long reach boom installation and operation manual · 2020. 4. 1. · 2.3.3.this “get...

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Long Reach Boom Installation and Operation Manual

2 Long Reach Boom Installation and Operation Manual

Contents

1. Introduction .................................................................................................................... 4

1.1. Safety Summary ..................................................................................................... 4

1.2. Potential Hazzard .................................................................................................. 4

1.3. Prohibited Operation ............................................................................................ 5

1.4. Precautionary Warning ........................................................................................ 6

2. Operation ........................................................................................................................ 7

2.1. Getting Started Safely............................................................................................ 7

2.2. General Rule for Safe Operation ......................................................................... 7

2.3. Getting the Feel of the Attachment ..................................................................... 7

3. Preventive Maintenance .............................................................................................. 8

3.1. Maintenance safety procedures .......................................................................... 8

4. Installation ...................................................................................................................... 9

4.1. Pre-Mounting Preparation .................................................................................. 9

4.2. Mounting Procedure ........................................................................................... 10

4.3. Fine Tuning and Adjustment ............................................................................. 14


We thank you for investing in the long reach attachments. Our attachments are designed

with many years of cumulative experience. Each attachment is designed for functionality

and engineered for reliability. This installation manual has been put together to assist our

customers in the safe handling of attachments during both installation and operation.

Please read through the manual thoroughly, as this will help you to better understand the

nature of your machine and its limitations after installing the attachment.


1. Introduction

1.1. Safety Summary

1.1.1. Your safety and the safety of others is a direct result of how you operate or

maintain your equipment. Read and understand this manual and other safety

information provided with the carrier machine and be sure that you

understand all controls and operating instructions before attempting to

operate the equipment. Failure to follow the precautions can result in

personal injury, death or property damage.

1.1.2. Observe the same safety precautions as with other machinery where

carelessness in operation and maintenance is hazardous to personnel.

Carefully read through all the safety messages in this manual and on your

equipment safety signs. Keep the safety signs in good condition and replace

missing or damaged safety signs.

1.1.3. EIK Engineering cannot foresee all hazardous circumstances; the precautions

listed in this manual and on the equipment are not all-inclusive. If a procedure,

method, tool or part is not specifically recommended by EIK Engineering, you

must satisfy yourself that it is safe for you and others, and that the equipment

will not be damaged or made unsafe as a result of your decision.

1.1.4. The basic rules are summarised in this section of the manual. They also appear

throughout the manual along with the additional specific rules fore safety and

operation.

1.2. Potential Hazzard

1.2.1. Avoid tipping. The attachment may have altered the lift capacities of the

carrier. Do not overload the excavator or serious injury could result. Lift

capacities may vary if the carrier is not on level ground.

1.2.2. Lifting incorrectly can cause severe injury or machine damage. Carry loads in

recommended positions (as per excavator hand book) for maximum stability.

Use the recommended excavator counterweight. Use short slings and lift the

load only as high as necessary.

1.2.3. Avoid Power Lines. Serious injury or death can result from contact with electric

lines. As long reach boom has a larger working radius, never move any part of

the machine or load close to electric lines.


1.3. Prohibited Operation

1.3.1. Do not perform hammering and piling operations using the bucket. Such

operations will cause damage to the long reach structure which is not design

for such operations, and it should be avoided in all circumstances.

Figure 1

1.3.2. Do not operate the machine by its swinging force. Moving load by the swinging

force of the long reach machine will shorten the service life of the long boom

and stick/dipper arm.

1.3.3. Do not jack the track off the ground by pushing the boom and stick/dipper arm

against the ground. The nature of the long reach boom and stick/dipper arm

structure and geometry is not designed for such operations. Avoid all such

operations in all circumstances.

Figure 2


1.3.4. Never operate the long reach excavator as a crane.

1.3.5. Do not use vibrating attachments on long reach equipment, such as hammer,

rock/concrete breaker, vibrator, etc.

1.4. Precautionary Warning

1.4.1. Under no circumstances should any modifications be made to EIK Engineering

equipment without factory authorization. This equipment was designed to do

a specific job and alterations to it could result in injury to the operator or

machine.

1.4.2. Always lower the boom to the ground before leaving the cab. If it is necessary

to work on an attachment off the ground, securely support the machine and

attachment. Do not support the machine on cinder blocks, hollow tiles, or

props that may crumble under continuous load. Do not rely on the cylinder to

hold the attachment in the air. If a control is moved or hydraulic pressure is

otherwise released, the attachment may drop. Do not work under a machine

that is supported solely by a jack.

1.4.3. Hydraulic oil becomes hot during operation. DO NOT let hot hydraulic oil get in

contact with the skin as it could cause severe burns. Wear adequate protective

clothing and safety equipment.

1.4.4. Do not tamper with any hydraulic line or component while it is pressurised.

Escaping fluid under pressure can penetrate the skin, causing serious injury.

Relieve pressure before unhooking hydraulic or other lines. Tighten all

connections before applying pressure. Keep hands and body away from

pinholes and nozzles which eject fluid under high pressure. Use a piece of

cardboard to check for leaks.

1.4.5. If ANY fluid is injected into the skin, seek medical assistance immediately by a

doctor familiar with this type of injury or gangrene may result.

1.4.6. Wear close fitting clothing and safety equipment appropriate for the job.

Safety equipment should be worn at all times when viewing, operating, or

maintaining the attachment to prevent injury. Safety equipment includes eye

protection, hard helmet, safety shoes, gloves, hearing protection, etc.


2. Operation

2.1. Getting Started Safely

2.1.1. Always walk around the machine before starting and moving it. Keep

bystanders clear, especially before moving boom, swinging upper structure, or

travelling. Always be alert for bystanders in or near the operating area.

2.1.2. Make sure work site footing has sufficient strength to firmly support the

machine. When working close to an excavation, position machine with the

propel motors at rear.

2.1.3. Inspect the entire machine carefully each day by walking around it before

starting.

2.2. General Rule for Safe Operation

2.2.1. Know the capacity of the excavator and its attachments. DO NOT overload the

machine or serious injury could result. KNOW YOUR LOAD! DO NOT GUESS.

The attachment may have altered the machine’s lift capabilities.

2.2.2. When leaving the machine for any reason, lower the attachment to the ground.

2.2.3. Avoid collision of the boom or attachment, especially when working with

limited visibility or inside buildings. Know the height and reach of the

attachment during operation, travel and swinging upper structure.

2.3. Getting the Feel of the Attachment

2.3.1. Before starting the first job with a new machine, it is suggested that the

operator find a good open spot on firm, level ground that is free of

obstructions such as trees, buildings and other equipment – and it must be

free of people too. Move the machine to this area – and spend some time just

getting to know the “operating feel” of the machine and attachment.

2.3.2. Every operating part of any machine has a slightly different “operating feel” –

an individual machine response to the movement of the controls.

2.3.3. This “get acquainted” time will allow the operator to become familiar with the

control levers and attachment before beginning work.

2.3.4. It is very important that you must reduce the dipper arm cylinder hydraulic

flow rate by at least 30%. The standard hydraulic flow rate on the cylinder/ram


was tuned for the standard boom. Long reach attachment has a must longer

geometry, a small stroke in the dipper arm cylinder will result in a big swing at

the bucket end. If left unadjusted, the operation of the machine will be very

jerky and hazardous, and potential causing premature failure to the long reach

attachment.

3. Preventive Maintenance

3.1. Maintenance safety procedures

3.1.1. Inspect the attachment daily. DO NOT operate a poorly maintained or

damaged attachment or major structural damage could result.

3.1.2. Always lower the boom to the ground before leaving the cab. If it is necessary

to work on an attachment off the ground, securely support the machine and

attachment. Do not support the machine on cinder blocks, hollow tiles, or

props that may crumble under continuous load. Do not rely on the cylinder to

hold the attachment in the air. If a control is moved or hydraulic pressure is

otherwise released, the attachment may drop. Do not work under a machine

that is supported solely by a jack.

3.1.3. During maintenance of the attachment, it is imperative to turn OFF the

excavator to prevent injury.

3.1.4. Never operate the machine if an unsafe condition exists. Attach a DO NOT

OPERATE tag to the machine.

3.1.5. Before working on a machine, be sure to tag the controls so no one else will

start it. If more than one person is working on a machine, each must be

familiar with the controls and aware of what the others are doing.

3.1.6. Always use two people when making checks with the engine running – the

operator at the controls must be able to see the person doing the checking.

3.1.7. Keep hands away from moving parts. Never lubricate or work on a machine

while it is moving.

3.1.8. Always wear proper safety equipment when maintaining the attachment

including eye protection, hard helmet, safety shoes, gloves, hearing protection,

etc.

3.1.9. Be sure to understand a service procedure before working on the machine. DO

NOT ATTEMPT REPAIRS YOU DO NOT UNDERSTAND.


4. Installation

Figure 3

4.1. Pre-Mounting Preparation

4.1.1. It is always a good practise to perform a visual inspection on the attachment

prior to carrying out any installation work. This precautionary step is necessary

to ensure the items are not damaged during the course of transportation, or

during the unloading process.

4.1.2. Prior to mounting the new long reach attachment, it is necessary to remove

the original boom and stick/dipper arm from the machine. It is important to

remove the boom and stick/dipper arm safely according to the recommended

procedure from the manufacturer’s service handbook.

4.1.3. After removal of original boom and stick/dipper arm, leave the 2 sets of lifting

boom cylinder/ram intact onto the machine body.

Figure 4


4.1.4. Retrieve the (1) arm cylinder/ram and the (2) pin A and (3) pin B from the

original boom. These 3 items will be required for the subsequent steps in

mounting the long reach attachment. (refer to figure 3)

4.1.5. While both boom cylinders are still intact on the machine, connect and

securely fasten all the hydraulic hoses. Run the machine and ensure the boom

cylinders are functioning properly.

4.1.6. Position the long boom as per figure #5. Checked and ensure the ground is firm

and solid. Sufficient safety measures should be taken to ensure the long boom

will not tip over or fall sideways during the course of subsequent installation

works.

Figure 5

4.1.7. Transfer the stick/dipper arm cylinder/ram onto the long boom and ensure the

cylinder/ram is properly installed. Connect and securely fasten all hydraulic

hoses.

4.1.8. Lay the long stick/dipper arm as per figure #6. Check and ensure the ground is

firm and solid. Sufficient safety measures should be taken ensuring the long

boom will not tip over or fall sideways during the course of subsequent

installation works.

Figure 6

4.2. Mounting Procedure

4.2.1. Lift the long boom carefully toward the machine. Align the boom boss hole to

boom mounting bracket on the machine.


SAFETY WARNING: a) Use only metal chain or cable that is capable of

withstanding the load of the boom.

b) Secure the chain/cable onto the lifting hooks located at

the top of the boom.

c) Ensure no personnel is directly under the boom at any

one time while it is being lifted.

Figure 7

4.2.2. Lift the long boom carefully toward the machine. Align the boom boss hole to

the boom mounting bracket on the machine.

4.2.3. Upon proper alignment of the boom onto the mounting bracket, lock and

secure the boom onto the machine with pin A. (reference to figure 3).

Figure 8


4.2.4. Lower the boom until the tip is firmly rested on the ground.

Figure 9

4.2.5. Lift and align both boom cylinders and secure it with pin B. (refer to figure 3).

4.2.6. Connect and securely fasten all hydraulic hoses linking the machine and the

boom, and at the end of boom.

4.2.7. After connecting all the hydraulic hoses, you are now ready to verify if the

hydraulic system is properly connected. Run the engine and test that the

booms hydraulic system is functioning properly.

SAFETY WARNING: a) Do not remove the chain/cable until you are completely

satisfied with the hydraulic installation.

b) Do not remove the hydraulic hose at the end of the boom

which was supplied together with the package. Removing

the hose at this instance will cause malfunction to the boom

hydraulic system.

c) Observe for any oil leak in the hydraulic system.

4.2.8. When you are completely satisfied with that the boom hydraulic system is

functioning properly, lower the rest the boom onto the ground. You may

proceed to remove the chain/cable from the lifting hook.

4.2.9. The boom cylinders should be functioning properly by now and should be able

to lift the boom with ease. Position the boom yoke onto the stick/dipper arm

as per figure 10. Once properly aligned, secure and lock it with the yoke pin

that was supplied with the package.


Figure 10

4.2.10. Mount the stick/dipper arm’s cylinder/ram onto the stick/dipper arm with

the pin supplied with the long reach package.

4.2.11. Connect and securely fasten all hydraulic hoses between the boom and

stick/dipper arm.

Figure 11

4.2.12. Mount the bucket that was supplied with the package.

Figure 12


4.2.13. The long reach package has a much longer geometry than the standard

boom. As a result, it is necessary to reduce the hydraulic flow rate of the

dipper arm cylinder. If the hydraulic flow of the cylinder is not reduced, it will

result in jerkiness and lack of accuracy in positioning the bucket.

Please refer to your excavator handbook on the procedure in adjusting

cylinder hydraulic flow rate.

4.2.14. Perform a final round of checking to ensure that all bolts, nuts, pins and

hydraulic hoses are properly installed and tightened. When you are

completely satisfied with the installation, you may proceed to test the entire

long reach set up on your machine.

4.2.15. Prior to the testing of the newly set up long reach machine, please ensure

you have read and fully understood section 1 & 2 in this installation manual.

Figure 13

4.3. Arm Speed Fine Tuning and Adjustment

4.3.1. This is an important step not only ensure that operation of the long reach

attached is smooth and precise, but also the reliability of the long reach

attachment. You must reduce the arm/stick cylinder hydraulic flow rate by at

least 30%. Refer to the excavator handbook on the proper procedure for

reducing the arm/stick cylinder flow rate. After you have reduced flow rate,

operate the long reach machine to determine if you are comfortable with the

bucket swing speed. If it still too fast and jerky in operation, further reducing

the hydraulic flow rate till you are completely comfortable with it.


4.3.2. Some of the long boom may supply with an optional hydraulic flow control

valve preinstalled onto the arm/stick cylinder’s hydraulic line as shown in

figure 14. The function of this valve is to regulate the rate of hydraulic oil flow

to the arm/stick cylinder when the cylinder is extending outward (bucket

swings toward the direction of the operator). Turning the valve clockwise or

anti-clockwise will vary the amount of hydraulic oil flow rate toward the

cylinder and thereby affecting the bucket swing speed.

Figure 14

4.3.3. Boom supplied without the optional hydraulic flow control valve would

require adjusting the hydraulic spool at the machine level to restrict the

hydraulic flow to stick/arm cylinder in achieving of reducing the speed of the

stick/arm cylinder.

Figure 15


4.3.4. Good maintenance and care ensures a good machine will work and last. If the

speed of arm is not within the standard value, we should adjust the flow

control valve as well. The standard speed for arm roll-in and roll-out is shown

as below:

Speed Standard for Arm Roll-In: 5.6 sec < X < 6.4 sec

Where X = Amr roll-in speed

Speed Standard for Arm Roll-out: 3.8 sec < X < 4.4 sec

Where X = Arm roll-out speed

4.4. Arm/Stick cylinder Pressure Adjustment

4.4.1. Long Reach boom is not designed for hard excavation or heavy duty

application. And most standard excavator has ‘high power’ or ‘heavy lift’ mode

designed for standard boom & arm combination which is not suitable for long

reach application. We recommend the Arm/Stick cylinder pressure to be

reduced to 3,800psi.


The End


Thanks for choosing EIK.

WE BUILD WITH PRIDE,

YOU USE WITH TRUST.

long reach boom installation and operation manual · 2020. 4. 1. · 2.3.3.this “get...

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