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Elliott Traffic Safety Service L60 Operator's Manual

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

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  • Page 1 Operator’s Manual Traffic Safety Service, LLC 601 Hadley Road South Plainfield, NJ 07080 Phone: 908-561-4800 Fax: 908-561-3800 E-mail: info@trafficsafetyservice.com...
  • Page 2 Updated: March 10, 2020...
  • Page 3 INTRODUCTION Proposition 65 Warning-California WARRANTY Warranty Statement Change of Ownership SAFETY & OPERATION Safety Responsibilities Responsibilities per ANSI/SIA A92.2 Aerial Device Setup Platform Safety Warnings Road Transport Outrigger Controls-MHA Outrigger Controls-MHMH Operating Controls-Lower Operating Controls-Upper Automatic Rotation Lockout (Optional) 6-10 Hand Signals 6-11 Platform Removal/Installation-EZR...
  • Page 4 Emergency Lowering Procedure 8-11 Piggyback Cylinder Removal 8-12 Hi-Reach Weld Repairs 8-13 Maintenance Schedules 8-14 Troubleshooting 8-15 COMPONENT SERVICE MANUALS Winch Service Manual--Tulsa 506W HFG938D Swing Drive Jib Winch Service Manual-Pullmaster PL-1 Appendix A:Pages Index Appendix B:Parts Index...
  • Page 6 If there is a question on application and/or operation, contact the Product Safety and Reliability Department at Elliott Equipment Company. If an Elliott aerial device is involved in a personal injury or property damage incident notify the Product Safety and Reliability Department as soon as possible.
  • Page 7 Introduction READ, UNDERSTAND AND FOLLOW ALL SAFETY LABELS BEWARE OF OVERHEAD POWER LINES UNDERSTAND AND NEVER ATTEMPT EXCEEDING AERIAL DEVICE LOAD CHARTS NEVER EXCEED PLATFORM CAPACITY AND AREAS OF OPERATION BEWARE OF ADVERSE WEATHER AND GROUND CONDITIONS This manual must be retained with this aerial device for use by subsequent operating personnel.
  • Page 8 WARNING Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.  Always start and operate the engine in a well-ventilated area.  If in an enclosed area, vent the exhaust to the outside. ...
  • Page 9 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 10 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 11 Your safety, along with the safety of all personnel involved with this aerial device, is of utmost concern to Elliott Equipment Company. This manual has been developed with the safety of all personnel that work around, with, or operate this equipment as our primary goal.
  • Page 12 Modifications to any part of this aerial device 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...
  • Page 13 Safety Responsibilities operator in safe operation of your equipment. It is also your responsibility to provide the operator with properly maintained equipment and qualified crewmembers. Verify that operators are properly trained, competent, physically fit, and if required by federal, state, local regulations or project requirements, licensed and/or certified. Good vision, good judgment, coordination, and mental ability are required.
  • Page 14 Safety Responsibilities The operator must see that unnecessary people, equipment, and material are kept out of the work area. The area around the machine shall be kept in order and properly barricaded. The operator must understand and be able to accurately interpret the load chart on the aerial device.
  • Page 15 Safety Responsibilities 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. Crewmember’s Responsibilities It is the responsibility of all crewmembers to report any unsafe condition or practice that is...
  • Page 16 Safety Responsibilities Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0074 Template 11/05/14 update Tech Spec. Doc update 1/26/15 Tech Spec. c/o changes, 2/13/18 3021163 Safety Responsibilities-aerial EEC-0074 V1.2...
  • Page 17 Responsibilities per ANSI/SAIA A92.2 NOTE: Unless otherwise specified, all section references in this chapter refer to the latest version of ANSI/SAIA A92.2. Responsibilities of Dealers and Installers A. General Responsibilities: Each dealer or installer as applicable shall comply with the requirements of this section. B.
  • Page 18 Responsibilities per ANSI/SAIA A92.2 the Qualification test requirements of 5.3.2 by either obtaining certification of the test and performing a periodic test after installation, or by performing the Qualification test. F. Quality Assurance: The installer shall have a documented quality assurance program which will ensure compliance with this standard.
  • Page 19 Responsibilities per ANSI/SAIA A92.2 accordance with the manufacturer’s recommendations. Such intervals are dependent upon component function and exposure to wear, deterioration and other agents which adversely affect component life. Two classifications are designated: a. Frequent Inspection and Test: Daily to monthly intervals. b.
  • Page 20 Responsibilities per ANSI/SAIA A92.2 b. Parts, such as pins, bearings, shafts, gears, rollers, locking devices, chains, chain sprockets, wire and synthetic ropes, and sheaves for wear, cracks or distortion. c. Hydraulic and pneumatic relief valve settings. d. Hydraulic system for proper oil level. e.
  • Page 21 Responsibilities per ANSI/SAIA A92.2 If the aerial device is used for AC bare hand work, the unit shall undergo a 60 Hz test as shown in Table 2 at least every three years; If the aerial device is used for DC bare hand work, the unit shall undergo a DC test as shown in Table 2 at least every three years;...
  • Page 22 Responsibilities per ANSI/SAIA A92.2 Should the original manufacturer no longer exist an equivalent entity may determine the required procedure. 1. Maintenance Training: The owner shall train their maintenance personnel in inspection and maintenance of the aerial device in accordance with the manufacturer’s recommendations and Section 8 of this standard.
  • Page 23 Responsibilities per ANSI/SAIA A92.2 J. Safety Bulletins: Owners shall comply with safety related bulletins as received from the manufacturer, dealer or installer. K. Manuals: The owner shall insure that the operating manual(s) is stored on the mobile unit. L. Training, Retraining, and Familiarization of Operators 1.
  • Page 24 Responsibilities per ANSI/SAIA A92.2 k. Actual operation of the aerial device. Under the direction of a qualified person, the trainee shall operate the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial device. l.
  • Page 25 Responsibilities per ANSI/SAIA A92.2 f. The purpose of placards and decals. g. Workplace inspection. h. Applicable safety rules and regulations, such as Part 4, ANSI C2- latest revision, National Electrical Safety Code. (Applies to utility workers as defined in ANSI C2). The above standard is an example; other industries using aerial devices have safety rules pertinent to that industry.
  • Page 26 Responsibilities per ANSI/SAIA A92.2 G. Bare-Hand Work: For bare-hand work, a Category “A” aerial device shall be used. H. Lower Controls: The lower controls of aerial devices shall not be used for continuous operation with personnel in the platform. Responsibilities of Operators A.
  • Page 27 Responsibilities per ANSI/SAIA A92.2 1. Pre-start Inspection: Items determined by the owner in accordance with the manufacturer’s recommendations for each specific aerial device shall be inspected for defects prior to each day’s operation. The following tests and inspections shall be performed by the operator once daily, prior to first use: a.
  • Page 28 Responsibilities per ANSI/SAIA A92.2 2. Insure that the load on the platform and / or load lifting devices are in accordance with the manufacturer’s rated capacity. 3. Insure that outriggers and stabilizers are used if the manufacturer’s instructions require their use. 4.
  • Page 29 Responsibilities per ANSI/SAIA A92.2 k. Actual operation of the aerial device. Under the direction of a qualified person, the trainee shall operate the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial device. l.
  • Page 30 Responsibilities per ANSI/SAIA A92.2 C. Obligations: Upon delivery each renter or lessor of an aerial device shall provide the operators manual and the ANSI/SIA A92.2-xxxx Manual of Responsibilities for dealers, owners, users, operators, lessors and lessees of Vehicle Mounted Elevating and Rotating Aerial Devices. These manuals shall be stored on the mobile unit.
  • Page 31 Responsibilities per ANSI/SAIA A92.2 k. Actual operation of the aerial device. Under the direction of a qualified person, the trainee shall operate the aerial device for a sufficient period of time to demonstrate proficiency in the actual operation of the aerial device. l.
  • Page 32 Responsibilities per ANSI/SAIA A92.2 Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0144 Template 7/29/15 update Tech Spec Content Update 7/18/19 anemometer Tech Spec Update ANSI 9/26/19 dates ANSI/SIA HiReach EEC-0144 V1.3...
  • Page 33 Aerial Device Setup A. Position the vehicle in an area free of overhead restrictions. Check capacity chart for tasks required and position the aerial device in the proper place to complete the task safely. B. Maintain a clearance of at least 10 feet (3.05M) between any part of the aerial device, load line or load and any electrical line carrying up to 50,000 volts.
  • Page 34 Aerial Device Setup NOTE: When ground conditions or terrain require the front tires to be off ground to level the unit, cribbing must be positioned under the front tires. Operation over the front of the truck requires the front wheels, or the front jack (if so equipped) to be in contact with ground or cribbing to ensure stability.
  • Page 35 Q. Do not allow anyone to ride the loadline, hook or load. R. Only use Elliott approved personnel baskets attached to the boom for lifting personnel. S. Do not operate the crane if the anti-two block safety system is inoperative until the person responsible for supervising the lifting operations establishes procedures (i.e.
  • Page 36 Aerial Device Setup Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0072 Template 11/05/14 update Tech Spec. Doc update 1/26/15 Tech Spec. Content update 8/6/15 Tech Spec. Content update 9/6/16 Tech Spec. c/o changes, 2/14/18 3021163 Tech Spec.
  • Page 37 Platform Safety Platform Safety-hireach EEC-0145 V1.1...
  • Page 38 Platform Safety Aerial devices are designed and intended to be used for handling personnel. Guidance on the use of aerial devices is from ANSI/SIA A92.2 (latest). Personnel Platform Usage Guidelines A. The aerial device shall not be used for other lifting operations while handling personnel.
  • Page 39 Platform Safety Recommended minimum working distances are to be maintained when working near power lines or electrical hazards. Distances are based on voltages of electrical hazards. I. If electrical voltage is unknown, assume maximum voltage and maintain the maximum clearance of at least 45 feet. J.
  • Page 40 Platform Safety B. When personnel lifts occur over water, personal flotation devices shall be provided and required to be worn. Platform personnel shall wear a body (fall protection device) that is securely attached to the platform or booms tip, while over land and detached while over water.
  • Page 41 Platform Safety  Any potentially hazardous conditions. F. Aerial device shall be operated with outriggers and stabilizers fully deployed and properly set. G. The operator shall verify that the aerial device is set up and maintained within one percent of level (0.56°) during a personnel lift. H.
  • Page 42 Platform Safety PERSONNEL PLATFORM OCCUPANTS A. Remain in continuous sight or in communication with the crewmembers on the ground. 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 43 Platform Safety CLEARANCE REQUIREMENTS table or the clearances as dictated by applicable governmental regulations. Platform Installation NOTE: THIS DOES NOT APPLY TO V60 MODELS A. Position the truck and aerial device for use as outlined in the Owner’s Manual. B. If the platform has been transported to the job site on the truck, attach the loadline hook to the platform and set the platform on the ground at a radius that will allow the platform to be pinned onto the boom.
  • Page 44 Platform Safety F. Elevate the boom with the personnel platform to the approximate angle before extending the boom and moving the personnel platform to the working position. When the boom is near full extension or elevated close to 80°, controls must be applied very gently to avoid dangerous sudden movements at the platform when the telescope or lift cylinders reach full extension.
  • Page 45 Platform Safety Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0145 Template update 8/7/15 Tech Spec. c/o changes, 2/13/18 3021163 Tech Spec Content update 7/18/19 anemometer Platform Safety-hireach EEC-0145 V1.1...
  • Page 46 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.  Make sure platform auto-leveling is shut off on units equipped with electric leveling sensors, and that the platform stow arrows are aligned. ...
  • Page 47 Road Transport Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0071 Template 11/05/14 update Tech Spec. Doc update 1/26/15 Tech Spec. Content update 8/7/15 Road Transport-aerial EEC-0071 V1.2...
  • Page 48 Outrigger Controls-HiReach A. Left/Right Rear Outrigger Beam Lever- Activate lever “UP” or ”DOWN” to extend/retract the left/right rear outrigger beam B. Left/Right Rear Outrigger Jack Lever-Activate lever “UP” or ”DOWN” to retract/extend the left/right rear outrigger C. Left/Right Front “A” Outrigger Lever-Activate lever “UP” or ”DOWN” to retract/extend the left/right front outrigger D.
  • Page 49 Outrigger Controls-HiReach Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0146 Created 7/30/15 Document Outrigger Controls Hi Reach MHA EEC-0146 V1.0...
  • Page 50 Outrigger Controls-HiReach MHMH A. Left/Right Rear Outrigger Beam Lever- Activate lever “UP” or ”DOWN” to extend/retract the left/right rear outrigger beam B. Left/Right Front Outrigger Beam Lever- Activate lever “UP” or ”DOWN” to retract/extend the left/right front outrigger beam C. Left/Right Rear Outrigger Jack Lever-Activate lever “UP” or ”DOWN” to lower/raise the left/right rear outrigger jack D.
  • Page 51 Outrigger Controls-HiReach MHMH Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0086 Created 2/6/15 Document Tech Spec. Content update 7/30/15 Outrigger Controls Hi Reach MHMH EEC-0086 V1.1...
  • Page 52 Operating Controls-HiReach     LOWER CONTROLS A  B  Boom Controls-Lower Power Take-Off (PTO) This is located in the truck cab. PTO must be engaged to provide power to HiReach functions. Refer to truck manuals for operating instructions. CAUTION: Driving truck with PTO engaged may damage hydraulic pump. A.
  • Page 53 Operating Controls-HiReach     C. Boom Control Lever Push Forward-“DOWN” position to lower boom Pull back-“UP” position to raise boom Lower Control Enable-Button must be pressed for lower controls to function. Only one must be pressed D. Boom Telescope Control Lever Push Forward -“IN”...
  • Page 54 Operating Controls-HiReach     I  J  A  B  Master Controls-Lower A. Horn Button Push to activate horn. B. Anti Two-Block Override Switch Up-Momentary switch that overrides the A2B function. This disables the function cut outs when switch is held in the UP (override) position. Down-Normal A2B operation resumes when momentary switch is released to a neutral (normal) position.
  • Page 55 Operating Controls-HiReach     Down-Digger operates at low speed F. Master Switch – Emergency Stop Switch  Switch Master Switch to “ON” position, to operate HiReach. Switch Master Switch to “OFF” position to disable HiReach. G. Control Switch Up-Switch control to platform controls Down-Switch control to turret controls NOTE: Turret controls are for material handling with the boom winch only.
  • Page 56 Operating Controls-HiReach     NOTE: For main boom, do not exceed the operating radius for the rated loads on the chart. Anti Two-Block System If a two-block condition exists, the telescope out, winch up and boom down functions will be disabled. Immediately correct this condition to prevent tipping or structural damage.
  • Page 57 Operating Controls-HiReach     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0099 Created 2/27/15   Document Tech Spec. Content update 5/29/15 Tech Spec. Content update 8/7/15 Tech Spec. Lwr. Ctrl. 9/15/17 Update Operating Controls Hi Reach Lower EEC-0099 V1.3...
  • Page 58 UPPER CONTROLS A  NOTE: Enable Foot Switch/Joystick Locking Collars Elliott HiReach aerial devices are equipped with a foot switch that must be activated, along with the locking collars on all joysticks. To avoid unintended/accidental aerial device movement, more than one movement of the levers or switches needs to occur for aerial device movement.
  • Page 59 Operating Controls-HiReach     B. Platform Leveling Momentary Switch Turn CW-“IN” position to raise platform towards boom Turn CCW-“OUT” position to lower platform away from boom C. Swing Control Joystick Pull back-“LEFT” position swings turret left (counterclockwise) Push Forward-“RIGHT” position swings turret right (clockwise) D.
  • Page 60 Operating Controls-HiReach     I. Jib Winch Control Joystick Push Forward-“UP” position – Winch winds up cable to raise load Pull Back -“DOWN” position – Winch pays out cable lowers load J. Truck Start Switch Turn CW-Press to activate the truck engine. Release the switch as soon as the engine starts.
  • Page 61 Operating Controls-HiReach     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0175 Created 4/13/16   Document   Operating Controls EEC-0175 V1.0...
  • Page 62 Automatic Rotation Lockout (Optional) The Automatic Rotation Lockout system allows for unrestricted operation over one side of the vehicle, while restricting the boom from swinging over the opposite side. This is accomplished by setting the outriggers full out and down on the work side, and setting the outriggers straight down on the non-working side.
  • Page 63 Automatic Rotation Lockout (Optional) Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0241 New Document 11/15/17 Automatic Rotation Lockout EEC-0241 V1.0...
  • Page 64 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 65 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 66 Platform Removal/Installation-     Removing EZR Platform A. With the boom slightly extended, lower the boom and lightly set the platform on a flat surface. B. Disconnect all hydraulic connections between the platform and rotation bracket. Lift Capacities aerial EEC-0176 V1.0...
  • Page 67 Platform Removal/Installation-     C. Pull and turn both platform locking pins to lock them in the OPEN position. D. Tilt the leveling bracket downwards (using platform leveling “OUT”) until the rotation bracket clears the top plate of the platform receiver, then retract the boom several inches to pull the rotation bracket away from the platform.
  • Page 68 Platform Removal/Installation-     Installing EZR Platform A. Start with both platform locking pins in the OPEN position. Make sure there are no hoses or cables hanging in front of the receiver area of the platform. B. Tilt the leveling bracket slightly downwards and position the boom so the rotation bracket is near the platform receiver.
  • Page 69 Platform Removal/Installation-     C. Extend the boom until the top of the rotation bracket starts to enter the platform receiver. Raise the boom slowly until the rotation bracket starts to contact the top plate of the platform receiver. D. Tilt the leveling bracket upwards (using platform leveling “IN”) until the platform attaches and starts to lift off the ground.
  • Page 70 Platform Removal/Installation-     E. Flip down both platform locking pins to engage them in the LOCK position. F. Reconnect all hydraulic connections between the platform and rotation bracket. Lift Capacities aerial EEC-0176 V1.0...
  • Page 71 Platform Removal/Installation-     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-076 New document 4/13/16         Lift Capacities aerial EEC-0176 V1.0...
  • Page 72 Platform Jib Safety-Aerial Device Do not operate the platform jib unless you have thoroughly read and understand the safety guidelines listed in this section. The proper procedures for jib deployment, raising, lowering, and stowing can be found in the Platform Jib Operation-Aerial Device section.
  • Page 73 Platform Jib Safety-Aerial Device • Weights of additional load handling devices such as slings and shackles shall be considered part of the load and must be deducted from the rated load • Maintain at least five full wraps of wire rope around the winch drum at all times •...
  • Page 74 Platform Jib Safety-Aerial Device Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0178 New Document 4/18/16 Tech Spec. c/o changes, 2/13/18 3021163 Platform Jib Safety-Aerial EEC-0178 V1.1...
  • Page 75 Platform Jib Operation- Aerial Device     Deployment Procedure A. Unstow the jib and remove the angle pin. B. Reach down and grab the jib near the middle. Lift up and allow the jib to slide backwards along the track as it swings upwards. Once the rear pin stops at the end of the track, lift the jib to the desired angle and install the angle pin.
  • Page 76 Platform Jib Operation- Aerial Device     C. Remove the front extension pin, pull out the jib’s inner section to the desired length, and reinstall the pin. D. Pay out the winch loadline and reeve loadline through the stow loop on the jib post and over the front and rear sheaves.
  • Page 77 Platform Jib Operation- Aerial Device     Raising Procedure A. To raise the jib, follow steps A and B from the Jib Deployment Procedure. B. Once the jib is in the lower and retracted position, pay out the winch loadline and remove the hook from the stow loop on the jib post.
  • Page 78 Platform Jib Operation- Aerial Device     D. Lift straight up on both the jib and post until the lift-assist latch “clicks” to engage. NOTE: The latch may engage the lower pin hole after raising 12 inches, which is NOT the final position. The post pin cannot be installed in this position. When this occurs, rotate the jib counterclockwise until the latch disengages and continue to lift the jib while rotating it back straight again.
  • Page 79 Platform Jib Operation- Aerial Device     E. Reinstall the post pin. F. Pull the lift-assist latch to disengage and the jib post will drop down slightly and onto the post pin. G. The jib is now in the raised position. Follow the remaining steps of the Jib Deployment Procedure to finish setting up the jib for use.
  • Page 80 Platform Jib Operation- Aerial Device     Lowering Procedure A. Remove the loadline and pin the jib in the retracted position. A. Lift up on both the jib and jib post until the lift-assist latch “clicks” to engage. The post pin will now be loose and can be removed. DISENGAGED ENGAGED WARNING: Be careful not to accidentally rotate the jib with the post pin...
  • Page 81 Platform Jib Operation- Aerial Device     B. Using both hands to support the jib and jib post, slowly rotate the jib counterclockwise until the lift-assist latch disengages and the jib starts to lower. Rotate the jib straight again while lowering down to the lower position. C.
  • Page 82 Platform Jib Operation- Aerial Device     Stowing Procedure A. The jib must be in the lower and retracted position before it can be stowed. B. Remove the loadline and hook it to the stow loop on the rear of the jib post. Winch UP slowly until the loadline starts to tighten.
  • Page 83 Platform Jib Operation- Aerial Device     C. Remove the angle pin. Pull the jib forwards slightly and slowly allow the jib to swing downwards while also sliding forwards in the track. D. Once the jib is hanging down in the stowed position, reinstall the angle pin and strap down the jib to secure it in place.
  • Page 84 Platform Jib Operation- Aerial Device     Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0177 New Document 4/13/16 Platform Jib Operation-Aerial Device EEC-0177 V1.0...
  • Page 85 F. Reduce load ratings to compensate for wind, ground conditions and the dynamic effects of swinging, hoisting, and lowering the load. NOTE: For units installed outside the factory, the installer must perform a stability test in compliance with instructions furnished by Elliott Equipment Company. Lift Capacities aerial EEC-0125 V1.2...
  • Page 86 Lift Capacities     Platform Removal: The load chart for the aerial device may be specified for use with the platform removed. Subtract the listed platform weight from the permitted lifting capacity if the platform is not removed. To remove the platform, follow the instructions in the platform installation and operation section of this manual.
  • Page 87 Lift Capacities     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0125 Template 6/25/15   update Tech Spec. Content update 8/3/15 Tech Spec. Update 11/9/17 danger/caution Lift Capacities aerial EEC-0125 V1.2...
  • Page 88 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 89 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 90 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 91 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 92 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 93 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 94 Be sure the unit is in an area free of overhead obstructions and power lines. The Walk-Around Inspection A. Frequency: Prior to operating an Elliott aerial device, complete a walk-around inspection and operation check on a daily basis. These should be a common practice for any safety-conscious equipment operator.
  • Page 95 Required Inspections fiber optic conductor), starting from the platform controls down through the cable carrier. Ensure the cable clamps are in a good position to secure the hoses and cables, and that they are in a proper working order. D. Platform Control Inspection: Inspect the safety chain (or rope) on the platform entrance to ensure it latches properly.
  • Page 96 Required Inspections necessary. The use of an aerial device without making the necessary corrections is a safety violation. Do not operate the aerial device until it has been serviced and maintained according to the manufacturer’s specifications and schedule. Functional Check of Lower Controls A.
  • Page 97 Required Inspections engage the Power Take Off (PTO) to start the HiReach hydraulic pump. NOTE: the PTO must not be engaged when the vehicle is moving. Switch the master switch on to provide power to the HiReach to permit pressurizing the hydraulic system.
  • Page 98 Required Inspections on a side slope, the upper leg of the A outrigger must still be extended to the stripe to prevent the unit from becoming unstable to the up-hill side. Use cribbing under the down-hill leg if necessary. Check the level bubble on the lower control panel bottom to ensure the bubble is centered right-to-left.
  • Page 99 Required Inspections hanging out of the cable carrier as this will cause damage or a possible leak in these components. Upon completing this check, retract the boom. Check to see that there is adequate clearance before operating boom rotation. Operate swing left and right, and then center the boom and operate boom down to restore the boom to the boom stand.
  • Page 100 Required Inspections with an EZR platform, check that all platform attachment pins are secure and in the locked position. To operate the multi-lever electronic upper controls (on units so equipped), the locking collar must be lifted up in order to move the individual electronic control levers in either direction.
  • Page 101 According to OSHA regulations, all personnel in the platform shall wear a safety harness with an energy-absorbing lanyard attached to the lanyard attachment point. Elliott also recommends that approved hard hats be worn by all operating and ground-level personnel, as the user’s head is the highest point when operating an aerial...
  • Page 102 Required Inspections personnel, their tools and equipment or lifting a load. Base controls are never to be used for positioning with personnel in the aerial work station, except in case of emergency as required by law, due to the hazard this practice presents to personnel.
  • Page 103 Required Inspections policy, and at least within the last 12 months. Do not operate an insulated unit near power lines if it has not been tested within the past 12 months. Insulating aerial devices must not be used near power lines with a higher voltage than the designed voltage of the aerial lift.
  • Page 104 Required Inspections the OFF position until the engine stops. Release the switch and let it return to the RUN position after the engine stops running. Turn the platform master switch OFF. Functional Check of HiReach Boom Mounted, Material Handling Winch A.
  • Page 105 Required Inspections By reeving the load line for two-part operation the lifting capacity of the winch and load line is doubled and the lifting speed is reduced 50 percent. Be sure not to exceed the load chart for each boom length and angle. To reeve the load line for two-part operation, first remove the down-haul ball or snatch block from the load line.
  • Page 106 If a load chart decal is not present or is not legible, do not operate the unit. Most Elliott load charts are shown with the platform removed. If the platform is on the boom, reduce the allowable lift capacity by the appropriate amount shown on the load chart.
  • Page 107 Required Inspections near power lines if it has not been tested within the past 12 months. Be sure the fiber rope on insulated units is clean and dry. Insulating boom vehicles must not be used near power lines with a higher voltage than the designed voltage of the aerial lift.
  • Page 108 Additional Information If the unit is equipped differently than those covered in this section or the operations manual, contact an authorized Elliott distributor in your area, or contact Elliott Equipment Company for proper operating procedures. Elliott Boom Disassembly and Inspection Elliott Equipment Company recommends that Boom Truck, HiReach and Digger Derrick booms be disassembled and inspected at seven-year intervals.
  • Page 109 The recommended seven-year disassembly and inspection does not remove the requirement for daily, weekly, monthly and periodic inspections as defined by Elliott, ASME B30.5, ANSI A92.2, ANSI A10.31 and OSHA CFR 1926.1400. Revision History Required Inspections-aerial1 EEC-0088...
  • Page 110 Required Inspections Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0088 New Document 2/10/15 Tech Spec. Content Update 5/28/15 Tech Spec. Content Update 8/7/15 Tech Spec. Content Update 4/19/16 Tech Spec. ADD: Boom 8/13/18 Disassembly and Inspection Tech Spec Content Update 7/18/19...
  • Page 111 Inspection Record The following periodic inspection is the responsibility of owner and user. These activities shall be performed by qualified personnel. No one set of instructions will apply to all HiReach units, but at a minimum will provide a record of daily, weekly, monthly, and yearly inspections.
  • Page 112 Inspection Checklist     PERIODIC INSPECTION CHECK LIST (Must be performed at least once every 12 months) Unit Number Owner License Number Date Model Hours & Mileage Location Operator/Inspector Item# Remarks 1. P.T.O.; Mounting & Leaks 2. P.T.O.; Operation, controls & installation of decals 3.
  • Page 113 Inspection Checklist       Item# Remarks 12. Throttle control; Mounting & operation. 13. Mounting /utility body; cracked welds, loose fasteners, etc. 14. Outriggers; Mounting brackets, mounting bolts, pads & pins 15. Outriggers; Cylinders, brackets, guards & hosing 16. Rotation gearboxes; Mounting, leaks, alignment of gears &...
  • Page 114 Inspection Checklist       Item# Remarks 25. Second boom & outer welds, dents, other damage 26. First telescoping boom; Inner & outer welds, dents, other damage, wear pad condition 27. Second telescoping booms; Inner & outer welds, dents, other damage, wear pad condition 28.
  • Page 115 Inspection Checklist     Item# Remarks 38. Outrigger valve(s); Operation & proper sequence pilot check valves hold? 39. Tool valve(s); Mounting, hosing & leak 40. Boom Rests & interlock switch(es) 41. Winch; Mounting, operation & Condition 42. Winch; Load line, hook & weight 43.
  • Page 116 Inspection Checklist       Item# Remarks 54. Tool compartments; Check & lubricate all hinges & paddle handles 55. Rotary beacon; Mounting & operation. Indicate location of fuse with decal 56. Spotlights and/or floodlights; Mounting & operation. Indicate location of fuse with decal 57.
  • Page 117 Inspection Checklist     Item# Remarks 68. Outrigger pin collars welded 69. Check welds on torgue frame, turret box. 70. Turret 71. Check tire pressure and adjust to recommended P.S.I. 72. Replace high pressure & return filter elements. 73. Wash out metal strainer on line and reinstall.
  • Page 118 Inspection Checklist     Revision History   Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0135 Template 7/7/15 update     Inspection Checklist EEC-0135 V1.0...
  • Page 119 Stability Load Test-Req’d for Non-Factory Install Aerial Devices     AERIAL DEVICE LOAD STABILITY TEST SUMMARY REF: OSHA 1910.180 and SAE J765 Testing Agency Location Make HiReach Model Serial No. Condition: Used Hours/Miles Mounting: Type Size Tires: Size Pressure (PSI) Boom: Type Length (Ft) Platform Jib: Type...
  • Page 120 Stability Load Test-Req’d for Non-Factory Install Aerial Devices     BALANCE POINTS Position of With Outriggers Superstructure Load (lb) Radius (ft) Remarks: Test Technician Date of Test Stability Load Test EEC-0134 V1.1...
  • Page 121 Stability Load Test-Req’d for Non-Factory Install Aerial Devices     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0134 Template 7/2/15   update   Tech Spec Title update 8/6/15     Stability Load Test EEC-0134 V1.1...
  • Page 122 L60 Specifications Hydraulic Max. Flow Flow Pressure PSI Pressure System L/Min (+/-100) Gear Pump 48cc 60.6 2500 (2.94 inch³) Pump Flows listed are at free flow condition (100 PSI) Functions Relief Setting Relief Flow Flow Operating Operating PSI (+/-100 unless Setting L/min Time...
  • Page 123 L60 Specifications Filtration 5 Micron (Pressure) Filtration (Return) NOTE: Lift Up time is full cylinder stroke Winch System Performance Category Standard Line Pull 4,000 lb. 3/8” 6 x 37 IWRC IPS Wire Rope Breaking Strength 14,000 lb. Cable Length 180 ft. Winch Line Pull Line Speed Layer...
  • Page 124 L60 Specifications Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0105 Doc creation 03/13/15 Tech Spec. Content update 7/22/15 Tech Spec. Tolerance 2/21/18 added L60 Specs EEC-0105 V1.2...
  • Page 135 Maintenance Safety Perform the following safety steps whenever possible before maintaining or repairing the aerial device: 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 136 Maintenance Safety Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0076 Template 11/05/14 update Tech Spec. Doc update 1/12/15 Maintenance Safety-aerial EEC-0076 V1.1...
  • Page 137 Cleanliness The long life of an aerial device’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 138 Cleanliness Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0077 Template 11/05/14 update Tech Spec. Doc update 1/26/15 Cleanliness-aerial EEC-0077 V1.1...
  • Page 139 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 140 Bolt Torque Bolt Torque EEC-0016 V1.2...
  • Page 141 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 142 Lubrication-L60R Lubrication Notes 1. Fully extend boom and apply a light coat of grease to sides and bottom of moving boom sections in area of wear pads. If extending the boom to its full length exceeds the allowable limits of the load/range chart, a means by which to support the boom shall be used to prevent tipping of the machine.
  • Page 143 Lubrication-L60R has a bypass that opens when the pressure exceeds 25 PSI. Operating the crane when the filter is bypassing may damage the pump, valves and hydraulic system. 10. Replace the filter after the break-in period of 20 hours. After that, replace the filter after 500 hours of usage or annually, whichever comes first.
  • Page 144 Lubrication-L60R 3. LUBRICATING OIL Normally the rotation gearbox, the platform jib winch gear box (on equipped units) or the turret winch gear box (on equipped units) will not require additional oil. However, an occasional oil level check should be made by removing the appropriate plug on the side of the gear case (see specific location in the parts section of this manual).
  • Page 145 Bubble Level Adjustment Check the adjustment of the bubble levels on the control consoles monthly: A. Extend outriggers and stabilizers and level the aerial device 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 146 Bubble Level Adjustment Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0079 Template 11/05/14 update Tech Spec. Doc update 1/12/15 Bubble Level Adjustment-aerial EEC-0079 V1.1...
  • Page 147 Changing Hydraulic Oil A. Bring the oil to operating temperature by running the aerial device functions. B. With all controls in neutral position, turn the truck engine off. C. Remove the drain plug from the tank bottom. If the oil is extremely dirty or contaminated, crack open fittings at high points on the system to vent the lines.
  • Page 148 Changing Hydraulic Oil Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0078 Template 11/05/14 update Tech Spec. Content update 1/12/15 Tech Spec. Content update 8/5/15 Tech Spec Delete Oil 9/19/19 Change Interval Changing Hydraulic Oil-aerial EEC-0078 V1.2...
  • Page 149 PQ Controller adjustment – Hi Reach Cranes Correct adjustment of the PQ controllers on Elliott cranes is crucial to the smooth operation of the boom. Elliott uses a dual range, dual coil controller. The following procedure can be followed for adjusting the PQ electronic controllers: Verify that the pilot pressure is correct.
  • Page 150 Platform Leveling System      The leveling system uses a master cylinder that pins to the turret and activates from the main boom elevation  Oil transfers between the master cylinder and the two slave cylinders that level the platform when booming up or down ...
  • Page 151 Platform Leveling System     the boom. Do not turn this valve up more than required or you will not be able to level the platform manually  If the platform lags when booming down, turn the retract relief cartridge on the master cylinder clockwise in ¼...
  • Page 152 Platform Leveling System     Platform Level System EEC-0137 V1.0...
  • Page 153 Platform Leveling System     Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0137 Template 7/20/15 update Platform Level System EEC-0137 V1.0...
  • Page 154 Air Bleed-Platform Leveling System     If the platform leveling system feels “loose” or “spongy”, it may be a sign there is air in the leveling system. The platform leveling system operates as a closed loop, so cycling the boom will not remove trapped air in the system. The following are steps to air from the platform leveling system: 1.
  • Page 155 Air Bleed-Platform Leveling System     14. Loosen fittings on extend hoses on both slave cylinders. 15. Activate the manual leveling extend switch until all air is removed from the extend circuit. 16. Tighten the extend hoses on slave cylinders. 17.
  • Page 156 Air Bleed-Platform Leveling System     Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0136 Template 7/17/15 update Air Bleed-Platform Level System EEC-0136 V1.0...
  • Page 157 Ensure all filters are properly maintained and serviced. Electrical 1. The Elliott HiReach electrical system power source is in the truck battery and alternator. Standard automotive testing procedures should be applied to the HiReach part of the total electrical system.
  • Page 158 Component Evaluation     4. Failure in the electrical system can result in intermittent or undesirable actuation of the control valves. When any malfunction occurs, the master switch must be turned OFF until the problem is resolved. Rotation Bearing and Gear Box 1.
  • Page 159 Component Evaluation     3. If the dirty-filter pop-up indicator on the pressure filter housing located between the pump and the boom control valve (on units with electronic or fiber optic platform controls) indicates the filter is dirty use the following procedure: A.
  • Page 160 Component Evaluation     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0131 Template 7/2/15   update   Tech Spec. Content update 8/5/15     Component Evaluation EEC-0131 V1.1...
  • Page 161 Emergency Lowering Procedure     In the event of a failure of the main hydraulic and/or electric power supply, follow the below listed procedure to lower the platform to the ground. 1. Utilize the 12-volt emergency pump system Use the emergency pump system to provide hydraulic power. Hold either of the two emergency pump switches (located in the platform or at the lower controls) in the ON position and operate the controls in the normal fashion to retract, rotate and lower the boom to ground.
  • Page 162 Emergency Lowering Procedure     Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0130 Template 7/2/15 update Tech Spec. Content update 8/5/15 Emergency Lowering Procedure EEC-0130 V1.1...
  • Page 163 Piggyback Cylinder Removal     Removal of Piggyback Cylinder from Three-Section Booms 1. Extend both smallest and second-smallest boom sections out equally, from 14 to 16 inches. This can be obtained by extending the first two sections and observe if they come out together or one at a time.
  • Page 164 Piggyback Cylinder Removal     10. Set the two removed sections of boom down on sawhorses, and remove the top wear pad from the platform end of the second-smallest section. Lift the tip section boom until bottom wear pads are loose, and then remove bottom and side wear pads.
  • Page 165 Piggyback Cylinder Removal     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0138 Template 7/21/15   update       Lift Capacities aerial EEC-0138 V1.0...
  • Page 166 HiReach Weld Repairs     All weld repairs must be performed in accordance with the following: 1. Welding & Structural design standards must be adhered to per ANSI A92.2. 2. Welding procedures & practices must be followed per AWS D1.1, American Welding Society Structural Welding Code.
  • Page 167 HiReach Weld Repairs     Revision History Document Document Revision Revision Notes Revision   type Number History Date   Tech Spec. EEC-0128 Template 7/2/15   update       HiReach Weld Repairs EEC-0128 V1.0...
  • Page 168 General Maintenance Proper maintenance of an Elliott HiReach will result in many years of quality service. The maintenance program shall require all daily, weekly, and annual inspections. Additionally the program will include the checking of all mechanical, electrical, and hydraulic equipment, as well as proper lubrication, and oil and filter changes.
  • Page 169 Maintenance Schedules     plate (  100 psi). If the pressure is not correct, re-set the boom control valve pressure relief cartridge. 4. Test outrigger control valve relief pressure. With warm oil and with engine on high speed, stow boom, retract outrigger, then continue to hold outrigger control lever in retract position.
  • Page 170 Maintenance Schedules     7. Weekly inspection should be documented for customer’s maintenance records. Monthly Maintenance Schedule 1. Perform daily and weekly maintenance schedule. 2. Polish the fiberglass boom(s) (on units so equipped) with fiberglass boat polish to seal boom so it will repel any moisture. 3.
  • Page 171 Maintenance Schedules     Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0129 Template 7/2/15 update Tech Spec Content update 8/5/15 Maintenance Schedules EEC-0129 V1.1...
  • Page 172 Troubleshooting Category Problem Possible Cause Diagnostic Action Corrective Action Boom Boom extends Internal or Check for oil leak Replace seals in during external leaks in inside boom area. extension transportation. extension cylinder(s). cylinder. Boom Boom extends Leaking holding Reset holding valve Clean or replace during valve.
  • Page 173 Troubleshooting Category Problem Possible Cause Diagnostic Action Corrective Action Boom Sloppiness of Missing wear Replace or shim platform or pads or worn boom wear pads. excessive side pads play in platform. Boom (DOES Boom down, Anti-2-block Check flag on switch Replace wires or NOT APPLY TO boom out and...
  • Page 174 Troubleshooting Category Problem Possible Cause Diagnostic Action Corrective Action Platform Platform will Defective system Repair leak, replace become out of relief valve. defective system level while boom relief. is stored or over a short period of time not being used. Winch Load will lift but Winch brake is...
  • Page 175 Troubleshooting Category Problem Possible Cause Diagnostic Action Corrective Action Outrigger Leg creeps up Pilot check valve Clean or replace under load or defective or check valve or down during Worn seals replace seals. storage. inside cylinder. Outrigger Leg will not Bent let causing Replace leg.
  • Page 176 Troubleshooting Category Problem Possible Cause Diagnostic Action Corrective Action Electrical One control Broken wire or Continuity check of Replace controller, function in upper plug, defective function wire, voltage solenoid or wire as control box controller, output check of needed. malfunctions. defective controller.
  • Page 177 Troubleshooting Category Problem Possible Cause Diagnostic Action Corrective Action Electrical Engine dies or Defective stop Replace kill relay in will not start relay. lower terminal box. with master switches off. Electrical Control will start Broken wire in Check voltage in wire Replace wire with or stop main harness...
  • Page 178 Troubleshooting Revision History Document Document Revision Revision Notes Revision type Number History Date Tech Spec. EEC-0132 Template 7/2/15 update Tech Spec. Content update 8/4/15 Troubleshooting aerial EEC-0132 V1.1...

  • Page 179: Table Of Contents

    Service Manual Model 506W Winch Table of Contents MODEL-CODE....................................2 PART & SERIAL NUMBER LOCATION..........................2 SAFETY NOTES ....................................2 INTRODUCTION AND THEORY OF OPERATION......................3 HYDRAULIC SCHEMATIC.................................4 MAINTENANCE....................................5 WIRE ROPE....................................5 LUBRICATION....................................6 DISASSEMBLY.....................................7 REASSEMBLY....................................8 SERVICING THE MOTOR................................9 SERVICING THE BRAKE................................10 SERVICING THE PLANETARY SET ............................12 TROUBLESHOOTING................................13 BILL OF MATERIALS ................................14 EXPLODED ISOMETRIC ASSEMBLY DRAWING......................16...

  • Page 180: Model-Code

    MODEL-CODE PART & SERIAL NUMBER LOCATION Part and serial numbers can be located on the winches as shown below: SAFETY NOTES WARNING FAILURE TO HEED 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 181: Introduction And Theory Of Operation

    INTRODUCTION AND THEORY OF OPERATION The 506W planetary winch design is composed of an input from a high torque, low speed geroler motor or a high speed gear or piston motor, driving through a multiple disc brake, through a planet set to the cable drum. The multiple disc brake is spring applied and hydraulically released through a port in the brake housing.

  • Page 182: Hydraulic Schematic

    HYDRAULIC SCHEMATIC...

  • Page 183: Maintenance

    MAINTENANCE Tulsa Model 506W 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 are no oil leaks present, that all mounting bolts and other fasteners are tight, and that wire rope is in good condition.

  • Page 184: 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 185: Disassembly

    DISASSEMBLY Drain brake and gear oil. See lubrication Section for instructions. Stand the winch on its end with the motor pointing up. Remove the brake line from the brake housing (Item 11). Remove the motor and brake valve assembly from the winch by removing two capscrews (Item 53) holding the motor to brake cover.

  • Page 186: Reassembly

    REASSEMBLY Thoroughly clean all parts. Replace those, which show wear or damage. Inspect the drum (Item 3) and base (Item 15) for structural integrity and replace if necessary. Install bearing (Item 5) and seal (Item 4) into drum. Slide drum onto shaft (Item 6) aligning and seating bearing to shaft.

  • Page 187: Servicing The Motor

    SERVICING THE MOTOR Tag brake line for proper re-installation and remove them from the motor and counterbalance block. Remove the four capscrews (Item 47) and the counterbalance block ( Item 18) from the motor (Item 17). 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 188: Servicing The Brake

    SERVICING THE BRAKE Evenly remove the one capscrew (Item 41) and five nuts (Item 40) holding the brake cover in place. Spring pressure will raise the cover up as the capscrew and nuts are loosened. Remove the cover from the brake housing. Remove the springs (Item 32) from the piston (Item 13) and check them for free height.
  • Page 189 Lubricate seals and back-up ring then install the piston into the brake housing tapping it gently down until it is seated. Install the springs (Item 32) into the spring pockets of the piston. If working in a horizontal position, coat the bottom of each spring with chassis lube to keep it in position. lubricate the new o-ring (Item 10) with light oil and install it into the groove on the brake cover.

  • Page 190: 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. Before reassembly, be sure to insert the round plates into the carriers.

  • Page 191: 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 192: Bill Of Materials

    BILL OF MATERIALS ITEM NO. TWI PART NO. QTY. DESCRIPTION CONTACT FACTORY SIDE PLATE CONTACT FACTORY SIDE PLATE 42351 DRUM (7 1/2” barrel, 11 1/8” flange) 42834 DRUM (7 1/2” barrel, 11 7/8” flange) 42837 DRUM (7 1/2” barrel, 12 3/4” flange) 43142 DRUM (7 1/2”...
  • Page 193 32186 O-RING 42337 BACK UP RING 42335 O-RING 42336 BACK UP RING 41718 BRAKE SPRING 41873 SWIVEL ADAPTER 41805 OIL SEAL 42392 O-RING PLUG 13050 BREATHER 41307 O-RING PLUG 32220 PIPE PLUG 24943 CAPSCREW 20271 42365 CAPSCREW 42397 CAPSCREW 30379 CAPSCREW 42089 ELBOW...

  • Page 194: Exploded Isometric Assembly Drawing

    EXPLODED ISOMETRIC ASSEMBLY DRAWING...
  • Page 195 Model HFG938D Service/Repair Manual TABLE OF CONTENTS SAFETY NOTES ............................2 MAINTENANCE AND SERVICE ........................3 OIL CHANGE ..............................4 DISASSEMBLY ............................5 ASSEMBLY ..............................6 TROUBLESHOOTING ..........................7 TORQUE SPECIFICATIONS CHART ......................8 BILL OF MATERIAL ............................. 9 CROSS SECTIONAL ASSEMBLY DRAWING ..................10 EXPLODED ASSEMBLY DRAWING ......................

  • Page 196: Safety Notes

    SAFETY NOTES FAILURE TO HEED THE FOLLOWING WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH!  Operators/Technicians must be trained in the proper, safe operation of the swing-drive gearbox.  All shields and guards must be in place during operation of swing-drive gearbox. ...

  • Page 197: Maintenance And Service

    MAINTENANCE AND SERVICE For safe and consistent operation of TWG hoists, gearboxes, and winches, a regular program of preventive maintenance is strongly recommended. Regular oil changes with the correct oil and frequency for the application and an annual inspection of the wear components will help ensure a long life for your planetary geared products.

  • Page 198: Oil Change

    OIL CHANGE Gearbox oil is drained by removing the drain plug and vent. Examine the used oil for signs of significant metal deposits and then dispose of it in a proper manner. Replace the drain plug. Fill the swing drive with the appropriate amount and type of oil and then See page 6 of this manual for the recommended oil type, amount and grade replace plug and vent.

  • Page 199: Disassembly

    DISASSEMBLY 1. Remove the housing (Item 4) from the machine. 2. Remove the 6 cap screws (Item 11) and remove the cover (Item 6). 3. Remove the O-ring (Item 10) from the cover. Inspect for damage and replace if necessary. 4.

  • Page 200: Assembly

    ASSEMBLY 1. Install the worm gear (Item 8). Use the bearings (Items 17, 25) to center the gear in the housing (Item 4). 2. Install the oil seal (Item 28) onto the end of the worm gear. 3. Install the O-ring (Item 21) onto the end cap (Item 20). Install the 4 cap screws (Item 31) through the end cap and tighten to spec.

  • Page 201: Troubleshooting

    TROUBLESHOOTING GEARBOX BRAKE WON’T HOLD Possible Solutions: 1. The brake discs and or stator plates are worn. Friction discs should measure no less than 0.075 inches thick and the stator plates should measure at least 0.045 inches thick and replace as necessary 2.

  • Page 202: Torque Specifications Chart

    TORQUE SPECIFICATIONS CHART Plated Lubricated Plated Lubricated Grade 5 Grade 5 Grade 5 Grade 8 Grade 8 Grade 8 Torque Torque Torque Torque Torque Torque Nominal Size *(Ft-Lbs) *(Ft-Lbs) *(Ft-Lbs) *(Ft-Lbs) *(Ft-Lbs) *(Ft-Lbs) ¼ ¼ 5/16 5/16 7/16 7/16 ½ ½...

  • Page 203: Bill Of Material

    END CAP, HFG938D O-RING, -152 CAP-END, MOTOR, HFG938D LOCKWASHER CAPSCREW-HH-1/2 CUP, BEARING SHIM, G1600D, CLEAR LOCKNUT, HFG938D SEAL, OIL SHIM, G1600D, BROWN SHIM, G1600D, HFG938D CAPSCREW, HH-1/2 PLUG, PIPE, PLATED BREATHER BUSHING, PIPE PLUG, PIPE FITTING, GREASE ZERK LABEL, ELLIOTT...

  • Page 204: Cross Sectional Assembly Drawing

    CROSS SECTIONAL ASSEMBLY DRAWING SECTION B-B FILL WITH GREASE SECTION A-A...

  • Page 205: Exploded Assembly Drawing

    EXPLODED ASSEMBLY DRAWING...

  • Page 206: Installation Drawing

    UNIT PRIMED WITH GRAY PRIMER. PRESSURE ANGLE MAX INPUT SPEED (RPM) GEARBOX FILLED WITH EP-140 OIL. (1.50 QTS) PITCH DIAMETER 2.800 EFFICIENCY UNIT SHIPPED FROM FACTORY AS PINION DOWN. STATIC ELLIOTT PART NO. 3012260 DYNAMIC INSTALLED WEIGHT (APPR) 64 LBS...
  • Page 211 ELLIOTT - Built for You L60 Operator's Manual Appendix A:Pages Index Presentation Drawing 7-2, 7-3 Aerial Device Setup Proposition 65 Warning-California Air Bleed-Platform Required Inspections 6-17 Automatic Rotation Lockout (Optional) Responsibilities per ANSI/SIA A92.2 Road Transport Bolt Torque Safety Responsibilities...
  • Page 212 ELLIOTT - Built for You L60 Operator's Manual Appendix B:Parts Index...

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