Engcon EC204 User Manual
  1. Manuals
  2. Brands
  3. Engcon Manuals
  4. Industrial Equipment
  5. EC204
  6. User manual

Engcon EC204 User Manual

Tiltrotator
Hide thumbs
Table of Contents

Advertisement

Quick Links

User manual
TILTROTATOR
EC204 | EC206 | EC209 | EC214 | EC219 | EC226 | EC233
Article 9000113 | Version 1.20
Original Instructions

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the EC204 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Engcon EC204

Summary of Contents for Engcon EC204

  • Page 1 User manual TILTROTATOR EC204 | EC206 | EC209 | EC214 | EC219 | EC226 | EC233 Article 9000113 | Version 1.20 Original Instructions...
  • Page 2 Dear Customer, Thank you for choosing a product from engcon. engcon is the market leader in tiltrotators and tools for excavators. We represent innovation, knowledge and experience, and we develop our products with a focus on the customer's needs. Please visit our website for contact information and details about the rest of our product range.

  • Page 3: Table Of Contents

    Table of Contents Table of Contents 1. Introduction 1.1. General......................6 1.2. Scrapping and recycling.................. 6 1.3. Transport and storage..................6 1.3.1. Temperature during operation and storage..........7 1.4. Warranty......................7 1.5. Technical support and spare parts..............7 1.6. Product approval..................... 8 1.6.1.
  • Page 4 Table of Contents 5.8.3. Control system 9-2 (for machines with two or more proportionally controlled hydraulic circuits)................5.8.4. Control system 1 (for machines with double-acting hydraulic circuit)..26 5.8.5. Control system 15 (for machines with double-acting hydraulic circuit)..26 5.8.6. Externally controlled quick hitch lock – SQ/QSC........26 5.9.
  • Page 5 Table of Contents 9. Technical data 9.1. Tiltrotator......................57 9.2. Integrated grab cassette..................59 9.3. Load-holding valve..................60 10. Glossary 10.1. Designations....................61 10.2. Tiltrotator overview..................62 11. Service 11.1. Service schedule................... 63 11.2. Service record....................64...

  • Page 6: Introduction

    1.2. Scrapping and recycling engcon makes constant efforts to reduce its environmental impact. engcon's products comprise at least 99 per cent recyclable material. All assembly and service work must take place in compliance with legislation and ordinances governing the environment, health and occupational safety.

  • Page 7: Temperature During Operation And Storage

    All customers receive a 2-year warranty on tiltrotators delivered after 1 January, 2018. We encourage you to register your tiltrotator to enjoy faster service. Visit www.engcon.com and search for "register your product". 1.5. Technical support and spare parts Contact information for support and spare parts can be found at www.engcon.com.

  • Page 8: Product Approval

    ISO 10567:2007, SAE J2506:2012, SAE J1362:2018 This declaration and engcon's warranties will cease to be valid immediately if spare parts other than engcon original spare parts are used, or if any changes or other interventions are made without engcon's permission.

  • Page 9: Type Certification For Lifting Hook

    1 Introduction 1.6.2. Type certification for lifting hook The following certification is valid for tiltrotators supplied with a lifting hook.

  • Page 10: Safety

    2 Safety 2. Safety 2.1. General It is important that you read and understand all warnings prior to installation work on this product or before you use it and any accessories supplied. The warning texts highlight potential risks and describe how to avoid them. The following warning levels are used in this user manual: DANGER Indicates that an accident will occur if the regulation is...

  • Page 11: Design And Function

    3 Design and function 3. Design and function 3.1. General The engcon tiltrotator adds flexibility and efficiency to an excavator and allows it to be used for more operations. The product provides the ability to both tilt and rotate a tool. 3.2. Tool(s) engcon’s tiltrotators are designed to be used with engcon’s hydraulic tools and tools that...

  • Page 12: Overview

    3 Design and function 3.3.1. Overview Figure 1. Position Description Power supply Alarm indication Sensor, machine hitch hook Sensor, machine hitch ejector Sensor, quick hitch hook Sensor, quick hitch ejector Warning lamp Table 1. For indications, see section 7.1.1. Indications...

  • Page 13: Hs And Sw Quick Hitch With Sensor

    3 Design and function 3.4. HS and SW quick hitch with sensor The HS and SW quick hitch with sensor monitors whether or not the quick hitch is in the open position. The alarm output is connected to a QLM module mounted on the stick. It uses sound and light warning signals when the tool’s locking cylinder is open, as the primary safety purpose of the quick hitch is to protect personnel nearby.

  • Page 14: Overview

    3 Design and function 3.4.1. Overview Figure 2. Position Description Power supply Alarm indication Indication for open quick hitch Warning lamp Table 2. For indications, see section 7.2.1. Indications...

  • Page 15: Ec-Oil

    3 Design and function 3.5. EC-Oil engcon’s system for more efficient tool changes. It provides the ability to switch hydraulic tools without leaving the cab. The system is designed for maximum reliability in harsh environments. It is a fully hydraulic system that handles the connection of tools under full system pressure.

  • Page 16: Eps/C2C

    3 Design and function 3.6. ePS/C2C Together with the tiltrotator, engcon's ePS rotation sensor creates an ePS-compatible excavator guidance system – a concept that provides the selected system with more functions. It provides full control of the bucket and the ability to see its exact rotational position.

  • Page 17: Installation

    Welding is not permitted. It can have a negative impact on safety. Risk of personal injury and damage to property. For welding, contact your dealer or engcon Nordic AB. WARNING Beware of moving parts. A lack of awareness may lead to crush injuries.

  • Page 18: Identification

    Risk of personal injury and damage to property. WARNING If you have any doubts concerning the safety aspects of your knowledge, the equipment or work, contact a dealer or engcon Nordic AB. Incorrect installation affect safety. IMPORTANT Assembly and installation may only be carried out at a workshop authorised by the manufacturer.

  • Page 19: Attaching The Tiltrotator

    4 Installation 4.3.1. Attaching the tiltrotator Before installation 1. Check the tipping load limits. Take tiltrotator weight and the extended risk area into account. Installation may entail a necessary reduction in the volume of the tool. 2. Position the base machine and the tiltrotator on a flat, non-slip surface.

  • Page 20: Electrical And Hydraulics

    4.4. Electrical and hydraulics For electrical and hydraulic hose installation, refer to the separate installation instructions supplied with the selected control system. Also available on the website or by contacting engcon. IMPORTANT Maintenance and repair of the electrical system may only be carried out by professionally qualified persons.

  • Page 21: Q-Safe

    Short circuits in electrical wiring can result in fires. 4.4.1. Q-Safe See separate installation instructions. Also available on the website or by contacting engcon. 4.5. On completion 1. Affix the warning decals supplied in a conspicuous place in the operator's cab, without obscuring operator visibility.

  • Page 22: Operation

    5 Operation 5. Operation 5.1. Before and during use Check your base machine manufacturer's recommendations for calculating tipping loads, and be sure to include the increased weight and reach the product entails. DANGER Do not exceed tipping load limits. The weight of the product and the increased reach may impair stability.

  • Page 23: Lifting Points

    5 Operation 5.2. Lifting points Approved Not approved Figure 12. Figure 13. Figure 14. Check max permitted load for the lifting hook, as stamped on the lifting hook and rating plate. Designed with safety factor 5:1. WARNING The base machine must be equipped with a load- holding valve on the boom/stick and an overload warning when using a lifting hook on the tiltrotator.

  • Page 24: Hydraulic Hammers

    5 Operation WARNING Make sure the load burdens both grab arms when lifting. Make sure the load cannot shift and only burden one grab arm. When all force is exerted by only one arm, the grab is at risk of opening. Risk of injury and damage to property.

  • Page 25: Crane Boom

    5.8.1. DC2 control system (for machines with double-acting hydraulic circuit) The engcon control system allows simultaneous operation of all functions. Refer to separate user manual supplied on delivery. Also available on the website or by contacting engcon.

  • Page 26: Control System 1 (For Machines With Double-Acting Hydraulic Circuit)

    5.9. Changing tools The following instructions concern general operation of the engcon quick hitch. For further information and instructions, refer to the separate user manual for the quick hitch concerned.
  • Page 27 5 Operation 3. Check that the indicator rod is out. Indicator rod location may vary depending on the tiltrotator model. ECPUP: Check that the red hook is in the open position. 4. Move the quick hitch towards the tool. EC-Oil: Make sure the tool is positioned such that the shaft with the EC-Oil block is located closest to the base machine.
  • Page 28 5 Operation 6. Raise the tiltrotator very slightly above the ground so that the tool moves towards the quick hitch. IMPORTANT The machine may only be operated with the quick hitch lock switch in the activated position when connecting and disconnecting tools.

  • Page 29: Disconnecting The Tool, Hydraulic Lock

    5 Operation 5.9.2. Disconnecting the tool, hydraulic lock 1. Place the tool on the ground, with the locking bolts pointing away from the cab. 2. Activate the quick hitch lock function. 3. Activate the hydraulics and the locking bolts. 4. The locking cylinders are activated and open position is reached when the indicator rod is visible.

  • Page 30: Connecting The Tool, Mechanical Lock

    5 Operation 5. The locking bolts are now in the open position and the tool is free. Carefully raise the tiltrotator from the tool. IMPORTANT The machine may only be operated with the quick hitch lock switch in the activated position when connecting and disconnecting tools.
  • Page 31 6. Check that the quick hitch lock's lock function has engaged. In the case of engcon’s other quick hitches, the blue indicator rod will no longer protrude from the hitch. Indicator rod location may vary depending on the...

  • Page 32: Disconnecting The Tool, Mechanical Lock

    5 Operation 5.9.4. Disconnecting the tool, mechanical lock 1. Place the tool on the ground, with the locking bolts pointing away from the cab. 2. Open the quick hitch lock with a suitable tool. On models with a screw, turn it anti-clockwise until the locking bolts engage and the indicator rod is in its outermost position.
  • Page 33 5 Operation WARNING Beware of moving parts. A lack of awareness may lead to crush injuries. Risk of personal injury. Shim the quick hitch and the tool for minimum play. Check that minimum locking wedge engagement is not below the minimum value: Quick hitch S30-S80 Quick hitch S1-S3 Figure 16.
  • Page 34 5 Operation Quick hitch RF40-90 (PUP) Quick hitch ECPUP Figure 19. Figure 18. Quick hitch A (max) Quick hitch A (max) PUP40-90 14mm ECPUP45 ECPUP50 Table 6. ECPUP60 22mm ECPUP65 25mm ECPUP70 25mm ECPUP80 30mm Table 7.
  • Page 35 5 Operation Quick hitch CW10-45 Quick hitch HS Figure 20. Figure 21. Quick hitch A (max) Quick hitch A (max) CW10-45 A ≥ B * 0.75 HS08 0 till 14mm HS10 0 to 5mm Table 8. HS20/21/25 -10 till 5mm Table 9.

  • Page 36: Maintenance

    6 Maintenance 6. Maintenance 6.1. General Intervals for greasing and inspections to be performed by the user: - Daily, carried out on all configurations before the machine is put into use for the working day. - Every 8 operating hours, lubrication as per lubrication schedule. - Every 250 operating hours;...

  • Page 37: Daily Inspections

    6 Maintenance IMPORTANT Review the personal and environmental risks of hydraulic oil and grease by reading the safety data sheets for the hydraulic oil and grease in use. Risk of personal injury and damage to surroundings. IMPORTANT Be sure to keep your product clean. Inadequate cleaning can cause damage to your equipment.
  • Page 38 Welding is not permitted. It can have a negative impact on safety. Risk of personal injury and damage to property. For welding, contact your dealer or engcon Nordic AB. WARNING Replace damaged or illegible signs and decals before using the machine. Risk of personal injury and...

  • Page 39: Special Maintenance

    6 Maintenance 6.3. Special maintenance 6.3.1. EC-Oil Cleaning - Clean oil connections, electrical connectors, grease connections and dirt guards before and after use in order to avoid oil or grease leakage and safeguard EC-Oil function. - If oil or grease leakage occurs despite cleaning, we recommend face seal replacement.

  • Page 40: Lubrication Every 8 Operating Hours

    Blockage in one grease channel will entail blockage of the entire lubrication system. For troubleshooting, contact your service partner or engcon Nordic AB. Grease recommendation: On delivery, we fill your product with our recommended universal mineral oil-based grease with an EP additive, a lithium soap thickener and a hardness of (NLGI) 2.

  • Page 41: Tiltrotator Lubrication

    6.4.1.1. Manual lubrication MIN quantity of grease: EC204: 10g | EC206: 10g | EC209: 15g | EC214: 20g | EC219: 20g | EC226: 20g | EC233: Grease the tiltrotator by removing the protective cap from the grease nipple and connecting a grease gun. Grease the tiltrotator until grease forces its way out at all axles and bearings.

  • Page 42: Greasing The Quick Hitch

    6 Maintenance IMPORTANT In winter, a higher system pressure is required for tiltrotator lubrication. IMPORTANT Check regularly that new grease is supplied to the tiltrotator. 6.4.2. Greasing the quick hitch Grease quantity: 3-4 pump strokes per nipple. Grease nipples on both sides, applies to all examples. The arrows show the location of the grease nipples.

  • Page 43: Lubrication, Integrated Grab Gr10, Gr20

    6 Maintenance 6.4.3. Lubrication, integrated grab GR10, GR20 Grease quantity: 3-4 pump strokes per nipple. The arrows show the location of the grease nipples. Figure 30. 6.4.4. Lubrication, integrated grab GR20RR Grease quantity: 3-4 pump strokes per nipple. The arrows show the location of the grease nipples. Figure 31.

  • Page 44: Service Every 250 Operating Hours

    6 Maintenance 6.5. Service every 250 operating hours Check is performed by operator. Make entry in service record; see 11.2. Service record. - Review of points according to section 6.2. Daily inspections. - Shimming, tilt upper section. - Visual inspection of bushings and spherical bearings; see section 10.2. Tiltrotator overview.

  • Page 45: Checking Lateral Play

    6 Maintenance 6.7. Checking lateral play 1. Raise the tiltrotator to a comfortable working height and switch off the machine. 2. Remove the protective cover on the left side of the tiltrotator and the plug on the bolted joint. 3. Clean and remove all grease from the hole where the plug was installed.

  • Page 46: Checking Rotational Play

    6 Maintenance 6.8. Checking rotational play 1. Use the crowbar to move the quick hitch to the left. 2. Remove the motor bolts and the motor. 3. Clean the worm screw thoroughly and remove all grease. 4. Mount the dial indicator on the rotator body and reset the dial gauge.

  • Page 47: Significance Of Rotation Play

    REMARKS Lack of lubrication can deform the thrust washers. 6.8.3. ePS If your tiltrotator is fitted with an engcon rotation sensor, it must be calibrated after servicing. 6.9. Tightening torque The rotator section is dimensioned to cope with major shear loads and torsional loads. For reasons of strength, it is essential that certain fasteners be torque tightened.
  • Page 48 6 Maintenance EC209 Fastener Dimension Quality Quantity Torque Screw cap 12.9 136 Nm Quick hitch 12.9 217 Nm Yoke bracket 12.9 333 Nm Tilt axle 12.9 333 Nm Clamping half 12.9 79 Nm Hydraulic motor 12.9 136 Nm Table 12. EC214 Fastener Dimension...
  • Page 49 6 Maintenance EC226 Fastener Dimension Quality Quantity Torque Screw cap 12.9 217 Nm Quick hitch 12.9 649 Nm Yoke bracket 12.9 333 Nm Tilt axle 12.9 333 Nm Clamping half 12.9 136 Nm Railway grab, grab 12.9 649 Nm axle Hydraulic motor 12.9 136 Nm...

  • Page 50: Troubleshooting

    7 Troubleshooting 7. Troubleshooting 7.1. Q-Safe 7.1.1. Indications Position Behaviour Indicates Remarks 1 flash Power supply OK Applies to DC2 without QSC *_*_*_ 2 flashes Power supply OK Applies to QSC **_**_**_ Constant light Power supply OK Applies to SS0-SS9 without 1 flash CAN time out Applies to QSC...
  • Page 51 7 Troubleshooting Position Behaviour Indicates Remarks 1 flash Tiltrotator removed Applies to DC2 *_*_*_ Constant light Connected tool Sensor, hook for quick hitch underneath tiltrotator 1 flash Tiltrotator removed Applies to DC2 *_*_*_ Constant light Connected tool Sensor, ejector for quick hitch underneath tiltrotator Flashing white and Unsafe tool connection...

  • Page 52: Hs And Sw With Sensor

    7 Troubleshooting 7.2. HS and SW with sensor 7.2.1. Indications Position Behaviour Indicates Remarks Flashing light Power supply OK Other control systems with Constant light Power supply OK Other control systems without 1 flash Short circuit, power to sensor Applies when starting up the *_*_*_ in RF system...

  • Page 53: Eps/C2C

    7 Troubleshooting 7.3. ePS/C2C 2 X2 3 Figure 39. 7.3.1. Indications Position Sign Indicates Remarks No power supply Constant light No communication in X1 Flashing CAN communication with the unit connected to X1 No power supply Constant light No communication in X2 Flashing CAN communication with the unit connected to X2...

  • Page 54: Decals

    8 Decals 8. Decals Machine instructions, decals and warning signs must be kept clearly legible. Contact your supplier to order replacements. WARNING Replace damaged or illegible signs and decals before using the machine. Risk of personal injury and damage to property. 8.1.

  • Page 55: Warning Decals On Product

    8 Decals 8.2.1.2. 9000157 Figure 41. Warning decal to the right of operator. 8.2.2. Warning decals on product 8.2.2.1. 980101 Figure 42. Warning decal on the tilt cylinder. 8.2.2.2. 9000338 WARNING Risk of injury Make sure locking cylinder is in its maximum extended position before removing locking hook.
  • Page 56 8 Decals Never stand under or pass beneath a raised tool. Leave room for rotating, tilting and sideways-moving tools. Risk area 3 metres. Crushing hazard from moving parts. Never exceed the base machine's approved tipping load. Warning, rotating tool. Warning, laterally moving tool. Warning, tilting tool.

  • Page 57: Technical Data

    9. Technical data The illustration shows a typical configuration. Technical data may vary. We reserve the right to make changes without prior notice. 9.1. Tiltrotator Figure 44. Description EC204 EC206 EC209 EC214 EC219 EC226 EC233 Max machine size 4,000 6,000 9,000 14,000...
  • Page 58 9 Technical data Description EC204 EC206 EC209 EC214 EC219 EC226 EC233 Rec open/close 21 / 3-6 21 / 3-6 21 / 3-6 21 / 3-6 21 / 3-6 21 / 3-6 21 / 3-6 pressure SQ S30- S3, HS03/08 Rec open/close...

  • Page 59: Integrated Grab Cassette

    2,234 1,956 1,750 - tip) at 21 MPa Max load 1,000 1,500 2,000 2,200 3,000 Weight Max hydraulic pressure Table 22. *Depending on attachment See separate user manual for detachable GRD. Also available on the website or by contacting engcon.

  • Page 60: Load-Holding Valve

    9 Technical data 9.3. Load-holding valve Listed below are the torques required to defeat the load-holding valves on the tilt cylinders. Description EC02 EC204 EC206 Torque 4,700 (rotation right) 5,000 (rotation right) 7,000 (rotation right) Torque 3,500 (rotation left) 4,000 (rotation left)

  • Page 61: Glossary

    10 Glossary 10. Glossary 10.1. Designations Term Description Base machine The machine carrying the equipment concerned. Excavator or backhoe loader. EC-Oil Automatic oil connection system for changing hydraulic tools from the cab. See section 3.5. EC-Oil. EC-Oil block H (Hitch) Located in the machine or in the quick hitch. EC-Oil block T (Top) Located on the upper section of the hydraulic tool and/or the tiltrotator.

  • Page 62: Tiltrotator Overview

    10 Glossary 10.2. Tiltrotator overview Pos. Designation Load-holding valve EC-Oil block T (Option) Tilt cylinder Yoke bracket Bushing, yoke bracket Spherical bearings QS/Q-safe Slip ring (Option) Single-point lubrication Tilt axle Shim set, tilt axle Cylinder axle Clamping half Hydraulic motor QS/Q-safe Sensor (Option) EC-Oil block H (Option) Locking cylinder...

  • Page 63: Service

    11 Service 11. Service 11.1. Service schedule Carried out by a specialist at initial machine service or no later than 500 operating hours: - Check the product compliance with the rating plate and user manual. - Review of points according to section 6.2. Daily inspections. - Tighten fasteners according to section 6.9.

  • Page 64: Service Record

    11 Service 11.2. Service record On the service record, there is space to note actions performed on the product that this user manual refer to. Specify the date of the action, what was done and who did it. Service partners must also imprint an ASP stamp in the space provided. This will make sure your product is a safe buy for any future owner.
  • Page 65 11 Service Date 500 h 250 h 2000 h Remark/Action Stamp/Signature...
  • Page 66 11 Service Date 250 h 2000 h Remark/Action Stamp/Signature...
  • Page 67 11 Service Date 250 h 2000 h Remark/Action Stamp/Signature...
  • Page 68 Uk Ltd 200B Ashchurch Business Centre, Tewkesbury GL20 8TD +44 1684 297168, uk@engcon.com www.engcon.com...

This manual is also suitable for:

Ec206Ec209Ec214Ec219Ec226Ec233 ... Show all

Table of Contents

Save PDF