Elliott MONSTER HAWK Troubleshooting guide
www.elliott-tool.com
Tube & Pipe Cleaners Tube Testers Tube Plugs Tube Removal Tube Installation
Hydraulically Driven Mechanical Rolling System
Operation and Maintenance Instructions
MONSTER TM
TABLE OF CONTENTS
Introduction .......................................................................................................... 4
Safety Guidelines ................................................................................................. 5
Receiving & Installation ........................................................................................ 7
General Information.............................................................................................. 8
Operation Instructions........................................................................................ 10
Technical Information ......................................................................................... 14
Parts List ............................................................................................................ 15
Maintenance Instructions ................................................................................... 39
Adjustment & Repair .......................................................................................... 41
Troubleshooting Guide ....................................................................................... 42
Warranty ............................................................................................................. 44
4 Monster Hawk
INTRODUCTION
Thank you for purchasing this Elliott product. More than 100 years of experience have been employed
in the design and manufacture of this control, representing the highest standard of quality, value and
durability. Elliott tools have proven themselves in thousands of hours of trouble-free eld operation.
If this is your rst Elliott purchase, welcome to our company; our products are our ambassadors.
If this is a repeat purchase, you can rest assured that the same value you have received in the past
will continue with all of your purchases, now and in the future.
The Monster Hawk has been designed for the following types of equipment:
Heat Exchangers
Condensers
Chillers
If you have any questions regarding this product, manual or operating instructions, please call Elliott
at +1 800 332 0447 toll free (USA only) or +1 937 253 6133, or fax us at +1 937 253 9189
for immediate service.
Monster Hawk 5
SAFETY GUIDELINES
Read and save all instructions. Before use, be sure everyone using this machine reads and
understands this manual, as well as any labels packaged with or attached to the machine.
• Know Your Elliott Tool. Read this manual carefully to learn your tool’s application and
limitations as well as the potential hazards specic to this tool.
• Keep Work Area Clean and Well Lit. Cluttered, dark work areas invite accidents.
• Dress Properly. Do not wear loose clothing or jewelry. Wear a protective hair covering
to contain long hair. It is recommended that the operator wear safety glasses with
side shields or a full face shield eye protection. Gloves and water repellant, nonskid
footwear are also recommended. Keep hands and gloves away from moving parts.
• Use Safety Equipment. Everyone in the work area should wear safety goggles or
glasses with side shields complying with current safety standards. Wear hearing
protection during extended use, respirator for a conned space and a dust mask for
dusty operations. Hard hats, face shields, safety shoes, respirators, etc. should be
used when specied or necessary. Keep a re extinguisher nearby.
• Keep Bystanders Away. Bystanders should be kept at a safe distance from the work
area to avoid distracting the operator.
• Use The Right Tools. Do not force a tool or attachment to do a job or operate at a
speed it was not designed for.
• Use Proper Accessories. Use Elliott accessories only. Be sure accessories are properly
installed and maintained.
• Check for Damaged Parts. Inspect guards and other parts before use. Check for
misalignment, binding of moving parts, improper mounting, broken parts or any other
conditions that may affect operation. If abnormal noise or vibration occurs, turn the
tool off immediately and have the problem corrected before further use. Do not use a
damaged tool. Tag damaged tools “Do Not Use” until repaired. A damaged part should
be properly repaired or replaced by an Elliott service facility. For all repairs, insist on
only identical replacement parts.
WARNING
!
To reduce the risk of injury, always unplug your
machine before performing any maintenance.
Contact Elliott for all repairs.
6 Monster Hawk
SAFETY GUIDELINES
Read and save all instructions. Before use, be sure everyone using this machine reads and
understands this manual, as well as any labels packaged with or attached to the machine.
• Keep Hands Away from All Moving Parts.
• Do Not Overreach. Maintain Control. Keep proper footing and balance at all times.
• Stay Alert. Watch what you are doing, and use common sense. DO NOT use a
tool when you are tired, distracted or under the inuence of drugs, alcohol or any
medication causing decreased control.
• Unplug Tool. Unplug tool when it is not in use, before changing accessories or
performing recommended maintenance.
• Maintain Tool Carefully. Keep tools sharp and clean for best and safest performance.
Follow instructions for lubrication, maintenance and changing accessories. For more
information see “Maintenance” section.
• Store Idle Tools. When not is use, store your tool in a dry, heated, secured place. For
more information see “Maintenance” section.
• Maintain Labels and Nameplates. These carry important information and will assist you
in ordering spare and replacement parts. If unreadable or missing, contact an Elliott
service facility for a replacement.
Monster Hawk 7
RECEIVING & INSTALLATION
Uncrating
Remove the machine from any protective wrapping/crating using the hoist ring located above the
hydraulic pump or fork lift pockets. Always enter the forklift pockets from the backside of the machine
to protect the control panel from damage. The arm should always be locked into position and secured
prior to transporting.
Assembly
The Monster Hawk should be delivered with the power head removed from the arm. Connect the
power head to the swivel rod located on the end of the arm and tighten the hex nut on the swivel rod
threads. Remove the plugs from the ends of the (4) hydraulic hoses on the arm, and caps from the
(4) hydraulic ttings on underside of the power head. Match the labeled hose with the corresponding
labeled tting.
Utility Hook-Up
The Monster Hawk requires an air supply of 90 psi at 10 cfm. A lter/regulator is supplied as standard.
The regulator should be set to 90 psi max.
Install the appropriate plug on the power supply cable located on the side of the electrical panel. Turn
the lockout handle on the front of the electrical panel to ‘ON’.
Start-Up
Always engage the caster locks located on (2) casters near the machine’s push handle prior to
operating, attaching tooling, or performing maintenance on the machine.
8 Monster Hawk
GENERAL INFORMATION
The power head is intended to hold and drive Elliott tube expanders (sold separately), and is to be
used only for such purpose.
The counter balance arm is intended to hold the expansion power head unit supplied with this
machine, and is to be used only for such purpose.
Pressure Regulator
The Monster Hawk uses a cable air cylinder, which is controlled by the pressure regulator, to
counter balance the weight of the arm and power head mounted to the arm. Once set, the arm will
be balanced and remain vertically static when the force of the air supply equals the weight of the
arm. The arm can then manually be moved and it will remain at this vertical position.
WARNING
!
WARNING: When adjusting the pressure regulator,
turn slowly to avoid sudden rise or fall of the arm.
Monster Hawk 9
WARNING
!
WARNING: If the arm is manually moved or the
controls on the control panel are adjusted prior to
the air supply being re-connected the system will
lose its pressure and the arm may fall rapidly.
GENERAL INFORMATION
The Monster Hawk contains several components intended for the safety of the operator.
Safety Shut-Off Control Valve
Located at the top of the column on the backside of the cable cylinder. This is a pilot-controlled valve
that opens when an air supply of at least 45 psi is supplied to the pilot. When pressure drops below
this the valve shuts and air cannot enter or escape from the cable cylinder.
Relief Valve
Located at the top of the column on the side of the cable cylinder. This valve relieves the pressure
inside the cable cylinder, which is necessary since the cable cylinder is equipped with the safety
shut-off control valve which could hold air pressure inside the cylinder. It is important to use this relief
valve prior to maintenance of any of the pneumatic components, especially the cable cylinder, or when
storing the machine for extended periods of time.
Arm Locking Mechanism
Located on the transporting handle. This is a spring plunger that prevents the arm from pivoting out of
position or raising in the event the pressure regulator dial on the control panel is inadvertently turned.
The arm should be lowered and locked when the machine is not in use or being transported.
Check Valve
Located at the underside of the control panel. In the event that the air supply is suddenly removed the
check valve will allow the system to maintain its current pressure and prevent the arm from dropping.
10 Monster Hawk
OPERATION INSTRUCTIONS
Always engage the caster locks when the machine is not being transported.
Prior to each use of the machine, please review and complete the “Before Each Use” maintenance
steps located in the Maintenance Section.
Prior to connecting the main air supply, ensure the following:
1. The arm locking mechanism on the machine’s push handle is engaged.
2. The regulator on the front control panel (controls the counter balance cable cylinder) is
rotated fully in the counter-clockwise direction to its ‘OFF’ position.
3. The valve at the main air supply inlet is off (the handle is turned to the horizontal position
90° to the line).
Connect the main air supply.
Supply air to the system by opening the valve at the main air supply inlet. To do this, rotate the handle
to its vertical position parallel to the line.
Disengage the arm locking mechanism by retracting the ‘L’ handle and turning into the resting open
position. Swing the arm out from under the handle toward the front of the machine.
To raise the arm, SLOWLY turn the pressure regulator dial on the control panel clockwise until the arm
starts to rise. Once the arm starts to elevate, stop turning the dial to hold the arm’s position.
NOTE: Typically, the required setting will be between 45-65 psi.
If the arm continues to rise, SLOWLY turn the dial slightly in the counter-clockwise direction until the
arm stops and maintains its position. The arm can now be manually moved into its desired vertical
position.
WARNING
!
WARNING: Failure to do the above could result
in component failure, damage to the machine,
or bodily injury.
WARNING
!
WARNING: Ensure the regulator at the main air inlet
is set to a max of 90 psi. Failure to do so could
result in component failure, damage to the machine,
or bodily injury.
Monster Hawk 11
To lower the arm via the dial on the control panel, turn the dial SLOWLY in the counter-clockwise
direction until the arm starts to lower.
NOTE: If the dial is turned too quickly while lowering the arm, the arm may stop and maintain its
position. This is because the safety shut-off valve has engaged before all of the air could bleed from
the cable cylinder and back through the pressure regulator on the control panel. To re-engage it and
continue to lower the arm, turn the dial slowly in the clockwise direction to slightly raise the arm then
repeat the process to lower.
Expanders
Locate the appropriate expander based on tube size, expansion range, expansion length, etc., for
installation onto the power head. Insert the expander into the front ange by rst sliding the mandrel
and lube spacer through the front ange, then threading the cage into the front bearing shoulder (left-
hand threads).
NOTE: It is acceptable to tighten the cage by hand at this point as it will tighten itself during the
expansion process.
The mandrel can now be connected. Slide the spring-loaded outer sleeve back on the quick chuck
assembly, insert the mandrel drive fully and rotate clockwise. Release the sleeve, making sure it fully
extends back into position.
Lubrication
The Monster Hawk has been supplied with a lubrication system that automatically supplies lubricant
to the expander through each expansion stroke. With each expander stroke 1.25ml (0.25 tsp) – 2.50ml
(0.50 tsp) of lubricant is deposited depending on the tube size. The lubricator can accommodate
a wide variety of lubricants including those with viscosities in excess of equivalent 10W oil. Elliott
recommends the P8395 or P8784 series water or petroleum based lubricants for use with the system.
NOTE: The pressure relief valve is factory set to 175 psi. If lubricant is leaking from the rear of relief
valve then either the setting has been changed or the lubricant used is too thick. The plug next to the
relief valve can be removed and temporarily replaced with a pressure gauge to reset the valve to 175
psi.
If the lubrication system is to be used, a shut-off valve is located under the lubricator on the power
head. To open, rotate the valve so the handle is parallel to the line. Locate the reservoir tank inside
the housing panel above the machine’s push handle. Fill the tank with the desired lubricant. An in-
line primer bulb is supplied to prime the lubrication line. Squeeze the primer bulb several times until
the lubricant is seen exiting the front of the cage or around the rolls. It is recommended to repeat the
priming process after each expander change.
If at any time lubrication is not desired simply turn the shut-off valve off. It may take a several strokes
for the lubricant to stop owing.
OPERATION INSTRUCTIONS
CAUTION
!
CAUTION: If replacing expander during use,
it may be hot. Use caution when touching
expander components.
12 Monster Hawk
OPERATION INSTRUCTIONS
Controls
Locate the control panel on the front of the machine and follow the steps below to set up the machine
for the expansion process.
1. Control Screen ‘OFF/ON’ (Selector Switch) - Turn to ‘ON’. The display screen will power
up.
2. Hydraulic Pump (Pushbutton) – Press the upper green pushbutton to turn the hydraulic
pump on.
NOTE: Upon initial setup jog the pump motor once, and verify the pump motor is rotating
in the same directions as the arrow tag on the motor. If the direction is incorrect, reverse
(2) of the (3) motor leads, and recheck the rotation.
3. Control Screen/Keypad – Enter the desired torque value into the display screen. Using
the keypad:
a. Press the ‘#’ key
b. Enter a torque value between 5.0 - 70.0. The decimal will remain stationary with the
number inputs rolling from right to left. For example, ‘5.0’ ft-lbs enter ‘5-0, ’12.0’ ft-lbs
enter ‘1-2-0’, ’45.5’ ft-lbs enter ‘4-5-5’.
c. Press the ‘#’ key once more to submit the value.
4. Start (Pushbutton) – Press to start the mandrel rotation.
Insert the expander into the tube.
NOTE: ONLY ADVANCE THE MANDREL WHILE INSIDE A TUBE. Failure to do so could allow the rolls
to break from inside the cage and result in tool failure and harm to the operator and any bystanders.
Locate the handle on the power head and follow the steps below to begin the expansion process.
1 / 9
2
3
4
7
8
Monster Hawk 13
5. Cycle Run (Pushbutton [green]) – Press and hold throughout the expansion process.
When pressed the mandrel will advance, achieve the desired torque, and will
automatically retract to its backmost position. Once it stops the button can be released.
NOTE: A torque value must be entered into the display screen in order for the cycle run
button to work.
6. Mandrel Retract (Pushbutton [yellow]) – Press to manually retract the mandrel to its
backmost position. This should be used if the cycle run button is let go prior to the full
retraction of the mandrel. The mandrel should be in this position prior to the expander
entering each tube to ensure the rolls have dropped to their minimum expanding
diameter.
If the required torque value is unknown, measure the expanded ID and adjust the torque as needed by
repeating steps 3 – 5. Once the expansion process is complete the machine can be shut down.
7. Stop (Pushbutton) – Once the expansion process is complete, press to stop the mandrel
rotation. NOTE: The ‘Stop’ pushbutton on the control panel can also be pressed to stop
the mandrel rotation.
8. Hydraulic Pump (Pushbutton) – Press the lower red pushbutton to turn the hydraulic
pump off.
9. Control Screen (Selector Switch) - Turn to ‘OFF’. The display screen will power down.
The mandrel advance feed rate has a 2-speed adjustment valve. This valve is located inside the
housing panel under the machine’s push handle. Rotate the lever up for the ‘high’ feed rate, down for
the ‘low’ feed rate. The ow control valve located next to the feed rate ball valve will control the ‘low’
feed rate only. NOTE: By design, the ‘low’ feed rate cannot exceed the ‘high’ feed rate.
OPERATION INSTRUCTIONS
5
6
7
14 Monster Hawk
TECHNICAL INFORMATION
Spares & Accessories Kit
Contact your Elliott representative
for Recommended Spares Kits.
Monster Hawk Specications
Horizontal Radius Reach 7’
Minimum Vertical Reach 24”
Maximum Vertical Reach 84”
Working Area/Footprint
91” height
42.5” width (base)
42.0” depth (base)
Unit Weight 1,690 lbs.
Hydraulic Pump Electric Motor 15 HP
Hydraulic Oil Tank Capacity 20 gallon
Min/Max Torque 5 ft-lbs / 70 ft-lbs
Monster Hawk 15
PARTS LISTS & DIAGRAMS - PXS230
16 Monster Hawk
PARTS LISTS & DIAGRAMS - PXS230
Monster Hawk 17
PARTS LISTS & DIAGRAMS - PXS230
18 Monster Hawk
PARTS LISTS & DIAGRAMS - PXS230
Monster Hawk 19
PARTS LISTS & DIAGRAMS - PXS230
20 Monster Hawk
PARTS LISTS & DIAGRAMS - PXS230
Table of contents
Other Elliott Industrial Equipment manuals
Popular Industrial Equipment manuals by other brands
SMC Networks
SMC Networks SFDA Series manual
Solimar
Solimar Air Knocker Series instruction manual
schmersal
schmersal AZM201Z-I2-ST2-T-1P2PW-DU Instructions for operation
Ashcroft
Ashcroft V02 Installation and maintenance instructions
Leroy-Somer
Leroy-Somer Nidec LSAP 40 POLE Installation and Maintenance
ABB
ABB HT610665 Operation manual
