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Elliott Digger Derrick Operation & Maintenance Manual

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

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Summary of Contents for Elliott Digger Derrick

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

  • Page 3: Table Of Contents

    Warranty Statement Change of Ownership SAFETY & OPERATION Safety Responsibilities Responsibilities per ANSI/ASSE A10.31 Nomenclature Platform Safety Jib Safety Road Transport On-Site Setup Operating Controls-Digger Derrick Digger Option Outrigger Controls 4-10 Remote Controls 4-11 LMI Controls 4-12 Lift Capacities 4-13...
  • Page 4 Lubrication Bolt Torque Changing Hydraulic Oil Bubble Level Adjustment Four Section Boom Operation Troubleshooting COMPONENT SERVICE MANUALS Tulsa 1200W Winch Manual Swing Drive Service Manual - Tulsa 6036S LMI Operator's Manual - Greer INSIGHT LMI Calibration and Troubleshooting Manual - Greer INSIGHT Remote Controls (Omnex) Installation/Configuration Manual Eskridge 75 Series Digger-(20K ft-lb 2 Speed High Performance Digger) Hawe Pump (130cc 20K ft-lb.

  • Page 5: Introduction

    If there is a question on application and/or operation, contact the Product Safety and Reliability Department at Elliott Equipment Company. If an Elliott Crane is involved in a personal injury or property damage incident notify the Product Safety and Reliability Department as soon as possible.
  • Page 6 Introduction This manual must be retained with this boom truck for use by subsequent operating personnel. Introduction EEC-0003 V1.2...
  • Page 7 Introduction Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0003 Template 11/05/14 update Tech Spec. Doc update 1/12/15 Tech Spec. Doc update 3/5/15 Introduction EEC-0003 V1.2...

  • Page 8: Warranty

    Subject to the terms and conditions of this warranty, Elliott Equipment Company ("Elliott") hereby warrants all equipment manufactured by Elliott (“Equipment”) to be free from defects in material and workmanship for a period of one year. There are no express or implied warranties, including the warranty of merchantability and fitness for a particular purpose, covering component parts or accessories manufactured or modifications made by someone other than Elliott.

  • Page 9: Change Of Ownership

    4427 South 76th Circle, Omaha, NE 68127 Phone: 402-592 4500 - Fax: 402-935-0313 CHANGE OF OWNERSHIP Please complete this form in full and return to Elliott Equipment Company Date Dealer Dealer Address, City, State, Zip Code Equipment Serial Number Crane Model...

  • Page 10: Safety Responsibilities

    Your safety, along with the safety of all personnel involved with this boom truck, is of utmost concern to Elliott Equipment Company. This manual has been developed with the safety of all personnel that work around, with, or operated this equipment as our primary goal.
  • Page 11 Modifications to any part of this boom truck can create a safety 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 boom truck is rebuilt or remounted, mounting procedures, re-testing, and re-certification are required in accordance to instructions provided by Elliott Equipment Company.
  • Page 12 Safety Responsibilities     Signal personnel must also have good vision and sound judgment, know standard crane signals and be able to clearly give signals. They must have sufficient experience to recognize hazards and signal the operator to avoid them. Riggers must have the ability to determine weights and distances.
  • Page 13 Safety Responsibilities     personnel or property. If high winds or adverse weather conditions are encountered, do not use the equipment. If high winds or adverse weather conditions develop during the lift, terminate the lift. The operator must see that unnecessary people, equipment and material are kept out of the work area.
  • Page 14 Safety Responsibilities     signals must be used unless operator and signal person agree upon an alternative method of communication. Rigger’s Responsibilities Riggers must be able to accurately determine weights and distances, and be able to select and properly use lifting tackle for the requirements of the lift. Riggers are also required to understand and abide by crewmember’s responsibilities.
  • Page 15 Safety Responsibilities     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0052 Template 11/05/14 update Tech Spec. Doc update 1/13/15 Tech Spec. Doc update 3/5/15 Safety Responsibilities EEC-0052 V1.2...

  • Page 16: Responsibilities Per Ansi/Asse A10.31

    The rear of cab to rear axle centerline dimension (CA) i. The minimum axle weights of the mobile unit required for stability 2. Digger Derrick Specifications: a. General: The digger derrick manufacturer shall clearly state in the manual and on the digger derrick the following information: Make and model Serial number III.
  • Page 17 Responsibilities per ANSI/ASSE A10.31     Cautions and restrictions of operation, including the applicable ambient temperature range where the digger derrick may be used VII. Rated load capacity VIII. Platform capacity Multiple configurations Compliance with ANSI/ASSE A10.31 b. Digger Derrick Component Ratings: The digger derrick components...
  • Page 18  Rated hydraulic flow  Rated hydraulic pressure d. Design Voltage and Qualification Voltage: If the digger derrick is the insulating type, the manufacturer shall state the design and qualification voltage in the manual, and the qualification voltage on the identification plate(s).
  • Page 19   no event shall markings be applied which reduce the insulating properties of the digger derrick. Markings on the digger derrick may refer to the unit manuals for additional identification, operation and instructional material. 1. Application of Markings: The manufacturer shall install on each digger derrick the markings or provide these markings with appropriate installation instructions.
  • Page 20 Information related to the use and load rating of the equipment for material handling. d. Information related to the use and load rating of the digger derrick for multiple configurations. e. Information warning the operator that winch lines are not insulating.
  • Page 21 Responsibilities per ANSI/ASSE A10.31     e. Safety devices (each digger derrick shall be operated to verify the function of all safety devices) f. Load hoisting and lowering mechanism g. Auger drive and stowage mechanism When the manufacturer does not complete the mobile unit, such as tests, which can be performed only after complete assembly and installation, shall be the responsibility of the installer.
  • Page 22 C. Vehicle Weight Distribution: The installer shall be responsible for the weight distribution of the completed mobile unit in accordance with the requirements of the digger derrick and the applicable regulations. Allowance shall be made for the weight of readily-removable tools and material specified by the user.
  • Page 23 Rated load capacity charts shall be provided by the manufacturer, or by the installer at the specific instruction of the manufacturer. The rated working load of the winch line may limit the maximum capacity of the digger derrick. Responsibilities ANSI/ASSE A10.31 EEC-0168...
  • Page 24 Responsibilities per ANSI/ASSE A10.31     Rated load capacity charts shall include the number of platforms, platform ratings, the options included, and the winch line rated working load (see ANSI/ASSE A10.31, Section 9.6). Responsibilities ANSI/ASSE A10.31 EEC-0168 V1.0...
  • Page 25 3. Frequent Inspection and Test: items determined by the owner in accordance with the manufacturer’s recommendations for each specific digger derrick shall be inspected for defects. Immediately prior to first use during each work shift, the operator shall perform the following tests and inspections: a.
  • Page 26 Check hydraulic and pneumatic systems for observable deterioration and excessive leakage. g. Check electrical systems related to the digger derrick for malfunctions, signs of excessive deterioration, dirt, and moisture accumulation. h. Check winch lines for any areas of gross damage or deterioration that would result in appreciable loss of original strength.
  • Page 27 Welds, in accordance with the manufacturer’s recommendation. n. Legible and proper identification, operational and instructional markings. o. If the digger derrick is rated as an insulating device, the electrical insulating components and system(s) shall be thoroughly inspected for lack of cleanliness and other conditions that compromise insulation.
  • Page 28 ANSI/ASSE A10.31     p. If the digger derrick is rated as insulating, it shall be tested for compliance with the rating of the digger derrick in accordance with one of the applicable methods as outlined in ANSI/ASSE A10.31, Section 5.4.3.
  • Page 29 E. Modifications: No modifications or additions that affect the stability, mechanical, hydraulic, or electrical integrity or the safe operation of the digger derrick shall be made without the written approval of the manufacturer. If such modifications or changes are made, the capacity, operation and maintenance instruction markings shall be changed accordingly.
  • Page 30 It is the responsibility of the purchaser to notify the manufacturer of the unit model, serial number, and the name and address of the new owner within 60 days.
  • Page 31 Authorization to operate. j. Operator warnings and instructions. k. Actual operation of the digger derrick. Under the direction of a qualified person, the trainee shall operate the digger derrick for a sufficient period of time to demonstrate proficiency in the actual operation of the digger derrick.
  • Page 32 Responsibilities per ANSI/ASSE A10.31     M. Owner as a Lessor: When owners function as lessors, they shall have the responsibilities of ANSI/ASSE A10.31, Section 11.   Responsibilities ANSI/ASSE A10.31 EEC-0168 V1.0...
  • Page 33 Responsibilities per ANSI/ASSE A10.31     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0168 New Document 11/13/15         Responsibilities ANSI/ASSE A10.31 EEC-0168 V1.0...

  • Page 34: Nomenclature

    C. Platform Pin: The horizontal pin that attaches the platform to the digger derrick boom, and about which the platform rotates with respect to the boom.
  • Page 35 U. Pedestal: The stationary base that affixes the rotation bearing of the digger derrick to the vehicle. V. Rotation Bearing: the rotating member of the digger derrick between the pedestal and the turntable that allows slewing of the booms. W. Rotation (Slewing) Mechanism: The mechanism of a digger derrick that controls rotation of the booms and turntable about the centerline of rotation.
  • Page 36 Jib: An auxiliary boom that attaches to the upper boom tip to extend the reach of the boom. Rated Load Capacity Chart: A chart that indicates the rated load capacity of the digger derrick in all positions specified by the manufacturer or installer. Remote Controls: Controls that are not permanently attached to the mobile unit.
  • Page 37 Nomenclature             Nomenclature EEC-0169 V1.0...
  • Page 38 Nomenclature     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0169 New Document 11/13/15         Nomenclature EEC-0169 V1.0...

  • Page 39: Platform Safety

    Platform Safety     Platform Safety EEC-0061 V1.1...
  • Page 40 Platform Safety     Boom truck cranes are designed and intended to be used for handling material, not personnel. Boom mounted personnel platforms can be used as long as guidelines are followed. Guidance on the use of personnel platforms is from ASME B30.5 (latest) and ASME B30.23 (latest).
  • Page 41 Platform Safety     H. The personnel platform and crane are not MINIMUM CLEARANCE REQUIREMENTS insulated. Do not operate near power lines or electrical hazards. Recommended Minimum minimum working distances are to be Nominal Voltage kV Distance maintained when working near power lines (Phase to Phase) Required or electrical hazards.
  • Page 42 Platform Safety     device) that is securely attached to the platform or booms tip, while over land and detached while over water. C. A boat with rescue personnel shall be available during a personnel lift over water. D. Special personnel protective equipment shall be provided and required to be worn around toxic, flammable or hazardous materials or fumes.
  • Page 43 Platform Safety     Pre-Lift Meeting Shall Cover These Items as a Minimum:  Proper use of all equipment.  Assignment and responsibilities of each person involved in the lift.  The procedures to be followed.  Guidance on general and specific safety precautions. ...
  • Page 44 Platform Safety      Require lift personnel to follow guidelines of standards. C. Shall designate person to perform duties of “Personnel Lift Supervisor”. Personnel Lift Supervisor shall:  Hold pre-lift meeting.  Verify required inspections have been performed.  Verify qualified are assigned to perform functions of ground crew, signalperson, operator, and platform occupants.
  • Page 45 Platform Safety      The operator has been working for more than ten hours prior to the start of the lift or the lift will not be completed before the operator has been working for twelve hours.  The operator did not have at least eight hours off immediately prior to the work shift containing the personnel lift operation.
  • Page 46 Platform Safety     N. Hoisting equipment shall be operated with outriggers and stabilizers fully deployed and properly set. O. The operator shall verify that the hoisting equipment is set up and maintained within one percent of level (0.56°) during a personnel lift. P.
  • Page 47 Platform Safety     The operator shall not move the platform over, under, or in the vicinity of power lines or electrical hazards unless the requirements of the minimum clearance table is met. Not lift any other loads, on any other load lines, while conducting a personnel lift. When the hoisting equipment has a boom attached platform without controls it shall not be used for other lifting service.
  • Page 48 Platform Safety     PERSONNEL PLATFORM OCCUPANTS A. Remain in continuous sight or in communication with the operator and the signalperson. B. Maintain a stable and even loading of the platform. C. Use protective equipment such as hard hats, safety glasses, hearing protection, and gloves in conditions where a hazard of injury exists.
  • Page 49 Platform Safety      As required by the hoisting equipment ASME B30 volume.  Inside the personnel platform.  At any platform motion control station. D. Some operations may require additions to, or modifications of standard signals.  Any special signal shall be agreed upon and understood by the signalperson and the hoisting equipment operator.
  • Page 50 Platform Safety     form in this section. The platform shall then be inspected at least once each day, before use, by a designated person to identify conditions that could create a hazardous operating condition. Any hazardous condition found shall be corrected before personnel are lifted.
  • Page 51 Platform Safety     G. When reinstalling the loadline, make sure the anti-two-block switch override flag is removed and the anti-two-block system tested for proper operation prior to hoisting loads on the crane loadline. To remove the platform, reverse the above procedure. Inspect the platform and replace any damaged parts or labels prior to the next use of the platform.
  • Page 52 Platform Safety     When the platform has been elevated to the working position, the platform can be rotated to move the platform personnel closer to the work. To rotate the platform to the desired position, first make sure all crane functions are in neutral. With the left hand, grasp the rotation crank and with the right hand, lift the locking lever.
  • Page 53 Platform Safety     Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0061 Template update 11/05/14 Tech Spec. Doc update 1/13/15 Platform Safety EEC-0061 V1.1...
  • Page 54 Platform Safety     Platform Safety EEC-0061 V1.1...

  • Page 55: Jib Safety

    Jib Safety     The proper procedures for jib deployment and stowing can be found in the Jib Operation section of the Safety & Operation chapter. Read and follow these safety guidelines when using the jib. A. The anti-two-block switch weight and cord must be attached to the jib when deployed.
  • Page 56 Jib Safety     I. Area where jib swings around must be clear of obstructions and power lines when stowing and unstowing jib. J. Use safety glasses when pounding pins with hammer. K. Do not extend/retract boom unless boom is horizontal when stow pin ‘A’ and jib- swing pin ‘B’...
  • Page 57 Jib Safety     Revision History   Document Document Revision Revision Notes Revision   type Number History Date Tech Spec. EEC-0045 Template 11/05/14 update Tech Spec. Doc update 1/13/15   Jib Safety EEC-0045 V1.1...

  • Page 58: Road Transport

    Road Transport  Make sure outriggers/stabilizers are retracted and removable pads stowed-if applicable. Always retract optional front bumper stabilizer before retracting outriggers and stabilizers.  Secure the loadline, headache ball or hook block to travel attach point.  Boom must be in boom rest and turret locked for optional turret locks. ...
  • Page 59 Road Transport Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0051 Template 11/05/14 update Tech Spec. Doc update 1/13/15 Road Transport EEC-0051 V1.1...

  • Page 60: On-Site Setup

    On-Site Setup     A. Position the vehicle in an area free of overhead restrictions. Check capacity chart for tasks required and position the crane in the proper place to complete the task safely. B. Maintain a clearance of at least 10 feet (3.05 M) between any part of the crane, loadline or load and any electrical line carrying up to 50,000 volts.
  • Page 61 Q. Do not allow anyone to ride the loadline, hook or load. R. Only use Elliott approved personnel baskets attached to the boom or jib for lifting personnel. S. Do not exceed 80 percent of the crane rating when using a clam bucket.
  • Page 62 On-Site Setup     Do not operate the crane if the Load Moment Limiter/Load Moment Indicator System installed on the crane is inoperative. On-Site Setup EEC-0024 V1.2...
  • Page 63 On-Site Setup     Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0024 Template 11/05/14 update Tech Spec. Doc update 1/12/15 Tech Spec. Content update 7/30/15 On-Site Setup EEC-0024 V1.2...

  • Page 64: Operating Controls-Digger Derrick

    Refer to truck manuals for operating instructions. CAUTION: Driving truck with the PTO switch engaged may damage hydraulic pump. A. Swing Control Joystick Push forward-“RIGHT” position-Turret swings right - Clockwise Pull back-“LEFT” position – Turret swings left – Counterclockwise Digger Derrick Op. Controls Sitting EEC-0172 V1.0...
  • Page 65 1. Winch Burst of Speed Switch: Depress button to start high speed winch operation. CAUTION: Only operate Burst-of Speed with unloaded loadline. Operating high speed with load on loadline may damage pump and PTO. Digger Derrick Op. Controls Sitting EEC-0172 V1.0...
  • Page 66 This momentary switch enables all lower operator joystick functions. Pressing the switch in the “ON” direction enables joystick function. Joystick inactivity for more than 14 seconds automatically disables all joystick functions, and the switch must be pressed to resume functionality. Digger Derrick Op. Controls Sitting EEC-0172 V1.0...
  • Page 67 “CLOSE” position. Once the cylinder extends and the latch is closed, the digger is stowed. NOTE: Ensure the latch is completely closed before continuing crane operation, or transporting the unit. Digger Derrick Op. Controls Sitting EEC-0172 V1.0...
  • Page 68 Located on either side of base boom-indicates the angle of the boom (in degrees) above or below horizontal. NOTE: For main boom, do not exceed the operating radius for the rated loads on the chart. Digger Derrick Op. Controls Sitting EEC-0172 V1.0...
  • Page 69 Immediately correct this condition to prevent tipping or structural damage. Lowering the load to ground and/or retracting the boom will resolve the problem.                               Digger Derrick Op. Controls Sitting EEC-0172 V1.0...
  • Page 70 Operating Controls-Digger Derrick       Revision History Document Document Revision Revision Notes Revision   type Number History Date Tech Spec. EEC-0172 New Document 11/24/15 Digger Derrick Op. Controls Sitting EEC-0172 V1.0...
  • Page 71 Digger Safety and Operation SAFETY The safe operation of the digger system depends on the operator, the condition of the equipment, and your maintenance and inspection procedures. The operator and service mechanic are key figures in any safety program, and must read and become familiar with all safety precautions presented to help prevent serious injury to themselves and other personnel.
  • Page 72 Digger Safety and Operation the hole and allow the flighting to clean itself before continuing the digging process OPERATION System The digger system consists of:  A two-speed, digger motor  Digger drive gearbox that drives the digger flighting  Stow bracket and lock mechanism with wind-up rope for storing he digger on the boom ...
  • Page 73 Digger Safety and Operation A more detailed description of these components is provided in the following Service and Maintenance section. The digger drive (and digger wind-up) is controlled by a level located at the operator’s station. Right next to the level is another that opens and closes the hydraulic stow latch mechanism, located inside the digger stow bracket.
  • Page 74 Digger Safety and Operation 8. Slowly operate the AUGER ROTATION lever in the CCW direction until the auger shaft raises itself up from the stow latch and contacts the over wind valve. While holding the auger in this position, operate the AUGER LATCH lever in the OPEN direction and hold until the auger latch is fully open Do not continue rotating the auger if contact with the over wind valve does not stop rotation.
  • Page 75 Digger Safety and Operation 7. Follow steps 3 through 5 until the hole is to the desired depth. For increased digging depth, the lower pin connecting the auger flighting to the Kelly bar may be unpinned and the digger drive can be raised to extend the length of the Kelly bar.
  • Page 76 Digger Safety and Operation bracket and is contacting the over wind valve, move the AUGER LATCH lever into the CLOSE position and hold until the latch is completely closed. Return the AUGER ROTATION lever to the neutral position and the auger flighting shaft will rest on the closed stow bar.
  • Page 77 Digger Safety and Operation The digger drive is powered by a two-speed, piston hydraulic motor. This motor has a bi-directional “kickdown” system. There is an over wind valve (see detail B in the corresponding system schematic) mounted on the digger stow bracket. This valve is also plumbed in parallel with the digger motor so when stowing the digger, if this valve is depressed by the auger flighting shaft, the...
  • Page 78 Digger Safety and Operation There is a proximity switch on the digger stow bracket that detects when the digger is stowed. When this switch is magnetized, it sends a signal to a normally open solenoid that is plumbed into the extend circuit and is located in the control console near the main control valve.
  • Page 79 Digger Safety and Operation Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0109 Template 11/05/14 update Tech Spec. Doc update 5/11/15 Tech Spec Doc update 11/23/15 Digger Safety/Operation EEC-0109 V1.2...

  • Page 80: Outrigger Controls

    Outrigger Controls     D  F  C  G  B  H  A  I  Note: When deploying outriggers, always set the beams to full- or mid-span prior to lowering the outrigger jacks. A. Right Front Outrigger Jack Switch-Activate switch “UP” or ”DOWN” to raise/lower right front outrigger jack B.
  • Page 81 Outrigger Controls     G. Left Rear Outrigger Jack Switch- Activate switch “UP” or ”DOWN” to raise/lower right rear outrigger jack H. Left Rear Outrigger Beam Switch- Activate switch “LEFT” or ”RIGHT” to retract/extend left rear outrigger beam I. Right Rear Outrigger Jack Switch- Activate switch “UP” or ”DOWN” to raise/lower right rear outrigger jack Note: Left and right are based on operator’s left and right as they stand at the outrigger control box facing the front of the truck.
  • Page 82 Outrigger Controls     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0037 Template 11/05/14   update Tech Spec. Doc update 1/12/15 Outrigger Controls E160 EEC-0037 V1.1  ...

  • Page 83: Remote Controls

    Remote Control (Optional)   G  H  I  A  K  J  O  N  DANGER DANGER ELECTROCUTION HAZARD This crane is not insulated, and the remote control provides no protection against electrocution hazards. Do not operate near live electrical power lines. All warnings in the Safety and Operation section of this manual, and on the crane relative to operating and safety procedures and power line clearances must be observed when using the crane remote controls.
  • Page 84 Remote Control (Optional)   In order to maintain a safe machine, a regular function check of the platform/radio control system is necessary. This check shall include verifying all safety features are operational before using this system. Controls are equipped to be connected to hard wired communication cable or be used as radio remote controls.
  • Page 85 Elliott remote controls provide the operator with the same load and capacity information to 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  ...
  • Page 86 Remote Control (Optional)   point with boom length, angle and load radius information along with allowable load and actual load values. Powering up the transmitter To start using the remote controls, this sequence must be followed to power up the transmitter for use.
  • Page 87 Remote Control (Optional)   Functions A. Emergency Stop button (red push 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.
  • Page 88 Remote Control (Optional)   D. Control Range Switch With this switch set to “HIGH”, the full activation of the joystick will move the valve spool to its maximum flow position. Setting this switch to “LOW”, the full movement of the joystick will move the control valve spool approximately 50% of the spool travel.
  • Page 89 Remote Control (Optional)   I. Engine Speed Switch This momentary toggle switch is used to activate the change engine speed between “HIGH” Idle and “LOW” Idle. Joystick Labels J. Boom Swing Joystick This joystick operates the boom rotation system. 1. Push forward-“CW” position to swing boom clockwise (right). 2.
  • Page 90 Remote Control (Optional)   O. Aux Winch Joystick This joystick operates the optional aux winch. 1. Push forward-“DOWN” direction to pay out winch line or lower load. 2. Pull back-“UP” direction to reel in winch line or raise load.   Optional Remote Control EEC-0039 V1.1...
  • Page 91 Remote Control (Optional)   Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0039 Template 11/05/14 update Tech Spec. Doc update 1/12/15   Optional Remote Control EEC-0039 V1.1...
  • Page 92 LMI Setup     You will use the Greer Insight system to aid in the crane’s operation. Please ensure only an operator properly trained in safety procedures, crane manufacturer’s specifications and the crane’s capacity information operates this unit. There are several operation functions to be aware of when using this unit: ...
  • Page 93 LMI Setup     Initial Setup NOTE-this section only covers the initial setup and usage of the LMI unit. For more detailed information about this product or for troubleshooting procedures, please consult the manufacturer’s insert under the “Component Service Manuals” section of this operator’s manual.
  • Page 94 LMI Setup     1. Home button: This returns the user to the Home display. 2. Outrigger button: The operator uses this option to select the outrigger position.   3. Parts Of Line button: This button selects the increment number of the POL (i.e.
  • Page 95 LMI Setup     Once the operator has made all necessary selections on the Crane Configuration screen, press the Home screen button to get to the Home Display: Home screen 1. Outrigger setting: Green indicator light reflects when the operator selects either full, intermediate, or retracted outriggers on the Crane Configuration screen.
  • Page 96 LMI Setup     5. Information: This button displays messages regarding the module’s software version and fault codes. Operator must keep button pressed to view informaiton. 6. Rated Capacity: This displays the crane’s maximum-rated capacity in its curent position.   7.
  • Page 97 LMI Setup     15. Boom Angle Symbol: This is displayed to the right of the boom angle display.   16. Load Radius Symbol: This is displayed to the right of the load radius display.   17. Swing Angle Symbol: This is displayed to the right of the swing angle display.
  • Page 98 LMI Setup     Revision History Document Document Revision Revision Notes Revision type Number History Date Tech. Spec. EEC-0066 Created 1/20/15 Document LMI Setup-Greer EEC-0066 V1.0...

  • Page 99: Lift Capacities

    Lift Capacities     Overloading this crane or disregarding Lift Capacity Chart directions can result in structural failure, tipping or injury to personnel. Read and understand all instructions before operating the crane. Do not lift any load without determining the total load lifted. The lifted load must always include the headache ball/hook block and any chains, slings, spreader bars etc.
  • Page 100 G. Reduce load ratings to compensate for wind, ground conditions and the dynamic effects of swinging, hoisting, and lowering the load. NOTE: The installer must perform a stability test in compliance with instructions furnished by Elliott Equipment Company. Lift Capacities EEC-0046 V1.1...
  • Page 101 Lift Capacities     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0046 Template 1/13/15   update Content update 6/25/15 Lift Capacities EEC-0046 V1.1...

  • Page 102: Wire Rope Anchoring

    Wire Rope Anchoring Cutting Wire Rope When cutting wire rope, it must be tightly seized on both sides of the point where the rope will be cut. Seize the wire rope with seizing wire or annealed wire. The seizing prevents the wire rope strands from unraveling and prevents distortion of the rope ends from the pressure applied during cutting.
  • Page 103 Wire Rope Anchoring Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0054 Template 11/05/14 update Tech Spec. Doc update 1/13/15 Wire Rope Anchoring EEC-0054 V1.1...

  • Page 104: Wedge Socket

    Wedge Socket       WARNINGS AND APPLICATION INSTRUCTIONS S-421T / US-422T ™ “TERMINATOR” NOTE: Existing Crosby S-421 Wedge Sockets can be retrofitted with the New Terminator Wedge. http://catalog.thecrosbygroup.com/qc.htm ® New QUIC CHECK “Go” and “No-Go” features cast into wedge. The proper size wire rope is determined when the following criteria are met: 1.
  • Page 105 Wedge Socket       Assembly Safety  Use only with standard 6 to 8 strand wire rope of designated size. For intermediate size rope, use next larger size socket. For example: When using 9/16" diameter wire rope use a 5/8" size Wedge Socket Assembly. Welding of the tail on standard wire rope is not recommended.
  • Page 106 Wedge Socket        Loads may slip or fall if the Wedge Socket is not properly installed.  A falling load can seriously injure or kill.  Read and understand these instructions before installing the Wedge Socket.  Do not side load the Wedge Socket.
  • Page 107 Wedge Socket       FIGURE 2 WRONG WRONG WRONG Rope Wedge Tail Clipped Backward Backward to live Line Operating Safety  Apply first load to fully seat the wedge and Wire Rope in the socket. This load should be of equal or greater weight than loads expected in use. ...
  • Page 108 Wedge Socket       Revision History   Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0054 Template 11/05/14 update Tech Spec. Doc update 1/13/15 Wedge Socket EEC-0053 V1.1...

  • Page 109: Multi-Part Reeving

    Multi-Part Reeving Reeve rope per diagram show below. Refer to the crane Capacity Chart to determine the parts of line required for each load lifted. Note: The type of rope used on the crane must be known in order to pick the correct capacities.
  • Page 110 Multi-Part Reeving Revision History Document Document Revision Revision Notes Revision type Number History Date Diagram EEC-0047 Template 11/05/14 update Diagram Doc update 1/13/15 Multi-Part Reeving EEC-0047 V1.1...

  • Page 111: Jib Operation

    Jib Operation A. The anti-two-block switch weight and cord must be attached to the jib when deployed. Do not lift load with the boom tip when the jib is pinned on the boom tip. 1. Operate with jib by radius when main boom is fully extended. If necessary, increase boom angle to maintain loaded radius.
  • Page 112 Jib Operation J. When the jib is stowed, the boom cannot be fully retracted if a boom tip attachment option is installed. K. For manually extendable jib options: 1. Extension retaining pin ‘E’ must always be installed before operation. 2. All swing around (stow and unstowing) operations shall be done with jib retracted and pinned.
  • Page 113 Jib Operation L. Remove loadline from boom sheave case and place in an area to minimize possible damage. M. Pivot jib into place, visually aligning the upper ‘C2’ pin holes. Install upper ‘C2’ pin and spring clip. A slight hammer strike may be necessary to install pins. Always use proper eye protection during this step.
  • Page 114 Jib Operation F. Attach tag line to sheave case end of jib. G. Remove spring clips from pins ‘C2’ on both upper and lower jib ears. H. Remove pins ‘C2’ from upper and lower jib ears. Do not remove ‘C1’ pins at this time.
  • Page 115 Jib Operation their proper locations. Failure to properly secure the jib during stowing and erecting may allow the jib to fall. Serious personal injury or death could result. Always have at least one, if not both of the following in place at all times: Side stow bracket completely engaged into stow hook with stow pin ‘A’...
  • Page 116 Jib Operation Jib Operation EEC-0044 V1.1...
  • Page 117 Jib Operation Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0044 Template 11/05/14 update Tech Spec. Doc update 1/13/15 Jib Operation EEC-0044 V1.1...
  • Page 118 Platform Operation The platform is permanently suspended in a yoke that can be attached to the boom or jib head. The platform leveling system consists of a function selector valve, a hydraulic cylinder and a hand pump assembly that includes a hydraulic oil reservoir and handle.
  • Page 119 Platform Operation the hydraulic system, the air will need to be bled out. The bleeding procedure is outlined below A. Remove leveling cylinder upper pin and suspend the cylinder horizontal to the ground (zip ties may be used) B. Ensure the oil level in the reservoir is above the minimum level for the entire procedure C.
  • Page 120 Platform Operation Kickstand deployed with cable unlatched Platform attached to Boom using Adaptor Platform Install/Operation EEC-0049 V1.1...
  • Page 121 Platform Operation Platform 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 float position unexpectedly. Float lock shown in the unlocked position Platform Install/Operation EEC-0049 V1.1...
  • Page 122 Platform Operation Labels: Platform selector valve positions Platform operation label Platform Install/Operation EEC-0049 V1.1...
  • Page 123 Platform Operation PLATFORM ASSEMBLY RIGGING FOR OPERATION PLATFORM TRANSFER FROM TRUCK BED A. Rig the platform from the yoke lift lugs as shown in Figure 1 B. Select the brake position on the platform selector valve C. Lift and set the assembly on level ground, with kickstand deployed. D.
  • Page 124 Platform Operation Figure 2: Platform location on ground Figure 3: Platform ground location RIGGING PLATFORM 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.
  • Page 125 Platform Operation E. With boom and platform aligned, extend boom to 46.6 ft radius on LMI display F. Lower platform arm hook into the adaptor, insert and secure horizontal pin RIGGING PLATFORM ASSEMBLY TO RETRACTED JIB (BOOM RETRACTED) A. Set the platform at a 65.8 ft radius from the truck center of rotation as shown in Figure 3.
  • Page 126 Platform Operation A. Set the platform at a 88.4 ft radius from the truck center of 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.
  • Page 127 Platform Operation Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0049 Template 11/05/14 update Tech Spec. Doc update 1/13/15 Platform Install/Operation EEC-0049 V1.1...

  • Page 128: Hand Signals

    Hand Signals     Standard Hand Signals for Crane Operators HOIST. With forearm LOWER. With arm extended vertical, and forefinger downward, forefinger ASME B30.5-1998 pointing up, move hand in pointing down, move hand in small horizontal circle. a small horizontal circle. MOVE SLOWLY.
  • Page 129 Hand Signals     Revision History   Document Document Revision Revision Notes Revision   type Number History Date Diagram. EEC-0043 Template 11/05/14 update Diagram Doc update 1/12/15 Hand Signals EEC-0043 V1.1  ...

  • Page 130: Required Inspections

    Required Inspections Government regulations and Elliott Equipment Company require the following inspections.  It is the responsibility of the operator to not operate this boom truck until the appropriate inspections are performed and documented, and any necessary repairs are made.
  • Page 131 Required Inspections H. Inspect the wire rope for wear and damage, check for corrosion, kinking, crushing, cuts, and slippage of clamps at wedge socket. I. Check for proper wire rope spooling on the winch drum and proper reeving. Make sure all sheaves turn freely. J.
  • Page 132 G. Verify owner’s manual is with unit. If manual is not present and cannot be located, either print new manual from CD provided, or provide serial number to Elliott Dealer to order replacement manual immediately. Be sure the unit is in an area free of overhead obstructions and power lines.
  • Page 133 Required Inspections G. Check hydraulic hoses for wear on outside surfaces and leakage at connections. H. Check hydraulic pump for loose bolts, leaks, noise and vibration. I. Check the hydraulic valves for leaking. J. Check the hydraulic cylinders for drifting due to holding valve failure, rod seal leakage, weld joint leaks, visual damage.
  • Page 134 Required Inspections H. Check Rotation bearing and gearbox mounting bolts for proper torque. See “Bolt Torque” chart for appropriate torque values. I. Check mounting bolts, except “huck-bolts” for proper torque. See “Bolt Torque” chart for appropriate torque values. J. Check all “huck-bolts” for damage and tightness. K.
  • Page 135 Required Inspections Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0050 Template 11/05/14 update Tech Spec. Doc update 1/13/15 Required Inspections EEC-0050 V1.1...

  • Page 136: Wire Rope Inspection

    Wire Rope Care/Maintenance It is important to ensure all wire ropes are provided proper maintenance and inspections on regular intervals. Failure to provide the proper care and maintenance can drastically reduce the lifespan of wire ropes, which increases the risk to personnel and property.
  • Page 137 Wire Rope Care/Maintenance Typical Evidence of Wear and Abuse A "birdcage" is caused by sudden release of tension and the resulting rebound of rope. These strands and wires will not be returned to their original positions. The rope should be replaced immediately.
  • Page 138 Wire Rope Care/Maintenance wire ends must be removed. It is recommended to move the wire ends back and forth until they break deep within the cord valley between two outer strands. At no time should the wire ends be pinched off with nippers. Replacement Criteria A.
  • Page 139 Wire Rope Care/Maintenance 2. 1/32 inch for rope diameters 3/8 through 1/2 inch 3. 3/64 inch for rope diameters 9/16 through 3/4 inch I. Core failure. This type of damage is usually indicated by a reduction in the nominal diameter or an increase in rope lay length.
  • Page 140 Wire Rope Care/Maintenance spray it on or brush it on. In all cases, you should apply it at a place where the rope is bending such as around a sheave. Apply it at the top of the bend, as that is where the rope's strands are spread by bending and more easily penetrated.
  • Page 141 Wire Rope Care/Maintenance Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0117 New Doc 6/5/15 Wire Rope Care/Maintenance EEC-0117 V1.0...

  • Page 142: Synthetic Rope Usage, Inspection And Retirement

    Elliott Equipment currently uses both Yale and Samson rope products in 9/16” (yellow) and 5/8” (blue) sizes. Fiber and construction being equal, a larger rope outlasts a smaller rope because of the greater surface wear distribution.
  • Page 143 Synthetic Rope Usage, Inspection, and Retirement Elongation It is well accepted that ropes with lower elongation under load will give you better load control-a big help at complicated job sites. However, ropes with lower elongation that are dynamic loaded, like a towering line, can fail without warning, even though it appears to be in good shape.
  • Page 144 Synthetic Rope Usage, Inspection, and Retirement found to be in good condition; and if the rope has not been subjected to dynamic loads, excessive use, elevated temperatures, or extended periods under load. For dynamic loading applications that involve severe exposure conditions, or for recommendations on special applications, consult the manufacturer.
  • Page 145 Synthetic Rope Usage, Inspection, and Retirement Assume that you have seven identical ropes, each with a 30,000-lb breaking strength and you work these ropes daily with each rope lifting a different load. The higher the working load factor, the greater the service life and the lower the replacement factor.
  • Page 146 Synthetic Rope Usage, Inspection, and Retirement Avoid All Abrasive Conditions All rope will be severely damaged if subjected to rough surfaces or sharp edges. Chocks, bitts, winches, drums, and other surfaces must be kept in good condition and free of burrs and rust. Pulleys must be free to rotate, and should be of proper size to avoid excessive wear.
  • Page 147 Synthetic Rope Usage, Inspection, and Retirement Removing Rope from a Reel or Coil Synthetic-fiber ropes are normally shipped on reels for maximum protection while in transit. The rope should be removed from the reel by pulling it off the top while the reel is free to rotate.
  • Page 148 Synthetic Rope Usage, Inspection, and Retirement Knots While it is true that a knot reduces rope strength, it is also true that a know is a convenient way to accomplish rope attachment. The strength loss is a result of the tight bends that occur in the know.
  • Page 149 Synthetic Rope Usage, Inspection, and Retirement However, all synthetics to subject to melting if subjected to enough friction and heat; therefore, practices such as surging on a gypsy-head winch, hard rendering around poles, over cross-arms, etc., should be avoided whenever possible. Temperature Friction can be your best friend or worst enemy if it is not managed properly.
  • Page 150 Synthetic Rope Usage, Inspection, and Retirement by UV exposure, and the resulting strength degradation of exposed fibers is negligible. Nylon is more susceptible to strength loss due to ultraviolet rays, but with both polyester and nylon, the degree of susceptibility to UV damage is dependent on the type of fiber and the various inhibitors with which the fiber manufacturer treats them.
  • Page 151 Synthetic Rope Usage, Inspection, and Retirement End-For-Ending It is recommended that every winch line be rotated end-for-end on a periodic basis. This will vary high stress and wear points and extend useful life. The recommended end-for-ending period is six months, at which time visual inspection and washing can also be done.
  • Page 152 Synthetic 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 diameter  Braided: 8 times the rope’s diameter Synthetic Rope Usage EEC-0060 V1.2...
  • Page 153 Synthetic Rope Usage, Inspection, and Retirement Rope Type Yale Ultrex Ultrex is a 12-strand, single braid comprised of 100 percent Ultra High Molecular Weight Polyethylene (UHMPE) fiber enhanced with Yale’s Maxijacket HP coating (see next section) supplying superior abrasion resistance. Ultrex’s braid angles and twist level are designed to optimize break strength and keep stretch low.
  • Page 154 Synthetic Rope Usage, Inspection, and Retirement Yale Ultrex Specifications Chart YELLOW highlighted section denotes Elliott Equipment sizes Synthetic Rope Usage EEC-0060 V1.2...
  • Page 155 Synthetic Rope Usage, Inspection, and Retirement Samson Amsteel Specifications Chart YELLOW highlighted section denotes Elliott Equipment size Synthetic Rope Usage EEC-0060 V1.2...
  • Page 156 Synthetic Rope Usage, Inspection, and Retirement Rope Coatings and Finishes Yale Maxijacket Coating This is a spliceable urethane coating, which is applied after the rope is braided. Maxijacket firms the rope, increases snag resistance, and helps keep contaminants from entering the rope. Unlimited lengths may be processed at our facility through our automated coaters, which apply and control the polymer penetration, curing the coating at precisely controlled temperatures.
  • Page 157 Synthetic Rope Usage, Inspection, and Retirement inspecting for abrasion, glossy or glazed areas, inconsistent diameter, discoloration, and inconsistencies in texture and stiffness. Visual Inspection The load-bearing capacity of double braid ropes is divided equally between the inner core and the outer cover. If upon inspection, there are cut strands or significant abrasion damage, the rope must be retired because the strength of the entire rope is decreased and, as such, is compromised.
  • Page 158 Synthetic Rope Usage, Inspection, and Retirement As a general rule for braided ropes, when there is 25 percent or more wear from abrasion, or the fiber is broken or worn away, the rope should be retired from service. For double-braided ropes, 50 percent wear on the cover is the retirement point, and with three-strand ropes, 10 percent or more wear is accepted as the retirement point.
  • Page 159 Synthetic Rope Usage, Inspection, and Retirement  Elastic Hysteresis: Elastic Hysteresis refers to a recoverable portion of stretch or extension over a period of time after a load is released. In measuring elastic recovery, it is the portion that occurs immediately when a load is removed. However, a remaining small percentage of elastic recovery occurs gradually over a period of hours or days.
  • Page 160 Synthetic Rope Usage, Inspection, and Retirement Revision History Document Document Revision Revision Notes Revision type Number History Date Tech. Spec. EEC-0060 New Document 1/13/15 Tech. Spec. Doc update 5/12/15 Tech Spec. Doc update 5/20/15 Synthetic Rope Usage EEC-0060 V1.2...

  • Page 161: Labels

    Digger Derrick Labels     Digger Derrick Labels EEC-0171 V1.0...
  • Page 162 1.0000 1209760 LBL-30T 5-SECT DGGR VLV 1.0000 1070970 LBL-CRANE OPRTN HND SGNL 1.0000 1065510 LBL-DNGR PERSON ON WINCH 6.0000 1007680 LBL-OAH TRVL HGHT LBL SHT 1.0000 NOTE: Highlighted items have corresponding pictures of labels below. Digger Derrick Labels EEC-0171 V1.0...
  • Page 163 Digger Derrick Labels       .    Digger Derrick Labels EEC-0171 V1.0...
  • Page 164 Digger Derrick Labels                                     Digger Derrick Labels EEC-0171 V1.0...
  • Page 165 Digger Derrick Labels     Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0171 New Document 11/18/15 Digger Derrick Labels EEC-0171 V1.0...

  • Page 166: Digger Derrick Specifications

    Once the inlet relief is adjusted, the pump relief valve must be reset to its proper pressure. Failure to do so will cause the truck engine to attempt to start under load, or create excess heat generation. Digger Derrick Specs EEC-0170 V1.2...
  • Page 167 Swing Left 2200 34 +/- 5 Swing Right 2200 34 +/- 5 Auger-Dig 4800 Auger-Clean 4800 Outriggers In/Out 2500 Outriggers 2500 Up/Down Front Stabilizers 2500 Reservoir Capacity Gallons Filtration 20 Micron (Pressure) Filtration (Return) 6 Micron Digger Derrick Specs EEC-0170 V1.2...
  • Page 168 375 ft. Winch Line Pull Line Speed Layer (Kg.) (MPM) 12,000 (5443) (32) 11,620 (5271) (35) 10,579 (4799) (39) 9,710 (4404) (42) Ratings based on 30 GPM at 3500 PSI (114 LPM at 241 Bar) Digger Derrick Specs EEC-0170 V1.2...
  • Page 169 23,000 lb. Rated Capacity 50,000 lb. Digger Specifications Low Speed High Speed Running Torque 20,000 ft-lb. 9,000 ft-lb. Rotation Speed 35 RPM 80 RPM Hydraulic Flow 55 GPM 55 GPM Hydraulic Pressure 4,800 PSI 4,800 PSI Digger Derrick Specs EEC-0170 V1.2...
  • Page 170 Digger Derrick Specifications Digger Derrick Specs EEC-0170 V1.2...
  • Page 171 Digger Derrick Specifications Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0170 New Document 11/16/15 Digger Derrick Specs EEC-0170 V1.2...

  • Page 184: Maintenance Safety

    Maintenance Safety Perform the following safety steps whenever possible before maintaining or repairing the crane: A. Apply the Parking brake. B. Lower all loads to ground and disconnect. C. Stow boom on rest if possible. D. Move all controls to off position. E.
  • Page 185 Maintenance Safety Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0022 Template 11/05/14 update Tech Spec. Doc update 1/12/15 Maintenance Safety EEC-0022 V1.1...

  • Page 186: Cleanliness

    Cleanliness The long life of a crane’s hydraulic components is dependent on keeping dirt out of the system. Whenever hydraulic lines are disconnected, clean the adjacent area, as well as the point of disconnection. Immediately cap or plug openings to prevent entry of dirt.
  • Page 187 Cleanliness Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0019 Template 11/05/14 update Tech Spec. Doc update 1/12/15 Cleanliness-crane EEC-0019 V1.1...

  • Page 188: Lubrication

    17. Hydraulic Tank Breather Semi-annually 18. Suction Strainer At Oil Change 19. Wire Rope See Section 2.6.3 20. Pump Drive U-Joint or Grease Remove Pump Pump Drive Spline Shaft Coupling Lube and Apply to Spline Lubricant Shaft Lubrication Digger Derrick EEC-0173 V1.0...
  • Page 189 F. The swing bearing race is lubricated from a remote grease fitting located on the top of the operator’s console on the driver’s side. Apply three or four pumps of grease, rotate 90 degrees and apply three of four more shots of grease. Repeat procedure through 360 degrees of operation. Lubrication Digger Derrick EEC-0173 V1.0...
  • Page 190 25 PSI. Operating the crane when the filter is bypassing may damage the pump, valves and hydraulic system. N. Replace at earlier intervals if required. Do not clean and reuse. Lubrication Digger Derrick EEC-0173 V1.0...
  • Page 191 Lubrication Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0173 New Document 11/25/15 Lubrication Digger Derrick EEC-0173 V1.0...

  • Page 192: Bolt Torque

    Bolt Torque The torque values for fasteners are listed below. Make sure each fastener is the correct size and grade prior to torqueing. Always use grade 8 nuts with grade 8 fasteners. Use hardened washers under screw heads and beneath nuts that are torqued.
  • Page 193 Bolt Torque Bolt Torque EEC-0016 V1.2...
  • Page 194 Bolt Torque Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0016 Template 11/05/14 update Tech Spec. Content update 1/12/15 Tech Spec. Content update 8/5/15 Bolt Torque EEC-0016 V1.2...

  • Page 195: Changing Hydraulic Oil

    Changing Hydraulic Oil Drain and refill the hydraulic system every six months unless an alternate interval has been established by oil analysis. A. Bring the oil to operating temperature by running the crane functions. B. With all controls in neutral position, turn the truck engine off. C.
  • Page 196 Changing Hydraulic Oil Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0018 Template 11/05/14 update Tech Spec. Doc update 1/12/15 Changing Hydraulic Oil EEC-0018 V1.1...

  • Page 197: Bubble Level Adjustment

    Bubble Level Adjustment Check the adjustment of the bubble levels on the control consoles monthly: A. Extend outriggers and stabilizers and level the crane with the bubble level. B. Raise the fully retracted boom to 80 degrees. C. Place an accurate carpenter’s level on either side of the turret top plate. D.
  • Page 198 Bubble Level Adjustment Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0017 Template 11/05/14 update Tech Spec. Doc update 1/12/15 Bubble Level Adjustment EEC-0017 V1.1...

  • Page 199: Four Section Boom Operation

    Four Section Boom Operation     Four Section Boom Operation-common EEC-0021 V1.3...
  • Page 200 Four Section Boom Operation     3/2/1 Retract Cable (Qty 2): Connects to the front of the 1st (Main) section and passes over sheave at back of 2nd (Next to Large) section and connects to back of 3rd (Next to Tip) section. Primary function of these cables is to retract the 3rd (Next to Tip) section.
  • Page 201 Four Section Boom Operation     Lubrication of the extend cable sheaves located on the boom tip end of the extend cylinder and the retract cable sheaves located on the inside rear of the 2 section and the extend cable sheave attached to the bottom of the top plate of the second section at the sheave case end of the boom are accomplished with the boom fully retracted.
  • Page 202 Four Section Boom Operation     Section 2 Section 3 Section 4 Section 2/3/4 Extend Cables 4/3/2 Retract Cables D. Torque the large extend cables to 22 ft-lb (12.2 N.m). Cable adjustment point is located at the rear of the boom on the cable anchor located in the rear of the 2 section.
  • Page 203 Four Section Boom Operation     Boom Removal A. Extend and set machine outriggers. Boom must be completely retracted and stowed in the boom rest. B. If equipped, remove swing around jib according to procedures outlined in the “Safety & Operation” section. C.
  • Page 204 Four Section Boom Operation     Boom Disassembly Alternative A. Gaining access through rear of boom, loosen capscrews retaining the keeper plates holding the extend cable anchor and retract cables in the rear of the 3 section, remove keeper plates. B.
  • Page 205 Four Section Boom Operation     J. Remove top rear wear pads on the 2 section. They will lift off the cam plates easily. Do not remove or loosen the capscrews holding the cam plates to the section. This will affect side clearance during re-assembly. K.
  • Page 206 Four Section Boom Operation     R. Remove the extend cylinder from the boom. Do not allow the sheaves to fall off the pin on the end of the extend cylinder. Remove extend cables. Place cylinder and cables in suitable area to prevent possible damage. S.
  • Page 207 Four Section Boom Operation     D. Clean and inspect all cable assemblies according to wire rope inspection procedures in this section. Pay particular attention to any wire breakage at the end connections. Replace cable assemblies as required. Lubricate all cable assemblies as required.
  • Page 208 Four Section Boom Operation     Four Section Boom Assembly Note: Do not use Loctite on any cable threaded ends. Always use the locknut and nut provided. A. When initially assembling threaded ends of cables, thread the first on past the flat in the cables so adjustment can be made later.
  • Page 209 Four Section Boom Operation     2/3/4 Extend Section Cable Anchor Cable Button Cable Thread K. Uncoil 4/3/2 retract cable assemblies and insert button end into anchors in back of the 4 section. Place uncoiled cable in area that will minimize the potential for damage.
  • Page 210 Four Section Boom Operation     O. Loop the 1/2/3 extend cable in half and place it on the top of the 3 section with the loop end towards the sheave case end and the threaded and button end towards the rear of the section. P.
  • Page 211 Four Section Boom Operation     Y. Position sheave and sheave pin located in cable loop on top of 3 to allow capscrew installation through top plate of 2 . Install capscrews and torque to specification, clamping sheave pin and sheave to the bottom of the 2 section.
  • Page 212 Four Section Boom Operation     Visually verify that the extend cables are properly routed on their sheaves and continue to slide with the extend cylinder and cables into the boom sections. Keep extend cables supported and slightly tensioned during insertion of cylinder to maintain proper cable placement.
  • Page 213 Four Section Boom Operation     use same shim quantity and location as was previously used. If locations are in question, refer to shim calibration section in this book. Push boom together until extend cylinder butt plate makes contact with the rear cylinder anchor plates in the rear of the 1 section.
  • Page 214 Four Section Boom Operation     position of the section can be used. It is often difficult to pry the very most inner sections over. B. Extended boom 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.
  • Page 215 Four Section Boom Operation     Retainer Plate Wear Pads Boom Top Plate Boom Side Plate FOUR AND FIVE SECTION TOP/BOTTOM PAD REPLACEMENT – ASSEMBLED BOOM Properly aligned wear pad: The retainer plate holes align with the threaded holes in the smaller boom section;...
  • Page 216 Four Section Boom Operation     Inspect top and bottom wear pads periodically for signs of abrasion or excessive wear. Excessive is defined as 3/16 of an inch (4.8mm) from the original pad thickness, top rear pad thickness .75 inch (19mm), bottom front 1 section 1 inch (25mm), bottom front 2 and 3...
  • Page 217 Four Section Boom Operation      Using an appropriate lifting device, sling around the 4 and 5 depending on configuration section boom and lift it up until weight is removed from the bottom pads in the front of the interior sections. ...
  • Page 218 Four Section Boom Operation     Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0021 Template 11/05/14 update Tech Spec. Doc update 1/26/15 Tech Spec. Illustration 3/25/15 update Tech Spec. Illustration/info 4/8/15 update Four Section Boom Operation-common EEC-0021 V1.3...

  • Page 219: Troubleshooting

    Troubleshooting BOOM EXTENDS DURING TRANSPORTATION Check for oil leaks. Clean or replace holding valve and check setting. Rebuild cylinder and replace seals. BOOM CREEPS BACK AFTER BEING EXTENDED As hydraulic oil cools it is normal for it to retract in the telescope cylinder and let the boom creep in slightly.
  • Page 220 Troubleshooting  Brake return springs broken or brake discs worn or damaged: Disassemble the brake and replace worn parts in brake  Clutch slipping: Improper oil can cause the clutch to slip. Drain the winch and refill with oil per the vendor’s specifications. Also, the clutch may be damaged or worn.
  • Page 221 Troubleshooting OUTRIGGER/STABILIZER CREEPS IN UNDER LOAD Clean holding valve and check relief setting. Replace as required. OIL CONTAMINATION PROBLEMS  Water in oil (milky)  Filter plugged (dirty)  Metal particles (mechanical failure)  Oil discolored or has burned odor (overheating) ...
  • Page 222 Troubleshooting PUMP MAKES NOISE  Low oil  Oil viscosity too high  Pump speed too fast  Suction plugged  Ball valve closed  Dirt in pump  Tank breather plugged  Air in oil  Worn pump bearings ...
  • Page 223 Troubleshooting Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0023 Template 11/05/14 update Tech Spec. Doc update 1/12/15 Troubleshooting EEC-0023 V1.1...
  • Page 224 Service Manual Model 1200W Winch Table of Contents PART & SERIAL NUMBER LOCATION....................2 SAFETY NOTES ..........................2 INTRODUCTION AND THEORY OF OPERATION .................3 HYDRAULIC SCHEMATIC........................4 MAINTENANCE..........................5 WIRE ROPE............................5 LUBRICATION ..........................6 DISASSEMBLY ..........................7 REASSEMBLY............................8 SERVICING THE MOTOR........................9 SERVICING THE BRAKE ........................10 SERVICING THE PLANETARY SET.....................

  • Page 225: Part & Serial Number Location

    PART & SERIAL NUMBER LOCATION Part and serial numbers can be located on the winches as shown below: Safety Notes WARNING FAILURE TO HEED THE FOLLOWING WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH! Tulsa winches are not to be used to lift, hoist, or move people. If your task involves lifting or moving people, you MUST use the proper equipment, not this winch.

  • Page 226: Introduction And Theory Of Operation

    INTRODUCTION AND THEORY OF OPERATION The 1200W planetary winch design is composed of an input either from a high torque; low speed geroler motor or a high-speed gear or piston motor, driving through a multiple disc brake, through a pair of planetary gear sets to the cable drum. The multiple disc brake is spring applied and hydraulically released through a port in the brake housing.

  • Page 227: Hydraulic Schematic

    HYDRAULIC SCHEMATIC...

  • Page 228: Maintenance

    MAINTENANCE Tulsa Model 1200W planetary winches, like any other pieces of machinery, need to be periodically serviced and well maintained to insure their proper operation. Good maintenance consists of three steps: A daily inspection to insure that there is no oil leaks present, that all mounting bolts and other fasteners are tight, and that wire rope is in good condition.

  • Page 229: Lubrication

    LUBRICATION The hydraulic system should use only high quality hydraulic oils from reputable suppliers. These oils should contain additives to prevent foaming and oxidation in the system. All winch hydraulic systems should be equipped with a return line filter capable of filtering 10-micron particles from the system.

  • Page 230: Disassembly

    DISASSEMBLY Stand the winch on its end with the motor pointing up. Remove the brake hose from the brake housing (Item 18). Remove the motor and brake valve assembly from the winch by removing the capscrews holding the motor to brake cover. See Servicing the Motor section for motor and counterbalance valve dis-assembly.

  • Page 231: Reassembly

    REASSEMBLY Thoroughly clean all parts. Replace those, which show wear or damage. Inspect the drum (Item 5) and base (Item 7) for structural integrity and replace if necessary. Set the drum so that it is centered on the hole in side plate (Item 26). Install the shaft (Item 29) through sideplate (Item 26) into the drum (Item 5) making sure the vent is oriented properly.

  • Page 232: Servicing The Motor

    SERVICING THE MOTOR Tag hoses for proper re-installation and remove them from the motor and counterbalance block. Remove the counterbalance block from the winch motor. 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.

  • Page 233: Servicing The Brake

    SERVICING THE BRAKE Evenly remove the four capscrews ( Item 41) holding the brake cover in place. Spring pressure will raise the cover up as the capscrews are loosened. Remove the cover from the brake housing. Remove the springs (Item 21) from the piston and check them for free height. Each spring should measure at least 1.200 inches with no force on them.
  • Page 234 Inspect each new seal (Item 19) to make sure it has an o-ring in the groove of the seal. Install one seal into the bore of the brake housing with the open side toward the brake pack. Place the other seal onto the piston with the open side toward the flange of the piston (See Fig.

  • Page 235: Servicing The Planetary Set

    SERVICING THE PLANETARY SET Remove the spiral rings from the planet pins. Remove the pins from the carrier by carefully tapping them out. Remove the planet gears, thrust washers and bearings from the carriers. Inspect the pins, bearings, and gear bores for evidence of wear and replace if necessary. On output planet sets, note that two bearings with a spacer between them are used.

  • Page 236: Troubleshooting

    TROUBLESHOOTING Problem: Winch won't hold load Solution 1: Excessive back pressure in the system. Check the system for restrictions and reduce the backpressure. Solution 2: Brake discs are worn out. Replace brake discs. Solution 3: Winch clutch is slipping. Inspect the clutch and driver for wear and replace worn parts.

  • Page 237: Bill Of Materials

    BILL OF MATERIALS ITEM NO. TWI PART NO. QTY. DESCRIPTION 29792 CAPSCREW 42134 SUPPORT ROD 29973 RETAINING RING 4142 OUTPUT GEAR SET 41755 OUTPUT CARRIER 41728 OUTPUT PLANET GEAR 41747 PLANET PIN 41716 RETAINING RING 41769 PLATE 41717 BEARING 41739 SPACER 939249 RACE...
  • Page 238 13050 BREATHER 41879 O-RING PLUG 41758 SHAFT 41719 O-RING PLUG 41759 CLUTCH 4137 INPUT GEAR SET (29:1 RATIO) 4138 INPUT GEAR SET (21:1 RATIO) 4139 INPUT GEAR SET (41:1 RATIO) 4140 INPUT GEAR SET (59:1 RATIO) 41765 INPUT PLANET CARRIER (59:1 RATIO) 41766 INPUT PLANET CARRIER (41:1 RATIO) 32-1...
  • Page 239 MOTOR BILL OF MATERIALS (Motor components may vary based upon OEM application. Consult factory if different from below). GEAR MOTOR ITEM NO. TWI PART NO. QTY. DESCRIPTION 38-1 42030 HOSE 38-2 42209 38-3 29421 CAPSCREW 38-4 42259 ELBOW 38-5 42211 FLANGE 38-6 32182...

  • Page 240: Exploded Isometric Assembly Drawing

    EXPLODED ISOMETRIC ASSEMBLY DRAWING...
  • Page 241 5200 SERIES 6000 SERIES SWING DRIVE SERVICE MANUAL G:\SERVICE LITERATURE\52-60 SWING SERVICE LIT\Sel-0007.DOC Rev-1...
  • Page 242 This manual will primarily assist in disassembly and assembly procedures of major components for all 52 & 60 series Swing Drives. Item numbers, indicated in parentheses throughout this manual, refer to the Tulsa Winch Model 52 and 60 series exploded assembly drawing located in the back of this manual.
  • Page 243 (37 & 38) and back-up rings (39 & 40) planet gear (10.2) and needle bearings for damage, replace if necessary. (Ref. (10.5). Inspect unusual wear. Fig. 2) On 52 series swingdrive inspect Replace as required. bearing (41) & seal (42) in brake housing (15) replace if necessary.
  • Page 244 ASSEMBLY PROCEDURE FOR 5200 & 6000 SERIES SWING DRIVES Press the inboard and outboard bearing (18) to the brake housing (15) and cup (4 & 8) into the gear housing (7) if torque to 10 ft. lbs. NOTE: Notice the replaced.
  • Page 245 5200S...
  • Page 246 6000S...
  • Page 247 Elliott Operating Manual...
  • Page 248 Introduction The GREER INSIGHT System is designed for use as an aid to crane operation. Do not use this system without a properly trained operator who is knowledgeable in safety guidelines, crane capacity information, and the crane manufacturer’s specifications. This manual describes the operation of the GREER INSIGHT, hereinafter referred to as the system.
  • Page 249 Swing Alarms Illustrated (If Equipped with Swing Sensor) ........... 24 Setting the Swing Alarms ..................... 25 Work Area Alarms (If Equipped with Swing Sensor) ............. 27 Setting the Work Area Alarms ....................28 W450320A 09/12...
  • Page 250 Outline of Operation The system is intended to aid the crane operator by monitoring the load and warning of an overload or two-block condition. Crane functions are monitored by a variety of sensors. The system compares the load suspended below the boom head to the crane capacity chart stored within the computer’s memory.
  • Page 251 PRESSURE SENSORS There are two pressure sensors which measure pressure in the boom hoist cylinder. One sensor to measure the rod-side pressure and one sensor to measure the piston-side pressure. ANTI-TWO-BLOCK (ATB) The ATB switch monitors the approach of the hookblock or overhaul ball to the boom head. The switch is held in the normal position until the hookblock or overhaul ball raises a weight that is mounted around the hoist rope.
  • Page 252 Power Up Self-Test Immediately following electrical power up, the system performs a system self-test which lasts for approximately 10 seconds. During this time the display shows the rating chart number, units in use, and load. After the startup screen, the Crane Configuration page will display. This will allow the operator to check the current setup of the machine.
  • Page 253 Home Display NOTE: The Configuration Display may be accessed from the Home Display by pressing the button indicated above. The system has the capability to remember the last configuration. When removing power to the system, and re-powering, the settings remain intact until reset by the operator. W450320A 09/12...
  • Page 254 The Configuration Display The Configuration Display gives a pictorial representation of the current system setup. Each shaded area contains a group of one or more green indicators and a button to change the setup selection, depending on the application. In groups with multiple options, green indicators illuminate individually to indicate the selection.
  • Page 255 2. The OUTRIGGER selections are made by pressing the button circled. NOTE: Some cranes will not have the option of selecting different outrigger positions. OUTRIGGER POSITION SENSING (IF EQUIPPED) At power up, the system will pick the chart based on the last used configuration. It will display a white arrow above the corresponding outrigger position on the screen.
  • Page 256 4. The JIB OPTIONS may be selected by pressing the jib button multiple times to scroll through the jib options. If there aren’t any options available, the display will show “None”. NOTE: The jib must be stowed before it is erected. 5.
  • Page 257 7. The WINCH group contains two green indicators, which indicate the selection of Front or Rear winch. NOTE: If the crane is equipped with two winches, always select the winch to be used for the lift, prior to selecting the parts of line selections for each winch. 8.
  • Page 258 The Home Display 1. The OUTRIGGER setting contains four green indicators. They indicate the selection of full, intermediate, retracted outriggers and the “On Tires” selection, if applicable. The user must make the selection from the Configuration display. NOTE: OUTRIGGER selections are dependent on the crane being used.
  • Page 259 2. The ACTUAL LOAD window displays the total load, including slings, etc., suspended below the lifting point. 3. The CANCEL ALARM BUTTON is used to silence the audible alarm generated by the following conditions: • Overload • ATB Alarm • Outrigger Position Mismatch •...
  • Page 260 4. The PARTS OF LINE window shows the amount of line chosen for the configuration selected. It is adjustable from the Configuration screen. 5. The INFORMATION button displays system generated messages regarding the software versions of the equipment and fault codes. When the information button is pressed, the data is displayed as long as the button is held.
  • Page 261 7. The ERECTED JIB window shows the jib options selected for the machine. If there are no jib options available, the display will show “None”. 8. The SYSTEM has the capability of showing Metric or Imperial units. 9. The ANTI-TWO-BLOCK indicator illuminates when the ATB Limit switch detects approach to a two-block condition.
  • Page 262 10. The JIB STOWED window shows the stowed jib from the configuration screen. The length and offset of the jib in use is also shown in the Home Display. 11. The BOOM LENGTH window shows the length of the main boom from the boom foot pin to the sheave pin of the main boom head machinery.
  • Page 263 13. Press the CONFIGURATION BUTTON to return to the Configuration display screen. 14. The BOOM LENGTH symbol is shown to the right of the boom length window. 15. The BOOM ANGLE symbol is shown to the right of the boom angle window. W450320A 09/12...
  • Page 264 16. The LOAD RADIUS symbol is shown to the right of the boom angle window. 17. The SWING ANGLE symbol is shown to the right of the swing angle window. NOTE: Not used on all models. 18. The LOAD RADIUS window indicates the current radius of the boom. W450320A 09/12...
  • Page 265 19. The SWING ANGLE window indicates the swing of the boom. NOTE: Not used on all models. 20. The BOOM ANGLE window indicates in degrees, the angle of the main boom relative to horizontal. 21. The BAR GRAPH indicates the actual load relative to the maximum rated capacity of the equipment being used.
  • Page 266 Cancel Alarm Button The cancel alarm button is used to silence the audible alarm. Pressing this button once will cancel an audible alarm from an: Overload, ATB Alarm, or Operator Programmable Alarm. The audible alarm remains cancelled until the condition which caused the alarm has been resolved. Reset Function Kick-Out When rigging the machine, it may be necessary to place the boom in a position which could cause a function kick-out.
  • Page 267 Operator Programmable Alarms Accessing the Operator Alarms 1. Press the configuration button to access the operator alarms from the main working screen. 2. Press the operator alarm button. The information screen will show the current status of the operator alarms. The system has default settings for minimum and maximum boom angle; negative 15°...
  • Page 268 Operator Programmable Alarms Setting the Minimum Boom Angle Alarm 1. Move the boom to the desired minimum angle, in this example, 12.4 °. 2. Press the “MIN ANGLE -15.0” button. 3. The display will show the desired minimum angle, in this example, 12.4°. 4.
  • Page 269 Operator Programmable Alarms Setting the Maximum Boom Length Alarm 1. Move the boom to the desired maximum length, in this example, 56.9 ft. 2. Press the “MAX LENGTH OFF” button. 3. The display will show the desired maximum length, in this example, 56.9 ft. 4.

  • Page 270: Swing Alarms Illustrated (If Equipped With Swing Sensor)

    Operator Programmable Alarms Swing Alarms Illustrated (If Equipped with Swing Sensor) These alarms permit the operator to define a working arc and an exclusion zone by two set points. The following diagram illustrates the working arc and exclusion zone. A left swing alarm is activated when swinging to the left. A right swing alarm is activated when swinging to the right.

  • Page 271: Setting The Swing Alarms

    Operator Programmable Alarms Setting the Swing Alarms (If Equipped with Swing Sensor) When the swing travels one degree past either set point, the operator will be visually and audibly warned. The display will show either, “WARNING! – RIGHT SWING!” or “WARNING! – LEFT SWING!” The alarm condition will once the crane is back into the working area.
  • Page 272 5. Swing the boom to the desired left swing point and press the “LEFT SWING OFF” button. This sets the left swing point value. 6. Press the “NEXT” button to continue. 7. Move the boom into the desired working area and press the “SET” button. 8.

  • Page 273: Work Area Alarms (If Equipped With Swing Sensor)

    Operator Programmable Alarms Work Area Alarms (If Equipped with Swing Sensor) This alarm permits the operator to define an operating zone by only two set points. The use of this method results in a more defined operating zone. The following diagram illustrates the operating zone and the exclusion zone.

  • Page 274: Setting The Work Area Alarms

    Operator Programmable Alarms Setting the Work Area Alarms 1. Press the configuration button to access the operator alarms from the main working screen. 2. Then press the operator alarm button twice. The information screen will show the current status of the swing and work area alarms. NOTE: The location of the operator alarm button moves after the first press.
  • Page 275 6. The display will now show “LEFT POINT OFF”, “RIGHT POINT OFF”. 7. Place the boom tip at the desired left point. This should be the point to the left of the obstacle facing the exclusion zone to be defined. 8.
  • Page 276 11135 South James • Jenks, OK 74037 Phone: (918) 298-8300 Fax: (918) 298-8301 www.team-twg.com Greer Company is a part of TWG. As a leader in product innovation, Greer Company is committed to the ongoing improvement of its equipment. We reserve the right to make changes to our products without notice. ©2012 TWG.
  • Page 277 Elliott Calibration and Troubleshooting Manual...
  • Page 278 TABLE OF CONTENTS Introduction ..........................3 1.1 Overview and Preparation ....................3 2.1 System Self-Test ......................... 4 2.2 Display Console Problems ....................5 2.3 Fault Reporting and Fault Codes ..................6 2.3.1 Group “A” Fault Codes ....................7 2.3.2 Group “B” Fault Codes ....................7 2.3.3 Group “C”...

  • Page 279: Introduction

    Introduction This system is designed as an aid to crane operation. The operator must be knowledgeable in safety guidelines, crane capacity information, and the crane manufacturer’s specifications. This manual describes the setup, operation, and maintenance of the System. Please read, understand, and follow the instructions in this manual.

  • Page 280: System Self-Test

    2.1 System Self-Test When the power is turned on, the System performs a “SELF-TEST.” This verifies the computer, display console, cable, and sensors are working properly. During the self-test, the display will show the crane model/load chart number and units of measurement. After the startup screen, the Crane Configuration page will display.

  • Page 281: Display Console Problems

    2.2 Display Console Problems Display console problems can be difficult to isolate due to the interaction between the display and the computer unit. Failure of either unit or the cabling connecting the units can cause a malfunction. “No Fault Code” diagnoses of other system problems can be completed without the display and it’s communication with the computer unit.

  • Page 282: Fault Reporting And Fault Codes

    2.3 Fault Reporting and Fault Codes System fault codes provide ways to locate and assess problems within the Insight system. Each time the system is turned on, it performs a self-test that lasts approximately 6 seconds. Faults detected during the self-test are indicated on the display console: •...

  • Page 283: Group "A" Fault Codes

    2.3.1 Group “A” Fault Codes NOTE: Check and repair “B” and “C” group faults before proceeding with group “A” fault finding sensors. Group “A” fault codes represent faults detected for analog sensors. The following chart details all the available codes in the left column and the actions to take in the right column.

  • Page 284: Group "D" Fault Codes

    2.3.4 Group “D” Fault Codes Group “D” fault codes represent faults detected for capacity chart selection. The following chart details all the available codes in the left column and the actions to take in the right column. WRONG WRONG CHART FAULT SWING BOOM...

  • Page 285: No Fault Code" Problems

    2.4 “No Fault Code” Problems This section addresses problems not reported by the computer fault code system. 2.4.1 Anti-Two-Block Alarm (ATB) This section aides diagnosing ATB alarm problems. For detailed information, schematic, and voltages, refer to ANTI-TWO-BLOCK FUNCTION OVERVIEW. PROBLEM: •...
  • Page 286 5. Check the extension value in the display window for the correct retracted boom length. The retracted boom length should match the retracted boom length from the load chart. The value must be within ± 0.2ft. Fully telescope the boom and ensure the displayed boom length value matches the maximum length of the boom.
  • Page 287 2.4.2.4 Check Pressure Sensors There are two pressure sensors installed as part of the system. Both pressure sensors are mounted within the computer unit. One is connected to the piston side of the boom hoist cylinder via flexible hose; the other is connected to the rod side of the boom hoist cylinder via flexible hose. Both hoses are protected by velocity fuses within the boom hoist cylinder valve block on the end of the cylinder.

  • Page 288: Computer Unit Overview

    3.1 Computer Unit Overview The Computer Unit is the center of the System. It reads the sensors, controls computations and disconnect functions, and communicates with the display console/internal bar graph. The two hydraulic pressure sensors required to sense pressure within the boom hoist cylinder contained within the unit. These sensors, as well as the computer are factory pre-calibrated as a unit and may not be separately replaced in the field.

  • Page 289: Function Kickout Fuse (Fus1)

    3.4 Function Kickout Fuse (FUS1) The computer unit contains a standard 10 AMP replaceable fuse. The fuse protects the function kickout circuit and relay contacts, if a short circuit occurs across the crane kickout solenoids. Replace the fuse, if the system error codes indicate that the function kickout power feed is missing. Ensure the crane circuit breaker is closed and power from the crane is present.

  • Page 290: Display Console Overview

    4.1 Display Console Overview The Display Console allows the user to see the crane values and crane configuration selection. The display also provides calibration functions used for testing and fault diagnosis. 4.2 Checking the Display Console When operated for extended periods under extreme conditions, the console can become damaged. The damage is not always apparent.

  • Page 291: Connectors

    4.4 Connectors There are four, 6-pin Deutsch connectors on the rear of the Insight. 4.5 Horn Ensure the horn is connected to the wiring harness via the two-pin Deutsch connector. 4.6 Moisture The Display Console conforms to IP67 in protection against dust and water, when correctly installed. W450321A 09/12...

  • Page 292: Replacing The Display Console

    4.7 Replacing the Display Console Removal 1. Ensure all power is shut off during this procedure. 2. Disconnect the electrical cable from the rear of the operator’s display console. 3. Remove the defective display console from the bracket in the cab. Installation 1.

  • Page 293: Calibration Mode

    5.1 Calibration Mode The Greer Insight is an aid to crane operation. Use this system with an operator trained in Safety Guidelines, crane capacity information, and the crane manufacturer’s specifications. When the computer is new, it has no “Zero” or “Span” calibrations. It is necessary to enter “Zero” and “Span”...

  • Page 294: Entering The Calibration Mode

    5.2 Entering the Calibration Mode Follow these steps to ensure proper calibration of the Element unit. The actual crane setup must be reflected on the display. Check the Greer Element Operator’s Manual for proper setup of the display unit. 1. To enter Calibration Mode, the display must be in “Normal Operating” mode as shown below. 2.

  • Page 295: Calibration Menus

    5.3 Calibration Menus Once the security code has been entered, the display will show the following menu. Scroll through the menu options by pressing the “Menu Up” or “Menu Down” buttons. To select an item, press the button adjacent to the menu listing as shown in the example. The main menu items used to calibrate the system are: •...

  • Page 296: Calibrating The Extension Sensor Zero

    5.4 Calibrating the Extension Sensor Zero The reeling drum must be installed on the machine, the cable tied-off and the potentiometer set to a starting point for the zero. 1. Fully retract the boom and lower to “0.0” while using a digital level. 2.
  • Page 297 7. Press the “Zero Extension” button to prompt with the question “YES! Calibrate!” Press the “YES! Calibrate!” button to calibrate zero. 8. The retracted boom length will be displayed in the boom length window. Extension Sensor Zero calibration is complete. W450321A 09/12...

  • Page 298: Calibrating The Angle Sensor Zero

    5.5 Calibrating the Angle Sensor Zero The angle sensors are preset to zero on the Potentiometer before leaving the factory. If the potentiometer is disturbed, the zero setting can be affected. If this happens, the angle sensor will be inaccurate. If the factory setting has been disturbed, reestablish it by loosening the attaching screws, and rotating the pot until the desired voltage reading is attained.

  • Page 299: Calibrating Span Of Extension And Angle

    5.6 Calibrating Span of Extension and Angle WARNING! THE AREA OVERHEAD ABOVE THE CRANE MUST BE CLEAR OF OBSTRUCTIONS PRIOR TO CALIBRATING SPAN OF EXTENSION AND ANGLE! In order for the system to properly calculate the boom length and the boom angle, the “Span Number” must be entered into the system.
  • Page 300 5. Press the “YES! Calibrate!” button. 6. The Span of Extension is now calibrated. And the maximum boom length will be displayed. 7. Press the “Menu Up” button to access the Span Angle option. 8. Press the “Span Angle” button to enter the current reading from the digital level. W450321A 09/12...
  • Page 301 9. Use the following screen to enter the number. Always enter numbers with a decimal point. UPPER LEFT UPPER RIGHT LOWER RIGHT LOWER LEFT 10. The lower left and lower right buttons are used to select the number. The number inside the brackets is the current selection, in the above image, the number 3 is between the brackets.

  • Page 302: Calibrating The Swing Sensor (If Equipped)

    5.7 Calibrating the Swing Sensor (If Equipped) After completing the extension and angle span, return to the main calibration screen. 1. Press the “Menu Up” button until “04 Swing Sensor” is reached. This menu will allow a zero point to be set on the swing circle and a direction for the system to track the rotation angle. 2.

  • Page 303: Calibrating The Swing Direction

    5.7.1 Calibrating the Swing Direction The swing sensor supplies data for either direction. For consistency, the swing should count upwards (0, 1, 2, 3, etc.) when rotating clockwise. The direction of the swing can be changed while using the Greer Insight display.

  • Page 304: Disabling The Swing Sensor

    5.7.3 Disabling the Swing Sensor If there is a problem with the Swing counter or the ISS Module, it may be necessary to disable the functionality in the calibration menu. This will remove any error codes and allow the crane to be operated until the problem can be fixed.
  • Page 305 6. The Swing sensor is now disabled. The Swing angle window will display “N/A” instead of a number. W450321A 09/12...

  • Page 306: Calibrating The Outrigger Position Sensor

    5.8 Calibrating the Outrigger Position Sensor For cranes with digital switch outrigger position sensors, replace the faulty sensor. No calibration is needed. At power up, the system will use the last used OPS position and select the corresponding chart. It will display a white arrow above the corresponding outrigger position on the screen.

  • Page 307: Reeling Drum Overview

    6.1 Reeling Drum Overview The primary operation of the Reeling Drum is to measure the extension of the telescoping sections of the main boom. The Reeling Drum also includes an angle sensor to measure the main boom angle, and an electrical slip-ring which transfers the Two-Block signal from the Reeling Drum cable to the system computer.

  • Page 308: Checking The Reeling Drum Cable Layering

    6.2 Checking the Reeling Drum Cable Layering The extension reel is designed to provide accurate measurement of boom extension. To provide accurate measurement, the Reeling Drum cable must form a single flat layer across the surface of the extension reel as the boom is telescoped in and out. Any stacking of the cable will cause extension errors as the boom retracts.

  • Page 309: Sensor Baseplate Assembly

    6.4 Sensor Baseplate Assembly The Sensor Baseplate Assembly supports and connects the extension and angles sensors. It also supports the two-block switch signal and signal cable to the computer. Electrical or mechanical failure of either the angle sensor or the extension sensor potentiometers cannot be repaired in the field.

  • Page 310: Reeling Drum Voltage Checks

    6.5 Reeling Drum Voltage Checks If problems occur with the two-block alarm operation, angle, or extension sensor, refer to the following chart. Follow the Boom Position/Action column before performing any voltage checks. Measure all voltages with a digital voltmeter set to DC volts range. BOOM VOLTAGE VOLTMETER CONNECTION...

  • Page 311: Anti-Two-Block Function Overview

    6.6 Anti-Two-Block Function Overview The computer supplies a protected positive feed to the Anti-Two-Block switches at the boom/jib head via the extension reel signal cable, slip-ring, and reeling drum cable. With the Anti-Two-Block weight hanging freely on the switch, the switch contact is closed and the signal return to the computer is high (6.25 volts).
  • Page 312 W450321A 09/12...

  • Page 313: Wad/Iss Overview

    7.1 WAD/ISS Overview (If Equipped) The WAD/ISS (Work Area Definition/Integrated Swing Sensor) incoporates a sensor housed in the swing drive of the crane that measures the angle of the upper structure of the crane relative to its carrier. The sensor measures the angle by counting electronic pulses on the target gear relative from the zero point (set by the operator) in either a positive or negative direction.

  • Page 314: Wad/Iss Troubleshooting Table

    7.2 WAD/ISS Troubleshooting Table Error Message / Problem Cause Correction “SWING SENSOR SIGNAL 1 ERROR!” Cable from sensor to condition box “SWING SENSOR SIGNAL 2 disconnected. ERROR!” Replace sensor. Cable from sensor to conditiong box “SWING SENSOR ERROR!” grounded. “SWING SENSOR LOGIC REPORT!”...
  • Page 315 7.3.2 Swing Sensor Installation 1. Insert the threaded end of the sensor into the sensor port of the swing drive and screw it in until the end of the sensor contacts the gear inside the swing drive housing. Do not force the sensor any farther past this point.

  • Page 316: Replacing The Conditioning Box

    7.4 Replacing the Conditing Box 1. Place the boom in the rest (stowed position). 2. Turn of power to the crane. 3. Disconnect the cables from the conditioning box. 4. Remove the two nuts attaching the conditiong box to the mounting bracket. 5.
  • Page 317 11135 South James • Jenks, OK 74037 Phone: (918) 298-8300 Fax: (918) 298-8301 www.team-twg.com Greer Company is a part of TWG. As a leader in product innovation, Greer Company is committed to the ongoing improvement of its equipment. We reserve the right to make changes to our products without notice. ©2012 TWG.
  • Page 318 Elliott LMI Interface Installation / Configuration Manual T2300 Transmitter R2170 Receiver D160 Expansion Module D180 Expansion Module October 7, 2008 Revision 2 DM-R2170-0002A #74-1833 Coast Meridian Road, Port Coquitlam, BC, Canada • V3C 6G5 Ph# (604) 944-9247 • Fax# (604) 944-9267...
  • Page 319 Table of Contents Safety Precautions................................3 System Overview .................................4 Features..................................4 T2300 Dimensions and Controls ..........................4 R2170 Pin Assignments ...............................5 Installing the D160 Expansion Module for T2300-000201 ...................6 Installing the D180 Expansion Module for T2300-000201 ...................7 Special Functions .................................7 Installing the D160 Expansion Module for T2300-000205 ...................8 Installing the D180 Expansion Module for T2300-000205 ...................9 Special Functions .................................9 Installation Considerations............................10...

  • Page 320: Safety Precautions

    Safety Precautions READ ALL INSTRUCTIONS CAUTION: Changes or modifications not expressly approved by the party responsible for compliance could void the user's authority to operate the equipment. Failure to follow the SAFETY PRECAUTIONS may result in radio equipment failure and serious personal injury Installation PROVIDE A SAFETY CUTOFF SWITCH.

  • Page 321: System Overview

    System Overview The ORIGA T2300 / R2170 / D180 / D160 is a portable, long range, programmable radio remote control sys- tem. Designed as a compact and easy-to-use product, this member of the ORIGA family puts complete con- trol of your crane where it’s needed most, with the operator. It’s robust, easy to install and has complete self- diagnostics.

  • Page 322: R2170 Pin Assignments

    R2170 Pin Assignments There are two connectors on the R2170. Connector A is Grey, while Connector B is Black. Normally, OMNEX will pro- vide you with the appropriate pre-terminated cables for connection to the R2170. For reference, the pin functions for both connectors are provided below: Connector B (Black) Connector A (Grey)

  • Page 323: Installing The D160 Expansion Module For T2300-000201

    Installing the D160 Expansion Module for T2300-000201 Use the Wiring Diagram and the Connector Diagram below to connect the receiver pins directly to the appropriate contacts of the machine electronics. D160 Output Cables can be provided with every system to simplify the wiring proc- ess.

  • Page 324: Installing The D180 Expansion Module For T2300-000201

    Installing the D180 Expansion Module for T2300-000201 Use the Wiring Diagram and the Connector Diagram below to connect the Expansion module pins directly to the ap- propriate contacts of the machine electronics. D180 Output Cables are provided with every system to simplify the wir- ing process.

  • Page 325: Installing The D160 Expansion Module For T2300-000205

    Installing the D160 Expansion Module for T2300-000205 Use the Wiring Diagram and the Connector Diagram below to connect the receiver pins directly to the appropriate contacts of the machine electronics. D160 Output Cables can be provided with every system to simplify the wiring proc- ess.

  • Page 326: Installing The D180 Expansion Module For T2300-000205

    Installing the D180 Expansion Module for T2300-000205 Use the Wiring Diagram and the Connector Diagram below to connect the Expansion module pins directly to the ap- propriate contacts of the machine electronics. D180 Output Cables are provided with every system to simplify the wir- ing process.

  • Page 327: Installation Considerations

    Installation Considerations NOTE: The FCC and ISC require that the antenna be restricted to that supplied by the manufacturer and approved for use with this product. An op- tional 0dB coax wire antenna may be supplied. For other antenna options, please contact OMNEX Control Systems ULC Mounting and Installation The receiver can be mounted by fastening two ¼”...

  • Page 328: Test The Transmitter / Receiver Link

    Test the Transmitter / Receiver Link Follow these steps to ensure that there is a Radio Link between the transmitter and receiver Refer to the Light Legend below for diagram details 1. Press [E-Stop] 2. Power the R170 STATUS The (E-Stop) light and the LINK (Link) light will display RED (provided the transmitter is...
  • Page 329 Downloading the Transmitter ID The R2170 requires a transmitter ID from an OMNEX wireless transmitter before it can be operated. The R2170 can only hold a single transmitter ID; if another ID is downloaded then the new ID will overwrite the previous ID. OMNEX transmitter IDs are unique, ensuring that the R2170 will only respond to the correct transmitter.

  • Page 330: Download Id Code

    Downloading the Transmitter ID (continued) 4. Power T2300 into Configuration A. Hold [Power] switch UP B. Press [E-Stop] C. Twist CW & release [E-Stop] D. Release [Power] Switch 5. Download ID Code NOTE: When downloading a new ID to a receiver, a safety feature requires that the transmitter be in close proximity to the receiver. This will prevent a transmitter from accidentally reprogramming a different receiver in the area.

  • Page 331: Lcd Display Operation

    LCD Display Operations The LCD display contains a 9 button keypad. For this version, the bottom left button is operational. Pressing this button toggles the LCD backlight feature to either ON or OFF. Note: Leaving the LCD backlight on will reduce battery life LCD Display LCD Backlight Button www.omnexcontrols.com...

  • Page 332: Calibrating Proportional Controls

    Calibrating Proportional Controls The transmitter’s Paddles control the receiver’s proportional output. The Paddles/Joysticks are used in conjunction with any of the transmitter’s switches. The proportional output can be activated when a switch is held UP or DOWN; it will be- come active at an increasingly high level as the Paddle/Joystick is pushed/pulled.

  • Page 333: Diagnostics-R2170 Receiver

    Diagnostics - R2170 Receiver Normal Operation Indicator Description Lights STATUS LINK Transmitter is OFF If the transmitter is off, the receiver is operating properly. This will be the status of the receiver after the Download ESTOP ID procedure as the transmitter automatically shuts off after ID download. CAN 1 CAN 2 STATUS...

  • Page 334: Diagnostics-T2300 Transmitter

    Diagnostics—T2300 Transmitter Tether connection detected STOP Low battery. Unit will run approximately 20 hours after Battery light starts flashing. STOP The transmitter is in Calibration mode STOP STOP Power switch is stuck in the “UP” position The Active light remain on momentarily when a function is activated (i.e. a switch or STOP paddle is triggered).

  • Page 335: Diagnostics-D160 Expansion Module

    Diagnostics - D160 Expansion Module FUNCTION/ STATUS Indicator lights for the D160 Expansion Module FAULT Status Indicator FAULT FAULT STATUS STATUS Module is operating properly with a function Low battery condition detected (refer to R160 diagnostic page for possible solution) FAULT STATUS FAULT...

  • Page 336: Troubleshooting Guide

    Troubleshooting Guide Chart #1 Test the Receiver—R2170 Start OK state: Initial Condition: Status—GREEN Turn transmitter off (all lights are off—press the E- What is the state Link—RED Stop button) of the lights on the E-Stop—RED Cycle power to receiver (turn off and back on) receiver? CAN 1—GREEN Go to Chart 2...
  • Page 337 Troubleshooting Guide (con’t) Chart #2 Test the Transmitter—T2300 Turn off the receiver Ensure there are good batteries in the transmitter Turn on the transmitter OK state: Active light—steady for about 3 seconds then Toggle a switch, What is the state of paddle or joystick goes to fast flash.
  • Page 338 Troubleshooting Guide (con’t) Chart #3 Testing the Transmitter / Receiver Communication Transmitter: Transmitter: Active light is flashing Active light is flashing Receiver: What is the status of Receiver: Status—GREEN the lights of both the Status—GREEN Link—RED transmitter and Link—Flashing GREEN Fault—OFF receiver? Fault—OFF...
  • Page 339 Troubleshooting Guide (con’t) Chart #4 Considerations when Downloading the ID Potential downloading issues If testing of the receiver and transmitter both show the system as working (Chart 1 & 2), then the transmitter and receiver will both go into Download/Configuration mode. Possible issues could arise during Step 4, the download phase of reprogramming.

  • Page 340: Parts & Accessories

    Parts & Accessories Part OMNEX Part Number Description Batteries B0012 4 x “C” alkaline Fuse F0055 36V Bi-directional, Bussman ATM-7.5 Shoulder Strap FMEC-2709-01 T300 Tear-away shoulder strap Output Cable ACAB– 2727-01 R170 Output Cable, Generic ACAB-2455-01 Cable, 10m Pendant Cable ACAB-2455-02 Cable, 8m ACAB-2710-01...
  • Page 341 Service Manual 75 SerieS Digger MoDelS example Part number Motor Motor Model Ratio Shaft Bail Boss Option 1 Option 2 Supplier Number ThiS Service Manual iS effecTive: noTe: Individual customer specifications (spindle mounting, sprocket pilot, brake assembly, etc.) may S/n: 102358 To currenT vary from exploded drawing and standard part num- DaTe: 7-2012 To currenT bers shown.
  • Page 342 exploded view Drawing Eskridge EFFECTIVE FROM: S/N 102358 07-01-2012 TO: CURRENT X75-0014ad ECN:3451E 07-11-12 HWP MODEL 75 SERIES (HYDRASYNC) AUGER DRIVE GROUP ITEM DESCRIPTION 51.43:1 40.25:1 37.80:1 29.58:1 BEARING CARRIER 75-004-3012 75-004-3012 75-004-3012 75-004-3012 RING GEAR- PRI 25-004-1012 25-004-1012 25-004-1012 25-004-1012 RING GEAR- SEC 25-004-1022...
  • Page 343 lubricaTion & MainTenance Using the chart below, determine an appropriate lubricant viscosity. Use only EP (extreme pressure) or API GL-5 designated lubricants. Change the lubricant after the first 50 hours of operation and at 500 hour intervals thereafter. The auger drive should be partially disas- sembled to inspect gears and bearings at 1000 hour intervals.
  • Page 344 unit Disassembly Procedure Remove planet gears (6b) and thrust washers (6D) from the carrier (6a). Scribe a diagonal line across the outside of the unit from Inspect the planet gear (6b) bearing bore, planet shaft (6c) the bail (15) to the base (1) before disassembly to aid in the and bearings (6e).
  • Page 345 reassembly Inspect inner and outer bearing cups (12b & 12D). If cups are damaged, drive them out using a brass drift and utilizing the Rebuild primary planet carrier assembly in reverse order bearing knock-out notches in the base (1) using any needed new parts. reassembly Install bearing (7e &...
  • Page 346 Lubricate o-ring (11b) and install on the pilot of the Stage I ring gear (2). Install ring gear and align mounting holes of ring gear with holes in base. Use the scribed line made during disassembly for reference. Slide Stage I carrier (6a) onto Stage II sun gear (9). Install input gear (5) and thrust washers (10a &...
  • Page 347 Variable displacement axial piston pump V60N Applications including commercial vehicles, open circuit Nominal pressure p 400 bar nom max Maximum pressure p 450 bar Geometric displacement V : 60 ... 130 cm³/rev. Circuit symbol: Product documentation D 7960 N 10-2014-2.1 S o l u t i o n S f o r a Wo r l d u n d e r P r e S S u r e...
  • Page 348 © by HAWE Hydraulik SE. The forwarding and reproduction of this document, as well as the use and communication of its contents, are forbidden unless expresse- ly permitted. Any breach or infringement will result in liability for damages. All rights reserved concerning patent or utility model registrations. 10-2014-2.1 - D 7960 N - V60N www.hawe.de | 2015...
  • Page 349 Contents Overview: variable displacement axial piston pump types V60N................4 Available versions, main data..........................5 Basic version..............................5 Controller switching symbols..........................12 Parameters..............................15 General................................15 Planning information for parameters........................17 Characteristic curves............................18 Controller characteristic curves...........................19 Dimensions..............................21 Basic pump..............................21 4.1.1 Type V60N-060..............................21 4.1.2...

  • Page 350: Overview: Variable Displacement Axial Piston Pump Types V60N

    Overview: variable displacement axial piston pump types V60N Variable displacement axial piston pumps adjust the geometric delivery volume from maximum to zero. As a result they vary the volumetric flow that is provided to the loads. The axial piston pump type V60N is designed for open circuits in mobile hydraulics and works according to the swash plate principle.

  • Page 351: Available Versions, Main Data

    Available versions, main data 2.1 Basic version Circuit symbol: Order coding example: V60N -090 /LSNR/ZL - 2/65 - 350 A00/76 - C 022 Flange version Table 13 Flange versions (output side) Suction intakes Suction intakes: see Section Chapter 7, "Accessories, spare parts and separate components"...
  • Page 352 Table 1: Nominal size Table 2: Rotation directions Coding Geometric displacement Nominal pressure Peak pressure Coding Description /rev) (bar) (bar) Anti-clockwise Clockwise When looking at the shaft journal (for information on change of rotation direction, seeChapter 3, "Parameters") Table 3 Shaft versions Coding Description Designation/Standard...
  • Page 353 Table 4 Flange versions (input side) Table 5 Seals Coding Description Designation Coding Description Flange ISO 7653-1985 (for trucks) Flange ISO 7653-1985 10° rotated (for trucks) (only V60N-110, V60N-130) Flange SAE-B 2-hole J 744 - 45° rotated 101-2 ISO 3019-1 (only V60N-060) Flange SAE-B 4-hole J 744...
  • Page 354 Table 8 Controllers Coding Description LSNR Load-sensing controller with integrated pressure limitation. The LSNR controller is a delivery flow controller that generates a variable volumetric flow independently of the speed. It sets a constant difference between the load pressure and pump pressure by continuously adapting the geometric displacement of the pump to the quantity required for the consumers.
  • Page 355 Table 8: Controllers Coding Description Electric proportional pressure controller with increasing characteristic curve. The maximum pressure and minimum pressure can be adjusted mechanically; in between these values, electrical adjustment is possible. Electric proportional pressure controller with decreasing characteristic curve. The controller is specifically developed for fan and generator drives. In the event of a power failure, the pump generates the maximum pressure.
  • Page 356 Table 9 Intermediate plates Intermediate plate version, only in combination with one of the controllers described above Coding Description Size 060, 090, 110: Intermediate plate with power controller (torque limitation) Product “Pressure x Delivery flow” = constant Adjustment range: 25 ... 100% max. drive torque Coding LLSN, LN: Discontinued units, see Chapter 7.1, "Discontinued controller units"...
  • Page 357 Order coding example: V60N-110 RDYN-2-0-01/LSNR-350-A00/76- C 022 Table 13 Flange versions (output side) Coding V60N Flange Shaft 090/110 C 010 C 030 ISO 7653-1985 DIN ISO 14 C 011 C 021 C 031 SAE-A 2-hole J 744 SAE-A J 744 (16-4 ISO 3019-1) 82-2 ISO 3019-1 9T 16/32 DP C 012...

  • Page 358: Parameters

    Parameters 3.1 General Description Variable displacement axial piston pump Design Axial piston pump according to the swash plate principle Mounting Power take-off on commercial vehicle gearboxes (flange ISO 7653-1985 for trucks) or flange mounting Surface Primed Drive/output torque Chapter 3, "Parameters", under "Additional parameters"...
  • Page 359 Pressure and delivery flow Operating pressure Chapter 2, "Available versions, main data" Geometric displacement Chapter 2, "Available versions, main data" Dimensions Type V60N With controller (kg) 30.8 Additional parameters Description Nominal size Max. swash plate angle 20.5° 21.5° 21.5° 21.5° Absolute inlet pressure required in open circuit 0.85 bar 0.85 bar...

  • Page 360: Planning Information For Parameters

    3.2 Planning information for parameters Determination of nominal sizes Delivery flow = Geom. delivery volume (cm /rev.) Δp = Differential pressure Drive torque = Speed (rpm) η = Volumetric efficiency η = Mechanical-hydraulic efficiency Drive power η = ηv · η = Overall efficiency (η...

  • Page 361: Basic Pump

    3.3 Characteristic curves Delivery flow and power (basic pump) The diagrams illustrate the delivery flow/pressure (without controller). Drive power at max. swash plate angle and drive power at zero stroke and 1500 rpm. Drive power/pressure at zero stroke and 1500 rpm Inlet pressure and self-suction speed The diagrams show the inlet pressure/speed at the max.
  • Page 363 Flange version Housing version Y, P 269.5 69.5 266.8 66.8 Y, P 323.5 69.5 320.8 66.8 A- V60 090 110 130 Ports P, S and D (ISO 228/1) For coding UNF, ports SAE J 514 Pressure port G 1 Pressure port 1 5/16-12 UN-2B Flange suction port Flange suction port Drain port G 3/4...
  • Page 364 Coding P (ISO 7653-1985) Housing version -1 (axial ports) Delivery includes attachment kit for suction intakes according to Section 7.2 Housing version -2 (radial ports, with thru-shaft) Rotation direction clockwise Rotation direction anti-clockwise 10-2014-2.1 - D 7960 N - V60N www.hawe.de | 2015...
  • Page 365 Flange version (output side) Coding C 030 (ISO 7653-1985) Coding C 031, C 032 Coding C 034 (SAE-A 2-hole) (SAE-B 2-hole) Coding C 035 Coding C 038 (SAE-B 4-hole) (SAE-C 4-hole) www.hawe.de | 2015 10-2014-2.1 - D 7960 N - V60N...

  • Page 366: Controllers And Intermediate Plates

    Housing version -3 (radial ports) Rotation direction clockwise Rotation direction anti-clockwise A = pressure port A = suction port B = suction port B = pressure port 4.2 Controllers and intermediate plates Coding LSNR, LSNRT, NXR Coding NR Pressure limitation Pressure limitation Dynamic throttle Dynamic throttle...
  • Page 367 Coding /ZL Coding /ZV, /ZV1 Intermediate plates version Torque setting Pressure adjustment Δp (bar) /revolution Pressure range (bar) Default pressure setting (bar) Pressure limitation 20 ... 400 approx. 50 Differential pressure Δp 20 ... 55 approx. 10 (only type LSNR) Differential pressure Δp 20 ...

  • Page 368: Installation Information

    Installation information 5.1 General information The V60N variable displacement axial piston pump is designed for use in an open circuit. It can be mounted directly on a truck power take-off (PTO) using a flange in accordance with ISO 7653-1985 or using a flange in accordance with specifications.

  • Page 369: Ports

    5.2 Ports The nominal diameter of the connecting lines depends on the specified operating conditions, the viscosity of the hydraulic fluid, the start-up and operating temperatures and the speed of the pump. In principle we recommend the use of hose lines due to the superior damping characteristics.

  • Page 370: Installation Positions

    5.3 Installation positions The variable displacement axial piston pump V60N can be installed in any installation position. Observe the truck manufacturer's specifications if installing the pump directly on a truck power take-off. A support is required for tandem pumps or two hydraulic pumps mounted in series. The following points must be observed: Horizontal installation: (pump below the min.

  • Page 371: Tank Installation

    5.4 Tank installation Tank installation (pump below the min. fill level) The pump can be operated either with or without a suction tube. Using a short suction intake is recommended. Additional notes regarding installation above the fill level Special measures are required if the pump is installed above the fill level. The pump must not run dry via the pressure, intake, drain, bleed or control lines.

  • Page 372: Installation, Operation And Maintenance Information

    Installation, operation and maintenance information 6.1 Designated use This fluid-power product has been designed, manufactured and tested using standards and regulations generally applicable in the European Union and left the plant in a safe and fault-free condition. To maintain this condition and ensure safe operation, operators must observe the information and warnings in this documentation. This fluid-power product must be installed and integrated in a hydraulic system by a qualified specialist who is familiar with and adheres to general engineering principles and relevant applicable regulations and standards.

  • Page 373: Suction Intakes

    7.2 Suction intakes Order coding example: V60N - 090 R DZ N - 1 - 0 - 01/LSNR - 350 - A00/76 Table of suction intakes (including attachment kit) Nominal width Flow Geometric shape Straight Order 45° Order 90° Order Thread Order (lpm)
  • Page 374 Additional versions ■ General operating manual for the assembly, initial operation and maintenance of hydraulic components and systems: B 5488 ■ Variable displacement axial piston pump type V40M: D 7961 ■ Variable displacement axial piston pump type V30D: D 7960 ■...
  • Page 375 ELLIOTT - Built for You Digger Derrick Truck Appendix B:Parts Index...
  • Page 376 ELLIOTT - Built for You Digger Derrick Truck Appendix A:Pages Index Outrigger Controls 4-10 Bolt Torque Platform Installation & Operation (Optional Yoke Style) Bubble Level Adjustment 4-18 Change of Ownership Platform Safety Changing Hydraulic Oil Presentation Drawing-D115 Cleanliness Remote Controls...

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