210 Inverness Center Parkway
Birmingham, AL 35242

Telephone: 205-991-7733
Facsimile: 205-991-9993
www.altec.com

This notice applies to your vehicle. See attached serial number list.

Dear Altec Owner,

January 29, 2021

Altec Industries, Inc. has developed a product improvement which relates to LS40/45 aerial devices built
from 2004 through 2015.
Refer to SIL 782 for the items covered under the warranty policy. Altec will supply the necessary parts to correct this condition free of charge.
In order to determine if your unit is affected by SIL 782, compare the serial number of your unit with the list
of affected units attached to the SIL. The product improvement can be performed by the customer or you may
contact Altec at 1-877-GO-ALTEC (1-877-462-5832) for further assistance.
At any time, you may contact Altec at 1-877 GO ALTEC (1-877-462-5832) with your unit’s serial number to
determine if there are any other outstanding notices.
If you have sold or retired the unit please call Altec at 1-877-GO-ALTEC (1-877-462-5832) so the records may
be changed.
We regret this inconvenience; however we are taking this action in the interest of your safety and continued
satisfaction with Altec products.
Thank you for your immediate attention on this important matter.

Altec Industries, Inc.
HiLine Operations
Duluth, MN

SIL 782

Service Information Letter
January 29, 2021
Units Affected: LS40/45 aerial devices built from 2004 through 2015 (Verify that your unit
serial number is affected by reviewing the attached list in this SIL or by accessing your fleet on
connect.altec.com/login)

Extension Cylinder Update
Altec is committed to providing our customers safe and reliable products from initial delivery
throughout the useful life of the machine.
Altec has discovered there may be inadequate weld fusion between the extension cylinder rod
and rod end on the affected units. This can lead to failure of the weld. Altec has developed a process to have the cylinder rod end attachment repaired by the cylinder manufacturer.
Altec requires the repair to be completed on the affected units by the next annual preventive
maintenance interval or within one year of receipt of the SIL. The actions required are listed
below.
a. Remove the cylinder from the unit according to the Extension Cylinder Removal Procedure
beginning on page 2 of the SIL or contact Altec Service to remove the cylinder.
b. Document the Altec part number and serial number shown on the cylinder.
c. Contact Altec Service to schedule the return of the cylinder to the manufacturer for repair and
receive the pickup date and time and estimated turnaround time. Provide the numbers from
step b.
d. Contact Altec Parts to order two part number 201465000 lock nuts.
e. Obtain or fabricate a suitable pallet to support the full length of the cylinder, and attach the
cylinder to the pallet. LS40 cylinder is about 136 lb and 138” long. LS45 cylinder is about
160 lb and 162” long.
f. Attach the shipping label furnished by Altec Service to the package.
g. The C.H. Robinson transport company will pick up the package.
h. Receive the repaired cylinder from the manufacturer.
i. Install the repaired cylinder on the unit according to Extension Cylinder Installation Procedure beginning on page 4 of the SIL or contact Altec Service to install the cylinder.
j. Perform a Structural Load Test according to Section 9 of the unit’s maintenance manual.
Inspection labor
Repair labor
Account #
Travel
NHTSA code
Prime fail P/N
Doc ref

Altec Use Only
0.0 hr
7.0 hr
010.0953.43151.000.9117.000
Not included
98
002110212, 002110226,
970177574, 970186080
N/A

Parts Kit
3/4-16 UNF Lock Nut

Page 1 of 7

Altec Use Only
Part No.
201465000

Qty
2

Warranty
Yes

SIL 782

This repair is covered under the Altec Warranty Policy. The cylinder removal, installation, and load testing
can be performed by Altec, the customer, or the customer’s warranty provider. Any repairs to the cylinder
found necessary by the cylinder manufacturer other than the rod end weld and seal kit replacement are not
covered under warranty. Altec will perform the cylinder removal, installation, and load testing for free at
an Altec facility. If the customer or the customer’s warranty provider performs this work, a warranty claim
must be submitted to be reimbursed for the cost of the labor. Altec will allow up to $630 for the labor to
perform the cylinder removal, installation, and load testing. Altec Service will coordinate the shipping of
the cylinder and Altec will pay for the shipping cost. Call 1-877-GO ALTEC (1-877-462-5832) to schedule the work to be done by an Altec service technician or to schedule the return of the cylinder. Customers
are responsible for the travel costs of an Altec Mobile Service technician if the technician performs the
work at the owner’s location.

Extension Cylinder Removal Procedure
Normal mechanic’s hand tools, hydraulic plugs and caps, and a hoist and sling rated for at least 200 lb are
required for this procedure. Read and understand all steps of the instructions before beginning the procedure.
Setup
1. Position the unit on a level surface. Apply the parking brake and chock the wheels. Engage
the unit’s hydraulic system.
2. Use the lower controls to rotate the boom to the best position for working on the boom tip
and place the boom in the horizontal position. Extend the upper boom about 30” so the pin
connecting the rod end of the extension cylinder to the fiberglass boom is visible.
3. Disengage the unit’s hydraulic system and turn off the engine.
Removing Cylinder
4. Install a strap to restrain the upper boom from extending when the cylinder is removed.
5. Remove the platform tip guard. Keep the fasteners for reuse.
6. Remove the six cap screws and nuts holding the platform end weldment to the upper boom.
Leave the platform end weldment on the upper boom. Keep the fasteners for reuse.
7. Remove the two cap screws connecting the rod end of the extension cylinder to the lower
boom near the turntable (refer to Figure 1). Keep the cap screws for reuse. Discard the nuts.
Rod End Cap
Screws

Lower Boom

Figure 1 — Disconnecting Cylinder from Lower Boom
Page 2 of 7

SIL 782

8. Start the engine and engage the unit’s hydraulic system. Use the lower controls to fully retract
the cylinder.

WARNING
Death or serious injury can result from hydraulic oil being injected into the flesh when loosening
or disconnecting hydraulic components. Wear appropriate personal protective equipment. Remove the 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.

9. Turn off the engine. Move the ignition key to the On position without starting the engine.
10. Use the lower controls to operate the upper boom extend and retract functions several times
to relieve any fluid pressure in the hoses connected to the cylinder.
11. Disengage the hydraulic system. Turn off the ignition.
12. Locate the two hydraulic hoses that run from the base end of the extension cylinder to the
upper control valve at the boom tip. Disconnect the hoses from the valve. Plug the hose ends
and cap the fittings on the valve. Keep the hoses for reuse.
13. Remove the pin connecting the base end of the extension cylinder to the upper boom. Keep
the pin and retaining rings for reuse.

WARNING
Death or serious injury can result from uncontrolled movement. Properly support a component
before loosening fasteners and removing the component.

14. Gently pull on the two extension cylinder hoses to start sliding the cylinder out of the upper
boom end. When the base end of the cylinder is out of the boom end, use a hoist and sling
to support the cylinder and continue to slide the cylinder out of the upper boom. Lower the
cylinder to the ground.
15. Document the Altec part number and serial number shown on the cylinder.
15. Install one cap screw and nut to retain the platform end weldment to the upper boom. Leave
the upper boom restraint strap in place.
16. Store the boom. Take the unit out of service.
17. Package the cylinder for shipment, using the shipping label provided by Altec Service.

Page 3 of 7

SIL 782

Extension Cylinder Installation Procedure
Normal mechanic’s hand tools and a hoist and sling rated for at least 200 lb are required for this procedure. Read and understand all steps of the instructions before beginning the procedure.
Setup
1. Position the unit on a level surface. Apply the parking brake and chock the wheels. Engage
the unit’s hydraulic system.
2. Use the lower controls to rotate the boom to the best position for working on the boom tip and
place the boom in the horizontal position.
3. Disengage the unit’s hydraulic system and turn off the engine.
Installing Cylinder
4. Remove the cap screw and nut holding the platform end weldment to the upper boom. Retain
the fasteners for reuse.
5. Confirm that the mounting holes in the rod end and base end of the repaired extension cylinder are parallel with each other. Rotate the rod end if necessary for proper alignment.
6. Apply anti-seize compound to the mounting holes in the rod end and base end of the cylinder.
7. Using the hoist and sling to support the extension cylinder, begin sliding the it into the upper
boom end. Continue to slide the cylinder in until the block on the base end is inside the end
of the fiberglass boom.
8.Connect the two hoses to the fittings on the base end of the cylinder and on the upper control
valve in the boom tip. Use the hydraulic power source to extend the cylinder about 30”.
9.Start the engine and engage the hydraulic system.
10. Use the lower controls to extend the cylinder until the mounting holes in the rod end are
aligned with the mounting holes in the side of the lower boom.
11. Turn off the engine and disengage the hydraulic system.
12. Apply anti-seize compound to the two cap screws. Install the cap screws to connect the rod
end of the extension cylinder to the lower boom. Install the new lock nuts on the cap screws
and properly torque the fasteners.
13. Remove the restraint from the upper boom.
14. Manually move the upper boom in or out until the mounting holes in the side of the fiberglass
are aligned with the mounting hole in the base end of the extension cylinder.

Page 4 of 7

SIL 782

15. Apply anti-seize compound to the cylinder mounting pin. Install the pin to connect the base
end of the extension cylinder to the upper boom. Install the retaining rings on the pin.
16. Install the six cap screws and nuts to attach the platform end weldment to the upper boom.
17. Install the platform tip guard using the original fasteners.
Testing and Completion
18. Start the engine and engage the hydraulic system.
19. Using the lower controls, extend and retract the upper boom several times to fill the cylinder
with oil and check for proper operation and any leaks. Make any necessary corrections.
20. Perform a 1.5 to 1 structural test as described in Section 9 of the unit’s maintenance manual.
21. Return the unit to service.
22. Complete the evaluation sheet at the end of the SIL showing the completion of the repair, and
return it to Altec as specified.

Page 5 of 7

SIL 782

THIS PAGE IS FOR ALTEC USE ONLY
Altec Service Procedure for returning cylinder to JARP for repair
1. Service: Click here to open the Cylinder Shipping Request form. Fill out all the fields on
the form, and click Submit to send an email to Materials and Parts.
2. Materials: Do the following.
a. Contact C.H. Robinson to request pickup of the cylinder at the requested location and
obtain the pickup date and time.
- LS40 cyl (002110212 or 970186080) is about 136 lb and 138“ long plus pallet.
- LS45 cyl (002110226 or 970177574) is about 160 lb and 162“ long plus pallet.
b. Make a shipping label with the shipping address shown below.
JARP RE
Attn: Kristofer Manhart
7811 West Stewart Ave.
Wausau, WI 54401
c. Notify Service of the pickup date and time and give them the shipping label.
3. Parts: Do the following.
a. Issue a PO to JARP for the cylinder repair. per quote #R1479-3.
b. Contact the associate shown below at JARP to obtain the estimated turnaround time for
the cylinder repair.
Kristofer Manhart
Phone: 715-804-5077 ext 617
Cell: 715-348-9741
Email: [email protected]
c. Notify Service of the estimated turnaround time.
4. Service: Provide the following items to the customer or the Service associate responsible
for shipping the cylinder.
a. Pickup date and time
b. Estimated turnaround time
c. Shipping label

Page 6 of 7

SIL 782

SIL 782 Extension Cylinder Evaluation Sheet
Complete this form and return to Altec to document inspection completion.
Choose one of these options.
• Online through the customer portal – Altec Connect*
Sign in or Register for an account at www.altec.com/altec-connect/
1. Select Equipment
2. Select Altec Product Notices
3. Select Report a Completed APN
• Scan and Email to [email protected]
• FAX to 1-877-659-9929
*Customer performed warranty can be submitted online for reimbursement
through Altec Connect.
Model

Altec Unit
Serial Number

To login to your existing
Altec Connect account,
scan here with your
smart phone!

Date Repaired Completed

Company Name: _______________________________________________

Phone____________________________

Service Company Name:_________________________________________

Phone:___________________________

Company Contact: _________________________________________________________________________________
Company Street Address:_____________________________________________________________________________
City _______________________________________________ State:_________________ ZIP Code:________________
Signature:_____________________________________________________

Submission of this form does not order parts or schedule service from Altec.
If the customer or the customer’s warranty provider performs the repair, a warranty claim must
be submitted to be reimbursed for the cost of the parts and/or labor through Altec Connect.
For more information or to schedule the work to be done by an Altec Service technician, call:
1-877-GO ALTEC (1-877-462-5832)
Make copies of this form for additional units if needed.
Page 7 of 7