade. Rotate
drum 180 degrees, lock to perform maintenance on the
second blade. Prior to closing the drum access hood, lift
and rotate the pin back to the start position.
Figure 3.4 — Rotational Indicator
Warning
Death, serious injury, or property damage can result
when attempting to access moving components.
Figure 3.5 — Drum Blade Change Pin
Warning
Death or serious injury can result while performing
blade maintenance. Wear appropriate safety equipment.
Wear cut resistant gloves when performing blade maintenance or inspection.
Guards
The chipper is equipped with safety guards (refer to Figure
3.6) to protect you from injury. Do not start or operate the
chipper with these guards removed. Inspect all guards
to make sure they are in place, in good condition, and
properly secured. Never attempt to install a guard or close
the drum hood while the chipper is running. Make any
necessary repairs prior to starting the chipper.
Section 3 — Safety • 7
Page 13
Figure 3.6 — Guards
Warning
Death, serious injury, or property damage can result
from starting or operating the chipper without the
guards in place. Make sure all guards are in place
before operating the chipper.
4. Using the lift cylinder control, slowly lower the feed
roll. Do not apply down pressure.
5. Perform LOTO procedures.
6. Slowly lower the feed roller.
Warning
Death or serious injury can result if the upper feed
roller is not returned to the proper position. Do not
feed material into the chipper with the upper feed
roller in the locked open position.
Caution
Injury can result from being pinched or trapped between moving components. Keep hands clear.
Safety Tow Chains
Tow chains (refer to Figure 3.8) are to be utilized every
time a chipper is transported. Chains must be routed
under the trailer tongue in an X pattern between the tow
vehicle and trailer.
Feed Roll Lock Pin
The feed roll lock pin (refer to Figure 3.7) holds the feed
roll in the raised position to assist operators in clearing
infeed material clogs. Make sure pin is in good condition
and tethered to the chipper. Make sure the lift cylinder
operating system is operating properly.
Pin
Figure 3.7 — Feed Roll Lock Pin
1. Disengage clutch and wait for all drum movement to
stop.
2. With the lift cylinder controls, fully raise the feed roll.
Hold while inserting pin.
3. Feed the pin though the feed roll box and feed roll
assembly. Make sure the pin goes completely through
both feed roll assembly and box uprights.
Figure 3.8 — Chain Routing
Slack in the chain should be adjusted by installing the
hook in the proper chain link to permit turning but not
dragging on the ground. Inspect chain, clevis, and hook
for damage or excessive wear.
Breakaway Switch
In the event of an unwanted separation of the chipper from
the tow vehicle, the tongue should drop into the cradle
formed by the X pattern of the chains. The breakaway
cable must pull the plunger from the switch before the
entire tongue weight of the chipper comes to rest in the
chain cradle.
When the breakaway switch is activated full voltage
from the chipper battery is applied to the brakes. The
chipper will come to a complete stop, but will not lock
up the wheels.
8 • Section 3 — Safety
Page 14
Testing of the breakaway can be accomplished by jacking up the chipper, spinning the wheel and pulling the
plunger. The brakes should apply. This test only ensures
the basic braking circuit is properly functioning. For complete testing and tow vehicle controller set-up, refer to
the chipper brake section in this manual.
Notice
The breakaway switch is to be used for emergencies
only. The breakaway system rapidly discharges the
battery when the plunger pin is removed. Reinstall
plunger immediately after completion of test.
Unauthorized alterations or modications will void the
warranty. However, of a greater concern is the possibility
that unauthorized changes could adversely affect the unit’s
operation that could endanger personnel and/or damage
property. Altec will not be responsible for unauthorized
alterations or modications that cause death, serious
injury, and/or property damage.
Altec Environmental Products, LLC assumes no liability
for any personal injury and/or property damage related
to the use of this manual when performing testing, operating, maintenance and/or repair procedures on this
Altec unit.
Disclaimer of Liability
Altec Environmental Products, LLC will not be liable for
unauthorized alterations or modications of the unit.
Altec Environmental Products, LLC will not be liable for
improper or abusive operation of the unit.
Do not alter or modify this unit in any way that might affect
its structural integrity, dielectric integrity, or operational
characteristics without specic written approval from Altec
Environmental Products, LLC.
Accident Prevention Signs
This unit was equipped with accident prevention signs
at the time of manufacture. If any of these are lost or
become illegible, obtain replacements from your Altec
representative.
The location, part numbers, and descriptions of all
placards are listed in the Parts Manual. Refer to the Ac-
cident Prevention Signs and Diagram for examples of
the placards and their locations.
Section 3 — Safety • 9
Page 15
Accident Prevention Signs Diagram
A
B
26
21
30
Both
Sides
7
8
B
A
C
4
7
Both
Sides
1
10 • Section 3 — Safety
31
30
21
18
12
2
20
28
4
1
C
Page 16
9
6
Section A - A Section B - B
16
13
29
14
Section C - C Front View
8 27 11
Per Engine
or
24
25
15
Section 3 — Safety • 11
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5
Rear View
30
3 2
12
19
20
17
30
102310
Top View
22
12 • Section 3 — Safety
Bottom View
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Section 3 — Safety • 13
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14 • Section 3 — Safety
970116652
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970116649
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WARNING
ALL DECALS AND PLACARDS
SHALL BE PROPERLY POSITIONED
ON THE EQUIPMENT, COMPLETELY
LEGIBLE AND UNDERSTOOD BY
ALL OPERATIONAL AND
MECHANICAL PERSONNEL PRIOR
TO OPERATION OR MAINTENANCE
OF THIS EQUIPMENT. FAILURE TO
ENSURE THIS COULD RESULT IN
EQUIPMENT DAMAGE, SERIOUS
INJURY OR DEATH.
TO OBTAIN DECAL & PLACARD
PLACEMENT GUIDES OR
REPLACEMENT DECALS &
PLACARDS, CONTACT ALTEC AT:
1-877-I FLY ALTEC
1-877-435-9258
OR ONLINE AT:
http://www.Altec.com
DO NOT REMOVE THIS TAG
970122659
16
970116654
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17
•
•
•
•
•
•
•
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18
20
21
Section 3 — Safety • 15
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3X
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Section 3 — Safety • 17
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18 • Section 3 — Safety
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Section 4 — Before You Operate…
Daily Preoperational Inspection
Notice
Before the chipper is put into operation it is very
important to read and follow procedures outlined in
the engine manufacturer’s Engine Owner’s Manual
(EOM).
To assist the reader in determining when to refer to the
Engine Owner’s Manual, look for this symbol (EOM).
You will nd this symbol used throughout the rest of this
manual.
Warning
Death, serious injury, or property damage can result
when attempting to access moving components.
Make sure components have come to a complete
stop before performing inspection or maintenance.
Do not access the drum or drive components until you
have read and understand the Operator’s Manual and
all safety decals and placards. Drum and drive systems
continue to move after the clutch has been disengaged
and the engine has been turned off. Make sure that the
drum and drive systems have come to a complete stop
before attempting any maintenance in this area. Blades
are extremely sharp. Care must be taken to avoid contact
with the blades and blade pinch points. Complete LOTO
procedures.
Warning
Serious injury can result while performing blade
maintenance. Wear appropriate safety equipment.
Always secure the cutter to prevent rotation before tightening fasteners or performing maintenance in the drum
housing areas. Never place any part of the body under
or behind guards or any other visually obscured area.
• Check clutch handle free play, if applicable.
• Check all cap screws and nuts to make sure they
are tight.
• Check cutting blades to make sure all attachment cap
screws are tight and blades are in good condition.
• Inspect the anvil to make sure all attachment and
adjustment cap screws are secure.
• Verify rotation indicator is clear of debris and fully
visible.
• Drum cover padlock is in place and key is in responsible party’s possession, if applicable.
• Drum hood switch is working properly, if applicable.
• Inspect safety tow chain for wear or damage.
• Check all controls for free and proper operation.
• Inspect discharge chute to determine if it is clear,
properly positioned and secure.
• Inspect the chipper frame and structure for any bent,
broken, cracked, missing or loose parts. This includes
the tongue tube, hitch, and all hardware associated
with these items. Damage may be hidden on removable tongues by the receiver section of the frame.
Make sure this area is undamaged and replace if unit
has been jackknifed or there is indications of fatigue
in this area.
• Check all guards to make sure they are undamaged,
in place and properly secured, including the chip
deector curtain.
• All decals and placards must be in place and legible
prior to operating the chipper.
Important Checks
The following checks should be performed prior to leav-
ing the storage area. A Daily Preoperational Checklist is
provided in the Appendix.
• Check engine fuel, coolant, and oil levels (EOM).
• Lubricate cutter bearings and feed roller bearings, if
applicable.
• Check the engine air lter (EOM).
• Check radiator ns and ensure free passage of air
through the radiator.
• Check hydraulic uid level. When the system is cold,
the uid must be between 2” to 3” (5.08 to 7.62 cm)
from the top of the tank or within the sight gauge, if
applicable.
• Check feed roller for debris.
• Check the transition area for debris that could lock
the drum or disc during start up.
• Make sure the safety devices are properly installed
and functioning properly.
Section 4 — Before You Operate… • 19
Page 25
• Make sure the chip curtain is properly fastened and
in good condition.
• Make sure the folding feed table is in place and
secure for both operation and travel.
Warning
Death or serious injury can result from being trapped
between moving components. Maintain a safe distance from the tow vehicle and the chipper.
• Verify that there are no loose tools or materials on
the chipper or on the infeed chute.
• Make sure the tires are properly inated and wheel
lug nuts torqued to the proper value in the Fastener
Specic Torque Application Chart in the Appendix.
• Verify proper operation of the panic bar.
• Inspect the hydraulic system and look for signs of
leaks or wear. Leaks shall be corrected, worn components replaced and the hydraulic level checked.
Danger
Death, serious injury, or property damage can result
when attempting to access moving components.
Make sure components have come to a complete
stop before performing inspection or maintenance.
Never open the drum hood while the drum is in motion.
Hitching to Tow Vehicle
Warning
Death, serious, or property damage can result from
uncontrolled movement of the chipper and/or tow
vehicle. Properly hitch chipper to tow vehicle, verify
the road-worthiness of the chipper and tow vehicle,
and verify all equipment is properly stowed. Check
the tow vehicle’s operating manual for rated towing
capacity.
Never stand between the tow vehicle and the chipper
while the tow vehicle is backing. Make sure the tow
vehicle is securely parked and the driver notied before
approaching the area between the chipper unit and the
tow vehicle.
Do not tow the chipper unless all the important checks
listed are satisfactorily completed.
• Chipper secured to tow vehicle and safety pin/latch
or hitch locking devices secured.
• Secure jack stand in the travel position.
Warning
Death, serious injury, and/or property damage can
result from uncontrolled movement. Check and
adjust for proper weight distribution when towing
the chipper.
• Chipper frame must be level or the tongue slightly
lower than the rear of the chipper while towing to
make sure proper weight distribution. The hitch height
may have to be adjusted when towing with vehicles
of varying hitch height.
• For proper towing weight distribution make sure the
discharge chute is properly secured in the forward
pointing position, if applicable.
• Make sure the folding feed table is secured in its
closed position.
Caution
Injury can result from being pinched or trapped between moving components. Keep hands clear.
The chipper and tow vehicle, as well as the hitch and
receiver create pinch points. Stay clear of these points
during all operations and be aware as they change during
movement of vehicles.
Caution
Injury can result when attempting to lift the chipper.
The chipper tongue weight is too great for one person
to lift safely.
20 • Section 4 — Before You Operate…
• Safety chains installed properly.
a. Route chains under trailer tongue in an X pattern
between tow vehicle and trailer.
b. Adjust slack in chain to permit turning but not
dragging on the ground.
c. Make sure that the chains and connection points
are secure and undamaged.
• Connect trailer wiring to the tow vehicle and make
sure all trailer lighting is operating properly.
• Make sure that the safety breakaway switch is functioning properly and attached securely to the tow
Page 26
vehicle. Allow enough slack to make sure vehicle
turns will not activate the safety breakaway switch.
To Minimize Health Risk
• Avoid prolonged breathing of vapors.
• Make sure the tow vehicle has a properly adjusted
brake controller. Refer to the brake controller’s op-
erating manual for proper operating, adjusting, and
maintenance information.
• Check the general condition of the tires, tire pressure
and make sure all lug nuts are securely fastened.
• Verify there are no loose tools or materials on the
chipper or in the infeed chute.
• Check all cones, wheel chocks, signs, or other support tools and materials to ensure proper stowage.
Fueling Chipper
Fill the fuel tank at the end of each work shift leaving a
gap at the top of the tank for expansion of fuel. A full tank
will not only maximize the work shift but will also reduce
the possibility of condensation forming in the tank and
moisture entering the fuel lines.
Warning
Death, serious injury, and/or property damage can
result from improper handling and storage of fuels.
Gasoline and diesel fuel are highly ammable. Exposure to gasoline or diesel fuel liquid or vapor can
adversely affect health.
To Avoid Fire
• Turn off all ignition sources (chipper and tow vehicle).
• Keep fuel away from any ame or spark.
• Discharge potential static electric charge buildup by
touching chipper metal away from fuel tank with your
hand prior to touching the fueling nozzle to the fuel
tank.
• Do not smoke.
• Keep face away from nozzle and fuel tank.
• Keep away from eyes and skin.
• Never siphon by mouth.
Controls
Danger
Death or serious injury will result from careless or
improper use of the unit. Do not operate the unit
without proper training.
All operators must be properly trained.
Always make sure the PTO is disengaged before starting the engine.
Always make sure the hydraulic feed roller feed control
bar is in its neutral position before starting the engine.
Always make sure all guards are in place and properly
secured.
Caution
Property damage can result from improper engine
operation. Refer to the Engine Operations Manual
before starting the engine.
Feed Roller Operation
The feed roller(s) is controlled by pushing or pulling the
feed control bar which is located on the top and both
sides of the infeed chute. The three control positions
are as follows.
Reverse – activates the rollers to push material out of
the chipper cutting zone.
Neutral – stops movement of the feed rollers.
Feed – pulls material into the chipper cutting zone.
Warning
Death or serious injury can result from breathing
engine exhaust. Engine exhaust and some of its
constituents are known to the State of California to
cause cancer, birth defects, and other reproductive
harm.
Warning
Death or serious injury can result if controls are not
operating properly. Do not operate the chipper if the
components are damaged or do not operate smoothly,
completely, and without binding.
Section 4 — Before You Operate… • 21
Page 27
Neutral
Reverse
Figure 4.1 — Feed Roller Control Arm Movement
PTO/Clutch Engagement
Warning
Death or serious injury can result from being trapped
between moving components. Maintain a safe distance while components are in motion.
Feed
Remove ignition keys, remove negative battery cable
and lock battery box. Follow OSHA statute 1910.147 for
proper lock-out procedures.
Do not leave the chipper unattended until all movement
of the engine disc/drum has stopped.
The drum/disc and drive system will continue to rotate
after the engine has stopped and the clutch has been
disengaged.
Do not attempt to perform service on the PTO, engine
or chipper head until all movement has come to a complete stop.
Engage
Disengage
Power Take-Off (PTO)
Clutch Assembly
Figure 4.2 — PTO/Clutch Engagement
Notice
Figure 4.2 shows a Stein PTO. The PTO supplied
with the chipper may operate in a different manner.
Please familiarize yourself with the proper operation
of your PTO prior to chipper operation.
1. Verify infeed chute and feed roller areas are free
from materials.
22 • Section 4 — Before You Operate…
Page 28
Warning
Death or serious injury can result from airborne
materials. Make sure no personnel are in the path of
material that might be discharged from chipper.
2. Verify discharge chute is properly directed and secured. Materials left in cutter housing or discharge
chute may discharge during clutch engagement and
rpm run-up.
3. Engine rpm should be at approximately 1,000 rpm or
the engagement setting on xed position throttles.
4. Slowly engage the clutch. Stop if any unusual sounds
are heard. Investigate prior to proceeding.
5. After engine has stabilized at the engagement rpm,
slowly increase engine rpm to the preset operating
speed.
Notice
Equipment damage can result when attempting a
clutch engagement with a plugged cutter housing or
discharge chute. Never attempt to unplug a chipper
using rapid or repeated clutch engagements.
Work Site Preparation
Warning
Death or serious injury can result from improper
chipper setup or work site preparation.
When unhitching the chipper from the tow vehicle,
conrm the chipper wheels are blocked. Make sure the
jack stand is undamaged and properly congured to
support the weight of the chipper. Damaged jack stands
should be replaced before supporting the chipper. Do
not operate the chipper without being properly hitched
to the tow vehicle.
The chipper tongue weight is too great for one person to
lift safely. Serious muscle strains can result if attempted
alone. Get help when hitching and unhitching the chipper.
Never stand between the tow vehicle and the chipper
while the tow vehicle is backing. Make sure the tow
vehicle is securely parked and the driver notied before
approaching the area between the chipper unit and the
tow vehicle. Coordinate signals with all personnel to
ensure accurate communication.
FeedSense® (Electronic Feed Control)
Maintaining proper operating rpm is a critical part of ef-
cient chipper operation. If rpm is allowed to fall below
design parameters the velocity of discharging chipped
material will fall, resulting in discharge chute clogging.
The FeedSense® system automatically controls rpm
through control of the hydraulically driven feed roller(s).
When the system is on, the controller senses cutter speed.
When the cutter drops to a preset minimum rpm, the feed
roller(s) is temporarily stopped until the engine recovers
to its preset operating rpm. After engine recovery, the
FeedSense® automatically begins the forward feeding
process and continues as long as rpm is maintained
above the low set point.
Warning
Death or serious injury can result from unexpected
movement. Material will advance automatically when
the FeedSense® is activated.
After material has been engaged by the chipper always
stay clear of possible entanglement hazards.
Make sure the discharge chute is properly directed and
locked in place.
Prior to starting the engine, check the infeed chute to
make sure it is clear of foreign material such as wrenches,
axes, etc.
Organization and preparation of the work site and brush
is a major factor in safe chipper operations.
Operating personnel must observe the following points
to ensure safety.
• Work sites should be clear of vehicle and pedestrian
trafc.
• Signs, cones, ropes, barriers, and/or agmen may be
required to provide adequate warning and diversion
of automotive and/or pedestrian trafc.
• Do not operate the chipper beneath a potential drop
zone and verify that no one is performing work overhead of the chipper or chipper work zone.
• Provide a clear area on the curb side of the chipper
to allow the operator to maneuver while feeding the
chipper.
Section 4 — Before You Operate… • 23
Page 29
• Position the chipper in an area free of ammable
materials to reduce the risk of starting a re from
sparks emitted from the engine exhaust or heat.
or be drug into the chipper with the brush. Ropes,
especially climbing ropes attached to someone, can
result in death or serious injury.
Danger
Death or serious injury will result from contact with
or proximity to equipment that has become electrically energized. Maintain safe clearances from all
energized conductors and any grounded device,
material, or equipment.
An electrically energized tow vehicle (such as an aerial
device or crane) can also energize the chipper and will
cause death or serious injury. Never approach a chipper
that is connected to a vehicle operating in the proximity
of power lines.
• Conrm that all operators are wearing the proper
clothes and personal protective equipment.
• Restrict all personnel, except the operators feeding
the chipper, from the feed and discharge areas of
the chipper.
Warning
Death or serious injury can result from airborne
materials. Make sure no personnel are in the path of
material that might be discharged from chipper.
Make sure pedestrian trafc, spectators, or any other
personnel not operating the chipper are prevented from
entering the work area around the chipper, or the chipper operational area. Secure and maintain an adequate
work zone to make sure that material being fed, ying
debris, and chips can not come in contact with those not
operating the chipper.
The action of chipping produces projectiles such as chips
and unchipped debris (sticks, limbs, brush, etc.) that can
cause serious injury from both the discharge chute as
well as the infeed chute.
• Set the chipper up on level ground with no stumps
or trip hazards in the loading area. During chipper
operation keep the loading area free of limbs, tools,
or other objects which may become a trip hazard.
• Conrm all operators are properly trained, have read
and understand all placards and decals, and are
authorized by the employer.
• Make sure that all tools, ropes, and other work related objects are clear of the chipper and the chipper operational area and cannot come into contact
Notice
The chipper operational area is the area around the
chipper that has the potential for ying debris from
the discharge chute or infeed chute and has the
potential for material to be engaged by the chipper
or to be fed by an operator into the chipper (material
being dragged to the chipper).
Brush Preparation
Warning
Death, serious injury, and/or property damage can
result from feeding material that is not wood into
the chipper. Inspect all material before it is fed into
the chipper.
Inspect brush for non-wood material such as anything
made of metal, glass, or stone. Feeding such materials
into the chipper will not only damage the cutting blades,
they can even shatter, scattering blade fragments.
Remove vines from the material being chipped and dispose of properly. Do not leave vines in the area around
the chipper and do not attempt to place vines into the
chipper. Material clothing or personnel entangled in vines
can result in death or serious injury. Vines may hide
foreign materials that can cause property damage.
Inspecting and organizing the brush prior to chipping
will allow the job to be performed more efciently and
provide added safety in performing the job by minimizing
the danger of foreign material, vines, etc., from entering
the chipper. Pretrimming and proper delimbing will allow
the brush to be drawn easily through the chipper.
• Arrange trees, tree limbs, or brush with the cut ends
facing the chipper infeed chute.
• Do not cut the trees, tree limbs, or brush into short
pieces, i.e., short logs or sticks.
• Do cut the trees, tree limbs, or brush into the longest
lengths that can be safely and easily handled. This will
reduce the number of pieces of material that have to
be handled and fed into the chipper and will reduce
the time required to perform the job. Cut wood at an
angle to help ease the feed roller open and facilitate
feeding. Chipper performance is best when the feed
wheels are securely gripping the material as it is
feeding into the cutter.
24 • Section 4 — Before You Operate…
Page 30
Caution
Injury can result from improper handling of materials. Do not attempt to lift material that is too heavy
to be lifted safely.
Warning
Death or serious injury or property damage can result
from airborne objects. Make sure all guards are in
place before operating the chipper.
Be sure to cut all trees, tree limbs, and brush into lengths
that can be safely handled by the operating personnel
available.
Notice
Know the limitations of the chipper. Never attempt
to feed material too large for the chipper. Always
precut large crotches to ensure adequate clearance
through the transition area.
When preparing large material for feeding the chipper,
properly trimming the crotches will greatly reduce the
amount of downtime clearing transition/feed roller jammed
materials. Either clear cut the limbs off the largest material
to be chipped, or courtesy cut partially though the limbs
which will allow the smaller limbs to fold back during the
chipping operation.
Consider the total width when utilizing a courtesy cut.
The total width will include the diameter and radius of
the bend of limbs as they fold back during the feeding
process. Exceeding the opening size can result in lodging
of material in the transition area.
Never start the engine with the drum hood open.
Before starting the engine, check the infeed chute to
make sure it is clear of any foreign objects and that the
discharge chute is directed away from personnel.
Notice
Disengage the clutch and place the feed control bar
in the center neutral position. Never force the clutch
lever. You can damage the linkage. Make sure the
clutch handle has adequate free play before operating.
Never engage the starter for more than 30 seconds continuously. Allow two minutes between attempts to start.
This will allow the starter to cool down.
Notice
Engine life will be signicantly increased by allowing
the engine to operate at a fast idle for 7 to 10 minutes
before engaging the clutch.
The greatest amount of wear to an engine occurs when it
is rst started and is cold. The lubricating oil has drained
back into the oil pan and does not ow freely to the entire
engine when rst started. To achieve the greatest life
from your engine, do not operate at high speed or heavy
loads until the engine has warmed up.
Clear Cut Courtesy Cut
Figure 4.3 — Type of Cut
Starting the Engine
Danger
Death or serious injury will result from careless or
improper use of the unit. Do not operate the unit
without proper training.
You must read and understand the entire Operator’s
Manual and all safety decals/placards prior to operation
of the chipper.
Refer to EOM supplied with the chipper for specic start-
up, operational, and maintenance instructions.
Engaging/Disengaging the Cutter Head
Engaging
Warning
Death or serious injury can result from airborne
materials. Make sure no personnel are in the path of
material that might be discharged from chipper.
Caution
Injury can result from potential hazards of operating
and being in the operational area of this unit. Wear
appropriate safety equipment.
Section 4 — Before You Operate… • 25
Page 31
Make sure that all personnel and individuals, not actively
involved in the chipper feeding process, are removed from
the chipper operational area and all personnel within the
chipper operational area are notied before starting the
engine on the chipper.
Notice
Failure to properly engage the PTO can damage the
drive system and the PTO, which will not be a warrantable repair.
1. When the engine has reached operating temperature
and is running smoothly at 1/4 to 1/3 throttle, slowly
engage the clutch. Engaging the clutch too quickly
or slowly can cause excessive clutch wear. During
clutch engagement the operator must ensure clutch
shaft movement. If no movement is heard or seen
stop and investigate immediately. The ideal rate of
engagement will cause the cutter to rotate up to
speed without causing the engine to lose speed or
stall. If any unusual sounds or noises are heard stop
engagement and investigate immediately.
Figure 4.4 — Rotational Indicator
3. When the engine and drum reach idle speed, disengage the clutch.
4. Turn off the ignition switch and remove the key.
2. With the clutch fully engaged and the engine running
smoothly, set the throttle control to its maximum setting to bring the cutter up to the factory set cutting
speed.
Notice
Always operate the chipper at full factory throttle position. The maximum throttle setting is factory preset.
This provides maximum efciency of the chipper.
Tampering with the engine speed governor can cause
property damage and will void the warranty.
Disengaging
Warning
Death, serious injury, or property damage can result
when attempting to access moving components.
Make sure components have come to a complete stop
before performing inspection or maintenance.
Caution
Injury can result from being pinched or trapped between moving components. Keep hands clear.
1. Disengage the hydraulic feed system by moving the
feed control bar to the neutral or center position.
2. Reduce engine speed to idle.
After the engine has stopped and the clutch has been
disengaged, the cutter and drive system will continue to
rotate, making the hydraulic feed system operational.
Do not remove guards, attempt repairs, or leave shipper
unattended, until the cutter and drive system have come
to a complete stop.
5. Engage the clutch and inspect the rotation indicator
on the cutter and belt at the clutch output shaft to
make sure there is no movement in the drive system.
Feeding Brush to the Chipper
Danger
Death or serious injury will result from careless or
improper use of the unit. Do not operate the unit
without proper training.
Feeding brush, limbs, and trees into the chipper is a
potentially dangerous task. It requires constant attention,
proper training, authorization by the employer, and an
awareness of the dangers associated with this unit.
Following the procedures outlined in this manual prior to
operation, reading the entire manual, proper training, safe
operations, preparation for operation, proper equipment
and clothing, work site preparation, and brush preparation will reduce the risk of injury. However, every situation
and action cannot be anticipated by Altec Environmental
Products. All operators must use common sense and
be constantly aware of the surroundings and situation.
26 • Section 4 — Before You Operate…
Page 32
Trafc, coworkers, spectators, debris, brush, and other
equipment constantly change the hazards so constant
awareness and adaptation to those changes must be
practiced. Placing yourself, or others into a dangerous
situation, being careless or simply not paying attention
can result in death or serious injury.
Never place hands, arms, legs, or feet into the infeed
chute.
Never attempt to push material into the infeed chute using your hands or feet.
bar and start the material again. Make sure the throttle
is completely advanced to the factory preset setting to
ensure proper operation of the FeedSense®.
Make sure the chip deector curtain is in proper condition, in place, and secure. This device is provided to stop
or reduce the velocity of any kickbacks during chipping
operations.
During chipping operations, never position yourself directly behind the infeed chute. Brush or debris can be
kicked back or up without warning.
Do not use any item with metal components as a tool
to push brush into the cutter mechanism. Blade failure
can occur and cause violent discharge from the cutter
mechanism causing death or serious injury. Only materials which are being chipped should be used as push or
drag tools.
• Feeding brush to the chipper involves a technique
that requires a smooth continuous motion. Place the
prepared brush on the feed table, push it into the
throat of the cutter housing, and then move quickly
to the curb side of the chipper.
• Please follow the procedures and safety designations
listed below.
Notice
Make sure the brush is not too large for the machine.
Placing material that is too large for the opening can
result in clogging or jamming of the material.
The operator shall stand to the side when operating the
chipper. Material in the transition area could be kicked
back while positioning the material into the infeed chute.
In the event there is debris in the transition, use another
piece of wood to clear the transition area before standing
behind the infeed chute with the feed roller in a raised
position.
While feeding the chipper it is common for material to be
suddenly and violently kicked up or to the side. Never
stand or position yourself directly above or beside mate-
rial while being fed. Once material is engaged, quickly
move away from the material.
On equipment with FeedSense®, special care must be
taken since the material starts and stops at intervals
without warning. Never approach the material once it
has become engaged by the feed roller. In the event
that material has not advanced in a reasonable amount
of time, reverse the material completely with the control
Do not feed material while another operator is between
you and the infeed chute. Only one operator should feed
the unit at any given time.
Never attempt to lift material that is beyond your lifting
capabilities and incorporate proper lifting techniques to
avoid injury.
Improper use of cranes, winches, and tractors to load
material can result in death or serious injury and can severely damage the equipment. The use of these types of
lifting tools should be operated by experienced personnel
that are trained in their proper use, understand the limita-
tions of the chipper, can comprehend the ramications
and dangers of improper use and have been authorized
by the employer to perform these procedures. Damage to the equipment through the use of non-attached
or improperly used lifting devices may not be covered
under the warranty.
Do not feed crotches or multiple pieces of wood that can
become a pinch point during feeding.
Do not lean, stand, sit, or permit others to lean, stand, or
sit on the feed table during chipping operations.
Never reach into or lean over the feed table or into the
infeed chute.
Keep the working area clear of limbs and debris. Tripping
or entanglement can allow the operator to be dragged
into the chipper.
Do not throw clean up sweepings into the cutter mechanism. Foreign material such as stones, wire or metal
scrap can cause blade failure.
1. Position the cut end of the brush toward the feed
table. Approach the feed table from the curb side at
an angle that will not position you directly in front but
to the side of the feed table to avoid brush kickback
and trafc hazards.
Section 4 — Before You Operate… • 27
Page 33
1. Feed the cut end of the
brush into the chipper.
3. Quickly turn face away.
3
2
2. Release.
1
4
Motion Path
4. Keep moving.
Figure 4.5 — Proper Brush Feeding Technique
2. Place the brush on the feed table and feed the cut
end toward the throat of the cutter housing. Release
the brush before the hydraulic feeding mechanism
fully grabs it and hydraulic auto-feed begins. Smaller
pieces of brush may be thrown in on larger pieces
being pulled.
3. As the brush begins to self-feed, quickly turn your
face away from the chipper.
4. Keep moving quickly forward and to the curb side of
the feed table and do not wait for the brush to nish
feeding. The distinctive sound of the chipper cutting
will conrm proper operation.
5. If the hydraulic feed wheels fail to grab and self-feed
the brush, use a separate piece of brush to push
28 • Section 4 — Before You Operate…
the stalled brush toward the cutter until it begins to
self-feed. Never position yourself directly behind the
feed table during this operation. Stand to the curb
side of the table.
6. Do not attempt to feed or re-feed small pieces of
brush which remain on the feed table. Reserve a
large piece of brush as the last piece to be fed to
the chipper. This will clean up any small pieces left
on the feed table.
Notice
Some chippers may be equipped with push paddles.
Employers/owners with this option must make sure
that all operators are instructed as to the following
special requirements involved with its use.
Page 34
7. Instruct operators to grip the handle with a relaxed
grip and to release if entrapped in brush or feed roller.
the chipper. Inspect all material before it is fed into
the chipper.
8. Replace damaged or missing pusher. Do not use
the paddle to push rakings that may contain rocks,
metal or other non-wood materials.
Warning
Death or serious injury can result if proper feeding
techniques are not followed. Never place any part
of the body including hands, arms, face, or torso
above a piece of material that is being engaged into
the feed rollers.
Material can be violently kicked up or shifted causing
direct impact or entrapment between the material being
fed and the chipper infeed chute.
Always remove the cable assembly prior to feeding material into the chipper.
Warning
Death or serious injury can result from personnel
entanglement or crushing. Always make sure personnel are aware of cable/material location and changing
pinch point hazards.
Safety
Wear all personal protective clothing and equipment
as designated by your company policy, OSHA, or other
governing organizations.
Make sure you place yourself and coworkers in proper,
safe positions while hoisting. Always increase chipper
operational area during winch operations. While hoisting always be aware of the pinch points between hand,
foot, and body with the cable, wood and between towed
object and any xed objects. These pinch points are
constantly changing during the hoisting operation. Cable
may create loops on the ground. Caution must be taken
to avoid entrapment in these loops. Never pull with tow
vehicle using the cable as a dragline. Always attempt to
pull from directly behind the chipper. When not in use
always properly stow hook and cable out of the feed zone
area. Chipper must always be properly hitched to the tow
vehicle and the vehicle must be properly chocked in place.
Figure 4.6 — Releasing the Material
Slide large material along bottom of infeed chute from
the rear pushing it into the chipper feeding rolls. Release
material as soon as it engages with the rolls.
Winch Safety and Operation
(Optional Equipment)
Read and understand the entire manual prior to operation
of the chipper or the winch.
Danger
Death or serious injury will result from careless or
improper use of the unit. Do not operate the unit
without proper training.
Only those properly trained and authorized by the employer shall operate the winch.
Warning
Death, serious injury, and/or property damage can
result from feeding material that is not wood into
Daily Inspection
Inspect winch line, hook assembly, and winch structure
for damage or excessive wear prior to use. Ensure proper
operation of winch controls. Cable must be inspected for
broken/worn strands, or other physical damage which
would degrade the operational load capacity. The hook
must be inspected for wear and deformation such as
hook opening spread. Winch structure must be inspected
for structural deformation, cracked or broken welds and
proper fasteners in place and tight.
Operation
Place panic bar in the non-operational position. This will
stop feed roller movement, and allow the winch and lift
cylinder to continue operation. The winch control valve
is located on the curb side of the infeed chute. Always
keep tension on the cable while unspooling. Have an
assistant walk the cable out to the desired location.
Secure the cable to the material to be chipped 2’ to 3’
(61 to 91.4 cm) from the end. This will allow you to place
the end of the material on the infeed chute. After hoisting
the material to the desired position. Remove the cable
and secure the hook in the storage position putting slight
Section 4 — Before You Operate… • 29
Page 35
tension on the cable to remove any slack in the cable/
hook assembly. To begin chipping, reposition the panic
bar into the operational position.
Notice
Use of a separate choker strap or rope will extend
the life of your winch cable.
30 • Section 4 — Before You Operate…
Page 36
Section 5 — Clearing Feed System and Discharge Chute
Feed System
Warning
Death or serious injury can result if proper feed roller
clearing procedures are not followed. Only personnel that have been properly trained, understand the
dangers, and are authorized by the employer may
perform this operation.
Caution
Injury can result from being pinched or trapped between moving components. Keep hands clear.
Never attempt to pry open the feed rollers. Rollers must
only be opened using either the lift cylinder or the Altec
Environmental Products supplied jack.
Always be aware of pinch points during the lifting operation. These dangerous pinch points are changing during
the lifting operation. Never place any part of your body
between the feed rollers.
Extreme care must be taken when removing material or
performing service in the feed roller area.
Never place any part of the body into the feed roller area.
Use a stick or other nonmetallic object to clear this area
of debris.
2. With the drum at operational speed, attempt to load
another log into the feed rollers. This action may
advance the jammed material.
3. With the drum at operational speed, attempt to load
brush on the top of the jammed material. This action
may advance the jammed material.
4. If equipped with a lift cylinder, raising or lowering the
cylinder may advance the material.
Raising the Feed Roll Assembly
1. Move feed roller control arm to the neutral position.
Make sure the feed rollers have come to a complete
stop.
2. Using the lift cylinder valve, raise the upper feed roll
assembly to its maximum position.
3. Install the upper feed roll lock pin into position (refer
to Figure 5.1).
Feed Roll Lock Pin
in Pinning Location
Lock Pin Storage
Location
Feed Roll
Lift Cylinder
Extreme care must be taken when removing material or
performing service in the transition chute area. Before
beginning any procedure make sure all movement of the
engine, disc, and feed roller have come to a complete
stop. Remove keys from the ignition and place in pocket.
Complete LOTO procedures.
Always make sure the feed roller assembly is secure
before attempting maintenance in the feed roller/transition area.
Never reach into or place any part of the body into the
transition chute.
Always use appropriate tools to remove jammed materials. Never reach into the infeed chute.
In the event of material jammed between the feed rollers
and the disc, attempt the following actions before attempting the mechanical actions contained in this section.
1. Push forward on the control bar to attempt to reverse
the material backward.
Figure 5.1 — Feed Roll Lock Pin
4. Turn engine off and remove keys.
5. Remove negative battery cable.
6. Lock battery box.
Warning
Death, serious injury, or property damage can result
when attempting to access moving components.
Make sure components have come to a complete stop
before performing inspection or maintenance.
7. Make sure all movement of drive components and
cutter assembly have come to a complete stop.
8. Using appropriate tools remove any material interfering with the rotation of the cutter mechanism.
Section 5 — Clearing Feed System and Discharge Chute • 31
Page 37
9. Reconnect battery cable.
10. Restart engine.
11. Return upper feed roll to the normal operating position.
Warning
Death or serious injury can result if the upper feed
roller is not returned to the proper position. Do not
feed material into the chipper with the upper feed
roller in the locked open position.
Discharge Chute
Warning
Death or serious injury can result if proper discharge
chute clearing procedures are not followed. Only
personnel properly trained and authorized may perform this operation.
Never operate the chipper with the discharge chute
removed or material jammed in the chute.
Never attempt to clear the discharge chute while the
chipper is in operation.
Always make sure the engine is shut off and all drive and
cutter components have come to a complete stop.
Complete LOTO procedures.
Always use proper hoisting equipment.
5. Check drum housing/chute transition and clean out
if necessary.
6. Reinstall discharge chute.
Notice
PTO or drive train may be damaged from chute plugging or attempting to start the chipper with obstructions in the drum housing or discharge chute. This
damage is not covered under the chippers warranty
policy.
There are many factors contributing to discharge chute
clogging. Most of these factors are controllable through
proper maintenance and operator training.
Listed below are the most common problems associated with chute clogging and the suggested corrective
action.
Stringy Chip Discharge
• Dull or damaged blades. Change blades.
• Dull or damaged anvil. Change anvil.
• Incorrect anvil/blade clearance. Adjust to proper
gap.
• Improperly sharpened blades.
Poor Chip Discharge Velocity
Engine must operate at the maximum factory preset gov-
ernor speeds. During operation the engine speed must
not be permitted to drop more than 200 to 300 rpm. For
chippers not equipped with FeedSense®, engine speed
is controlled by using the control bar and through proper
brush preparation and feeding techniques.
The plugged discharge chute can weigh more than 200
pounds (90.7 kg). Use appropriate hoisting equipment
when removing the chute.
1. Attach hoisting equipment to chute.
2. Unbolt the split ring attachment bolts. Remove the
split ring.
3. Using the hoisting equipment remove the chute.
4. Use appropriate tools to unplug the chute.
32 • Section 5 — Clearing Feed System and Discharge Chute
A clogged, or partially clogged, discharge chute may also
cause poor chip discharge velocity. Make sure the chute
is clear of all obstructions.
Chipping Leafy or Wet Materials
Feed chipper slower than dry material and mix large
heavier limbs with leafy wet material to purge the drum
housing and discharge chute of smaller wet materials.
Drum Speed Slows But Engine rpm Remains High
• Make sure belts are properly adjusted and belt or
• Make sure the clutch is properly adjusted.
pulleys are not worn.
Page 38
Section 6 — Care of the Unit
Warning
Death, serious injury, and/or property damage can
result from improper maintenance of the unit. Do
not perform maintenance procedures on this unit
without proper training.
Notice
Use the checklists in the Appendix as daily, weekly,
monthly, and yearly guides for preventive maintenance.
The following engine information is general in nature
and applies to some of the popular engines available
for the chipper. For specic information please refer to
your EOM.
Warning
Death or serious injury can result from unexpected
movement. Follow the lock-out tag out procedure
before accessing internal components of the unit.
Death, serious injury, or property damage can result
when attempting to access moving components.
Make sure components have come to a complete stop
before performing inspection or maintenance.
Remove keys from the ignition switch and place in
pocket.
Never reach into the engine cowling or within the engine
panels with the engine running.
Caution
Injury can result from contact with engine components that are hot. Use caution when accessing
the engine cowling or in the vicinity of the engine
exhaust.
Engine Coolant
Caution
Injury can result from contact with engine components that are hot. Use caution when removing the
radiator cap.
Never check the coolant when the engine is hot. Allow
the engine to cool down rst. Refer to the EOM for proper
procedures. Always make sure proper eye and hand
protection is worn when servicing the coolant system.
Check the coolant level before starting the engine at the
beginning of each work period. The coolant level should
not be less than 1” (2.54 cm) below the top of the radiator upper tank. Refer to the EOM for proper coolant and
mixture ratio.
The engine radiator can quickly become plugged with
wood particles. This will cause improper engine cooling,
and may cause extensive damage to your engine. Many
factors contribute to the buildup of wood particles in the
radiator. The main contributor to radiator plugging is
buildup of airborne particles in the engine radiator area.
Directing chipper discharge downwind of the engine
radiator area, discharging into a chip body, and using
chip body screens or canvases will greatly reduce this
condition. Proper belt condition and coolant mix-ratio/
level are also critical to proper engine cooling. The radiator should be inspected and cleaned on a daily basis
using compressed air only. Do not use water to ush the
coolant ns of the radiator. Any wood particles left from
a water ush will harden and become extremely difcult
to remove.
Notice
Improper radiator maintenance can result in engine
damage that will not be covered under the engine
warranty.
Engine Oil
The engine oil level should be checked each day or when
the engine has been operated for 10 hours, whichever
comes rst. It is preferable to check the oil level after the
engine has been stopped for a period of time. This allows
the oil in the upper section of the engine to drain down
into the oil pan. This will allow you to obtain an accurate
measurement of the level of oil in your engine. If the level
is low, refer to your EOM for the recommended viscosity
and type of oil for your engine.
Change the engine oil and lter according to schedules
and instructions provided in your EOM.
Engine Air Filter
Due to the varying degrees of dust produced during the
normal chipper operation, it is critical to the life of your
engine to maintain a clean air lter. Do not hit the lter
against an object to clean the lter. Check your lter
weekly and clean or replace as specied in your EOM.
Failure to properly maintain the engine intake system
and lters can quickly decrease the engine’s effective
horsepower and cause engine failure. Failures due to
improper air intake system maintenance are not covered
under engine warranty.
Section 6 — Care of the Unit • 33
Page 39
Clutch and Power Take-Off (PTO)
The PTO clutch mechanism is supplied by the engine
manufacturer. It is very important to lubricate the PTO
bearings, clutch levers, and linkage. For specic informa-
tion and lubrication interval requirements refer to your
clutch/PTO owner’s manual. Proper inspection, operation,
and maintenance of the clutch will greatly increase the
useful life of the chipper clutch. Improper operation or
maintenance of the clutch will void clutch warranty.
at the terminals. If found, mix two tablespoons of baking
soda to one pint of water and apply with a small brush
to terminals. When nished, be sure to ush the surface
of the battery with water. Remove any excess water and
coat the terminals with light grease or petroleum jelly to
reduce the possibility of corrosion forming. Also check
the battery cables for wear and all cable connections and
battery tie downs to be certain that they are not loose.
Fasteners
Inspection
• Verify all cap screws, pins, and linkage components
are in good condition and properly tightened.
• Verify adequate free play on the clutch handle/linkage
assembly. With the clutch in the engaged position
(handle vertical) there should be approximately 1”
to 11/2” of free play at the end of the handle without
pressure being applied to engage the clutch.
• Without proper free play, premature failure of the
clutch will occur.
Notice
Damage resulting from improper clutch adjustment
will not be covered under warranty. Refer to PTO owner’s manual for detailed adjustment procedures.
1” to 11/2”
Fasteners should be visually inspected on a daily basis,
physically torqued weekly for the rst 30 days of operation
and monthly thereafter. All fasteners must be in place at
all times and properly torqued. Torque values are given
for specic fasteners where applicable. For fasteners in
general, refer to Torque Values in the Appendix.
Tires and Wheels
Refer to tire manufacturer specication for proper tire
ination. Make sure tires are in good condition. Tire ina-
tion pressure can be found on the tire.
Torque wheel lug nuts to the value in the axle owners
manual.
Tongue and Hitch
Warning
Death, serious injury, and/or property damage can
result from towing the chipper with a damaged hitch
or tongue tube. Thoroughly inspect the hitch and
tongue tube before towing the chipper. Make repairs
as necessary.
Figure 6.1 — Clutch Free Play
Battery
Caution
Injury can result from exposure to battery acid. Wear
appropriate safety equipment.
After 100 hours of operation or once per month, whichever
occurs rst, inspect the battery for accumulated corrosion
34 • Section 6 — Care of the Unit
Damage as a result of jackkning the chipper may
require the removal of the tongue tube (on units with
removable tongue tubes) from the frame for a thorough
inspection.
• Inspect tongue and hitch cap screws for wear or
elongation of the mounting holes.
• Grease all contact and moveable components of the
hitch.
• If tongue or hitch show any wear they must be repaired or replaced immediately.
Notice
Always utilize a spotter when backing to prevent
jackkning and the serious damage that will result.
Page 40
Chipper Electric Braking System
The primary activation of the braking system is through
the brake controller of the tow vehicle to the electrical
chipper/tow vehicle connection through the chipper
wiring harness and into the electrically operated brake
assemblies. A secondary system starts with the chipper
battery through the breakaway switch, chipper wiring
harness and into the electrically operated brake assemblies. This secondary system is only operational when
the breakaway switch is activated. This system should
never be activated except for testing or in an emergency
chipper/tow vehicle separation.
Brake Adjustment
Adjust brakes at the following intervals. Refer to the axle
owners manual.
• After the rst 200 miles of operation when the brake
shoes and drums have seated.
• At 3,000 mile intervals.
• As use and performance requires.
Hinge and Friction Points
Chipper operation and longevity can be improved by
keeping all hinges and friction points lubricated. Altec
Environmental Products, LLC recommends that lubri-
cation be performed weekly. Use SAE 30 weight oil on
hinges and a premium grade, high temperature lithium
based EP #2 grease on friction points.
Drum and Feed Roll Bearings
Lubricate daily with a premium quality NLGI #2 grade
multipurpose roller bearing grease. Some suggested
greases are: Mobile Mobilith AW 2, Shell Alvaina Grease
2, Texaco 1939 Premium RB, Amoco Rykon Premium
Grease #2 or an equivalent. Grease each bearing daily
with three or four pumps using a standard grease gun.
Feed Roller Pivot Points
Feed roller pivot points have a non-greaseable, oil impregnated bushing. Lubrication of these points will inhibit the
designed method of lubrication and may cause excessive
wear of the bushings and shaft.
Notice
Always lubricate bearings and ll fuel and hydraulic
tanks at the end of each work day. This will displace
any moisture in the bearings and tanks. Also lubri-
cate thoroughly prior to any extended shutdown or
storage.
Due to extended use or extreme conditions, additional
maintenance intervals and/or component inspections
may be necessary.
Section 6 — Care of the Unit • 35
Page 41
36 • Section 6 — Care of the Unit
Page 42
Section 7 — Maintenance
This unit is the result of Altec’s advanced technology and
quality awareness in design, engineering, and manufacturing. At the time of delivery from the factory, this unit met
or exceeded all applicable requirements of the American
National Standards Institute. All information, illustrations,
and specications contained within this manual are based
on the latest product information available at the time of
publication. It is essential that all personnel involved in
the use and/or care of this unit read and understand the
Operator’s section of this manual.
Given reasonable care and operation, according to the
guidelines set forth in the manuals provided, this unit will
provide many years of excellent service before requiring
major maintenance.
The scope of this manual is limited to periodic maintenance. It does not cover methods that may be required
to inspect and repair major damage to the unit. Impacts
to and excessive forces on the unit, through vehicular
accidents, rollovers, excessive loading, and the like, may
result in structural damage not obvious during a visual
inspection. If the unit is subjected to such impacts or forces,
a qualied person may need to perform additional testing
such as magnaux or ultrasonic testing as applicable. If
structural damage is suspected or found, contact Altec
for additional instructions.
Warning
Death or serious injury can result from component
failure. Continued use of the unit with hidden damage
could lead to component failure.
Never alter or modify this unit in any way that might affect the structural integrity or operational characteristics
without the specic written approval of Altec Industries,
Inc. Unauthorized alterations or modications will void
the warranty. Of greater concern, is the possibility that
unauthorized modication could adversely affect the safe
operation of this unit, resulting in personal injury and/or
property damage.
Set-up requirements, work procedures, and safety precautions for each particular situation are the responsibility of
the personnel involved in the use and/or care of this unit.
Danger
Death or serious injury can result when performing
maintenance on the unit.
Maintenance personnel must be trained in safe service procedures.
Proper unit maintenance will reduce downtime, lower
operating and repair costs, and extend equipment life.
Safety alone justies a preventive maintenance program.
This type of program is less expensive than making
major repairs.
This section contains information on properly inspecting
the hydraulic system, structures, individual unit components, and lubrication.
Checklists are provided in the Appendix. Use these
checklists when performing routine maintenance and
inspections to make sure no areas are overlooked. Keep
permanent, written, and dated records of all service
performed on the unit.
More frequent maintenance may be necessary if the unit
is operated under severe conditions.
It is essential that all personnel involved in the care of
this unit read and understand the manual. Safety alerts
throughout the manual highlights situations in which accidents can occur. Give special attention to all safety alerts.
The safety information in this section applies only to the
maintenance of this unit. Although procedures have been
written to protect the mechanic and other personnel,
there is no safety system to account for human error or
negligence.
Warning
Death or serious injury can result from careless
or improper use of the unit. The mechanic bears
ultimate responsibility for following all regulations
and safety rules of their employer and/or any state
or federal law.
Work practices may expose maintenance personnel to
hazardous materials. Before using any chemical, read
and understand the manufacturer’s label and the material safety data sheet (MSDS). These sheets explain
emergency and rst aid procedures and waste disposal
methods. Properly dispose of oil and hazardous materials.
Caution
Injury can result from slipping and falling. Use care
and suitable work platforms during maintenance.
Maintenance procedures may require the use of ladders,
platforms, scaffolding, etc., to access the unit. Provide
suitable work surfaces clear of obstructions for mainte-
nance procedures. Do not stand or walk on surfaces that
are not intended as such.
Section 7 — Maintenance • 37
Page 43
General Maintenance Information
• Read and understand the complete procedure before
beginning.
• Remove the pressure in a hydraulic circuit before
disconnecting its components.
• Use lifting devices of suitable capacity to support
and handle components.
• Use a test block to adjust the relief setting on counterbalance holding valves.
• Be aware of your surroundings.
• Fully open all shutoff valves after servicing the unit.
• Complete the required procedures before returning
the unit to operation.
• After completing a procedure, check the oil level in
the hydraulic reservoir and add oil if necessary.
• Many inspections require the removal of covers.
After the inspection is complete, replace the covers
before returning the unit to service.
Equipment Storage
4. Cover or wrap exposed rubber or neoprene parts
with an ultraviolet resistant covering to shield the
parts from sun exposure.
5. Unplug electrical connectors and apply a dielectric
grease or an aerosol product designed for protecting electrical connectors. Plug the connector back
together.
6. Cover switch panels and control panels to prevent
direct intrusion of rain or moisture, while allowing air
to circulate over the panel.
7. While greasing slowly rotate all bearings until new
grease is seen purging from the bearing.
8. Repack axle wheel bearings.
9. Refer to engine manufacturer’s recommendations
on storage procedures.
Mobile hydraulic equipment needs maintenance when
stored, or not used, for extensive periods of time. Depending upon the climate, lack of use may begin to have
a negative effect in as little as two weeks. Storage for a
period of several months will almost certainly produce
some deterioration of the equipment.
Rust will form on unprotected ferrous metal surfaces very
quickly and water will collect inside unit structures. In dry
climates, gaskets will begin to shrink during long periods
of non-use, and lubricants will lose their ability to provide
lubrication. In cold climates, condensation may occur in
uid reservoirs and other components.
Even when protective measures have been taken prior
to storage, some degradation of performance must be
expected when the equipment is put back into use.
Protective Measures
If it is known that equipment will be stored for a month
or more, some steps should be taken to preserve the
equipment.
1. The best preservative is to fully cycle (operate) the
equipment once weekly if even for a short time.
2. Coat exposed ferrous (iron or steel) bare metal
surfaces with a light grease or heavy oil compatible
with system hydraulic oil. This includes cylinder rods,
shafts, gears, linkages, and unpainted parts.
10. Make sure the engine exhaust system and air intake
system are protected from water intake.
11. Secure all padlocks and remove keys from ignition.
12. Disconnect or remove battery.
Extended Storage
Engine Storage
Prior to extended storage, please refer to your engine
owner’s manual for proper storage procedure.
Chipper Storage
Things to do prior to extended chipper storage.
• Let the chipper cool to ambient temperature.
• While slowly rotating the drum, grease both bearings
until new grease is seen purging from the bearing
shaft/seal area.
• Repack wheel bearings.
• While slowly rotating the drive rollers, grease all drive
roll bearings until new grease is seen purging from
the shaft seal area.
• Make sure the fuel tank is full and not containing
water.
3. Top off uid reservoirs to allow as little air space as
possible, to limit the effects of condensation. Remove
excess oil before operating to limit the chance of
overow when cylinders are cycled.
38 • Section 7 — Maintenance
• Make sure the hydraulic tank is full and not containing
water.
Page 44
• Make sure the exhaust system is protected from
water intake.
• Make sure the air intake system is protected from
water intake.
• Disconnect or remove the battery.
• Make sure the chipper has a secure “footing” and that
the supporting jack stand is properly positioned.
• Make sure the tires are properly inated.
• After servicing the reservoir, immediately replace
the cover.
• Make sure quick disconnect couplers are clean
before connecting them.
• Do not spray water on the reservoir ller breather cap.
This could force contaminants into the reservoir.
Filtration
The unit is equipped with a complete ltration system.
When properly maintained, this system will reduce contamination of the hydraulic system. The ltration system
must be serviced regularly to be effective.
• Secure all padlocks and remove the ignition keys.
Hydraulic System
Maintaining the hydraulic system is critical to the proper
operation of the unit. Using the proper type of oil helps
to prevent many hydraulic system problems. Maintaining
the oil is also important. If the oil is dirty or contaminated,
components may be damaged.
Notice
Only use hydraulic oil as recommended. Other uids
added to the hydraulic system can increase component wear and affect the lubricating characteristics
of the oil.
Check the oil level in the reservoir with the vehicle level.
The proper oil level is between 2” and 3” (5.08 to 7.62
cm) from the top of the tank.
Cleanliness Precautions
Contamination will ruin any hydraulic system. It is very
important that no contamination enter the system. Dirt,
water and air are types of contaminants. They can enter
the hydraulic system in many ways. Contaminants can
enter the system when lling the reservoir or changing
lters. They can also enter when changing components
or performing other service procedures.
The following precautions will help protect the cleanliness
of the hydraulic system.
• Filter new oil with a 10 micron lter as it is added to
the reservoir.
• Clean hydraulic connections before opening them.
• Cap or plug ports and lines opened for service.
• Keep replacement hoses and other components
plugged while stored.
• Clean the reservoir and return line lter covers before
opening them.
• Make sure components are clean before installation.
• Clean the ller breather cap before opening it.
Breather
The breather is located on the side of the ll hole on the
reservoir. The breather allows air to ow in and out of the
reservoir as the oil level changes. It contains a lter that
cleans the air as it enters the hydraulic system.
Notice
When adding oil, always pump oil through a 10 micron
lter prior to adding.
Replace the ller breather as needed. If the unit is operated
in an extremely dusty environment, it may be necessary
to replace the breather more often.
Suction Filter
Hydraulic oil leaving the reservoir through the suction
line, on its way to the pump, passes through a suction
lter which is accessible from inside the hydraulic tank.
The suction lter contains a 100 micron wire mesh ele-
ment. Although the element may be cleaned, it is also
available as a service part.
Clean the lter whenever the hydraulic oil is changed. Oil
will not ow into the pump fast enough if the lter becomes
clogged. If the pump does not receive sufcient oil ow,
pump damage will result.
Warning
Death or serious injury can result from improper
use of solvents. Follow the manufacturer’s label for
proper use and disposal.
Caution
Injury can result from airborne particles entering the
eyes. Wear appropriate safety equipment.
Clean the lter element by ushing it with solvent. Blow it
dry with an air hose from the inside of the screen to the
outside. Check for holes or other damage.
Section 7 — Maintenance • 39
Page 45
Return Line Filter
The return line lter is a cartridge type 10 micron lter
that cleans the oil before it enters the reservoir.
The return line lter head contains a lter bypass valve.
This bypass valve opens when there is a pressure drop
of 15 psi (1.03 bar) across the lter cartridge. When the
valve is open, oil ows directly into the reservoir bypassing the lter. This prevents the cartridge from bursting
during cold start ups or if it is clogged.
If the lter becomes clogged the oil ows directly into
the reservoir bypassing the lter. The lack of ltration will
eventually damage hydraulic components.
During the break-in period of a new unit, the hydraulic
components will deposit break-in wear particles in the
return line lter cartridge. Change the return line cartridge after the rst 15 to 25 PTO hours. Then, change
the cartridge as recommended by the checklists in the
Appendix. If the unit is operated in very dusty conditions,
replace the return line lter more often. Also, replace the
cartridge after new oil has circulated through the system
for the rst time.
Always replace the return line lter cartridge with a
genuine Altec replacement part. Other lters may screw
or t into the lter housing, but may not have the same
micron rating. Also, other lters may allow oil to bypass
at a different rate.
Oil Specications
Use high quality oil in the hydraulic system. The oil should
contain rust, oxidation, and corrosion inhibitors. It should
also contain antifoam and antiwear additives.
Hydraulic oil is commonly classied by viscosity. The
viscosity of hydraulic oil changes with temperature. The
higher the viscosity index of an oil, the less the viscosity
will change as the temperature changes. A multiviscosity
oil contains additives which increase the viscosity index.
Multiviscosity oils should have high shear stability to
maintain oil performance by avoiding excessive change
in viscosity.
The ability of hydraulic oil to provide adequate uid at
low temperatures is measured by its pour point. If the
pour point is not low enough, oil will not ow into the
pump at a fast enough rate when the pump is operated
at low temperatures. This will cause cavitation, which
can quickly destroy the pump.
Notice
nent wear and affect the lubricating characteristics
of the oil.
Only use oils meeting the viscosity rating for military
specication MIL-5606 in extremely cold climates.
These oils have fewer antiwear characteristics and
are not recommended for full time use.
Most companies can supply equivalent oils. The oil
selected for the hydraulic system depends on the temperature during unit operation.
Oil Condition
An important part of hydraulic system preventive maintenance includes checking the condition of the hydraulic
oil.
Periodic laboratory analysis is the most accurate method
of determining the condition of hydraulic oil and determining when it should be changed. A visual inspection may
also be useful to check oil condition.
A hydraulic oil supplier should be able to do testing or
recommend a test laboratory. The laboratory should
provide the following information.
• Particle count
• Trace element analysis (component wear, outside
contaminants, and oil additive concentrations)
• Viscosity test
• Water content test
Before taking a sample of oil, operate the unit to circu-
late the oil. Warm it to operating temperature. Take the
sample from the middle level of the reservoir using a
clean hand pump, such as a disposable syringe and a
piece of plastic tubing. If this is not available, drain the
sample from the bottom of the reservoir. Allow several
quarts of oil to ow out before collecting the sample to
remove any dirt and water that has collected in the reservoir near the drain.
If a sample container has not been provided by the laboratory, use a wide mouth, screw top, clear glass container.
Clean it with hot water and detergent. Rinse it thoroughly
and let it air dry before putting oil into it.
Once the report is received, compare it to previous oil
analysis reports for the same unit. This information will
provide trends toward oil deterioration. It may give early
warnings of a problem developing within hydraulic system
components.
Only use hydraulic oil as recommended. Other uids
added to the hydraulic system can increase compo-
40 • Section 7 — Maintenance
Page 46
Notice
Change the oil if the sample has any of the characteristics listed in Figure 7.1.
• In climates with a wide variation in operating temperatures between summer and winter months, change
to the appropriate weight oil each spring and fall.
If making a visual inspection, compare the sample of oil
to a sample of new oil of the same type. Also, compare
it to previous samples taken from the same unit. Look for
the signs of oil deterioration listed in Figure 7.1.
There are uid contamination detector kits available
which allow for rapid, on-the-spot analysis of the hydraulic
system’s condition. Contact your Altec representative for
further information.
Oxidation produces varnishes that bake onto hot surfaces. Oxidation products are acidic and tend to attack
metal surfaces. This can damage pumps, motors, and
valves. High operating temperatures will increase the
rate of oxidation of the oil. The presence of water or air
in hydraulic oil also causes oxidation.
The presence of water may cause rust and corrosion. If
laboratory analysis or visual inspection indicate that the
oil is deteriorating prematurely, determine the cause of
the problem and correct it.
Changing Oil and Flushing the System
A properly maintained ltration system greatly extends
the useful life of the hydraulic oil. However, the oil will
eventually need to be replaced due to contaminants that
form during normal operation of the unit.
It is impossible to recommend an exact time interval for
oil changes due to varying conditions of unit use. Use
the following guidelines to determine when the hydraulic
oil should be changed.
• Change the oil as recommended by the checklists
in the Appendix.
• If a hydraulic component fails and contaminates the
system with metallic particles, change the component
and the oil immediately.
Replace the return line lter cartridge and ller breather
cap every time the hydraulic oil is changed. Also, clean
or replace the suction lter.
A signicant quantity of oil remains in the hydraulic system
when the reservoir is drained. Flush the system when the
oil is changed. This is especially important if the system
is heavily contaminated with metal particles.
If the oil is contaminated with water, it may not be neces-
sary to change the oil and ush the system. Follow the
instructions under Water Removal in this section.
The following equipment and supplies are necessary to
properly ush the hydraulic system.
• Approximately 13 gallons (49 l) of proper hydraulic
oil
• Three return line lter cartridges
• Clean, lint-free rags
• Breather (if component has not been replaced
within one year)
Caution
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
work areas clean.
Use the following procedure to ush the hydraulic system.
1. If the oil is being changed because of contamination
due to hydraulic component failure, proceed to step
2. Otherwise, operate the unit to circulate the oil and
warm it to operating temperature. This will allow many
of the impurities to drain off in suspension.
2. Drain the oil reservoir completely.
Condition Possible Cause
Dark color Oxidation; contamination
Cloudiness or milky appearance Presence of water or wax
Rancid or burned odor Oxidation
Increase in viscosity Oxidation; addition of improper uids; presence of water
Decrease in viscosity Addition of improper uids; additive deterioration
Separation of water or other uids from the oil Presence of water; addition of improper uids
Foreign particles or other visible contamination Contamination; emulsion of water with oil additives
Figure 7.1 — Hydraulic Oil Conditions
Section 7 — Maintenance • 41
Page 47
3. Wipe off the top of the reservoir and the ller breather
cap.
Warning
Death or serious injury can result from improper
use of solvents. Follow the manufacturer’s label for
proper use and disposal.
4. Inspect the inside of the reservoir. If sludge or other
contamination is found, thoroughly clean the inside
of the tank using lint free wipes and a solvent which
leaves no residue. Change the return line lter and
clean or change the suction lter.
Notice
Only use hydraulic oil as recommended. Other uids
added to the hydraulic system can increase component wear and affect the lubricating characteristics
of the oil.
5. Fill the reservoir with new hydraulic oil of the proper
grade. The proper oil level is between 2” and 3”
(5.08 and 7.62 cm) from the top of the tank. Do not
ll tank completely full so as to leave room for uid
expansion. Filter the oil through a 10 micron lter as
it is put into the reservoir.
6. Install the ller breather cap. If the ller breather cap
has not been replaced in one year, or is damaged,
replace it.
Notice
Oil change has been completed at step 6 for routine
oil changes. If changing oil due to contamination,
continue through step 11.
7. Cycle all cylinders, hydraulic motor and all valves to
ush contaminated oil from the lines and components
of the hydraulic system.
Water Removal
If the hydraulic system was contaminated with water,
special water removal ltration may be necessary. An
oil supplier or a qualied laboratory can determine if
water has caused excessive oil oxidation or additive
deterioration.
If analysis shows oil deterioration beyond an accept-
able level, drain the reservoir and ush the system as
described earlier in this section. Use a water removal
ltration system during the ushing process to remove
any residual water from the system.
If the condition of the oil is acceptable except for the water
content, allow time for it to separate from the oil. Then
drain the water off the bottom of the reservoir. Circulate
the oil in the entire system through a separate water
removal lter system.
Continue this process until the water content in the oil is
reduced to an acceptable level. The preferred method
of determining the water content in the oil is laboratory
testing. Once the water content has been reduced to an
acceptable level, replace the cartridge with a new return
line cartridge.
Lubrication
Proper lubrication will extend the life of the equipment
and reduce maintenance problems. The frequency of
lubrication required will depend on the amount of use
and the conditions the unit is operated in. Operation in
extremely dusty, sandy, or rainy environments will require
more frequent lubrication. Lubricate the unit as recommended by the Preventive Maintenance and Inspection
Checklist in the Appendix.
The Lubrication Chart identies each component, type of
lubricant, and method of application. Any brand of lubricant
that meets or exceeds the specications of the products
listed is acceptable. Select the appropriate interval and
lubricate the components as identied in the chart.
8. Change the return line lter cartridge and clean
the suction lter element.
9. Drain the reservoir completely.
10. Fill the reservoir with new hydraulic oil of the proper
grade. The proper oil level is between 2” and 3”
(5.08 and 7.62 cm) from the top of the tank. Do not
ll tank completely full so as to leave room for uid
expansion. Filter the oil through a 10 micron lter as
it is put into the reservoir.
11. Change the return line lter cartridge after approximately 25 hours.
42 • Section 7 — Maintenance
Always wipe grease ttings clean before and after greasing
to keep contaminants from entering the points of lubrication. To avoid bearing damage, use manually operated
grease guns. Air-driven grease guns may have enough
force to cause bearing damage.
If the unit is not used, or is stored for any length of time,
apply fresh lubricant at all points indicated on the Lubrication Chart. This will help prevent corrosion during the
idle period.
Page 48
Lubrication Chart
10 Hours 50 Hours 200 Hours 1,000 Hours
Component Lubricant Applicator Daily Weekly Monthly Yearly
Cutter bearings A Grease gun •
Feed roll bearings A Grease gun •
Slide box A Grease gun •
Chute rotation A Grease gun •
Hinges, friction points B, C Spray •
Linkages B, C Spray •
Axle bearings A Grease gun Refer to axle owners manual
Jack A Grease gun •
Hydraulic oil ISO 46 •
PTO As required As required by PTO manufacturer
Engine As required As required by engine oil manufacturer
Letter Lubricant
A Use a premium grade, high temperature, lithium based grease. Some suggested greases include:
Mobile Mobilith AW 2, Shell, Alvaina Grease 2, Texaco 1939 Premium RB, Amoco Ryko Premium Grease.
B General purpose spray lubricant
C Spray lubricant that penetrates and adheres with good water resistance, is unaffected by temperature
extremes and has extreme pressure properties. Anti-seize compound with extreme pressure lubrication
that prevents seizure, corrosion, rust, and galvanic pitting.
Bearings
Spherical roller bearings are used on the cutter head and
feed roll assemblies. They require periodic lubrication
with a chassis lubricant.
It is very important to grease this type of bearing regularly. If they are not greased properly, the usable life of
the bearing will be greatly reduced.
Remove any exposed grease from the bearing. Grease
each bearing daily with three or four pumps with a standard grease gun.
Slide Box
Clean exposed existing grease from the outside areas
of the way surfaces. Pump grease in all four ways until
new grease is observed.
Chute Rotation
Clean exposed existing grease from the outside areas of
the chute rotation area. Pump grease in all four grease
ttings until new grease is observed.
Hinge and Friction Points
Chipper operation and longevity can be improved by
keeping all hinges and friction points lubricated. Remove
all dirt, corrosion, or foreign matter. Lubricate with appropriate applicator.
Axle Bearings
Standard axles on Altec Environmental Products, LLC
chippers have the UltruLube feature. This feature ushes
and lubricates both the inner and outer wheel bearings.
If your axle is equipped with the UltruLube feature, the
bearings can be periodically repacked and lubricated
without removing the hubs.
The procedure is as follows.
1. Remove the rubber plug from the end of the grease
cap.
2. Place a standard grease gun onto the grease tting
located in the end of the spindle. Make sure the
grease gun is fully engaged on the tting.
Section 7 — Maintenance • 43
Page 49
3. Pump grease into the grease tting. The old, displaced
grease will begin to ow back out the cap around the
grease gun nozzle.
4. When the new, clean grease is observed, remove
the grease gun, wipe off any excess, and replace
the rubber plug in the cap.
Care of Exterior Surfaces
Altec units are manufactured out of structural steel, galvanized steel and/or aluminum components with differing
resistance to corrosion. While Altec uses components,
designs and coatings that maximize corrosion resistance,
regular cleaning and maintenance is necessary to pre-
serve the nish over the life of the equipment.
Refer to the axle manufacturer’s manual for more infor-
mation.
Jack Stand
Depending on the model jack stand supplied with the
chipper there may be a grease tting. If so, lubricate with
one or two pumps.
Engine Power Take-Off (PTO)
The PTO clutch mechanism is supplied by the engine
manufacturer. It is very important to lubricate the PTO
bearings, clutch levers, and linkage. For specic informa-
tion and lubrication interval requirements refer to your
PTO owner’s manual.
Engine
Due to varying engine models and engine specications,
check the engine owner’s manual (EOM) for the specic
lubrication requirements of your supplied engine.
Structures
The structural components of the unit are identied in the
Component Identication in Section 2. The unit has been
designed to meet or exceed the ANSI Specications for
Z133.1 Safety Requirements.
Regular inspection of the welds and structures is required
to make sure that components maintain their strength.
Periodic cleaning of the structures is also recommended.
This will prevent damage that can result from dirt accumulation.
Caution
Injury can result from slipping and falling. Use care
when cleaning the unit.
Periodic inspection of the structures is recommended
to be certain there is no deformation, abnormal wear or
abrasion, interference between moving parts, or cracking
of the welds on structural members.
Inspect the structures and welds as recommended by
the checklists in the Appendix.
Frequent and regular washing will lengthen the life of the
new equipment’s painted nish and components. Wash
the equipment frequently with warm or cold water to
remove dirt and preserve the original luster of the paint.
Never wash the equipment in direct sunlight or when
the metal surfaces are hot to the touch as it may cause
streaks on the nish. Caution must be used in selecting
detergents and degreasers that may damage the nish.
Use only commercially available automotive grade cleaners. High pressure washing systems should be used with
caution, with the tip of the nozzle maintained at a distance
of 12” (30.5 cm) or more from the surface.
It is particularly important to wash the unit during winter
months as salt and other ice melting products are ex-
tremely corrosive and can damage the vehicle. Other
corrosive environments that would necessitate additional
washing may include coastal areas, farming communities
where chemicals are sprayed, or mining operations.
Waxing of the exterior is typically not required, however
waxing will provide additional protection and help restore
the nish to the original luster. This may not only improve
appearance, but will likely extend the service life of the
equipment.
It is important to repair any chips or scratches that occur
to prevent further corrosion. If the paint damage exposes
primer, then a liquid touch up paint may be used. Damage that extends to unpainted metal must be primed
prior to applying a top coat. Touch up paint for standard
Altec colors may be ordered by calling 1-877-GO ALTEC.
Your local auto body shop can assist you with matching
a custom color.
Equipment that is used in harsh environments and off road
use needs to have more routine washing and maintenance
to the under body area. When the equipment is washed
it should washed on the underside as well and routinely
checked for any damage to the paint/undercoat. Any
damage discovered should be touched up accordingly
with a good rust preventative material and/or undercoat.
This will help prevent corrosion that could spread from
these areas that are not easily seen.
Accumulated dirt can damage the unit and cause it to
malfunction. Dirt buildup also accelerates wear on the
components.
44 • Section 7 — Maintenance
Page 50
Caution
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
work areas clean.
If a pressure washer or steam cleaner is used to clean
the unit, be careful where the spray is directed. Do not
direct the spray where the cleaning liquid might get into
electrical components, such as electrical connections,
switches or lights. Even though all electrical components
on the unit are designed for all weather use, it is possible
for water pressure from the nozzle to push a seal out of
position. Do not direct the spray at the ller breather cap
of the reservoir. The high pressure can force water and
cleaning liquid into the reservoir and contaminate the
hydraulic oil. Do not clean any of the hydraulic valve spool
ends or near cylinder rod seals with direct pressure from
a pressure washer. Limit the water pressure to 500 psi
(34.47 bar) and keep the spray tip at least 18″ (45.72 cm)
away from these components while washing. After washing and cleaning the unit, relubricate as necessary.
Welds
All welds on the unit are originally applied in conformance
to AWS standards. Every weld on the unit is important
and should be periodically inspected.
Warning
Death or serious injury can result from improper
use of solvents. Follow the manufacturer’s label for
proper use and disposal.
If paint has lifted off the weld, or if rust is found, a closer
inspection is required. Remove any loose paint or rust
with a wire brush. Clean the area with a solvent such
as acetone. Closely inspect the area for cracks in the
welds. Dye penetration and magnetic particle testing are
simple processes that may be used to verify or disprove
a suspected problem.
Visual inspections can be very effective if conducted
properly. Clean the area to be inspected. Look for visible cracks in the weld and at the weld-to-parent material
joint. Use a bright light to provide adequate visibility of
the inspection area.
Pay close attention to welds that are located where
changes in cross section take place and near the attachment points of highly loaded components. If any cracks
or unacceptable conditions are discovered, report them
to your Altec representative.
Any welds added in the eld should be done by qualied
personnel and also conform to AWS standards.
After doing repair work on the unit, such as weld repair,
some testing of the unit may be required.
Fasteners
A variety of fasteners are used on the unit. Different fasteners have different inspection and installation requirements depending on their use and design.
The standard grade of fastener used on the unit is a
zinc plated, SAE Grade 8, steel cap screw. A variety
of fasteners such as hex socket head, at countersunk
head, button head cap screws, eye bolts and carriage
bolts are also used on the unit.
Check all fasteners for tightness as recommended by
the checklists.
When inspecting fasteners, pay particular attention to
the following fasteners.
• Blade fasteners
• Anvil fasteners
• Hitch and/or tongue fasteners
• Cutter bearing fasteners
• Control bar linkage fasteners
• Panic bar linkage fasteners
Refer to Torque Values in the Appendix as a guide to
determine the proper cap screw torque value. The proper
value is necessary to overcome the friction of the threads
and develop the required clamping force.
A properly installed cap screw applies a clamping force
equal to or greater than the load applied to it. A cap screw
installed at less than the recommended torque value
does not provide enough clamping force. The cap screw
may fatigue, causing it to loosen or fail. If the cap screw
is torqued beyond the recommended torque value, the
elastic range of the cap screw may be exceeded. This
may result in premature failure of the cap screw.
When checking fastener torque value, check at 90 percent
of the original value. For example, if the torque value for
a cap screw is 100 foot-pounds (136 N•m), check the cap
screw for tightness at 90 foot-pounds (122 N•m).
Certain types of fasteners or fasteners used in special
applications often require torque values that differ from
common torque charts. Check the Fastener Specic
Torque Application Chart in the Appendix.
Section 7 — Maintenance • 45
Page 51
System Operation
The chipper operates as an open center hydraulic system.
There is limited pressure in the system until the actuators
demand additional pressure. The system then responds
with a maximum of 2,900 psi (200 bar). Standard ow rate
is approximately 6.5 gpm (24.6 l/m). This may vary with
engine selection and customer drive speed specications.
The normal ow of hydraulic uid is from the pump to the
main control valve. The second spool from the right on
the main control valve routes the uid through into the
two motors in either the forward or reverse direction. Fluid
then ows through the return lter and returns to the tank.
The rst spool in the main control valve is for the panic
bar. This spool when activated routes all uid directly
back to the return lter bypassing the directional valve.
It is used to stop feed roll motion in an emergency mode
of operation.
is for a pressure connection, one is for a return line connection, and the other two ports are the working ports.
Leakage
If components and connections are installed properly,
leakage can be kept to a minimum. Small external leaks
are usually easy to nd because dust will collect on the
hydraulic oil lm.
External leakage is the escape of hydraulic oil outside
the hydraulic system. Improperly tightened ttings are a
primary cause of external leakage.
Warning
Death or serious injury can result from hydraulic
oil being injected into the esh. Do not use hands
or other body parts to check hydraulic lines and t-
tings for leaks.
Oil Reservoir
The reservoir will hold 12 gallons (45.4 l). A 100 micron
suction lter is located at the outlet of the reservoir. A
breather is located on the side of the ll on the reservoir. The breather contains a lter that cleans the air as
it enters the reservoir. The return lter is located under
the ll cap. When lling the reservoir remove the return
lter cartridge.
Oil Pump
The standard hydraulic pump used on DRM 12 is a 0.5
cubic inch (8.2 cc) per revolution displacement gear
pump. The pump is normally directly coupled to the
engine auxiliary drive.
Hydraulic Motors
Two motors drive and control the brush feeding rate to
the cutter. The motor tapered shafts are directly coupled
to the feed rolls.
Valves
When describing hydraulic valves, “position” identies
the number of operating positions of the valve spool. A
two-position blocking valve has two operating positions,
open and closed.
The word “way” identies the number of ports in a valve
section. A four-way control valve has four ports. One port
Seek immediate medical attention if injured by escaping hydraulic oil. Serious infection or reaction can
result if medical treatment is not given immediately.
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
work areas clean.
If a connection is properly tightened but continues to
leak, disassemble the connection. Seal the necessary
parts and/or replace the defective part.
Worn or damaged parts such as scratched cylinder rods
can cause leaks. A worn or scratched output shaft on a
hydraulic motor can also cause a leak. Such conditions
must be repaired or replaced. A new seal should also
be installed.
Internal leaks allow pressurized hydraulic oil to escape
to tank or another hydraulic circuit. Most hydraulic components have a small internal leak due to machining
tolerances.
An internal leak can cause a variety of problems in a
hydraulic system. An internal leak in a cylinder can cause
drifting or malfunction of a cylinder.
After extended hours of operation, hydraulic motors will
increase the internal leakage until a noticeable loss of
power is apparent. At this time, you must replace the
motor. To minimize motor wear it is essential to maintain
clean ltered oil in the system.
46 • Section 7 — Maintenance
Page 52
Heat Generation
Heat is the result of pressurized uid escaping to the
reservoir. Most hydraulic components have a small internal leak due to machining tolerances. This type of leak
generates a very small amount of heat that is taken into
account when the component is designed.
Internal leaks in the system may be caused by internal
housing cracks, bad relief valves, or leaking seals. This
type of leak allows a large volume of pressurized oil to
return to the reservoir, creating excessive heat in the
hydraulic system. Continuous operation with excessive
heat will damage the hydraulic oil, seals, and O-rings
throughout the system.
pressure before loosening or disconnecting hydraulic
components.
Seek immediate medical attention if injured by escaping hydraulic oil. Serious infection or reaction can
result if medical treatment is not given immediately.
Spilled hydraulic oil creates slick surfaces and can
cause personnel to slip and/or fall. Keep the unit and
work areas clean.
Caution
Injury can result from airborne particles entering the
eyes and lungs. Wear appropriate safety equipment.
The following conditions cause heat generation.
• Excessive pump speed
• Worn or defective pump
• Defective or improperly adjusted relief
valve cartridges
• Low hydraulic oil level
• Improper hydraulic oil
• Internal component leakage
Hydraulic Lines
Hydraulic lines provide a passageway for uid ow
between components in the hydraulic system. Fluid is
transmitted through the lines from the pump to the actuator to operate the unit. A variety of lines may be used on
the unit depending on the specic application.
Most hoses have a lay line on them. The lay line contains
the following information.
• Manufacturer’s name
• Manufacturer’s part number
• SAE rating
• Burst pressure (sometimes)
• “Nonconductive” appears on nonconductive hoses
When replacing a hose, use one the same size, length,
and pressure rating. If hose size is doubled, four times
the amount of oil will ow at the same pressure. If hose
size is decreased, the ow in the circuit will decrease and
back pressure will increase. The increase in back pressure will cause heat to build up and system malfunction.
Injury can result from being pinched or trapped between moving components. Keep hands clear.
Use caution when access covers have been removed
to service the unit. Pinch points and shear points may
exist between moving parts. Replace the access covers
immediately after servicing.
Remove all uid pressure from a hydraulic circuit before
disconnecting lines or ttings.
Mark all hydraulic line ttings before disconnecting them
to ease installation later. Place a container under the
hoses to catch the hydraulic oil. Cap or plug all open
ports, hoses, and ttings to prevent contamination.
Warranty will be denied on components returned to Altec if
ports are not plugged and cylinder rods are not retracted.
After completing a procedure, check the oil level in the
hydraulic oil reservoir and add oil if necessary.
Drive Belt/Pulleys
Caution
Injury can result from being pinched or trapped between moving components. Keep hands and body
parts clear.
Never place any part of the body in a potential pinch
point. This not only applies to the heads and chutes, but
also drum and engine sheave/belt contacts.
Warning
Death or serious injury can result from hydraulic
oil being injected into the esh when loosening or
disconnecting hydraulic components. Remove the
Disengage clutch and the hydraulic feed system. Remove
keys from the ignition switch and place in pocket. Lock
out chipper.
Drum and drive system continue to move after the clutch
has been disengaged and the engine has been cut off.
Section 7 — Maintenance • 47
Page 53
Make sure that the drum and drive system have come
to a complete stop before attempting any maintenance
in this area.
Inspect belt/pulley condition according to Figure 7.2.
Replace as necessary.
face of the drum cutter head sheave and the engine
sheave. Alignment is correct when both inner and
outer surfaces of both sheaves are in contact with
the straight edge (refer to Figure 7.3).
Belts
Good Belt
Belts
Worn Belt
Belts
Space
No Gaps
Straight Edge
Reduced
Space
Figure 7.3 — Sheave Alignment
No gaps between straight edge and sheave on both
sheaves.
Belt Adjustment
1. Back-off the engine mounting adjusting screws.
2. Loosen all of the engine mounting bolts.
3. Tighten or loosen the adjusting screws, as appropriate, while monitoring the sheave alignment and belt
tension.
Worn Sheave
Figure 7.2 — Belt Wear
1. Remove belt guard.
2. Visually inspect drive belt for cracks or fraying. Visually inspect sheaves for signs of wear, cracks, or
loose bushings.
3. Inspect belt tension. At the center point between the
sheaves, the belt should deect 3/8” with 8 pounds of
pull. Under-tensioning can cause unnecessary belt
wear.
4. Overtensioning can cause premature PTO and/or
bearing failure.
5. Check drum cutter head/engine alignment by placing
a non-exible straight edge against the outside sur-
48 • Section 7 — Maintenance
4. When the proper sheave alignment and belt tension
have been achieved, retighten the engine mounting
bolts.
5. Retighten the adjusting screw locking nuts.
6. Reinstall the belt guard and tighten all fasteners
securely.
Warning
Death or serious injury may result if maintenance
procedures are not completed.
Make sure that all tools and hardware are removed from
the head and discharge chutes or any other area where
maintenance, inspection or service was performed.
Make sure that all fasteners and adjustments are secured
properly before starting the unit.
Page 54
Do not operate the equipment unless all covers and
guards are in place and properly secured.
Troubleshooting,
Testing, and Adjustments
Synchronizing Tow
Vehicle Brake Controller
To ensure safe brake performance and synchronizing,
read the brake controller manufacturer’s instructions completely before attempting any synchronization procedure.
In the event of an unwanted separation of the chipper from
the tow vehicle, the tongue should drop into the cradle
formed by the X pattern of the chains. The breakaway
cable must pull the plunger from the switch before the
entire tongue weight of the chipper comes to a rest in
the chain cradle.
When the breakaway switch is activated, full voltage
from the chipper battery is applied to the brakes. The
chipper will come to a complete stop, but will not lock
up the brakes.
Caution
Injury and property damage can result from failure to
brake safely. Make sure the area is clear of vehicular
and pedestrian trafc.
Make several hard stops from 20 mph (32.3 kph) on a dry
paved road free of sand and gravel. If the trailer brakes
lock and slide, slightly decrease the gain setting on the
controller. If they do not slide, slightly increase the gain
setting. Adjust the controller just to the point of impending
brake lockup and wheel skid.
Notice
Not all trailer brakes are capable of wheel lockup.
Loading conditions, brake type, wheel and tire size
can all affect whether a brake can lock up. It is not
generally considered desirable to lock up the brakes
and slide the tires. This can cause unwanted spotting of tires and could also result in a loss of control.
For proper braking performance, it is recommended that
the controller be adjusted to allow the trailer brakes to
come on just slightly ahead of the tow vehicle brakes.
When properly adjusted, there will be no sensation of
trailer jerking or pushing the tow vehicle during braking.
Breakaway Braking System
To ensure proper operation of the breakaway system, the
chipper battery and charging system must be operating
properly. The chipper must be properly hitched to the tow
vehicle. This must include the following.
• The hitch properly fastened and all retaining pins
secured.
Testing of the breakaway can be accomplished by jacking up the chipper, spinning the wheel, and pulling the
plunger. The brakes should apply. The tires may lock up
on a slick or unstable surface.
Notice
The breakaway switch is to be used for emergencies
only. The breakaway system rapidly discharges the
battery when the plunger pin is removed. Reinstall
plunger immediately after completion of test.
Inspection and Maintenance
Your chipper brakes must be inspected and serviced
immediately if a loss of performance is indicated. With
normal use, servicing at one year intervals is usually
adequate. With increased usage, this work should be
done more frequently as required. Magnets and shoes
must be changed when they become excessively worn
or scored, a condition which can reduce vehicle braking.
Clean the backing plate, magnet arm, magnet and brake
shoes. Make certain that all the parts removed are replaced in the same brake and drum assembly. Inspect for
any loose or worn parts, stretched or deformed springs
and replace as necessary. For ease of maintenance
Altec parts department can supply complete backing
plate assemblies. This includes new shoes, magnets,
springs, and connecting hardware already assembled,
ready to bolt in place.
Caution
Serious illness can result from breathing asbestos
dust. Avoid breathing or creating dust when servicing the brakes.
• Safety chains crossed in an X pattern under the
tongue and secured to the tow vehicle. Allow enough
slack in the chains for turning.
• Breakaway cable must be of shorter length than the
chains.
Avoid machining, lling, or grinding the brake linings.
Do not use compressed air or dry brushing for cleaning
(dust can be removed with a damp brush).
Brake Adjustment
Adjust brakes at the following intervals. Refer to the axle
owners manual.
Section 7 — Maintenance • 49
Page 55
• After the rst 200 miles of operation when the brake
shoes and drums have seated.
• At 3,000 mile intervals.
Warning
Serious injury can result while performing blade
maintenance. Wear appropriate safety equipment.
• As use and performance requires.
Mechanical
Blade/Anvil Replacement
Warning
Death, serious injury, and/or property damage can
result from improper maintenance of the unit. Do
not perform maintenance procedures on this unit
without proper training.
Only properly trained, authorized personnel which have
read and understand the entire manual, placards and
decals shall access the cutter head or perform blade
maintenance.
Accessing the Cutter Head
1. Reduce engine speed to low idle.
2. Turn engine off. Remove keys from the chippers
ignition. Place these keys in your pocket.
3. Remove negative battery cable.
4. Properly lock-out chipper (refer to LOTO procedure).
Blades are extremely sharp. Care must be taken to avoid
contact with the blades and blade pinch points. Always
wear appropriate hand protection when performing in-
spections or replacing blades. Failure to do so will result
in severe injury.
The recommend service interval for blade maintenance is
eight hours or daily. However, the actual service interval
may be more or less, depending upon the wood being
chipped and the chipping conditions. Always complete
a thorough inspection if foreign objects are fed through
the chipper.
Notice
Always replace blades as sets. Drum balance can
be affected if matched blades are not kept together.
Blade Installation and Adjustment
Warning
Death, serious injury, or property damage can result
from operating the chipper with damaged or chipped
blades. Replace damaged or chipped blades to
prevent breaking and discharging of blades during
operation.
5. Inspect cutter and drive train to ensure no movement
of drive components.
Warning
Death, serious injury, or property damage can result
when attempting to access moving components.
Make sure components have come to a complete
stop before performing inspection or maintenance.
Drum and drive system components continue to move
after the clutch has been disengaged and the engine has
been turned off. Make sure the drive system has come
to a complete stop prior to accessing this area.
Caution
Injury can result from being pinched or trapped between moving components. Keep hands clear.
Never place any part of the body in a potential pinch
point. This not only applies to the head and feed roller,
but also drum and engine sheave/belt contacts.
Always use Altec supplied chipper blades. These blades
are manufactured using special chipper blade steel and
selectively hardened to reduce the possibility of blades
shattering.
1. Complete LOTO procedures.
Danger
Death, serious injury, or property damage can result
when attempting to access moving components.
Make sure components have come to a complete
stop before performing inspection or maintenance.
Caution
Injury can result from being pinched or trapped between moving components. Keep hands clear.
Never start the engine with the drum hood open. Never
attempt to open or close the drum hood with the drum
moving.
2. Remove the six 1/2” cap screws securing the top rotor
access cover.
50 • Section 7 — Maintenance
Page 56
Figure 7.4 — Drum Locking Pin
3. Position the drum and install the drum locking pin.
4. Remove anvil access cover (refer to Anvil Removal).
5. Loosen anvil screws (do not remove) and push anvil
back to achieve maximum blade/anvil clearance.
cessive wear on drive components, i.e., drive belt, drive
pulleys, bearings, drive clutch, and engine.
Equipment damage that results from the use of worn
or damaged blades will not be considered for warranty.
Operators and others are exposed to unnecessary risk
by operating a unit in this negligent condition. Owners
subject themselves to increased operating costs, sig-
nicant downtime and premature equipment wear as a
result of improper blade maintenance.
Warning
Death, serious injury, or property damage can result
from overtorquing the blade bolts. Overtorquing may
stress and break the blades.
12. Inspect threaded blade keeper bars for corrosion or
damaged threads. Replace if any damage or corrosion is found.
13. Install new or rotated blades with sharp edge out.
6. Remove blade bolts, Do not use impact tool to remove
or install bolts.
7. Make sure all mating surfaces between the cutter
blades and drum are clean and free of debris and
corrosion.
8. When a blade is removed from the drum, the blade
mounting surfaces must be clean of any debris or
corrosion and inspected for any damage. An uneven
or damaged surface may cause blade separation.
9. Thoroughly clean the blades and inspect both sides
of each blade for cracks. If any cracks are found,
discard the blade.
10. Using a straight edge against the blade mounting
surface, check for any blade distortion by sliding the
straight edge both perpendicular and parallel to the
bolt holes. Any light seen between the blade and the
straightedge indicates a distorted blade. Any distorted
blade must be discarded.
11. Inspect bolts for damage or corrosion. Replace as
necessary. Always replace blade bolts when using
resharpened or new blades.
Operation with worn or dull blades will result in poor chip
quality, stringy material output, possible discharge chute
clogging, additional fuel consumption, unnecessary stress
on structural components, engine overheating and ex-
Removable
Threaded Block
Blade
Mounting Plate
Blade
Figure 7.5 — Blade Cross Section
14. Tighten blade cap screws per specications given in
the fastener torque table. Do not use an impact tool.
15. Refer to anvil installation for anvil/blade clearance
procedure.
16. Replace all guards and safety devices.
Danger
Death or serious injury can occur if using cracked or
distorted blades. Inspect blades per required inspection intervals and discard cracked or distorted blades.
Death or serious injury can occur if blade separation occurs. Any debris left on the mounting surface
Section 7 — Maintenance • 51
Page 57
can prevent the blade from lying perfectly at on
its matting surface. Improper cap screw torque or
use of worn or damage cap screws can cause blade
separation. Always make sure proper maintenance
and replacement parts are used.
Notice
When installing new or sharpened blades, discard
the existing mounting cap screws and use new Altec
approved cap screws. Repeated reuse of the cap
screws will decrease their clamping capacity.
Drum Inspection
The cutter drum, air paddles, and blade pockets must
be thoroughly inspected for cracking or deformation. If
cracking or deformation is found please contact Altec
Environmental Products.
Blade Sharpening
Notice
The blades are double edged and have a minimum
usable size of 2” (5.08 cm) measured from the centerline of the cap screw holes to the blade edge. Do not
use a side of a blade that measures less than this.
• Sharpen blades at a 30 degree angle.
• Use a soft J grade grinding wheel with a 36 to 40
grit.
• Use adequate coolant while grinding.
• Hone blades between sharpening.
Notice
On resharpened blades, measure the distance from
the mounting holes to the sharpened edges. Mount
blades so edges with the same measurements are
oriented the same way at both blade locations.
Anvil Removal/Installation
Danger
Blades and anvils are extremely sharp and can
severely cut your hands. Anytime you are storing,
handling or performing maintenance on blades or
anvils you must wear good quality leather palm
work gloves. This will greatly reduce the possibility
of serious injury.
Outboard Cap Screws
Figure 7.6 — Anvil
2. If needed rotate the drum so cutter blades are not in
the work area.
3. Remove the four 5/8-11 cap screws.
4. Remove the anvil and thoroughly clean all anvil/drum
head mating surfaces.
Anvil Installation
1. If blades are to be rotated or changed this should be
completed rst. Refer to blade installation.
2. With all areas in the anvil location clean and free of
debris, install the anvil positioned with an unused
cutting edge at the blade to anvil cutting point.
3. Install the four anvil cap screws, do not tighten.
4. Slowly hand rotate the drum. Using the anvil gap
gauge, set the anvil to a blade clearance at the outboard cap screw to 1/8”. Hand tighten this outboard
cap screw.
5. Rotate the drum to the other blade, set the outboard
gap and hand tighten the outboard cap screw.
6. While verifying correct gap setting. Slowly hand
rotate the rotor across all anvil/blade contact points
to ensure proper blade/anvil clearance. Adjust as
necessary.
Falling objects can cause serious eye injury.
Always wear goggles when working overhead.
Anvil Removal
1 . Remove the four 1/2-13 cap screws securing the hinged
anvil access cover and anvil/blade gap gauge.
52 • Section 7 — Maintenance
7. Torque anvil cap screws to specications in the
fastener torque table.
Warning
Death or serious injury can occur from blade separation. Never use an impact wrench to tighten blade
or anvil cap screws. Always use a torque wrench.
Page 58
Engine/Clutch
Check engine/clutch operator’s manuals for specic
bearing lubrication, maintenance, and replacement
procedures.
12. Reinstall blades and adjust the anvil/blade gap.
13. Reinstall pulleys or auxiliary equipment previously
removed.
Bearing Replacement
Spherical Bearings
Spherical roller bearings are used on both sides of the
cutter assembly and all feed roll bearings. Self-aligning
bearings such as these are used in areas where perfect
alignment is difcult to maintain. This type of bearing
allows the component to follow the movements of the
structure without applying a side load to the internal
components of the cylinder. Daily lubrication of these
bearing is required to prevent the inner rim that maintains
the alignment from seizing to the outer rim of the bearing.
Daily lubrication ensures contamination is ushed from
the bearings inner components.
Cutter Bearing Replacement
1. Perform LOTO procedures.
2. Remove blades.
3. Remove top cutter housing, belt guard, and bearing
cover.
Warning
Death or serious injury may occur when using improper lifting rigging. Use properly rated hoist, spreader
bar and straps when hoisting drum assembly.
4. Support the cutter assembly using an overhead
crane or hoist. Refer to unit specications for weight
of cutter assembly.
5. Remove any pulleys or auxiliary equipment from the
out board sections of the cutter shaft.
6. Clean and de-bur the exposed sections of the shaft.
7. Remove the two set screws on each bearing assembly.
8. Remove the four bearing ange bolts and remove
the bearing.
9. Install bearings. Apply Loctite #242 to all four bearing
ange bolts. Torque the four bearing ange bolts to
the torque values in the Appendix.
10. Center the cutter assembly in the cutter housing.
11. Make sure one set screw on each bearing is aligned
with the at on the cutter shaft. Apply Loctite #242
to all four set screws. Tighten all four set screws.
14. Reinstall all guards and covers.
Electrical
Electrohydraulic Control
The DRM 12 is equipped with both electronic and hydraulic
controls. The system is comprised of the following parts.
• Hydraulic reservoir located on the street side of the
drum housing.
• Hydraulic pump mounted on the engine inside the
engine housing.
• Main control valve located on top of the infeed chute.
• Hydraulic cylinder anchored at the feed box and feed
roller assembly.
• Holding valve located on the curb side of the feed
box.
• EFC valve located on the infeed chute.
• Feed motor located on the curb side of the feed roller
assembly.
• Magnetic speed sensor (magnetic pickup sensor)
located on the street side of the drum shaft behind
the bearing guard.
• Control module located underneath the control valve
mounting bracket.
FeedSense® (EFC)
FeedSense® is a sub-system of the overall electrohydraulic operation of the chipper which manages the cutting
drum speed. This system ensures that the drum is cutting at an optimal speed which yields best efciency and
maximum throughput. The specic components involved
in the system are the control module, electrohydraulic
EFC valve, and the magnetic speed sensor.
Using the magnetic pickup sensor, the control module
monitors the drum rpm. The EFC valve remains in the
neutral (blocked) state until the proper rpm have been
reached. This prevents rotation of the motor in both
forward and reverse directions. When the drum rpm is
above 2,150 rpm, the EFC valve allows hydraulic ow
to the motor. Now the operator can manipulate the feed
control bar forward and reverse to feed the material in
and out respectively. When feeding wood forward, the
Section 7 — Maintenance • 53
Page 59
material will cause the drum rpm to reduce. In the event
that the rpm drop below 2,000 rpm, the control module will
automatically send a signal to the EFC valve and reverse
the rotation of the feed wheel. This will remove the fed
material from the cutting drum and allow the system to
regain speed. During this time, the EFC valve is in the
neutral state. The system will not automatically resume
forward feed until the drum rpm have recovered. This
event occurs quickly and can last less than a second.
During any point in operation, the panic bar can be pulled
stopping all hydraulic ow to the system. This will divert
all pump ow directly to tank rendering all successive
functions (feed motor, lift cylinder, etc.) disabled. The
panic bar solenoid must be reset in order to resume
system operation.
Troubleshooting
Refer to Figure 7.7 for troubleshooting information.
Advance System Recovery
Advance system recovery is a secondary security measure designed to ensure that the wood fed is controlled.
In the event that the EFC cannot reverse the fed material
due to the wood being too short, the advance system
recovery prevents the wood from being pushed into the
cutting mechanism as the feed wheel descends. It also
monitors the drum rpm disabling the fed material from
dropping the drum rpm to the point where the system would
shut down the engine. This ensures longer component
life and more effective performance. The specic compo-
nents involved in the system are the control module, lift
cylinder, holding valve, and the magnetic speed sensor.
Using the magnetic pickup, the control module monitors
the drum rpm. When feeding wood forward, the material
will cause the drum rpm to reduce. In the event that the
fed material cannot be reversed because it is too short, the
feed wheel will advance it forward as it descends about
the pivot point. If the rpm drop below 1,300, the control
module will automatically send a signal to the holding
valve and block the ow of oil from the lift cylinder. This
will prevent the cylinder from descending. The system
will not automatically resume the descend until the drum
rpm have recovered. This event occurs quickly and can
last less than a second.
While the EFC valve will only allow ow to the motor in a
specic rpm range, the lift cylinder can be used any time
that the engine is running. The feed roller assembly can
be lifted up allowing brush or logs to be tethered through,
or lowered down putting pressure and compressing the
fed material. It is important to note that in the descend
of the feed wheel will have a timed delay in the range
between 200 rpm and 1,300 rpm. The system will allow
for upward motion, but will not allow downward motion
until several seconds have passed.
Drum Magnetic Pickup
Speed (rpm) Frequency (Hz)
500 167
600 200
700 233
800 267
900 300
1,000 333
1,100 367
1,200 400
1,300 433
1,400 467
1,500 500
1,600 533
1,700 567
1,800 600
1,900 633
2,000 667
2,100 700
2,200 733
2,300 767
Figure 7.8 — Frequency to rpm Conversion
C
Warning
Death, serious injury, or property damage can result
when attempting to access moving components.
Make sure components have come to a complete
stop before performing inspection or maintenance.
54 • Section 7 — Maintenance
Measure
Gap Here
Figure 7.9 — Magnetic Sensor Pickup
Page 60
Symptom
Possible Cause
Test Procedure/Corrective Action
Unit will not
feed.
Panic bar tripped.
Controller not
receiving power.
Drum speed too
low.
When tripped, the panic bar will mechanically deect a cam attached to the rst spool of the
main control valve. This will in turn shift the valve to dump oil directly to tank. Reset panic bar
by returning the red valve handle to the neutral state.
Disconnect the harness from the controller. Using a test light, or multimeter, probe pin 13 (module
ground) and pin 14 (module power) to ensure that power is delivered to the module. If no power
is detected, conrm that the connection is adequate, and the harness is not damaged.
The controller receives a drum speed signal from a magnetic speed sensor. If the controller
does not receive the signal, or the signal (rpm) read is too low (below 2,000 rpm), it will not allow
forward/reverse motor functions.
Engine throttle is not in the high position. The engine throttle needs to be in the high position
running at about 2,600 rpm at Idle for the feed system to activate.
Engine not increasing in speed when shifted from the low to high position. For proper throttle
adjustment, refer to the engine manual.
The drum may be jammed preventing it from rotating. Check the drum shaft for rotation. If no
movement is visually detected, refer to the section labeled Clearing Feed System and Discharge
Chute in the manual.
Controller is not receiving a signal from the magnetic pickup. If the controller is not receiving a
signal from the magnetic pickup or the signal is too low, the system will not allow the forward/
reverse function of the feed wheel.
Check the magnetic pickup output at full rpm for correct signal. At full drum rpm, the magnetic
pickup should read 2.5 VAC. Refer to Figure 7.8 for the correct frequency to rpm conversion.
This can be measured by disconnecting the magnetic pickup from the harness and measuring
frequency (Hz) across the connector terminals.
EFC valve
directing oil to
the feed roller
motor.
Oil pressure is
too low.
Verify all the wires intact and the connectors between the magnetic pickup and controller connected.
Proper adjustment of magnetic pickup end should be approximately 0.030” to 0.050” from rpm
sprocket on drum shaft. Refer to Figure 7.9 for clarity.
The valve is activated by a signal delivered from the controller. It shifts when the controller
energizes one of two solenoids. The VF solenoid delivers ow in normal operation. The VR
solenoid reverses ow during normal operation, and more specically during the activation of
the EFC function.
When the control bar is in the forward feed position (pulled towards the rear of the unit), it shifts a
spool on the main control valve through a series of linkages. The spool directs ow to the motor
allowing it to feed forward or in reverse (depending on the control bar position).
Disconnect the connector labeled VF/VR. Using a test light, or multimeter, probe the pins to en-
sure that power is delivered to the solenoid. You can also check the voltage from pin 1 to ground.
It should be 12 V. If no voltage is read, check to make sure that the harness is not damaged.
For the feed roller to operate, the system has to produce both pressure and ow. If no material
is in the infeed chute, the rollers will only require about 150 to 200 psi (10.3 to 13.8 bar) to turn.
When feeding brush and logs, the system normally requires 1,000 to 1,500 psi (68.9 to 103.4
bar). The system relief is set to 2,500 psi (172.4 bar).
If the feed roller does not move when the feed control bar is in the forward feed position, and
all the previous checks show that the system is functioning properly, install a pressure gauge
in the system. The main control valve has a quick connect port located by the panic bar spool
which will allow for connection to a pressure gauge. If the feed wheel is in a bind, the pressure
should read 2,500 psi (172.4 bar). Another option to conrm hydraulic ow to the feed wheel is to
install a pressure gauge in the hose going to the P (or A) port of the EFC valve. With the control
bar and valve in the forward feed position, this should read approximately 2,500 psi (172.4 bar).
Figure 7.7 — FeedSense® Controller Troubleshooting
Section 7 — Maintenance • 55
Page 61
Symptom
Possible Cause
Test Procedure/Corrective Action
Unit will not
feed (cont.)
Feed roller is
jammed.
Material will not
move forward.
If the feed roller does not move when the feed control bar is in the reverse feed position, and
all the previous checks show that the system is functioning properly, install a pressure gauge
in the system. The main control valve has a quick connect port located by the panic bar spool
which will allow for connection to a pressure gauge. If the feed wheel is in a bind, the pressure
should read 2,500 psi (172.4 bar). Another option to conrm hydraulic ow to the feed wheel is to
install a pressure gauge in the hose going to the T (or B) port of the EFC valve. With the control
bar and valve in the reverse feed position, this should read approximately 2,500 psi (172.4 bar).
Material can build up around the feed roller, or wedge between the feed roller assembly and
feed box causing a jam.
With the unit running, cycle the feed control bar from forward to reverse several times. This may
sometimes “back ush” jammed material or debris and allow the unit to continue operating normally.
With the unit locked out and tagged out according to instructions previously mentioned in the
manual, try moving the feed roller slightly back and forth. If the system is jammed, refer to the
Clearing Feed System and Discharge Chute section of the manual.
At times, all systems may check out ne, but material may not move forward. The feed roller
may climb the limbs and pull them slightly but will stall or spin on the material.
The feed opening is 12” high by 17” wide (30.5 cm high by 43.2 cm wide). Anything wider than
this will not advance forward. Remove the material from the chipper, and proceed to cut the
material to a dimension which will t in the opening.
Some materials like cedar and cypress can be very resilient or slippery preventing the feed wheel
from gripping and pulling it through. Use the lift cylinder for down pressure to gain better traction
in order to advance the material forward.
Lift cylinder
malfunction.
Lift cylinder does
not operate up/
down.
Lift cylinder is
stuck (at any
point in the
range of stroke).
If the system is jammed, refer to the Clearing Feed System and Discharge Chute section of the
manual.
The lift cylinder can be used to hydraulically lift the feed roller assembly open, or it can be used
to apply down pressure to large piles of debris for traction.
When the panic bar is tripped, it will mechanically deect a cam attached to the rst spool of the
main control valve. This will in turn shift the valve to dump oil directly to tank. Reset panic bar
by returning the red valve handle to neutral state.
The cylinder needs both pressure and ow to actuate in/out. Install a gauge on the quick connection on the main control valve, and measure the pressure while toggling the cylinder rise/
lower lever. At full rise, and at full lower, the pressure should read around 1,160 psi (80 bar).
Material blocking the feed roller assembly from traveling up and down. If the system is jammed,
refer to the Clearing Feed System and Discharge Chute section of the manual.
The lift cylinder can be hydraulically actuated up or down. By releasing the lift cylinder lever, a
spool in the main control valve will shift to neutral. The cylinder will lose pressure allowing the
feed roller assembly to descend to rest.
Check linkages to ensure the cylinder lift lever returns to neutral.
Electrical problem if the cylinder stays up when the machine is off. Check the connector going
to the holding valve (labeled H). Using a test light, or multimeter, probe the pins to ensure that
power is not delivered to the solenoid. If the ground signal wire is loose and touching metal, it
can cause false trips. This valve is an integral part of the advance system recovery and will only
energize for a short period of time (no more than ve seconds at a time).
A jam could cause the cylinder to stay up even in machine off state? If the system is jammed,
refer to the Clearing Feed System and Discharge Chute section of the manual.
56 • Section 7 — Maintenance
Page 62
Appendix
Page 63
Page 64
Glossary
2nd stage boom — see intermediate boom.
3rd stage boom — see upper boom.
A-frame outrigger — an extendible outrigger having two diagonal
members which are connected at the top and joined near the midsection
by a horizontal cross piece. Resembles a broad based “A.”
above rotation — in reference to a position on or about a unit that is
vertically above the rotation bearing.
absolute — a measure having as its zero point or base the complete
absence of the item being measured.
absolute pressure — a pressure scale with the zero point at a perfect
vacuum.
access hood ― hinged part of the disc housing used to access the
cutter disc.
accumulator — a container used to store uid under pressure as
a source of hydraulic power or as a means of dampening pressure
surges.
actuator — a device for converting hydraulic energy into mechanical
energy, such as a motor or cylinder.
adapter — a device used to connect two parts of different type or
diameter.
adhesion promoter — surface prepping solvent for UV coating.
adjusting stud — a component of a cable drive system that is threaded
on both ends and has a hex adjusting at in the center. It secures the
drive cable to the cylinder rod and can be used to adjust the tension
of the drive cable.
aeration — the entrapment of air in hydraulic uid. Excessive aeration
may cause the uid to appear milky and components to operate erratically because of the compressibility of the air trapped in the uid.
aerial control valve — the control valve on the turntable of an elevator
unit which operates the movement functions of the aerial device.
aerial device — a vehicle-mounted device with a boom assembly
which is extendible, articulating, or both, which is designed and used
to position personnel. The device may also be used to handle material,
if designed and equipped for that purpose.
Allen wrench — a six-sided wrench that ts into the hex socket of a
cap screw or set screw.
American National Standards Institute (ANSI) — a self-governing
body of professionals whose primary objective is to prevent accidents
by establishing requirements for design, manufacture, maintenance,
performance, use and training for manufactured goods including aerial
devices and digger derricks.
anaerobic adhesive — a bonding agent or adhesive that cures in
the absence of air.
analog signal — an electrical signal that communicates information
by the continuous variation of voltage or current level within a dened
range, in proportion to an input parameter such as pressure or control
lever position.
annular area — a ring shaped area. Usually refers to the piston area
minus the cross-sectional area of the rod of a hydraulic cylinder.
ANSI — see American National Standards Institute.
anti-two-block (ATB) system – the system that helps prevent dam-
age to the winch line or boom by preventing a two-blocking condition
from occurring, by shutting off certain functions when the load hook,
overhaul ball, hook block, or other lifting component that is attached
to the winch line approaches near the boom tip.
antirotation fork — a two-pronged retainer which is fastened to the
inside of the turntable and used to prevent movement of the rotary
joint outer housing.
antifoam additive — an agent added to hydraulic uid to inhibit air
bubbles from forming and collecting together on the surface of the
uid.
antiwear additive — an agent added to hydraulic uid to improve
the ability of the uid to prevent wear on internal moving parts in the
hydraulic system.
anvil — The stationary blade on a chipper cutting mechanism.
arbor bar — the shaft or spindle that is used to support a cable reel.
arbor bar collar — a cylindrical device that is used to secure a cable
reel on an arbor bar.
arm — 1: the primary load-carrying structure of an articulating arm. 2:
the primary load-carrying structure of a single elevator. 3: the articulat-
ing structure which supports the arbor bar for reel lifting.
arm cylinder — the hydraulic cylinder that moves the arm of a single
elevator up and down.
articulating arm — a system located between the turntable and lower
boom of an aerial device which is used for lifting the boom assembly
to increase the platform working height. This system includes the arm,
link(s), riser and articulating arm cylinder.
articulating arm cylinder — the hydraulic cylinder that moves an
articulating arm up and down.
articulating-boom aerial device — an aerial device with two or more
boom sections that are connected at joint(s) which allow one boom to
pivot with respect to the adjacent boom.
ASTM — American Society for Testing and Materials.
atmosphere (one) — a pressure measure equal to 14.7 psi.
atmospheric pressure — pressure on all objects in the atmosphere
because of the weight of the surrounding air. At sea level, about 14.7
psi absolute.
atmospheric vents — a vacuum prevention device designed to allow
air to enter a hydraulic line that has encountered an internal pressure
below that of the atmosphere (vacuum).
attention — information that must be followed to reduce the likelihood
of property damage. Property damage could include structural damage
to the unit, component failure, or damage to nearby property.
auger — the hole boring tool of the digger, consisting of a hollow tube
with hardened teeth attached at one end to dig into and break up soil
and/or rock as the auger is rotated. Several turns of ighting are welded
to the tube to carry the loose material away from the teeth.
auger extension shaft — a shaft which ts into the auger tube to
connect the digger output shaft to the auger.
auger rotation hydraulic system — the hydrostatic system on a pressure digger which operates the auger transmission gearbox.
auger stow bracket — the bracket on a digger derrick lower boom
which stores the digger and auger assembly when it is not in use.
auger stow switch — a limit switch which is actuated by the auger
to shut off digger operation in the stowing direction when the auger
reaches its fully stowed position in the auger stow bracket.
auger transmission gearbox — the gearbox mounted on the mast
weldment of a pressure digger that is used to rotate the kelly bar.
auger tube — the hollow tube at the centerline of an auger to which
the auger ighting is welded.
auger windup sling — the cable or strap attached to the auger stow
bracket which is used to store the digger and auger.
auxiliary engine — a separately mounted engine that is used to provide
power for the unit’s hydraulic system.
auxiliary hydraulic system — the secondary hydraulic system of a
pressure digger that operates all the hydraulic functions except auger
rotation.
AWS — American Welding Society.
back pressure — pressure existing in the discharge ow from an ac-
tuator or hydraulic system. It adds to the pressure required to operate
an actuator under a given load.
backlash — the clearance at the tooth contact point between the
adjacent gear teeth of two or more meshing gears.
bafe — a device, usually a plate, installed in a reservoir to separate
the return line inlet from the suction line outlet.
band of arrows — decals used on extendible and articulating upper
booms to dene the boom tip area and the insulating portions of the
upper boom and lower boom insert.
bare-hand work — a technique of performing live line maintenance on
energized conductors and equipment whereby one or more authorized
persons work directly on an energized part after having been raised
and bonded to the energized conductors or equipment.
barrel — the hollow body of a hydraulic cylinder into which the piston
and rod are assembled.
base boom — see lower boom.
base end — 1: the closed end of a hydraulic cylinder, opposite from the
end that the rod extends from. 2: the end of an extendible boom that is
1
Appendix — Glossary
Page 65
closest to the turntable. 3: the end of an articulating boom that remains
positioned closest to the turntable when the boom is fully unfolded.
basket — see platform.
battery charger — a device used to restore the electrical charge in
a battery.
bearing — a machine part that is installed between two adjacent machine
parts to allow those parts to rotate or slide with respect to each other.
Commonly used to decrease friction or wear on components.
behind cab mount — a pedestal mounting position located immediately
behind the vehicle cab on the longitudinal centerline of the chassis.
below rotation — in reference to a position on or about a unit that is
vertically below the rotation bearing.
below rotation controls — controls that are located on the chassis,
used for operating some or all of the functions of the unit.
bleed-off — to reduce the trapped pressure in a hydraulic system,
line, or component, to a zero state by allowing uid to escape under
controlled conditions through a valve or outlet.
blocking valve — a two-position, two-way valve that blocks pump ow
to a hydraulic circuit or system when it is not actuated, and opens to
allow uid when actuated.
body — a structure containing compartments for storage of tools,
materials, and/or other payload which is installed on a vehicle frame
or subbase.
body belt — a component in a personal fall protection system consisting
of a strap which is secured about the waist of a person, with a means
for attaching it to a lanyard. (As of January 1, 1998, the use of a body
belt for personal fall protection is prohibited by OSHA.)
body harness — a component in a personal fall protection system
consisting of an assembly of straps which are secured about the waist,
chest, shoulders, and legs of a person, with a means for attaching the
assembly to a lanyard.
bolt — a cylindrical fastener with external screw threads at one end
and a head conguration such hexagonal, square, or round at the other
end, which conforms to the dimensional and material specications
published for bolts. (These specications are different from those for
cap screws.)
boom — a movable, mechanical structure that is used to support a
platform, material handling components and/or other attachments on
a unit.
boom angle indicator — a device which indicates the angle between
the boom centerline and a horizontal plane.
boom ares — steel structures mounted on the boom tip of a digger
derrick which are used to protect the boom tip from loads and support
poles carried on the winch line.
boom functions valve — the control valve on a digger derrick that
directs hydraulic pressure and ow to the boom functions (boom, rotation, intermediate boom, upper boom) hydraulic circuits.
boom limiting system — the system of hydraulic cylinders or a
combination of switches that prevent the platform from moving into a
non-working position.
boom pin — the horizontal pin that connects the lower boom to the
turntable or riser.
boom rest — the structural member attached to the chassis or body
to support the lower boom in the travel or rest position.
boom stow switch — a limit switch which is actuated to shut off the
boom lower function when the boom reaches its stowed position in
the boom rest.
boom stow valve — a mechanically actuated hydraulic valve that limits
the downward pressure of a boom as it is placed in its rest.
boom tip — the area at the end of an extendible or articulating upper
boom that is farthest from the turntable when the boom assembly is
extended or unfolded. This area includes all components at the end
of the boom above the band of arrows.
boom tip idler sheave — the upper sheave in a digger derrick upper
boom tip containing two sheaves, which carries the winch line as it
travels from the winch to the lower sheave (boom tip sheave).
boom tip pin — a horizontal pin at the upper boom tip. Platform mounting
bracket(s) and material handling devices are fastened to this pin.
boom tip sheave — 1: the sheave in a digger derrick upper boom tip
containing only one sheave, which carries the winch line as it travels
from the winch to the load. 2: the lower sheave in a digger derrick up-
per boom tip containing two sheaves, which carries the winch line as it
travels from the upper sheave (boom tip idler sheave) to the load.
boom tip tools — see upper tool circuit.
boom tip winch — a winch located at the tip of a boom.
bore — the inside diameter of a pipe, tube, cylinder barrel, or cylindrical
hole in any of various other components.
boss — protruding material on a part which adds strength, facilitates
assembly, provides for fastenings, etc.
brake — a device used to slow or stop the rotation or movement of a
component such as a rotation gearbox, winch, gravity leveled platform,
or arbor bar.
brake caliper — mechanical assembly that houses the brake pads
and piston used to apply stopping force on the brake rotor.
brake controller — interface between tow vehicle and electric trailer
brakes. Can be inertia activated or based on time delay from activation
of vehicle brakes. Typically in the tow vehicle’s driving compartment
with electrical line running to the trailer wiring connector. Most require
the user to adjust brake gain to compensate for varying trailer load.
Necessary for the use of electric trailer brakes.
brake rotor — rotating disk attached to a shaft that transfers the force
from the brake caliper to the shaft.
break-away switch — a device which automatically activates the
breaking system of a towed unit when unintentionally separated from
the towing vehicle.
breather — a device that permits air to move in and out of a container
or component to maintain atmospheric pressure.
bridge mount — a unit mounting conguration in which the turntable
is mounted on a pedestal structure which forms a bridge over the
cargo area.
broadband — a high speed telecommunication system utilizing ber
optic and/or coaxial cable.
bucket — see platform.
buckeye — see forged pin retainer.
bullwheel assembly — an assembly of steel rollers used as a portion
of a cable stringing system.
burst pressure — the minimum internal pressure that will cause a
hose, tube, cylinder, or other hydraulic or pneumatic component to
rupture or split open.
button head — a type of cap screw with a rounded head containing a
socket into which a tool can be inserted to turn the cap screw.
bypass — a secondary passage for uid ow.
bypass valve — a hydraulic valve that allows for an alternate pas-
sage for uid ow.
cable — 1: a wire or wire rope by which force is exerted to control or
operate a mechanism. 2: an assembly of two or more electrical conduc-
tors or optical bers laid up together, usually by being twisted around a
central axis and/or by being enclosed within an outer covering.
cable chute — a device used to guide cable into strand for lashing
the cable to the strand when placing cable. A trolley allows the device
to ride on the strand as cable is fed through the chute.
cable drive system — an upper boom drive mechanism which utilizes
cables to produce upper boom movement.
cable guide — a bracket which is mounted on a boom to guide the
winch line.
cable keeper — 1: a mechanical device attached to a cable that is used
to maintain the position of the cable on a sheave. 2: a component used
to prevent a cable or winch line from coming off a sheave.
cable lasher — a mechanical device which wraps lashing wire in a
spiral conguration around a length of suspension strand and adjacent
communication cable.
cable lug — a mechanical device attached to a cable that is used to
maintain the position of the cable on a sheave.
cable placer — a type of aerial device which contains a cable stringing system and associated components for use in erecting overhead
communication cable.
cable slug — the steel end tting at each end of the drive cable in an
upper boom drive system. One end is attached to the cylinder rod and
the other is secured in a pocket on the elbow sheave.
Appendix — Glossary
2
Page 66
cable stringing system — the group of steel rollers, bullwheel assemblies, strand sheave assemblies and fairlead which directs communication cable or suspension strand from the reel it is stored on to
the working position of the operator.
calibrate — to check, adjust, or determine by measurement in com-
parison with a standard, the proper value of each scale reading or
setting on a meter or other device.
caliper — a measuring instrument with two legs or jaws that can be
adjusted to determine the distance between two surfaces.
cam — a rotating or sliding piece that imparts motion to a roller moving
against its edge or to a pin free to move in a groove on its face or that
receives motion from such a roller or pin.
candling — a method of inspecting lament wound berglass booms
by slowly passing a light through the inside of the boom in a darkened
area. Cracks, crazing, and other damage show up as dark spots or
shadows.
cap — a device located on the hand of a reel lifter that is used to
retain the arbor bar.
cap end — see base end.
cap screw — a cylindrical fastener with external screw threads at
one end and a head conguration such as hexagonal, hex socket, at
countersunk, round, or slotted at the other end, which conforms to the
dimensional and material specications published for cap screws.
capacitive coupling — the transfer of electrical energy from one
circuit to another through a dielectric gap.
capacity chart — a table or graph showing the load capacity, rated
capacity, or rated load capacity gures for a unit or accessory.
captive air system — a closed circuit, low pressure pneumatic system
used to actuate a pressure switch by means of a manually operated
air plunger.
cartridge — 1: the replaceable element of a uid lter. 2: the replace-
able pumping unit of a vane pump, composed of the rotor, ring, vanes
and side plates. 3: A removeable hydraulic valve that is screwed into
place in a cavity in a hydraulic manifold or cylinder.
catrac — see hose carrier.
caution — information that indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
cavitation — the formation of gaseous voids in hydraulic uid caused
by a low pressure condition which typically occurs when inlet starvation
prevents the pump from lling completely with uid. The characteristic
sound of cavitation is a high pitched scream.
center mount — see behind cab mount.
center of gravity — the point in a component or assembly around
which its weight is evenly balanced.
centerline of rotation — the vertical axis about which the turntable
of a unit rotates.
centrifugal pump — a pump in which motion and force are applied
to uid by a rotating impeller within a housing.
chain — a series of identical rigid segments connected to each other
at joints which allow each segment to pivot with respect to adjacent
segments, used to transmit mechanical force.
chain extension system — a mechanical system consisting of a mo-
tor, gearbox, chains, and sprockets that is used to extend and retract
an extendible upper boom.
chain sling — an inverted Y-shaped length of chain used for lifting a
strand reel with an aerial device and placing it in a strand carrier.
chamber — a compartment within a hydraulic component that may
contain elements to aid in operation or control, such as a spring chamber or drain chamber.
channel — a uid passage that has a large length dimension compared
to the dimension of the cross-section.
charge — to ll an accumulator with uid under pressure.
charge pressure — the pressure, above atmospheric pressure, at
which replenishing uid is forced into the hydraulic system.
charge pump — the hydrostatic hydraulic system pump that provides
uid at low pressure to make up for internal leakage, provides cooling
uid ow, and tilts the hydrostatic pump swash plate.
chassis — a vehicle on which a unit is mounted, such as a truck,
trailer, or all-terrain vehicle.
check valve — a valve that permits ow of uid in one direction, but
not in the reverse direction.
chip curtain — rubberized deection curtain attached to the infeed
chute.
chip deector — directs chip discharge.
circuit — the complete path of ow in a hydraulic or electrical sys-
tem.
circuit breaker — a form of electrical switch which opens (trips) to
interrupt a circuit when it senses excessive current ow that may be
caused by a short circuit, to protect wiring and components from damage.
Some types of circuit breakers reset automatically when the excessive
current discontinues and others must be reset manually.
clean out — clean out area under the lower feed roll.
clevis — a U-shaped fastening device secured by a pin or bolt through
holes in the ends of two arms.
closed center — a directional valve design in which pump output is
blocked by the valve spool(s) when the valve spool(s) is in the center
or neutral operating condition.
clutch — 1: the device on a reel lifter which allows the connection and
disconnection of the arbor bar and the driver. 2: controlled transfer of
rotational power from engine to output PTO shaft.
coaxial cable — a type of shielded cable used for conducting telecommunication signals, in which the signal carrier is a single wire at
the core, surrounded by a layer of insulating material, which is in turn
surrounded by a metallic, conductive layer which serves as a shield,
with an overall outer layer of insulation.
combined digger derrick and platform use — the stability criteria
for a digger derrick mobile unit which indicates that the load capacity
chart and stability requirements apply to the use of the derrick for lifting
of loads with the winch line at the upper boom tip or material handling
jib tip, with the platform occupied.
come-along — a device for gripping and putting tension into a length
of cable, wire, rope, or chain by means of two jaws or attaching devices
which move closer together when the operator pulls on a lever.
communication cable — a copper wire, coaxial, or ber optic cable
used for conducting telecommunication signals.
compensating link — a mechanical linkage that serves as a connector
between the turntable and the upper boom drive mechanism. As the
lower boom is raised or lowered, this linkage causes the upper boom
to maintain its relative angle in relationship to the ground.
compensator — a valve spool that is used to maintain a constant
pressure drop regardless of supply or load pressure.
compensator control — a control for a variable displacement pump
that alters displacement in response to pressure changes in the system
as related to its adjusted pressure setting.
component — a single part or self-contained assembly.
compressibility — the change in volume of a unit volume of a uid
when it is subjected to a unit change in pressure.
conductive — having the ability to act as a transmitter of electricity.
Electricity will ow through metal, therefore metal is conductive.
conductive shield — a device used to shield the lower test electrode
system from capacitive coupling.
conductor — a wire, cable, or other body or medium that is suitable
for carrying electric current.
constant resistivity monitor — device used to continuously measure
the electrical resistance of the wash water in the tank of an insulator
washer.
contaminate — to render unt or to soil by introduction of foreign or
unwanted material.
continuous rotation — a rotation system in which the turntable is
able to rotate an unlimited number of revolutions about the centerline
of rotation without restriction.
control — a device, such as a lever or handle, which is actuated by
the operator to regulate the direction and speed of one or more functions of a unit.
control bar — when manually activated, controls the movement of
feed roll(s) on a chipper.
control feed — a wood chipper which controls the infeed rate to the
cutting mechanism.
3
Appendix — Glossary
Page 67
control station — a position where controls for unit operation are
located. These positions may include the platform, upper boom tip,
turntable, pedestal or vehicle tailshelf.
control valve — a directional valve controlled by an operator, used to
control the motion or function of an actuator or system.
cooler — a heat exchanger used to remove heat from hydraulic uid.
corner mount — a pedestal mounting position located behind the
rear axle(s) with the centerline of rotation located to one side of the
chassis.
corona ring — see gradient control device.
counterbalance valve — a load holding valve that can be opened
to allow ow in the normally blocked direction by applying hydraulic
pressure to a pilot port, and which contains a relief capability to allow
ow from the blocked direction if the blocked pressure exceeds a
certain value.
courtesy cut — partial cut through limbs so as to allow limbs to fold
towards tree trunks and allow ease of feeding chipper.
cracking pressure — the pressure at which a pressure actuated valve,
such as a relief valve, begins to pass uid.
crazing — a network of ne cracks on or below the berglass surface.
Crazing often occurs when the berglass is struck with a blunt object,
sometimes causing deformation and breakdown of the berglass
resin.
crosstalk — a form of interference in which one circuit or channel
receives some unintentional signal from another.
cross-ported — a hydraulic path connected between the two opposite
ow paths of a hydraulic circuit that allows a route for ow between
the two paths in lieu of ow thru an actuator. To allow sensing of the
pressure in one path by a component installed in the other path.
cSt (centistoke) — a metric unit of kinematic viscosity. In customary
use, equal to the kinematic viscosity of a uid having dynamic viscosity
of one centipose and a density of one gram per cubic centimeter.
curb side — the side of a vehicle which is opposite from oncoming
trafc when the vehicle is traveling forward in the normal direction in
a lane of trafc.
cushion — a device built into a hydraulic cylinder that restricts the ow
of uid at the outlet port to slow the motion of the rod as it reaches
the end of its stroke.
custom option — an option which is not shown on a standard order
form and which requires additional engineering work to supply.
cylinder — a device that converts uid power into linear mechanical
force and motion. It usually consists of a moveable piston and rod, or
plunger, operating within a cylindrical bore.
danger — information that indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury. This signal
word is to be used in the most extreme situations.
DC pump — a pump which is powered by a direct current electric
motor.
dead band — the area or range near the center rest position of a
hand control where the function does not respond to movement of
the lever or handle.
decal — a thin sheet of exible material which is attached to another
surface by adhesive, and is used to convey instructions, information
and warnings.
deenergize — to remove electrical power from a device, as from the
coil of a solenoid valve.
delivery — the volume of uid discharged by a pump in a given time,
usually expressed in gallons per minute (gpm).
demulsibility — the ability of a liquid to expel another type of liquid.
Commonly used to describe a uid’s ability to cause water to separate
out rather than being held in suspension.
design voltage — the maximum rated line voltage for which an aerial
device has been designed, and for which it can be qualied.
desolve — surface prepping solvent for low voltage coating.
detent — a device for positioning and holding one mechanical part in
relation to another so that the device can be released by force applied
to one of the parts.
diagnostic — relating to the practice of investigation or analysis of the
cause or nature of a condition, situation, or problem.
diagonal brace — the structural member attached near the top of a
corner mount pedestal and extending downward and forward to a point
of attachment on the subbase or vehicle frame between the pedestal
and the vehicle cab.
dial indicator — a meter or gauge with a calibrated circular face and
a spring-loaded plunger, used as a measuring device.
diegrinder — a small, hand held, rotary grinding tool.
dielectric — nonconductive to electrical current.
differential cylinder — any cylinder that has two opposed piston
areas that are not equal.
digger — the mechanism which drives the auger.
digger bail — a tubular housing attached to the gearbox portion of a
digger, which surrounds the motor and provides an attachment point
to the digger link.
digger derrick — a multipurpose, vehicle-mounted device with an
extendible boom which may accommodate components that dig
cylindrical holes, set utility poles, and position materials, apparatus,
and/or personnel.
digger derrick use — the stability criteria for a digger derrick mobile
unit which indicates that the load capacity chart and stability require-
ments apply to the use of the derrick for lifting of loads with the winch
line at the upper boom tip or material handling jib tip, with the platform
stowed or removed, if so equipped.
digger hanger bracket — the structural member on a digger derrick
which supports the digger link on the extendible boom.
digger latch mechanism — a mechanism which secures the digger
to the lower boom when it is stowed and to the extendible boom when
it is unstowed.
digger link — the structural member which attaches the digger to the
digger hanger bracket.
digger/winch valve — the control valve on a digger derrick that
directs hydraulic pressure and ow to the digger and winch hydraulic
circuits.
digital signal — an electrical signal that communicates information
by the use of two distinct levels of voltage or current, a high “on” level
and a low “off” level, which are sent in a series of pulses. The timing
of the pulses is used to indicate the level of an input parameter such
as control lever position, or information such as the address setting of
a radio control transmitter linking it to its receiver.
diode — an electrical component that allows current ow in one direc-
tion but not in the reverse direction.
directional valve — a valve that selectively directs or prevents uid
ow through desired passages.
disc — the rotating component, housing the knifes on a disc chip-
per.
disc chipper — a wood chipper which utilizes a disc shaped, rotating
cutter mechanism.
disc housing — weldment housing the cutting disc, comprising of the
base, stationary hood and access hood.
discharge chute — directs chip discharge from the cutter mechanism
in the desired direction.
displacement — the quantity of uid that can pass through a pump,
motor or cylinder in a si ngle revolution or stroke.
docking station — a device used to mount a remote control transmitter on a platform.
dog clutch — see drum clutch.
double-acting cylinder — a cylinder in which uid pressure can be
applied to either side of the piston to move the rod in either direction.
double elevator — an elevator lift with two load carrying arms. The
double elevator system includes a lower pedestal, lower arm, lower arm
cylinder(s), riser, upper arm, upper arm cylinder(s), and upper pedestal,
plus parallel links in both the lower and upper sections.
double-pole, double-throw (DPDT) switch — a six-terminal electrical
switch or relay that connects, at the same time, one pair of terminals
to either of two other pairs of terminals.
double-pole, single-throw (DPST) switch — a four-terminal electrical
switch or relay that, at the same time, opens or closes two separate
circuits or both sides of the same circuit.
down load — the downward force created when an external force is exerted on the boom, such as a winch pulling cable on a cable placer.
Appendix — Glossary
4
Page 68
drain — a passage or a line from a hydraulic component that returns
leakage uid to the reservoir.
drift — 1: a gradual, uncontrolled change from a set position of an
actuator or component. 2: a tool for ramming or driving something.
driver — the gearbox and motor assembly on a reel lifter which is
connected to and disconnected from the arbor bar through the clutch
assembly.
drop pocket — an open top tool storage area on the chassis of a
unit.
drum — the rotating component, housing the knifes on a drum chip-
per.
drum chipper — a wood chipper which utilizes a drum shaped, rotating cutter mechanism.
drum clutch — a clutch consisting of two or more drive lugs that engage
similar driven lugs to transmit torque. Commonly used between the
gearbox and cable drum on front or bed mounted winches.
dump valve — a normally open, two-position, two-way valve that sends
pump ow through a path going directly to the reservoir or bypassing
hydraulic circuit when it is not actuated, preventing operation of the
hydraulic system or circuit. When it is actuated, it closes off this path,
redirecting ow to the hydraulic system or circuit to allow operation.
dynamometer — an instrument for measuring mechanical force or
power.
earth anchor — see screw anchor.
eccentric ring — a ring with the center hole located in a position off the
geometric center, commonly used to adjust the position of the rotation
pinion with respect to the rotation bearing gear teeth.
eccentric ring lock — a device which engages a hole or notch in an
eccentric ring to prevent the ring from rotating.
efciency — the ratio of output to input. Volumetric efciency of a pump
is the actual output in gpm divided by the theoretical or design output.
The overall efciency of a hydraulic system is the output power divided
by the input power. Efciency is usually expressed as a percent.
elbow — the structure on an articulating-boom aerial device that connects the upper boom to the lower boom. The elbow allows the upper
boom to pivot relative to the lower boom.
elbow bearing — the rotating member that allows the upper boom to
rotate around the end of the lower boom. Used on aerial devices with
the upper and lower booms mounted side by side.
elbow pin — the horizontal pin that attaches the upper boom to the
lower boom on an articulating-boom aerial device. Used on aerial
devices with the upper boom mounted over the lower boom.
electrical harness — an assembly of electrical wires that is used to
deliver electrical current between components.
electrocution — receiving an electrical shock resulting in death.
electrohydraulic — a combination of electric and hydraulic control
mechanisms in which an electrically controlled actuator is used to shift
the spool in a hydraulic control valve.
electrohydraulic control system — a control system in which the
function control handles are connected to electric controls. The electric controls actuate electrohydraulic valves to operate the functions
of the unit.
electrohydraulic valve — a directional valve that receives a variable or controlled electrical signal which is used to control or meter
hydraulic ow.
elevator lift — a system located between the turntable and subbase
of an aerial device which is used for lifting the aerial device to increase
the platform working height. This system may be congured as a single
elevator or a double elevator.
elevator unit — the overall device including the subbase, elevator lift
and the aerial device.
emergency operating DC pump — see secondary stowage DC
pump.
emergency operating system — see secondary stowage system.
end gland — a hollow, cylindrical part that screws into or is retained
in the open end of a hydraulic cylinder barrel, through which the rod
protrudes.
end-mounted platform — a platform which is attached to a mounting
bracket that extends beyond the boom tip, positioning the platform
(and platform rotation pivot, if so equipped) beyond the end of the
upper boom.
energize — to send electrical power to a device, as to the coil of a
solenoid valve.
energized conductor — an apparatus that is transmitting electric
current.
energy — the ability or capacity to do work, measured in units of
work.
engine protection system — a system which detects when the
auxiliary engine oil pressure or temperature is out of the proper range
and shuts the engine off.
extendible — capable of linear movement of one or more portions of
an assembly to increase the overall length or reach of the assembly.
extendible-boom aerial device — an aerial device with a telescopic
or extendible boom assembly.
extension cylinder — a hydraulic cylinder which extends and retracts
an extendible boom(s).
fairlead — the group of steel rollers at the platform of a cable placer which
guide the cable or suspension strand during the placing process.
fairlead receptor tube — part of the pulling arms used to support
the fairlead.
fall protection system — a system consisting of a body harness or
body belt, a decelerating lanyard, connectors, and an anchor point at
the boom tip, used to catch and hold a person who falls from a plat-
form. (As of January 1, 1998, the use of a body belt for personal fall
protection is prohibited by OSHA.)
fan — part of the disc or drum chipper which propels chipped debris
and increases airow into the discharge chute.
feed box — assembly housing the feed roll(s).
feed roll — a mechanical controlled roll or rollers used to control the
feed rate to the cutter mechanism.
feed table — folding or xed position guard which restricts operators
access to the cutter mechanism.
feedback (feedback signal) — the return of part of an output signal to
the input for the purpose of modication and control of the output.
feeder tube — a telescopic hydraulic tube assembly mounted on an
extendible boom which carries pump ow to a device mounted on the
extendible portion of the boom such as a digger or boom tip winch.
FeedSense® — Automatically maintains cutter mechanism speed.
ber optic cable — a type of cable used for conducting control or
telecommunication signals, in which the signal carrier(s) is one or more
optical bers, enclosed within an outer covering.
ber optic receiver — an electronic module that collects ber optic
signals and converts them into electrical signals.
ber optic transmitter — an electronic module that converts elec-
trical signals into ber optic signals and sends them through a ber
optic cable.
ber optics — the use of transparent bers of glass or plastic which
transmit light signals throughout the length of the ber. Commonly used
to transmit signals from a remote control.
berglass — glass in brous form added as a reinforcement to a plastic
for use in making various products.
ller breather cap — the component on the top of a reservoir that
allows air to enter and exit the reservoir as the uid level changes,
and which can be removed to access a ll hole when adding hydraulic
uid to the reservoir.
lter — a device through which uid is passed to remove and retain
insoluble contaminants from a uid.
lter cart — a portable device which can be connected to a unit’s
hydraulic system to lter water and/or other contaminants out of the
hydraulic system uid.
lter cartridge — a component containing ltration material which is
installed within a lter housing or attached to a lter receptacle for use,
and can be removed and replaced as a self-contained unit.
rm footing — outrigger placement and extension in accordance with
the instructions in a unit’s operator’s manual to ensure proper leveling
of the vehicle and adequate stability when operating the unit.
xed displacement pump— a pump in which displacement is con-
stant, so that the output ow can be changed only by varying the
drive speed.
5
Appendix — Glossary
Page 69
ange — on a ange and lug pin retaining system, an end plate that is
welded to one end of the pin. The purpose of the ange is to position
the pin in the connection.
ange and lug pin retaining system — a connecting pin retention
system in which an end plate is welded to one end of the pin and a
retaining plate is attached with cap screws to the other end to hold
the pin in position.
ashover — a disruptive electrical discharge at the surface of electrical
insulation or in the surrounding medium, which may or may not cause
permanent damage to the insulation.
ats from nger tight (F.F.F.T.) — a method of counting the number
of wrench ats when tightening a hydraulic adapter to establish a
torque value.
at-shoe outrigger — an outrigger which has a shoe that is xed in
a horizontal position.
ighting — a curved plate or series of curved plates welded together,
spiraling along the axis of an auger tube or screw anchor rod.
ow — the movement of uid generated by pressure differences.
ow control valve — a valve that regulates the rate of uid ow.
ow rate — the volume, mass or weight of a uid passing through any
conductor per unit of time.
ow straightener — a component part of a nozzle used to straighten
or remove any swirling motion of uid going through the nozzle.
owmeter — an instrument used to measure the ow rate of uid in
a hydraulic tube or hose.
uid — a liquid that is specially compounded for use as a power
transmitting medium in a hydraulic system.
fold — to move a pivoting structure such an articulating upper boom
toward its stowed position.
fold-up shoe outrigger — an outrigger which has a shoe that pivots
into a vertical position when the outrigger is fully retracted.
force — any push or pull measured in units of weight.
forged pin retainer — a pin retainer made from forged steel, consisting
of a slender, cylindrical body with a attened, circular head at one end,
with a mounting hole through the head perpendicular to the body. The
body is inserted through a hole in the pin to be retained, and the head
is fastened to the adjacent structure with a cap screw.
four-way valve — a valve having four ports for direction of uid ow.
FPS — Fluid Power Society.
frequency — the number of times an action occurs in a unit of time.
gasket — a packing made of a deformable material, usually in the
form of a sheet or ring, used to make a pressure tight t between
stationary parts.
gate valve — see shutoff valve.
gauge pressure — a pressure scale that ignores atmospheric pres-
sure by establishing atmospheric pressure as its zero point. Its zero
point is 14.7 psi absolute.
gauge snubber — see snubber valve.
gearbox — an assembly with internal speed changing gears; a transmis-
sion. Gearboxes are commonly used to transmit power from a hydraulic
motor to operate a function through an output shaft.
gelcoat — a protective coating used on berglass components to
prevent the wicking of moisture into the berglass strands and to retard
the degrading effect of ultraviolet light on the berglass.
GFI — ground fault interrupter.
gib assembly — secures cutter knives in place on drum chippers.
gin pole — a vertical phase-holding apparatus which is attached to a
platform or upper boom tip.
gpm — gallons per minute.
gradient control device — a device at the upper end of an insulating
boom that reduces electrical stress level(s) below that considered to
be disruptive.
gravity leveling system — a system which uses the force of gravity
to keep the bottom of a platform parallel to level ground as the boom
is raised or lowered. One means of accomplishing this is by allowing
the platform to pivot freely about a horizontal shaft attached above the
platform’s center of gravity.
grease tting — a small tting that acts as the connection between a
grease gun and the component to be lubricated.
gripper tool — a component used for grasping an object or electrical
lines through the use of an articulated mechanism.
ground — 1: a large conducting body with a potential of zero volts
used as a common current return for an electric circuit. 2: an object that
makes an electrical connection with a ground or with the earth.
ground fault interrupter (GFI) — a fast acting form of circuit breaker
that opens to interrupt an electrical circuit if it senses a very small
current leakage to ground, to protect personnel against a potential
shock hazard from defective electrical tools or wiring. It does this by
monitoring for any difference in current ow between the hot and neu-
tral wires in the circuit. An imbalance exceeding a very small preset
value indicates that current is nding an improper path to ground, and
causes the breaker to trip.
guard ring — see conductive shield.
hand — an extension of the reel lifter arm that allows for loading the
arbor bar.
hand control — a hand operated control lever or handle located at a
control station used to regulate a function of a unit, where the speed of
the function is proportional to the distance the control is moved.
hand latch — mechanical device used to retain the arbor bar in the
reel lifter or strand carrier hand.
heat — the form of energy that has the capacity to create warmth or
to increase the temperature of a substance. Any energy that is wasted
or used to overcome friction is converted to heat. Heat is measured in
calories or British thermal units (Btu). One Btu is the amount of heat
required to raise the temperature of one pound of water one degree
Fahrenheit.
heat exchanger — a device that transfers heat through a conducting
wall from one uid to another or into the atmosphere.
hertz (Hz) — a unit of frequency equal to one cycle per second.
high tooth — the individual tooth out of all the gear teeth on a rotation
bearing at which the minimum backlash occurs with the rotation pinion.
This is because of a slight difference between the actual and theoretical
tooth pitch lines due to manufacturing tolerances.
HLIW — hot line insulator washer.
holding valve — see load holding valve.
hood pin — in conjunction with bolts, secures the two top halves of
the disc housing together.
HOP — see hydraulic overload protection system.
horsepower (HP) — the power required to lift 550 pounds one foot in
one second or 33,000 pounds 1 foot in one minute. One horsepower
is equal to 746 watts or to 42.4 British thermal units per minute.
hose carrier — a exible component which contains hydraulic, elec-
trical, and/or air lines, usually mounted inside or along the side of an
extendible boom. As the boom is extended, the hose carrier unfolds in
a rolling motion to allow the lines to extend with the boom.
hose carrier tube — a rigid, enclosed tube which contains hydraulic,
electrical, and/or air lines, and may contain components for upper
controls. It is usually attached to a hose carrier on the side of an
extendible boom.
hot line insulator washer (HLIW) — a vehicle-mounted device which
is designed and used for cleaning pole and structure mounted transmission and distribution insulators.
HTMA — Hydraulic Tool Manufacturer’s Association.
Huck bolt — a bolt-like fastener that is placed in position and then
stretched while an end tting is swaged on. Commonly used to attach
a pedestal, subbase, and/or outriggers to a vehicle frame.
hydrant — a discharge pipe with a valve and spout at which water
may be drawn from a water main.
hydraulic control — a control that is actuated by hydraulically induced
forces.
hydraulic leveling system — an automatic hydraulic control system
which keeps the bottom of a platform parallel to or at a xed angle to
the turntable base plate as the boom is raised or lowered. One means
of accomplishing this is by transferring hydraulic uid between a master
cylinder actuated by movement of the lower boom and a slave cylinder
mounted between the platform and the upper boom.
hydraulic overload protection (HOP) system — the system on a
digger derrick that shuts off certain functions to help prevent damage
to the digger derrick structure when an overload is applied to the boom
in the downward direction.
Appendix — Glossary
6
Page 70
hydraulic schematic — a drawing that uses common hydraulic symbols
to represent the hydraulic system of the unit.
hydraulic swivel — a uid conducting tting having two joined parts
that are capable of pivoting freely about each other to accommodate
motion of an attached hydraulic line.
hydraulically extendible jib — a jib boom that may be extended or
retracted by hydraulic power.
hydraulics — an engineering science pertaining to liquid pressure
and ow.
hydrostatic hydraulic system — any hydraulic drive in which a positive displacement pump and motor transfer rotary power by means of
uid under pressure.
individual address setting — the code that identies a specic
transmitter as the one emitting the signal corresponding to a specic
receiver’s reception address.
infeed chute — tapered weldment attached prior to the feed/cutter
mechanisms, assisting in the centering of the tree canopy.
in-line — the installation of a component in series between two por-
tions of a hydraulic line or electrical conductor so that ow in the line
or conductor toward the component passes through the component
and continues on in the line or conductor on the other side.
instability — a condition of a mobile unit where the sum of the moments tending to overturn the mobile unit is equal to or exceeds the
sum of the moments tending to resist overturning.
insulating aerial device — an aerial device with dielectric components
designed and tested to meet the specic electrical insulating rating
consistent with the manufacturer’s name plate.
insulating digger derrick — a digger derrick designed for and manufactured with a berglass boom(s) for use around energized conductors
at a maximum of 46 kV phase to phase.
insulating liner — see platform liner.
insulating portions — those sections which are designed, main-
tained, and tested in accordance with the electrical requirements of
ANSI A92.2.
insulator — a device that isolates the energized conductor of a power
line from the support structure.
intercom system — a transmitter and receiver system that allows
two-way verbal communication between a platform operator and a
person at ground level.
interference — any energy that inhibits the transmission or reception
of electrical or radio signals.
intermediate boom (INT BOOM) — an extendible boom section
which is located between the upper boom and the lower boom in an
extendible boom assembly.
ISO — International Standards Organization.
jam nut — a nut that is screwed down rmly against another nut to
prevent loosening.
jaw clutch — see drum clutch.
jib — an auxiliary boom which attaches to the upper boom tip to extend
the reach of the boom.
JIC — Joint Industry Conference.
joystick — a two or three axis control lever which allows the operator
to simultaneously control multiple functions.
junction box — an enclosed central connecting point for electrical
wiring.
kelly bar — 1: for derricks see auger extension shaft. 2: the auger drive
shaft of a pressure digger which is extendible from the ram cylinder.
key — a parallel-sided piece that ts into grooves in two adjacent parts
to prevent movement between the parts. Often used as the driving
member between a shaft and a sheave or winch drum.
keyway — a groove that is cut in a shaft or bore for a key to t into.
kilovolts (kV) — a unit of potential difference equal to 1,000 volts.
knife — the rotating blade on a chipper cutting mechanism.
knuckle — see elbow.
L-bracket — an L-shaped weldment that is used to connect a splicer
platform to the upper boom tip.
lanyard — a component in a personal fall protection system consisting
of a exible, nonmetallic strap or rope with a connector at each end
for connecting a body harness or body belt to a specied anchor point
provided at the boom tip, used to catch and decelerate a person in a
fall from the platform. (As of January 1, 1998, the use of a body belt
for personal fall protection is prohibited by OSHA.)
lashing wire — a thin, solid wire which is wrapped in a helix congura-
tion around a length of suspension strand and adjacent communication
cable so that the suspension strand carries the weight of the cable.
lay — the length of wire rope in which one strand makes one complete
spiral around the rope.
layer — all wraps of winch line on a winch drum which are on the same
level between drum anges.
leakage monitor system — a means by which current leakage is
measured through the insulating section(s) of a boom to conrm of
dielectric integrity.
leveling cable — the wire rope portion of a mechanical leveling system
that passes over the sheaves.
leveling chain — the chain portion of a mechanical leveling system
that passes over the sprockets.
leveling cylinder — 1: a cylinder that is used in a master/slave arrange-
ment in a hydraulic leveling system to hydraulically level the platform. 2:
the hydraulic cylinder that is used to tilt the pivot and mast weldments
of a pressure digger to either side of the vertical position.
leveling rod — a slender, round, berglass rod used in a mechani-
cal leveling system that passes through a unit’s boom to connect the
leveling chains or cables at each end of the boom.
leveling system — see platform leveling system.
leverage — a gain in output force over input force; mechanical advan-
tage or force multiplication.
lift cylinder — the hydraulic cylinder that moves the lower boom up
and down on a digger derrick or extendible-boom aerial device.
lifter cylinder — the hydraulic cylinder that moves the reel lifter
arms.
lifting eye — a shackle or weldment used for attaching chain, cable,
rope, etc. to a boom for material handling.
light emitting diode (LED) — a semiconductor diode that emits light
when subjected to an applied voltage. LEDs are used for electronic
display.
line — a tube, pipe or hose used as a passageway to move hydraulic
uid.
linear — in a straight line.
linear actuator — a device for converting hydraulic energy into linear
motion such as a cylinder or ram.
linear position transducer — an extendible length measuring device
which produces a variable electrical signal that is proportional to the
length to which the device is extended.
liner — see platform liner.
link — the secondary load-carrying structure of an articulating arm.
load capacity — (as dened by ANSI for digger derricks) the maximum
load, specied by the manufacturer, that can be lifted by the mobile unit
at regular intervals of load radius or boom angle, through the specied
ranges of boom elevation, extension and rotation, with options installed
and inclusive of stability requirements.
load holding valve — a hydraulic valve which blocks uid ow from
a hydraulic actuator, such as a cylinder or motor, to prevent motion
when the control valve is not being operated or in case of a hydraulic
line failure.
load radius — the horizontal distance from the centerline of rotation
to the winch line load attachment point.
load sensing — (see sense line) the signal when a function is operated
that tells the hydraulic pump to stroke up from a non-stroked (neutral)
position to supply oil to that function.
lock washer — a solid or split washer that is placed underneath a nut
or cap screw to help prevent loosening by exerting pressure against
the fastener.
locknut — see self-locking nut.
lockwire — a wire that is installed to prevent loosening of fasteners
or components.
low voltage coating — a sprayed on layer that provides low voltage
insulating properties.
7
Appendix — Glossary
Page 71
lower arm — the primary load-carrying structure of a double elevator
which is located between the lower pedestal and the riser.
lower arm cylinder — the hydraulic cylinder that moves the lower arm
of a double elevator up and down.
lower boom (LWR BOOM) — the boom section in a boom assembly
which is attached to the turntable or riser, and which supports the upper
boom or intermediate boom.
lower boom cylinder — the hydraulic cylinder that moves the lower
boom about its pivot point on an articulating-boom aerial device.
lower boom insulator — the part of the lower boom made of high
dielectric strength material (usually berglass reinforced plastic or
equivalent) to interrupt the conductive path for electricity through the
lower boom.
lower boom winch — a winch that is located on the lower boom.
lower control valve — the hydraulic valve on the vehicle, turntable,
or pedestal of an aerial device used for operating some or all of the
functions of the aerial device.
lower controls — the controls on the vehicle, turntable, or pedestal,
used for operating some or all of the functions of the unit.
lower pedestal — the structure within an elevator lift that connects
the elevator lift to the subbase.
lower test electrode system — a system on an insulating aerial
device utilizing conductive bands installed permanently on the inside
and outside surfaces of the insulating portion of the upper boom and
conductive connections to components inside that portion of the boom
such as leveling rods and hydraulic lines. All the bands and component
connections are connected to a common pickup point for use in measuring current leakage to conrm of dielectric integrity.
lower tool circuit — a hydraulic tool circuit with quick disconnect
couplings located on the pedestal or on the vehicle.
lug — a metal part which serves as a cap, handle, support, or tting
connection.
lunette eye — a round metal ring used in place of a ball coupler on a
trailer. It attaches to a pintle hook on the towing vehicle.
magnetic suction separator lter — see magnetic suction strainer.
magnetic suction strainer — a suction lter consisting of a strainer
which contains one or more magnets to trap ferrous metallic contaminants that are small enough to pass through the strainer.
mainframe — see pedestal.
man-and-a-half platform — an oversized one-man platform.
manifold — a uid conductor that provides multiple connection
ports.
manual lowering valve — a manually operated hydraulic valve used
to lower the boom in the event of power failure.
manual override — a means of manually actuating an automatically
or remotely controlled device.
manually extendible jib — a jib that is capable of being extended and
retracted by human force.
mast — the structure on a pressure digger which supports the auger
transmission gearbox, ram cylinder, kelly bar, and pole setter.
master control panel — the primary derrick lower control panel which
contains the electrical connections between the derrick control system
and components such as the power module and the dump or blocking
valve. The master control panel is used in conjunction with a slave
panel to provide dual station lower controls.
master cylinder — a cylinder in which motion of the piston under an
external force transfers hydraulic uid to a slave cylinder to produce
corresponding motion.
material handling — having the ability to use the boom or attachments
on the boom to lift and position materials.
material handling system — the system on an aerial device that
consists of a jib and winch used to lift material to the upper boom tip.
mechanical leveling system — a mechanical system which keeps
the bottom of a platform parallel to or at a xed angle to the turntable
base plate as the boom is raised or lowered. One means of accomplishing this is by utilizing a parallelogram arrangement of leveling rods
attached to cables or chains operating around sheaves or sprockets
at boom pivot points.
mercury switch — a switch that is closed or opened when an internal globule of mercury moves to or away from the contacts when the
switch is tilted.
meter — to regulate the amount of uid ow.
meter-in — to regulate the amount of uid ow into an actuator or
system.
meter-out — to regulate the ow of the discharge uid from an actua-
tor or system.
micron (micrometer) — one-millionth of a meter or about 0.00004″.
micron rating — the minimum size of the particles that a lter is
designed to remove.
microswitch — a small electrical device that is used to turn an electrical
current on or off, or to change the connections in a circuit.
minimum approach distance — the three dimensional area surrounding a conductor into which a person may not enter nor bring any
conductive object unless they are: qualied electrical workers, wearing
insulating gloves (and sleeves when required), protected against contact
with any other objects at a different electrical potential.
mobile operation — the use of the aerial device or digger derrick while
the mobile unit is traveling.
mobile unit — the combination of a unit, its chassis and related permanently attached equipment.
modied A-frame outrigger — an extendible outrigger that is congured like a large broad based “A” with an open top.
modulation ratio — the “on” time vs. the “off” time of a pulse width
modulated digital signal. This ratio is determined by dividing the on
time during one cycle by the total cycle time.
moly — see molybdenum disulde.
molybdenum disulde — a black inorganic chemical that is used as
a dry lubricant and as an additive for grease and oils. Molybdenum
disulde has a very high melting point and is insoluble in water.
molydisulde — see molybdenum disulde.
moment — a force multiplied by the perpendicular distance from the
line of action of the force to an axis or point. The force may be the
weight of an item, with the vertical line of action located at the item’s
center of gravity. Moment is measured in units of force times distance;
for example, pound-feet or foot-pounds.
monitor head — remotely controlled articulated assembly with a nozzle,
mounted at the upper end of an HLIW.
motor — a device that converts hydraulic or electrical energy into
continuous rotary motion and torque.
multiple-part line — the arrangement of the winch line in which the
winch line is routed between the boom tip and the load two or more
times. A snatch block is used at the load and a snatch block or additional
boom tip sheave(s) is used on the boom to reverse the direction of
the winch line. The end of the winch line is connected to a stationary
attachment point on the boom or lower snatch block. A multiple-part
line is used to reduce the tension in the winch line to a value below
the winch line rated working load when a lifting load that exceeds the
winch line rated working load.
multiplexing — a process by which signals from multiple inputs are
combined and transmitted simultaneously over a single channel.
multiviscosity — the viscosity characteristic of a uid which contains
additives that increase the viscosity index. The uid does not become
as thin at high temperatures or as thick at low temperatures as a uid
without these additives. This allows the uid to be used over a wider
temperature range.
nonconductive — the characteristic of a substance that allows it to
transmit electricity only in a very small degree when it is clean, dry and
properly maintained.
noncontinuous rotation — a rotation system in which the turntable is
prevented from rotating more than approximately one revolution about
the centerline of rotation.
non-insulating aerial device or digger derrick — an aerial device
or digger derrick which is not designed, manufactured, or tested to
meet any dielectric rating.
nonmetallic — formed of materials which are not any type of metal.
non-overcenter aerial device — a type of articulating-boom aerial
device on which the upper boom will not unfold from the stored position to beyond a vertical position regardless of the position of the
lower boom.
Appendix — Glossary
8
Page 72
nontransferable boom ares — boom ares that are permanently
attached to the boom tip of a digger derrick.
nontransferable upper controls — an upper control panel on a digger
derrick that is permanently attached to the upper boom tip.
normally closed switch — a switch which is closed to allow current
to ow through it when it is not actuated, and opens to interrupt current
ow when actuated.
normally closed valve — a two-way valve which is closed to block
uid from owing through it when it is not actuated, and opens to allow
ow when actuated.
normally open switch — a switch which is open to prevent current
from owing through it when it is not actuated, and closes to allow
current ow when actuated.
normally open valve — a two-way valve which is open to allow uid
to ow through it when it is not actuated, and closes to block ow
when actuated.
nozzle — a tube-like device for accelerating and directing the discharge
ow of uid.
NPT — National Pipe Thread.
NPTF — National Pipe Thread Fluid, a pipe thread form which is
modied from the NPT form to improve the resistance to uid leakage
through the threads in a connection.
O-ring — a ring of material with a circular cross section that is used
as a gasket, usually made of synthetic rubber.
ohmmeter — an instrument used to measure the resistance in ohms
between two points in an electrical component or circuit.
on/off circuit — circuit that supplies constant electrical power to a
solenoid or other component when a relay or switch is closed and
removes the power when the relay or switch is opened.
one-man platform — a platform designed to carry one person. It is
usually 24″ wide x 30″ wide or 24″ wide x 24″ wide.
open center — a directional valve design in which pump output re-
turns freely to the reservoir when the valve spool(s) is in the center
or neutral position.
open circuit — an electric circuit that has innitely high resistance,
resulting in no current ow. An open circuit may be caused by a loose
connection, broken wire, corrosion or poor contact where an electrical
component is grounded to the unit structure.
operational area — the area surrounding a chipper effected by chip
discharge, noise, or any chipper operations.
operator — a person trained, authorized and engaged in the operation of the unit.
optical ber — a thin strand of transparent glass or plastic used to
transmit signals using light throughout the length of the strand.
orice — a restriction in a hydraulic or pneumatic circuit, the length of
which is small in respect to its diameter.
OSHA — Occupational Safety and Health Administration.
out and down outrigger — an outrigger that has independently-
controlled horizontal and vertical extendible outrigger legs.
outboard bearing — a bearing which supports the end of a gearbox
output shaft farthest from the gearbox.
output signal — a radio wave intended to pass communication from
a source to a destination.
outrigger — a structural member, which when properly extended or
deployed on rm ground or outrigger pads, assists in stabilizing the
mobile unit.
outrigger controls — the controls for operating the outriggers.
outrigger cylinder — the hydraulic cylinder which extends and retracts
or unfolds and folds an outrigger leg.
outrigger interlock system — a system which requires all outriggers
to be extended to a specied position before other unit functions are
allowed to operate.
outrigger interlock valve — a valve which prevents above rotation
sense line signals from reaching the pump until the outriggers have
been lowered.
outrigger leg — 1: the moveable structural component of an outrigger
which extends or unfolds to position the outrigger shoe on the ground,
and which retracts or folds to return the outrigger shoe to the stored
position. 2: the stationary structural component of an extendible outrig-
ger from which the moveable outrigger leg extends.
outrigger motion alarm — an audible warning system to alert personnel that outriggers are being lowered or moved.
outrigger pad — a portable piece of rigid material which is placed
under an outrigger shoe to increase the contact area with the ground
surface when the ground surface is not rm enough to support direct
contact from the outrigger shoe.
outrigger shoe — the component of an outrigger that is attached to
the moveable leg and that contacts the ground or outrigger pad to
stabilize the mobile unit.
outrigger signal valve — a valve used to provide a signal to the pump
when the outriggers are being operated and to allow a separate signal
system to control the aerial device operation.
outrigger spread — the distance between the outer edges on xed
shoes, or between pin centerlines on pivoting shoes, of opposite outriggers which have been extended or deployed to a given position.
over travel — movement of a mechanism beyond its normal stopping point.
overcenter aerial device — a type of articulating-boom aerial device
on which the upper boom can unfold from the stored position to beyond
a vertical position.
overframe — an outrigger weldment mounting position located above
the vehicle chassis frame.
overload — the condition existing when a load greater than the rated
capacity or design lead is applied to a unit or component.
override — the takeover of boom movement control functions from
the platform controls by the activation of the lower control station
controls.
overtighten — to torque a threaded fastener beyond the recommended
torque value.
oxidation — the reaction of a substance with oxygen.
paddle — part of the disc assembly which propels chipped debris into
the discharge chute.
panic bar — a safety system which when manually activated stops
movement of the feed roll(s) on a chipper.
parallel link — the secondary load-carrying structure of an elevator
lift.
particle count — a visual count of the numbers of particulate contami-
nants in a quantity of a hydraulic uid.
passage — a machined or cored uid conducting path that lies within
or passes through a component.
payload — any tools, materials, fuel and occupants carried by the
mobile unit that are not permanently attached.
pedestal — the stationary base of a unit that supports the turntable
and is attached to the subbase or vehicle frame.
pedestal mount — a mounting conguration for an aerial device in
which the turntable is mounted on a pedestal consisting of a box-like
structure.
penetration — the distance the vehicle frame is lifted after the outriggers contact the ground surface.
phase — a conductive wire or cable used for transmitting high voltage
electrical current. The phrase “phase to phase” can be referenced as
any two conductors of a three-phase electrical power line system.
pilot operated — condition in which a valve is actuated by hydraulic
uid pressure.
pilot operated check valve — a check valve that can be opened
to allow ow in the normally blocked direction by applying hydraulic
pressure to a pilot port.
pilot pressure — auxiliary pressure used to actuate or control hydraulic
components.
pilot valve — an auxiliary valve used to control the operation of
another valve.
pin — a cylindrical structural device used to allow a pivoting joint or
to connect mating parts.
pin retainer — a device which is used to hold a pin in place in an
assembly.
pinch point — a particular location in which a human body or a part
of the body may become pinched or pinned between moving mechanical parts.
9
Appendix — Glossary
Page 73
pinion — a gear with a small number of teeth that has been designed
to mesh with a larger gear.
pintle hitch — a common heavy duty coupling type which utilizes a pintle
hook attached to a tow vehicle to pull a trailer having a lunette eye.
pintle hook — the “jaw” portion of a pintle hitch which attaches to
the tow vehicle.
piston — a cylindrically shaped part that ts within a cylinder or cy-
lindrical bore and transmits or receives linear motion by means of a
connecting rod or other component.
piston pump — a pump in which motion and force are applied to uid
by a reciprocating piston(s) in cylindrical bore(s).
pivot weldment — the structure located above the slide frame on a
pressure digger which supports the mast.
placard — 1: a thin sheet of rigid material which is attached to another
surface by adhesive and/or mechanical fasteners, and is used to convey
instructions, information and warnings. 2: May also refer to a decal.
planetary gear set — an assembly of meshed gears consisting of a
central gear (sun gear), a coaxial internal tooth ring gear and several
intermediate pinions (planet gears) supported on a revolving carrier.
planetary gearbox — a gearbox containing one or more planetary
gear sets.
platform — the personnel-carrying component of a unit, mounted at
the upper boom tip.
platform elevator — a mechanism, at the boom tip, to which the platform is mounted, allowing vertical motion of the platform with respect
to the rest of the boom tip.
platform heater — an electrically powered device mounted in a splicer
platform which is used to warm the occupant.
platform leveling system — a system which keeps the bottom of a
platform parallel to or at a xed angle to the base plate of the turntable,
or parallel to level ground, as the boom is raised or lowered. The system
may be mechanically, hydraulically, or gravity operated.
platform liner — a component made of material having a high dielectric
strength which is designed to be inserted into a platform to cover the
walls and bottom of the platform.
platform pin — the horizontal pin that is used to fasten a platform
mounting bracket to the upper boom tip. The mounting bracket pivots
about this pin for platform leveling or positioning.
platform rest — the structural member attached to the chassis or body
to support and cushion the platform in the travel or rest position.
platform ring — a metal band around the lip of a splicer platform
which supports and guides the platform as it is rotated about its vertical centerline.
platform rotation override system — a system which allows the
zone of platform rotation to extend beyond a predetermined limit when
actuated by the operator.
platform rotator — a system which allows the operator to rotate the
platform about a vertical axis. This permits the position of the platform
to be changed with respect to the boom tip.
platform tilt system — a system which allows the operator to adjust
the orientation of the platform about a horizontal axis. Some systems
allow the operator to adjust the working position of the platform oor
and tilt the platform for cleaning. Other systems allow tilting of the
platform for cleaning but do not provide for operator adjustment of the
working position.
platform use — the stability criteria for a digger derrick mobile unit
which indicates that the load capacity chart and stability requirements
apply to the use of the derrick with the platform occupied, with no lifting
of loads with the winch line.
plunger — a cylindrically shaped part that is used to transmit thrust;
a ram.
pole — a long cylindrical piece of material such as wood, metal, or
concrete which is installed in a vertical position for use as a support
structure for power and communication lines.
pole guide — a mechanism at the tip of a boom used for guiding and
stabilizing a utility pole while using the winch line to raise or lower
the pole.
pole guide tilt cylinder — the hydraulic cylinder which is used to tilt
(raise or lower) the pole guide.
pole guide tong cylinder — the hydraulic cylinder which opens and
closes the pole guide tongs.
pole guide tongs — moveable arms on a pole guide used to stabilize
and guide a utility pole as it is being raised or lowered with the winch
line.
pole puller — an apparatus consisting of a hydraulic cylinder, chain
and other components used to loosen a utility pole from the ground.
pole setter — an assembly attached to the mast of a pressure digger
that is used to pick up, position, and set a pole.
polyethylene — a moisture proof plastic.
poppet — that part of certain valves that prevents ow when it closes
against a seat and allows ow when it moves away from the seat.
port — an internal or external opening for intake or exhaust of uid
in a component.
portable resistivity tester — a device used for testing the electrical
resistance of water. Commonly used for testing the wash water for
insulator washers.
position — a term which describes the number of possible positions
a valve spool or mechanism can be shifted to.
post mount — a mounting conguration for an aerial device in which
the turntable is mounted on a pedestal which utilizes a round vertical
tube as its primary load-carrying structure.
potentiometer — a variable resistor that is connected to act as an
electrical voltage divider.
pour point — the lowest temperature at which a uid will ow or pour
under specic conditions.
power — work per unit of time, measured in horsepower (HP) or
watts.
power module — the central connection point between the chassis and
unit electrical systems. This device is used to provide battery power to
the unit when the truck/machine selector is in the machine position.
power take-off (PTO) — a supplementary mechanism enabling vehicle engine power to be used to operate non-automotive apparatus
such as a pump.
precharge pressure — the pressure of compressed gas in an ac-
cumulator before any uid is added.
pressure — the force applied in a given area. It can be expressed in
pounds per square inch (psi).
pressure compensator — a device on a variable displacement
pump that adjusts pump output ow to develop and maintain a preset
maximum pressure.
pressure differential — the difference in pressure between two points
in a system or component.
pressure drop — the reduction in pressure between two points in a
line or passage due to the energy required to maintain ow.
pressure gauge — an instrument which displays the hydraulic or
pneumatic pressure sensed at a port on the device.
pressure line — the line carrying uid from a pump outlet to the pres-
surized port of a valve or actuator.
pressure override — the difference between the cracking pressure of
a valve and the pressure reached when the valve is passing full ow.
pressure reducing valve — a pressure control valve whose primary
function is to limit its outlet pressure.
pressure switch — an electric switch which is actuated when the hydraulic or pneumatic pressure applied to a port on the switch reaches
a specied value.
pressure transducer — a pressure measuring device which produces
a variable electrical signal that is proportional to the hydraulic pressure
applied to a port on the device.
proportional circuit — a circuit that supplies a varying voltage to a
coil in a pilot valve as electrical current applied to the circuit is varied
by a hand control.
proximity alarm — a system which measures the distance from a
detector to another object, and sounds an alarm when this distance
is less than a specied value. Commonly used to inform the operator
of an HLIW of the distance between the boom tip nozzle and a power
line insulator or support structure.
psi — pounds per square inch.
PTO — see power take-off.
pulling arms — mechanical structure used to attach the platform to
the boom tip and supports the fairlead receptor tube.
Appendix — Glossary
10
Page 74
pullout upper controls — an upper control panel on a digger derrick
which is mounted on a housing that can be extended from inside an
outer housing when additional length is needed, such as to attach the
control panel to a personnel jib with the outer housing attached to the
upper boom tip, or to attach the upper control panel to the upper boom
tip with the outer housing attached to the transferable boom ares.
pulse width modulation (PWM) — a means of transmitting a digital
signal in continuous cycles of pulses where the total length of time for
a cycle of one “on” pulse and the following “off” period is constant, and
the length of time (width) of the “on” pulse within each cycle is varied
(modulated) in proportion to the level of an input parameter such as
control lever position.
pump — a device that converts mechanical force and motion into
hydraulic ow and pressure.
purge system — a system of check valves that allows hydraulic
uid ow in a reverse manner through the hydraulic system, usually
from the lower control valve to the upper controls. This actions frees
or purges the control system of any trapped air and restores a solid
column of uid for precise control. The purge system may also be used
to warm up the control system in cold weather conditions if the uid
in the reservoir is warm.
purge/upper/lower controls selector valve — a valve which is used
to direct hydraulic uid to the purge system, the upper control valve,
or the lower control valve.
PWM — pulse width modulation.
quick disconnect couplings — hydraulic ttings designed for fast
and easy attachment and separation.
radial ball bearing — an antifriction bearing with rolling ball contact
in which the direction of action of the load transmitted is perpendicular
to the axial centerline of the bearing.
radial outrigger — an outrigger in which the moveable outrigger leg
pivots in an arc around a pin connection between the leg and a supporting structure as the leg is lowered and raised.
radio communication — communication by means of radio waves.
ram — 1: a single-acting cylinder with a single diameter plunger rather
than a piston and rod. 2: the plunger in a ram-type cylinder.
ram cylinder — the hydraulic cylinder that is used to retract and extend
the kelly bar on a pressure digger.
ramp — an adjustable delay to govern the response of the hydraulic
valve when a unit is operated from the electronic controls.
range diagram — a diagram which shows the load radius and sheave
height of a digger derrick at all the congurations of boom extension
and boom angle covered by the corresponding load capacity chart
.
rated capacity — (as dened by ANSI for digger derricks) the maximum
load, specied by the manufacturer, that can be lifted by the digger
derrick at regular intervals of load radius or boom angle, through the
specied ranges of boom elevation and extension, with specied op-
tions installed, and exclusive of stability requirements.
rated line voltage — the nominal voltage, phase to phase, at which
electrical systems are rated.
rated load capacity — (as dened by ANSI for aerial devices) the
maximum loads, specied by the manufacturer, which can be lifted
by the aerial device through the specied range of boom elevation
and extension with specied options installed and in consideration of
stability requirements.
reach diagram — a drawing that shows the horizontal and vertical
limits of travel of the platform, upper boom tip, and/or jib tip throughout
all possible congurations of lower boom angle, boom extension, upper
boom angle, articulating arm travel, and/or elevator lift travel.
rear jack stand — adjustable rear support used when the chipper is
in operation and not coupled to the tow vehicle.
rear mount — a pedestal mounting position located over or near the
rear axle(s) on the longitudinal centerline of the chassis.
receiver — a device that converts radio waves into electrical signals
for communication and/or control purposes.
reel brake — a component of the reel driver which prevents the overrunning of cable reels carried by a strand carrier and reel lifter. The
brake is used to maintain tension in the cable or suspension strand
when used with the reel driver.
reel driver — a component of a strand carrier and reel lifter used for
paying in or paying out cable or suspension strand.
reel lifter — a device used to support and move cable reels from the
ground to the vehicle.
reel lifter arms — the structure on a reel lifter used to lift and store
reels of cable or suspension strand on the chassis.
reengage — to repeat the activation of a function after it has been
momentarily halted.
relay — an automatic switch with contacts that can be closed or opened
by electrical current in a coil.
relief valve — a pressure operated valve that bypasses pump delivery
to the reservoir to limit system pressure to a predetermined maximum
value.
remote arm — a remotely operated jib used to handle equipment or
electrical lines.
remote assist — a vehicle-mounted device with a boom assembly
which is extendible, articulating, or both, which is designed and used to
accommodate attachments for performing operations such as supporting
or cutting electrical conductors, lifting or holding objects, or cutting tree
branches. It is operated by remote control from the ground or from the
platform of an adjacent personnel lifting device. It may be mounted on
the vehicle by itself or in addition to a personnel lifting device.
remote control system — a system used for operating some or all
of the functions of a unit from a portable control station. The control
station may be a transmitter which sends signals by radio waves to a
receiver on the unit, or a control module which sends signals through
a ber optic or electrical cable to the unit.
remote operated auxiliary control system (ROACS) — a radio
controlled system for starting and stopping certain functions of the
mobile unit.
remote start/stop system — the components used to actuate a
function of the unit from a location other than for normal operation.
The most common functions controlled are engine start/stop and the
secondary stowage DC pump.
reservoir — a container for storage of liquid in a uid power system.
resistance — the opposition to the ow of electricity or hydraulic
uid.
restriction — a reduced cross-sectional area in a line or passage that
produces a pressure drop.
retaining ring — a hardened, washer-like ring that may be spread
apart or compressed and installed into a groove or recess to serve
as a retaining device.
return line — a hydraulic line used to carry discharge ow from a
hydraulic system or actuator back to the reservoir at low pressure.
return line lter — a lter located in a hydraulic system return line or
at the inlet of a hydraulic reservoir which cleans uid owing from the
hydraulic system to the reservoir.
reversing valve — a four-way directional valve used to change the direction of movement of a double-acting cylinder or reversible motor.
ribbon hose — a group of hoses that are attached side by side to
produce a at bundle. Commonly used to carry hydraulic uid, air and/
or electrical cable(s) to the boom tip or upper controls.
riding seat — an operator’s control station attached to the side of the
turntable, with a seat on which the operator rides with the rotation of
the unit.
riser — 1: the structure on a double elevator that connects the lower
elevator arm to the upper elevator arm. 2: the structure within an articulating arm to which the lower boom is connected.
ROACS — see remote operated auxiliary control system.
rod — the cylindrically shaped part of a cylinder which extends and
retracts from the barrel to actuate or move a component.
rod end — the end of a cylinder that the extending component or
rod is on.
roller — a cylindrical device which spins freely about a pin or shaft,
used to guide the motion of another component.
rollpin — a pin that has been formed by rolling up a thin, at strip of
metal to form a cylinder. Commonly used by being driven into a hole
to serve as a retaining device.
rope — a stout, exible cord, which consists of many strands of wire
or bers that are twisted or braided together.
rotary actuator — a device for converting hydraulic energy into rotary
motion and torque in which the rotary motion is restricted to within
certain angular limits.
11
Appendix — Glossary
Page 75
rotary joint — a multiple port manifold that has a rotating portion and
a stationary portion, used to provide a continuous hydraulic connection
between rotating and stationary hydraulic lines. Commonly used at the
centerline of rotation of units equipped with continuous rotation.
rotate frame — the structure located above the stationary frame on a
pressure digger that is used to support and rotate the slide frame.
rotating platform — a platform which can be rotated about a vertical
axis to change its position in relationship to the boom tip.
rotation bearing — the rotating member, usually a shear ball bearing, located between the pedestal and the turntable which allows the
turntable to rotate and which contains gear teeth that mesh with the
rotation pinion.
rotation chain — a chain attached to the stationary frame of a pressure
digger that is used by the rotation gearbox to rotate the rotate frame.
rotation gearbox — the gearbox which drives the rotational motion
of the turntable.
rotation pinion — the gear on the output shaft of the rotation gearbox
which meshes with the rotation bearing gear teeth and drives the
turntable rotational motion.
rotation resistant wire rope — wire rope which is constructed to resist
the tendency to untwist or rotate when carrying a suspended load. This
is accomplished by laying the outer strands in the opposite direction
to the lay of the inner strands or core.
rotation system — the system which drives the rotation of the turntable
about the centerline of rotation. It typically consists of a rotation bearing,
rotation gearbox, hydraulic motor, and load holding valve.
rpm — revolutions per minute.
running torque — the torque produced by a rotating device such as
a motor or gearbox at a specied rotational speed.
SAE — Society of Automotive Engineers.
safety belt — see body belt.
safety chains — the chains that are attached to the trailer tongue with
hooks on their free ends. These chains keep the trailer connected to
the tow vehicle should the coupler or hitch ball detach from the tow
vehicle. Safety chains must be secured every time you tow.
saybolt universal viscosity — A measure of viscosity equal to the time
it takes in seconds for 60 milliliters of uid to ow through a capillary
tube in a Saybolt universal viscosimeter at a given temperature.
scissor link — the mechanical linkage on a reel lifter used to connect
the lifter cylinder to the arm.
screw anchor — a rod with an eye on one end and auger ighting on
the opposite end. It is designed to screw into the ground and serve as
an anchor to hold an attached cable such as a guy wire.
seating in — an initial microscopic surface deformation of components
that are clamped together with threaded fasteners. This causes a slight
reduction in the dimension of the components, reducing the clamping
force applied by the fasteners.
secondary stowage DC pump — a low ow hydraulic pump driven by a
direct current electric motor. This pump is used to provide hydraulic ow
to stow the unit when the system for normal operation has failed.
secondary stowage system — those components used to stow the
unit when the system for normal operation has failed.
selector switch — a switch which is used to direct electrical current
to one of two or more electrical circuits.
selector valve — a valve which is used to direct hydraulic uid to one
of two or more hydraulic circuits.
self feed — a wood-chipper with no control of the infeed rate to the
cutting mechanism.
self-locking nut — a nut which contains a built-in device or shape to
increase thread friction so as to resist loosening due to vibration or
repeated loading.
self-lubricating bearing — an antifriction bearing in which lubricating
material is incorporated in the bearing.
sense line — a line that carries a hydraulic pressure signal from a
valve or actuator to the compensator control on a variable displacement pump.
sense selector valve — a valve which prevents hydraulic uid in
the sense line from reaching the pump until a certain function(s) is
operated.
sequence — 1: the order of a series of operations or movements. 2:
to divert ow to accomplish a subsequent operation or movement.
sequence valve — a pressure operated valve that diverts ow to a
secondary actuator while holding pressure on the primary actuator at
a predetermined minimum value after the primary actuator completes
its travel.
sequential extension — the operation by which one boom section
in an extendible boom assembly reaches full extension or retraction
before the next boom section begins movement.
set screw — a short screw, typically with an Allen type head, that is
used as a clamp to bind parts together.
shackle — see clevis.
shear — an action or stress resulting from opposing applied forces that
attempt to separate a part into two pieces that would then slide along
each other in opposite directions along the plane of separation.
shear ball bearing — an antifriction bearing with rolling ball contact
in which the direction of load transmitted through the balls is parallel
to the axial centerline of the bearing, producing shear loading on the
balls. The bearing can support axial, radial, and tilt loading. Commonly
used as a rotation bearing.
shear pin — a replaceable pin which prevents motion between two
adjacent parts by the production of shear loading in the pin, and which
may be designed to fail under overload to protect other parts.
shear stability — resistance of a hydraulic uid viscosity index improver
additive to shearing.
shearing — molecular damage or breakdown of the viscosity index
improver additive in hydraulic uid. Shearing can occur when the uid
ows through ne clearances at high velocity. Shearing can cause
permanent loss in uid viscosity.
sheave — a grooved wheel used to support and guide a winch line
or leveling cable at a point of change in the direction of motion of the
line or cable.
sheave height — the vertical distance from ground level to the centerline
of the boom tip sheave in a digger derrick upper boom tip.
short circuit — an inadvertent path of low resistance established
between two points of an electrical circuit. A short circuit will result in
excessive current ow.
shutoff valve — a device which is used to stop hydraulic uid ow.
shuttle valve — a three-port valve that accepts hydraulic uid pres-
sure from two inlets and allows only the highest pressure uid to pass
through it to a single outlet while keeping the inlet uid pressure isolated
from one another.
side gun — a hand held water nozzle and hose that can be used from
the ground for washing or re ghting.
side load — an external horizontal load placed on a boom from one
side.
side load protection system — the system on a digger derrick that
helps prevent damage to the digger derrick structure when excessive
side loads are applied to the booms.
side-mounted platform — a platform which is attached to a mount-
ing bracket that extends from one side of the boom tip, positioning
the platform (and platform rotation pivot, if so equipped) beside the
boom tip.
sideslip — sideways motion of a component caused by an externally
applied sideways force which overcomes resistive forces from hydraulics, friction, etc. Commonly used to describe rotation of a digger
derrick boom caused by side loading which exceeds the side load
protection setting.
signal — a command or indication of a desired position, velocity, ow
or pressure.
signal line — see sense line.
single-acting cylinder — a cylinder in which uid pressure can be ap-
plied to move the rod in only one direction. Return motion is produced
by an external force such as a spring or gravity.
single elevator — an elevator lift with one load carrying arm. The
single elevator system includes a lower pedestal, arm, arm cylinder(s),
parallel links, and upper pedestal.
single handle control — a control, with an interlock trigger incorpo-
rated in the handle, which allows the operator to simultaneously control
multiple functions of the booms and turntable from the platform.
Appendix — Glossary
12
Page 76
single-pole, double-throw (SPDT) switch — a three-terminal electrical switch or relay that connects one terminal to either of two other
terminals.
single-pole, single-throw (SPST) switch — a two-terminal electrical
switch or relay that opens or closes one circuit.
slave control panel — a secondary derrick lower control panel that
is congured as a remote terminal of the master panel. The slave
panel is used in conjunction with a master panel to provide dual station lower controls.
slave cylinder — a cylinder in which motion of the piston is produced
by the transfer of hydraulic uid from a master cylinder, resulting in
corresponding motion.
slide frame — the structure on a pressure digger used to support the
auxiliary engine, hydraulic reservoir, control station, and pivot weldment.
The slide frame can be extended horizontally from its stowed position
to adjust the distance of the kelly bar from the rotate frame.
slide pad — a rectangular block used as a bearing between extend-
ible boom or outrigger sections, usually composed of a non-metallic
material.
slip ring — an assembly of one or more conductive, rotating rings and
stationary brushes used to provide a continuous electrical connection
between rotating and stationary conductors. Commonly used at the
centerline of rotation of units equipped with continuous rotation.
slug face — the extreme end of the cable slug which is secured to the
cylinder rod or adjusting stud.
SMA connector — metal connector used for connecting ber optic
components.
snatch block — a device which has a means of attachment to connect
it to a boom or load, and which can be opened to receive a winch line
around an internal sheave.
snubber valve — a two-port valve with a manually adjustable orice
that restricts the ow of uid through the valve.
socket head — a cylindrical cap screw head design containing a
hexagonal (six-sided) female socket into which an Allen wrench can
be inserted to turn the cap screw.
solenoid — a coil of insulated wire that produces a magnetic eld within
the coil when electrically energized. When attached to a hydraulic valve,
the magnetic eld acts upon the valve to move internal valve parts.
solenoid valve — a valve which is actuated by a solenoid to controlling
the ow of hydraulic uid.
speed reducer — see gearbox.
spherical bearing — a bearing with a spherically shaped inner race
that is allowed to move freely inside a stationary outer race to accommodate misalignment.
splicer platform — a berglass platform equipped with a door and
latch.
spline — one of a number of equally spaced, load carrying teeth that
have been cut on the outside diameter of a shaft or inside diameter of
a bore, parallel to the shaft or bore centerline.
spool — a moving, cylindrically shaped part of a hydraulic valve that
moves to direct ow through the valve.
spring lockouts — a mechanical system which is engaged to keep
a vehicle’s suspension system from exing during operation of the
unit.
sprocket — a wheel with teeth along the circumference which are
shaped so as to engage with a chain, used to support and guide the
chain at a point of change in the direction of motion of the chain.
SSU (Saybolt Second Universal) — the unit of measure for Saybolt
universal viscosity.
stability — a condition of a mobile unit in which the sum of the moments which tend to overturn the mobile unit is less than the sum of
the moments tending to resist overturning; the mobile unit’s ability to
resist tipping.
stabilize — to provide adequate stability for a mobile unit to allow
operation of the vehicle-mounted device(s).
stabilizer — a device used to assist in stabilizing a mobile unit, such
as an outrigger, torsion bar or spring lockout.
stake — to slightly deform the threads of a fastener or material at the
joint between two components by placing the blade of punch or chisel
on the threads or joint and tapping on the handle with a hammer. The
deformed material serves to prevent loosening of the components.
stall torque — the torque produced by a rotating device such as a
motor or gearbox at zero rotational speed.
standard option — an option which can be ordered from a standard
order form and can be supplied without additional engineering work.
start/stop control module — an electrical device that relays sig-
nals from the unit’s remote start/stop system to the component(s) or
system(s) being controlled, such as the secondary stowage DC pump
and/or vehicle ignition system.
static mixer — a tube with no moving parts used to combine two or
more uids.
stationary frame — the structure attached to the subbase of a pressure
digger that supports the outriggers and rotate frame.
stationary hood — normally non-removable part of the disc housing
in which the discharge chute attaches.
stationary platform — a platform which can not be rotated about a
vertical axis to change its position in relationship to the boom tip.
stow — to place a component such as a boom or digger derrick auger
in its rest position.
strainer — a coarse lter.
strainer basket — a coarse, basket shaped lter which is mounted in
the ll hole of a reservoir and projects into the reservoir.
strand — 1: one of the groups of individual bers or wires within a
synthetic winch line or wire rope. 2: see suspension strand.
strand carrier — a device used to support and transport strand reels
on a vehicle.
strand reel — a reel or spool used for carrying suspension stand.
street side — the side of a vehicle toward oncoming trafc when the
vehicle is traveling forward in the normal direction in a lane of trafc.
stroke — 1: total linear movement in either direction of a piston or
plunger. 2: to change the displacement of a variable displacement
pump or motor.
subbase — a structural mounting interface between the pedestal and
the vehicle frame. It provides torsional stiffness and strength in addition
to that which would be provided from the vehicle frame alone.
subweldment — a smaller welded subassembly used within a more
complex welded structure.
suction lter — a lter located in a hydraulic system suction line or at
the outlet of a hydraulic reservoir which cleans uid owing from the
reservoir to the pump inlet.
suction line — the hydraulic line connecting the pump inlet port to
the reservoir outlet.
surge — a momentary rise of pressure in a circuit.
surge brake system — a surge brake system is entirely self-contained
on the trailer and is activated when the tow vehicle decelerates. The
momentum of the trailer pushes the surge brake housing forward. This
drives the push rod that is connected to the coupler into the master
cylinder. Brake uid is then forced out of the master cylinder into the
wheel cylinders or pistons that apply the trailer brakes. The entire
activation process is completed in less than one second.
suspension strand — a type of wire rope which is used to support
the weight of an attached communication cable suspended between
poles or other overhead support structures.
swage — to taper or reduce the diameter of a rod, tube or fastener by
forging, squeezing or hammering.
synthetic winch line — a winch line made from nonmetallic synthetic
bers which are formed into strands that are then braided together to
make a complete rope.
T-stand — a “T” shaped weldment for mounting lower controls to the
vehicle.
tachometer — an instrument used for displaying the speed of rotation
of an engine output shaft.
tailshelf — the rear portion of the mobile unit above and behind the
rear axle.
tailshelf tools — see lower tool circuit.
tank — the hydraulic reservoir.
telescopic — having sections that slide within or over one another to
change overall length.
tension spring — springs controlling downward force of the upper
feed roll.
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Appendix — Glossary
Page 77
terminal block — an insulating mounting used for making electrical
terminal connections.
test block — a manifold with ports for connecting a hydraulic pressure
source, pressure gauge and a cartridge valve such as a counterbalance
valve or relief valve used for testing and adjusting the relief setting of
the valve.
thimble — a metal ring around which a rope is passed and spliced to
make a loop or eye.
thread locking adhesive — an anaerobic adhesive that is applied
to fastener threads to prevent loosening due to vibration or repeated
loading.
three-phase — a system for transmitting high voltage, alternating current, electrical power along three separate conductors, with 120 degrees
between the voltage waveform cycles of any two conductors.
three-position valve — a valve having three positions for direction
of uid ow, such as neutral, ow in one direction, and ow in the opposite direction.
three-way valve — a valve having three ports for direction of uid
ow.
threshold — the amount of signal (starting power) given to a control
valve when the control is just moved from neutral position.
throttle control — a manual, hydraulic, or electrical device used to
regulate vehicle or auxiliary engine speed.
toggle switch — an electrical switch operated by a short projecting
lever combined with a spring to quickly open or close a circuit when
the lever is pushed through a small arc.
tongue weight — the downward weight applied by the towable equipment on the hitch ball. Generally tongue weight should not be more
than 10 percent of the gross trailer weight.
topping cylinder — see lift cylinder.
torque — 1: a rotational twisting force. 2: to preload a threaded fastener
by application of a rotational twisting force.
torque converter — a rotary device for transmitting and amplifying
torque, especially by hydraulic means.
torsion bar — a rod-like spring which is exed by being twisted about
its axis, used to assist in stabilizing a mobile unit.
tow line winch — a winch located on a cable placer which is used
for tensioning suspension strand or self-supporting cable or towing a
cable lasher.
tow vehicle (towing vehicle) — the vehicle that pulls a trailer or
towed vehicle.
trace element analysis — analysis of a small sample of hydraulic uid
to determine contamination level and condition of additives.
tracking — a current leakage path created across the surface of
insulating material when a high-voltage current forms a carbonized
path within a foreign material on the surface.
transducer — a device that converts input energy of one form into
output energy of another, such as hydraulic pressure into an electrical signal.
transferable boom ares — boom ares, on which a pole guide may
be mounted, that can be pinned to either the intermediate boom tip or
the upper boom tip of a digger derrick.
transferable upper controls — an upper control panel on a digger
derrick that can be attached to either the upper boom tip or the transferable boom ares by the use of a detent pin.
transition — the area between the feed box and the cutter mechanism.
transmitter — a device used to generate and emit a radio frequency
carrier signal. The signal is sent to a receiver which translates the
signal into usable information.
trim pot — a potentiometer which is used to make ne adjustments
in a circuit during manufacture or calibration, typically by turning a
slotted adjusting screw.
troubleshoot — to locate and diagnose problems in a system or a
component.
trunnion — a mounting device consisting of a pair of opposite, projecting
cylindrical pivots on which something can be rotated or tilted.
trunnion bearing — a bearing that a trunnion pin pivots in.
trunnion pin — a cylindrical pivot pin that is a part of a trunnion.
turnbuckle — a link with screw threads at both ends that is turned to
bring the ends closer together for tightening purposes.
turns from nger tight (T.F.F.T.) — a method of counting the number
of turns of a hydraulic adapter to establish a torque value.
turntable — the structure located above the rotation bearing which
supports the lower boom or articulating arm, and rotates about the
centerline of rotation.
turntable winch — a winch located on the turntable.
turret — see turntable.
two-blocking — a condition in which the load hook, overhaul ball, hook
block, or other lifting component that is attached to the winch line comes
in contact with the boom tip during winch or boom operation.
two-man platform — a platform designed to carry two people. It is
usually 24″ wide x 48″ wide.
two-part line — a multiple-part line on a digger derrick in which the
winch line is routed from the boom tip sheave down to a snatch block
at the load and then back up to a stationary attachment point on the
boom.
two-position valve — a valve having two positions for direction of
uid ow, such as open and closed.
two-speed motor — a motor which has two operating speed and torque
modes (a low-speed, high-torque mode, and a high-speed, low-torque
mode) that can be selected by the operator.
two-way valve — a valve having two ports for direction of uid ow,
with one internal ow path which can be open or blocked.
ultraviolet inhibitor coating — a sprayed or brushed on layer that
provides ultraviolet light resistant properties.
UNC — Unied National Coarse, a thread description.
underframe — an outrigger weldment mounting position located
beneath the unit subbase or vehicle chassis frame.
undertighten — to torque a threaded fastener below the recommended value.
UNF — Unied National Fine, a thread description.
unfold — to move a pivoting structure such as an articulating upper
boom away from its stowed position.
unit — the Altec device(s), subbase, outriggers, body and associated
interface items mounted on a chassis, but not including the chassis
itself.
unload — to release hydraulic ow, usually directly to the reservoir, to
prevent pressure buildup.
unloaded vehicle weight — the total weight of the completed mobile
unit without payload.
unloading valve — a valve that bypasses ow to the reservoir when
a set pressure is maintained on its pilot port.
upper arm — the primary load-carrying structure of a double elevator
which is located between the riser and the upper pedestal.
upper arm cylinder — the hydraulic cylinder that moves the upper
arm of a double elevator up and down.
upper boom (UPR BOOM) — the boom section in a boom assembly
which is farthest from the turntable when the boom assembly is fully
extended or unfolded, and which supports the boom tip sheave and/
or platform(s).
upper boom cylinder — the hydraulic cylinder that moves the upper
boom about its pivot point on an articulating-boom aerial device.
upper boom drive mechanism — the components used to produce
upper boom movement on an articulating boom-aerial device, such as
linkage, cables, sheaves and/or gears.
upper boom rest — the structural member that supports the upper
boom in the rest or travel position.
upper boom tip — the boom tip of an upper boom.
upper control valve — the hydraulic valve on or beside the platform
of an aerial device used for operating some or all of the functions of
the aerial device.
upper controls — the controls located on or beside the platform used
for operating some or all of the functions of the unit.
upper controls primary battery — the preferred source of power for
ber optic upper controls.
Appendix — Glossary
14
Page 78
upper controls secondary battery — the backup power source for
ber optic upper controls.
upper pedestal — the structure within an elevator lift that connects
the elevator lift to the aerial device rotation bearing.
upper tool circuit — a tool hydraulic circuit with quick disconnect
couplings located at the upper boom tip.
vacuum — the absence of pressure. A perfect vacuum is the total
absence of pressure; a partial vacuum is some condition less than
atmospheric pressure. Vacuum is measured in inches of mercury
(in. Hg.).
valve — a device that controls uid ow direction, pressure or ow
rate.
vane pump — a type of pump with a rotor and several sliding vanes in
an elliptical chamber. Hydraulic uid enters the expanding area and is
forced out as the uid is moved to the decreasing chamber area.
variable displacement pump — a pump in which the size of the
pumping chamber(s) can be changed, so that the output ow can
be changed by moving the displacement control or varying the drive
speed or both.
vehicle — a carrier for a unit.
velocity — the speed of linear motion in a given direction.
velocity fuse — a hydraulic valve that is used to stop uid ow through
it when the ow rate reaches a predetermined cut-off value.
vent — an air breathing device on a uid reservoir or hydraulic line.
VI — see viscosity index.
viscosity — a measure of the internal friction or resistance to ow
of a uid.
viscosity index (VI) — a measure of the resistance to change in viscosity of a uid with change in temperature. The higher the number,
the less the viscosity will change as the temperature changes.
voltmeter — an instrument used to measure the potential difference
in volts between two points in an electrical circuit.
volume — 1: the size of a space or chamber in cubic units. 2: loosely
applied to the output ow of a pump in gallons per minute (gpm).
vortex — a whirlpool of liquid.
waist harness — a belt device worn by the operator of a radio remote
control system to which the transmitter is attached.
walking beam outrigger — an extendible outrigger which has a pivot
point at the top of the nonextending leg and a linkage attached to the
extending leg, so that the leg assembly rotates about the pivot point
to increase the outrigger spread as it is extended.
warning — an instruction that indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
water monitor — an articulating mechanism that is used to direct the
ow of a high pressure water stream.
water removal lter cartridge — a special lter cartridge designed
to absorb and remove water from hydraulic uid. It is not intended
for use during normal operation, but is for use when water removal
is required.
way — a term which describes how many ports are in a valve or valve
section.
weldment — a structural unit formed by welding together an assembly
of pieces.
wheel chock — a wedge or block placed on the ground in front of or
behind the wheel of a vehicle to block the movement of the wheel.
winch — a mechanism consisting of a gearbox with a cylindrical rotating
drum on which to coil a line for load hoisting or line tensioning.
winch capacity — the maximum load, specied by the manufacturer,
that can be pulled on the rst layer of line on the winch drum at rated
system pressure.
winch line — a load hoisting line consisting of a synthetic or wire
rope.
winch line rated working load — the average breaking strength of
a winch line (as specied by the line manufacturer) divided by the appropriate design factor as specied by ANSI.
wire rope — a rope made from steel wires which are formed into strands
that are then twisted about each other in a spiral conguration.
wood chipper — reduces above ground tree materials to uniform
chips.
work — the exertion of a force moving through a denite distance.
Work is measured in units of force multiplied by distance; for example,
pound-feet.
worm gearbox — a gearbox that utilizes a gear which has a continuous
helix tooth or teeth similar to a large screw thread along shaft (worm),
that drives a gear which has teeth cut at an angle along a its outside
diameter (worm gear). The rotational axis of the worm is perpendicular
to the rotational axis of the worm gear.
wrap — a single coil of winch line on a winch drum.
X-frame outrigger — an extendible outrigger having two diagonal
members which are connected at the top in an overlapping manner.
Resembles a broad based “X”.
Y-cable — an electrical cable assembly which contains three branches
joined at a common point, similar to a “Y.”
zerk — see grease tting.
15
Appendix — Glossary
Page 79
Appendix — Glossary
16
Page 80
Torque Values
Fasteners
Grade 8
Bolt Size - Grade 5 Hex Hex Head, Socket Head, Button Head Cap Screw
Thread Pitch Head Cap Screw and 12 Point Cap Screw and Flat Head Socket Screw
1
/4″ - 20 5 (7) 7 (10) 6 (8)
5/16″ - 18 10 (14) 15 (20) 13 (17)
3
/8″ - 16 19 (25) 26 (35) 22 (30)
7/16″ - 14 30 (40) 42 (57) 36 (49)
1
/2″ - 13 45 (61) 64 (87) 55 (74)
9/16″ - 12 65 (89) 92 (125) 79 (107)
5
/8″ - 11 90 (122) 127 (172) 109 (148)
3
/4″ - 10 160 (217) 226 (306) 193 (262)
7
/8″ - 9 258 (349) 364 (493) 312 (422)
1″ - 8 386 (524) 545 (739) 467 (633)
1
Values are foot-pounds (N•m).
2
Values apply for both lubed and not lubed applications with any style nut or threaded hole.
3
Values apply for torque applied to either the head of the bolt or the nut.
4
This chart only applies for general application fasteners where a specic torque is not dened. Refer to the fastener section for special applica-
tions where the torque is specically dened.
Bushing-Sheave
Bushing Cap Screw Torque
Size Size and Thread ft-lbs (N•m)
SK
SF
E
F
J
5
/16-18 15 (20)
3
/8-16 30 (41)
1
/2-13 60 (81)
9
/16-12 75 (102)
5
/8-11 135 (183)
Appendix — Torque Values
Page 81
Fastener Specic Torque Application [Ft-lbs (N•m)]
Item Description Fastener DRM 12
Blade/Anvil
Anvil cap screws Hex head *
Blade cap screws Hex head, Bowmalloy 210 (285)
Bearings
Cutter bearing cap screws Ferry cap or hex head 160 (217)
Feed roller bearing cap screws Hex head, Bowmalloy 127 (172)
Structural
Pintle ring cap screws Hex head 5/8-11 120 (163)
Drum draw ring cap screws Hex head 64 (87)
Axle
Axle mounting cap screws Hex head 120 (163)
Axle spindle nut Hex nut Refer to axle owners manual
Wheel lug nuts Wheel lug Refer to axle owners manual
Specic Component
Hydraulic motor shaft nut Hex nut 265 (359)
* Refer to General Fastener Torque
Appendix — Torque Values
Page 82
Daily Preoperational Checklist
VIN No. _________________________ Location ___________________________ Date __________________
Model Number ___________________________ Date of Manufacture __________________________________
Hours Meter _________________________ Inspector _______________________________________________
Symbols
/O = Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
Chip curtain is properly fastened and in good repair
Rotation indicator is clear of debris and fully visible
Disc/drum cover padlock is in place and key is in
responsible party’s possession
Disc/drum hood switch is working properly
Inspect safety tow chains for wear or damage
Check engine fuel, coolant, and oil levels (refer to EOM)
Checktheengineairlter(refertoEOM)
Check clutch handle free play
Checkradiatornsandensurefreepassageofair
through the radiator
All cap screws and nuts are tight and secure
Inspect anvil to make sure all attachment and
adjustment cap screws are secure and anvil edge
is in good condition
Check all controls for free and proper operation
Inspect the chipper frame and structure for any bent,
broken, cracked, missing, or loose parts
Check all guards to make sure they are undamaged,
in place, and properly secured
All decals must be in place and legible prior to
operating the chipper
Hydraulicuidlevelmustbewithin2”to3”(5.08to
7.62cm)oftopofthetankwhentheuidiscold
Lubricate cutter and feed roll bearings
Inspect and operate panic bar
Inspect for hydraulic leaks
Check cutting blades to make sure all attachment cap
screws are tight and blades are in good condition
Inspect discharge chute to determine if it is clear,
properly positioned, and secure
Check feed roller for debris
Check the transition area for debris that could lock
the drum or disc during start up
Make sure the safety devices are properly installed
and functioning properly
Make sure the feed table is in place and secure for
both operation and travel
No loose tools or materials on the chipper or on the
infeed chute
Wheelsandtiresaresecureandproperlyinated
Make sure a complete AEP Operator’s Manual is
available for all operators to review
Comments __________________________________________________________________________________
___________________________________________________________________________________________
Appendix — Daily Preoperational Checklist
Page 83
Appendix — Daily Preoperational Checklist
Page 84
Preventive Maintenance and Inspection Checklist
VIN No. _________________________ Location ___________________________ Date __________________
Model Number ______________________________ Date of Manufacture _______________________________
Hours Meter ____________________________ Inspector ____________________________________________
Intervals
Weekly Monthly Yearly
Symbols
/O = Okay or completed C = Corrected by inspector R = Repair or replacement required
U = Unsafe to operate N/A = Not applicable
Weekly
Complete daily preoperational checklist
Test breakaway switch system
Check general condition of tires and tire pressure
Lubricate clutch bearings (refer to clutch
operator’s manual)
Complete weekly checklist
Where applicable check battery water level
Check drive belt tension and alignment
Where applicable check pump belt and alignment
Inspect hitch for wear or damaged components
Lubricate all hydraulic valve connecting linkages
Lubricate slide box
Lubricate chute rotation
Lubricate hinges and friction points
Monthly
Lubricate clutch lever and linkage (refer to clutch
operator’s manual)
Lubricate drive roller bearings
Lubricate all pivot points and pins
Lubricate jack
Yearly
Complete monthly checklist
Change hydraulic oil lter
Lubricate trailer wheel bearings (refer to axle manual)
Replace fuel lter (refer to engine operating manual)
Flush and replace engine coolant (refer to engine
operator’s manual)
Flush and replace hydraulic uid
Comments __________________________________________________________________________________
___________________________________________________________________________________________
Appendix — Preventive Maintenance and Inspection Checklist
Page 85
Appendix — Preventive Maintenance and Inspection Checklist
Page 86
Troubleshooting Chart
This chart is general to all Altec chippers. Some information may be excluded or unimportant to certain models.
Symptom
Starter will not crank
engine.
Engine will not start.
Possible Cause
Weak battery.
Battery terminals corroded or poor ground
connection.
Defective ignition switch or starter solenoid.
Malfunctioning starter.
Hood safety switch not engaged or damaged.
Fuel tank empty.
Hood safety switch not engaged or damaged.
Choke inoperative (gasoline engines only).
Engine ooded.
Battery partially discharged.
Faulty engine carburetion or ignition.
For specic information pertaining to one model, refer to
the Maintenance Section of this manual.
Text Procedure/Corrective Action
Charge battery.
Clean and tighten connections.
Replace defective components.
Replace starter.
Verify cutter hood and switch activator plate properly secured.
Refuel.
Verify cutter hood and switch activator plate properly secured.
Refer to engine owner’s manual.
Refer to engine owner’s manual.
Charge battery.
Refer to engine owner’s manual.
Engine runs but cutting
implement does not turn.
Feed rollers do not turn.
Feed roller only turns in
reverse.
Air in fuel line (diesel only).
Preheater not working (diesel only).
Material wedged against cutting implement.
Slipping or broken drive belt.
Defective clutch.
Panic bar activated.
Ensure proper control bar position.
Debris jammed in roller area.
Improper hydraulic uid level.
Engine not operating at full throttle.
1
Cutting implement not turning at correct rpm.
Engine not operating at full throttle.
1
Cutting implement not turning at correct rpm.
Material blockage.
Belt slippage.
Clutch slippage.
Refer to engine owner’s manual.
Refer to engine owner’s manual.
Refer to Section 5: Clearing Feed System and
Discharge Chute.
Refer to Maintenance section.
Refer to Care of the Unit.
Reset panic bar and return feed control bar to
neutral position.
Place in forward or reverse position.
Refer to Section 5 — Clearing Feed System and
Discharge Chute.
Fill hydraulic tank.
Increase engine speed to maximum setting.
1
Refer to Section 5 — Clearing Feed System and
Discharge Chute.
Increase engine speed to maximum setting.
1
Refer to Section 5 — Clearing Feed System and
Discharge Chute.
Refer to Maintenance section.
Refer to Care of the Unit.
1
1
Appendix — Troubleshooting Chart
Page 87
Symptom
Possible Cause
Text Procedure/Corrective Action
Engine overheats.
Chute clogging.
Chipper will not self-feed
properly or rejects mate-
3
rial.
1
FeedSense equipped
2
DC 610 only
3
WC 126A/166A only
Radiator ns clogged.
Improper coolant level or mixture.
Damaged fan or fan belt.
Engine ns not clean.
2
Cutting implement not turning at correct rpm.
Dull blades.
Improper blade/anvil gap.
Feeding wet or sappy material.
Material too large for chipper.
Feed system not operating properly.
Cutter housing vents covered.
Dull blades.
Improper blade setting.
Improper setting of bed blade or feed plate.
Material is too large for chipper.
Clean radiator ns of debris (let engine cool rst).
Fill radiator and coolant reservoir (let engine cool rst).
Refer to engine owner’s manual.
Clean engine cooling ns (let engine cool rst).
2
Increase engine speed to maximum setting.
Refer to Maintenance section.
Refer to Maintenance section.
Mix heavier stock in with lighter/wet materials.
Cut large material into smaller sizes.
Refer to Maintenance section.
Clear cutter housing vents of any blockage.
Refer to Maintenance section.
Refer to Maintenance section.
Refer to Maintenance section.
Cut large material into smaller sizes.
Appendix — Troubleshooting Chart
Page 88
Page 89
Page 90
CALL
1-877-GO-ALTEC
(877-462-5832)
For all Parts and service needs
• Prompt 1 Parts/Tools & Accessories
- Order parts
- Order tools and accessories
- Determine shipping status
- Technical support to order parts
• Prompt 2 Shop Service
- Arrange for service at the nearest Altec Service Center
- Obtain a service quotation
• Prompt 3 Mobile Service
• Prompt 4 Technical Support
Order Parts Online at www.altecconnect.com
Media\National Service\Service Insert-Rev 8-11
- Arrange for a mobile service technician to visit your
location for on-site repair
- Answer technical questions to assist in repairs
Page 91
Page 92
ALTEC SERVICE CENTERS
Alabama
1730 Vanderbilt Road
Birmingham, AL 35234
(205) 458-3839 fax
Arizona
2505 West Durango Street
Phoenix, AZ 8500
(602) 252-8843 fax
Northern California
325 Industrial Way
Dixon, CA 95620
(707) 678-1038 fax
Southern California
2882 Pomona Boulevard
Pomona, CA 91766
(909)444-0448 fax
Colorado
641 Telluride Street
Aurora, CO 80011
(303)364-9523 fax
Florida
2570 Old Okeechobee Road
West Palm Beach, FL 33409
(561) 686-6972 fax
Georgia
287 First Street
Forest Park, GA 30050
(404) 363-2180 fax
Indiana
5201 West 84th Street
Indianapolis, IN 46268
(317) 876-3620 fax
9
Maryland
1434 Hughes Ford Road
Frederick, MD 21701
(301) 694-9644 fax
Massachusetts
28 Wales Street
Millbury, MA 01527
(508) 752-4791 fax
West Missouri
2106 South Riverside Road
St. Joseph, MO 64507
(816) 236-1356 fax
East Missouri
1125 South Callahan Road
Wentzville, MO 63385
(636) 639-2261
North Carolina
800 Highway 152 East
China Grove, NC 28023
(704) 856-2044 fax
Ohio
1236 Township Road 1175
Ashland, OH 44805
(419) 289-7444 fax
Oregon
13817 NE Sandy Boulevard
Portland, OR 97230
(503) 253-1191 fax
Pennsylvania
250 Laird Street
Plains, PA 18705
(570) 822-7062 fax
North Texas
1001 Solon Road
Waxahachie, TX 75165
(972) 937-8253 fax
South Texas
6902 E. Orem Drive
Houston, TX 77075
(713) 336-6249 fax
Crossroads Chevrolet
(Independent Service Provider)
420 S. Roth Street
Reed City, MI 49677
(231) 832-4362
Utility Equipment Specialists
(Independent Service Provider)
1111 S. 3200 W.
Salt Lake City, UT 84104
(801) 972-6168
Utility Truck Services
(Independent Service Provider)
14601 Ramsey Blvd.
Ramsey, MN 55303
(763) 323-4236
Altec Worldwide LLC
2106 South Riverside Road
St. Joseph, MO 64507
(816) 236-1279
(816) 236-1361 fax
Altec Limited - Milton
831 Nipissing Road
Milton, Ontario L9T 4Z4
(905) 875-2000
(905) 875-2009 fax
Altec Limited - Surrey
12352 84th Avenue
Surrey, British Columbia V3W 0J5
(604) 597-0355
(604) 597-0357 fax
Altec Limited - Winnipeg
570 Durand Road
Winnipeg, Manitoba R2J 3T1
(204) 663-8362
(204) 663-4798 fax
General Body & Equipment Ltd. - Calgary
3773 19th Street NE
Calgary, Alberta, Canada T2E 6S8
(403) 250-2115
(403) 250-1925 fax
General Body & Equipment Ltd.
Edmonton
8124 Davies Road
Edmonton, Alberta, Canada T6E 4N2
(780) 468-5331
(780) 468-5301 fax
Altec Parts
2106 South Riverside Road
St Joseph, MO 64507
(816) 236-1356 fax
www.altecconnect.com
Call 1-877-GO ALTEC (1-877-462-5832)
to reach your local parts, shop, or mobile service representative.
Page 93
Page 94
ASSEMBLY, ROLLING HEAD AND FRAME, DRM 12
6
1
9
1
7
1
4 X
3
1
10
1
4
1
2
1
10
1
1
1
1
3
1
5
1
928
7
4 X
1
1
NOTE:
LUG NUTS (P/N 970130501) ARE DISPLAYED FOR REFERENCE ONLY. 1.
THEY ARE LOCATED ON THE AXLE BILL OF MATERIAL.
970413406-A
1A
[PAGE 1 OF 2]
07-13
Page 95
ASSEMBLY, ROLLING HEAD AND FRAME, DRM 12
ITEM NO. QTY PART NUMBER DESCRIPTION
970398796 ASSEMBLY, HEAD FRAME, 50 IN W X 30 IN H FEED HORN, DRM 12
2 970413441 KIT, LUG NUT, ONE WHEEL, REF 970130501, 8-LUB WHEEL
0 2 970413441 KIT, LUG NUT, ONE WHEEL, REF 970130501, 8-LUG WHEE L,
1 1 970398731 HEAD AND FRAME, WELDMENT, DRM-12,
2 1 970234727 TORSION AXLE, SI DE MOUNT, 7000 LBS, 55.00 IN OB, 70.00 HF, .50 -20 UNF
3 2 970127225 TIRE, 245/75R16, LOA D RA T ING E
4 1 970116490 JACKSTAND SIDEWIND, TAIL HITCH, 5000 LB CAPACITY, 15 IN TRAVEL
5 1 970122563 DRAWBAR, 4-BOLT MOUNT, 42, 000 LBS MGTW, 7, 000 LB S VERT LOAD, FORGED
6 4 020041612 CAPSCREW, STEEL, HEX HEAD, .63-11 UNC, 2.50 IN L, GR 8
7 8 020391609 NUT, STEEL, T O P LOCK , .63-11 UNC, GR C, PLATED 18,
8 4 970116588 CAPSCREW, S/R/B 980114139, STEEL, HEX HEAD, .63-11 UNC, 1.50 IN L, GR 8, PLATE D,
9 12 020401706 WASHER, STEEL, F LAT, .63 IN DIA, ASTM F436, PLATED,
10 2 970122596 RIM, 16X6K, 8 LUG ON 6.50 IN DIA, .50-20 STUD 60 DEG TAPER, .50 IN OFFSET "IN", BLACK
970413406-A
1A
[PAGE 2 OF 2]
07-13
.
.
Page 96
ASSEMBLY, FEED SYSTEM, HYDRAULIC LIFT, DRM 12
970413443-A
2A
[PAGE 1 OF 2]
07-13
Page 97
ASSEMBLY, FEED SYSTEM, HYDRAULIC LIFT, DRM 12
FOR REFERENCE
4
27
4
26
33 3217
1
2
38
4X
43
1
37
1
36
1
2
2X
10
42
41
1
1
21
1
2X
40
4
1
1
36
1
1
38
2X
1
2
23222
12
22
28
4
1
52 53
8
22 2330
1
4
11
1
611
4
44
LOWER PIVOT HOUSING-
2
FOR REFERENCE
1
4
1
25
29
4
2
2
1
1
15
1
1
16
1
3
26
4
4
27
2X
1
2
48
51
1
2X
39
22
28
1
UPPER DRUM HOUSING WELDMENT-
1
9
8
3
8
28
1
2X
18
28
22
1
1
13
22
8
1
7
50
1
1
1
15
1
22123
49
5
3
1
2
4X
4
25
26
27
44
2322 12
1
2
2X
2
1
1
831
20
1
14
24
1
19
FOR REFERENCE
1
970413443-A
2
323534
NOTE:
ITEM 45 P/N 970476789 (QTY. 2.5FT) AND
2
4
2
2
33
32
3332
2
2
DRUM HOUSING WELDMENT-
ITEM 46 P/N 970476780 (QTY. 2) ARE NOT SHOWN.
2A
[PAGE 2 OF 2]
07-13
Page 98
ASSEMBLY, FEED SYSTEM, HYDRAULIC LIFT, DRM 12
Y
87906018
CAPSC
8 9060 8
C SC , S , , 5 0 U C, 00 , G 8, ,
338020031104
CAPSCREW, STEEL, HEX HEAD
31 18 UNC
PLATED
512970413430
BEARING, SLIDE PAD, UHMW POLYETHELENE, 4.50 X 2.00
T
ITEM NO. QTYPART NUMBER DESCRIPTION
970398738 ASSEMBLY, FEED ROLLER & ROTOR, HYDRAULIC FEED ROLLER LIFT, DRM 12
1 1 970398707 UPPER PIVOT HOUSING, WELDMENT, UNIVERSAL FEED SYSTEM,
2 2 044115014 BEARING, CYLINDRICAL, BACKED, 2.00 IN BORE, 2.25 IN OD, 1.50 IN L,
3 2 970113602 BEARING, ROLLER, STEEL, 2.000 IN BORE, 2.23 IN L, 5.118 BOLT PATTERN,
4 2 970260503 BUMPER, RUBBER, 1.50 IN DIA X 1.00 IN L, .38-16 UNC X .75 IN L STUD,
5 1 970398720 FEED WHEEL, WELDMENT, 20 IN OD, UNIVERSAL FEED SYSTEM,
6 1 970398739 PIN, PIVOT, SNAP RING, 20.00 IN L, 19.69 IN USABLE LENGTH, 2.00 IN OD,
7 1 970398721 HYDRAULIC CYLINDER, LIFT CYLINDER, 2.00 IN BORE, 1.125 IN ROD, 16.25, 6.00 IN
8 2 970116846 BEARING, ROLLER, STEEL, 2.4375 IN BORE, 3.500 IN L, 4.77 BOLT PATTERN,
9 1 970108997 ANVIL, BAR, CFD 1217
10 1 970398741 FEED WHEEL SHAFT, COUPLER, 2.00 IN ID, 2.975 IN OD, UNIVERSAL FEED SYSTEM,
11 1 970398742 HYDRAULIC MOTOR, GEROLLER, 32.3 CU IN, 4 BOLT MOUNT, TAPERED SHAFT
12 4 970273285 ROD END, STEEL, THREADED, .50-13, 4.00 IN L, .50, 5, PLATED,
13 1 970181850 DRUM CONTROL FED, DUAL FIN, 20 IN, ASSEMBL
14 1 970202502 SPROCKET, EFC/SPACER, 4.50 IN DIA, 20 TOOTH, DC-1317, CFD-1217, DC-912A
15 2 044112003 BEARING, CYLINDRICAL, FRP, 1.00 IN BORE, 1.25 IN OD, 1.00 IN L,
16 1 970398744 COUPLER PIN, DOWEL, CHAMFERED ENDS, 0.50 IN OD, 3.00 IN L,
17 1 970200546 GUARD, BREARING, DRIVE SIDE, BACKING PLATE MOUNT, CFD-1217,
18 2 970398757 WELDMENT, DRUM HOUSING VENT COVER, SIDE MOUNT, CFD1217A,
19 1 970368630 COVER, COMPONENT, BEARING AND EFC, STREET SIDE, CFD-1217
20 1 970368635 MOUNT, WELDMENT, EFC SENSOR, STREET SIDE, CFD-1217
21 1 970398752 PIVOT BOX OPENING COVER, WELDMENT, UNIVERSAL FEED SYSTEM,
22 38 020401404 WASHER, STEEL, FLAT TYPE A NARROW, .50 IN DIA, PLATED 18,
23 16 020391404 NUT, HEX, SELF-LOCKING, STEEL, OVALATED, .50-13 UNC, GR C, PLATED,
24 1
4
REW, STEEL, HEX HEAD, .75-10 UNC, 2.00 IN L, GR 8, PLATED,
25 8 970179927 CAPSCREW, STEEL, FERRY CAP, 2.00 IN L, .63 IN DIA, .63-11 UNC, GR 8, PLATED,
26 12 970032732 CAPSCREW, STEEL, HEX HEAD, .63-11 UNC, 1.50 IN L, GR 8, W/LOCKING PATCH PLATED,
27 12 020401706 WASHER, STEEL, FLAT, .63 IN DIA, ASTM F436, PLATED,
28 14 020031406 CAPSCREW, STEEL, HEX HEAD, .50-13 UNC, 1.00 IN L, GR 5, PLATED,
29 1 023017001 RETAINING RING, EXTERNAL, 2.00 IN ID, BASIC
30 4 020031409 CAPSCREW, STEEL, HEX HEAD, .50-13 UNC, 1.75 IN L, GR 5, PLATED,
32 12 020401102 WASHER, STEEL, FLAT TYPE A NARROW, .31 IN DIA, PLATED 18
-
, .
, .75 IN L, GR 5,
,
34 2 020031106 CAPSCREW, STEEL, HEX HEAD, .31-18 UNC, 1.00 IN L, GR 5, PLATED, YELLOW ZINC
35 2 020391102 NUT, STEEL, NYLON INSERT, .31-18 UNC, PLATED 18,
36 10 020401202 WASHER, STEEL, SAE FLAT TYPE A NARROW, .38 IN DIA, PLATED 18,
37 4 020031207 CAPSCREW, STEEL, HEX HEAD, .38-16 UNC, 1.25 IN L, GR 5, PLATED,
38 6 020391205 NUT, STEEL, CENTER LOCK, .38-24 UNF, GR A,
39 2 970398725 SPRING, EXTENSION, MUSIC WIRE, 11.106 IN L, .242 WIRE DIA, 1.900 COIL OD, 30.769 LBF/IN,
40 1 970413426 SOLENOID VALVE, ELECTRO HYDRAULIC, 2 WAY POPPET, 3000 PSI, 8 GPM
41 2 020031010 CAPSCREW, STEEL, HEX HEAD, .25-20 UNC, 2.00 IN L, GR 5, PLATED,
42 4 020401004 WASHER, STEEL, FLAT TYPE A NARROW, .25 IN DIA, PLATED
43 2 020391022 NUT, TOP LOCK, 1/4-20 UNC, 18-8 STNL STL
44 4 020031204 CAPSCREW, STEEL, HEX HEAD, .38-16 UNC, .75 IN L, GR 5, PLATED,
45 2.5 970476789 WIRE ROPE, WIRE COIL, .0625 IN DIA, 250 FT L, 480 LBS, VINYL COAT, 1.00 IN DIA ID COIL
46 2 970476780 SLEEVE, .0625 IN DIA, .375 IN L, FERRULE
48 4 020411201 WASHER, STEEL, LOCK SPLIT TYPE, .375 IN DIA, PLATED,
49 4 020041408 CAPSCREW, STEEL, HEX HEAD, .50-13 UNC, 1.50 IN L, GR 8, PLAIN FINISH
50 1 970115949 SPECIAL TOOL, BLADE/ANVIL GAP SET, 1.00 IN W, 12.00 IN L, .125 IN T
, .31
52 1 970466917 PIN, DRM-12 ROTATION LOCK, .875 IN DIA, 1.75 IN GRIP, W/ RING HANDLE
53 1 970121057 PIN, STEEL, HAIRPIN, 2.63 IN L, .13 IN DIA, PLATED 18,
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Page 99
ASSEMBLY, FEED CONTROL, HYDRAULIC LIFT, DRM 12
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ASSEMBLY, FEED CONTROL, HYDRAULIC LIFT, DRM 12
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32
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FEED HORN
1
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FOR REFERENCE ONLY:
40
38
22
1
3
1
21
21
1
1
40
1
47
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3
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ITEM # 100, 970180830 NOT SHOWN
NOTE:
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