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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

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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.

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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.

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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

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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.

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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

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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.

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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

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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.

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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

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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.

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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

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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. 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.

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