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Service Manual

Model 1200W Winch

Table of Contents

PART & SERIAL NUMBER LOCATION.................................................................................................2

SAFETY NOTES .................................................................................................................................2

INTRODUCTION AND THEORY OF OPERATION .................................................................................3

HYDRAULIC SCHEMATIC..................................................................................................................4

MAINTENANCE................................................................................................................................5

WIRE ROPE.......................................................................................................................................5

LUBRICATION ..................................................................................................................................6

DISASSEMBLY ..................................................................................................................................7

REASSEMBLY....................................................................................................................................8

SERVICING THE MOTOR...................................................................................................................9

SERVICING THE BRAKE ..................................................................................................................10

SERVICING THE PLANETARY SET.....................................................................................................12

TROUBLESHOOTING.......................................................................................................................13

BILL OF MATERIALS........................................................................................................................14

EXPLODED ISOMETRIC ASSEMBLY DRAWING................................................................................17

Summary of Contents for Digger Derrick

Page 1: ...Operations Maintenance Manual Digger Derrick Truck Elliott Equipment Company 4427 South 76th Circle Omaha NE 68127 402 592 4500 www elliottequip com Elliott PN 3020571 Updated November 18 2015...

Page 2: ......

Page 3: ...eration Optional Yoke Style 4 18 Hand Signals 4 19 Required Inspections 4 20 Wire Rope Inspection 4 21 Synthetic Rope Usage Inspection and Retirement 4 22 Labels 4 23 SPECIFICATIONS SERVICE TOOLS Digg...

Page 4: ...1 Swing Drive Service Manual Tulsa 6036S 7 2 LMI Operator s Manual Greer INSIGHT 7 3 LMI Calibration and Troubleshooting Manual Greer INSIGHT 7 4 Remote Controls Omnex Installation Configuration Manu...

Page 5: ...ident notify the Product Safety and Reliability Department as soon as possible Have the model and serial number and details of the incident recorded prior to contacting the factory Elliott Equipment C...

Page 6: ...Introduction EEC 0003 V1 2 Introduction This manual must be retained with this boom truck for use by subsequent operating personnel...

Page 7: ...1 2 Introduction Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0003 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 1 12 15 Tech Spec...

Page 8: ...January 1 2012 EXCLUSIONS No warranty claims shall be valid unless Elliott is notified in writing of the defect within a reasonable time following its discovery The one year warranty and lifetime war...

Page 9: ...ial Number Crane Model Customer Unit Number Chassis Year Truck Make Model Chassis VIN New Owner Individual or Company Mailing Address Street address or PO Box City State Zip Code Shipping Address If d...

Page 10: ...o know and understand the specific requirements and hazards that exist including adverse weather and ground conditions Remember that YOU are the key to safety Good safety practices not only protect yo...

Page 11: ...g and re certification are required in accordance to instructions provided by Elliott Equipment Company Safety is dependent on all people associated with this boom truck The overall condition of the e...

Page 12: ...is unsafe and should always consult his her supervisor if there is any doubt regarding safety The operator must read and understand the Owner s manual and verify that the equipment is in proper worki...

Page 13: ...eas of the work area a signal person may be necessary at other times The operator must understand standard crane signals and take signals from only one designated signal person The operator however sh...

Page 14: ...ies Crewmember s Responsibilities It is the responsibility of all crewmembers to report any unsafe condition or practice that is recognized to the job supervisor Everyone who works around cranes or bo...

Page 15: ...1 2 Safety Responsibilities Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0052 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 1 13 1...

Page 16: ...as applicable for the following characteristics of vehicles required to provide a stable and structurally sound vehicle for the digger derrick a Front gross axle weight rating GAWR front b Rear gross...

Page 17: ...the hydraulic system and voltage of the electrical control system VI Cautions and restrictions of operation including the applicable ambient temperature range where the digger derrick may be used VII...

Page 18: ...he operator s manuals shall accompany each digger derrick Two parts and maintenance manuals either hard copy or electronic format shall be provided for each digger derrick The manuals shall contain 1...

Page 19: ...e Serial number f Year of manufacture g Rated load capacity h Digger derrick hydraulic system pressure or digger derrick control system voltage or both i Unit equipped with platform s and platform s...

Page 20: ...s injuries b Hazards resulting from failure to operate the equipment in a prescribed manner c Information related to the use and load rating of the equipment for material handling d Information relate...

Page 21: ...ons The manufacturer shall provide instruction for installing or mounting the digger derrick to the installer I Welding All welds whose failure could result in uncontrolled motion of the digger derric...

Page 22: ...and manuals for auxiliary equipment added by the installer E Installations The installer shall comply with ANSI ASSE A10 31 Sections 5 6 relating to proper installations and shall follow the instruct...

Page 23: ...ting is designated the particular method used shall be in accordance with ANSI ASSE B1 10 H Training The dealer or installer shall offer training or training materials that aid owners users operators...

Page 24: ...31 EEC 0168 V1 0 Responsibilities per ANSI ASSE A10 31 Rated load capacity charts shall include the number of platforms platform ratings the options included and the winch line rated working load see...

Page 25: ...based upon the intervals that inspections and tests shall be performed The owners shall set intervals in accordance with the manufacturer s recommendations Such intervals are dependent upon component...

Page 26: ...ength i Perform functional test to include but not limited to the following I Set up the digger derrick for operation including outriggers II Cycle the digger derrick functions through the complete ra...

Page 27: ...f such systems on digger derricks that have a sheave height or platform height greater than 50 feet h Hydraulic and pneumatic cylinders and holding valves for malfunction and visible damage i Hydrauli...

Page 28: ...f a digger derrick are suspected of being subjected to loading of stresses in excess of design stress such as after an accident involving overturning of the digger derrick or application of unintended...

Page 29: ...o longer exist an equivalent entity may determine the required process E Modifications No modifications or additions that affect the stability mechanical hydraulic or electrical integrity or the safe...

Page 30: ...issing or illegible markings shall be promptly replaced I Parts When parts or components are replaced they shall be identical In specification and function to the original digger derrick parts or comp...

Page 31: ...ficient period of time to demonstrate proficiency in the actual operation of the digger derrick l Proper use of personal fall protection equipment when the digger derrick is equipped with a platform s...

Page 32: ...ponsibilities ANSI ASSE A10 31 EEC 0168 V1 0 Responsibilities per ANSI ASSE A10 31 M Owner as a Lessor When owners function as lessors they shall have the responsibilities of ANSI ASSE A10 31 Section...

Page 33: ...ties ANSI ASSE A10 31 EEC 0168 V1 0 Responsibilities per ANSI ASSE A10 31 Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0168 1 0 New Docume...

Page 34: ...quivalent device including the attachment means to the boom C Platform Pin The horizontal pin that attaches the platform to the digger derrick boom and about which the platform rotates with respect to...

Page 35: ...ase end of the lower boom T Lower Controls The controls either remote on the vehicle on the turntable or on the pedestal which are designed to operate the functions of the digger derrick U Pedestal Th...

Page 36: ...om tip to extend the reach of the boom FF Rated Load Capacity Chart A chart that indicates the rated load capacity of the digger derrick in all positions specified by the manufacturer or installer GG...

Page 37: ...Nomenclature EEC 0169 V1 0 Nomenclature...

Page 38: ...Nomenclature EEC 0169 V1 0 Nomenclature Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0169 1 0 New Document 11 13 15...

Page 39: ...Platform Safety EEC 0061 V1 1 Platform Safety...

Page 40: ...d ground signalperson shall be in constant communication D Boom and platform load ratings or work areas shall not be exceeded The combined weight of the personnel platform any attached devices personn...

Page 41: ...tion of the structural integrity of the personnel platform shall not be done without written approval of the manufacturer L Personnel platforms are to be used only for personnel their tools and suffic...

Page 42: ...fety issues associated with the proposed personnel lift and verify the platform and hoisting are suitable for use B For each personnel lifting event the person responsible for the work shall issue a s...

Page 43: ...ll perform a test lift This test lift is to be 125 of rated load Test weights are to be attached to an empty platform for this test The test is to verify that the machine is operating on a firm bearin...

Page 44: ...onally the operator shall have been tested for substance abuse Testing shall be in accordance with applicable government regulations and policies of the employer C Successfully meet training and quali...

Page 45: ...m mounted platform that does not have controls for the duration of the lifting event J When performing a lift when the boom mounted platform has upper controls the operator shall be free to not remain...

Page 46: ...prior to lifting personnel with the platform on each shift and after any change of setup location hoist equipment configuration or operator These lifts shall be used to ascertain that hoist equipment...

Page 47: ...re than one of the hoisting equipment motion controls unless such practice increases the safety of the lift operations GROUND CREW A Visually inspect the platform prior to each lift to verify all atta...

Page 48: ...s G Have materials and equipment evenly distributed and secured while the platform is lifted H Not stand sit on or work from the top rail intermediate rail toe board or use any device to enhance their...

Page 49: ...cal communication devices are used Lifting Personnel Near Electrical Power Lines Lifting personnel near electrical power lines is not allowed unless there is no less hazardous way to do the job Liftin...

Page 50: ...ther proof test conducted The most recent record of proof testing shall be maintained at the job site Platform Installation A Position the truck and crane for use as outlined in the Owner s Manual B I...

Page 51: ...mitter before performing any lift operations with the personnel platform occupied D Referring to the load chart plan the platform lift operation and review where the load chart will allow the loaded p...

Page 52: ...oser to the work To rotate the platform to the desired position first make sure all crane functions are in neutral With the left hand grasp the rotation crank and with the right hand lift the locking...

Page 53: ...afety EEC 0061 V1 1 Platform Safety Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0061 1 0 Template update 11 05 14 Tech Spec 1 1 Doc updat...

Page 54: ...Platform Safety EEC 0061 V1 1 Platform Safety...

Page 55: ...Operate with jib by boom angle when main boom is not fully extended Do not exceed rated jib capacities at any reduced boom lengths 2 When angle is between points listed on capacity chart the load sho...

Page 56: ...stalled before operation 2 All swing around stow and unstowing operations shall be done with jib retracted and pinned 3 Extendable section may slide out of 1st section jib when pin E is removed Keep p...

Page 57: ...afety EEC 0045 V1 1 Jib Safety Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0045 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 1 1...

Page 58: ...avel attach point Boom must be in boom rest and turret locked for optional turret locks Secure all items on the truck bed Make sure jib if supplied is stowed properly and pinned to boom Disengage the...

Page 59: ...sport EEC 0051 V1 1 Road Transport Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0051 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update...

Page 60: ...ane and load to energized power lines and warn when approaching the minimum safe distance Use non conductive tag lines D The crane must be set up on a firm level surface with adequate support for outr...

Page 61: ...ts in wind speeds exceeding 20 miles per hour 32 kilometers per hour at the raised platform height when the platform is attached to the main boom Do not allow personnel lifts during electric storms sn...

Page 62: ...On Site Setup EEC 0024 V1 2 On Site Setup Do not operate the crane if the Load Moment Limiter Load Moment Indicator System installed on the crane is inoperative...

Page 63: ...2 On Site Setup Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0024 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 1 12 15 Tech Spec...

Page 64: ...manuals for operating instructions The PTO switch must be engaged to provide power to crane functions Refer to truck manuals for operating instructions CAUTION Driving truck with the PTO switch engag...

Page 65: ...tes the swing drive brake If the Glide Swing Switch T is in the ON position the swing system will not have any brakes until the pedal is applied To stop rotation apply pressure to the pedal D Boom Tel...

Page 66: ...r can toggle back and forth between these options based on load or proximity of the crane to other objects I Pole Shift Tilt This momentary switch is used to tilt the boom mounted pole grab Pressing t...

Page 67: ...s manual N Auger Shift This switch is used to shift the digger into either HI or LOW speed For most digging operations select LOW speed for digging and HI Speed for cleaning the flighting If soil cond...

Page 68: ...he OFF position Q Horn Press momentary button to sound horn R 12V Power Outlet Remove cover to insert 12V power adapter cord Keep outlet cover on when not in use Hyd System Pressure Gauge Located insi...

Page 69: ...l for set up and operation information Set for proper boom jib configuration prior to operation LMI manufacturer manual is included with this manual See table of contents for page number Anti Two bloc...

Page 70: ...rick Op Controls Sitting EEC 0172 V1 0 Operating Controls Digger Derrick Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0172 1 0 New Documen...

Page 71: ...ilities services i e power lines telephone lines gas lines and water lines before digging Before operating the digger set outriggers following the normal procedures described in the operation section...

Page 72: ...er flighting Stow bracket and lock mechanism with wind up rope for storing he digger on the boom Digger mount assembly and boom transfer mechanism Digger drive hydraulic circuit with proximity sensors...

Page 73: ...s station System 1 Visually inspect the auger system to ensure all pins and keepers are in place and all fasteners are properly tightened Repair or replace damaged parts as required 2 Inspect all tub...

Page 74: ...s the boom can be retracted or extended to maintain a vertical hole 2 Start rotating the auger in the CW direction and slowly lower the boom until the auger comes in contact with the ground 3 Apply sl...

Page 75: ...1 Clean the flighting before stowing to maintain a longer life and to reduce excessive strain on the stow bracket due to additional weight This will also prevent dirt from falling off the flighting d...

Page 76: ...towing the machine after use Machine Use with Auger Stowed 1 Refer to normal Operating Procedures as outlined in the Operation Section of the Owner s Manual to set the crane up properly 2 Inspect the...

Page 77: ...on several factors such as oil viscosity temperature return filter condition etc do not continue rotating the auger if contact with the over wind valve does not stop rotation Damage may occur to the...

Page 78: ...cuit and is located in the control console near the main control valve When this solenoid is energized the boom extend circuit will have full extend pressure When the auger is deployed and the proximi...

Page 79: ...Digger Safety and Operation Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0109 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 5 11...

Page 80: ...lower left front outrigger jack C Right Rear Outrigger Beam Switch Activate switch LEFT or RIGHT to retract extend right rear outrigger beam D Right Front Outrigger Beam Switch Activate switch LEFT o...

Page 81: ...ger jack H Left Rear Outrigger Beam Switch Activate switch LEFT or RIGHT to retract extend left rear outrigger beam I Right Rear Outrigger Jack Switch Activate switch UP or DOWN to raise lower right r...

Page 82: ...ols E160 EEC 0037 V1 1 Outrigger Controls Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0037 1 0 Template update 11 05 14 Tech Spec 1 1 Doc...

Page 83: ...ntrol provides no protection against electrocution hazards Do not operate near live electrical power lines All warnings in the Safety and Operation section of this manual and on the crane relative to...

Page 84: ...p Button Verify that the button locks itself in and then make sure the remote control power switch is switched to the off position This will prevent inadvertent operation of the aerial device by activ...

Page 85: ...boom platform operation slowly meter the joystick away from the center position Multiple functions can be operated simultaneously with this system The layout of the joysticks and switches on the trans...

Page 86: ...ill not power up if the switches are not in neutral position 2 Select and release the Power switch in the ON Horn direction The Red Emergency Stop light will flash quickly 3 Release the Emergency Stop...

Page 87: ...e joysticks The horn will sound momentarily when the button is pushed to alert personnel in the working area that aerial device movement is about to begin Any time the transmitter is inactive the enab...

Page 88: ...Pump by holding in either direction To operate the unit with the pump hold this switch and activate desired functions F Tool Circuit Switch This switch is used to operate the Tool Circuit by holding...

Page 89: ...on to swing boom counter clockwise left K Boom In Out Joystick This joystick operates the boom telescoping system 1 Push forward OUT position to extend boom 2 Pull back IN position to retract boom L S...

Page 90: ...0039 V1 1 Remote Control Optional O Aux Winch Joystick This joystick operates the optional aux winch 1 Push forward DOWN direction to pay out winch line or lower load 2 Pull back UP direction to reel...

Page 91: ...ntrol EEC 0039 V1 1 Remote Control Optional Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0039 1 0 Template update 11 05 14 Tech Spec 1 1 D...

Page 92: ...sensor measures pressure on the piston Anti Two Block switch The ATB switch monitors the hookblock overhaul ball on its approach to the boom head The switch remains closed until the hookblock overhau...

Page 93: ...Component Service Manuals section of this operator s manual Once the unit is powered up the system conducts a brief system test During the test the system shows the unit s model load chart number and...

Page 94: ...position options If no options are available the display reads None 5 Pick Long Pick Short Pick Main button This feature is not used on all models 6 Stow button This button refers to the position of...

Page 95: ...retracted outriggers on the Crane Configuration screen 2 Actual Load Value This displays the total load amount including slings etc suspended below the lifting point 3 Cancel Alarm button The operato...

Page 96: ...shows either Metric or Imperial units 9 Anti Two Block This indicator illuminates when the ATB Limit switch detects approach to a two block condition 10 Jib Stowed This display shows the stowed jib f...

Page 97: ...dels 18 Load Radius This display is to the left of the Load Radius Symbol 19 Swing Angle This display shows the swing angle of the boom and is to the left of the Swing Angle Symbol 20 Boom Angle This...

Page 98: ...LMI Setup Greer EEC 0066 V1 0 LMI Setup Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0066 1 0 Created Document 1 20 15...

Page 99: ...n is reached Do not exceed radius indicated on the load chart at full boom extension Main boom and jib load ratings above the heavy line on the Capacity Chart are based on structural strength and not...

Page 100: ...Reduce load ratings to compensate for wind ground conditions and the dynamic effects of swinging hoisting and lowering the load NOTE The installer must perform a stability test in compliance with inst...

Page 101: ...apacities EEC 0046 V1 1 Lift Capacities Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0046 1 0 Template update 1 13 15 1 1 Content update 6...

Page 102: ...ly wind it onto the drum The first layer must be spooled with wraps tight and close together since this layer forms the foundation for succeeding layers Tap the adjacent wraps against each other with...

Page 103: ...oring EEC 0054 V1 1 Wire Rope Anchoring Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0054 1 0 Template update 11 05 14 Tech Spec 1 1 Doc u...

Page 104: ...ole in the wedge 2 The wire rope shall NOT pass through the No Go hole in the wedge Inspection Maintenance Safety Always inspect socket wedge and pin before using Do not use part showing cracks Do not...

Page 105: ...or seized before inserting the wire rope into the wedge socket to prevent core slippage or loss of rope lay The tail length of the dead end should be a minimum of 20 rope diameters but not less than...

Page 106: ...edge Socket Apply first load to fully seat the Wedge and Wire Rope in the socket This load should be of equal or greater weight than loads expected in use Do not interchange wedges between S 421Tand U...

Page 107: ...dge and Wire Rope in the socket This load should be of equal or greater weight than loads expected in use Efficiently rating of the Wedge Socket termination is based upon the catalog breaking strength...

Page 108: ...ocket EEC 0053 V1 1 Wedge Socket Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0054 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 1...

Page 109: ...o the Transmitter Do not shorten the length of chain a shortened chain may result in a two block condition Make sure the counterweight is on the correct line part C Test the ATB switch by raising the...

Page 110: ...Reeving EEC 0047 V1 1 Multi Part Reeving Revision History Document type Document Number Revision History Revision Notes Revision Date Diagram EEC 0047 1 0 Template update 11 05 14 Diagram 1 1 Doc upda...

Page 111: ...ow pin A and jib swing pin B may allow jib to fall 2 Extending boom with jib stowed and failure to remove swing pins C will damage boom and or jib C Only attempt to swing jib to working or stowed posi...

Page 112: ...Install retainer spring clips These pins will be used as a pivot point to swing jib into the deployed position D Locate the stowed position of pins C2 If in jib attachment holes or boom sheave case ji...

Page 113: ...ock weight chain assembly from boom tip switch and install on jib top switch Be certain to use keeper provided with switch R Install jib swing pin B and spring clip into jib ears S Remove tag line fro...

Page 114: ...This pin will keep the jib assembly in line parallel with the 1st section boom Jib swing pin B does not retain the jib in its stowed position on the 1st section boom M Using boom telescope function sl...

Page 115: ...h mating holes in boom tip Jib Maintenance A Lubricate sheave pin on jib with grease gun containing chassis grease weekly B Check for free rotation of jib sheave daily when using jib C Lubricate jib s...

Page 116: ...Jib Operation EEC 0044 V1 1 Jib Operation E C B A C2 C1 B...

Page 117: ...ation EEC 0044 V1 1 Jib Operation Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0044 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update...

Page 118: ...and pump to raise yoke to position for attachment to boom or jib Stow the platform in the yoke Select the PLTF LVL CCW Yoke Down position use pump to raise the platform into stow position engage the s...

Page 119: ...orm CCW position and loosen the bleeding cap on the extend port Pump until cylinder is fully retracted Tighten the bleeding cap E Repeat steps 3 and 4 two to three times or until all air is removed fr...

Page 120: ...Platform Install Operation EEC 0049 V1 1 Platform Operation Kickstand deployed with cable unlatched Platform attached to Boom using Adaptor...

Page 121: ...m Function Selector and Float lock Large Red knob Function selector Small Black knob Float lock Float lock shown in the lock position Prevents function selector from being inadvertently bumped into fl...

Page 122: ...Platform Install Operation EEC 0049 V1 1 Platform Operation Labels Platform selector valve positions Platform operation label...

Page 123: ...B Select the brake position on the platform selector valve C Lift and set the assembly on level ground with kickstand deployed D Locate the platform at a radius corresponding to boom retracted jib or...

Page 124: ...RM ASSEMBLY TO THE BOOM HEAD A Set the platform at a 51 5 ft radius from the truck center of rotation as shown in Figure 3 B Raise the platform arm to its maximum angle refer to the platform operation...

Page 125: ...et the platform at a 65 8 ft radius from the truck center of rotation as shown in Figure 3 B Raise the platform arm to approximately 7 degrees angle refer to the platform operation label for operation...

Page 126: ...rotation as shown in Figure 3 B Raise the platform arm to 5 degrees angle refer to the platform operation label for operation details C Lower boom to maximum possible negative angle align jib and pla...

Page 127: ...Operation EEC 0049 V1 1 Platform Operation Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0049 1 0 Template update 11 05 14 Tech Spec 1 1 Do...

Page 128: ...AND LOWER THE LOAD With arm extended thumb pointing up flex fingers in and out as long as load movement is desired LOWER THE BOOM AND RAISE THE LOAD With arm extended thumb pointing down flex fingers...

Page 129: ...Signals EEC 0043 V1 1 Hand Signals Revision History Document type Document Number Revision History Revision Notes Revision Date Diagram EEC 0043 1 0 Template update 11 05 14 Diagram 1 1 Doc update 1 1...

Page 130: ...rea free of overhead obstructions and power lines Daily Inspection A Perform all items required in a standard walk around vehicle inspection in accordance with US DOT Commercial vehicle requirements P...

Page 131: ...en released to the neutral position all functions stop R Make sure all control mechanisms are free of excessive wear and are not contaminated by lubricants or other foreign matter S Check the hook blo...

Page 132: ...ided or provide serial number to Elliott Dealer to order replacement manual immediately Be sure the unit is in an area free of overhead obstructions and power lines Monthly Inspection A Perform the da...

Page 133: ...w should be inspected on a periodic basis with the interval to be determined by the amount and serverity of the operation of the unit This inspection should be performed at least once every twelve mon...

Page 134: ...uck bolts for damage and tightness K Inspect all electrical wires and connections for wear cuts deterioration etc Replace as required L Check condition of extend and retract cables for wear or damage...

Page 135: ...tions EEC 0050 V1 1 Required Inspections Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0050 1 0 Template update 11 05 14 Tech Spec 1 1 Doc...

Page 136: ...test loads that exceed the working load limit Wire Rope Cleaning Wire ropes that operate in extremely harsh conditions and come into regular contact with certain chemicals should be cleaned on a regu...

Page 137: ...h one or more strands are worn before adjoining strands This is caused by improper socketing or seizing kinks or dog legs It reoccurs every 6th strand in a six strand rope A kinked wire rope is shown...

Page 138: ...ed below B Six randomly distributed broken outer wires in one rope lay length or three broken outside wires in one strand of one rope lay length Note One rope lay length is the distance measured along...

Page 139: ...anufacture so that the strands as well as the individual wires in the strands may move and adjust as the rope moves and bends But no wire rope can be lubricated sufficiently during manufacture to last...

Page 140: ...available commercially The rope s service life will be directly proportional to the effectiveness of the method used and the amount of lubricant that reaches the rope s working parts A proper lubrican...

Page 141: ...Wire Rope Care Maintenance EEC 0117 V1 0 Wire Rope Care Maintenance Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0117 1 0 New Doc 6 5 15...

Page 142: ...urer before using rope when personal safety or possible danger to property is involved Make sure the rope is adequate for the job Do not use rope that is too small or the wrong type The following area...

Page 143: ...s occur more rapidly or suddenly which is known as dynamic or shock loading An example of applications where dynamic loading occurs includes ropes used as a tow line picking up a load on a slack line...

Page 144: ...e it affects resistance to normal wear and abrasion Ropes can be severely damaged if subjected to rough surfaces or sharp edges Chocks bits winches drums and other surfaces must be kept in good condit...

Page 145: ...may recoil with considerable force and speed In all cases where any such risks are present or where there is any question about the load involved or the condition of use the working load should be sub...

Page 146: ...ayer below 2 Cross Winding When the rope is placed under load it can dive or push into the previously wrapped level below it To avoid diving cross winding is recommended When cross winding start with...

Page 147: ...and hockles Braided ropes on the other hand have no built in twist and are far more resistant to kinking Even if kinks do develop they cannot develop further into hockles Eye Splices The standard eye...

Page 148: ...pe strength for new and used ropes Use of Slings with Winch Lines The winch line itself should not be used as a choker to pick up a pole or other objects The hook attached on the end of the winch line...

Page 149: ...cient of friction resistance to slipping in a new or used state It is important to understand the operational demands and take into account the size of the rope construction and fiber type to minimize...

Page 150: ...re information Avoid Dynamic Loading Dynamic loading of any line synthetic manila or wire produces a drastically different set of physical properties and results as compared with normal loading Dynami...

Page 151: ...the diameter of the rope Using a ratio of 4 1 or greater is better because the durability of the rope increases substantially as the diameter of the surface of which it is worked increases On a cleat...

Page 152: ...hetic Rope Usage Inspection and Retirement surfaces should be kept smooth and free of burrs and gouges Bearings should be maintained to ensure smooth rotation Twisted Plaited 10 times the rope s diame...

Page 153: ...fiber and provides better sheave cycling capabilities than other high tech fibers Ultrex also has zero water absorption and maintains its flexibility even in freezing conditions As is the case for all...

Page 154: ...Synthetic Rope Usage EEC 0060 V1 2 Synthetic Rope Usage Inspection and Retirement Yale Ultrex Specifications Chart YELLOW highlighted section denotes Elliott Equipment sizes...

Page 155: ...Synthetic Rope Usage EEC 0060 V1 2 Synthetic Rope Usage Inspection and Retirement Samson Amsteel Specifications Chart YELLOW highlighted section denotes Elliott Equipment size...

Page 156: ...ed for specific rope constructions and related applications Some of the advantages of a Samthane coating include reduced snagging improved service life enhanced abrasion resistance and reduced cutting...

Page 157: ...tands carries approximately 8 33 percent or one twelfth of the load Upon inspection if it is discovered there are cut strands or significant abrasion damage to the rope the rope must be retired or the...

Page 158: ...ration and replace the rope if it is brittle or stiff Inconsistent Diameter Inspect area for flat edges bumps or lumps This can indicate core or internal damage from overlooking or dynamic loads and i...

Page 159: ...ion such as during repeated surges in towing or other similar cyclical operations The percentage of PE over the working load range is generally in order of 4 6 percent for braided ropes and 2 3 times...

Page 160: ...ic Rope Usage Inspection and Retirement Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0060 1 0 New Document 1 13 15 Tech Spec 1 1 Doc updat...

Page 161: ...Digger Derrick Labels EEC 0171 V1 0 Digger Derrick Labels...

Page 162: ...AINT SPEC 28T 32T 1870CP 1 0000 EA 11 1201850 LBL DEDUCTIONS 1 0000 EA 12 100142CP LBL HYD OIL 4 75X1 1 0000 EA 20 1087710 LBL DNGR ELE HZRD CNTACT 7 0000 EA 22 1003360 LBL FAILURE TO OBEY 1 0000 EA 2...

Page 163: ...Digger Derrick Labels EEC 0171 V1 0 Digger Derrick Labels 12 20 22 23 24 28 29...

Page 164: ...Digger Derrick Labels EEC 0171 V1 0 Digger Derrick Labels 30 38 39...

Page 165: ...Digger Derrick Labels EEC 0171 V1 0 Digger Derrick Labels Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0171 1 0 New Document 11 18 15...

Page 166: ...ith the work port blocked function stalled or cylinder at the end of stroke The system pressure gauge on the control console displays the pump pressure Pump pressure is the total of work port pressure...

Page 167: ...00 241 14 53 30 5 Boom Extend 2700 186 31 117 54 Boom Retract 2200 152 15 57 60 Winch Up 3500 241 39 148 See Winch Line Pull Table Winch Down 3500 241 39 148 See Winch Line Pull Table Swing Left 2200...

Page 168: ...ory Standard Line Pull 9 060 lb Wire Rope 9 16 Spin Resistant Breaking Strength 45 300 lb Cable Length 375 ft Winch Line Pull Line Speed Layer Lb Kg FPM MPM 1 12 000 5443 105 32 2 11 620 5271 116 35 3...

Page 169: ...ght Retracted 43 B3 Horizontal Reach Max Extension 102 B2 Horizontal Reach Intermediate Extension 45 B1 Horizontal Reach Retracted 28 S2 Digging Radius Maximum 44 S1 Digging Radius Minimum 27 a Elevat...

Page 170: ...Digger Derrick Specs EEC 0170 V1 2 Digger Derrick Specifications...

Page 171: ...igger Derrick Specs EEC 0170 V1 2 Digger Derrick Specifications Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0170 1 0 New Document 11 16 1...

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Page 177: ...R POS OR POS OR POS 85 30 87A 86 87 YW GY BL GY YW RD GN BK WH BK YW BLK RD GN WH BK 30 DISABLE 136 723 722 122 124 122 114 122 145 122 116 122 147 122 101 122 102 122 103 122 104 122 105 122 106 122...

Page 178: ...10 GA RD 10 GA 312 YW 14 GA 10 AMP C B 10 AMP C B 301 8GA RD 10GA YW RD CHASSIS HARNESS REFERENCE 2070230 322 10 GA TO TRUCK HORN CIRCUIT BATTERY STUD ON FIRE WALL TRUCK BATTERY 12 VOLT RED 8 GA C B...

Page 179: ...3 2 1 4 6 5 3 2 1 4 6 5 3 2 1 4 6 5 TITLE...

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Page 184: ...is running or boom sections are moving H Read and thoroughly understand all applicable instructions I Pressurized oil can penetrate human skin causing serious injury Do not use bare hands to check for...

Page 185: ...afety EEC 0022 V1 1 Maintenance Safety Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0022 1 0 Template update 11 05 14 Tech Spec 1 1 Doc up...

Page 186: ...nt of disconnection Immediately cap or plug openings to prevent entry of dirt Clean all parts and cover to keep clean If evidence of foreign particles is found in the hydraulic system flush the system...

Page 187: ...ss crane EEC 0019 V1 1 Cleanliness Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0019 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update...

Page 188: ...inch Brake SAE 20W 20 Motor Oil Check Level Monthly 5 10 Winch Gearbox SAE 90EP Gear Lube Check Level Monthly 5 11 Swing Bearing Grease Fitting Grease Gun Monthly 6 12 Swing Bearing Gear Teeth Grease...

Page 189: ...om sections are moving C Fitting is located on end of extend sheave pin on outboard end of telescope cylinder in boom Extend boom to align holes in sides of mid and fly booms Caution Do not place hand...

Page 190: ...e L When checking the level on the hydraulic tank the boom must be retracted and stowed and all outriggers and stabilizers must be fully retracted Add hydraulic oil as required to keep the level on th...

Page 191: ...Lubrication Digger Derrick EEC 0173 V1 0 Lubrication Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0173 1 0 New Document 11 25 15...

Page 192: ...nual See engineering drawings Parts Manual for rotation bearing bolt torque values Grade Grade Grade Grade UNC 5 8 UNF 5 8 Size TPI ft lb ft lb Size TPI ft lb ft lb 1 4 20 8 12 1 4 28 10 14 5 16 18 17...

Page 193: ...Bolt Torque EEC 0016 V1 2 Bolt Torque...

Page 194: ...Bolt Torque Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0016 1 0 Template update 11 05 14 Tech Spec 1 1 Content update 1 12 15 Tech Spec...

Page 195: ...emove the suction strainer Soak in solvent and blow off with compressed air before reinstalling G Reinstall the cover on the tank top replace gasket as required H Replace the filter element I Replace...

Page 196: ...c Oil EEC 0018 V1 1 Changing Hydraulic Oil Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0018 1 0 Template update 11 05 14 Tech Spec 1 1 Do...

Page 197: ...iggers and stabilizers so the crane is level from front to rear according to the carpenter s level E Swing the boom 90 degrees over either side of the truck and adjust the outriggers and stabilizers s...

Page 198: ...tment EEC 0017 V1 1 Bubble Level Adjustment Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0017 1 0 Template update 11 05 14 Tech Spec 1 1 D...

Page 199: ...Four Section Boom Operation common EEC 0021 V1 3 Four Section Boom Operation...

Page 200: ...th Tip section 1 2 3 Extend Cable Proportioning Cable Qty 2 Connects to the back of the 1st Main section and passes over sheave at front on top of 2nd Next to Large section and connects to Back of 3rd...

Page 201: ...pressure At full retraction observing through the winch mount end of the boom the second section should be bottomed on the extend cylinder butt plate the third section should be bottomed on the thick...

Page 202: ...extend cable to 9 ft lb 12 2N m Cable adjustment point is located at rear of boom on the winch crossbar spanning the 1st section G Repeat steps 4 5 6 and 7 torqueing the 4 3 2 retract cables to 14 ft...

Page 203: ...Attach a lifting device to provide even weight distribution and raise the boom until weight is removed from the boom pivot pin Remove boom pivot pin keeper and boom pivot pin Lift boom free of turret...

Page 204: ...ront of the 1st section Remove spacer bar F Loosen and remove four capscrews securing wear pads to the bottom of the 1st section Removal of side wear pads is optional Adequate clearance exists between...

Page 205: ...etract cables N Loosen and remove two capscrews securing lock bar to the extend cylinder collar This bar constrains the vertical movement of the extend cylinder Remove bar O Loosen capscrews retaining...

Page 206: ...he front top of the third section W Loosen and remove four capscrews attaching the bottom pad plate to the third section Slightly lift 4th section and remove pad plate X Slide 4th section out of 3rd s...

Page 207: ...connections Replace cable assemblies as required Lubricate all cable assemblies as required Lubricate all cable assemblies before reinstalling them in boom E Inspect all sheave pins for nicks gouges o...

Page 208: ...te assembly Slide sections together within 12 inches 30cm of full retraction G Install cable guide and upper spacer to front of 3rd section H Install front side wear pads with appropriate shims betwee...

Page 209: ...emble retract sheaves and retract sheaves and retract sheave pins in rear of 3rd section Coat surfaces of bearings and keeper plates with grease before assembly M Place retract cables anchored to 4th...

Page 210: ...installation in front of 2nd Install wear pad pad plate assembly Slide sections together within 12 inches 30cm of full retraction U Install cable guide and spacer to top of 2nd section V Install front...

Page 211: ...tend cylinder Install bearings into extend cable sheaves Coat surface of bearings with grease and assemble extend sheaves on sheave pin DD Wrap approximately 10 feet 300cm of each diameter 2 3 4 exten...

Page 212: ...xtend cylinder collar in the 3rd section LL Install large extend cable anchor into anchor cutouts in the doubler plates in the rear of the 2nd by routing extending cables through the anchor and the sm...

Page 213: ...3 16 inch 4 8mm by rotating end for end the wear pad and plate or the wear pads and plate independently This is possible because the holes in these parts are offset from the center The holes are 06 i...

Page 214: ...ns D The wear pad on each side at the top rear of the boom can be adjusted over a range of 3 16 inch 4 8mm by rotating end for end the wear pad and plate or the wear pads and plate independently This...

Page 215: ...ith the threaded holes in the smaller boom section the wear pad is tight against the side plate of the larger boom section with properly aligned adjusted wear pads install the capscrews and torque to...

Page 216: ...section by loosening the large extend cables and removing the extend cable anchor located in the 2nd section Retract boom completely Remove capscrews through access holes on top rear of sections Remov...

Page 217: ...is removed from the bottom pads in the front of the interior sections Loosen and remove the capscrews holding the pad doubler plates in the front of the sections Remove plates Remove pads from these...

Page 218: ...eration Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0021 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 1 26 15 Tech Spec 1 2 Illu...

Page 219: ...r s manual for trouble shooting this system Also check the wiring from the system to the solenoid valves and the operation of the valves to make sure they are not jammed BOOM DEFLECTS EXCESSIVELY UP D...

Page 220: ...hould fully release between 340 400 PSI Clean and replace the hose as required Disassemble the winch and replace faulty parts as required SWING INOPERATIVE OR ERRATIC Swing park brake should fully rel...

Page 221: ...ve Air leak in pump suction replace suction line Dirt in pump flush system rebuild pump Worn pump repair or replace Relief valves not properly adjusted check and adjust valves Dirty or collapsing hose...

Page 222: ...ERHEATING Operator holds control lever in position too long oil dumps over relief valve generating excess heat Using incorrect oil Low oil Dirty oil Engine running too fast Incorrect relief valve sett...

Page 223: ...oting EEC 0023 V1 1 Troubleshooting Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0023 1 0 Template update 11 05 14 Tech Spec 1 1 Doc updat...

Page 224: ...ON 2 SAFETY NOTES 2 INTRODUCTION AND THEORY OF OPERATION 3 HYDRAULIC SCHEMATIC 4 MAINTENANCE 5 WIRE ROPE 5 LUBRICATION 6 DISASSEMBLY 7 REASSEMBLY 8 SERVICING THE MOTOR 9 SERVICING THE BRAKE 10 SERVICI...

Page 225: ...signed to hold the rated load of the winch You must keep at least five 5 wraps of cable on the drum to insure that the cable doesn t come loose Stay clear of suspended loads and of cable under tension...

Page 226: ...rough a one way cam clutch bypassing the brake When the load comes to a stop the cam clutch locks up and the load is prevented from moving by the brake During payout a brake valve is used to prevent t...

Page 227: ...4 HYDRAULIC SCHEMATIC...

Page 228: ...500 operating hours and changed every 1000 operating hours Factors such as extremely dirty conditions or widely varying temperature changes may dictate even more frequent servicing 3 Complete teardown...

Page 229: ...oil to drain then with a 3 8 hex wrench remove the drain plug located inside of 1 pipe See Fig 2 Examine the used oil for signs of significant metal deposits and then dispose of it in a proper manner...

Page 230: ...anet set from the drum Inspect the planet set for wear and repair as needed See Servicing the Planetary Set section for dis assembly and repair 7 Remove the output sun gear Item 14 8 Check the drum te...

Page 231: ...making sure that it fits over the output sun gear Item 14 8 Install the input sun gear Item 8 and thrust washer Item 6 into the input planet set Again coat the thrust washer with a light coat of grea...

Page 232: ...eplace if necessary 4 Units with geroler type motors have only one external line Pilot pressure to operate the brake valve is obtained from inside the counterbalance block 5 On units with gear motors...

Page 233: ...e housing Item 18 is removed from winch examine the journal on the brake housing where the seal Item 22 runs for wear If severely worn replace the brake housing 9 Carefully dis assemble the brake driv...

Page 234: ...assis lube to keep it in position 17 Coat the new o ring Item 43 with light oil and install it into the groove on the brake cover Item 20 18 Install the brake cover onto the brake housing Item 18 and...

Page 235: ...for evidence of wear and replace if necessary 5 On output planet sets note that two bearings with a spacer between them are used 6 Before reassembly be sure to insert the round plates into the carrier...

Page 236: ...2 Load being lifted may be more than the winch s rating Reduce the load or re rig to increase mechanical advantage Problem The winch will not lower the load Solution 1 The brake valve was improperly h...

Page 237: ...rel 18 flange 42510 1 DRUM 9 3 4 barrel 13 3 4 flange 5 43171 1 DRUM 10 5 8 barrel 14 flange 6 41722 2 RACE 7 42393 1 BASE 41734 1 INPUT SUN GEAR 41 59 1 Ratios 41735 1 INPUT SUN GEAR 29 1 Ratios 8 41...

Page 238: ...T PLANET CARRIER 21 1 RATIO 41761 3 INPUT PLANET GEAR 21 1 RATIO 41762 3 INPUT PLANET GEAR 29 1 RATIO 41763 3 INPUT PLANET GEAR 41 1 RATIO 32 2 41765 3 INPUT PLANET GEAR 59 1 RATIO 32 3 41760 3 PLANET...

Page 239: ...25 1 ADAPTER PLUG 42021 1 MOTOR 4 Bolt B 4 46 cu In 42022 1 MOTOR 4 Bolt B 6 38 cu In 42023 1 MOTOR 4 Bolt B 5 10 cu In 38 13 42131 1 MOTOR 4 Bolt C 4 46 cu In 38 14 20524 4 CAPSCREW 38 15 CONTACT FAC...

Page 240: ...17 EXPLODED ISOMETRIC ASSEMBLY DRAWING...

Page 241: ...G SERVICE LITERATURE 52 60 SWING SERVICE LIT Sel 0007 DOC Rev 1 5200 SERIES 6000 SERIES SWING DRIVE SERVICE MANUAL...

Page 242: ...screws 18 NOTE Notice the position of the brake port in conjunction with the drain and fill holes in the housing for reassembly 4 Inspect the brake housing o ring 14 for damage Replace if necessary 5...

Page 243: ...eplace as required 13 Remove race 12 from output planet set 10 14 Remove the output sun gear 11 from the output planet carrier 10 Lift the output planet set out of the housing 7 15 Remove the retainin...

Page 244: ...input carrier section 13 with race 12 10 Assemble the brake section by first installing the o ring 14 on the brake housing 15 Install eight capscrews 18 to the brake housing 15 and torque to 10 ft lbs...

Page 245: ...4 5200S...

Page 246: ...5 6000S...

Page 247: ...Elliott Operating Manual...

Page 248: ...ome Button 8 Outrigger Selection 9 Parts of Line 9 Jib Options 10 Pick Points 10 Stow Stowed Jib 10 Winch 11 Operator Alarms 11 The Home Display 12 Outrigger 12 Actual Load 13 Cancel Alarm Button 13 P...

Page 249: ...3 W450320A 09 12 Swing Alarms Illustrated If Equipped with Swing Sensor 24 Setting the Swing Alarms 25 Work Area Alarms If Equipped with Swing Sensor 27 Setting the Work Area Alarms 28...

Page 250: ...puter Unit Pressure Sensors Swing Sensor Reeling Drum Assembly with Extension and Angle Sensors Anti Two Block Switches Cables Audible Alarm Installation Operator Manuals Display Unit The display unit...

Page 251: ...Electrically operated hydraulic solenoids disconnect the control lever functions for boom hoist lower telescope out and winch up when an overload or ATB alarm condition occurs OPERATOR PROGRAMMABLE A...

Page 252: ...t which lasts for approximately 10 seconds During this time the display shows the rating chart number units in use and load After the startup screen the Crane Configuration page will display This will...

Page 253: ...isplay may be accessed from the Home Display by pressing the button indicated above The system has the capability to remember the last configuration When removing power to the system and re powering t...

Page 254: ...dicators illuminate individually to indicate the selection When the configuration is complete press the Home button to return to the Home display NOTE Always check the point of lift and parts of line...

Page 255: ...The selection will have a solid green indicator when the selected and detected outrigger positions match Incorrect Selection The detected position will flash a red indicator and the selected position...

Page 256: ...show None NOTE The jib must be stowed before it is erected 5 The PICK POINT selections are dependent upon the model of crane being used 6 The STOW STOWED JIB group contains one green indicator This w...

Page 257: ...cate the selection of Front or Rear winch NOTE If the crane is equipped with two winches always select the winch to be used for the lift prior to selecting the parts of line selections for each winch...

Page 258: ...hey indicate the selection of full intermediate retracted outriggers and the On Tires selection if applicable The user must make the selection from the Configuration display NOTE OUTRIGGER selections...

Page 259: ...The CANCEL ALARM BUTTON is used to silence the audible alarm generated by the following conditions Overload ATB Alarm Outrigger Position Mismatch Operator Programmable Alarm The audible alarm remains...

Page 260: ...iguration screen 5 The INFORMATION button displays system generated messages regarding the software versions of the equipment and fault codes When the information button is pressed the data is display...

Page 261: ...lected for the machine If there are no jib options available the display will show None 8 The SYSTEM has the capability of showing Metric or Imperial units 9 The ANTI TWO BLOCK indicator illuminates w...

Page 262: ...e Home Display 11 The BOOM LENGTH window shows the length of the main boom from the boom foot pin to the sheave pin of the main boom head machinery This measurement can be shown in Imperial or Metric...

Page 263: ...ress the CONFIGURATION BUTTON to return to the Configuration display screen 14 The BOOM LENGTH symbol is shown to the right of the boom length window 15 The BOOM ANGLE symbol is shown to the right of...

Page 264: ...RADIUS symbol is shown to the right of the boom angle window 17 The SWING ANGLE symbol is shown to the right of the swing angle window NOTE Not used on all models 18 The LOAD RADIUS window indicates t...

Page 265: ...he swing of the boom NOTE Not used on all models 20 The BOOM ANGLE window indicates in degrees the angle of the main boom relative to horizontal 21 The BAR GRAPH indicates the actual load relative to...

Page 266: ...ould be necessary to use the bypass Cancel Alarm Button In order to move the boom the button must be held down If the button is released the until will revert to the alarm mode The cancel alarm button...

Page 267: ...e negative 15 for minimum boom angle and 80 for maximum boom angle Each button corresponds to the displayed alarm These buttons operate as a toggle switch If the alarm to be set is OFF pressing the bu...

Page 268: ...LE button again will cancel user set value and return to the default negative 15 setting The display will read MIN ANGLE 15 0 Setting the Maximum Boom Angle Alarm 1 Move the boom to the desired maximu...

Page 269: ...h in this example 56 9 ft 4 Pressing the MAX LENGTH button again will cancel the alarm The display will read MAX LENGTH OFF Setting the Maximum Tip Height Alarm 1 Move the boom to the desired maximum...

Page 270: ...ivated when swinging to the right In this example the working arc is the larger piece of the pie WARNING THE OPERATOR DEFINED SWING ALARM IS A WARNING DEVICE ALL FUNCTIONS REMAIN OPERATIONAL WHEN ENTE...

Page 271: ...either WARNING RIGHT SWING or WARNING LEFT SWING The alarm condition will once the crane is back into the working area 1 Press the configuration button to access the operator alarms from the main work...

Page 272: ...left swing point value 6 Press the NEXT button to continue 7 Move the boom into the desired working area and press the SET button 8 Press the NEXT button 9 Swing the boom to the desired right swing po...

Page 273: ...the operating zone and the exclusion zone The set points are calculated using the tip of the boom This means the set point isn t determined just by the swing of the boom but also the distance from th...

Page 274: ...he swing and work area alarms NOTE The location of the operator alarm button moves after the first press 3 Press NEXT button adjacent to SET WORKING AREA ALARM 4 To set a new swing area the left and r...

Page 275: ...n The left point will now be set 9 Rotate the boom to the right taking care to avoid the obstacle by raising or retracting the boom Or rotate the boom to the left to avoid moving the boom through the...

Page 276: ...0 Fax 918 298 8301 www team twg com Greer Company is a part of TWG As a leader in product innovation Greer Company is committed to the ongoing improvement of its equipment We reserve the right to make...

Page 277: ...Elliott Calibration and Troubleshooting Manual...

Page 278: ...placing the Display Console 16 5 1 Calibration Mode 17 5 2 Entering the Calibration Mode 18 5 3 Calibration Menus 19 5 4 Calibrating the Extension Sensor Zero 20 5 5 Calibrating the Angle Sensor Zero...

Page 279: ...des general information and methods for isolating problems that may happen during operation Some problems may require the replacement of parts or return of parts to the factory for servicing Service p...

Page 280: ...ing properly During the self test the display will show the crane model load chart number and units of measurement After the startup screen the Crane Configuration page will display Use this screen to...

Page 281: ...and it s communication with the computer unit To solve problems using the display indications observe the display at Power On and through the self test Use the following chart to help with the diagnos...

Page 282: ...e the system is turned on it performs a self test that lasts approximately 6 seconds Faults detected during the self test are indicated on the display console WARNING SYSTEM FAULT will display at the...

Page 283: ...le and Reeling Drum Calibration instructions 2 3 2 Group B Fault Codes Group B fault codes represent faults detected for internal analog functions and power feeds to the function kickout and anti two...

Page 284: ...n the left column and the actions to take in the right column FAULT CODE WRONG SWING AREA WRONG BOOM LENGTH CHART NOT FOUND ACTION 000 No Fault Found NONE 001 X Check other sensor faults first Reselec...

Page 285: ...tch Check the reeling drum cable for damage Ensure the two block switches are correctly connected Check the slip ring and wiring inside the extension reel Check the reel to computer cable Check the co...

Page 286: ...ain Boom Radius NOTE The required accuracy of taped radius measurements is within 0 5 feet When taking radius measurements use a good quality tape that does not stretch The tape should be graduated in...

Page 287: ...ng pressure for the sensors is 250 bar 3625 PSI The pressure sensing system is calibrated at the factory Pressure sensors may not be individually replaced Any serious problem will necessitate changing...

Page 288: ...the field 3 2 Computer Unit Layout NOTE Due to differences in computer unit configurations the locations of board components may vary Blade Style Computer 3 3 Internal Status Indicators The computer...

Page 289: ...removed 3 5 Replacing the Computer Unit Computer Removal 1 Lower the boom until the boom hoist cylinder is completely retracted and on its stop or the boom is firmly in the boom rest 2 Disconnect the...

Page 290: ...pparent To help identify subtle faults that are sometimes difficult to find please review 4 3 through 4 6 4 3 Unresponsive Buttons All button options are not available for use at all times It is impor...

Page 291: ...Deutsch connectors on the rear of the Insight 4 5 Horn Ensure the horn is connected to the wiring harness via the two pin Deutsch connector 4 6 Moisture The Display Console conforms to IP67 in protec...

Page 292: ...Disconnect the electrical cable from the rear of the operator s display console 3 Remove the defective display console from the bracket in the cab Installation 1 Put the operator s display console on...

Page 293: ...ssary to enter Zero and Span settings for accurate length and angle calculations Tools Needed Digital level accurate to 0 1 150 200ft tape measure graduated in tenths of a foot Digital multimeter Pre...

Page 294: ...for proper setup of the display unit 1 To enter Calibration Mode the display must be in Normal Operating mode as shown below 2 Press and hold the indicated buttons simultaneously until the display pr...

Page 295: ...n menu items used to calibrate the system are 02 Zero Sensors 03 Span Sensors 04 Swing Sensor The only calibrations needed are for the Boom Extension Function and the Boom Angle Function They must be...

Page 296: ...expose the baseplate sensor assembly 3 Rotate the extension sensor gear clockwise until the clutch drags clicks and rotate a turn counterclockwise 4 The voltage reading between the blue wire and the w...

Page 297: ...Zero Extension button to prompt with the question YES Calibrate Press the YES Calibrate button to calibrate zero 8 The retracted boom length will be displayed in the boom length window Extension Senso...

Page 298: ...een disturbed reestablish it by loosening the attaching screws and rotating the pot until the desired voltage reading is attained 1 Raise the boom to 0 0 degrees Verify using a digital level 2 Check t...

Page 299: ...Span Number must be entered into the system Obtain the Span Number with the following steps 1 Measure the boom from the base foot pin to the center of the head sheave pin Record this measurement 2 Ra...

Page 300: ...ate button 6 The Span of Extension is now calibrated And the maximum boom length will be displayed 7 Press the Menu Up button to access the Span Angle option 8 Press the Span Angle button to enter the...

Page 301: ...mber inside the brackets is the current selection in the above image the number 3 is between the brackets 11 Use the upper left button to enter the numbers one at a time 12 When the number is entered...

Page 302: ...reen 1 Press the Menu Up button until 04 Swing Sensor is reached This menu will allow a zero point to be set on the swing circle and a direction for the system to track the rotation angle 2 Press the...

Page 303: ...button until Direction is displayed 2 Press the Direction button to toggle directions on the swing count 5 7 2 Enabling the Swing Sensor 1 Enter the calibration menu and press Menu Up to display 04 S...

Page 304: ...on menu This will remove any error codes and allow the crane to be operated until the problem can be fixed 1 Enter the calibration menu and press Menu Up to display 04 Swing Sensor 2 Press the 04 Swin...

Page 305: ...29 W450321A 09 12 6 The Swing sensor is now disabled The Swing angle window will display N A instead of a number...

Page 306: ...al The system will pick the chart based on these inputs DI1 DI2 Chart 0 1 No Span 1 0 Mid Span 1 1 Full Span 0 0 Error 5 9 After the Calibration Routine When the calibration routine is complete thorou...

Page 307: ...ling Drum also includes an angle sensor to measure the main boom angle and an electrical slip ring which transfers the Two Block signal from the Reeling Drum cable to the system computer It is importa...

Page 308: ...cking or build up of the cable occurs ensure the first cable guide at the top of the boom root section is correctly aligned with the outside edge of the extension reel Clean the reeling drum cable and...

Page 309: ...ot be repaired in the field The angle sensor pendulum is factory set on the potentiometer shaft and the extension potentiometer gear contains a protection clutch which is difficult to replace in the f...

Page 310: ...ages with a digital voltmeter set to DC volts range SIGNAL BOOM POSITION ACTION VOLTAGE VOLTMETER CONNECTION MIN MAX RED BLACK SENSOR DRIVE 4 7V 5 3V RED BLUE ANGLE SENSOR OUTPUT 0 degrees 0 4V 0 6V G...

Page 311: ...6 7 Checking the Anti Two Block Circuit Before continuing ensure the connectors are correctly connected to the ATB switches at the boom head jib This procedure checks the ATB circuit when no power is...

Page 312: ...36 W450321A 09 12...

Page 313: ...the information window of the display console WAD ISS Conditioning Box The advantage of the WAD ISS over a typical swing potentiometer is the swing potentiometer is housed in the collector column and...

Page 314: ...itiong box and computer Replace cable If display shows load angle radius etc replace the conditioning box Intermittent inaccurate or no output activity WAD ISS too far from target within swing drive W...

Page 315: ...notch on the sensor Rotate the sensor counterclockwise a turn Illustrations on next page 3 Note the position of the index notch on the sensor and continue to rotate counterclockwise until the index no...

Page 316: ...towed position 2 Turn of power to the crane 3 Disconnect the cables from the conditioning box 4 Remove the two nuts attaching the conditiong box to the mounting bracket 5 Install the new conditioning...

Page 317: ...0 Fax 918 298 8301 www team twg com Greer Company is a part of TWG As a leader in product innovation Greer Company is committed to the ongoing improvement of its equipment We reserve the right to make...

Page 318: ...Interface Installation Configuration Manual T2300 Transmitter R2170 Receiver D160 Expansion Module D180 Expansion Module 74 1833 Coast Meridian Road Port Coquitlam BC Canada V3C 6G5 Ph 604 944 9247 Fa...

Page 319: ...ions 10 Power the Transmitter 10 Test the Transmitter Receiver Link 11 Download ID Code 12 LCD Display Operation 14 Calibrating Proportional Controls 15 Diagnostics R2170 Receiver 16 Diagnostics T2300...

Page 320: ...ety MAKE SURE MACHINERY AND SURROUNDING AREA IS CLEAR BEFORE OPERATING Do not activate the remote system unless it is safe to do so TURN OFF THE RECEIVER POWER BEFORE WORKING ON MACHINERY Always disco...

Page 321: ...rom an OMNEX wireless transmitter and translates the commands into CANbus or 485 protocol messages The R2170 receiver may also be configured as a CANbus bridge The D180 Expansion Unit has up to fourte...

Page 322: ...n Assignments Connector A Grey Pin Function 1 n c 2 n c 3 Main Ground Connection 4 Power in to E Stop Relay internally fused to 7 5A 5 Output of E Stop Relay 6 Positive Battery supply for R2170 Electr...

Page 323: ...ntary Digital Output AUGER LATCH CLOSE Momentary Digital Output AUGER LATCH OPEN Momentary Digital Output ENGINE SPEED LOW Momentary Digital Output HYD ENABLE On while any paddle is activated ENGINE S...

Page 324: ...used Output Unused Output BOOM UP Proportional PWM BOOM DOWN Proportional PWM WINCH UP Proportional PWM WINCH DOWN Proportional PWM POLE GRAB LEVELING OUT Proportional PWM POLE GRAB LEVELING IN Propor...

Page 325: ...H Momentary Digital Output Spare Down Momentary Digital Output Spare Up Momentary Digital Output ENGINE SPEED LOW Momentary Digital Output HYD ENABLE On while any paddle is activated ENGINE SPEED HIGH...

Page 326: ...utput Unused Output Unused Output AUX WINCH UP Proportional PWM AUX WINCH DOWN Proportional PWM WINCH UP Proportional PWM WINCH DOWN Proportional PWM BOOM UP Proportional PWM BOOM DOWN Proportional PW...

Page 327: ...ecting the power from the charging side of existing wiring or making use of existing ACC or other peripheral connection points Make sure that wire of sufficient gauge and insulator type is used when c...

Page 328: ...the two exists The E Stop light and the Link light will display RED provided the transmitter is off and the Status light will show GREEN NOTE The transmitter will shut itself off and the receiver will...

Page 329: ...enter Setup mode D If the SW1 button is held for more than 10 seconds the Status and Link LEDs will rapidly flash RED showing the stuck switch indicator CAN 2 CAN 1 ESTOP LINK STATUS CAN 2 CAN 1 ESTOP...

Page 330: ...he R2170 enters Setup Mode it shuts down the CAN ports and opens the Emergency Stop Relay thus disabling normal operations If for some reason SW 1 or SW 2 is stuck on the R2170 will indicate this faul...

Page 331: ...ay Operations The LCD display contains a 9 button keypad For this version the bottom left button is operational Pressing this button toggles the LCD backlight feature to either ON or OFF Note Leaving...

Page 332: ...3 4 by holding the Power switch UP or DOWN for 5 seconds A Refer to steps in Power the Transmitter B Supply power to the R2170 B 1 Power T2300 Power R2170 A Hold Power switch DOWN for 5 seconds until...

Page 333: ...is OFF A low battery condition has been detected To detect intermittent conditions caused by poor or corroded ground or power circuits the GREEN light will continue to flash for Transmitter is OFF E S...

Page 334: ...power up the transmitter or the unit will power down On Power Up Press and release the E Stop button within 10 seconds to power up the transmitter or the unit will power down The transmitter is in Ca...

Page 335: ...refer to R160 diagnostic page for possible solution Module is operating properly with a function off Fuse blown refer to R160 diagnostic page for possible solution Module has an unrecoverable fault r...

Page 336: ...s Solid GREEN CAN1 light is Flashing GREEN CAN1 light is OFF Set up Download ID has failed Note This should only occur when the transmitter is on and the Download ID procedure has been tried Retry the...

Page 337: ...k Does the Active light go to solid YELLOW YES Either the switch paddle is defective or the switch paddle connection to the circuit board is broken Call for service Complete the following steps in ord...

Page 338: ...nsmitter to check if the units function correctly If not proceed to Chart 1 NO YES The transmitter code may need to be re downloaded to the receiver NO Caution Note Before you proceed with the Downloa...

Page 339: ...from the transmitter Possible Solutions 1 Try the Downloading steps again 2 If this doesn t correct the problem send both the transmitter and receiver in for service Note you could try to determine w...

Page 340: ...device complies with Part 15 of the FCC Rules Operation is subject to the following two condi tions 1 This device may not cause harmful interference and 2 this device must accept any interference rec...

Page 341: ...Sm75_0413 NOTE Individual customer specifications spindle mounting sprocket pilot brake assembly etc may vary from exploded drawing and standard part num bers shown If applicable refer to customer dra...

Page 342: ...1132 25 004 1132 CARRIER THRUST WASHER 2 10A 81 004 2883 81 004 2883 81 004 2883 81 004 2883 INPUT THRUST WASHER 1 10B SEALS 0 RINGS 11 01 405 0500 01 405 0500 01 405 0500 01 405 0500 OUTPUT SHAFT SE...

Page 343: ...pecial consideration The max operating temp must not be exceeded under any circumstances regardless of ambient temperature If your unit was specified shaft up or with a Z option a grease zerk was prov...

Page 344: ...mpletely into the planet shafts 6C 3 Press or drive planet shafts 6C out of carrier 6A 4 Remove planet gears 6B and thrust washers 6D from the carrier 6A 5 Inspect the planet gear 6B bearing bore plan...

Page 345: ...aring cone 12C large end down as shown onto the shaft 8 until it seats against the shoulder Note Press bearing cone onto output shaft by pressing on in ner race only DO NOT press on roller cage as it...

Page 346: ...cover 4 Noting the scribed line made during disassembly install cover 10 Ensure the unit spins freely by using a splined shaft to drive the input gear 5 11 Install motor 17 onto cover 4 using hex hea...

Page 347: ...pressure pnom max 400 bar Maximum pressure pmax 450 bar Geometric displacement Vmax 60 130 cm rev Circuit symbol Solutions for a World under Pressure Variable displacement axial piston pump V60N Appli...

Page 348: ...rwarding and reproduction of this document as well as the use and communication of its contents are forbidden unless expresse ly permitted Any breach or infringement will result in liability for damag...

Page 349: ...p 21 4 1 1 Type V60N 060 21 4 1 2 Type V60N 090 26 4 1 3 Type V60N 110 31 4 1 4 Type V60N 130 36 4 2 Controllers and intermediate plates 40 5 Installation information 43 5 1 General information 43 5 2...

Page 350: ...option of a thru shaft for operating additional hydraulic pumps in series The pump is fitted above all to the power take off on commercial vehicle transmissions The range of pump controllers allows t...

Page 351: ...and separate components Ports Table 12 Ports Pressure specification bar Stroke limitation Table 11 Stroke limitations Controller Table 8 Controllers Table 9 Intermediate plates Table 10 Solenoid volt...

Page 352: ...arameters Table 3 Shaft versions Coding Description Designation Standard Max drive torque Nm D Parallel key splined shaft Similar to DIN ISO 14 trucks 800 M Spline shaft DIN 5480 only V60N 090 V60N 11...

Page 353: ...ISO 3019 1 only V60N 060 F Flange SAE C 4 hole J 744 127 4 ISO 3019 1 G Flange 125 B4 HW ISO 3019 2 only V60N 090 Table 5 Seals Coding Description N NBR V FKM Table 6 Housing versions Coding Descripti...

Page 354: ...maintains a constant system pressure independently of the required delivery flow It is suited to constant pressure systems where differing delivery flows are required or for efficient pressure limita...

Page 355: ...lectrically actuated controller that sets an appropriate geometric displacement for the pump in accordance with a current value Therefore the pump generates a variable volumetric flow that is dependen...

Page 356: ...eliable adjustment The ZV controller is designed as an intermediate plate It acts on the set piston from above and electrically adjusts the pivoting angle of the pump ZV1 Size 060 090 110 Electric pro...

Page 357: ...2 hole J 744 101 2 ISO 3019 1 SAE B J 744 22 4 ISO 3019 1 13T 16 32 DP SAE B 2 hole J 744 101 2 ISO 3019 1 SAE BB J 744 25 4 ISO 3019 1 15T 12 24 DP C 015 C 025 C 035 SAE B 4 hole J 744 101 4 ISO 3019...

Page 358: ...displacement axial piston pump type V60N B 7960 N Ports Suction port Pressure port Drain port Pressure gauge connection Hydraulic fluid Hydraulic oil according to DIN 51 524 Part 1 to 3 ISO VG 10 to 6...

Page 359: ...pressure 3000 rpm 3000 rpm 3000 rpm 3000 rpm Min speed in continuous operation 500 rpm 500 rpm 500 rpm 500 rpm Required drive torque at 100 bar 100 Nm 151 Nm 184 Nm 230 Nm Drive power at 250 bar and 2...

Page 360: ...ing information for parameters Determination of nominal sizes Delivery flow Drive torque Drive power Vg Geom delivery volume cm3 rev p Differential pressure n Speed rpm V Volumetric efficiency mh Mech...

Page 361: ...t zero stroke and 1500 rpm Drive power pressure at zero stroke and 1500 rpm Inlet pressure and self suction speed The diagrams show the inlet pressure speed at the max swash plate angle and an oil vis...

Page 362: ......

Page 363: ...ange suction port D Drain port G 3 4 X G 1 4 For coding UNF ports SAE J 514 P Pressure port 1 5 16 12 UN 2B S Flange suction port D Drain port 1 1 16 12 UN 2B X G 1 4 ISO 228 1 with adapter for 7 16 2...

Page 364: ...5 Coding P ISO 7653 1985 Housing version 1 axial ports 1 Delivery includes attachment kit for suction intakes according to Section 7 2 Housing version 2 radial ports with thru shaft Rotation direction...

Page 365: ...awe de 2015 10 2014 2 1 D 7960 N V60N 39 Flange version output side Coding C 030 ISO 7653 1985 Coding C 031 C 032 SAE A 2 hole Coding C 034 SAE B 2 hole Coding C 035 SAE B 4 hole Coding C 038 SAE C 4...

Page 366: ...pressure port 4 2 Controllers and intermediate plates Coding LSNR LSNRT NXR Coding NR 1 Pressure limitation 2 Dynamic throttle 3 Differential pressure Sp stand by pressure only codings LSNR and LSNRT...

Page 367: ...20 400 approx 50 300 Differential pressure p only type LSNR 20 55 approx 10 27 Differential pressure p only type QNR 20 55 approx 10 20 Torque setting M Nm revolution Default torque setting Nm Power...

Page 368: ...ling the motor above the tank see Installation positions inChapter 5 3 Installation positions Observe the reference values in Section Chapter 7 Accessories spare parts and separate components Prior to...

Page 369: ...apter 5 Installation information The absolute intake pressure must not fall below 0 85 bar A hose line should generally be used in preference to a rigid pipe Drain port The V60N pumps have 2 drain por...

Page 370: ...stallation pump below the min fill level For horizontal installation use the uppermost drain port Vertical installation pump below the min fill level Mount the pump so that the pump mounting flange is...

Page 371: ...in particular to long periods of downtime A check valve opening pressure approx 0 5 to 0 6 bar in the overflow oil line can prevent the pump housing from being emptied Facilitate bleeding of connectin...

Page 372: ...HAWE Hydraulik 6 2 Assembly information The hydraulic accumulator must be integrated in the system via state of the art connection components screw fittings hoses pipes etc The hydraulic system must...

Page 373: ...85 40 79 93340 00 50 2 125 65 79 93337 00 96 40 79 93341 00 53 84 79 93345 00 64 2 1 2 190 90 79 93338 00 96 40 79 93342 00 109 129 79 93346 00 76 3 250 106 79 93339 00 106 40 79 93343 00 7 1 1 2 125...

Page 374: ...0 2 Proportional directional spool valve type PSL PSM and PSV size 3 D 7700 3 Proportional directional spool valve type PSL PSM and PSV size 5 D 7700 5 Proportional directional spool valve type PSLF P...

Page 375: ...Appendix B Parts Index ELLIOTT Built for You Digger Derrick Truck B 1...

Page 376: ...HT 7 3 Labels 4 23 Lift Capacities 4 13 Lubrication 6 3 Main Boom Full Span Lift Chart 5 5 1 Main Boom Full Span Range Diagram 5 5 2 Main Boom Mid Span Lift Chart 5 5 3 Main Boom Mid Span Range Diagra...

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Summary of Contents for Digger Derrick

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Elliott Digger Derrick, Operation & Maintenance Manual, Page: 224 / 376

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Summary of Contents for Digger Derrick

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