Elliott Digger Derrick - User Manual

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

Summary

WARRANTY

LIMITATION OF LIABILITY

Limits Elliott's liability for losses and damages, not exceeding purchase price or repair/replacement.

DISCLAIMER

States warranty is in lieu of all other warranties and obligations.

Safety Responsibilities

Management;Supervisory Responsibilities

Outlines employer's duties for establishing a safe environment and providing qualified personnel.

Operator’s Responsibilities

Details operator's duties including refusal to operate if unsafe, alertness, and pre-operation checks.

Signal Person’s Responsibilities

Defines duties of signal personnel, including clear signals and hazard recognition.

Rigger’s Responsibilities

Outlines riggers' duties regarding weight, distance, and lifting tackle selection.

Crewmember’s Responsibilities

Specifies crewmembers' duty to report unsafe conditions and watch for hazards.

Responsibilities per ANSI;ASSE A10.31

SECTION 6-Responsibilities of Manufacturers

Details manufacturer's general and specific responsibilities regarding vehicle and digger derrick specifications and manuals.

SECTION 7-Responsibilities of Dealers and Installers

Outlines dealer/installer responsibilities for vehicle specs, weight distribution, manuals, and installations.

SECTION 8-Responsibilities of Owners

Defines owner's responsibilities for inspection, testing, maintenance, modification, and training.

B. Inspection and Testing Classifications

Divides inspections into initial, regular (frequent and periodic) classifications.

Nomenclature

Digger Derrick Nomenclature

Lists and defines key components and terms used for digger derricks.

A. Upper Controls

Refers to controls located in or near the optional platform.

B. Platform

Describes the personnel-carrying component of a digger derrick.

C. Platform Pin

Identifies the horizontal pin attaching the platform to the boom.

Platform Safety

Personnel Platform Usage Guidelines

Provides guidelines for safe use of personnel platforms on boom truck cranes.

Special Work Considerations

Highlights special precautions for specific work situations like welding or working over water.

Pre-Lift Requirements and Planning

Details procedures and planning necessary before personnel lifting events.

Personnell Reponsibilites and Qualifications

Outlines responsibilities and qualifications for management, supervisors, and equipment operators.

Jib Safety

A. The anti-two-block switch weight and cord must be attached to the jib when deployed.

Specifies requirements for ATB switch weight and cord attachment when using the jib.

B. Ensure jib is stowed correctly.

Emphasizes the importance of correctly stowing the jib and the risks associated with improper stowage.

C. Only attempt to swing jib to working or stowed position when boom is horizontal

Advises to only swing the jib when the boom is horizontal to prevent uncontrolled swinging.

Road Transport

On-Site Setup

Operating Controls-Digger Derrick

OPERATING CONTROLS (Seated)

Illustrates and describes the controls for seated operation of the digger derrick.

Boom Controls

Details the operation of boom-related controls like PTO, Swing, Digger, Boom Telescope, Boom Control Lever, and Winch.

D. Boom Telescope Pedal

Explains how to extend and retract boom sections using the pedal.

E. Boom Control Lever

Describes the operation of the lever for raising and lowering the boom.

F. Winch Control Lever

Explains how to operate the winch lever for paying out or reeling in cable.

G. Master Switch - Emergency Stop Switch

Details the function and operation of the master and emergency stop switch.

H. Range - High;Low Switch

Explains how the range switch affects joystick control flow.

L. Truck Start Switch

Describes the momentary switch for starting and stopping the truck engine.

N. Auger Shift

Explains how to shift the digger into different speed ranges for operation.

O. Digger Latch

Details the momentary switch for opening and closing the digger stow latch.

P. Glide Swing Switch

Explains how to switch Glide Swing on and off, and its interaction with the brake.

Hyd. System Pressure Gauge

Locates and explains the hydraulic system pressure gauge.

Bubble Level

Describes the location and use of bubble levels for crane leveling.

Boom Length Indicators

Explains the location and function of boom length indicators.

LMI (Load Moment Indicator) & Anti-Two Block Control

Provides information on the LMI and ATB system setup and operation.

Digger Safety and Operation

SAFETY

Emphasizes the importance of operator, equipment condition, and maintenance for digger system safety.

Safety Tips

Lists essential safety tips for digger operation, including stowing, clearances, and digging procedures.

OPERATION

Details the operational aspects of the digger system, including its components and controls.

System

Describes the auger system components and inspection procedures.

Digging

Provides step-by-step instructions for safe and effective digging operations.

Stowing

Details the procedure for properly stowing the auger system.

Outrigger Controls

A. Right Front Outrigger Jack Switch

Explains the switch for raising/lowering the right front outrigger jack.

G. Left Rear Outrigger Jack Switch

Explains the switch for raising/lowering the left rear outrigger jack.

H. Left Rear Outrigger Beam Switch

Explains the switch for retracting/extending the left rear outrigger beam.

I. Right Rear Outrigger Jack Switch

Explains the switch for raising/lowering the right rear outrigger jack.

Remote Control (Optional)

DANGER ELECTROCUTION HAZARD

Warns about electrocution hazards when operating near live electrical power lines.

Operation

Details how to operate the remote control system, including truck engine control and function activation.

Aerial device and Option Function Joysticks

Describes the transmitter's joysticks and toggle switches for controlling various functions.

Powering up the transmitter

Provides sequential steps for powering up the remote control transmitter.

Indicator Panel

Explains the interpretation of lights on the remote control indicator panel.

Functions

Lists and describes the functions of various buttons on the transmitter.

Joystick Labels

Provides labels and descriptions for the transmitter's joysticks.

LMI Setup

Initial Setup

Covers the initial setup and usage of the LMI unit, referencing component service manuals for details.

Crane Configuration screen

Explains the crane configuration screen and the meaning of green indicator dots.

1. Home button

Describes the function of the Home button to return to the Home display.

2. Outrigger button

Explains how the operator uses this button to select the outrigger position.

3. Parts Of Line button

Details how the Parts Of Line button selects the increment number of the POL.

1. Outrigger setting

Explains the green indicator light reflecting outrigger selection on the Crane Configuration screen.

2. Actual Load Value

Describes how the Actual Load Value window displays the total load suspended.

3. Cancel Alarm button

Explains the use of the Cancel Alarm button to silence audible alarms.

5. Information

Explains how the Information button displays software version and fault codes.

6. Rated Capacity

States that the Rated Capacity window shows the maximum rated capacity in the current configuration.

9. Anti-Two-Block

Explains when the ATB indicator illuminates, signaling an approach to a two-block condition.

Lift Capacities

Wire Rope Anchoring

Cutting Wire Rope

Instructions on how to properly cut and seize wire rope.

Anchoring Wire Rope to Winch Drum

Refers to the Tulsa Winch Service Manual for anchoring wire rope to the winch drum.

Winding Wire Rope on to Winch Drum

Details how to properly inspect the drum and spool wire rope onto the drum.

Wedge Socket

WARNINGS AND APPLICATION INSTRUCTIONS

Provides warnings and instructions for the application of wedge sockets.

Inspection;Maintenance Safety

Details safety precautions for inspecting and maintaining wedge sockets.

Assembly Safety

Provides safety guidelines for assembling wedge sockets with wire rope.

TABLE 1

Lists torque values for rope clip sizes.

Operating Safety

Provides safety instructions for using wedge sockets during operation.

Multi-Part Reeving

Reeve rope per diagram show below

Instructs to reeve rope according to the diagram and refers to capacity chart for parts of line.

Check the operation of the Anti Two-Block (ATB) as outlined below

Details how to check the operation of the Anti Two-Block system.

Jib Operation

A. The anti-two-block switch weight and cord must be attached to the jib when deployed.

Specifies requirements for ATB switch weight and cord attachment when using the jib.

B. Ensure jib is stowed correctly.

Emphasizes the importance of correctly stowing the jib and the risks associated with improper stowage.

C. Only attempt to swing jib to working or stowed position when boom is horizontal

Advises to only swing the jib when the boom is horizontal to prevent uncontrolled swinging.

Deployment Procedure

Provides a step-by-step procedure for deploying the jib.

Stowing Procedure

Details the step-by-step procedure for stowing the jib.

Platform Operation

Platform selector valve function positions

Lists the functions achievable with the platform leveling system's selector valve.

Float position lock

Explains the function of the float position lock to prevent accidental float function selection.

Air Bleeding Process

Outlines the procedure for bleeding air from the platform hydraulic system.

Kickstand

Describes the kickstand assembly and its function during platform landing and yoke alignment.

Platform Function Selector and Float lock

Explains the function and float lock knobs for platform operation.

PLATFORM ASSEMBLY RIGGING FOR OPERATION PLATFORM

Details the steps for rigging the platform assembly for operation, including transfer from the truck bed.

RIGGING PLATFORM ASSEMBLY TO THE BOOM HEAD

Provides instructions for rigging the platform assembly to the boom head.

RIGGING PLATFORM ASSEMBLY TO RETRACTED JIB (BOOM RETRACTED)

Details rigging the platform assembly to a retracted jib.

RIGGING PLATFORM ASSEMBLY TO EXTENDED JIB (BOOM RETRACTED)

Provides instructions for rigging the platform assembly to an extended jib.

Hand Signals

Standard Hand Signals for Crane Operators

Illustrates and defines standard hand signals used by crane operators.

Required Inspections

Daily Inspection

Lists critical items to inspect daily on the boom truck vehicle and its optional equipment.

Weekly Inspection

Outlines weekly inspection tasks for the crane, including lubrication and component checks.

Monthly Inspection

Lists monthly inspection tasks, focusing on structural components, wire rope, and wiring.

Periodic Inspection

Details periodic inspection requirements for various components, including fasteners, valves, and systems.

Wire Rope Care;Maintenance

Breaking in Wire Rope

Explains the procedure for breaking in new wire rope to allow it to settle.

Wire Rope Cleaning

Details the importance and method of cleaning wire ropes, especially those in harsh conditions.

Wire Rope Inspections

Provides guidance on inspecting wire ropes at regular intervals and maintaining inspection records.

Typical Evidence of Wear and Abuse

Illustrates and describes common types of wire rope wear and abuse requiring replacement.

Replacement Criteria

Lists guidelines for determining when a wire rope needs to be replaced based on wear and damage.

Synthetic Rope Usage, Inspection, and Retirement

Rope Selection

Guides the user on factors to consider when selecting appropriate synthetic rope for a job.

Strength

Discusses how rope strength affects its lifespan and the importance of choosing stronger ropes.

Elongation

Explains the concept of elongation in synthetic ropes and its impact on load control and strength.

Dynamic (Shock) Loading

Describes dynamic loading and its potential to cause rope failure, emphasizing safe practices.

Firmness

Discusses the importance of rope firmness for durability and strength.

Abrasion

Details how abrasion affects rope strength and the need for good condition of contact surfaces.

Assigned Working Load Factors

Explains working load factors and provides a recommended minimum safety factor.

Rope Handling;Usage

Provides warnings and precautions regarding safe rope handling and usage.

Attaching Line to a Winch Drum

Describes various methods for attaching winch lines to a winch drum.

Avoid All Abrasive Conditions

Advises avoiding abrasive conditions that can damage rope.

Winding onto a Winch

Explains proper techniques for winding rope onto a winch drum (level and cross winding).

Winding Rope on the Winch Drum

Details the initial winding tension and process for winding rope onto the winch drum.

Removing Rope from a Reel or Coil

Provides instructions on how to remove synthetic rope from reels or coils.

Rope Storage: Coiling, Flaking and Bagging

Discusses proper care for storing synthetic ropes to prevent kinks.

Eye Splices

Explains the importance of proper eye splices and lock stitching for safety.

Knots

Discusses the impact of knots on rope strength and recommends splices over knots.

Use of Slings with Winch Lines

Advises against using winch lines as chokers and recommends separate slings.

Sharp Cutting Edges

Warns about sharp edges that can cut or damage winch lines and the need for proper inspection of metal surfaces.

Temperature

Explains how friction creates heat, which is detrimental to synthetic fibers, and how to manage heat buildup.

Strength Degradation from Ultraviolet Light

Discusses how UV radiation degrades synthetic rope strength.

Harmful Chemicals

Lists chemicals that can break down synthetic fibers and advises on precautions.

Avoid Dynamic Loading

Explains dynamic loading and its severe impact on synthetic ropes, urging caution.

Fatigue

Describes how synthetic fibers retain effects of overloading and dynamic loading, emphasizing winch line procedures.

End-For-Ending

Recommends rotating winch lines end-for-end periodically to extend useful life.

Bending Radius

Provides guidelines for selecting proper bending radii for components to avoid rope damage.

Boom-Sheave Recommendations

Offers recommendations for sheave dimensions to ensure efficiency and safety with braided ropes.

Rope Type

Describes Yale Ultrex and Samson Amsteel ropes, including their features and benefits.

Yale Ultrex Specifications Chart

Presents specifications for Yale Ultrex ropes, highlighting Elliott Equipment sizes.

Samson Amsteel Specifications Chart

Provides specifications for Samson Amsteel ropes, highlighting Elliott Equipment sizes.

Rope Coatings and Finishes

Details Yale Maxijacket and Samson Samthane coatings and their properties.

Rope Retirement

Discusses factors influencing rope retirement decisions and the importance of inspection.

Visual Inspection

Explains how to visually inspect double braid and core-dependent double braid ropes.

Abrasion

Describes how abrasion affects single-braid ropes and how to estimate fiber loss.

Single Braid;Double Braid Retirement Checklist

Provides a checklist for retiring single and double braid ropes based on wear criteria.

Elongation (Stretch);Components of Stretch

Defines elastic elongation, permanent extension, creep, and constructional elongation.

Elastic Hysteresis

Defines elastic hysteresis as a recoverable portion of stretch after load release.

Permanent Extension (PE) After Relaxation

Explains permanent extension and its calculation for different rope types.

Creep

Defines creep as slow material deformation under load over time.

Constructional Elongation

Describes elongation resulting from fiber and strand alignment during loading.

Slice Setting

Defines elongation caused by adjustment of strands in a splice.

Digger Derrick Labels

Digger Derrick Specifications

Pump Specs

Provides specifications for the hydraulic pump, including speed, flow, and pressure ratings.

Control Valve Specs

Explains pressure measurement in load sense lines and the function of the control valve.

Functions

Details functions with their corresponding max load sense pressure, flow rates, and operating speeds.

Winch System Performance

Presents data on winch system performance, including line pull and line speed by layer.

D115 Physical Specifications & List

Lists physical specifications and dimensions for the D115 model.

Digger Specifications

Provides specific performance data for the digger function, including torque, speed, flow, and pressure.

Figure 2 - Digger Derrick Specifications

Illustrates the digger derrick with labels for various specifications and dimensions.

ELLIOTT ELECTRICAL BOX

CHASSIS HARNESS REFERENCE

Refers to chassis harness information for specific connections.

UPPER CONTROL BOX INTERNAL SCHEMATIC

Maintenance Safety

Cleanliness

Lubrication

Lubrication notes

Provides specific notes and cautions regarding lubrication procedures for boom sections and cylinders.

Bolt Torque

Tightening Torque

Provides torque values for coarse and fine threaded fasteners based on size and grade.

GRADE MARKINGS

Illustrates grade markings for bolts and screws.

Changing Hydraulic Oil

Bubble Level Adjustment

Four Section Boom Operation

Top View

Shows a top-down view of the four-section boom, illustrating cable routing.

Four Section Boom

Labels the different sections of the four-section boom diagram.

3;2;1 Retract Cable (Qty 2):

Describes the connection and function of the 3/2/1 retract cable.

Extension Cylinder - Two Stage (Qty 1):

Details the connection and primary function of the two-stage extension cylinder.

Internal Cable Sheave Lubrication

Provides notes on observing sheave cases to determine the amount of grease needed for proper lubrication.

Four Section Cable Tensioning

Explains the process and importance of cable tensioning for boom section sequencing.

Boom Removal

Outlines the procedure for safely removing the boom from the machine.

Boom Disassembly

Provides instructions for disassembling the boom, including references to other sections.

Boom Disassembly Alternative

Offers an alternative procedure for disassembling the boom, detailing component removal.

Additional Maintenance, Disassembled Boom

Details maintenance tasks for disassembled boom sections, including inspection and cleaning.

Four Section Boom Assembly

Guides the user through the process of assembling four-section boom components.

FOUR AND FIVE SECTION TOP;BOTTOM PAD REPLACEMENT - ASSEMBLED BOOM

Describes the process for replacing top and bottom wear pads on assembled boom sections.

Top Pad Replacement

Explains how to replace top wear pads on four or five-section booms.

Front Bottom Pad Replacement

Details the procedure for replacing front bottom wear pads on boom sections.

Troubleshooting

BOOM EXTENDS DURING TRANSPORTATION

Addresses issues related to the boom extending unintentionally during transport.

BOOM CREEPS BACK AFTER BEING EXTENDED

Provides solutions for the boom creeping back after extension, often due to hydraulic oil cooling.

BOOM TELE OUT, WINCH UP AND BOOM DOWN ARE NOT WORKING

Troubleshoots issues where specific boom functions are not working, checking for two-blocking or overloads.

WINCH WILL NOT RAISE LOAD

Guides troubleshooting for a winch that fails to lift the load, checking capacity charts and LML systems.

SWING INOPERATIVE OR ERRATIC

Addresses issues with the swing mechanism being inoperative or behaving erratically, checking brakes and gears.

OUTRIGGER;STABILIZER BEAM WILL NOT EXTEND OR MAKES EXCESSIVE NOISE WHEN EXTENDING:

Troubleshoots outrigger/stabilizer beam extension problems, including noise and lack of extension.

OIL CONTAMINATION PROBLEMS

Lists common oil contamination issues like water, plugged filters, and metal particles.

PUMPING PROBLEMS

Details troubleshooting steps for pumping problems, including suction lines, valves, and worn components.

SYSTEM OPERATES SLOWLY OR ERRATICALLY

Provides causes and solutions for systems operating slowly or erratically, such as air in the system or cold oil.

PUMP MAKES NOISE

Lists potential causes for pump noise, including low oil, high viscosity, or worn bearings.

OIL OVERHEATING

Addresses oil overheating issues, such as holding levers too long or using incorrect oil.

Tulsa Winch Service Manual Model 1200 W Winch

Table of Contents

Lists the sections and page numbers for the Tulsa Winch Service Manual.

PART & SERIAL NUMBER LOCATION

Shows where to find part and serial numbers on the winch.

Safety Notes

Provides critical safety warnings regarding winch operation and load handling.

INTRODUCTION AND THEORY OF OPERATION

Explains the design and operating principles of the 1200W planetary winch.

HYDRAULIC SCHEMATIC

Presents the hydraulic schematic for the winch's hoist and lower functions.

MAINTENANCE

Outlines the three main steps for good winch maintenance: inspection, periodic servicing, and teardown.

WIRE ROPE

Shows how wire rope should be installed and notes the wedge's suitability for specific cable diameters.

LUBRICATION

Details the type of hydraulic oil and gear lube to use, and lubrication intervals.

DISASSEMBLY PROCEDURE

Provides a step-by-step procedure for disassembling the winch.

REASSEMBLY

Details the steps for reassembling the winch after service or repair.

SERVICING THE MOTOR

Explains how to service the motor and counterbalance valve, noting which parts are not field-serviceable.

SERVICING THE BRAKE

Provides a detailed procedure for disassembling and servicing the winch brake assembly.

SERVICING THE PLANETARY SET

Outlines the procedure for servicing the planetary gear sets, including inspection and reassembly.

TROUBLESHOOTING

Lists common winch problems and their potential solutions.

BILL OF MATERIALS

Lists all parts for the winch with item numbers, TWI part numbers, quantities, and descriptions.

Eskridge Service Manual 75 Series Digger models

Example Part Number

Shows an example of how to interpret an Eskridge digger model part number.

Eskridge Model 75 service manual

Exploded View Drawing

Provides an exploded view of the Model 75 Auger Drive with component item numbers.

Lubrication & Maintenance

Details lubricant viscosity, change intervals, and ambient temperature considerations for the gearbox.

ESKRIDGE MODEL 75 OIL CAPACITY

Shows oil capacity for single, double, and triple stage configurations and oil level indication.

ESKRIDGE PART NUMBER INTERPRETATION

Explains how to interpret Eskridge part numbers based on model, retention, and other specifications.

Unit Disassembly Procedure

Provides a step-by-step procedure for disassembling the unit into subassemblies.

Stage I Carrier Subassembly

Details the disassembly and reassembly steps for the Stage I carrier subassembly.

Disassembly

Details disassembly steps for the base subassembly.

Reassembly

Provides steps for reassembling the base subassembly.

Unit Assembly

Guides the final assembly of the unit from its subassemblies.

Appendix B:Parts Index

Elliott Digger Derrick Specifications

General

Brand	Elliott
Model	Digger Derrick
Category	Utility Vehicle
Language	English