OPERATION & MAINTENANCE MANUAL

Transcription

1 POWER CLAW Imagery does not reflect actual product size PC2017A OPERATION & MAINTENANCE MANUAL 1

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3 CONTENTS INTRODUCTION Owner Information 5 Warranty Registration 6 Key Features 7 To the Owner 8 SAFETY Safety Instructions 9 Pre-Start Check List 10 INSTALLATION PROCEDURE Installation 12 General Maintenance & Servicing 16 Precautions 17 Suggested Greasing Products 18 OPERATION Hydraulic Requirements & Plumbing 19 Plumbing Circuit Diagram 20 Maintenance & Repair Log 21 PC2017A 3

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5 INTRODUCTION OWNER INFORMATION Thank you for choosing to purchase your new Calibre (Power Claw) from Calibre Contracting Equipment s (Calibre) range of earthmoving products. This manual contains important information about the installation, maintenance and safe operation of your Power Claw. You can assist in this proactive safety approach by ensuring that all persons involved with the fitting and operation of the Power Claw, read and understand these basic safety features and instructions. Calibre reserves the right of modification as a result of further technical developments with regard to the information and illustrations cited in this manual: Calibre and its suppliers have sole copyright of this manual The manual is intended solely for the use of the Power Claw No part of this manual may be reprinted, translated or reproduced by any means without prior written permission from Calibre Utilisation for the purposes of competition is forbidden The Power Claw is designed for safe and dependable service if installed, maintained and operated correctly We request that time be devoted to the study of installation and maintenance requirements. Users are also expected to familiarise themselves with the correct operation and use of the Power Claw and its advised safety procedures. IMPORTANT NOTE To comply with Occupational Safety and Health requirements, a record must be made of all repairs, adjustments and regular maintenance events involving your Power Claw. PC2017A 5

6 INTRODUCTION WARRANTY REGISTRATION Upon purchasing your Power Claw please complete and return this form immediately to your local Calibre branch. DATE OF DELIVERY: SERIAL NUMBER: I confirm that the operator(s) of the relevant excavator has read and understands the Operating Instructions and Warranty Terms, which relate to the Power Claw. The Operator accepts that he/she is responsible for understanding safety and operation features of the Power Claw. NAME: POSITlON: COMPANY: SIGNATURE: THE PURCHASER SHALL: Follow the recommended installation, testing and maintenance and operating procedures Comply with safety and training guidelines for use of equipment (not totally exclusive) Keep an accurate maintenance, operation, malfunction and repair log of equipment Ensure that the equipment is used for the purpose it was intended for 6 PC2017A

7 INTRODUCTION KEY FEATURES Smart Valve Technology incorporated into cylinder base No parking pin required Mounts Off dipper boss giving highest strength pivot possible 7 7

8 INTRODUCTION TO THE OWNER As the new owner and/or operator of the Power Claw we recommend that you take the time to read this Operation Manual carefully before commencing work. FOLLOW THE SAFETY INSTRUCTIONS Carefully read all the safety information contained in this manual Make sure all warning signs are securely fitted Immediately replace any signs which are missing or damaged Before starting work make sure you are familiar with the equipment, and where necessary with the machine and its control devices INFORMATION FOR THE USER The user of the Power Claw is obliged to ensure that the equipment is always in safe working order in accordance with accident prevention regulations, Occupational Safety and Health or any other official instructions. WARRANTY REGULATION Calibre provides guarantees according to its sales and delivery conditions, extended to twelve months from delivery. The extended guarantee assumes proper operation and use as intended but will be nullified as a result of: Repairs or other intervention not undertaken by persons authorised by Calibre With use of accessories or replacement parts not approved by Calibre or which are not original replacement parts supplied by Calibre After the warranty period has expired, we strongly recommend the use of original replacement parts and manufacturer s replacement parts approved by Calibre. 8 PC2017A

9 SAFETY SAFETY INSTRUCTIONS This safety alert symbol indicates important safety messages in this manual. When you see this symbol carefully read the message that follows and be alerted to the possibility of personal injury or death. WARNING: Incorrect operation of this machine can cause injury or death. Before using this machine make sure that every operator: Is instructed in safe and proper use of the attachment Reads and understands the manual pertaining to the attachment Reads and understands all safety decals and tags on the machine Clears the area of all other persons Learns and practices safely using attachment controls in a safe, clear area before operating this machine on a job site It is your responsibility to observe pertinent laws and regulations and follow Calibre instructions for operation and maintenance. PC2017A 9

10 SAFETY PRE-START CHECK LIST Location: Date: Ref no: Hazards Identified: Work equipment Lifting devices Ergonomics Entanglement Crushing Access / exit Slip, trip and fall Plant movement Warning devices on equipment Noise Vibration Fumes Environmental People Affected YES NO N/A Involved in activity Close to activity Everyone on site Members of the public Expected Precautions YES NO N/A Has the operator been adequately trained on the use of the Power Claw in general? Is there a checklist of daily and weekly inspections? Personal Protective Equipment (PPE) Hard Hat High Visibility Vest Safety Boots Gloves Ear Protection Safety Glasses Other Management Assessed by: Name: Date: Reported to: Name: Date 10 PC2017A

11 SAFETY Operator s Name: Calibre Model : Calibre Serial No.: Date: In Cab Operating and Maintenance Manual M O N T U E W E D T H U F R I S A T S U N Hydraulic System Wear or damage to hoses or fittings Security of hoses Hydraulic oil leaks Power Claw Security of mounting pins, locking bolts and nuts Is the attachment safe to use? YES or NO Lubrication Greasing in accordance with Calibre instructions Operator Signature Manager Signature PC2017A 11

12 INSTALLATION PROCEDURE INSTALLATION STEP 1 : CHECK EXISTING DIPPER SURFACE FOR DOUBLER PLATES/WEAR BARS Some machines have a doubler plate (Fig 1.1) or wear bars (Fig 1.2) welded to the inside of the dipper arm. Before fitting the Power Claw to the dipper arm these may have to be modified or removed. If your machine has either of these they need to be removed locally where the cylinder mount and bash plate of the Power Claw attaches (Fig 1.3), or otherwise removed completely. Failure to do so will result in the Power Claw s operating geometry being incorrect. Fig 1.1 Doubler Wear bars Fig 1.2 Cylinder mount Bash plate IMPORTANT: The dipper arm must be clear where both the cylinder mount and bash plate are welded. The space in between the dipper arm and Power Claw when it is in the parked position must also be clear from obstructions so that the cylinder does not interfere. Fig PC2017A

13 INSTALLATION PROCEDURE STEP 2 : LAYOUT OF POWER CLAW 1. With the cylinder fully retracted (closed), mount the Power Claw assembly to the end dipper pivot pin. Use necessary spacers/shims as required to set the correct width. Ensure the Power Claw is central. 2. Swing the entire Power Claw assembly about the dipper pivot pin until the cylinder mount makes contact with the inside of the dipper arm. Cylinder base mount has to be central on the arm. PC2017A 13

14 INSTALLATION PROCEDURE Stitch weld 3. Stitch weld (approx. 20mm stitches) each side of the cylinder mount as shown. 4. Standing clear of the Power Claw and attachment, crowd the attachment in/out and open/close the Power Claw to check the Power Claw operates unobstructed in the desired range. 6. Slide the stopper plate into position on the dipper arm so it is under the stops on the Power Claw arm when retracted. Tack weld the stopper plate to the dipper arm. Bash plate 14 PC2017A

15 INSTALLATION PROCEDURE STEP 3 : WELDING WARNING: Never weld straight across the dipper as this can cause the dipper arm to crack/fail along the weld. Always curve/angle plates running across the dipper arm. Make sure machine or batteries are isolated before welding. 1. Ensure that the earth lead is attached near the cylinder mount. DO NOT attach earth lead to the hydraulic cylinder. 2. Grind all surfaces that will be welded before welding. 3. The welds should be a well penetrated fillet of approximately 8-10mm all around. 8-10mm fillet weld all around Fig 1.4 PC2017A 15

16 DAILY MAINTENANCE - Grease all grease points daily (see greasing tips) - Remove solid materials, stones etc. from around moving parts - Check hoses and fittings for signs of leak or wear - Check all pin retainer bolts and nuts for tightness - Check hydraulic cylinder mounting bolts for tightness - Check for damage and cracks INSTALLATION PROCEDURE GENERAL MAINTENANCE & SERVICING GREASING Greasing must be carried out twice daily! We recommend before starting work, and before restarting after lunch. 1 Grease point Grease point 2 Grease point 4 & 5 Grease point 16 PC2017A

17 INSTALLATION PROCEDURE PRECAUTIONS The Calibre Power Claw is not to be used for purposes other than what it has been designed for. The Power Claw is designed to be used in conjunction with a standard bucket and should only experience forces exerted by the opposing bucket as shown below. Care needs to be taken when the Power Claw cylinder is fully extended, that the Power Claw does not experience any loading that tries to over extend the cylinder. (e.g. When the dipper is being moved towards the operator and the Power Claw catches onto an object). Failure to do so will result in evident damage to the cylinder end and will VOID ANY WARRANTIES. û FORCE PC2017A ü FORCE 17

18 INSTALLATION PROCEDURE SUGGESTED GREASING PRODUCTS SUGGESTED REQUIREMENTS: NLGI Grade 2 Lithium Complex Base Better ones contain 3-5% Moly (MoS2/ Molybdenum Disulfide) additive Base Oil 40 degrees C exceeds 300 cst Exceeds 28kg on Timken OK Load Test Contains high tack / adhesive qualities / Resists water washout SUGGESTED PRODUCTS: Moreys BigFoot EP2 Moreys Moly Complex EP2 Moreys Super Red Premium Waterproof Cat Ultra 3Moly Grease NGI2 Trans Diesel Super Red Lith Tac EP2 Shell Gadus S3 V460D Mobil Grease XHP 462 Moly Any Mobil XHP 460 Grease Gulf Western Red Lith Tac GENERAL NOTE: Recommended greases are generally hard to pump because of their high viscosity. A quality 10000psi gun will give guaranteed results. 18 PC2017A

19 OPERATION HYDRAULIC REQUIREMENTS & PLUMBING POWER CLAW CIRCUIT REQUIREMENTS Operating Pressure Hose/ Tube Size Flow Rate PSI 3/8 Minimum 15 LPM Min. 47 LPM Max (must not be exceeded) Port Connecting (Calibre supplied) 3/8 BSPP Female x3 *Ensure that the operating hydraulic pressure is set at a minimum of 206 Bar (3000PSI) on A and B line. Pressure and flow need to be checked at connecting hose to Power Claw cylinder. PC2017A 19

20 OPERATION PLUMBING CIRCUIT DIAGRAM 20 PC2017A

21 OPERATION MAINTENANCE & REPAIR LOG DATE FAULT REPAIR BY WHOM PC2017A 21

22 22 PC2017A January Version 2017

23 CALIBRE Contracting Equipment Australia 59 Magnesium Drive, Crestmead, Australia CALIBRE Contracting Equipment New Zealand 49 McLaughlins Road, Wiri, Auckland PC2017A 23