Elliott Traffic Safety Service L60 Operator'S Manual Download Page 1

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Operator’s Manual

L60

Traffic Safety Service, LLC

601 Hadley Road

South Plainfield, NJ 07080

Phone: 908-561-4800

Fax: 908-561-3800

E-mail: [email protected]

Summary of Contents for Traffic Safety Service L60

Page 1: ...Operator s Manual L60 Traffic Safety Service LLC 601 Hadley Road South Plainfield NJ 07080 Phone 908 561 4800 Fax 908 561 3800 E mail info trafficsafetyservice com...

Page 2: ...Updated March 10 2020...

Page 3: ...6 13 Platform Jib Operation Aerial Device 6 14 Lift Capacities 6 15 Wire Rope Care Maintenance 6 16 Required Inspections 6 17 Inspection Record 6 18 Inspection Checklist 6 19 Stability Load Test 6 20...

Page 4: ...8 12 Hi Reach Weld Repairs 8 13 Maintenance Schedules 8 14 Troubleshooting 8 15 COMPONENT SERVICE MANUALS Winch Service Manual Tulsa 506W 9 1 HFG938D Swing Drive 9 2 Jib Winch Service Manual Pullmaste...

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Page 6: ...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 7: ...D CHARTS NEVER EXCEED PLATFORM CAPACITY AND AREAS OF OPERATION BEWARE OF ADVERSE WEATHER AND GROUND CONDITIONS This manual must be retained with this aerial device for use by subsequent operating pers...

Page 8: ...eproductive harm Always start and operate the engine in a well ventilated area If in an enclosed area vent the exhaust to the outside Do not modify or tamper with the exhaust system Do not idle the en...

Page 9: ...ent shipped from Elliott after 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...

Page 10: ...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 11: ...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 12: ...ety hazard and therefore shall not be made without written approval from Elliott Equipment Company Use only Elliott factory approved parts to maintain this equipment If this aerial device is rebuilt o...

Page 13: ...ts and distances Riggers must also demonstrate the ability to select and properly use lifting tackle It is the responsibility of the management and supervisor to see that riggers are properly trained...

Page 14: ...ne designated signal person The operator however shall take a stop signal from anyone Signal Person s Responsibilities The signal person must have good vision and sound judgment The signal person must...

Page 15: ...sponsibility of all crewmembers to report any unsafe condition or practice that is recognized to the job supervisor Everyone who works around aerial devices must obey all warning signs and watch out f...

Page 16: ...2 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 1 Doc update 1 26 15...

Page 17: ...f 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 18: ...dealer or 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...

Page 19: ...neumatic systems for observable deterioration or excessive leakage d Fiberglass and other insulating components for visible damage or contamination e Missing or illegible operational and instructional...

Page 20: ...aerial 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 s...

Page 21: ...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 22: ...alent 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 appli...

Page 23: ...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 manuals...

Page 24: ...characteristics 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 pe...

Page 25: ...the operator 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 an...

Page 26: ...levated except when the aerial device is being used in accordance with ANSI A92 2 Mobile Operator E Loading Any loading which includes a horizontal load shall be avoided unless the mobile unit is desi...

Page 27: ...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 28: ...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 covered s...

Page 29: ...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 Installer...

Page 30: ...ration 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 limited t...

Page 31: ...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 32: ...per ANSI SAIA A92 2 Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0144 1 0 Template update 7 29 15 Tech Spec 1 2 Content Update anemometer...

Page 33: ...ned to monitor the distance from the aerial device and load 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...

Page 34: ...in sudden structural failure or tipping Side loading occurs when Rapidly starting and stopping swing operations operating out of level dragging or pulling loads sideways or operating in high winds K A...

Page 35: ...the winch drum at all times In some multi parted cases the hook block cannot be lowered to the ground if the boom tip is too high before all rope is unspooled from the winch P Always keep space betwee...

Page 36: ...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 Spec 1 2 Content update 8 6 15 Tech Spec 1 3 Content update 9 6 16 Tech Spec...

Page 37: ...Platform Safety hireach EEC 0145 V1 1 Platform Safety...

Page 38: ...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 39: ...erratic winds electric storms snow ice sleet or other adverse weather conditions that could affect the safety of personnel or property If high winds or adverse weather conditions are encountered do n...

Page 40: ...d gloves in conditions where a hazard of injury exists C Shall be responsible for complying with the requirements of the standards as they relate to Aerial device capability Rated load constraints Ope...

Page 41: ...rm M Set all brakes and locks on the aerial device after positioning of the personnel platform and before any personnel platform work N Move the platform under controlled conditions O The operator sha...

Page 42: ...d while the platform is in use H Shall always stand firmly on the floor of the platform and not climb or sit on the rails of the platform Nor should platform personnel use planks ladders or any other...

Page 43: ...ti two block override flag onto the anti two block switch E Follow instructions in the Platform Installation and Operation section of this manual Operation A When setting up at a job site make sure al...

Page 44: ...pproximate angle before extending the boom and moving the personnel platform to the working position When the boom is near full extension or elevated close to 80 controls must be applied very gently t...

Page 45: ...tform Safety Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0145 1 0 Template update 8 7 15 Tech Spec 1 1 c o changes 3021163 2 13 18 Tech S...

Page 46: ...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 47: ...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 48: ...ft Right Front A Outrigger Lever Activate lever UP or DOWN to retract extend the left right front outrigger D Engine Throttle Switch E Hydraulic Selector Valve pull OUT to divert hydraulic control to...

Page 49: ...Controls Hi Reach MHA EEC 0146 V1 0 Outrigger Controls HiReach MHA Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0146 1 0 Created Document...

Page 50: ...t right rear outrigger jack D Left Right Front Outrigger Jack Lever Activate lever UP or DOWN to lower raise the left right front outrigger jack E Engine Throttle Switch F Hydraulic Selector Valve pul...

Page 51: ...MHMH EEC 0086 V1 1 Outrigger Controls HiReach MHMH Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0086 1 0 Created Document 2 6 15 Tech Spec...

Page 52: ...truck manuals for operating instructions CAUTION Driving truck with PTO engaged may damage hydraulic pump A Platform Leveling Lever Push Forward IN position to raise platform towards boom Pull back O...

Page 53: ...s on the chart cannot be telescoped However it is safe to attempt to telescope all loads within the chart limits E Platform Rotation Lever Push Forward RIGHT position turns platform right clockwise Pu...

Page 54: ...the function cut outs when switch is held in the UP override position Down Normal A2B operation resumes when momentary switch is released to a neutral normal position C Winch Speed Switch Option not...

Page 55: ...to operate pump functions Down Release momentary switch to neutral off position to stop emergency pump I Chassis Engine Speed Control Switch Up press switch to increase truck engine speed to high set...

Page 56: ...ng radius for the rated loads on the chart Anti Two Block System If a two block condition exists the telescope out winch up and boom down functions will be disabled Immediately correct this condition...

Page 57: ...ols HiReach Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0099 1 0 Created Document 2 27 15 Tech Spec 1 1 Content update 5 29 15 Tech Spec...

Page 58: ...f the levers or switches needs to occur for aerial device movement To move the aerial device boom or jib winch functions controlled with joystick the Upper Control Master Switch must be in the ON posi...

Page 59: ...w Maintain Switch HIGH Setting this switch at the HIGH position full activation of the joystick will move the control valve section to its maximum output LOW Setting this switch at the LOW position fu...

Page 60: ...s still turning over the truck will restart K Upper Control Master Switch Emergency Stop Button Twist and release button to operate HiReach Push button to disable HiReach L Anti Two Block Override Mom...

Page 61: ...Operating Controls EEC 0175 V1 0 Operating Controls HiReach Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0175 1 0 Created Document 4 13 16...

Page 62: ...n the beam is fully extended the target is directly under the proximity switch which senses the cam moves the switch contacts and the LED indicator is illuminated Full span indication labels or green...

Page 63: ...ic Rotation Lockout EEC 0241 V1 0 Automatic Rotation Lockout Optional Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0241 1 0 New Document 1...

Page 64: ...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 65: ...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 66: ...0 Platform Removal Installation EZR Removing EZR Platform A With the boom slightly extended lower the boom and lightly set the platform on a flat surface B Disconnect all hydraulic connections between...

Page 67: ...k them in the OPEN position D Tilt the leveling bracket downwards using platform leveling OUT until the rotation bracket clears the top plate of the platform receiver then retract the boom several inc...

Page 68: ...both platform locking pins in the OPEN position Make sure there are no hoses or cables hanging in front of the receiver area of the platform B Tilt the leveling bracket slightly downwards and position...

Page 69: ...top of the rotation bracket starts to enter the platform receiver Raise the boom slowly until the rotation bracket starts to contact the top plate of the platform receiver D Tilt the leveling bracket...

Page 70: ...es aerial EEC 0176 V1 0 Platform Removal Installation EZR E Flip down both platform locking pins to engage them in the LOCK position F Reconnect all hydraulic connections between the platform and rota...

Page 71: ...t Capacities aerial EEC 0176 V1 0 Platform Removal Installation EZR Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 076 1 0 New document 4 13...

Page 72: ...m Do not lift loads with the lift assist latch engaged or with the post pin removed Always install the post pin and disengage the lift assist latch before operation Do not attempt to lift loads with t...

Page 73: ...vices such as slings and shackles shall be considered part of the load and must be deducted from the rated load Maintain at least five full wraps of wire rope around the winch drum at all times Do not...

Page 74: ...EEC 0178 V1 1 Platform Jib Safety Aerial Device Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0178 1 0 New Document 4 18 16 Tech Spec 1 1 c...

Page 75: ...yment Procedure A Unstow the jib and remove the angle pin B Reach down and grab the jib near the middle Lift up and allow the jib to slide backwards along the track as it swings upwards Once the rear...

Page 76: ...er section to the desired length and reinstall the pin D Pay out the winch loadline and reeve loadline through the stow loop on the jib post and over the front and rear sheaves Install the cable retai...

Page 77: ...tion Aerial Device Raising Procedure A To raise the jib follow steps A and B from the Jib Deployment Procedure B Once the jib is in the lower and retracted position pay out the winch loadline and remo...

Page 78: ...ich is NOT the final position The post pin cannot be installed in this position When this occurs rotate the jib counterclockwise until the latch disengages and continue to lift the jib while rotating...

Page 79: ...ial Device E Reinstall the post pin F Pull the lift assist latch to disengage and the jib post will drop down slightly and onto the post pin G The jib is now in the raised position Follow the remainin...

Page 80: ...and pin the jib in the retracted position A Lift up on both the jib and jib post until the lift assist latch clicks to engage The post pin will now be loose and can be removed WARNING Be careful not...

Page 81: ...Using both hands to support the jib and jib post slowly rotate the jib counterclockwise until the lift assist latch disengages and the jib starts to lower Rotate the jib straight again while lowering...

Page 82: ...he jib must be in the lower and retracted position before it can be stowed B Remove the loadline and hook it to the stow loop on the rear of the jib post Winch UP slowly until the loadline starts to t...

Page 83: ...C Remove the angle pin Pull the jib forwards slightly and slowly allow the jib to swing downwards while also sliding forwards in the track D Once the jib is hanging down in the stowed position reinst...

Page 84: ...Operation Aerial Device EEC 0177 V1 0 Platform Jib Operation Aerial Device Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0177 1 0 New Docu...

Page 85: ...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 86: ...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 87: ...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 update 8 3 15 Tech Sp...

Page 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...Inspection A Frequency Prior to operating an Elliott aerial device complete a walk around inspection and operation check on a daily basis These should be a common practice for any safety conscious equ...

Page 95: ...when released E Bearing and Boom Inspection Ensure the turntable bearing and pinion are not damaged and has no loose or missing parts and check for proper lubrication Additionally ensure there is no...

Page 96: ...oot of additional clearance is required for every additional 30 000 volts or less Set up the unit in such a manner as to allow for the boom to sway rock or sag and for movement of the hoist line and e...

Page 97: ...controls B Set Outriggers If the unit is not on firm ground place ground boards of suitable size under the outrigger pads This will help distribute the weight of the unit making it more stable Do not...

Page 98: ...ront to rear check the level bubble Continue to adjust until the bubble is in the center of the indicator Lower the front stabilizer on units so equipped while watching under the vehicle to prevent lo...

Page 99: ...Level Platform Leveling System Raise the boom to the horizontal position and operate the leveling valve in both directions to circulate the oil in the closed leveling system and to purge air from the...

Page 100: ...ll function and it provides an emergency stop means when the operator releases the switch enable collar or trigger valve thus stopping all control functions Do not block or disable this safety feature...

Page 101: ...ravel locking pin E Stop the engine turn on the emergency pump and raise lower boom to test emergency pump When finished turn off the emergency pump Operation of Aerial Lift A Personal Protection Equi...

Page 102: ...tform both feet must be firmly positioned on the deck Lower controls are not to be used to position personnel in the platform Platform personnel shall position the platform using the upper controls as...

Page 103: ...unit must always be positioned to allow the unit to be re leveled so that the level bubble is within the center marks At no time can the unit be operated with the turret box more than one percent 0 56...

Page 104: ...d attach the cable hook to the top bolt of the snatch block or the top thimble of the down haul ball Models with a 2 000 lb winch have a down haul ball only Models with larger winches have a snatch bl...

Page 105: ...to rotate under load D Test the Anti Two Block System The anti two block system must be functioning properly prior to using the aerial device Raise the boom to the level position Slowly extend the bo...

Page 106: ...or other adverse weather conditions that could affect the safety of personnel or property If high winds or adverse weather conditions are encountered do not use the equipment If high winds or adverse...

Page 107: ...ust be cribbed with suitable material to allow for leveling The unit must always be positioned to allow the unit to be re leveled so that the level bubble is within the center marks At no time can the...

Page 108: ...t idle speed for 70 percent of 7 GPM Connect the open center tool to the quick disconnects before turning on the tool circuit NOTE Running the tool circuit with no open center tool connected will dead...

Page 109: ...d inspection criteria is essential for determining the frequency to disassemble and inspect the boom The recommended seven year disassembly and inspection does not remove the requirement for daily wee...

Page 110: ...on History Revision Notes Revision Date Tech Spec EEC 0088 1 0 New Document 2 10 15 Tech Spec 1 1 Content Update 5 28 15 Tech Spec 1 2 Content Update 8 7 15 Tech Spec 1 3 Content Update 4 19 16 Tech S...

Page 111: ...gned records shall be made of yearly inspections and tests and retained for a period of five years Reference ANSI A92 2 The Operations Maintenance Manual lists the Lubrication Chart Daily Weekly and M...

Page 112: ...Mounting Leaks 2 P T O Operation controls installation of decals 3 P T O Drivelines set screws lubrication 4 Pump Mounting connections leaks 5 Pump heat shield condition mounting 6 Hydraulic reservoir...

Page 113: ...gearboxes Mounting leaks alignment of gears lube level 17 Bolts torqued according to specs in manual 18 Rotation bull gear bearing Mounting wear excessive movement 19 Check upper lower bearings on mai...

Page 114: ...s check for loose fasteners 29 Main lift cylinder Leaks hosing Check for damage on shaft 30 Main lift cylinders Pilot checks brackets welds 31 Telescope cylinder Pins bushings 32 Telescope cylinder Le...

Page 115: ...on Condition 42 Winch Load line hook weight 43 Winch gear box lube 44 Angle indicators capacity charts 45 Winch cable guards 46 Boom tip Broken welds 47 Digger head Attachment welds hosing leaks 48 Di...

Page 116: ...hts wiring Indicate location of fuse with decal 58 Check grab handles Cracked welds attachment 59 Mud flaps Mounting condition 60 Rear bumper attachment cracked welds etc 61 Check trailer control outl...

Page 117: ...Item N A OK Remarks 68 Outrigger pin collars welded 69 Check welds on torgue frame turret box 70 Turret 71 Check tire pressure and adjust to recommended P S I 72 Replace high pressure return filter el...

Page 118: ...Inspection Checklist EEC 0135 V1 0 Inspection Checklist Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0135 1 0 Template update 7 7 15...

Page 119: ...TEST SUMMARY REF OSHA 1910 180 and SAE J765 Testing Agency Location Make HiReach Model Serial No Condition New Used Hours Miles Mounting Type Size Tires Size Ply Pressure PSI Boom Type Length Ft Platf...

Page 120: ...ity Load Test EEC 0134 V1 1 Stability Load Test Req d for Non Factory Install Aerial Devices BALANCE POINTS Position of With Outriggers Superstructure Load lb Radius ft Remarks Test Technician Date of...

Page 121: ...ability Load Test Req d for Non Factory Install Aerial Devices Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0134 1 0 Template update 7 2 1...

Page 122: ...etting Bar Flow GPM Flow L min Operating Time Seconds Operating Speed FPM Platform Leveling Up Down 2350 162 1 3 4 9 N A Boom Up Down 2500 172 11 41 6 32 22 30 4 Up 24 8 Down Tele Out In 2500 172 11 4...

Page 123: ...Performance Category Standard Line Pull 4 000 lb Wire Rope 3 8 6 x 37 IWRC IPS Breaking Strength 14 000 lb Cable Length 180 ft Winch Line Pull Line Speed Layer Lb Kg FPM MPM 1 4 131 1874 77 23 2 3 77...

Page 124: ...Specifications Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0105 1 0 Doc creation 03 13 15 Tech Spec 1 1 Content update 7 22 15 Tech Spec...

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Page 135: ...ile 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 t...

Page 136: ...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 137: ...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 138: ...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 139: ...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 140: ...Bolt Torque EEC 0016 V1 2 Bolt Torque...

Page 141: ...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 142: ...nto opening when truck engine is running and or boom sections are moving 4 Grease fittings for the hoist cylinder pivots are on the middle of the cylinder end mounts Boom pivot grease fittings are on...

Page 143: ...tly below 0 F requires that fluid be used which has a lower viscosity Any high quality brand of ISO grade 15 hydraulic fluid may be used This fluid must be changed as soon as temperatures are consiste...

Page 144: ...ppropriate plug on the side of the gear case see specific location in the parts section of this manual If the oil level is below the plug add Multi purpose EP SAE 80 140 until it reaches the level of...

Page 145: ...ers 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 stabiliz...

Page 146: ...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 147: ...he 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 the bre...

Page 148: ...l 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 12 15 Tech Spec 1 2 Conten...

Page 149: ...should be set to operator s preference NOTE THIS ACTS AS THE THREASHOLD HI A B You should adjust this trim pot next This is the maximum PWM signal out of controller outputs A and B that is applied to...

Page 150: ...elief cartridge on the master cylinder counterclockwise in turn increments until the platform can be leveled manually Do not turn this valve down more than required or it may cause the platform to lag...

Page 151: ...tform manually If the platform lags when booming down turn the retract relief cartridge on the master cylinder clockwise in turn increments until the platform keeps up with the boom Do not turn this v...

Page 152: ...Platform Level System EEC 0137 V1 0 Platform Leveling System...

Page 153: ...Platform Level System EEC 0137 V1 0 Platform Leveling System Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0137 1 0 Template update 7 20 15...

Page 154: ...tivate the manual leveling retract switch until all air is removed from the retract hose 6 Tighten the retract hose fitting at leveling block 7 Position Master Cylinder so that rod can be fully extend...

Page 155: ...tend switch until both slave cylinders are fully extended This forces any air out of the rod side of the slave cylinders back into the long retract hose that runs through the catrac system 18 Loosen b...

Page 156: ...Platform Level System EEC 0136 V1 0 Air Bleed Platform Leveling System Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0136 1 0 Template upda...

Page 157: ...akage between the cylinder case and head indicates a worn O ring seal Rebuild the cylinders by replacing the O rings CAUTION All hydraulic equipment will wear rapidly if dirt or abrasive materials are...

Page 158: ...ght A Loosen the bolts that connect the gear box to the turret box B Rotate the eccentric ring to move the gear box closer or further from the bearing C Once the gear box is in positon tighten the bol...

Page 159: ...nd press the reset button on the indicator so the red indicator disappears Restart the engine on low engine speed then increase to high speed for 15 seconds Cold oil air in the system or starting the...

Page 160: ...ation EEC 0131 V1 1 Component Evaluation Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0131 1 0 Template update 7 2 15 Tech Spec 1 1 Conten...

Page 161: ...Utilize the 12 volt emergency pump system A Use the emergency pump system to provide hydraulic power B Hold either of the two emergency pump switches located in the platform or at the lower controls i...

Page 162: ...edure EEC 0130 V1 1 Emergency Lowering Procedure Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0130 1 0 Template update 7 2 15 Tech Spec 1...

Page 163: ...the pivot end 5 Remove bolt or snap rings that keeps the holding pin in place and then drive the pin out that holds the piggyback cylinder 6 Remove both the platform and A frame bracket from tip of bo...

Page 164: ...n of boom Slide out tip section of boom with cylinder still attached to tip 12 Once the tip section boom is placed on saw horses attach the overhead lifting device to the piggyback cylinder sticking o...

Page 165: ...ft Capacities aerial EEC 0138 V1 0 Piggyback Cylinder Removal Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0138 1 0 Template update 7 21 1...

Page 166: ...2 Welding procedures practices must be followed per AWS D1 1 American Welding Society Structural Welding Code 3 All structural welds are critical welds whose failure could result in motion of the plat...

Page 167: ...HiReach Weld Repairs EEC 0128 V1 0 HiReach Weld Repairs Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0128 1 0 Template update 7 2 15...

Page 168: ...General Maintenance Proper maintenance of an Elliott HiReach will result in many years of quality service The maintenance program shall require all daily weekly and annual inspections Additionally the...

Page 169: ...ion oil and dirt Clean the fiberglass boom tube s of any contamination and dry thoroughly 7 On equipped units test all limit switches for rotation stop system boom sequence control system boom range c...

Page 170: ...sure bubbles and repair or replace 7 Grease all fittings according to lubrication chart 8 Inspect electrical system for frayed or worn wiring loose connections etc 9 Grease rotation gear and gear box...

Page 171: ...dules EEC 0129 V1 1 Maintenance Schedules Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0129 1 0 Template update 7 2 15 Tech Spec 1 1 Conte...

Page 172: ...while extended upward Leaking holding valve Reset holding valve adjustment Clean or replace pilot check valve Boom DOES NOT APPLY TO SINGLE STAGE CYLINDERS On three section booms mid boom will retract...

Page 173: ...toming out boom retract Reset relief valve or replace relief cartridge Platform Platform is slow to level as boom is raised or lowered Air in leveling circuit Purge system as instructed in manual Plat...

Page 174: ...ssive backlash or play Rotation gear box mounting needs adjustment or gear box bolts are loose or broken Adjust gear box backlash Adjust backlash per instruction in turret assembly chapter of parts ma...

Page 175: ...release Check pressure filter Remove unloader spool and clean if necessary Valves Pressure will drop at low RPM unit is very slow Main pump is worn or trans torque converter is slipping Measure pump...

Page 176: ...mote station continuity check between terminals and to relay in lower terminal box check relay function Replace wire with spare replace switch or relay Electrical Engine kill will not function remotel...

Page 177: ...ill not start with master switches off Defective stop relay Replace kill relay in lower terminal box Electrical Control will start or stop unexpectedly as boom is being extended or retracted from uppe...

Page 178: ...g aerial EEC 0132 V1 1 Troubleshooting Revision History Document type Document Number Revision History Revision Notes Revision Date Tech Spec EEC 0132 1 0 Template update 7 2 15 Tech Spec 1 1 Content...

Page 179: ...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...

Page 180: ...not designed 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 t...

Page 181: ...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 the load from...

Page 182: ...4 HYDRAULIC SCHEMATIC...

Page 183: ...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 184: ...pipe to allow the 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 i...

Page 185: ...s into the three planet pins in the planet set Item 8 and with a piece of chain pull the planet set from the drum Inspect the planet set for wear and repair as needed See Servicing The Planetary Set s...

Page 186: ...g Item 7 properly 7 Install the sun gear Item 16 into the planet set 8 Install a new o ring Item 10 and if necessary bearing Item 5 seal Item 4 into the bearing carrier Item 9 Grease the o ring and se...

Page 187: ...m 17 3 Remove the counterbalance valve from the counterbalance block and inspect the small metering hole located on the side of the cartridge valve to make sure it is not obstructed See Fig 5 Also ins...

Page 188: ...l Item 4 runs for wear If severely worn replace the brake housing 8 Carefully dis assemble the brake driver clutch assembly noting the direction of lockup for the clutch Item 26 The clutch assembly mu...

Page 189: ...ver 17 Install the cover onto the brake housing Item 11 and draw it down evenly alternating between opposite capscrew Item 41 and nuts Item 40 Make sure that the cover is aligned properly with the bra...

Page 190: ...Inspect the pins bearings and gear bores for evidence of wear and replace if necessary 5 Before reassembly be sure to insert the round plates into the carriers 6 To re assemble be careful to line up...

Page 191: ...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 192: ...G 8 6 42184 3 PLANET PIN 8 7 42383 1 PLATE 9 42379 1 BEARING CARRIER 10 33094 2 O RING 42355 1 BRAKE HOUSING 43168 1 BRAKE HOUSING 43509 1 BRAKE HOUSING 11 43512 1 BRAKE HOUSING 42353 1 BRAKE COVER 2B...

Page 193: ...1 O RING PLUG 38 32220 1 PIPE PLUG 39 24943 10 CAPSCREW 40 20271 5 NUT 41 42365 1 CAPSCREW 42 42397 6 CAPSCREW 43 30379 4 CAPSCREW 44 42089 1 ELBOW 45 41838 1 STRAIGHT ADAPTER 46 CONTACT FACTORY 1 TUB...

Page 194: ...16 EXPLODED ISOMETRIC ASSEMBLY DRAWING...

Page 195: ...Repair Manual TABLE OF CONTENTS SAFETY NOTES 2 MAINTENANCE AND SERVICE 3 OIL CHANGE 4 DISASSEMBLY 5 ASSEMBLY 6 TROUBLESHOOTING 7 TORQUE SPECIFICATIONS CHART 8 BILL OF MATERIAL 9 CROSS SECTIONAL ASSEM...

Page 196: ...e gearbox Be aware of and stay clear of all pinch points during operation of swing drive gearbox Boom must be stowed and properly secured while removing swing drive gearbox Avoid shock loads This type...

Page 197: ...ation Some units may be equipped with a grease fitting for lubrication of the output shaft bearings pinion up applications The shaft bearings should be greased sparingly at every 50 operating hours wi...

Page 198: ...the appropriate amount and type of oil and then replace plug and vent See page 6 of this manual for the recommended oil type amount and grade for your application Gearbox oil level inspection is achie...

Page 199: ...ng Item 1 and the cone bearing Item 15 Inspect for wear or damage replace if necessary 7 Remove the gear Item 9 from the housing Inspect for wear or damage replace if necessary 8 Remove the motor from...

Page 200: ...n to spec See Torque Specifications Chart 7 Install the gear Item 9 Ensure the grooves are properly aligned on the teeth of the worm gear 8 Install the thrust washer Item 13 cone bearing Item 15 cup b...

Page 201: ...GEARBOX UNABLE TO ROTATE Possible Solutions 1 Motor failure Remove motor and rotate both directions verifying pressure rotating in both directions is appropriate 2 Gearing Failure See page 13 for serv...

Page 202: ...7 45 106 80 64 20 85 64 51 120 90 72 9 16 12 109 82 65 153 115 92 9 16 18 122 91 73 172 129 103 5 8 11 150 113 90 212 159 127 5 8 18 170 128 102 240 180 144 10 266 200 160 376 282 226 16 297 223 178 4...

Page 203: ...0 KEY 2 150 CONE BEARING 1 160 SCREW SET 1 170 CONE BEARING 2 190 CAPSCREW SH 1 2 2 200 END CAP HFG938D 1 210 O RING 152 2 220 CAP END MOTOR HFG938D 1 230 LOCKWASHER 1 240 CAPSCREW HH 1 2 2 250 CUP BE...

Page 204: ...CROSS SECTIONAL ASSEMBLY DRAWING A A B B 11 6 33 4 2 5 22 21 17 25 8 21 26 29 30 20 28 31 17 25 34 35 38 SECTION A A 37 12 27 11 6 10 23 9 13 15 1 7 3 16 33 4 14 FILL WITH GREASE 19 24 5 SECTION B B...

Page 205: ...11 EXPLODED ASSEMBLY DRAWING 1 28 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 21 22 23 24 25 26 27 2 29 30 31 33 34 35 33 36 37 38...

Page 206: ...WN 250 28UNF HOLE PLUGGED FOR PINION UP REMOVE PLUG TO GREASE AND REINSTALL PLUG GREASE ZERK HOUSING MAT L DUCTILE IRON 1 BACKLASH 005 007 2 UNIT PRIMED WITH GRAY PRIMER 3 GEARBOX FILLED WITH EP 140 O...

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Page 211: ...Chart 5 900 lb 7 7 1 Maintenance Safety 8 1 Maintenance Schedules 8 14 Operating Controls Lower 6 8 Operating Controls Upper 6 9 Outrigger Controls MHA 6 6 Outrigger Controls MHMH 6 7 PQ Controller Ad...

Page 212: ...Appendix B Parts Index ELLIOTT Built for You L60 Operator s Manual B 1...

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