I. Purpose & Scope

To safely and effectively provide instruction on the inspection and proper use of bucket trucks.

II. Definitions

Standard PPE – High Viz Garment, Hard Hat, Z-87.1 Safety Glasses, Gloves, Pants, Work Boots

III. Process

NOTE: Work instruction does not supplement the manual. For specific instructions for the exact model please refer to the owner’s manual.

A. Potential Hazards

• Hydraulic Pressure Hazard
• Airborne Particles Hazard
• Tipping or Rolling Hazard
• Falling Objects Hazard
• Electric Shock Hazard

B. PPE

• Standard PPE

C. Inspection

1. Prepare the unit for inspection at the beginning of each shift before going out on the job.
   • Position the unit on a level surface.
   • Engage the PTO with the transmission in neutral or park without apply the parking brake.
   • Verify the aerial device functions do not operate.
   • Apply the parking brake, and chock the wheels.
   • Turn off the engine.
2. Make sure the vehicle tires are in good condition and properly inflated to the pressure posted on the drivers side door.
3. When the booms and outriggers stowed, check the oil level in the hydraulic reservoir. The oil level must be to the indicated mark on the dipstick or at the top of the sight gauge. If necessary, add oil as needed.
4. Visually inspect the unit for hydraulic leaks. Continue to look for hydraulic leaks while performing the inspection.
5. Throughout the inspection, verify proper operation. Lok for damage or excessive wear, cracks or corrosion, missing or loose fasteners, cracked or broken inspection marks. Pay particular attention to the following components.
   • Articulating arm and link fiberglass
   • Articulating arm pivot pins (arm and link)
   • Articulating arm cylinder mounting pins
   • Rotation bearing and gearbox
   • Lower boom pin
   • Lower boom cylinder mounting pins
   • Upper boom extension cylinder mounting pins
   • Leveling cylinder mounting pins
   • Upper leveling bracket pivot pin
   • Platform mounting bracket
   • Platform rotation pin
   • Pedestal mounting
   • Personal fall protection attachment points
   • Rotary joint mounting
   • Outrigger anchor pins
   • Platform secure
   • Material handling secure
6. Inspect all covers to make sure they are in place, secure, and in good condition.
7. Check visual and audible safety device for proper operation. Check operational and instructional placard. Replace missing and/or illegible placards.
8. Inspect the fiberglass booms, arm and link sections, single handle control, control handle covers, boom tip covers, and platform(s) for any conditions that could reduce the limited dielectric properties including the following items.
   • Dirt, moisture, foreign objects, and/or oil
   • Damage including chipped or scratched surfaces
   • Holes in the platform, liner, and control handle covers
9. Check the expiration date on the annual inspection placard. Verify the current dielectric test date for the unit and platform liner.
10. Start the engine and engage the PTO.
    NOTE: Do not put the unit in service and run the pump at normal operating speeds until the hydraulic oil reservoir feels warm to the touch.
11. Test the outrigger interlock system.
    • Move the aerial device/outriggers selector to make the aerial device operational.
    • With all outriggers fully raised, place the lower boom control in the raise position.
    • If movement occurs, the outrigger interlock system is not functioning properly.
    • If the unit is equipped with an automatic boom restraint, make sure the restraint is not engaged when the aerial device is operational.
12. Test the outriggers.
    • Move the aerial device/outriggers selector to make the outriggers operational.
    • Properly set the outriggers. Confirm proper operation and audible alarm function.
    • Move the aerial device/outriggers selector to make the aerial device operational.
    • Hold one outrigger control in the raise position while watching that outrigger for movement.
    • If the outrigger retracts, the cylinder, holding valve, or aerial device/outriggers selector is not functioning properly.
    • Hold the outrigger control in the lower position. If the outrigger extends, the aerial device/outriggers selector is not functioning properly.
    • Repeat this test each outrigger.
    • Verify the outriggers are properly set, and not how far each outrigger is extended.
13. Inspect chassis coupling devices (hitches, inserts, and safety chain points) for any damage or condition that would reduce the structural integrity. Inspect pins, latches, and locking devices for proper operation.
14. Throughout the preoperational test of all unit controls, confirm the following items.
    • When controls are released, they must return to neutral without sticking and all motion for that function should stop. If movement continues, a control valve may not be functioning properly.
    • While cylinders are extended and under load, no movement should occur while controls are in neutral. Any movement indicates a cylinder or holding valve malfunction.
15. Test the lower controls emergency stop.
    • Engage the emergency stop.
    • Operate each control, and observe for movement. If movement occurs, the emergency stop is not functioning properly.
16. Test the start/stop and secondary stowage DC pump controls from the lower controls.
    • Move the control selector to the Lower Controls position.
    • Turn off the engine with the start/stop control.
    • Press and hold the secondary stowage control or combined function start/stop control until the DC pump begins to operate.
    • While holding the control with the DC pump operating, raise and lower the upper boom a small amount (movement will be slow). If no boom movement occurs, the secondary stowage system may not be functioning properly.
    • Release the control, and start the engine using the start/stop control to complete the test.
17. Test the lower controls.
    • Move the control selector to the Lower Controls position. Release the control, and verify it returns to neutral.
    • Without moving the control selector, operate all boom and platform positioning controls, if equipped. If movement occurs, the lower control interlock is not operating properly.
    • Move and hold the control selector in the Lower Controls position. If equipped, operate all boom and platform positioning controls throughout their full range of motion, and observe for proper operation.
    • Verify proper operation of the auxiliary winch controls.
18. Test the interlock blocking valve.
    • With the control selector in the Lower Controls position, verify all upper controls, except platform tilt, do not function. If movement occurs, the interlock system is not functioning properly.
    • Place the control selector in the Upper Controls position. Operate the boom raise function from the lower controls. If boom movement occurs, the interlock system is not functioning properly.
19. Test the upper controls emergency stop.
    • Engage the emergency stop.
    • Operate each control. If movement occurs, the emergency stop is not functioning properly.
    • Disengage the emergency stop.
20. Test the single handle control interlock. Without engaging the interlock trigger, operate the single handle control. If boom movement occurs, the interlock system is not functioning properly.
21. Test the platform start/stop and secondary stowage DC pump controls.
    • Turn off the engine with the start/stop control, and continue holding the control down until the secondary stowage pump beings to operate.
    • While holding the control down with the DC pump operating, raise and lower the lower boom a small amount (movement will be slow). If no boom movement occurs, the secondary stowage system may not be functioning properly.
    • Release the control. Start the engine by pressing the control down to complete the test.
22. If equipped, operated all boom and platform positioning-controls throughout their full range of motion, and observe for proper operation.
23. Operate all platform, tilt, and elevator controls throughout their full range of motion, and observe for proper operation.
24. Test the winch and jib control function.
    • Position the upper boom so the job can move through its full range of motion without contacting the boom.
    • Operate the job through its full range of motion, and observe for proper operation.
    • Operate the winch pay in and pay out functions, and observe for proper operation and winch drum winding. Inspect the condition of the winch line.
25. Verify the material handling attachment and/or load hook are in good condition and properly secured to the end of the winch line. Confirm that any originally equipped latch on the load hook is in place and working properly.
26. Verify that each outrigger is still extended to the position. If any retraction has occurred, the outrigger cylinder or its holding valve is not functioning properly.
27. Make sure the booms are properly stowed, raise the outriggers, disengage the PTO, and turn off the engine.

D. Use

Preparing for Road Travel

1. Stow the booms and platforms.
2. Stow the outriggers.
3. Rotate the outrigger shoes and material handling equipment into positions that will not exceed the allowable travel measurements. If equipped with removable outrigger shoes, remove and secure them for road travel.
4. Secure any objects that could move during road travel.
5. Check that all items are secured and bin doors are properly latched.

Cold Weather Start-Up

1. Start the engine, and engage the PTO.
2. Without connecting any tools, activate the upper tool circuit. This is done by first selecting the Unit position at the tailshelf controls and then selecting the Upper Controls position at the turntable.
3. Run the unit for approximately five (5) minutes. Check the reservoir about once a minute to see if it is warm to the touch. When it is warm to the touch the unit is warmed up.
4. From the lower controls, cycle each boom function at least once through its complete range of motion.

Ground Level Controls

1. The ground level controls located at the tailshelf have switches for the operation of the following functions (if equipped).
   • Outriggers
   • Engine start/stop or DC pump
   • Throttle
   • Tools
   • Aerial device/outriggers selector
2. The surface that the outrigger shoe will rest on must be firm and capable of supporting a substantial load in a concentrated area. If there is any doubt about the surface being firm enough to support the weight, place sturdy outrigger pad supports beneath each outrigger shoe to increase the support area and load holding capability.
3. Downward movement on the outrigger switch lowers the outrigger and upward movement raises the outrigger. The switches return to neutral when release.

Properly Setting on a Level Surface

1. With the booms stowed, lower the outriggers to a firm footing.
2. Lower the outriggers as far as possible while allowing the vehicle to be level within 1 degree of 0 (1-0-1 on the slope indicator) and with all tires maintaining contact with the ground surface.
3. Although the tire-to-surface contact pressure may vary, extend the outriggers to remove the bulge from the tires.
4. Lower the outriggers approximately 3″ after reaching ground level. This will usually be enough to remove the bulge and still be able to see some tire-to-surface contact at each tire.
5. To ensure proper outrigger spread when using outrigger pads or blocks, extend the outriggers approximately 3″ after reaching ground level (not pad surface level). This may result in tires coming off the ground.

Properly Setting on a Sloping Surface (One set of Outriggers)

1. With the booms stowed, lower the low side outriggers to a firm footing.
2. Lower the high side outriggers only after a frim footing has been reached with the low side outriggers.
3. Lower the high side outriggers only after a frim footing has been reached with the low side outriggers.
4. Lower the high side outriggers approximately 3″ after reaching ground level.
5. Extend the low side outrigger to establish a more level vehicle.
6. Do not retract the side outrigger.
7. Lower the low side outriggers as far as possible while allowing the vehicle to be level within the limits as marked on the slope indicator placard.
8. Do not extend the low side outrigger any farther if the vehicle gets to level.
9. It may not be possible to get the vehicle to 0 degrees (level) even with the low side outrigger at full extension. All tires should maintain contact with the ground surface.
10. To ensure proper outrigger spread when using outrigger pads or blocks, extend the outriggers approximately 3″ after reaching ground level (not pad surface level).

Properly Setting on a Sloping Surface (Two Sets of Outriggers)

1. With the booms stowed, lower the low side outriggers to a firm footing.
2. Lower the high side outriggers only after a firm footing has been reached with the low side outriggers.
3. Lower the high side outriggers approximately 3″ after reaching ground level.
4. Extend the low side outrigger to establish a more level vehicle. Do not retract the high side outrigger.
5. Lower the low side outriggers as far as possible while allowing the vehicle to be level within the limits as marked on the slope indicator placard.
6. Do not extend the low side outrigger any farther if the vehicle gets to level.
7. It may not be possible to get the vehicle to 0 degrees (level) even with the low side outrigger at full extension. All tires on the high side should maintain contact with the ground surface.
8. Tires on the low side of the slope may or may not remain in contact with the ground, depending on how much slope is present.
9. To ensure proper outrigger spread when using outrigger pads or blocks, extend the outriggers approximately 3″ after reaching ground level (not pad surface level). This may result in all tires coming off the ground.

Properly Setting on a Sloping Surface Using Cribbing or Blocking of the Outriggers

1. With the booms stowed, lower the high side outriggers approximately 3″ after reaching the ground level. Do not retract the high side outriggers.
2. Lower the low side outriggers as far as possible while allowing the vehicle to be level within the limits as marked on the slope indicator placard.
3. Do not extend the low side outriggers any farther if the vehicle gets to level (0 degrees). It may not be possible to get the vehicle to level (0 degrees) even with the low side outriggers at full extension.
4. Operation is allowed if within the limits as marked on the slope indicator placard. If the slope indicator is not within the limits, additional cribbing and blocking is required.
5. Cribbing and blocking must be properly constructed and positioned such that it can support the weight of the vehicle, unit, and load without slipping or failure.
6. Outriggers must be deployed again as described until the slope indicator is within the limits marked on the placard.
7. To ensure proper outrigger spread when using outrigger pads or blocks on the high side, extend the high side outriggers approximately 3″ after reaching the level of the bottom of the tires (not necessarily the same as the top of the pad or blocking). This may result in all the tires coming off the ground. Set up must account for the potential role that tires play in stability and traction on a slope.

Interlock System

1. An outrigger interlock system is provided. The system requires that the outriggers be lowered to within 4″ to 6″ of the ground before operation of the aerial device is allowed.
2. Outrigger interlocks do not assure full stability, but simply prevent the operation of the unit until the outriggers have been lowered.
3. Outrigger interlock is achieved with proximity sensors mounted on the outrigger weldments.
4. The sensors detect a retracted outrigger cylinder and prevent unit operation if all the outrigger legs are not adequately extended.
5. If all of the outrigger legs are adequately extended, the yellow lights on the sensors illuminate, and a signal is sent to the control module to allow unit functions.
6. If an outrigger legs is not adequately extended, the proximity sensor for that leg will not send a signal (complete the circuit) to the control module and unit operation is disabled.

Motion Alarm

1. The unit is equipped with an outrigger motion alarm. An audible alarm alerts personnel in or near the work area that the outriggers are in motion.
2. When the outrigger switches are moved from neutral, the warning is sounded.
3. Returning the switch to neutral turns the alarm off.

Lower Controls

1. The lower controls are located on the turntable.
2. To operate the DC pump from the lower controls, push the DC pump control with right hand thumb, move the station selector control to the lower controls position with right hand fingers, and operate the function with left hand.
3. The following functions can be operated from the lower controls.
   • Articulating arm raise/lower
   • Upper boom extend/retract
   • Lower boom raise/lower
   • Turntable rotation
   • Control selector
   • Winch pay in/out
   • Emergency stop
4. The following functions can be selected by the control selector.
   • Upper controls
   • Lower controls
   • Emergency stop
5. Place the control selector in the Upper Controls position to operate the unit from the upper controls at the platform.
6. Move and hold the control select in the Lower Controls position to operate the unit form the lower controls at the turntable.
7. The upper controls at the platform, except platform tilt, are not operational while the selector is in the Lower Controls position.
8. When released, the control selector will return to the Emergency Stop position.
9. This prevents movement of the unit form unintentional movement of the lower control handles.
10. When the station selector is move from the Upper Controls position to the Emergency Stop position, all hydraulic oil will flow back to tank.

Upper Controls

1. Various controls are used to operate unit functions from the upper control station.
2. The following functions can be operated from the upper controls.
   • Lower boom raise/lower
   • Upper boom extend/retract
   • Turntable rotate
   • Platform rotate
   • Platform tilt
   • Articulating arm raise/lower
   • Jib functions
   • Winch pay in/out
   • Tools
   • Emergency stop
   • Remote start/stop
   • Secondary stowage DC pump
   • Throttle high/low
   • Platform elevate
3. An emergency stop is located at the upper control station. When engaged, the upper controls will not operate.
4. One or more functions may be operated at a time. The speed of movement is relative to the movement of the control.
5. The following functions can be operated with the single handle control.
   • Lower boom raise/lower
   • Upper boom extend/retract
   • Turntable rotate
   • Articulating arm raise/lower
6. The interlock system is intended to prevent unintentional boom movement that might result from accidental bumping of the single handle control.

Booms

1. The unit is a telescopic type. The upper boom, lower boom, and articulating arm may be actuated individually or in conjunction with one another. The boom functions may be controlled form the lower or upper controls.

Lower Boom

1. The steel lower boom is a box type design. The lower boom is capable of movement from approximately 25 degrees below horizontal to 85 degrees above horizontal.
2. The lower boom may be operated from the upper controls by engaging the interlock on units equipped with a single handle control. Operate the controls to move the lower boom to the desired position.
3. The lower boom may also be operated from the lower controls. Operate the lower boom from the lower controls when using the lower boom lifting eye, while testing, or in an emergency.
4. A double-acting cylinder is used to raise and lower the lower boom. The cylinder is held in position at all angles by two counterbalance holding valve cartridges in the base end of the cylinder. The holding valves prevent oil from escaping form the cylinder in the even of a hydraulic line failure.
5. The unit will either have a manual or automatic boom restraint to hold the boom in the rest.
6. The automatic restraint requires no action by the operator. The boom restraint locking mechanism will open when the upper boom is raised.
7. The automatic boom restraint may be connected to a light in the vehicle cab that indicates when the boom is not properly stowed.

Upper Boom

1. The upper boom may be operated by the single handle control at the platform. To do this, engage the interlock trigger on the single handle control, and move the control in the direction as shown on the single handle control placard.
2. The upper boom may also be operated from the lower controls. Operate the upper boom from the lower controls only while testing or in an emergency.
3. A double-acting cylinder is used to extend and retract the upper boom. Two counterbalance holding valves are installed in a valve block mounted to the base end of the upper boom extension cylinder. The holding valves prevent oil from escaping the cylinder in the event of the hydraulic line failure.

Boom Storage

1. If the booms bounce while the vehicle is in motion, damage may be caused to the booms, cylinders, turntable, and/or the platform.
2. Excessive downward force after the booms are in the rest may also damage the booms and/or boom rest.
3. Use the following procedure when stowing the booms for road travel.
   • Rotate the booms over the boom rest. If the unit is equipped with a platform rotator, position the platform in its normal stowed position, to the side of the boom tip.
   • Fully retract the upper boom. The lower boom should be slightly above horizontal.
   • Stow the articulating arm fully down.
   • If the unit is equipped with a job, make sure it is properly stowed. If the unit has an arm jib, make sure the cylinders are fully retracted. If the unit has a side-mount jib, make sure it is parallel to the upper boom.
   • Stow the lower boom. Make sure the platform clears any obstacles as it is placed in the platform rest.
   • Use the boom tie down strap, if equipped, to secure the upper boom to the rest for road travel.
   • If the unit is equipped with an automatic boom restraint, make sure the restraint does not engage when the upper boom is raised.
   • If equipped, the boom out-of-stow system detects if the lower and/or upper booms are properly seated in the rest. If equipped, make sure the boom out-of-stow light in the cab is off. If the lower and/or upper booms are properly seated and the out-of-stow light is on, the boom out-of-stow system is not functioning properly.

Rotation

1. The turntable can be rotated through 360 degrees continuously after the booms are elevated.
2. The rotation system is self-locking, intending to assure that the turntable will remain in position when hydraulic pressure is not applied to the hydraulic motor. This system is capable of holding the turntable in position without the use of a brake.
3. At the upper controls, engage the interlock trigger, and move the single handle control in the appropriate direction to rotate the turntable. Return the control to neutral to stop rotation.
4. Rotate the turntable from the lower controls by moving the control handle in the appropriate direction.

Personnel Platform

Platform Rotator

1. The unit is equipped with a rotary actuator. A side-mounted platform has a 90 degree arc of rotation, and as end-mounted platform has 180 degree arc of rotation.
2. This allows the platform to be positioned beside the boom tip or to be rotated beyond the boom tip for increased reach and better access to the job and winch line.
3. The control handle for the platform rotator is at the platform, housed inside a fiberglass control cover on the side of the platform.
4. Engage the upper control interlock, and move the platform rotator control in the desired direction.
5. If equipped with the platform elevator or side-mount configuration, lift up on the platform rotator control interlock, and move the platform rotator control in the desired direction.
6. When stowing the unit for road travel, always rotate the platform to its stowed position before stowing the lower boom. This will aid in avoiding contract with the vehicle body.

Platform Leveling System

1. The platform leveling system continually adjusts the position of the platform to keep the platform floor nearly parallel to the turntable base as the booms move. This is accomplished with two cylinders of equal bore.

Platform Tilt

1. Platform tilt can be used to remove injured personnel in an emergency, to remove water or debris from the platform, or to tilt the platform as desired by the operator.
2. The platform can be fully tilted down 90 degrees (platform floor vertical). All operators should become familiar with this procedure.
3. Engage the upper control interlock, and move the platform tilt control in the desired direction.
4. If equipped with the platform elevator or side-mount configuration, lift up on the platform tilt control interlock, and move the platform tilt control in the desired direction.
5. Return the platform to a vertical position before operating the unit.

Lanyard Anchor

1. The lanyard anchor is part of the personal fall protection system. The lanyard must be properly attached to the anchor. The operator(s) must use an OSHA approved fall arrest or fall restraint fall protection system. Refer to the lanyard attachment placard on the unit for its use.

Platform Elevator

1. The platform elevator allows the operator to raise the platform 24″ above the stowed height. To elevate the platform, raise the platform elevator control interlock, and move the control to the Raise position.
2. Moving the control to the Lower position lowers the platform.
3. The platform elevator function does operate if the single handle control interlock trigger is engaged, the control selector is in the Lower Controls position, or the upper controls emergency stop is engaged.
4. Make sure the arm jib is stowed away from the platform prior to operating the platform elevator. Fully lowering the lower arm and fully raising the upper arm will ensure the arm jib remains clear of the platform elevator movement.
5. Before stowing the booms or operating the arm jib, return the platform to the stowed position.
6. During operation of the elevator function the extend and retract oil levels may become unequal. This prevents the cylinder from fully retracting.
7. Fully raise the platform and hold the control in the Raise position for five seconds to make the oil levels equal. The cylinder should fully retract when lowering the platform.

Material Handling System

1. The jib, winch, and tool functions are not operational form the upper controls when the interlock trigger on the single handle control is engaged or when the control selector is in the Lower Controls position.
2. The winch may be operated from the lower controls when the control selector is in the Lower Controls position for emergencies and stability testing.
3. If the jib/winch is used with loose and/or irregular winding on the winch drum, the load can drop suddenly. When winding the winch drum apply tension and observe the drum.
4. Verify that consecutive winds lay side-by-side within each layer and that new layers do not cut into the lower layers.
5. If this occurs, the lower layer is too loose and must be rewound.
6. Check the drum winding prior to loading the jib/winch. If there is any doubt the drum is not wound properly, pay out the entire line, and wind it properly before applying a load.

Telescopic Jib

1. The jib portion of the material handling system consists of a one piece, fiberglass, telescopic lifting arm mounted to a hydraulically tilted jib support weldment. The lifting arm may be tilted 89 degrees.
2. The jib is tilted by a double-acting hydraulic cylinder capable of lifting 300 pounds with the jib fully extended through its travel arc.
3. A removable sheave head is attached to the end of the telescopic jib section for use with the winch line. Several lifting attachments are available to lift insulator strings, conductors, or multiple conductors.
4. The telescopic arm portions pins to the jib bracket weldment with a detent pin. To extend the jib, remove the pin and pull outward from the jib support weldment.
5. Then replace the pin in the working position. When the jib is in the working position, it provides up to 4’4″ of extension from the platform shaft.
6. The jib may be stowed out of the way by removing the detent pin and sliding the jib back into the jib support bracket. Then install the pin to properly secure the jib for travel or when it is not being used.
7. The jib functions are operated by the jib/winch/tools control valve at the platform. To operate the jib tilt function, move the jib control handle in this desired direction.
8. Returning the jib control handle to the neutral causes the jib tilt function to stop.

Arm Jib

1. The arm jib consists of a bracket base, lower and upper arm, and a fiberglass jib. The jib can be tilted 183 degrees. The jib is operated by two double-acting hydraulic cylinders.
2. Think of the components of this jib in relation to the components of the aerial device.
   • The lower arm acts like a lower boom.
   • The upper arm acts like an upper boom.
   • The bracket base pivots the jib like a turntable.
3. To pivot the jib, pull the handle near the jib base to release the pin. Rotate the jib as needed.
4. The jib will latch in increments of 45 degrees. Do not attempt to pivot the jib if it is under the load.
5. With the jib perpendicular to the boom, the platform has limited rotation.
6. The jib can also be removed by pulling the handle near the jib base to release the pin and lifting the jib. An option jib removal device can be used to lift the jib.
7. A removable sheave head is attached to the end of the telescopic jib section for use with the winch line. Several lifting attachments are available to lift insulator strings, conductors, or multiple conductors.
8. The jib pins to the upper arm with a detent pin. The arm jib has four positions. The shortest reach position is stowed. To extend the jib, remove the pin and pull outward from the upper arm. Then replace the pin.
9. The jib may be stowed out of the way by removing the detent pin and sliding the jib back into the upper arm bracket. Install the pin to properly secure the jib for travel or when it is not being used.
10. The jib functions are operated by the jib lower arm/jib upper arm/winch controls at the platform. To operate the jib tilt function, move the jib control handle in the desired direction.

Jib Removal Device

1. Attach the jib removal device to the side of the platform over the platform rib between the lanyard bracket and the dashboard covers. If using a platform liner, remove the plastic piece on the jib removal device by removing the countersunk screws.
2. Move the retention plates to the appropriate holes on the mount to adjust the secondary engagement to the platform.
3. Make sure the device is locked in place.
4. Remove the telescopic jib from the jib/winch assembly, and position it in the tube on the jib removal device.
5. Attach the end of the load line to the handle on the device.
6. Raise the lower section of the jib until the load line is vertical.
7. Release the pin that locks the jib/winch assembly to the unit.
8. Use the winch controls to raise the jib/winch assembly out o fits socket. The assembly may need to be rocked to alleviate any binding.
9. Set the assembly where desired.
10. Disconnect the hoses. The hoses are color coded to ensure proper connections.
11. Reassemble the telescopic jib into the jib/winch assembly.
12. Remove the jib removal device from the platform lip by rotating both secondary retention plates and then lifting up.
13. The jib/winch assembly can be placed back onto the unit by reversing the procedure.

Winch

1. The winch is equipped with a mechanical brake to prevent unintentional movement of the load. The winch has an average line speed of 42fpm. Speeds form the lower controls average 26fpm due to hose restriction.
2. The lower control station is equipped with a winch control handle. This control is for emergency operation of the winch or stability testing only.
3. The winch functions are operated by the jib/winch/tools control valve at the platform. To operate the winch line, move the winch control handle in the desired direction.
4. Returning the winch control handle to neutral blocks the flow of oil to the winch. The winch function will stop.

Phase Lifter

1. The phase lifter raises a single conductor using the hydraulic jib. The load applied to the phase lifter must not exceed the least of the applicable values of the phase holder, the jib structural, or the material handling capacity of the unit. If the conductor is energized, the phase lifter assembly must be rated, tested, and maintained for the appropriate line voltage.

Lower Boom Lifting Eye

1. The lower boom lifting eye adapts the lower boom for light duty material handling. This attachment provides a secure mounting shackle on the end of the lower boom.
2. the platform must not be occupied when using the lower boom lifting eye. Furthermore, the upper boom must be fully retracted.
3. The capacity of the lower boom lifting eye is constant at all boom angles. Lower boom lifting eye capacity placards are located on the control side of the turntable and at the lifting eye on the lower boom. Do not exceed the capacity stated on the placard.

Tool System

1. Hydraulic tool connections may be available at ground level and at the platform. The tool circuits are factory set at 6gpm and 2,000psi.
2. the pressure and flow of the tool circuits are adjustable to accommodate hydraulic tools with various pressure and flow requirements.
3. The lower tool circuit quick disconnects are mounted on the tailshelf. The upper tool circuit quick disconnects are located at the platform. The tool circuit will accommodate open center tools such as wrenches, drills, chain saws, or other hydraulic tools. HTMA quick disconnect fittings allow for easy attachment and removal of the tool.
4. To use the lower tool circuit, move the aerial device/out-riggers selector to make the outriggers operational and move the tools switch to the Tools A or Tools B position.
5. To use the upper tool circuit, move the tools control handle to the Tools A or Tools B position until it locks in the detent position.
6. Return the tool control handle to the off position when the tool circuit is not being used. This prevents pressure from being trapped in the tool hose and allows for easy disconnect of the tool. Always place the control handle in the off position before disconnecting a tool.

Remote Throttle System

1. The remote throttle control provides the capability of alternately switching vehicle engine speed from idle to unit operating speed.
2. Switching from idle speed to unit operating speed is achieved from the platform controls by engaging the throttle control. Each engagement changes the engine speed from the existing speed to the alternate speed.
3. At the lower controls, a push button throttle control changes engine rpm with successive engagements.

Remote Start/Stop System

1. The remote start/stop system may be used to start and stop the vehicle engine from a remote location. This system can be controlled by a switch at the turntable, a switch at the tailshelf, or an air operated cylinder at the platform.
2. If the unit is equipped with a DC pump, the same controls can be used to operated it.
3. For a remote start/stop system to operate, the vehicle ignition switch must be on.
   NOTE: Release the start/stop control immediately after the engine has started to prevent damage to the starter.

Switch

1. To start the engine, push the switch until the engine is running and release.
2. If the engine does not start, push the toggle switch and release. Then repeat the procedure.
3. To turn off the engine, push the toggle switch and release.

Captive Air Cylinder

1. To start the engine, push and hold the captive air cylinder rod in until the engine is running.
2. If the engine does not start, push the captive air cylinder rod in again and release. The repeat the procedure.
3. To turn off the engine, push the captive air cylinder rod in and release.

Stopping Hydraulic Power to the Platform

1. Hydraulic power to the platform can be shut off from the lower, ground (tailshelf), or platform controls. Perform one of the following.
   • Shut off the engine power with the start/stop system, if equipped.
   • Shut off the power source, whether it be the chassis engine or an auxiliary power unit.
   • At the lower controls, shift the control handle to lower controls.
   • At the tailshelf controls, move the selector to disable the aerial device.
   • Engage the emergency stop.

Other Methods of Lowering/Stowing the Unit

1. Used the lower controls to lower the platform and/or store the booms if the upper controls are not operational.
2. After determining that it is is safe to touch the vehicle, use the lower controls for boom and platform movement.
3. Control from the platform may be stopped by positioning the station selector handle in the Lower Controls position. This permits operation of the aerial device from the lower controls.
4. If the unit cannot be operated due to a loss of hydraulic power, such as engine or pump failure, use the following methods for lowering and/or stowing the unit.
   • Secondary Stowage DC Pump
     • The pump can be heard while it is operating. The functions will move slowly when using the pump because of the flow capacity of the pump.
   • Switch
     • The switch is located on the turntable or at the tailshelf.
     • For units without remote engine start/stop, start the pump, push the toggle switch and continue holding while operating the control handles.
     • Releasing the switch stops the pump.
     • For units with remote engine start/stop and DC pump, to start the pump, push the control during the stop cycle.
     • After five seconds, the pump will start.
     • The pump will operate as long as the control is held up.
   • Captive Air Cylinder
     • The captive air cylinder is located at the platform.
     • For units without remote engine start/stop, push the captive air cylinder rod in and hold to operate the pump.
     • For unites with remote engine start/stop and DC pump, push and hold the captive air cylinder rod in during the stop cycle.
     • After five seconds the pump will start.
     • The pump will operate as long as the cylinder rod is pushed in.

Raising the Outriggers

1. Stow the booms.
2. If the equipment is available, raise the vehicle to remove the load from the outrigger leg.
3. Locate the two holding valves installed in the base end of the cylinder. One valve has a screw in the top of the cartridge. Turn the screw in (clockwise) until the cylinder begins to retract. Control the speed of retraction using the screw.
4. When there is no vehicle weight on the outrigger, lift the outrigger leg with a come-along or pry bar. Block up the outrigger shoe at intervals if lifting in successive steps with a pry bar. Use the come-along to retract the extended outrigger leg.
5. Secure the outrigger legs in the stowed position until the hydraulic system is operational.
6. After the outrigger cylinder has been retracted, return the screw to its original position.
7. Perform a structural test as described in the Maintenance Manual before returning the unit to service.

E. Maintenance

1.  Check the oil level in the hydraulic reservoir each shit. When checking the oil level, the vehicle should be on level ground with the booms stowed and all other cylinders retracted. Add oil as needed.
2. Keep the fiberglass upper boom and lower boom insulators and optional ISO-Boom clean to maintain the nonconductive properties of the fiberglass. Periodically clean the fiberglass with mild detergent in warm water. Do not scratch the boom surface.
3. Check all of the seals between the fiberglass and steel. Over time, it may become necessary to clean and repair a seal between the fiberglass and steel.
4. Keep the green single handle control clean, dry and in good condition. Wipe any contaminants or moisture from the surface of the control handle assembly and dashboard with a clean, dry cloth.
5. Lower the bellows and wipe contaminants or moisture from the insulating linkages. Make sure the control area is free of foreign objects and reposition the bellows.
6. Keep the rubber control valve handle covers in place and in good condition. Replace damaged covers.

F. Live Line Contact

1. Immediately stop work.
2. Treat equipment, attachments and ground as energized.
3. Warn people nearby that an electric strike has occurred.
4. DO NOT exit equipment and stay inside cab while contact or arcing is occurring.
5. Ensure equipment is barricaded.
6. If there is an immediate hazard (i.e. fire hazard) that requires the exiting of equipment employee shall jump out of equipment with both feet together, landing on the ground.
7. Employee shall than shuffle away from equipment, not walk or run, taking small steps and feet together to minimize voltage difference in the ground until they reach a safe location.

IV. Reference Documents

Bucket Truck Manuals