Elliott Digger Derrick Operation & Maintenance Manual

Operations/Maintenance Manual

Digger Derrick Truck

Elliott Equipment Company

4427 South 76th Circle

Omaha, NE. 68127

(402) 592-4500

www.elliottequip.com

Elliott PN: 3020571

Updated: November 18, 2015

Contents

INTRODUCTION 1

WARRANTY

Warranty Statement 3-1

Change of Ownership 3-2

SAFETY & OPERATION

Safety Responsibilities 4-1

Responsibilities per ANSI/ASSE A10.31 4-2

Nomenclature 4-3

Platform Safety 4-4

Jib Safety 4-5

Road Transport 4-6

On-Site Setup 4-7

Operating Controls-Digger Derrick 4-8

Digger Option 4-9

Outrigger Controls 4-10

Remote Controls 4-11

LMI Controls 4-12

Lift Capacities 4-13

Wire Rope Anchoring 4-14

Wedge Socket 4-15

Multi-Part Reeving 4-16

Jib Operation 4-17

Platform Installation & Operation (Optional Yoke Style) 4-18

Hand Signals 4-19

Required Inspections 4-20

Wire Rope Inspection 4-21

Synthetic Rope Usage, Inspection and Retirement 4-22

Labels 4-23

SPECIFICATIONS & SERVICE TOOLS

Digger Derrick Specifications 5-1

Presentation Drawing-D115 5-2

Hydraulic

Hydraulic Schematic-20K ft-lb.2 Speed High-Performance Digger, Pilot Controls 5.3-1

Electrical

Electric Schematic-Above Rotation 5.4-1

Electric Schematic-Below Rotation 5.4-2

Electric Schematic-Upper Control Box 5.4-3

LOAD CHART-D115

Main Boom Full Span Lift Chart 5.5-1

Main Boom Full Span Range Diagram 5.5-2

Main Boom Mid Span Lift Chart 5.5-3

Main Boom Mid Span Range Diagram 5.5-4

MAINTENANCE

Maintenance Safety 6-1

Cleanliness 6-2

Lubrication 6-3

Bolt Torque 6-4

Changing Hydraulic Oil 6-5

Bubble Level Adjustment 6-6

Four Section Boom Operation 6-7

Troubleshooting 6-8

COMPONENT SERVICE MANUALS

Tulsa 1200W Winch Manual 7-1

Swing Drive Service Manual - Tulsa 6036S 7-2

LMI Operator's Manual - Greer INSIGHT 7-3

LMI Calibration and Troubleshooting Manual - Greer INSIGHT 7-4

Remote Controls (Omnex) Installation/Configuration Manual 7-5

Eskridge 75 Series Digger-(20K ft-lb 2 Speed High Performance Digger) 7-6

Hawe Pump (130cc 20K ft-lb. 2 Speed High Performance Digger) 7-7

Appendix B:Parts Index B

Appendix A:Pages Index A

Introduction EEC-0003 V1.2

Introduction

Do not operate this crane until you have read and thoroughly understand this

manual, the accompanying Association of Equipment Manufacturers “SAFETY

MANUAL FOR OPERATING AND MAINTENANCE PERSONNEL”, all decals on the

crane and you have been properly trained by an experienced, qualified crane operator.

The information in these manuals is a guide to assist qualified personnel in safe

operation and maintenance of this crane and is not a substitute for training, experience

and common sense.

If there is a question on application and/or operation, contact the Product Safety

and Reliability Department at Elliott Equipment Company. If an Elliott Crane is involved

in a personal injury or property damage incident notify the Product Safety and Reliability

Department as soon as possible. Have the model and serial number and details of the

incident recorded prior to contacting the factory.

Elliott Equipment Company

4427 South 76th Circle

Omaha, NE 68127-1806

Ph. 402-592-4500 FAX 402-592-4553

e-mail [email protected]

www.elliottequip.com

Always refer to the latest version of ANSI/ASME B30.5 standards for safe

operation, inspection and maintenance of this crane. Federal, state and local laws, rules

and regulations along with safety codes and insurance requirements take precedence

over any information in this manual.

See the CIMA manual for correct, safe operation near power lines and hand

signals.

READ, UNDERSTAND AND FOLLOW ALL SAFETY LABELS

BEWARE OF OVERHEAD POWER LINES

UNDERSTAND AND NEVER ATTEMPT EXCEEDING CRANE LOAD CHARTS

NEVER EXCEED OPTIONAL PLATFORM CAPACITY AND AREAS OF OPERATION

BEWARE OF ADVERSE WEATHER AND GROUND CONDITIONS

Introduction EEC-0003 V1.2

Introduction

This manual must be retained with this boom truck for use by subsequent operating

personnel.

Introduction EEC-0003 V1.2

Introduction

Revision History

Document

type

Document

Number

Revision

History

Revision Notes Revision

Date

Tech Spec. EEC-0003 1.0 Template

update

11/05/14

Tech Spec. 1.1 Doc update 1/12/15

Tech Spec. 1.2 Doc update 3/5/15

Rev. 01/12

ELLIOTT EQUIPMENT COMPANY

WARRANTY

Subject to the terms and conditions of this warranty, Elliott Equipment Company ("Elliott") hereby warrants all equipment

manufactured by Elliott (“Equipment”) to be free from defects in material and workmanship for a period of one year. There are no

express or implied warranties, including the warranty of merchantability and fitness for a particular purpose, covering component

parts or accessories manufactured or modifications made by someone other than Elliott.

All Equipment shall have a limited one-year warranty (“one-year warranty”), effective from the date that the Equipment is shipped

from Elliott and subject to the terms and conditions contained herein. Elliott’s sole obligation under the one-year warranty shall be

the replacement of the defective part(s), but specifically excludes paint. This one-year warranty is limited to the original purchaser of

equipment from Elliott or from an authorized Elliott distributor only and is not transferable to any other person or entity.

In addition to the one-year warranty, the following structural components shall have a lifetime parts-only warranty from the date of

shipment from Elliott: Subframe, Turrets and Structural Components of all steel booms (“lifetime warranty”). Elliott’s sole obligation

under the lifetime warranty is replacement of the defective part(s), but specifically excluding any labor or other costs incurred. This

lifetime warranty for structural components excludes hydraulic and electrical components, bed and body components, chassis, jibs,

outriggers and platform. This lifetime warranty also specifically excludes any other parts or components, including without limitation

seals, gaskets, hydraulic components and exterior coatings. All replacement parts are original equipment parts from Elliott. In the

event ownership of the Equipment is transferred to a person or entity other than the original purchaser of the Equipment, the lifetime

warranty shall terminate.

The lifetime warranty and one-year warranty as set forth herein apply only to Equipment shipped from Elliott after January 1, 2012.

EXCLUSIONS: No warranty claims shall be valid unless Elliott is notified in writing of the defect within a reasonable time following

its discovery. The one-year warranty and lifetime warranty are valid only if an annual service inspection is performed and

documented by an authorized Elliott distributor. The one-year warranty and lifetime warranty shall not apply with respect to any

claimed defect which in Elliott's sole judgment has arisen from repair, alteration, damage during shipment, accident, negligence,

failure to perform routine maintenance, overloading or misuse, including without limitation, an operator's failure to follow the

instructions issued with the equipment. The one-year warranty and lifetime warranty are void if any modifications are made to the

Equipment.

Elliott reserves the right to make changes in design or construction of its equipment at any time without obligating itself to make

such changes on equipment previously manufactured.

LIMITATION OF LIABILITY: ELLIOTT'S LIABILITY FOR ANY LOSSES AND DAMAGES RESULTING FROM ANY CAUSE

WHATSOEVER, INCLUDING WITHOUT LIMITATION, ELLIOTT'S NEGLIGENCE OR FROM DAMAGED OR DEFECTIVE

EQUIPMENT, IRRESPECTIVE OF WHETHER SUCH DEFECTS ARE DISCOVERABLE OR LATENT, SHALL IN NO EVENT

EXCEED THE PURCHASE PRICE OF THE PARTICULAR EQUIPMENT TO WHICH LOSSES OR DAMAGES ARE CLAIMED, OR

AT THE ELECTION OF ELLIOTT, THE REPAIR OR REPLACEMENT OF THE DEFECTIVE EQUIPMENT. IN NO EVENT SHALL

ELLIOTT BE LIABLE FOR ANY SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION

COMMERCIAL LOSSES, LOST PROFITS OR COSTS OF ANY KIND OR FOR ANY DAMAGES FOR WHICH BUYER MAY BE

LIABLE TO OTHER PERSONS.

DISCLAIMER: THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT

LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND IS ALSO

IN LIEU OF ANY OTHER OBLIGATIONS ON THE PART OF ELLIOTT. No agent, employee or representative of Elliott may bind

Elliott to any other warranty. In the event any provision of the warranty is for any reason held ineffective, the remaining provisions

shall remain full and intact. In particular, the remedy of replacement provided for herein is the exclusive remedy for breach of the

one-year warranty and lifetime warranty.

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 Customer Unit Number

Chassis Year Truck Make & Model Chassis VIN

New Owner (Individual or Company)

Mailing Address (Street address or PO Box)

City, State, Zip Code

Shipping Address ( If different from mailing address )

City, State, Zip Code ( If different from mailing address )

Phone Number ( Please include area code ) Fax number ( Please include area code )

Email Address

Name of person safety information should be addressed to



Safety Responsibilities EEC-0052 V1.2

Safety Responsibilities

Safety is more than reading and following proper operating instructions or

procedures. Safety is achieved by having the appropriate state of mind at all times while

operating or working around this equipment. Having a positive attitude towards safety is

the most important factor in accident and equipment failure prevention.

Any individual who will operate, supervise, rig loads, service, or work near this

boom truck shall read and understand this manual prior to operation. Failure to read

this manual is a misuse of this boom truck. Death or serious injury can result from the

misuse or improper maintenance of this boom truck.

It is your responsibility to know and understand the specific requirements and

hazards that exist, including adverse weather and ground conditions. Remember that

YOU are the key to safety. Good safety practices not only protect you, but also protect

the people around you. Study this manual and make it a working part of your safety

program. Keep in mind that this manual is written only for this specific type of machine.

Practice all other usual and customary safe working precautions, and above all:

REMEMBER – SAFETY IS UP TO YOU

YOU CAN PREVENT SERIOUS INJURY OR DEATH

Why is SAFETY important to YOU?

3 BIG REASONS

 Accidents DISABLE and KILL

 Accidents COST

 Accidents CAN BE AVOIDED

Your safety, along with the safety of all personnel involved with this boom truck,

is of utmost concern to Elliott Equipment Company. This manual has been developed

with the safety of all personnel that work around, with, or operated this equipment as

our primary goal.



Safety Responsibilities EEC-0052 V1.2

Safety Responsibilities

It is your responsibility to know and understand this specific requirements and

hazards that exist. It is also your responsibility to know and understand all government

regulations that apply to the work being performed with this boom truck. You shall

make these items known to all personnel working with this equipment or in the area, so

that everyone can take the necessary and required safety precautions. Failure to read

these instructions can result in death or serious injury.

It is your responsibility to operate and maintain your boom truck with skill, good

judgment, and caution. Following recognized safety procedures will help you avoid

accidents. Modifications to any part of this boom truck can create a safety hazard and

therefore shall not be made without written approval from Elliott Equipment Company.

Use only Elliott factory approved parts to maintain this equipment. If this boom truck is

rebuilt or remounted, mounting procedures, re-testing, and re-certification are

required in accordance to instructions provided by Elliott Equipment Company.

Safety is dependent on all people associated with this boom truck. The overall

condition of the equipment, maintenance and inspection procedures are just as

important as safe operating procedures and a positive attitude towards safety. All of

these procedures properly applied will significantly reduce the likelihood of an accident

or equipment failure.

Management/Supervisory Responsibilities

As an owner or employer, it is your responsibility to establish a safe working

environment for your operator and other employees or people working in within

proximity of your equipment. It is your responsibility to instruct or provide instruction

to the 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

local regulations or project requirements, licensed. Good vision, good judgment,

coordination, and mental ability are required. Any individual that lacks any of these

qualities should not be allowed to operate a boom truck.



Safety Responsibilities EEC-0052 V1.2

Safety Responsibilities

Signal personnel must also have good vision and sound judgment, know

standard crane signals and be able to clearly give signals. They must have sufficient

experience to recognize hazards and signal the operator to avoid them.

Riggers must have the ability to determine weights and distances. Riggers must

also demonstrate the ability to select and properly use lifting tackle. It is the

responsibility of the management and supervisor to see that riggers are properly

trained.

Crewmembers must be given specific safety responsibilities and potential

hazards. Crewmembers not required for the lifting operation shall be instructed to stay

clear of the lift. Crewmembers must also be instructed to report any unsafe

conditions to the operator, supervisor or management.

Operator’s Responsibilities

Safety must be the operator’s most important concern. The operator must refuse

to operate the boom truck when knowing it is unsafe and should always consult his/her

supervisor if there is any doubt regarding safety. The operator must read and

understand the Owner’s manual and verify that the equipment is in proper working order

and properly set up before operating. The operator must be alert, physically fit, and free

from the influence of alcohol, drugs, or medications that might affect his/her eyesight,

hearing, reactions, or judgment.

Before and during each use, the operator shall measure wind speed from the

aerial platform at the height of use with an anemometer. Do not allow personnel lifts in

wind speeds exceeding 20 miles per hour (32 kilometers per hour) at the raised platform

height when the platform is attached to the boom or jib unless otherwise indicated on

the load chart.

Winds aloft can be much stronger than at the ground. Follow all applicable

instructions for operating an anemometer. Weather can be unpredictable, and the

operator must determine prior to operation whether it is safe to use the equipment given

the conditions. Operators should be aware of high or erratic winds, electric storms,

snow, ice, sleet, or other adverse weather conditions that could affect the safety of



Safety Responsibilities EEC-0052 V1.2

Safety Responsibilities

personnel or property. If high winds or adverse weather conditions are encountered, do

not use the equipment. If high winds or adverse weather conditions develop during the

lift, terminate the lift.

The operator must see that unnecessary people, equipment and material are

kept out of the work area. 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 boom truck. It is the operator’s responsibility to determine that the machine can

safely lift and maneuver the load though the range of the lift prior to attempting to lift it.

If any portion of the lift creates a condition of blocked eyesight for the operator, or

when operating in or around hazardous areas, a signal person must be used. Because

the operator is not in the best position to judge distances and may not be able to see all

areas of the work area, a signal person may be necessary at other times. The operator

must understand standard crane signals and take signals from only one designated

signal person. The operator, however, shall take a stop signal from anyone.

Signal Person’s Responsibilities

The signal person must have good vision and sound judgment. The signal

person must know the standard crane signals and be able to give these signals clearly

and quickly. The signal person must also have appropriate experience to be able to

recognize hazards and be able to signal the operator to avoid them. The signal

person’s primary duty is to assist the operator in safe and efficient operation. The

operator’s must depend on the signal person to direct load movements without

endangering people or property. The signal person must also have a clear

understanding of the work being done, and how all steps of the operation fit together.

This will allow the signal person to safely coordinate the job with the operator and

all other crewmembers. The signal person must take up a position where they can be

clearly seen by the operator and clearly observe the entire operation. Standard crane



Safety Responsibilities EEC-0052 V1.2

Safety Responsibilities

signals must be used unless operator and signal person agree upon an alternative

method of communication.

Rigger’s Responsibilities

Riggers must be able to accurately determine weights and distances, and be

able to select and properly use lifting tackle for the requirements of the lift. Riggers are

also required to understand and abide by crewmember’s responsibilities.

Crewmember’s Responsibilities

It is the responsibility of all crewmembers to report any unsafe condition or

practice that is recognized to the job supervisor. Everyone who works around cranes or

boom trucks, must obey all warning signs and watch out for his or her own safety and

the safety of others. Crewmembers setting up equipment or handling loads are

expected to know proper machine erection and rigging procedures.

Crewmembers must watch for hazards during operations and alert the operator

and signal person of any dangers such as power lines, unexpected presence of people,

other equipment or unstable ground conditions.



Safety Responsibilities EEC-0052 V1.2

Safety Responsibilities

Revision History



Document

type

Document

Number

Revision

History

Revision Notes Revision

Date

Tech Spec. EEC-0052 1.0 Template

update

11/05/14

Tech Spec. 1.1 Doc update 1/13/15

Tech Spec. 1.2 Doc update 3/5/15



Responsibilities ANSI/ASSE A10.31 EEC-0168 V1.0

Responsibilities per

ANSI/ASSE A10.31

NOTE: Unless otherwise specified, all section references in this chapter refer to

the latest version of ANSI/ASSE A10.31.

SECTION 6-Responsibilities of Manufacturers

A. General Responsibilities: Each manufacturer of a digger derrick covered by

this standard shall comply with all requirements of ANSI/ASSE A10.31, Section

4 for mechanical design, Section 5 for electrical performance (where related to a

manufacturer) and the requirements of this section.

B. Specifications

1. Vehicle Specifications: The digger derrick manufacturer shall provide to the

installer the minimum values, as applicable, for the following characteristics of

vehicles required to provide a stable and structurally sound vehicle for the

digger derrick:

a. Front gross axle weight rating (GAWR front)

b. Rear gross axle weight rating (GAWR rear)

c. Gross vehicle weight rating (GVWR)

d. The frame section modulus

e. Yield strength of the vehicle frame

f. Frame resisting bending moment (RBM)

g. Wheelbase dimension (WB)

h. The rear of cab to rear axle centerline dimension (CA)

i. The minimum axle weights of the mobile unit required for stability

2. Digger Derrick Specifications:

a. General: The digger derrick manufacturer shall clearly state in the manual

and on the digger derrick the following information:

I. Make and model

II. Serial number

III. Year of manufacture

IV. Insulating or non-insulating

V. Maximum pressure of the hydraulic system and voltage of the

electrical control system



Responsibilities ANSI/ASSE A10.31 EEC-0168 V1.0

Responsibilities per

ANSI/ASSE A10.31

VI. Cautions and restrictions of operation, including the applicable

ambient temperature range where the digger derrick may be used

VII. Rated load capacity

VIII. Platform capacity

IX. Multiple configurations

X. Compliance with ANSI/ASSE A10.31

b. Digger Derrick Component Ratings: The digger derrick components

shall be rated in the following terms:

I. Make and model

II. Serial number

III. Year of manufacture

IV. Insulating or non-insulating

V. Maximum pressure of the hydraulic system and voltage of the

electrical control system

VI. Cautions and restrictions of operation, including the applicable

ambient temperature range where the digger derrick may be used

VII. Rated load capacity

VIII. Platform capacity

IX. Multiple configurations

X. Compliance with ANSI/ASSE A10.31

c. Digger Derrick Component Ratings: Digger derrick components shall be

rated in the following items:

I. Winch capacity

II. Winch line. Manufacturers should recommend the size, length, type

and average breaking strength of the synthetic rope and minimum

breaking strength of wire rope for use with the winch

III. Rating classification

IV. Rated capacity

V. Platform capacity

VI. Digger rating. The manufacturer shall specify for each speed range:



Responsibilities ANSI/ASSE A10.31 EEC-0168 V1.0

Responsibilities per

ANSI/ASSE A10.31

 Running torque

 Rotation speed in RPM at rated hydraulic flow

 Rated hydraulic flow

 Rated hydraulic pressure

d. Design Voltage and Qualification Voltage: If the digger derrick is the

insulating type, the manufacturer shall state the design and qualification

voltage in the manual, and the qualification voltage on the identification

plate(s).

NOTE: ANSI/ASSE A10.31, Section 5 details the procedures for

electrical requirements.

C. Quality Assurance: The manufacturer shall have a documented quality

assurance program that will ensure compliance with this standard.

D. Manuals: The manufacturer shall provide a separate operator’s manual and a

separate parts/maintenance manual for each digger derrick. Two hard copies of

the operator’s manuals shall accompany each digger derrick. Two parts and

maintenance manuals, either hard copy or electronic format, shall be provided for

each digger derrick. The manuals shall contain:

1. Descriptions, specifications and ratings of the digger derrick

2. Operating instructions for the digger derrick and its auxiliary systems

3. Precautions relating to multiple configurations such as personnel platforms,

jibs, etc.

4. Instructions regarding routine and frequency of recommended maintenance

5. Replacement part information

6. Instructional markings, per the Instructional Markings section on page 4.

7. Facsimiles of all safety and operating decals and their location

8. Notice of the requirement of dealers, installers, owners, users, operators,

lessors, lessees, and brokers to comply with the appropriate section(s) of this

standard

E. Markings: The digger derrick shall have identification, operation, and instruction

placards, decals, plates or the equivalent, which are legible and readily visible. In



Responsibilities ANSI/ASSE A10.31 EEC-0168 V1.0

Responsibilities per

ANSI/ASSE A10.31

no event shall markings be applied which reduce the insulating properties of the

digger derrick. Markings on the digger derrick may refer to the unit manuals for

additional identification, operation and instructional material.

1. Application of Markings: The manufacturer shall install on each digger

derrick the markings or provide these markings with appropriate installation

instructions.

2. Identification Markings: The manufacturer shall install or provide an

identification plate(s) to indicate the following minimum information:

a. Make

b. Model

c. Insulating or non-insulating

d. Qualification voltage and date of test

e. Serial number

f. Year of manufacture

g. Rated load capacity

h. Digger derrick hydraulic system pressure or digger derrick control system

voltage, or both

i. Unit equipped with platform(s) and platform(s) capacity

j. Unit equipped with jib and the rated capacity of the jib

k. Minimum ambient temperature for operation of the digger derrick to

maintain structural integrity

l. Name and location of manufacturer

m. Installer

3. Operational Markings: The manufacturer shall install or provide markings

describing the function of each control and a boom angle indicator readable

from the lower control station(s). See ANSI/ASSE A10.31, Appendix B for

recommended symbols for control functions.

4. Instructional Markings: Markings shall be determined by the manufacturer,

or the manufacturer and user jointly to indicate hazards inherent in the

operation of a digger derrick. Instructional markings shall be provided for:



Responsibilities ANSI/ASSE A10.31 EEC-0168 V1.0

Responsibilities per

ANSI/ASSE A10.31

a. Electrical hazards involved in the operation of the machine to warn that:

I. A digger derrick does not provide protection to platform occupant(s)

from contact with, or in proximity to, electrically-charged equipment,

conductor, or other components when the platform occupants(s) is

in contact with, or in proximity to, another electrical component.

II. A digger derrick in proximity to energized conductors, including load

line and load being lifted, shall be considered energized, and that

contact with the digger derrick, winch line, load being lifted or

vehicle (including attached trailers) under those conditions may

cause serious injuries.

b. Hazards resulting from failure to operate the equipment in a prescribed

manner.

c. Information related to the use and load rating of the equipment for material

handling.

d. Information related to the use and load rating of the digger derrick for

multiple configurations.

e. Information warning the operator that winch lines are not insulating.

f. Information related to operator cautions.

g. Notice of the requirement to comply with the appropriate section(s) of this

standard.

F. Mechanical Tests and Inspection

1. Operational Tests: In addition to the manufacturer’s prototype tests and

quality assurance measures, each digger derrick, including mechanisms,

shall be tested by the manufacturer as necessary to ensure compliance with

the operational requirements of this section. Some examples are:

a. Boom(s) elevating and lowering mechanism

b. Boom(s) extension mechanism

c. Rotating mechanism

d. Stability tests

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