Engcon EC204 User manual

User manual
TILTROTATOR
EC204 | EC206 | EC209 | EC214 | EC219 | EC226 | EC233
Article 9000113 | Version 1.20
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
2

Table of Contents
Table of Contents
1. Introduction
1.1. General............................................................................................................ 6
1.2. Scrapping and recycling..................................................................................6
1.3. Transport and storage..................................................................................... 6
1.3.1. Temperature during operation and storage..............................................7
1.4. Warranty.......................................................................................................... 7
1.5. Technical support and spare parts.................................................................. 7
1.6. Product approval............................................................................................. 8
1.6.1. EC Declaration of Conformity.................................................................. 8
1.6.2. Type certification for lifting hook.............................................................. 9
2. Safety
2.1. General............................................................................................................ 10
3. Design and function
3.1. General............................................................................................................ 11
3.2. Tool(s).............................................................................................................. 11
3.3. Q-Safe............................................................................................................. 11
3.3.1. Overview.................................................................................................. 12
3.4. HS and SW quick hitch with sensor................................................................13
3.4.1. Overview.................................................................................................. 14
3.5. EC-Oil.............................................................................................................. 15
3.6. ePS/C2C..........................................................................................................16
3.6.1. Overview.................................................................................................. 16
4. Installation
4.1. Oil.................................................................................................................... 17
4.2. Identification.....................................................................................................18
4.3. Mechanical.......................................................................................................18
4.3.1. Attaching the tiltrotator.............................................................................19
4.4. Electrical and hydraulics..................................................................................20
4.4.1. Q-Safe......................................................................................................21
4.5. On completion................................................................................................. 21
5. Operation
5.1. Before and during use.....................................................................................22
5.2. Lifting points.................................................................................................... 23
5.3. Integrated grab................................................................................................ 23
5.4. Hydraulic hammers..........................................................................................24
5.5. Augers............................................................................................................. 24
5.6. Pallet forks.......................................................................................................24
5.7. Crane boom.....................................................................................................25
5.8. Manoeuvring.................................................................................................... 25
5.8.1. DC2 control system (for machines with double-acting hydraulic circuit)... 25
5.8.2. Control system 10 (for machines with proportional control hydraulic
circuits).................................................................................................................
25
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Table of Contents
5.8.3. Control system 9-2 (for machines with two or more proportionally
controlled hydraulic circuits)................................................................................
25
5.8.4. Control system 1 (for machines with double-acting hydraulic circuit).......26
5.8.5. Control system 15 (for machines with double-acting hydraulic circuit).....26
5.8.6. Externally controlled quick hitch lock – SQ/QSC..................................... 26
5.9. Changing tools.................................................................................................26
5.9.1. Connecting the tool, hydraulic lock..........................................................26
5.9.2. Disconnecting the tool, hydraulic lock..................................................... 29
5.9.3. Connecting the tool, mechanical lock...................................................... 30
5.9.4. Disconnecting the tool, mechanical lock..................................................32
5.10. Fitting and setting up quick hitch locks......................................................... 32
6. Maintenance
6.1. General............................................................................................................ 36
6.2. Daily inspections..............................................................................................37
6.3. Special maintenance....................................................................................... 39
6.3.1. EC-Oil.......................................................................................................39
6.4. Lubrication every 8 operating hours................................................................40
6.4.1. Tiltrotator lubrication................................................................................ 41
6.4.2. Greasing the quick hitch..........................................................................42
6.4.3. Lubrication, integrated grab GR10, GR20............................................... 43
6.4.4. Lubrication, integrated grab GR20RR..................................................... 43
6.5. Service every 250 operating hours................................................................. 44
6.5.1. Shimming, tilt upper section.................................................................... 44
6.6. Checking axial and radial play........................................................................ 44
6.7. Checking lateral play.......................................................................................45
6.8. Checking rotational play..................................................................................46
6.8.1. Thrust washers........................................................................................ 46
6.8.2. Significance of rotation play.....................................................................47
6.8.3. ePS.......................................................................................................... 47
6.9. Tightening torque.............................................................................................47
7. Troubleshooting
7.1. Q-Safe............................................................................................................. 50
7.1.1. Indications................................................................................................ 50
7.2. HS and SW with sensor..................................................................................52
7.2.1. Indications................................................................................................ 52
7.3. ePS/C2C..........................................................................................................53
7.3.1. Indications................................................................................................ 53
8. Decals
8.1. Decal disposition............................................................................................. 54
8.1.1. Control systems 9 and 10....................................................................... 54
8.2. Warning decals................................................................................................54
8.2.1. Warning decals in cab............................................................................. 54
8.2.2. Warning decals on product......................................................................55
8.2.3. Symbol legend......................................................................................... 55
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Table of Contents
9. Technical data
9.1. Tiltrotator..........................................................................................................57
9.2. Integrated grab cassette..................................................................................59
9.3. Load-holding valve.......................................................................................... 60
10. Glossary
10.1. Designations.................................................................................................. 61
10.2. Tiltrotator overview........................................................................................ 62
11. Service
11.1. Service schedule........................................................................................... 63
11.2. Service record................................................................................................64
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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.
6

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 tiltrotators delivered after 1 January, 2018.
We encourage you to register your tiltrotator to enjoy faster service. Visit
www.engcon.com and search for "register your product".
1.5. Technical support and spare parts
Contact information for support and spare parts can be found at www.engcon.com.
7

1 Introduction
1.6. Product approval
1.6.1. EC Declaration of Conformity
Manufacturer:
engcon Nordic AB
Address:
Box 111
Postal address:
SE-833 22 STRÖMSUND
Country:
SWEDEN
Telephone:
+ 46 670 178 00
Telefax:
+ 46 670 178 28
Email:
[email protected]
Hereby declare that:
Type designation:
Part no:
Serial No:
Lifting hook, max:
Max hydraulic pressure:
Date of delivery:
Other:
has been manufactured in accordance with the EC Machinery Directive 2006/42/EC
The following standards and directives have also been applied and complies with:
-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
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.
Title: CEO
Name: Stig Engström
Date:
Signature:
Qualified person authorised to compile the technical documentation:
Fredrik Jonsson, Head of R&D, engcon AB
8

1 Introduction
1.6.2. Type certification for lifting hook
The following certification is valid for tiltrotators supplied with a lifting hook.
9

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
!
13 4
56
2
7
Figure 1.
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. HS and SW quick hitch with sensor
The HS and SW quick hitch with sensor monitors whether or not the quick hitch is in the
open position. The alarm output is connected to a QLM module mounted on the stick.
It uses sound and light warning signals when the tool’s locking cylinder is open, as the
primary safety purpose of the quick hitch is to protect personnel nearby. 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.
13

3 Design and function
3.4.1. Overview
!
!
EC
!
1
3
2
4
Figure 2.
Position
Description
1
Power supply
2
Alarm indication
3
Indication for open quick hitch
4
Warning lamp
Table 2.
For indications, see section 7.2.1. Indications
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3 Design and function
3.5. EC-Oil
engcon’s system for more efficient tool changes. It provides the ability to switch hydraulic
tools without leaving the cab. The system is designed for maximum reliability in harsh
environments. It is a fully hydraulic system that handles the connection of tools under full
system pressure.
Figure 3.
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3 Design and function
3.6. ePS/C2C
Together with the tiltrotator, engcon's ePS rotation sensor creates an ePS-compatible
excavator guidance system – a concept that provides the selected system with more
functions. It provides full control of the bucket and the ability to see its exact rotational
position. C2C acts as a connection point between two different systems.
3.6.1. Overview
X1 1 2X2 3
Figure 4.
Figure 5.
Position
Description
Remarks
X1
CAN Excavator guidance system
X2
CAN Rotation sensor
1
Traffic indication, Excavator guidance
system
Green LED
2
Status C2C (Alarm indication)
Red LED
3
Traffic indication, Rotation sensor
Green LED
Table 3.
For indications, see sections 7.3.1. Indications.
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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 personal injury and damage
to property. For welding, contact your dealer or
engcon Nordic AB.
WARNING
Beware of moving parts. A lack of awareness may lead
to crush injuries. 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.
17

4 Installation
4.2. Identification
Check that your product's rating plate matches the information on the EC Declaration
of Conformity. If there is any deviation, contact the supplier before you begin initial
installation.
The rating plate is located on the tiltrotator's yellow frame or its black protective cover.
Rating plate content:
Part number
Type designation
Serial number
Year of manufacture
Weight
Lifting hook, max
Max hydraulic pressure
Figure 6.
4.3. Mechanical
The following assembly and installation instructions refer to direct attachment of the
tiltrotator.
If the tiltrotator will be installed on a machine hitch, use the user
manual for connecting tools.
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.
WARNING
If you have any doubts concerning the safety aspects
of your knowledge, the equipment or work, contact
a dealer or engcon Nordic AB. Incorrect installation
affect safety.
IMPORTANT
Assembly and installation may only be carried out at a
workshop authorised by the manufacturer. Changes to the
assembly may not be carried out without the manufacturer’s
consent.
18

4 Installation
4.3.1. Attaching the tiltrotator
Before installation
1. Check the tipping load limits. Take tiltrotator weight
and the extended risk area into account. Installation may
entail a necessary reduction in the volume of the tool.
2. Position the base machine and the tiltrotator on a flat,
non-slip surface. Make sure the tiltrotator is upright and in
line with the stick and break link.
Figure 7.
3. If necessary, use a firmly planted ladder.
Installation
1. Fit any O-rings if such must be used.
2. Position the dog bone linkage to align with the
appropriate holes in the upper section of the tiltrotator.
3. Shim the width if necessary.
4. Insert the intended shaft journal.
Figure 8.
5. Fit the shaft journal lock and make sure it locks
correctly.
19

4 Installation
Figure 9.
6. Align the break link such that it corresponds to the
holes in the upper section of the tiltrotator/rotator.
7. Lower the stick carefully; make sure that no shear
forces occur.
8. Shim the width if necessary.
9. Apply plenty of grease in the cavity and bushings.
IMPORTANT
Fill the bushings and the cavity
in the stick with grease. Central
lubrication only provides top-ups.
Figure 10.
10. Insert the intended shaft journal.
11. Fit the shaft journal lock and make sure it locks
correctly.
4.4. Electrical and hydraulics
For electrical and hydraulic hose installation, refer to the separate
installation instructions supplied with the selected control system. Also
available on the website or by contacting engcon.
IMPORTANT
Maintenance and repair of the electrical system may only be
carried out by professionally qualified persons.
WARNING
Switch off power when working on the electrical
system and remove any live objects before starting
work Risk of personal injury.
20