Hydraulic Thumb Installation, Operation, & Maintenance

Transcription

1 Progressive Link Hydraulic Thumb Installation, Operation, & Maintenance

2 Table of Contents Section 1 Safety Section 2 Progressive Link Hydraulic Thumb Installation... 4 Section 3 Welding Procedures 6 Section 4 Operation Procedures. 7 Section 5 Maintenance Procedures... 8 Section 6 Parts List IMPORTANT: Please read this manual carefully and completely, to familiarize yourself with the correct operation and installation of this unit. NOTE: All references to left and right refer to the operator's point of view as the person is sitting in the operator s seat facing the backhoe bucket. Solesbee s Equipment & Attachments, LLC is Not Liable for OIL LOSS caused by leaks in the hydraulic system. Owners are responsible for maintaining the hydraulic system according to the manufacturer's instructions. DAMAGE OR INJURIES resulting from the failure to maintain the hydraulic system, or as a result of operating the equipment or product at temperatures exceeding safe limits. DAMAGE to the product or the machine caused by the loss of oil resulting from poor workmanship or improper maintenance by either the owner, the dealer, or their representatives. 2

3 Section 1 Safety General/Safety Information The safety practices described in this manual are meant as guidelines for safe operation under most conditions and are meant to supplement any safety rules and/or laws that may be in force in your area. Your safety and the safety of others results from putting into practice your knowledge of the correct operating procedures. The word "machine" in these instructions refers to the excavator onto which the thumb is installed. Before operating the progressive link hydraulic thumb familiarize yourself with any laws and regulations for your operation's site and make sure the machine you are operating is fitted with the equipment necessary to comply with them. Signal Words Throughout this manual are statements preceded by a special attention symbol: "!!!". The symbol is used with the following signal words to attract your attention to information of special priority. Read the paragraphs carefully and make sure you understand their significance, especially the possible causes of injury.!!! WARNING: A statement preceded by "WARNING" is information that should be acted upon to prevent serious injury.!!! CAUTION: A statement preceded by "CAUTION" is information that should be acted upon to prevent machine damage. Additional signal words that are not preceded by the attention symbol are: Personal Safety!!! WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing maintenance work should wear OSHAapproved hard hat, safety glasses, steel-toed shoes, and gloves.!!! WARNING: Before operating the hydraulic thumb, make sure you clearly understand how to operate the machine and are thoroughly familiar with all controls. Keep other people away from the job site when using the thumb, to prevent them from being accidentally struck or injured. 1. Do not use your hand to check for hydraulic leaks; use a piece of cardboard or paper. Do not attempt to repair or tighten any hydraulic hose or fitting when the engine is running or when the hydraulic system is under pressure.!!! WARNING: Hydraulic fluid can cause permanent eye injury. 2. When connecting or disconnecting hydraulic lines for any reason, always wear appropriate eye protection, stop the engine, and relieve hydraulic pressure before beginning. 3. Before disconnecting hydraulic lines, wait until the fluid cools down to a safe temperature.!!! WARNING: Hot hydraulic fluid can cause severe burns. IMPORTANT: A statement preceded by the word "IMPORTANT" is information that possesses special significance. Tip: A statement preceded by the word "Tip" is information that is handy to know and may make your job easier. 3

4 Section 2 Progressive Link Hydraulic Thumb Installation IMPORTANT: Included in the back of this manual is a general parts list. Please call Solesbee s Equipment & Attachments at (800) with the thumb serial number for any additional parts information required. 1. Park excavator on smooth, level surface. Leave space for fork lift or any other equipment used for lifting and placing the thumb. 2. With bucket or coupler installed, position the stick perpendicular to the ground, placing the bucket or coupler firmly on the ground. 7. Position the pin block using the pin lock as a guide. Tack pin block to bucket to ensure proper placement. Weld the pin block to the side of the bucket using 10mm 3/8 fillet weld all the way around the pin cap retainer. Depending on the design, some blocks may need to have excess length trimmed. (NOTE: Coupler application uses a bolt through the boss hole.) 8. The thumb linkage ships pre-installed to the thumb body from the factory. Remove the original stick pivot pin and align the pin holes of the thumb linkage with the stick pivot pin hole. 9. Using the provided shim kit, place shim(s) along the stick pivot pin axis. 10. Secure the linkage by inserting the longer stick pivot pin provided with the thumb. Weld the proper provided collar to the excess pin length after checking alignment. Bucket placement for proper installation 3. Remove OEM provided stick main pin. 4. Mount the thumb body over the stick main pin hole and the bucket or coupler. Align the pin holes in the thumb body, the stick and the bucket or coupler. 5. Center the thumb on centerline of stick. Using the provided shim kit, place shim(s) along the stick main pin axis to maintain the thumb alignment. 6. Slide the provided stick main pin (see parts page) through the thumb and bucket or coupler. Placement of shims for insertion of stick pivot pin!!! CAUTION: Battery must be disconnected prior to any weld activity. Placement of shims for insertion of stick main pin (NOTE: Shims may be required on both sides of bucket) 4

5 Section 2 Progressive Link Hydraulic Thumb Installation 11. Weld the pin lock to the main stick pin using 10mm 3/8 fillet weld all the way around the pin lock. (NOTE: Optional pre-welded pin lock may be provided.) Correctly placed and welded pin lock and pin block 12. (a) Lay thumb back onto the stick. Place the bump plate on the stick so that the thumb ribs hit the bump plate when the thumb is in the travel position. Center and tack weld the bump plate to the stick. 13. Pin the cylinder rod eye to the thumb linkage using the thumb linkage pin. 14. Position the cylinder anchor plate on the stick so that the cylinder is fully closed when the thumb is in the travel position. Both ends of the anchor plate must be centered horizontally on the stick. 15. Pin the cylinder to the anchor plate. Extend 1/2 of rod from the cylinder, moving the anchor plate accordingly up the stick. 16. Securely tack the anchor plate to the stick, using four 38mm 1 ½ long welds equally spaced on each side of the plate. 17. Remove the thumb linkage pin. 18. Complete the hose connections to the stick plumbing and reconnect the battery. Set hydraulic relief pressures at 2500 psi.!!! CAUTION: It is extremely important that the thumb be controlled by a four-way, three-position, single spool valve that provides 2500 psi circuit relief in all positions to avoid damage to the cylinder. 19. Uncurl the bucket and operate the thumb slowly while checking for any type of interference or misalignment during operation.!!! CAUTION: Do not curl the bucket against the thumb with full force at this point. The cylinder anchor plate and linkage stops are only tacked on. Correctly placed and welded bump plate 12. (b) When used, the optional bump plate (with risers) should be positioned above the H-Link bosses. The thumb must stop at the rest position on the H-Link thumb bosses before the cylinder is parallel to the stick. Adjust the angle as required. 20. The thumb linkage is to contact the bump plate equally when the cylinder is fully retracted. Adjust position if necessary. Once proper position of the bump plate is determined, weld around plate with 10mm 3/8 to 13mm 1/2 fillets. 21. After correct position of the cylinder anchor plate is verified, weld anchor plate to the stick. Reconnect the battery. Extend rod outwards 1/2" 5 Correctly placed and welded bump plate (with risers) Correctly placed and welded cylinder anchor plate (NOTE: Optional available reinforcement plate for cylinder hitch base plate not shown) 22. Lubricate ALL grease fittings daily.

6 Section 3 Welding Procedures Weld Procedures Use AWS E-7018 low hydrogen rod for manual electrode welding. For semiautomatic gas shielded arc, use AWS E70S wire or AWS E70T-2. Electrodes MUST be dry and properly stored according to the electrode manufacturer's recommended procedures. 1. Disconnect the battery ground cable to the machine to prevent damage to the machine's electrical system. 2. Existing cracks and/or weld joint repair should begin with the removal of damaged metal. This can be performed with oxy-fuel, plasma cutting or carbon arc. Oxy-fuel and carbon arc can leave a carbon track or carbon deposits. 3. It is important to remove all remnants of the damaged metal and grind all joints to remove any traces of carbon. 4. Remove any grease, oil, rust, paint or mill scale from all surfaces that are to be welded. 5. Preheat all areas to be welded to 300 F. Slowly heat from the opposite side of the plate to be welded. Check temperature on weld side 3 from the center line of weld. Maintain a 300 F temperature while welding. All welds must be allowed to slowly cool. Do not quench with water. In cold weather, do not permit drafts over welds that are cooling. 6. Use stringer beads. Do not create wide beads, because they cause severe shrinkage and may crack while cooling. 7. Do not exceed 450 F interpass temperature. Check the interpass temperature at the beginning of the most recent weld with a 450 F thermal crayon. If it does not melt, continue welding. 8. When a long continuous weld is required, do not start a weld at one end and continue to the opposite end. Run short beads, always back stepping them to ensure a quality weld. Weld Acceptance Standard Cracks: No cracks, including crater cracks, are allowed in welds or heat effected zones. Undercutting: Undercutting shall not exceed 1.5mm 1/16. Any undercutting must be ground to a smooth radius to prevent cracking. Undercutting which exceeds 1.5mm 1/16 must be ground out and re-welded. Rollover: Rollover or weld overlap shall not exceed 1.5mm 1/16 beyond the fusion line of the weld. Porosity: Porosity shall not exceed 4 holes in every 100mm 4 of length of a single weld bead. No single void shall exceed 1.5mm 1/16 in diameter. Slag: No visual slag in any layer is allowed. Note: For CASE machines, prior to welding, disconnect the alternator B+ and D+ terminal wires. Disconnect the engine controller and disconnect the machine controller. DO NOT connect the welding apparatus to hydraulic components. Connect the welding ground directly to the part being welded.!!! WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing any type of work should wear OSHAapproved hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way. 6

7 Section 4 Operation Procedures Please read everything in this section. Clamping a Load When the thumb is fully extended and the bucket clamps a load against the thumb, the curl forces generated by the bucket create hydraulic pressure in the thumb cylinder. If the pressure reaches a preset maximum, the circuit relief valve will permit oil to flow back to the tank and the hydraulic cylinder rod will slowly retract. THIS IS NORMAL AND IT PROTECTS THE THUMB CYLINDER AND HOSES FROM BEING SUBJECTED TO EXCESSIVE HYDRAULIC PRESSURE AND DAMAGE. For this reason it is extremely important that the thumb is controlled by a four-way, three-position, single-spool valve that provides circuit relief in all positions. The maximum pressure is 2500 psi. Storing the Thumb Always completely retract the thumb when it is not being used. Keep it elevated and out of the way so it is not subject to damage caused by accidentally striking an object when the machine is in use or moving. For Hydraulic Thumb Operation 1. Always make certain anyone operating the excavator equipped with this thumb is thoroughly trained in the safe operation of the excavator and has read these instructions. 2. Always secure the bucket thumb against the stick when not in use. Accidental contact with fixed objects will damage the bucket thumb. 3. Always pick up loads at the center. 4. Never curl an empty bucket into the thumb. The curl forces are strong enough to damage both the bucket and the thumb. 5. Thumbs clamp loads, but they cannot hold loads safely for an extended period of time. A load clamped at night needs to be re-clamped in the morning. 6. Never shut off the excavator and leave a clamped load suspended. The excavator's hydraulic circuits are not designed to be used in this manner. 7. Never attempt to disassemble the thumb with the thumb in such a position that heavy parts could fall and cause an injury. 8. Never allow anyone to get between the bucket and the thumb while the excavator is running. 9. Never push trucks with the bucket thumb. 10. Never carry material over any person or object that could be injured or damaged by accidental release of the load. 11. Never swing loads rapidly because centrifugal forces may cause the load to drop. 12. Always make certain that there is plenty of room for swinging and placing loads. 13. Never push objects with the side of the thumb by swinging the excavator. Side loading your thumb will break the pivot pin. There is NO warranty on broken pins. There is NO warranty for damage to the stick or any other part of the excavator. 14. Do not tend fires with the bucket thumb. 15. Never dig, rip, pry, pull stumps, or back drag with the bucket thumb. The thumb is a gripper, not a ripper. There is NO warranty on thumbs that have been abused. 16. Never operate a machine that is not working properly or is in need of maintenance. 17. Never swing the excavator stick toward the boom with the thumb in the operating position. If the thumb hits the boom, both the boom and the thumb will be damaged. 18. Watch out for overhead obstructions of any kind and never work near high voltage power lines. 19. Never allow the thumb cylinder and cylinder rod to be damaged by incidental contact with objects. Rod damage can cause thumb pin breakage, dents in cylinder barrels, and bent cylinder rods. There is NO warranty on broken pins, bent or broken cylinder barrels caused by improper or careless operation. 20. Thumbs are a tool and must be used properly to avoid personal injury or damage to the excavator. 21. Never lift a load and then attempt to adjust the thumb. Thumbs are designed to be used with the excavator bucket to lift and load material. With proper use the thumb will provide years of productive service. 7

8 Section 5 Maintenance Procedures Please read everything in this section. The key to years of peak performance and dependable service is the daily inspection and maintenance of your hydraulic thumb. It will provide years of excellent performance provided it is used in the correct manner and properly maintained.!!! CAUTION: Thumbs should be inspected daily. Check for possible structural failures during every inspection. Serious damage to your bucket thumb and machine may result if you fail to perform this important procedure.!!! CAUTION: After the first 8 hours of operation check all nuts and cap screws for tightness. Following are maintenance procedures that are to be performed daily. 1. Lubricate ALL grease fittings daily. 2. Inspect hydraulic system and hoses for leaks and wear. Repair any leaks immediately. Replace worn parts as needed. 3. Check for material buildup that can obstruct free movement, especially around pivot points, cylinders, and hoses. 4. Conduct a thorough walk-around inspection for excessive wear, cracks and other factors that may affect performance. Repair as needed. Every 500 hours Inspect pins for wear. If pin wear exceeds 3/16, replace pin and bushing. Tooth wear will occur over time Teeth may be hard-faced for additional life. Replacement tooth sections are available and should be installed as soon as teeth are worn to 25% of their original height.!!! WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. All persons performing maintenance work should wear OSHAapproved safety equipment to help avoid injury such as hard hat, safety glasses, steel-toed shoes, and gloves. To avoid injury to others, keep bystanders well out of the way while performing maintenance work. Cylinder Maintenance Seals are wear items and must be periodically replaced. If cylinder seals are not replaced promptly, it may significantly shorten the life of the machine's pump and control valves. New seals have sharp edges that wipe the oil off the rod. Over time, they become rounded and let more and more oil remain on the rod which attracts more dirt every time the rod is extended. Those dirt particles eventually work their way into the cylinder and the hydraulic oil. Once the dirt gets in the oil, it can ruin a valve by getting between the valve spools and valve body, damaging the finely machines surfaces needed for proper operation. When seals are worn to the extent that there is an obvious amount of fluid on the rod, it's time for replacement. Keep the oil clean - follow all procedures recommended by the machine manufacturer and remember the importance of replacing cylinder seals at the first sign of too much oil on the cylinder rods. Proper Lubrication Properly lubricate the rod eye of the cylinder or it is likely to seize on the pin. When the rod eye does not pivot freely, it puts side loads on the cylinder rod as the cylinder is extended and retracted. Side loads will cause premature seal wear, and is often caused by lack of proper lubrication. Attachment Stop Maintenance Prevent cylinder damage - There are stops that prevent the cylinder piston from full retraction. Regular inspection of the stop surfaces is required. Shims or weld buildups may be required to prevent cylinder damage. 8

9 Section 6 Parts List Part Number Part Name Quantity 1 SPT- HS 1 2 SPT- L COLLAR 1 3 SPT- MAIN PIN 1 4 SPT- 2.5 HSLP 2 5 SPT- HLA 1 6 SPT- HL SPACER- L 2 7 SPT- HL SPACER- S 2 8 SPT- 2.5 HLDB Pin 1 9 SPT- 2.5 L COLLAR 1 10 SPT- HLRP 1 11 SPT- L COLLAR 1 Part Number Part Name Quantity 12 SPT- SPACER 1 13 SPT- COLLAR 1 14 SPT- SPACER 2 15 SPT- BAA 2 16 SPT- BUS 2 17 SPT- DB 2 18 SPT- DBBA 2 19 SPT- DBBA BUS 2 20 SPT- CY 1 21 SPT- BPA 1 22 SPT -CY BPA PIN 1 All parts must be ordered with machine name, model, and serial number 9