Ez Crauler

Transcript

EZ Crauler Training & Procedure Manual After completely reading and reviewing this manual, it is required that you take an online test to ensure safe operation of the EZ Crauler unit. The steps below are how to access and complete the test. 1. Access www.testmoz.com/532566 through the nearest computer. 2. In the box labeled Your Name, place your name and the company that you are associated with and press continue. 3. Proceed to take the test by answering all questions. 4. Submit the test. 5. If a score of 100% is achieved you are ready to operate the EZ Crauler unit. If a score below 100% is achieved, please retake the test until a score of 100% is reached. REV. 8/15/2016 10:32 Introduction DANGER! Operators are required to read and understand this manual before operating the unit. Failure to do so could result in property damage, serious injury, or death. This manual outlines important information that is essential to safely operate the EZ Crauler unit. Personnel operating the unit should be aware of all safety concerns and responsibilities outlined within this manual. Maintenance is required on all EZ Crauler units for safe and efficient operation. Routine maintenance is extremely important in maintaining a reliable unit. Users must read and understand all manuals included with the EZ Crauler unit. The safety guidelines in this manual must be followed in addition to your companies safety guidelines. This includes working with potentially energized equipment. Also fallow federal and district/state regulations. It is impossible for a manual cover all hazards. Always use your companies safety practices at all times to avoid unnecessary risks. REV. 8/15/2016 10:32 Explain responsibilities • Dealers, Owners, Users, Operators, Lessors and Lessees must comply with A10.31 responsibilities. • Only trained and authorized personnel shall be permitted to operate the digger derrick. Altering or disabling the function of safety devices, guards or interlocks, if so equipped, is prohibited. Taken from A10.31 REV. 8/15/2016 10:32 • All applicable safety related work practices intended to protect from electrical hazards shall be defined and explained to the operator by a qualified person. The Operator shall maintain the appropriate minimum approach distance (MAD) from energized conductors and apparatus, commensurate with the operator’s qualifications. • When an operator is directed to operate digger derrick with which they are not familiar, they shall receive prior instruction regarding the following items: 1) The location of the manuals. 2) the purpose and function of all controls. 3) Safety devices and operating characteristics specific to the digger derrick. 4) under the direction of a qualified person, the trainee shall operate the digger derrick for a sufficient period of time to demonstrate proficiency in the actual operation of the digger derrick. Taken from A10.31 REV. 8/15/2016 10:32 DANGER, WARNING, CAUTION, and NOTE The signal words DANGER, WARNING, CAUTION, and NOTE are used to identify levels of hazard seriousness. The signal word DANGER is only used on product labels to signify an immediate hazard. The signal words WARNING, CAUTION, and NOTE will be used on product labels and throughout this manual and other manuals that may apply to the product. • DANGER! - Immediate hazards which will result in severe personal injury or death. • WARNING! - Hazards or unsafe practices which could result in severe personal injury or death. • CAUTION! - Hazards or unsafe practices which may result in minor personal injury or product or property damage. • NOTE or IMPORTANT - Used to highlight suggestions which will result in enhanced installation, reliability, or operation. REV. 8/15/2016 10:32 Specification • The EZ Crauler is a Digger Derrick designed to move across difficult terrain to access hard to reach areas. • Reference unit placard for information on load limits hydraulic pressure rating and voltage rating. REV. 8/15/2016 10:32 Top Winch Nomenclature Upper Boom Intermediate Boom Extension Lower Boom Cylinder Boom Rest Lower Cylinder Boom Angle Indicator Hydraulic Top Seat Lines Winch Auger Stow Auger Bracket Boom Windup Sling Controls Digger link Digger Pole Guide Auger Extension Shaft Controls Panel Bucket Liner Bucket Bracket Outrigger Controls Auger Turntable Bucket Hydraulic tank Pedestal Pole Carrier Outriggers Jib REV. 8/15/2016 10:32 Safety Guidelines Before operating any heavy machine, it is important to learn its safety rules. All of your existing in-house safety precautions must be followed as well as the precautions listed in this manual. The EZ Crauler has no electrical insulation until final stage boom is extended into place. Be sure to follow your company’s safety procedures to protect against electrocution, as well as federal and district/state regulations. NEVER consider the unit to be primary insulation. Primary insulation should always be gloves, mats, and all applicable safety gear. Operators must be properly trained before operating any part of the EZ Crauler. Properly set the outriggers whenever the boom is in use. NOTE! Pictures in manual may not be a true representation of your machine. REV. 8/15/2016 10:32 Insulation Insulated non-insulated Fiberglass final stage boom extension, when fully extended provides secondary insulation only. NOTE! Entire rope is non-insulated REV. 8/15/2016 10:32 Safety Guidelines Operate the EZ Crauler in a well-ventilated area only. The engine emits exhaust gases, which can cause sickness and death. The EZ Crauler’s controls react to input rapidly. Know the location and function of all controls before starting the machine. The EZ Crauler can be shut down in an emergency by releasing all drive controls and turning the ignition switch to the “off” position. Digger Derrick can be shut down by pressing the stop on digger or remote. The EZ Crauler must be properly secured on its trailer before transporting it. REV. 8/15/2016 10:32 Load Capacity One of the most important considerations when operating this machine is the Load Capacity of the EZ Crauler’s boom. The load capacity of the boom depends upon the distance from center line of boom turret** CAUTION! UNIT MUST BE LEVEL. CAUTION! Weight of load must be known at all times. Boom capacity at any angle should never be exceeded. **See load capacity from load chart on machine. REV. 8/15/2016 10:32 EZ Crauler Safety All safety precautions that would apply to a line truck also apply to the EZ Crauler. The EZ Crauler is a powerful machine that should be operated with respect & caution. WARNING! Misuse or carelessness can result in serious injury, property damage or death. REV. 8/15/2016 10:32 EZ Crauler Safety Hard hats and protective gear must be worn by all personnel when operating the EZ Crauler. Also fallow all company, state and federal regulations and policies. Always use common cense. REV. 8/15/2016 10:32 Refer to the load capacity chart or on the machine itself for more specific indications of the digger derrick’s capacity. When operating any EZ Crauler, the weight of a load must be known at all times. Boom capacity at any angle should never be exceeded. Please follow the load capacity chart posted on each EZ Crauler for weight capacity. Properly use all outriggers whenever the boom is in use. If unit is equipped with a debris blade it must be lowered to contact ground. DANGER! The EZ Crauler’s boom must never be operated without the outriggers being properly set. REV. 8/15/2016 10:32 DANGER! ALL OUTRIGGERS MUST BE PROPERLY EXTENDED BEFORE OPERATING THE BOOM! Pre-trip Inspection Picture is only for reference of main components. Pin Hydraulic Lines Auger Windup Sling Winch Rope Hydraulic Hoses Refer to Morooka manual for information on chassis. REV. 8/15/2016 10:32 Pre-trip Inspection Before each day’s operation, the EZ Crauler must be inspected by the operator. Do a visual inspection to check for lose, worn, missing or broken parts such as bolts, nuts, wires & retaining pins. 1. Check hydraulic hoses for cuts, wear, and loose connections. 2. Check hydraulic system. 3. Check ropes and lines for cuts and wear. REV. 8/15/2016 10:32 Pre-trip Inspection Check all tires on the EZ Crauler trailer for wear & proper inflation. Test all turn signal, parking and brake lights by turning them on. Be sure to test the braking action on the trailer before traveling to the work site. REV. 8/15/2016 10:32 Pre-trip Inspection Check to make sure that EZ Crauler is properly secured to the trailer. Look inside EZ Crauler toolbox & make sure it contains all tools & equipment necessary for operating the EZ Crauler. REV. 8/15/2016 10:32 Pre-trip Inspection Inspect the lift line and hook for signs of wear or damage. Replace any worn or damaged parts before using the EZ Crauler. REV. 8/15/2016 10:32 Pre-trip Inspection Turn on the remote control & check the function of all controls. REV. 8/15/2016 10:32 EZ Crauler Controls Spare Battery PTO Interlock Override Emergency Stop Switch (Pictures may not be a true representation of your machine.) Hydraulic gauge will be added next to the spare battery REV. 8/15/2016 10:32 Remote Control Basic Operation A. Turn E-stop counterclockwise to turn on remote and press to shut off remote. B. Operation switch must be in boom position to operate digger derrick. C. Auger switch: A position to dig, B position to reverse (clean). C B A NOTE! Auger will stop digging during overload, reverse auger to stop overload. Audible alarm will sound. REV. 8/15/2016 10:32 Remote Control Basic Operation Removable battery for easy charging REV. 8/15/2016 10:32 Remote Control Basic Operation A. Raise/Lower boom B. Rotate boom A B C. Extend/Retract boom D. Raise/Lower winch E. Extend/Retract fiberglass NOTE! Use remote as primary operation. REV. 8/15/2016 10:32 C D E The EZ Crauler is able to travel over difficult terrain. DANGER! All travel angle limits must be followed during operation. That does not mean it can travel anywhere. REV. 8/15/2016 10:32 Moving the EZ Crauler With a Load Moving a pole: Lifting and carrying a pole can be performed easily with Digger Derrick. Attach the provided rope to the pole and slowly lift it onto extendable supports for transportation (Picture may not be a true representation of your machine.) REV. 8/15/2016 10:32 Moving the EZ Crauler With a Load Extend the metal support poles rest and secure pull on booth supports. Secure with provided strap to unit. (Picture may not be a true representation of your machine.) Reverse procedure when pole is ready to be lowered to the ground. REV. 8/15/2016 10:32 Setting a Pole With the EZ Crauler Remember the EZ Crauler should never be considered electrically insulated. Use your company’s safety procedures to avoid electrocution. Before setting a pole the load capacity chart must be thoroughly understood. – See load capacity chart on machine CAUTION! Weight of load must be known at all times. Boom capacity at any angle should never be exceeded. Please follow the weight scale posted on each EZ Crauler for weight capacity. REV. 8/15/2016 10:32 Setting the Outriggers Use the outrigger controls to lower (extend) outriggers to level and support the machine. If unit is equipped with debris blade lower until ground contact. (Picture may not be a true representation of your machine.) Outrigger pads should always be used. REV. 8/15/2016 10:32 Auger Operation Procedure REV. 8/15/2016 10:32 1. Make sure that boom sections are fully retracted 2. Using the auger remote circuit wind up the auger slightly to release tension on latch locking pin. 3. Pull pin and release auger. Speed control NOTE! Use the flow control on the remote control to control the speed of the auger. REV. 8/15/2016 10:32 Auger release 4. Raise the boom up to 30 degrees to avoid the auger making contact with the machine. Using the remote, reverse the auger rotation and slowly lower the auger. CAUTION! You must raise the boom to safely lower auger assembly. REV. 8/15/2016 10:32 (Pictures may not be a true representation of your machine.) Carefully unwind the auger and remove the strap. You are now ready to use the remote control to control the auger as needed. REV. 8/15/2016 10:32 Reverse this procedure to store the auger, again making sure to have boom extensions fully retracted before stowing auger. CAUTION! Do not “Over Store” the auger as damage can occur! Travel Pin NOTE! Make sure to place boom extensions are retracted fully. Replace the travel pin. REV. 8/15/2016 10:32 Setting the Auger Lock On the EZ Crauler the auger lock is set automatically when the auger is brought down from the stowed position. When the lock is engaged the auger can then travel with the extension function to reach the maximum distance. CAUTION! Make sure all extensions are retracted before using the auger function. REV. 8/15/2016 10:32 Digging the Hole Position the machine over the desired hole replacement area. Extending boom 12 or 14 inches and allowing enough slack in rope to drill a hole straight down. Turn on the remote and toggle the Auger switch to the correct direction then lower the auger to begin digging. NOTE! It may be required to lower the auger speed to allow for booming down of the digger derrick while digging. DANGER! Buried lines may be in (Pictures may not be a true representation of your machine.) your digging area. Never dig unless located. REV. 8/15/2016 10:32 Take small bites and let the auger dig at its own pace until the hole is the proper depth. Different regions have many different soil compositions; familiarize yourself with your digging surface for your safety and those around you. (Pictures may not be a true representation of your machine.) REV. 8/15/2016 10:32 If needed, the extension bar may adjusted for more digging depth. (Pictures may not be a true representation of your machine.) REV. 8/15/2016 10:32 Setting the Pole (Pictures may not be a true representation of your machine.) 1. Set the outriggers and level the machine. CAUTION! To 2. Unwind winch line to avoid two-blocking. avoid wrapping do 3. Extend the boom out until the unit stops. not let winch go slack on ground 4. Raise the boom to at least 60 degrees elevation. 5. Fiberglass final stage must be fully extended for dielectric REV. 8/15/2016 10:32 insulation! 6. Install hydraulic pole guide. (Refer to installation instructions.) 7. Raise the boom into position so that the lift line will be lifting straight up. Follow load chart specifications on weight in relationship to boom angle. 8. Install the lifting strap, remember to position the lifting strap according to pole weight for balance in lifting. REV. 8/15/2016 10:32 9. Lift the pole straight up and set into the hole. Always operate EZ Crauler from a safe distance using the remote control. Never use manual lever overrides for normal operation, they are for emergency use only. Load capacity chart in manual is for reference only, refer to chart posted on EZ Crauler. REV. CAUTION! Weight of load must be known at all times. Boom capacity at any angle should never be exceeded. Please follow the load capacity chart posted on each EZ Crauler for weight capacity. 8/15/2016 10:32 Bucket Assembly Standard Operating Procedure REV. 8/15/2016 10:32 CAUTION! Prior to using the bucket assembly, extend and secure all outriggers to the fullest settings. If unit is equipped with debris blade it must be lowered until making contact with the ground. NOTE! The bucket assembly has the capacity of 300 pounds. The following instructions are provided to ensure safe operation of the bucket assembly. Always engage bucket attachment switch. REV. 8/15/2016 10:32 Make sure that locking mechanism on the bucket mount is unlocked by pulling it up and twisting counterclockwise into the position show. This allows the bucket to swing freely and remain perpendicular while the boom is being raised or REV. 8/15/2016 10:32 lowered. Once the boom is working height, lock the bucket in place by rotating the mechanism clockwise allowing the spring to engage the working parts of the lock. Remember to unlatch the lock each time before raising or lowering the boom! REV. 8/15/2016 10:32 Lower and extend the boom to accommodate installation of the bucket mount. After completing the tasks, return the hydraulic boom sections to the retracted “stowed” position before lowering the bucket to a flat surface. CAUTION! Stay clear of the bucket while in operation. REV. 8/15/2016 10:32 Retract winch rope back to the stowed position if it is not in use. Winch rope kill switch REV. 8/15/2016 10:32 Shows the bucket mount installed and pinned in place REV. 8/15/2016 10:32 The bucket can now be mounted to either side of the mount to best accommodate working from it. REV. 8/15/2016 10:32 Connect tool here Reel connections pin bucket With the bucket mounted, connect the hoses from the tool reel. Connect tools to outlets. REV. 8/15/2016 10:32 Slide the bucket upper mount in to the machines receiver. (Pic 1) Pin the upper mount securely in place. (Pic 1) Slide the bucket lower mount on to the upper mount. (Pic 2) Pin the lower mount securely in place on either side of the upper mount. (Pic 3) Pic 1 Pic 2 Pic 3 DANGER! DO NOT EXCEED BUCKET CAPACITY! REV. 8/15/2016 10:32 Material Handler The EZ material handling pin on jib which is designed to be used while a man is in the bucket and has a maximum capacity of 1000 lbs. Follow load chart. DANGER! DO NOT USE IN CONJUCTION WITH MAIN WINCH! DEATH OR SERIOUS INJURY WILL OCCUR! (Pictures may not be a true representation of your machine.) REV. 8/15/2016 10:32 Material Handler Pic 1 Pic 2 Pic 3 Pic 4 1. Attach jib and secure with pin (Pic 1 and Pic 2) 2.Attach quick couplers (Pic 3) 3.Secure rope around pulleys (Pic 4) REV. 8/15/2016 10:32 To Enable control of hydraulic tools from the bucket REV. 8/15/2016 10:32 1. Turn this rheostat counter clockwise to off position CAUTION! USE OPEN CENTER TOOLS ONLY REV. 8/15/2016 10:32 rheostat push enable button press forward 2. While holding the yellow “enable” button down press both momentary auxiliary switches forward. Hold for approximately 2 seconds You may now control oil flow to the upper tool reel using the rheostat on the right of the remote panel. CAUTION! USE OPEN CENTER TOOLS ONLY REV. 8/15/2016 10:32 Material Handler Use accessory toggle switches on remote control to operate the material handler winch. REV. 8/15/2016 10:32 Control Chair Use for operation point if equipped. WARNING! Never ride in seat during machine drive operation. WARNING! Seat belt must be worn at all times during operation. REV. 8/15/2016 10:32 Hydraulic Pole Guide Procedure REV. 8/15/2016 10:32 Install the pole guide and pin it in place. Connect the four hoses to operate it. REV. 8/15/2016 10:32 The hoses are each fitted with connectors that match the correct fittings on the pole guide. REV. 8/15/2016 10:32 The pole guide is installed with hoses connected. REV. 8/15/2016 10:32 Remember that the pole guide is conductive so it will not be insulated against cross fazing, but with the fiberglass boom properly extended the EZ Crauler and its operator will be substantially protected. REV. 8/15/2016 10:32 Pole Pulling Always use a suitable open center “pole pulling” tool for pole removal! The EZ Crauler can be used as a guide and steady the pole as the pole pulling tool is in use. WARNING! Never use the EZ Crauler in conjunction with a pole pulling tool or as a secondary pole removing tool! Structural damage will occur! No Pole Pulling The pole must be completely free of the hole before lifting with the EZ Crauler! REV. 8/15/2016 10:32 Interlock Override DANGER! Digger must not be rotated or taken out of stow with this operation. • Momentary switch to be used for momentary operation of boom function when outriggers are not set. REV. 8/15/2016 10:32 Tilt Sensor This unit can be equipped with a pre set tilt sensor. If the unit exceeds a pre set slope, an audible alarm will sound. This indicates that the unit is in danger of tipping over. (Pictures may not be a true representation of your machine.) REV. 8/15/2016 10:32 IMPORTANT! The EZ Crauler series of machines are all dielectrically tested to 46kv category “C” guidelines. This qualification test is performed at the factory in accordance with ANSI A10.31 guidelines. It is important that periodic tests be performed to the EZ Crauler just as any other digger-derrick in a companies fleet. REV. 8/15/2016 10:32 Boom Pedestal and Rotator Back Controls 1 2 10 9 11 26 17 8 7 6 18 16 12 21 25 22 14 13 15 19 4 3 23 5 Outriggers and body Top Seat 27 24 20 28 30 29 36 34 35 33 31 32 REV. 8/15/2016 10:32 Boom Decals, Right Side 38 Boom/Auger Decals, Left Side 45 42 37 43 47 44 48 39 41 49 46 40 Pole Guide Decals Bucket Mount Decals, Left & Right Side 50 53 51 52 REV. 8/15/2016 10:32 (Right side shown) Bucket Decals 55 54 58 57 56 REV. 8/15/2016 10:32 Decal Serial Number Key 1-15 Back Controls 1) 060115-1035 2) 091306-1308 3) 081312-0916 4) 110915-0857 5) 080912-1635 6) 032905-1254 7) 010713-1232 8) 082405-0150 9) 032905-1258 10) 032905-1259 11) 081406-1501 12) 030805-0408 13) 032805-0401 14) 032905-1248 15) 032905-0907 16-26Boom Pedestal and Rotator 16) 082505-0907 17) 082405-0150 18) 071708-1023 19) 060706-0231 20) 081312-0916 21) 082505-0906 22) 060706-0231 23) 071310-0929 24) 081312-0916 25) 082405-0150 26) 032905-1252 27-33 Top Seat 27) 032905-1256 28) 030805-0408 29) 080912-1635 30) 082505-0908 31) 032905-0909 32) 081312-0916 33) 120911-0728 34-36 Outriggers and body 34) 032805-0401 35) 082505-0904 36) 060706-0231 37-41 Boom Decals, Right Side 37) 082505-0229 38) 032905-0908 39) 032905-0909 40) 032905-1256 41) 082505-0908 42-49 Boom/Auger Decals, Left Side 42) 032905-0908 43) 082505-0231 44) 032905-1250 45) 082505-0902 46) 082505-0904 47) 032905-0909 48) 032905-1256 49) 082505-0908 REV. 8/15/2016 10:32 50-51 Pole Guide Decals 50) 082505-0904 51) 032905-1301 52-53 Bucket Mount Decals, Left & Right Side 52) 032905-0905 53) 080912-1851 54-58 Bucket Decals 54) 071806-0139 55) 032905-0906 56) 071806-0136 57) 032905-0910 58) 091508-1124