Engcon EC319 User manual

User manual
TILTROTATOR
EC319
Article 9000682 | Version 1.2
Original Instructions

Preface
Preface
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.
www.engcon.com
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Table of Contents
Table of Contents
1. Introduction
1.1. General............................................................................................................ 5
1.2. Scrapping and recycling.................................................................................. 5
1.3. Transport and storage..................................................................................... 5
1.3.1. Temperature during operation and storage..............................................6
1.4. Warranty.......................................................................................................... 6
1.5. Technical support and spare parts.................................................................. 6
1.6. Product approval............................................................................................. 7
1.6.1. EU Declaration of Conformity.................................................................. 7
2. Safety
2.1. General............................................................................................................ 8
3. Design and function
3.1. General............................................................................................................ 9
3.2. Tool(s).............................................................................................................. 9
3.3. Q-Safe............................................................................................................. 9
3.3.1. Overview.................................................................................................. 10
3.4. EC-Oil.............................................................................................................. 11
4. Installation
4.1. Oil.................................................................................................................... 12
4.2. Identification.....................................................................................................13
4.3. Electrical and hydraulics..................................................................................13
4.3.1. Q-Safe......................................................................................................14
4.4. On completion................................................................................................. 14
4.4.1. Apply decals.............................................................................................14
4.4.2. Function check.........................................................................................14
5. Operation
5.1. Before and during use.....................................................................................15
5.2. Lifting points.................................................................................................... 16
5.3. Tool(s).............................................................................................................. 16
5.3.1. Hydraulic hammers.................................................................................. 16
5.3.2. Augers......................................................................................................16
5.3.3. Pallet forks............................................................................................... 16
5.3.4. Crane boom............................................................................................. 17
5.4. Manoeuvring.................................................................................................... 17
5.4.1. DC3 Control System................................................................................17
5.5. Changing tools.................................................................................................17
5.6. Work under water............................................................................................17
5.6.1. Before performing work under water....................................................... 17
5.6.2. After performing work under water.......................................................... 18
6. Maintenance
6.1. General............................................................................................................ 19
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Table of Contents
6.2. Daily inspections..............................................................................................20
6.3. Tiltrotator lubrication........................................................................................ 21
6.3.1. Grease recommendation......................................................................... 21
6.3.2. Lubrication every 8 operating hours........................................................ 21
6.3.3. Worm gear lubrication..............................................................................23
6.4. Service every 250 operating hours................................................................. 23
6.4.1. Shimming, tilt upper section.................................................................... 23
6.5. Special maintenance....................................................................................... 24
6.6. Breakout play and rotational play....................................................................25
6.6.1. Checking lateral play............................................................................... 26
6.6.2. Checking rotational play.......................................................................... 27
6.6.3. Thrust washers........................................................................................ 28
6.6.4. ePS.......................................................................................................... 28
6.7. Testing load-holding valves............................................................................. 28
6.8. Tightening torque.............................................................................................28
7. Troubleshooting
7.1. Q-Safe............................................................................................................. 30
7.1.1. Indications................................................................................................ 30
8. Decals
8.1. Warning decals................................................................................................32
8.1.1. Warning decals in cab............................................................................. 32
8.1.2. Warning decals on product......................................................................32
8.1.3. Symbol legend......................................................................................... 33
9. Technical data
9.1. Tiltrotator..........................................................................................................35
9.1.1. Overview.................................................................................................. 37
9.2. Load-holding valve.......................................................................................... 38
10. Glossary
10.1. Abbreviations................................................................................................. 39
11. Service
11.1. Service schedule........................................................................................... 40
11.1.1. Service every 500 operating hours........................................................ 40
11.1.2. Service every 250 hours........................................................................ 41
11.2. Service record................................................................................................41
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1 Introduction
1. Introduction
1.1. General
This user manual contain important information about your product's functions and
characteristics, and how to use it in the best way. Before you begin using the product, it is
important that you read and understand the content of these instructions, especially the
sections that address safety.
In addition to these instructions, you must study and understand the applicable safety
information for the relevant base machine as well as any other equipment involved.
The user manual is supplied with supplementary documentation providing more detailed
descriptions of the installation, fitting, operation and maintenance of control systems and
custom modifications for your specific product.
Information, images, illustrations and specifications used in the instructions are based
on product information that was available at the time of going to press. Images and
illustrations used in the instructions are typical examples and not intended to be exact
depictions of various part of the product. We reserve the right to make changes without
prior notice.
Always store the user manual together with any other supplementary information in a safe
manner and such that it is always available.
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. This refers to all work with residual materials including
handling, storage and processing. To prevent contamination of soil and water, spillages
must be avoided. Should a spillage occur, it must be dealt with.
Hazardous waste may only be disposed of by those authorised to do so. All waste
produced must be disposed of in compliance with applicable legislation and ordinances:
- Metal and plastics to be recycled.
- Hydraulic hoses are normally used for energy recovery (sort as hazardous waste).
- Oils and greases are normally used for energy recovery (sort as hazardous waste).
- Electronic components to be recycled for materials (sort as hazardous waste).
- Packaging to be sorted at source and recycled for materials.
- Paper to be sorted at source and recycled for materials.
If in doubt, contact the environmental manager at engcon.
1.3. Transport and storage
There are no lifting or attachment points on the tiltrotator. The tiltrotator may only be
handled, moved or transported while strapped to a pallet.
5

1 Introduction
When storing the piston rod of a cylinder for a long period, treat it with corrosion protection
or push it inside the cylinder.
1.3.1. Temperature during operation and storage
Description
Temperature
Operating temperature
-30° to +50°C
Temperature range during storage
-30° to +50°C
1.4. Warranty
All customers receive a 2-year warranty on their tiltrotator.
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.
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1 Introduction
1.6. Product approval
1.6.1. EU Declaration of Conformity
Manufacturer:
engcon Nordic AB
Address:
Box 111, SE 833 22 Strömsund, SWEDEN
Telephone:
+ 46 670 178 00
Email:
[email protected]
engcon hereby declares that the below is manufactured in conformance with Machinery Directive 2006/42/EU.
Type designation:
Part no:
Serial No:
Max jacking point:
Max hydraulic pressure:
Date:
Other:
Because the following standards and regulatory directives are also applied, the product complies with the
requirements for CE marking.
-EMC Directive 2014/30/EU
-SS-EN ISO 12100:2010, SS-EN 474-1:2006+A5:2018 and SS-EN 474-5:2006+A3:2013, SS-ISO
13031:2016
-ISO 10567:2007, SAE J2506:2012, SAE J1362:2018
dold text
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.
Osynlig fras
Krister Blomgren - Signatory for engcon Nordic AB
Osynlig fras
Qualified person authorised to compile the technical documentation:
Fredrik Jonsson, Head of R&D, engcon AB
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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
not followed. Risk of personal injury or death.
WARNING
Indicates that an accident may occur if the regulation
is not followed. Risk of personal injury or death.
CAUTION
Indicates that an accident may occur if the regulation
is not followed. Risk of personal injury.
IMPORTANT
Indicates that an accident may occur if the regulation is
not followed. Risk of damage to property, process or the
surroundings.
REMARKS
Specifies additional information that may make performance or
understanding of specific operations easier.
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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
are type-approved in the base machine’s operator’s manual.
DANGER
Do not exceed tipping load limits. The weight of the
product and the increased reach may impair stability.
Risk of personal injury and damage to property.
3.3. Q-Safe
Q-Safe is a warning system that monitors the connection of tools to the machine quick
hitch and/or the quick hitch beneath the tiltrotator. It has a double mechanical lock to
prevent the tool coming loose from the hitch, even if some part of the locking system
should fail. The alarm outputs are connected to a QLM module mounted on the stick. It
uses sound and light warning signals when a tool is incorrectly connected, as the primary
safety purpose of the quick hitch is to protect personnel nearby. The operator must inform
personnel concerned what the alarms mean.
WARNING
Stop work immediately and begin troubleshooting if
the system warns of a faulty tool connection during
operation. Risk of personal injury and damage to
property.
CAUTION
Use hearing protection when close to or handling
the Q-Safe quick hitch when it is connected. Risk of
hearing damage.
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3 Design and function
3.3.1. Overview
!
!
EC
!
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56
2
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Figure 1.
EC
!
Position
Description
1
Power supply
2
Alarm indication
3
Sensor, machine hitch hook
4
Sensor, machine hitch ejector
5
Sensor, quick hitch hook
6
Sensor, quick hitch ejector
7
Warning lamp
Table 1.
For indications, see section 7.1.1. Indications
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3 Design and function
3.4. 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.
Figure 2.
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4 Installation
4. Installation
It is important to check the necessary additional documentation before installation. At time
of delivery, your product and supplementary documentation are as far as possible adapted
to your base machine.
WARNING
Never attempt to increase the maximum capacity
of the equipment by modifications not approved by
the supplier. Risk of personal injury and damage to
property.
WARNING
Welding is not permitted. It can have a negative
impact on safety. Risk of injury and damage to
property. For welding, contact your dealer or engcon
AB.
WARNING
Beware of moving parts. A lack of awareness may lead
to crush injuries. Risk of personal injury.
4.1. Oil
On delivery, your product is filled with Fuchs Hydraway White 46, a white oil-based
hydraulic oil.
An oil drain pan must be available during installation.
T and P are labelled with:
Max 2,5 MPa
(if possible, use
free return)
T
Max 22 MPa
P
IMPORTANT
Ensure miscibility with the base machine's hydraulic oil
prior to installation. If you are in any doubt, contact your
lubricant supplier. An incorrect mixture could damage hydraulic
components.
12

4 Installation
4.2. Identification
Check that your product's rating plate matches the information on the EU Declaration
of Conformity. If there is any deviation, contact the supplier before you begin initial
installation.
The rating plate is located on the tiltrotator yellow body.
Rating plate content:
Part number
Type designation
Serial number
Year of manufacture
Weight
Max jacking point
Max hydraulic pressure
Figure 3.
4.3. 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.
WARNING
Switch off power when working on the electrical
system and remove any live objects before starting
work Risk of personal injury.
WARNING
Be meticulous with the insulation of electrical
conductors and components when installing/fitting
electrical equipment. Short circuits in electrical wiring
can result in fires.
13

4 Installation
4.3.1. Q-Safe
See separate installation instructions. Also available on the website or
by contacting engcon.
4.4. On completion
4.4.1. Apply decals
Affix the warning decal supplied in a conspicuous place in
the cab where it does not distract the operator.
WARNING
Replace damaged or
illegible signs and
decals before using
the machine. Risk of
personal injury and
damage to property.
4.4.2. Function check
Carry out a function test according to the following items.
- Run all the tiltrotator functions a few times to remove any air from the system. Important
for preventing uncontrolled movement.
- Check that the tiltrotator functions according to section 5.4. Manoeuvring.
- Make sure the tool operates when the hydraulics are activated.
- Check that hoses and cables are not exposed to wear or pinching.
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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.
Risk of personal injury and damage to property.
The tiltrotator may be used only for the brackets and tools it is intended for.
See additional information in the separate user manual for each tool.
WARNING
Take care when handling long objects. Take dynamic
load and the extended risk area into account. Risk of
personal injury and damage to property.
WARNING
Always make sure of a good grip when lifting objects.
Risk of personal injury and damage to property.
WARNING
Using the tiltrotator to lift people or work platforms
is prohibited. Risk of personal injury and damage to
property.
IMPORTANT
Check the base machine's specified max capacity. Any use
of the product in excess of base machine max capacity may
damage the machine.
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5 Operation
5.2. Lifting points
Approved
Not approved
Figure 4.
Figure 5.
Figure 6.
Check the maximum permitted load for the lifting point as stamped on the lifting hook / lug
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 jacking point on the tiltrotator.
Risk of injury and damage to property.
5.3. Tool(s)
5.3.1. Hydraulic hammers
The use of hydraulic hammers together with the tiltrotator is not recommended as this
leads to increased wear.
5.3.2. Augers
The use of augers together with the tiltrotator is not recommended as this leads to
increased wear.
IMPORTANT
Avoid rotation for extended periods; it can cause the worm gear
to overheat. Risk of property damage.
5.3.3. Pallet forks
When using pallet forks, the tiltrotator's cylinders must be fitted with load-holding valves. If
uncertain, contact your supplier.
To avoid overloading the quick hitch locking pins, the pins must be turned away from the
forklift tines.
16

5 Operation
WARNING
The excavator arm system cylinders must be fitted
with valves to prevent the load from dropping in the
event of a hose failure. Risk of personal injury and
damage to property.
WARNING
When using pallet forks together with the tiltrotator,
exercise caution and manoeuvre carefully. The load
can easily fall off during rapid rotation or tilting.
5.3.4. Crane boom
The tiltrotator may not be used together with a crane boom. During crane boom operation,
the tiltrotator must be disconnected from the carrier.
5.4. Manoeuvring
The functions described for each control system apply to the recommended installation/
configuration. Deviations may occur depending on the user's preferences for alternative
button functionality and configuration.
5.4.1. DC3 Control System
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.
5.5. Changing tools
Refer to separate user manual supplied on delivery. Also available on
the website or by contacting engcon.
5.6. Work under water
We do not recommend work under water as this leads to increased wear and risks
reducing tiltrotator service life. Work in brackish or salt water will reduce the service life of
EC-Oil electrical connectors by more than half.
5.6.1. Before performing work under water
- Fill the tiltrotator with grease as described in section 6.3.3. Worm gear lubrication.
Ideally, use grease that is more water repellent. Always check with your dealer to
ensure miscibility.
17

5 Operation
- Fill all connectors with contact grease. Ideally, use contact grease that is water
repellent.
- Check the condition of the O-ring between the rotator frame and the quick hitch. See
section 9.1.1. Overview.
5.6.2. After performing work under water
- Always finish the working day by rotating, tilting and filling grease via the central
lubrication to expel water from bearings.
- Apply oil to shiny surfaces.
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6 Maintenance
6. Maintenance
DANGER
Check the attachment points regularly and be alert for
the formation of cracks. Risk of personal injury and
damage to property.
WARNING
Make sure that service and maintenance is carried out
according to the manufacturer's recommendations.
Inadequate maintenance may cause defects on the
base machine and its equipment.
WARNING
When changing hoses, only hoses with press
couplings may be used. Screw connections may
not be used. Risk of personal injury and damage to
property.
6.1. General
Scheduled greasing and inspections to be performed by the operator:
-Daily: To be performed according to section 6.2 before the working day is begun. Daily
service.
-Every 8 operating hours: Lubrication according to section 6.3. Lubrication every 8
operating hours.
-Every 250 operating hours: Perform according to section 6.4. Service every 250
operating hours.
In addition to the above, service must be performed by a service technician during the
first machine service or no later than 500 operating hours. Then at 500-hour intervals
according to section 11.1. Service schedule.
Fill in section 11.2. Service record after completed service.
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.
19

6 Maintenance
IMPORTANT
Be sure to keep your product clean. Inadequate cleaning can
cause damage to your equipment.
6.2. Daily inspections
Check that:
- Visible fasteners are tightened (see section 6.8. Tightening torque).
- The shaft journal lock attachment points are not loose.
- No damage or cracks are present.
- The tiltrotator is correctly attached to the machine and tool.
- Warning decals are present and legible.
- The quick hitch is clean, without visible damage and is functioning normally.
- No breakout play or rotational play is present (see section 6.6. Breakout play and
rotational play).
- There are no hydraulic leaks.
- No grease leakage is present on hoses or in connectors.
- The QLM electronics modules signals correctly when attaching and detaching tools.
WARNING
Avoid contact with hydraulic oil. Risk of burns.
WARNING
Never use your hands to search for leaks in the
hydraulic system. Use the necessary protective
equipment. Pressurised hydraulic oil can penetrate
the skin. Risk of personal injury.
WARNING
Beware of moving parts. A lack of awareness may lead
to crush injuries. Risk of personal injury.
WARNING
The hydraulic system must be de-pressurised before
work on the system is begun. Risk of personal injury
and damage to property.
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