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Elliott E190, Operation And Maintenance Manual

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Elliott E190 Operation And Maintenance Manual Download Page 290

   

Abbreviation

Description

n/a

Not applicable

PWM

Pulse Width Modulation

PCU

Portable Control Unit

CU

Central Unit

LED

Light Emitting Diode

ST

Status LED

DV

Dump Valve

Item no:

Description

Program version

3010

G2B Central Unit PWM EU

4.10

3011

G2B Central Unit PWM NAFTA

4.10

2010

G2B Central Unit Danfoss EU

2.14

2011

G2B Central Unit Danfoss NAFTA

2.14

1602

G3B Central Unit Type 1 EU

1.00

1603

G3B Central Unit Type 1 NAFTA

1.00

1604

G3B Central Unit Type 2 EU

1.00

1605

G3B Central Unit Type 2 NAFTA

1.00

n/a*

G2B Portable Control Unit Maxi Linear

1.07

n/a*

G2B Portable Control Unit Maxi Joystick

1.07

n/a*

G2B Portable Control Unit Mini Linear

1.07

n/a*

G2B Portable Control Unit Mini Joystick

1.07

1.4           Applicable products

                 

                 

This document is applicable on the below declared products and program versions.

1.3           Terminology

                 

     

*Due to the variety of configurations available for the Portable Control Units, item numbers are not 

declared; only the available Portable Control Unit platform types are declared, for more detailed 

information refer to customer part list where available.

Document type

Document number

Page

Rev

Service Manual

S071

C

4 of 46

Summary of Contents for E190

Page 1: ...Operations Maintenance Manual E190 Elliott Equipment Company 4427 South 76th Circle Omaha NE 68127 402 592 4500 www elliottequip com Elliott PN 3020339 Updated October 27 2015...

Page 2: ......

Page 3: ...atic Above Rotation 5 3 1 Electric Schematic Below Rotation 5 3 2 Wiring Schematic LMI Layout 5 3 3 Wiring Schematic LMI Display 5 3 4 Wiring Schematic Junction Box Assembly 5 3 5 Wiring Schematic PAT...

Page 4: ...Adjustment 6 6 Four Section Boom Operation 6 7 Five Section Boom Operation 6 8 Troubleshooting 6 9 COMPONENT SERVICE MANUALS Brevini Service Manual 7 1 Swing Drive Service Manual Tulsa 6036S 7 2 LMI O...

Page 5: ...ment at Elliott Equipment Company If an Elliott aerial device is involved in a personal injury or property damage incident notify the Product Safety and Reliability Department as soon as possible Have...

Page 6: ...BEWARE OF OVERHEAD POWER LINES UNDERSTAND AND NEVER ATTEMPT EXCEEDING AERIAL DEVICE LOAD CHARTS NEVER EXCEED PLATFORM CAPACITY AND AREAS OF OPERATION BEWARE OF ADVERSE WEATHER AND GROUND CONDITIONS Th...

Page 7: ...on Aerial EEC 0095 V1 1 Introduction Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0095 1 0 Template Update 11 5 14 Tech Spec 1 1 Doc updat...

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: ...ility to 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 pro...

Page 11: ...testing and re certification are required in accordance to instructions provided by Elliott Equipment Company Safety is dependent on all people associated with this aerial device The overall condition...

Page 12: ...unsafe and should always consult their 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 working ord...

Page 13: ...ps of the operation fit together This will allow the signal person to safely coordinate the job with the operator and all other crewmembers The signal person must take up a position where they can be...

Page 14: ...74 V1 1 Safety Responsibilities Crewmembers must watch for hazards during operations and alert the operator and signal person of any dangers such as power lines unexpected presence of people other equ...

Page 15: ...es aerial EEC 0074 V1 1 Safety Responsibilities Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0074 1 0 Template update 11 05 14 Tech Spec 1...

Page 16: ...this standard and manuals for auxiliary equipment added by the installer E Installations The installer shall comply with Sections 5 and 6 and shall follow the instructions of the manufacturer In the...

Page 17: ...r installer directs personnel to operate an aerial device inspecting sales demonstrations or any form of use the dealer or installer shall assume the responsibilities of users as specified in Section...

Page 18: ...malfunction c Hydraulic or pneumatic systems for observable deterioration or excessive leakage d Fiberglass and other insulating components for visible damage or contamination e Missing or illegible o...

Page 19: ...erial devices i Hydraulic and pneumatic cylinders and holding valves for malfunction and visible damage j Hydraulic and pneumatic filters for cleanliness and the presence of foreign material in the sy...

Page 20: ...ermination made by a qualified person as to whether they constitute a safety hazard All unsafe items shall be replaced or repaired before use C Inspection and Test Records 1 Items to be inspected shal...

Page 21: ...lent entity may approve required modification F Weight Distribution Changes in loading or additions made to the mobile unit after the final acceptance that affect weight distribution shall meet applic...

Page 22: ...ards associated with their operation shall operate an aerial device Such items covered shall include but not necessarily be limited to the following issues and requirements a The purpose and use of ma...

Page 23: ...haracteristics specific to the aerial device Responsibility of Users A General Responsibilities Each user shall comply with the requirements of this section B Personnel Only trained and authorized per...

Page 24: ...erator 3 Familiarization When an operator is directed to operate an aerial device he she is not familiar with the operator prior to operating shall be instructed regarding the following items and issu...

Page 25: ...ny loading which includes a horizontal load shall be avoided unless the mobile unit is designed for that application F Wind and Weather Conditions Before and during each use the operator shall measure...

Page 26: ...operational and instructional markings f Electrical systems of or related to the aerial device for malfunction signs of excessive deterioration dirt and moisture accumulation g Visual inspection of bo...

Page 27: ...tions regarding the inspection application and operation of aerial devices including recognition and avoidance of hazards associated with their operation shall operate an aerial device Such items cove...

Page 28: ...rs Lessors or Lessees A General Responsibilities Each renter or lessor or lessee shall comply with the requirements of the applicable section or sections below 1 Lessor or Lessee as Dealer or Installe...

Page 29: ...d operation of aerial devices including recognition and avoidance of hazards associated with their operation shall operate an aerial device Such items covered shall include but not necessarily be limi...

Page 30: ...operator is directed to operate an aerial device he she is not familiar with the operator prior to operating shall be instructed regarding the following items and issues a The location of the manuals...

Page 31: ...sibilities per ANSI SIA A92 2 Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0041 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 1 12...

Page 32: ...securely attached to the supplied lanyard attachment points at all times Personnel in the platform shall always stand firmly on the floor of the platform and not climb or sit on the rails of the platf...

Page 33: ...e much stronger than at the ground Follow all applicable instructions for operating an anemometer Weather can be unpredictable and the operator must determine prior to operation whether it is safe to...

Page 34: ...al device B Use protective equipment such as hard hats safety glasses hearing protection and gloves in conditions where a hazard of injury exists C Shall be responsible for complying with the requirem...

Page 35: ...tform in a slow controlled manner to minimize sudden and unexpected movements of the platform M Set all brakes and locks on the aerial device after positioning of the personnel platform and before any...

Page 36: ...Limit their number to the minimum number of personnel to complete the task platform design and aerial device limitations G Have materials and equipment evenly distributed and secured while the platfo...

Page 37: ...loadline and stow loadline on the block provided on top of the main boom section D Attach anti two block override flag onto the anti two block switch E If the platform is to be used on the jib tip de...

Page 38: ...nd review where the load chart will allow the loaded personnel platform to travel E Have platform personnel put on the body harnesses with the attached safety lanyard and attach the safety lanyards to...

Page 39: ...ty Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0070 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 1 13 15 Tech Spec 1 2 Content u...

Page 40: ...c leveling sensors and that the platform stow arrows are aligned Secure the load line headache ball or hook block to travel attach point Boom must be retracted and in the boom rest Secure all items on...

Page 41: ...V1 2 Road Transport Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0071 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 1 26 15 Tech...

Page 42: ...to energized power lines and warn when approaching the minimum safe distance Use non conductive tag lines when using boom or jib winch D The aerial device must be set up on a firm level surface with...

Page 43: ...gths or radii on the load rating chart use the next lower rated capacity M Keep the load as close to the ground as possible N Do not allow personnel lifts in wind speeds exceeding 30 miles per hour 48...

Page 44: ...Setup EEC 0072 V1 2 Aerial Device Setup R Only use Elliott approved personnel baskets attached to the boom for lifting personnel S Do not operate the aerial device if the anti two block safety system...

Page 45: ...2 Aerial Device Setup Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0072 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 1 26 15 Tech...

Page 46: ...This is located in the truck cab Refer to truck manuals for operating instructions PTO must be engaged to provide power to aerial device functions Refer to truck manuals for operating instructions CA...

Page 47: ...sition Winch pays out cable lowers load Pull back UP position Winch winds up cable to raise load D Boom Control Lever Push forward DOWN position to lower boom Pull back UP position raise boom E Emerge...

Page 48: ...ementally to the maximum speed to order the hydraulic pump at the maximum flow 2 Decrease throttle speed Press and hold switch to the low position The engine speed decreases incrementally down to idle...

Page 49: ...ators Located on either side of the first moving boom section The letters correspond with the letters on the load chart LMI Load Moment Indicator Anti Two Block Control For initial LMI setup and opera...

Page 50: ...the speed of the boom raise and lower speed and the swing speed when the boom is near or at its full extension The slow down feature activates when the boom length exceeds 100 feet during extension an...

Page 51: ...id flow through the needle valve The ERFSD reduces hydraulic output by approximately 50 percent so boom function speeds will be cut by half The following LMI modes will activate the slow down function...

Page 52: ...rst is on the standup console for this unit where two outrigger control pads are mounted at the top of the unit Both pads are identical Here the LEFT pad controls the truck s REAR outriggers and the R...

Page 53: ...outriggers When the operator deploys the outriggers always extend the beams to full span prior to lowering the outrigger jacks NOTE roadside left and curbside right are referenced by the operator sta...

Page 54: ...l stop the truck engine however pushing button with the Master Power switch in the OFF position will not affect truck operations J Bubble Level Master Level located on sub base top plate adjustable le...

Page 55: ...35 V1 2 Operating Outrigger Controls Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0035 1 0 Template update 11 05 14 Tech Spec 1 1 Doc upda...

Page 56: ...linder rod and the other 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 unt...

Page 57: ...tion Once the outriggers are extended to full span follow the onscreen prompt Press to Confirm Selection and press the bottom right button NOTE The yellow arrow denotes the selection knob and contains...

Page 58: ...with the platform removed When finished press one of the indicated buttons on either the bottom left or bottom right of the screen to get to the rigging line screen This screen allows the operator to...

Page 59: ...w asks the operator to confirm selection and press the bottom right button Personnel in the platform while material handling from the load line is unsafe and is NEVER allowed If the operator selects t...

Page 60: ...tton 4 Once the user has pressed the button to confirm their selection the following screen appears This screen indicates the aerial device is ready for operational use If at any time the operator mak...

Page 61: ...up EEC 0002 V1 1 LMI Setup Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0002 1 0 Created Document 1 9 15 Tech Spec 1 1 Illustration update...

Page 62: ...N TRUCK CHASSIS J1939 NETWORK Tools Needed CAN USB Adapter Elliott uses GridConnect part number GC CAN USB CAN traceing software Elliott uses PCAN View Software comes bundled with GridConnect USB adap...

Page 63: ...39 Network Installation NOTE In order for the Hirschmann display unit to correctly relay J1939 truck information found by pressing the Engine icon on the home screen the J1939 network on the truck cha...

Page 64: ...Hirschmann J1939 Install EEC 0110 V1 0 Hirschmann J1939 Network Installation...

Page 65: ...onsult the dealer or service manuals to connect to the correct CAN bus network RECORDING THE MESSAGES ON THE TRUCK CAN NETWORK A Power off the truck B Locate the diagnostic connector inside the cab of...

Page 66: ...Hirschmann J1939 Install EEC 0110 V1 0 Hirschmann J1939 Network Installation Below shows the connector in the released position...

Page 67: ...ll be CAN HI and green will be CAN LO Industry standard wiring color Consult manufacturer s specifications to confirm D Connect to the CAN network using the USB CAN adapter and connect the USB to a co...

Page 68: ...0 Hirschmann J1939 Network Installation Choose 250 kbit s may vary depending on manufacturer in the drop down box and click OK E The Receive portion of PCAN View should populate with the truck s J1939...

Page 69: ...1 0 Hirschmann J1939 Network Installation F Run a trace on the CAN bus by clicking on the Trace tab and clicking on the red circle in the upper tool bar G Let the trace run for 10 20 seconds and press...

Page 70: ...hat was traced in order to avoid confusion in the future I PCAN View can now be closed and the CAN USB interface can be unplugged from the computer and the truck s diagnostic connector CONNECTING THE...

Page 71: ...continuity check of the CAN system will now need to be done Find a desirable location under the hood of the truck near the truck s ECU modules where the CAN wires are visible On current generation Fr...

Page 72: ...Hirschmann J1939 Install EEC 0110 V1 0 Hirschmann J1939 Network Installation...

Page 73: ...is ensures the wires are on the same CAN network 4 Once it is verified the wires are continuous find the connector on Elliott s outrigger control harness labeled Truck Engine Canbus Connection located...

Page 74: ...cur in the CAN network and cover wires with corrugated wire loom ENSURING THE DISPLAY HAS THE CORRECT SOURCE ADDRESS FOR THE REQUIRED PNGs 1 After the two CAN networks are spliced together it is possi...

Page 75: ...Hirschmann J1939 Install EEC 0110 V1 0 Hirschmann J1939 Network Installation...

Page 76: ...nding and related CAN network PNGs that will need to be searched for is shown below PNG I D Description F004 Engine Speed FEFC Fuel Level FEF2 Fuel Rate FEEF Engine Oil Pressure FEEE Engine Oil Temper...

Page 77: ...esponding PNG from the list above In Notepad with the can trace open press Ctrl F on the keyboard to open up the Find dialog box For example if the Fuel Level gauge wasn t responding the PNG FEFC will...

Page 78: ...ta Length Code and the following letters and numbers are the Data Bytes To determine which address is correct the Data Bytes are to be examined The FF byte is a byte placeholder and contains no data T...

Page 79: ...Hirschmann J1939 Install EEC 0110 V1 0 Hirschmann J1939 Network Installation Use the rotary encoder to scroll right until this screen is displayed PNG ADDRESS VALUE...

Page 80: ...ll over to 7 and then press the SYSTEM button to confirm the address change 7 If a gauge responds incorrectly and a search for the PNG in the trace document in Notepad provides no results then the dat...

Page 81: ...ann J1939 Install EEC 0110 V1 0 Hirschmann J1939 Network Installation Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0110 1 0 New Document 5...

Page 82: ...es 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 operating an...

Page 83: ...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 84: ...o the operator using the remote controls as if they were operating from the operator s cap or platform This provides the operator in the platform or at the hook point with boom length angle and load r...

Page 85: ...communication information Functions A Start Stop Switch This is a momentary switch used to start or stop the truck engine Holding the switch in the start position within 5 seconds of pressing the enab...

Page 86: ...sh button Press this button in to kill the truck s engine When the Emergency Stop button is pushed in completely it will automatically lock and keep the button in a depressed state To release the Emer...

Page 87: ...OTE High speed winch feature is currently not available on the E145 model K Disable Button This momentary button provides an override lockout of the LMI ATB function Press to disable L Boom Swing Leve...

Page 88: ...n winch 1 Push forward DOWN position to pay out winch line or lower load 2 Pull back UP position to reel in winch line or raise load Q Boom Up Down Lever This lever operates the boom lift cylinder 1 P...

Page 89: ...Remote Control EEC 0001 V1 0 Remote Control Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0001 1 0 Created Document 1 9 15...

Page 90: ...rmine the capacity on the jib until full extension is reached Do not exceed radius indicated on the load chart at full boom extension Before lifting any load make sure that A Outriggers and stabilizer...

Page 91: ...r the aerial device may be specified for use with the platform removed Subtract the listed platform weight from the permitted lifting capacity if the platform is not removed To remove the platform fol...

Page 92: ...s aerial EEC 0125 V1 1 Lift Capacities Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0125 1 0 Template update 6 25 15 Tech Spec 1 1 Content...

Page 93: ...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 94: ...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 95: ...Platform Install Operation EEC 0049 V1 1 Platform Operation Kickstand deployed with cable unlatched Platform attached to Boom using Adaptor...

Page 96: ...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 97: ...Platform Install Operation EEC 0049 V1 1 Platform Operation Labels Platform selector valve positions Platform operation label...

Page 98: ...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 99: ...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 100: ...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 101: ...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 102: ...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 103: ...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 104: ...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 105: ...n an area free of overhead obstructions and power lines Daily Inspection A Perform all items required in a standard walk around vehicle inspection in accordance with U S DOT Commercial Vehicle Require...

Page 106: ...t that could interfere with proper operation Q Verify that all control mechanisms when released to the neutral position all functions stop R Make sure all control mechanisms are free of excessive wear...

Page 107: ...ervices B Perform the Daily Check List and Weekly Check List C Check the boom and all structural components especially welds for deformation cracks corrosion and other forms of damage D Inspect full l...

Page 108: ...ognized by the U S Department of Labor Periodic Inspection A Perform all lube services B Perform the Daily Weekly Monthly and Semiannual Checklist C Check all fasteners and retighten Check torque of a...

Page 109: ...heck condition of extend and retract cables for wear or damage M Re shim the boom wear pads as required Replace worn or damaged wear pads as required N Check boom angle and boom length indicators for...

Page 110: ...ns aerial EEC 0075 V1 1 Required Inspections Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0075 1 0 Template update 11 05 14 Tech Spec 1 1...

Page 111: ...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 112: ...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 113: ...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 114: ...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 115: ...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 116: ...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 117: ...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 118: ...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 119: ...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 120: ...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 121: ...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 122: ...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 123: ...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 124: ...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 125: ...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 126: ...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 127: ...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 128: ...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 129: ...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 130: ...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 131: ...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 132: ...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 133: ...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 134: ...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 135: ...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 136: ...d sense line with 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...

Page 137: ...p Ltd 3500 241 10 6 40 Gravity Boom Extend 2700 186 30 114 147 10 44 Boom Retract 2500 172 9 34 180 10 36 Winch Up Down 3500 241 30 114 See Winch Line Pull Table Swing Left 2100 145 9 34 45 5 Swing Ri...

Page 138: ...ard Line Pull 9 000 lb Wire Rope 9 16 Yale Ultrex Breaking Strength 40 500 lb Cable Length 400 ft Winch Line Pull Line Speed Layer Lb Kg FPM MPM 1 15 000 6804 122 37 2 13 571 6156 135 41 3 12 377 5614...

Page 139: ...E190 Specs EEC 0126 V1 0 E190 Specifications Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0126 1 0 Doc creation 6 26 15...

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Page 142: ...WH BK WH WH BK YW CAN L CAN H CAN BUS LOW CAN BUS HIGH CAN H CAN L 127 126 CAN L CAN H PWR CAN H CAN S CAN L GND RD 10GA CAN H CAN L MASTER 127 126 122 100 CAN H CAN L GY RD 130 RANGE FUNCTION SLOW D...

Page 143: ...87A 86 87 85 30 87A 86 87 GRY RD GRY YLW GRN BLU WH ORG YW 14GA 322 10 GA C B 30 AMP OIL COOLER 322 10 GA WH BK OIL COOLER 85 30 87A 86 87 RELAY WH RD BU 12G RD 12G RD 12G BU 12G WH RD RD WH WH RD BU...

Page 144: ...A ADDED 1x 536408 JD JD ETH USB CAN 1 I O 1 1 I O 1 2 HIRSCHMANN RUN ERR S1 PON POK SR CAN 2 CAN 3 OPT 4 TO CUSTOMER SUPPLIED DWG20 125 kB SLEW SENSOR P N 061031 TO HED MODULE TO POWER GROUND TO SCAN...

Page 145: ...Power GND vSCALE D3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 AMP BATT TITLE IN DIM 1 16 GENERAL TOLERANCES HAC reserves proprietary rights to this drawings and to the data...

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Page 148: ...gh 5 CAN Low 3 2 1 5 4 TO REMOTE CONTROL 3 GND 2 V 1 SHLD TITLE IN DIM 1 16 GENERAL TOLERANCES HAC reserves proprietary rights to this drawings and to the data shown thereon The drawing and data are c...

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Page 163: ...USE ONLY 9 16 DIAMETER ROPE AS SPECIFIED WITH THE PROPER BREAKING STRENGTH LISTED ANTI TWO BLOCK SYSTEM MUST BE IN GOOD OPERATING CONDITION BEFORE LIFTING MATERIAL SEE OPERATION SAFETY MANUAL A DEAD...

Page 164: ...engine 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 c...

Page 165: ...ty aerial EEC 0076 V1 1 Maintenance Safety Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0076 1 0 Template update 11 05 14 Tech Spec 1 1 Do...

Page 166: ...e point 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 s...

Page 167: ...ss aerial EEC 0077 V1 1 Cleanliness Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0077 1 0 Template update 11 05 14 Tech Spec 1 1 Doc updat...

Page 168: ...Brake SAE 20W 20 Motor Oil Check Level Monthly 5 10 Winch Gearbox SAE 90 EP Gear Lube Check Level Monthly 5 11 Swing Bearing Grease Fitting Grease Gun Monthly 6 12 Swing Bearing Gear Teeth Grease Gun...

Page 169: ...end 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 hands or tools into opening when truck engine is running and...

Page 170: ...st be retracted and stowed and all outriggers and stabilizers must be fully retracted Add hydraulic oil as required to keep the level on the sight gauge between the high and low marks Use high quality...

Page 171: ...E160 EEC 0006 V1 1 Lubrication E160 Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0006 1 0 Template update 11 05 14 Tech Spec 1 1 Doc upda...

Page 172: ...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 173: ...Bolt Torque EEC 0016 V1 2 Bolt Torque...

Page 174: ...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 175: ...he cover E Clean out any sediment inside the tank F Remove the suction strainer Soak in solvent and blow off with compressed air before reinstalling G Reinstall the cover on the tank top replace gaske...

Page 176: ...1 2 Changing Hydraulic Oil Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0078 1 0 Template update 11 05 14 Tech Spec 1 1 Content update 1 1...

Page 177: ...rs and stabilizers so the aerial device 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 stabilize...

Page 178: ...nt aerial EEC 0079 V1 1 Bubble Level Adjustment Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0079 1 0 Template update 11 05 14 Tech Spec 1...

Page 179: ...Four Section Boom Operation aerial EEC 0081 V1 3 Four Section Boom Operation...

Page 180: ...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 181: ...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 182: ...from turning while torqueing retainer nuts F Torque 1 2 3 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 ste...

Page 183: ...nd winch hydraulic lines Cap all open lines and ports F 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...

Page 184: ...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 185: ...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 186: ...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 187: ...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 188: ...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 189: ...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 190: ...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 191: ...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 192: ...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 193: ...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 194: ...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 195: ...he side plate of the larger boom section with properly aligned adjusted wear pads install the capscrews and torque to 75 lb feet 100N m Improperly aligned wear pad A gap exists between wear pad and si...

Page 196: ...located in the 2nd section Retract boom completely Remove capscrews through access holes on top rear of sections Remove wear pads shims and cam plates from the rear of the boom through open winch moun...

Page 197: ...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 198: ...eration Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0081 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 1 26 15 Tech Spec 1 2 Illu...

Page 199: ...Five Section Boom Operation aerial EEC 0080 V1 3 Five Section Boom Operation...

Page 200: ...Section 3 4 5 Extend Cable Qty 2 Connects to the back of the 3rd Mid section and passes over sheave at front of 4th Next to Tip Section and Connects to Back of 5th Tip Section Primary function of the...

Page 201: ...der rod end to the deck E Tag and disconnect extend cylinder lines and winch hydraulic and electric lines Cap all openings Attach a lifting device to provide even weight distribution and raise the boo...

Page 202: ...section bottoms out in the base of the 2nd bottom the base of the 4th section boom bottoms out in the base of the 3rd section boom and the base of the 5th section boom bottoms out in the base of the...

Page 203: ...2 retract cables to 7 ft lb 9 5 N m Use the flats at the front of the cable ends to keep the cables from rotating while torqueing These cables are located at the bottom tip of the 2nd section boom G T...

Page 204: ...bles and tighten 2 3 4 extend cables This will cause the 4th and 5th sections to bottom out later and the 2nd and 3rd sections to bottom out sooner 4 If the 5th section is bottoming out first equally...

Page 205: ...the hex nuts which secure the 1 2 3 extend cables to the cable anchor Remove hex nuts and washers from 1 2 3 extend cables Leave the cable ends draped inside the boom F Attach a sling or chain to the...

Page 206: ...e to the 2nd section Remove pad plate Remove and tag four side wear pads with shims from front of 2nd section Pull the retract cables out and keep retract cables taut while pulling the 3rd 4th 5th ass...

Page 207: ...m and pull the 4th 5th assembly out of the 3rd approximately 12 inches 30cm Suspend the 4th section off of the lower wear pads T Remove 4 capscrews which retain the lower front pad plate to the 3rd se...

Page 208: ...nd spacers until All sheaves are removed from boom sheave case Additional Maintenance Disassembled Boom A Clean all boom sections and inspect for wear dents bent or crooked boom sections gouged metal...

Page 209: ...crews C Position 5th section boom in front of the 4th section boom ready to slide together Route 3 4 5 extend cables through 4th section boom with the threaded end of the cable at the rear of the 4th...

Page 210: ...bar and cable guide with wear pad and related hardware on the top of the 4th section Shim according to calibration instructions or as pads were originally removed and tagged I Push the 5th section co...

Page 211: ...les P Assemble bottom wear pads on 3rd section pad plate raise 4th 5th section high enough in 3rd to allow plate with pads to slide between the sections place retract cables in the grooves in the bott...

Page 212: ...ension cylinder in a workable location and install the 3 extend sheaves in the sheave case end of the cylinder orientate the pin so that the bearing grease holes are on the unloaded side of the pin to...

Page 213: ...o boom sections to avoid damaging cables EE Raise extend cylinder up to allow cylinder collar to slide through and align with the anchor pocket on the back of the 3rd lower cylinder collar will move d...

Page 214: ...on install cable guide and wear pad to the top of the 2nd section MM Slide the 3rd 4th 5th and cylinder assembly into the 2nd section until the extend cylinder collar bottoms out in its anchor pocket...

Page 215: ...tween the sections place retract cables in the grooves in the bottom pad plate as the boom sections are slid together retract cables will pull through these grooves use appropriate hardware and fasten...

Page 216: ...straightness is critical in proper boom operation The extended boom straightness required is a deviation of 50 inch 13mm or less from the theoretical centerline of the boom A stringline from the cent...

Page 217: ...over the holes in the sections the wear pads and plates have to be removed and adjusted either towards or away from the side plate of the next larger section until the holes will align When properly a...

Page 218: ...ar pad would be considered excessive as well If any of these conditions exist the top and bottom pads can be replaced without complete disassembly of the boom Top Pad Replacement Pad maintenance on th...

Page 219: ...te lifting device sling around the 4th and 5th depending on configuration section boom and lift it up until weight is removed from the bottom pads in the front of the interior sections Loosen and remo...

Page 220: ...eration Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0080 1 0 Template update 11 05 14 Tech Spec 1 1 Doc update 1 26 15 Tech Spec 1 2 Illu...

Page 221: ...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 222: ...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 223: ...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 224: ...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 225: ...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 226: ...da sollevamento e traino Installation operation and maintenance manual hoisting and recovery winches BREVINI WINCHES S p A 42100 REGGIO EMILIA Italy Via Degola 1 Tel 39 0522 277711 Fax 39 0522 514977...

Page 227: ......

Page 228: ...NTAMINATI pag 21 3 6 VIBRAZIONI pag 22 3 7 RUMORE pag 22 3 8 ATMOSFERA CON RISCHIO DI ESPLOSIONE E O INCENDIO pag 22 INDEX 1 GENERAL INFORMATION 1 1 INTRODUCTION page 9 1 2 AIM OF THIS MANUAL page 9 1...

Page 229: ...te manuale e tutte le pubblicazioni allegate in un luogo accessibile e noto a tutti gli utilizzatori operatori e personale addetto alla manutenzione W A R N I N G Please read the technical information...

Page 230: ...1 INFORMAZIONI GENERALI GENERAL INFORMATION...

Page 231: ...na del suo funzionamento delle sicurezze e delle loro modalit d intervento ATTENZIONE Norme antinfortunistiche per l Operatore e il Tecnico qualificato 1 1 INTRODUCTION Brevini Winches would like to t...

Page 232: ...FLOW MAX PORTATA www breviniwinches it PRESSIONE MAX TIROMAX1 STRATO MAXLINEPULL1 LAYER ROPE DIAMETER DIAMETRO FUNE VIA U DEGOLA 1 Tel 39 0522 277711 42100 REGGIO EMILIA ITALY bar l min Kg mm CAUTION...

Page 233: ...revisioni a seguito di modifiche funzionali o di applica zione 2 IMBALLO SPEDIZIONE MOVIMENTAZIONE RICEVIMENTO PACKING SHIPMENT HANDLING INCOMING GOODS PROCEDURES due authorisation issued by Brevini...

Page 234: ...TELEFONO 39 0522 277711 FAX 39 0522 514977 indicando A TIPO DI ARGANO B NUMERO DI MATRICOLA DELL ARGANO C ANNO DI COSTRUZIONE 2 1 PACKING AND SHIPMENT Winches are packed and shipped in crates or on pa...

Page 235: ...TA www breviniwinches it PRESSIONE MAX TIROMAX1 STRATO MAXLINEPULL1 LAYER ROPE DIAMETER DIAMETRO FUNE VIA U DEGOLA 1 Tel 39 0522 277711 42100 REGGIO EMILIA ITALY bar l min Kg mm This information can b...

Page 236: ...g gio Non appoggiare l argano direttamente sul pavimento 3 DESCRIZIONE DELLA MACCHINA E DATI TECNICI MACHINE DESCRIPTION AND SPECIFICATIONS WARNING If the storage period is to be longer than six month...

Page 237: ...AMINATI Qualora si utilizzi l argano in ambienti cor rosivi con inquinanti grossolani con polveri estremamente fini procedere al lavaggio 3 1 OPERATING PRINCIPLE In its various configurations this win...

Page 238: ...plosiva Nel caso dovesse essere previsto questo uti lizzo occorre obbligatoriamente consultare il Servizio Tecnico Brevini Winches 4 INSTALLAZIONE INSTALLATION priate liquid to prevent deposits which...

Page 239: ...mm Vite classe 8 8 Vite classe 10 9 M12 90 113 M14 144 180 M16 225 281 M18 309 387 M20 439 549 M22 597 747 M24 759 949 M27 1110 1388 M30 1508 1885 4 1 RULES FOR CORRECT INSTALLATION WARNING The winch...

Page 240: ...cSt 10 6 m2 s 1 mm s 850 775 700 625 550 500 450 400 365 315 280 240 205 175 140 115 85 60 40 20 10 0 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2 0 cSt a 40 C cSt at 40 C cSt a 100 C c...

Page 241: ...arga SCHEMA IDRAULICO CONSIGLIATO CON DRENAGGIO MOTORE MESSO A SCARICO DIRETTO IN SERBATOIO RECOMMENDED HYDRAULIC LAYOUT WITH DIRECT MOTOR DRAIN INTO THE TANK CODICE SALITA LIFTING CODE CODICE SALITA...

Page 242: ...chi molto pericolosi comunque assolutamente VIE TATO manomettere la valvola di sovrapressione per carichi supe riori a quelli consentiti 5 MESSA IN FUNZIONE START UP order to allow the negative brake...

Page 243: ...viamento un funziona mento di circa dieci minuti senza carico per WARNING Before starting up the winch for the first time check the following the level of the lubricant is correct all bolts and screws...

Page 244: ...pre sente che la messa in funzione di una qua lunque apparecchia tura implica dei rischi pertanto bene affrontare ogni tipo di operazione con la massima atten zione e concentrazione 6 MANUTENZIONE MAI...

Page 245: ...iche NOTA Si consiglia per ogni argano di tenere una scheda che verr de bitamente compilata e aggiornata ogni qualvolta si esegua una ope razione di manutenzione NOTE Maintenance may be classed as rou...

Page 246: ...tema freno negativo Questa operazione deve essere eseguita presso il Servizio Tecnico Brevini Winches o suo centro di riparazioni autorizzato 7 DEMOLIZIONE DISPOSAL 6 2 SPECIAL MAINTENANCE CAUTION Bre...

Page 247: ...re e stoccare le differenti tipologie di materiali per avviarli alla raccolta differenziata per lo smaltimento dei rifiuti WARNING Disposal must be carried out by a Qualified Te chnician NOTE As diffe...

Page 248: ...8 ACCESSORI PER ARGANI DA SOLLEVAMENTO E TRAINO LIFTING AND RECOVERY WINCH ACCESSORIES...

Page 249: ...lla mes sa in funzione dell argano Le operazioni sopra descritte valgono anche per tutti i sistemi realizzati in collaborazine con l in stallatore finale atti a controllare il sovracarico dell argano...

Page 250: ...e apertura freno negati vo lamellare NOTE Gli argani da traino sal vo ordine contrario vengono forniti con desinnesto tamburo manuale 8 2 RECOVERY The following accessories are available for correct o...

Page 251: ...menti ad essa collegati prima di utilizzarla perch la descrizione e o la sua designazione permetter di identificare le parti che la com GENERAL INFORMATION FOR USE AND MAINTENANCE OF ROPES MAIN FEATUR...

Page 252: ...ticolarmente importante che le spire della fune degli strati inferiori siano avvolte in modo serrato alla superficie del tamburo avere un precarico che tiene in tensione la fune in fase d avolgimento...

Page 253: ...o definire avvolgimento Z quello dove tenendo la fune in posizione verticale presenta all osserva tore le spire visibili nella direzione del tratto REGULAR CROCIATA LANG PARALLELA RIGHT DESTRA Z S LEF...

Page 254: ...ere controllati per eventuali danni libert di movimento od usura Ogni gancio a gambo filettato ed il dado di sicurezza dovrebbero essere con trollati per accertare eventuali movimenti non consentiti c...

Page 255: ...DESTRA USARE LA MANO DESTRA USE RIGHT HAND FOR RIGHT TORQUE ROPE AVVOLGIMENTO DA SOPRA TOP WINDING AVVOLGIMENTO DA SOTTO BOTTOM WINDING CON FUNE A TORSIONE SINISTRA USARE LA MANO SINISTRA USE LEFT HA...

Page 256: ...gando il passo di avvolgimento risultando in una riduzione della performance della fatica e nel peggiore dei casi in un danno strutturale della fune che prende la forma di infiascature bird cage All a...

Page 257: ...olo interferenza ma l ampiezza di quest ultimo pu essere ridotta selezionando una fune parallela se il sistema di avvolgi mento lo consente o una fune compattata Figura 11 Feature 11 Figura 10 Feature...

Page 258: ...oprire even tuali rotture di fili e usura 6 Check the section winding onto the pulley for any worn or dama ged wires 7 Punti d attacco controllare le rotture dei fili analogamente esaminare la sezione...

Page 259: ...ione di trefoli Strand protrusion Riduzione localizzata del diametro della fune Local reduction of rope diameter Espulsione di trefoli Strand protrusion A B C D Parte appiattita Flattened portion Pieg...

Page 260: ...nto della Fig N Enlargement of fig N Fili rotti nella parte esterna della fune Broken wires on the crowns of the strands of the rope Fili rotti nei solchi a volte chiamati fazzoletto o interstizi tra...

Page 261: ...a fune dovuto all espulsione dell anima Local increase in rope diameter due to core protrusion Occhiello Kink Parte appiattita Flattened portion S T U 10 APPENDICE B TEORIA DEL RECUPERO E DEL TRAINO A...

Page 262: ...ino corrispondente a circa il 4 del suo peso complessivo per indurlo in movimento mentre invece un veicolo che deve essere You can achieve the best results in using winches for recovery if you know a...

Page 263: ...sollevamento puro Questa formula puramente pratica va ag giunta alla precedente quando si in presen za di superfici inclinate ne risulta indicando con G i gradi che W x S G x W x 0 017 Forza resisten...

Page 264: ...i un apparecchio da traino VEICOLO BLOCCATO WHEELS BLOCKED PUNTO DI ANCORAGGIO ANCHOR POINT 10 Ton PULEGGIA RINVIO PULLEY BLOCK Min 20 Ton 10 Ton Figura C Figure C VEICOLO BLOCCATO WHEELS BLOCKED PUNT...

Page 265: ...11 TABELLE DI CONVERSIONE CONVERSION TABLES...

Page 266: ...4 1 millimetro 1 millimetre 0 03937 0 0033 0 00109 0 001 1 metro 1 meter 39 37 3 2808 1 0936 1 000 Lunghezze Lengths INCH OUNCE INCH POUND FOOT POUND KILOGRAMMETRO KILOGRAM METER NEWTON METER 1 inch o...

Page 267: ...a Force ONCE POUND KG 1 once 0 0625 0 0283 1 pound 16 0 4536 1 kg 35 274 2 2046 Massa Mass FOOT S FOOT MIN MILE HOUR METRI S METER S KM ORA KM HOUR 1 foot s 60 0 6818 0 3048 1 097 1 foot min 0 017 0 0...

Page 268: ...12 CONDIZIONI GENERALI DI VENDITA CONDITIONS OF SALE...

Page 269: ...Gli obblighi del FORNITORE ed il con tratto non entreranno in vigore fintanto che il FORNITORE non ha provveduto ad inviare conferma scritta di accettazione dell ordine al CLIENTE o a fatturare quale...

Page 270: ...d technical infor mation contained in the offer or supplied in connection with the supply shall remain the SUPPLIER s property and cannot be repro duced or divulged to third parties without dotti o co...

Page 271: ...is deemed such that it is a risk to attaining the price 8 6 Salvo diverso accordo scritto qualora la merce venga pronta per la consegna pri ma della data stabilita il FORNITORE potr effettuare la spe...

Page 272: ...re qualora il prodotto sia stato mano messo e o riparato non dal FORNITORE e comunque da persone non autorizzate per iscritto dal FORNITORE stesso 10 4 Le sostituzioni e o riparazioni in ga ranzia ven...

Page 273: ...laws fires floods delays resulting from the failed incendi inondazioni ritardi per mancata con segna da parte di fornitori e o vettori ed ogni altra causa al di fuori del ragionevole controllo da part...

Page 274: ...enti la loro esistenza validit efficacia interpretazione esecuzione etc saranno soggette alla giurisdizione esclu siva del Foro di Reggio Emilia Italia 17 2 The contract shall be rescinded if the CUST...

Page 275: ...G SERVICE LITERATURE 52 60 SWING SERVICE LIT Sel 0007 DOC Rev 1 5200 SERIES 6000 SERIES SWING DRIVE SERVICE MANUAL...

Page 276: ...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 277: ...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 278: ...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 279: ...4 5200S...

Page 280: ...5 6000S...

Page 281: ...n its approach to the boom head The switch remains closed until the hookblock overhaul ball raises a weight that connects to the hoist rope which opens the switch Once open the switch sends a signal t...

Page 282: ...n and press the bottom right button NOTE The yellow arrow denotes the selection knob and contains the same functionality as using the soft keys The operator turns the knob left or right to scroll thro...

Page 283: ...ns on either the bottom left or bottom right of the screen to get to the rigging line screen This screen allows the operator to select the parts of the line rigged Select one or two parts and then pre...

Page 284: ...oad line is unsafe and is NEVER allowed If the operator selects the Platform Removed option this screen asks the operator to confirm selection and press the bottom right button B If the operator selec...

Page 285: ...firm their selection the following screen appears This screen indicates the crane is ready for operational use If at any time the operator makes a selection in error simply press the X button and the...

Page 286: ...LMI Setup EEC 0002 V1 0 LMI Setup Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0002 1 0 Created Document 1 9 15...

Page 287: ...Document number S071 Revision C Date 2011 10 17 Document type Manual SERVICE MANUAL Remote Control System RC400 G2B G3B...

Page 288: ...ational indications 23 6 1 Central Unit status and operational indications 23 6 2 Central Unit LED display 24 6 3 Portable Control Unit status indications 25 7 Error code indications 26 7 1 General de...

Page 289: ...Scanreco AB G2B Standard Cable kit chapter added Minor changes in document Name Rule Internal Only within own organization Document information Revision history 1 General Synopsis Scanreco Remote Con...

Page 290: ...5 G3B Central Unit Type 2 NAFTA 1 00 n a G2B Portable Control Unit Maxi Linear 1 07 n a G2B Portable Control Unit Maxi Joystick 1 07 n a G2B Portable Control Unit Mini Linear 1 07 n a G2B Portable Con...

Page 291: ...serial number for verification Below illustrations shows where these numbers can be located Always check and verify product item and serial no before any type of service is commisioned refer to custom...

Page 292: ...chaser to determine the suitability of any Scanreco remote control product for an intended application and to insure that it is installed and guarded in accordance with all country federal state local...

Page 293: ...width or protocol steered found on the market In its basic form the remote control system is comprised of a portable control unit with manoeuvre levers for proportional control and switches for ON OF...

Page 294: ...cables digital outputs 1 8 Cable kit valves cables analogue outputs 1 3 2 Schematic overview of Scanreco RC 400 G2B 1 4 2 3 5 Below illustrations shows a typical system consistory for the G2B system...

Page 295: ...Charger 10 30 VDC 1 4 Battery cassette NiMH 7 2 VDC 2 5 Manoeuvre cable 10 meters 1 3 3 Schematic overview of Scanreco RC 400 G3B 1 4 3 5 Below illustrations shows a typical system consistory for the...

Page 296: ...ted The illustrations below aims to delare all entities mentioned in this document Insert battery or connect cable connector 1 Twist up the Stop button 2 Press the On button once LED Power will be ill...

Page 297: ...REMOTE mode the Central Unit is controlled by the PCU in MANUAL mode the system supplies only the DV output intended for Dump valve supply the complete system is by passed allowing manual operation o...

Page 298: ...ting the Central Unit G3B The Central Unit G3B is supplied thru Cable A and requires external power switching see chapter 5 8 for further info The Central Unit G3B exists in 2 different versions one w...

Page 299: ...connector Portable Control Unit Pin assignments Central Unit G2B G3B Pin Assignments 1 1 1 2 3 4 2 2 3 3 4 4 5 5 Brown Data Brown Data White GND White GND n a n a Blue RS 232 TX Black RS 232 RX Grey...

Page 300: ...AXI Joystick MINI Linear and MINI Joy stick are by default assigned an analogue output on the Central Unit below figures declares the standard assignments PCU MAXI Linear standard assignments PCU MAXI...

Page 301: ...Linear standard assignments PCU MINI Joystick standard assignments 1A 1B 1A 2A 2A 5A 3A 3B 5B 6B 4B 4A 6A 2B 2B 1B 3A 3B 4A 4B 5A 5B 6A 6B Document type Document number Page Rev Service Manual S071 C...

Page 302: ...nput 32 Purple 5 6 Digital input 05 Orange 6 5 Digital input 31 Black 7 4 Digital input 07 White 8 3 Digital input 04 Blue 9 2 Digital input 03 Green 10 1 Digital input 01 Yellow 11 Supply output Red...

Page 303: ...31 Black 7 4 Digital input 07 White 8 3 Digital input 04 Blue 9 2 Digital input 03 Green 10 1 Digital input 01 Yellow 11 Supply output Red 12 No Type Colour code Amp Pin no Common GND Black 1 20 Digit...

Page 304: ...osition Type Central Unit 301 3 way detent toggle Digital output 1 Digital output 1 Parallel with ana logue input movement AutoRPM engine feature 302 3 way spring back toggle Digital output 2 Digital...

Page 305: ...C 10 Digital input 3 9 Digital input 2 8 Digital input 1 7 GND 6 Digital output 6 5 Digital output 5 4 Digital output 4 3 Digital output 3 2 Digital output 2 1 Digital output 1 1 Supply 1 DV 2 GND 2 D...

Page 306: ...5 2 Module supply voltage 21 6 Module supply voltage 6 2 Regulated supply voltage 22 6 Regulated supply voltage 7 2 GND 23 6 GND 8 2 Error input optional 24 6 Error input optional 9 3 Module supply vo...

Page 307: ...specification for fur ther information The Central Unit G2B is not equipped with a specific STOP loop connection if needed a digital output are in such cases assigned if more info is required refer t...

Page 308: ...onnection Pin no Colour Function 1 Brown DV2 2 White LOOP1_OUT 3 Blue LOOP1_IN 4 Black LOOP2_OUT 5 Grey LOOP2_IN Cable C 3 meters 5 pole male M12 connector 5 pole male M12 connector 5 pole female M12...

Page 309: ...operator controlled functions and is then triggered by an event the type of indication will be declared for each event further in this document 6 1 Central Unit status and operational indications The...

Page 310: ...radio frequency locked on channel 6 Communication link via radio frequency locked on channel 7 Communication link via radio frequency locked on channel 9 Communication link via radio frequency locked...

Page 311: ...o step 5 active Note that these LEDs are used also for error code alarms and operator controlled functions and are then triggered by an event the type of indication will be declared for each event fur...

Page 312: ...atus and indicate the appropriate error code via the LED display the Central Unit will then reset to operational mode if possible Below example flowchart on behaviour This fault sequence will take an...

Page 313: ...n Remove terminal connector and reset system 02 03 Safety switch error Safety switch output read back error incorrect voltage High instead of Low System will self reset Remove all terminal connectors...

Page 314: ...controller 08 03 CAN physical layer error Bad communication transmission System will self reset Check CAN connections Check other nodes on bus and reset system 08 04 CAN PDO length exceeded PDO lengt...

Page 315: ...VDC System will self reset Check power supply and supply connections 98 n a Undefined PCU error Undefined error in PCU Diagnose PCU via TEST MODE 99 n a Undefined CU error Undefined error in CU Syste...

Page 316: ...ined by the external status LED and or the first 7 segment on the LED display during radio communication When an optimal communication is acquired the external Status LED will be fixed green and the C...

Page 317: ...direc tion 15 times or until the Central Units LED display indicates D i 0 0 5 Diagnostics mode is now active The diagnostics mode consist of 8 different menus that can be toggled using the on button...

Page 318: ...is actuated display responds by indicating related output for 1 second In example 1 A 2 A 3 A 4 A 5 A 6 A 7 A 8 A 1 b 2 b 3 b 4 b 5 b 6 b 7 b 8 b Followed by the current value in correspondance to le...

Page 319: ...egistered by the Central Unit refer to chapter 7 for error code information The LED display will toggle the logged error codes continuously Hold Micro toggle in LEFT position for 5 seconds E r C L is...

Page 320: ...ts program is presented in two sequences continuously repeated In example Press On button eight times from position D i 0 0 D i 0 8 is displayed followed by the current firmware version V n n n The cu...

Page 321: ...changes caused by this The system has 4 levels of authorisation Authorisation level 1 Installer Change direction of analogue movement Authorisation level 2 Well trained installer well trained service...

Page 322: ...the Central Units LED display indicates P o 0 0 5 Online programming mode is now active The online programming mode consist of 15 different menu s that can be toggled using the On button once a menu i...

Page 323: ...nt Available values 0 or 1 Normal or reversed direction When actuating a lever joystick the LED display will indicate which output that is active and its cor responding direction Example 1 b 0 1 meani...

Page 324: ...ed 10 3 9 Position 09 Micro speed SET2 For individual adjustment of 1st step micro speed Available values Values ranging from 1 100 When activating a lever joystick the LED display will indicate which...

Page 325: ...d Available values Values ranging from 1 100 When activating a lever joystick the LED display will indicate which output that is active and its corresponding start speed For individual adjustment of s...

Page 326: ...until the Power LED is distinguished approx 10 times 4 Portable Control Unit Self Test Mode is now active Each time a switch is activated manoeuvred the control unit should beep Each time a manoeuvre...

Page 327: ...he deactivate 6 When ID programming is completed remove the cable control insert battery pack and test run the system application with radio control If the initial short beep is followed by one long b...

Page 328: ...coils Typically two sets of cable kits are required one for power supply and digital functions and one for analogue functions see below illustration 1 Left side Supply Cable kit for power supply and...

Page 329: ...chapter 5 7 for assignments Power supply See chapter 5 5 5 6 for assignments DV Dump Valve output Hirchmann GDM3009 1 DV 2 DV Cable specification Cable Lenght Wires x Dim 2 5 meters 2 x 2 5mm DV 2 met...

Page 330: ...ation Cable Lenght Wires x Dim 1 8 2 meters 3 x 0 5mm 4 3 1 MODULE SUPPLY 1 MODULE SUPPLY 1 1 2 2 3 3 2 3 GND 3 GND 1 2 REGULATED SUPPLY 2 REGULATED SUPPLY WIRE WIRE Girder cable alignment 13 3 Standa...

Page 331: ...ann GDM3009 1 2 3 Cable specification Cable Lenght Wires x Dim 1 8 2 meters 3 x 0 5mm 1 PWM A 3 PWM B 2 PWM WIRE Girder cable alignment 1 2 3 13 3 Standard valve cable kits for HAWE For connection of...

Page 332: ...4A 4B 2A 2B 5A 5B 3A 3B 6A 6B 7A 7B 8A 8B CONNECTOR AMP JPT 2 pol CONNECTOR Hirchmann GDM3009 1 2 Cable specification Cable Lenght Wires x Dim 1 8 A B 2 meters 2 x 0 5mm 2 PWM 2 PWM 1 PWM 1 PWM WIRE W...

Page 333: ......

Page 334: ......

Page 335: ...ng requirements REL 10 I 10 000 PSI INTENSIFIER This system combines the power of a high pressure intensifier with the simplicity of a fixed position three way control valve This revolutionary intensi...

Page 336: ..._______ PHONE _______________________ FAX___________________________ SERIAL NUMBER ______________________________________________ DATE OF PURCHASE___________________________________________ DEALER NAM...

Page 337: ...efore Disassembly 17 REL 10 I Drawings Parts Lists Fig 1 2 18 19 REL 10 I Drawing Parts List Fig 3 20 PVA 00L3 Control Valve Drawing Parts List Figure 4 21 Maintenance Record 22 Manufacturer Contact I...

Page 338: ...A BIG JOB A BIG JOB This revolutionary intensifier will increase line pressure to a maximum of 10 000 psi and is fully compatible with all high pressure hydraulic equipment i e Crimping Cutting Speari...

Page 339: ...i and is fully compatible with all high pressure hydraulic equipment The PVA 00L3 single acting control valve provides 3 way control Advance Neutral Retract direct from the high pressure source Togeth...

Page 340: ...n line control valve When using the double acting connection REL 10 I SA D provides quick advance and retract for high pressure 10 000 psi double acting tools combined with the versatility and efficie...

Page 341: ...irements above ADJUSTABLE MOUNTING BASE DOUBLEACTING HIGHPRESSURECONNECTIONS 1 4 N P T RETURNPORT FORDOUBLEACTING TOOLCONNECTION LOW PRESSURE PORTS TO POWER SUPPLY PVA 00L3 SINGLE ACTING CONTROL VALVE...

Page 342: ...to avoid injury from flying debris or hydraulic oil leaks Failure to do so can result in serious personal injury Hard Hat WARNING Always wear a hard hat to avoid injury from falling debris Failure to...

Page 343: ...OSESAND COUPLINGS before each use Repair or replace if any cracking leakage wear or damage is is found Worn or damaged hoses may fail resulting in personal injury or property damage CLEAR WORK AREA of...

Page 344: ...ose proximity could be injured and property damaged if the tool were to malfunction This tool should always be used within the limits and purposes stated by the product manufacturer Abuse or usage bey...

Page 345: ...C 40 minimum FLASH POINT 340O F min 170O C min POUR POINT 30O F min 34O C min HOSES AND FITTINGS There exists the potential for shock in using anything other than certified nonconductive hoses and hyd...

Page 346: ...HYDRAULIC FLOW IS TURNED OFF 3 ALWAYS ENSURE CONNECTORS ARE CLEAN 4 CONNECT HOSES TO HYDRAULIC SUPPLY 5 ENSURE THAT THE VALVE IS IN THE RETRACT POSITION 6 CONNECT THE REL 10 I SA INTENSIFIER 7 ENSURE...

Page 347: ...tool action allowing for confirmation and repositioning as needed When relief valve popping occurs desired pressure has been achieved and operation should be complete Repeat as necessary NOTE Holding...

Page 348: ...firmation and repositioning as needed When relief valve popping occurs desired pressure has been achieved and operation should be complete Repeat as necessary NOTE Holding valve handle in the ADVANCE...

Page 349: ...ete NOTE Holding control valve in theADVANCE position after relief valve has popped will cause unnecessary wear on relief valve and pump assembly Use the in line control valve to open or retract tool...

Page 350: ...via hydraulic fluid dirty connections or accumulation of sediment SCHEDULED MAINTENANCE The life reliability and safety of the tool is dependent on proper maintenance DAILY MAINTENANCE Clean all surf...

Page 351: ...surface covered with towels or wipers so as to have a clean space for the disassembled parts Inspect each part during disassembly for wear scratches and cuts Discard the worn or damaged parts and repl...

Page 352: ...18 REL 10 I INTENSIFIER DRAWING 1 REL 10 I INTENSIFIER DRAWING 2 Reference Parts List on Next Page Reference Parts List on Next Page...

Page 353: ...32 12783 2 BALL 3 16 34 12786 4 SCREW 39 12791 5 1 16 NPT PLUG 40 12792 1 1 4 NPT PLUG 42 12794 1 1 2 NPT PLUG 45 12741 1 O RING REAR SEAL REF PART QTY DESCRIPTION 2 12731 1 CAM SHAFT ASSEMBLY 6 12736...

Page 354: ...RN 30 12781 2 MOUNT 36 12788 4 SCREW SCFH 37 12789 6 SREW SHCS 38 12790 6 LOCKWASHER 43 12795 4 PINS DRIVE 44 12796 4 DOWELS SUPPLIED IN SEAL KIT K3195 SAPRTLST 12 20 96 DRAWING 3 PARTS LIST Reference...

Page 355: ...1 END BLOCK 18 35018 1 STUD 19 35019 1 PLASTIC BALL 20 35020 1 SCREW BHSC 21 35021 4 SCREW SHCS 22 35022 2 PLUG NOT SHOWN 23 35022 1 SHAFT SEAL SUPPLIED IN SEAL KIT PART R35100 DRAWING 4 PARTS LIST T...

Page 356: ...215 357 9193 Visit us on the web at www Reliable Equip com If you have any questions regarding the information found in this manual please contact RELIABLE EQUIPMENT at the address phone or fax number...

Page 357: ...Appendix B Parts Index ELLIOTT Built for You E190 Manual B 1...

Page 358: ...4 Platform Range Diagram Main Boom Full Rotation 5 5 1 Platform Range Diagram Main Boom Over Rear 5 5 3 Platform Safety Warnings 4 3 Plumbing Schematic Above Rotation 5 4 3 Plumbing Schematic Below R...

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