PLEASE PUT THIS OPERATOR'S MANUAL IN THE DRIVER'S CAB

Transcription

1 PLEASE PUT THIS OPERATOR'S MANUAL IN THE DRIVER'S CAB OPERATOR'S MANUAL Nelson Street, Bolton, Lancs. BL3 2JJ Telephone: Fax: Spares fax: Edbro publication - Modified March Ref. number E5226 E5226 ROLATIP

2 FAULT FINDING GUIDE CONTENTS 12. Container not Container Check the width of secure on hoist the container rails Check the dimensions of the container locking pockets under the floor, compare with the container drawing not the hoist. Never modify the hoist always correct the faulty container stops. 13. Front body ratchets Seizure of pins or Check air lines for damage inoperative cylinders Remove pins, clean and (optional) lubricate Check return springs Replace air cylinders Safety precautions... 1 Correct use... 2 Identification Warning labels... 3 Familiarisation... 5 Major component parts... 6 Controls... 7 Power take-off operation 8 General safety instructions Before starting work... 9 Check site conditions... 9 General operating advice Noise Operating instructions To pick up a container To demount a container To tip a container Use of short containers Truck/Trailer applications Red Forge load weighing Static Cell load weighing Health & safety during maintenance Safety props Safety during maintenance Maintenance instructions In the first few weeks of operation Weekly Monthly Every 3 months Yearly or every 2000 operations Lubrication/greasing points Safety Interlock checks Pressure setting Oil specification Lifting the equipment Fault finding guide Identify problems and remedies

3 SAFETY PRECAUTIONS FAULT FINDING GUIDE The following universal safety symbol is used throughout this handbook to indicate information which is essential for the health and safety of all operating personnel. Information indicated by this safety symbol MUST be adhered to. Read carefully the instructions printed on labels affixed to the vehicle and obey them. They are for your protection. Wear suitable protective clothing when using the equipment; boots, gloves, and hard hat are a mimimum requirement. Ensure that all personnel are clear of any rotating parts or moving components. Do not climb onto the equipment. Wear ear defenders outside the vehicle, when necessary. The vehicle must be situated on firm level ground with a mimimum height clearance of 5 metres, for safe operation. Make a visual check of all pipes, fittings and moving parts for wear, fretting or binding at the beginning of every shift. Refer any defects to the relevant authority immediately. DO NOT overload or allow material to protrude above the container lip. Keep hands well clear of mechanism when in operation. Be aware of sharp objects which may tear the tarpaulin. Ensure, before operation, that the equipment is well clear of over head obstructions (cables, bridges, etc.) Check suction line for ingress of air and restriction. Pump vibrating due to one or more pistons not pumping-repair or replace pump Drive shaft (if fitted) Bolts loose. Hardy Spicer yoke worn. Out of balance Pins and joints Lack of lubrication Worn or damaged bushings at ends of arm cylinders Worn rollers or bushes 9. Screeching or Load holding valve Adjust the load holding squealing noise valve 10.External oil leaks Pump shaft Change the shaft seal Rod seals Change the seal and examine the rod for scoring (Changing the seal is useless if the rod is damaged) Fittings Check tightness especially after the first days of operation DO NOT OVER-TIGHTEN FITTINGS Tank over-flowing Oil level too high. Check level with cylinders extended. Check anti-foam properties of oil. Control Valve Change the cap and piston assembly on the corresponding spindle 11.No dumping even Safety hooks not Hooks don t catch the end of with extended jib engaged the tilting frame. Free the hooks, clean and lubricate. Overload Check the payload and it s distribution in the container. 1 46

4 FAULT FINDING GUIDE CORRECT USE Vehicle will not move Be sure to release the brakes while lifting. If the ground is soft, lay plates under the rear wheels to spread the load. Relief valve Check the setting of the main relief valve. The correct value is in the front of this book and on the serial plate. By pass valve in arm Change leaking by-pass cylinder valve inside the piston. To ascertain which cylinder has a faulty bypass valve plug off each of the arm cylinders in turn. Dirty or contaminated Dirty or contaminated oil can damage spool valves and score cylinders and seals. The Rolatip is a hooklift demountable system. It has the capability to transport CHEM standard bins. Other types such as Dinosaur bins may be carried in certain circumstances. If in doubt, contact Edbro Sales. The equipment specification may vary depending on the chassis installation, and the type of application. These differences are identified in the equipment model code. This operator s handbook is a guide to the safe use of this equipment but if you need further assistance, please call Edbro Sales. It is the operators responsibility to ensure that road regulations are adhered to. Do not use this equipment for recovery purposes or any other purpose for which it has not been designed. Repair and flush out the circuit as per the draining instructions. 5. Backward Oil level Check and top up movement Check for any external stops before leakage end of stroke 6. Slow movement Air pocket in the Examine the pump suction of arm after the hydraulic circuit line and tighten the pump is stopped suction hose clips Check oil has anti-foam additives 7. Delayed control Air lines partly Look for kinks or damaged obstructed air lines to the control valve. Renew and re-route if necessary 8. Noise - vibration Pump Check oil level with cylinders extended 45 2

5 IDENTIFICATION FAULT FINDING GUIDE This is a sample of the identification plate fitted by Edbro. In the event of problems, always quote the serial number and model type. The plate is fitted on the near side of the Rolatip subframe behind the cab. MODEL SERIAL N O YEAR OF MANUFACTURE EQUIPMENT WEIGHT kg. BOLTON ENGLAND TELEX FAILURE FAULT ORIGIN REMEDIES 1. Sluggish operation Oil restriction Check oil level, top up if to pump necessary Check pump suction line for air intake, tighten clips. In cold weather warm oil by operating the jib backwards.keep the control operated for a few minutes Check strainer and suction hose. Check oil type (viscosity index and grade) 2. Jerky operation Load holding valve Check or change the load holding valve 3. No movement even Air or hydraulic controls Check air supply to air without a load control Check air lines for kinks or breaks FITTED BY MAX. PRESSURE bar. MAX. WORKING LOAD kg. It is the operators responsibility to ensure that for road use maximum axle loads are not exceeded Your ROLATIP equipment is marked with a serial plate in the position shown. The CE mark indicates that this equipment complies with all relevant essential safety requirements of the EC Machinery Directive 89/ 392/EEC. The maximum working load stated on the CE plate is the safe working load and the maximum pressure has been set accordingly. On no account should this pressure be increased. 3 PTO Oil Pump faulty Check the air and hydraulic control valves If pump does not rotate check PTO control and air line. Check oil level and top up if necessary Replace pump. We advise you to contact the nearest EDBRO agent for this repair. After any pump repair the circuit must be flushed and bled as per the maintenance instructions. 4. Arm does not lift a Heavy load Overload or poor load loaded container or distribution. Remove some stops when the rear load from the front of the tipping frame comes container. to rest on the frame 44

6 OTHER MAINTENANCE INSTRUCTIONS IDENTIFICATION LIFTING THE EQUIPMENT If it is necessary to remove the equipment from the chassis, the lifting eyes shown should be used. A four chain sling is recommended. The weight of the equipment is shown on the CE plate at the front of the subframe. 9. ENP231 x 1 CAB CONTROL (VARIABLE WITH DIFFERENT VEHICLES) 6. ENP226 x ENP276 x ENP289 x ENP232 x ENP104 x 2 2. ENP253 x 1 3. ENP256 x 1 4. ENP224 x 1 5. ENP225 x ENP230 x ENP240 x 1 12, ENP290 x ENP228 x ENP252 x 2 RECOMMENDED POSITIONS FOR ROLATIP RLT32 INSTRUCTION LABELS 8. ENP229 x

7 FAMILIARISATION OTHER MAINTENANCE INSTRUCTIONS Before operating this equipment read these operating instructions and ensure that you understand them. Using the assembly drawing on the next page walk round the equipment and familiarise yourself with the major components. Take due regard of all warning labels. Also refer to the description of the controls in this manual and familiarise yourself with each of the air switches in the cab and the function that they perform. When this vehicle is delivered, initial training must be overseen by a competent person. On no account should the equipment be operated until this training has taken place. For other drivers or second users it is recommended that training is given by an experienced user. If you are in any doubt please tell your transport manager to ensure that you receive adequate training. During the training period you are advised to operate the equipment with an empty bin and in good operating conditions until you become familiar with the function of the equipment. On no account should this equipment be operated by untrained personnel. This may be dangerous and may damage the equip ment. It may also be an offence. PRESSURE SETTING The relief valve on your vehicle is set to the maximum pressure stated on the CE plate on the front of the equipment and in the front of this book. The pressure must not be increased beyond this figure. If for maintenance purposes the pressure needs to be reset, proceed as follows: Remove the cover over the control valve. Connect a pressure gauge to the fitting provided on the control valve. (See diagram on page 6). Extend the main lift cylinders until the relief valve opens. Check the pressure. To adjust, slacken the lock nut on the top of the relief valve and adjust the setting with an allen key. When the correct setting is reached re-tighten the lock nut. IF THE PRESSURE IS RESET TO A HIGHER VALUE THAN THE MAXIMUM STATED, THIS WILL INVALIDATE YOUR WARRANTY. OIL SPECIFICATION Use new, clean oil to /4-HM32 for normal conditions (-15 o to 270 o C). For example Castrol AWS 32 Esso VG 32 Gulf Hydrasil 32 Mobil DTE 24 Shell Tellus

8 ANNUAL MAINTENANCE INSTRUCTIONS FAMILIARISATION C B 41 A FIT AT REAR OF JIB Vents x-locks close breaks feed to PR6 and tip vento D FIT ON LATCHES Vents tip line when latches move open FIT ON X-LOCKS Vents jib line when x-locks closed INTERLOCK POSITIONS FIT UNDER ARM Vents jib line when body raised Item No. Description 1 Jib 2 Lifting arm 3 Tipping frame 4 Subframe 5 Rear rollers 6 Hydraulic body locks/rollers 7 Bogie blocking cylinder (2-off). Only fitted when instability may otherwise occur 8 Main lifting/tipping cylinder (2-off) 9 Jib cylinder 10 Body locking cylinder 11 Control valve 12 Load holding valve 13 Oiltank 14 Front body locks 15 Return line filter 16 Lifting arm/tip frame safety latches 6

9 FAMILIARISATION - CONTROLS ANNUAL MAINTENANCE INSTRUCTIONS BAIL BACK AND CLAMP LIGHTS The equipment is operated by pneumatic switches in a control box in the cab. The number of switches will depend on the specification of your Rolatip For the comfort of the operator the switch box is not permanently fixed in the cab. However, the driver must not leave the driving seat whilst operating the equipment. Mode Function Check routine 1 Jib cannot be moved Pull jib forward when arm is tipped. Tip main arm Confirm that jib switch is now inoperative. 2 Jib cannot be moved Close bin locks (jib must when bin locks are closed. be fully forward) and confirm that jib switch is inoperative. 3 Bin locks cannot be Pull jib forward closed unless jib fully Confirm locks operate forward Open bin locks, retract jib and confirm bin locks cannot be closed. 4 Chassis suspension On RLT3204A model, cylinders at full stroke activate alarm and light in cab. operate suspension cylinder switch on control panel to confirm operation of alarm and light. On RLT3203A model, retract jib arm to lower suspension cylinders and sound alarm and illuminate light. If any functional check identifies a problem, locate the relevant sensor according to the following diagram and investigate. If necessary contact your local service agent for repairs. 7 40

10 ANNUAL MAINTENANCE INSTRUCTIONS POWER TAKE-OFF OPERATION SAFETY INTERLOCK CHECKS The Edbro Rolatip can contain up to four non-contacting proximity sensors depending on the model type. Over-riding a proximity sensor could cause unexpected movement during an operation and result in extensive damage to the equipment. MAINTENANCE SECTION The proximity sensors are installed primarily to prevent mis-use. They should not be tampered with. Annual checks should MAINTENANCE be carried to your SECTION equipment to ensure all sensors are working correctly. The following charts identify which proximity switches have been installed for which model and operational function together with the check routine. MAINTENANCE SECTION Proximity Sensor fitted Model - Operational Mode - RLT3201 RLT3202 RLT3203 RLT3204 (A) (C) (A) (A) MAINTENANCE - SECTION MAINTENANCE SECTION To engage the PTO. Run the engine at idling speed with the transmission in neutral. Depress the clutch and wait at least 4 seconds, then engage the PTO and slowly release the clutch. A warning light will now show on the vehicle instrument panel or pto control. DO NOT run the pump too quickly: Recommended 1500 rpm Maximum 1750 rpm Depending on the truck type, maximum speed may be limited automatically by the engine management system. NEVER DRIVE YOUR VEHICLE WHEN THE PTO IS ENGAGED When an operation with a container is finished, the PTO must be disengaged until the next operation, even if it is in the same loading area. 39 8

11 GENERAL SAFETY INSTRUCTIONS ANNUAL MAINTENANCE INSTRUCTIONS REFER ALSO TO CHEM CODE OF PRACTICE N 0 4 The safe operation of ground level demountable body systems (hook type) BEFORE STARTING WORK D C Where equipment height including the bin exceeds 3.0 m above ground level, it is the operators responsibility to ensure that a warning label is present in the cab. (This label must show the overall height in feet and inches and with 40 mm high numerals). D C The user must check that the equipment and bins can be operated safely. For example, any damage to fabricated parts, wearing of hoses or leaks from fittings on pipes should be reported to the relevant authority. The operator must ensure that no one can use the equipment until safe use can be guaranteed. K B D Check tyre pressures, oil and water levels, mirrors. E E Check that the air pressure exceeds 60 psi (4 bar). Where fitted, check that the bogie blocking cylinders are retracted. In very cold conditions, check that the equipment is functioning properly before starting work. A A E E B I With high loads, and especially with a high centre of gravity load, beware of the stability risk when driving. CHECK SITE CONDITIONS F A Ensure that the operating area around the equipment is free of people, animals and property when operating. Never allow anyone to go underneath the container during operation. H J Check that the ground is firm, stable and level. Avoid slippery ground and narrow places. A F Ensure that electricity cables are more than 5 metres clear of the equipment. 9 38

12 ANNUAL MAINTENANCE INSTRUCTIONS GENERAL OPERATING ADVICE With reference to the diagram on the following page, lubricate as follows: With a grease gun A B C the cylinder and piston rod eye end bearings (4 grease nipples) the arm articulation (2 grease nipples) the rear articulation (2 grease nipples) When an operating cycle is complete, to avoid overheating the hydraulics, release the control lever. During operation the driver must remain at the controls of the vehicle and equipment at all times. If he must leave the cab the PTO must be disengaged, the handbrake must be applied and all controls released. If the vehicle is to be left for some time, switch the engine off and remove the keys. The operator should be suitably dressed when using this equipment. Protective boots, gloves and hard hat are a minimum requirement. D E F G the rear rollers (4 grease nipples) the cylinder rollers and pivot pins (4 grease nipples) front body locks (2 grease nipples) joints on pump drive shaft (if fitted). Check that the container in use conforms to the specification for this equipment. Check that the load in the container is adequately tied down and evenly distributed and adequately sheeted. Always drive with the hook in the forward position and the bin down on the subframe. With a brush H the lifting hook Check that your container is restrained and the rear doors are shut and locked. Where body locks are fitted, make sure these are on. I J K the safety hooks mechanism the top and bottom of the jib slide in the arm the rear combi-lock slides. Ensure that you grease after each steam wash 37 No one should be allowed to climb onto the equipment when in operation in service or during maintenance. When sheeting or unsheeting a loaded bin, it is preferable to do so when the bin is on the ground. If this is not possible, access equipment would be required to reach high bins unless a mechanical sheeting system is provided. Where a trailer coupling is fitted, always ensure that it is working satisfactorily and not excessively worn or damaged. When the trailer is attached the coupling must be fully locked. NOISE Depending on the specification of the equipment, typical in-cab noise levels can exceed 80 dba. Noise levels outside the vehicle can reach 90 dba. If subject to this noise for an extended period ear defenders are recommended. 10

13 OPERATING INSTRUCTIONS ANNUAL MAINTENANCE INSTRUCTIONS TO PICK UP A CONTAINER Position the truck to the approximate container pick up area. If manual body locks are fitted, ensure that they are open. Apply the handbrake and engage PTO. If applicable, lower the bogie blocking cylinders. A warning buzzer will sound. Retract the jib completely by operating jib-back lever. Make sure that the jib is fully retracted in order to release the safety locks. YEARLY OR EVERY 2000 OPERATIONS Change the oil every 2,000 operations or once a year, just before winter. (For oil specification refer to page 41) With all cylinders retracted and the pump stopped, drain the tank, replace the return line filter and refill with fresh oil according to the specification. Disconnect the return line to the tank and place in a suitable container to collect the waste oil. To clear the pump of old oil, run the pump, extending all the cylin ders in sequence, topping up the oil level as necessary. Immediately stop the pump when this is complete. Reconnect the return line to the tank. Run the pump, operating all the cylinders in order to bleed the system. When all cylinders are fully extended, i.e. full tip position, check the oil level again. Adjust as necessary to bring the oil level between the two marks on the dipstick. NEVER RUN A PUMP WITHOUT OIL Change the air breather filter set on the oil tank return filter. Operate body-off lever to move the hook to the rear of the vehicle. If both sections of the arm lift together, the safety locks have not disengaged. Lower the arm and ensure that the jib is fully retracted. Then try again

14 3 MONTHLY MAINTENANCE INSTRUCTIONS OPERATING INSTRUCTIONS Current Type Proximity Sensor (Older Versions May Vary). Operate body-off lever until the hook opening is lower than the bin hook bar. Disengage PTO. Then reverse the vehicle to strike the hook bar on the jib just above the hook opening. Engage PTO. Lift the main arm slightly to engage the hook. Do not extend the jib to reach the hook bar. Make sure the bar is properly engaged in the hook. View of catch in fully engaged position

15 OPERATING INSTRUCTIONS 3 MONTHLY MAINTENANCE INSTRUCTIONS Operate the body-on lever (chassis will roll back under the container). At this point steer the chassis under the container making sure that the container subframe rails are aligned with the rear rollers. When the container leaves the ground apply the hand brake. Continue until the container contacts the equipment subframe. Release the control lever. Ensure that the jib remains fully retracted throughout. If the load is lifted only a short distance and stops, it is likely that the maximum lifting capacity has been exceeded. Check your load. If the front axles lift off the ground as the bin leaves the ground, the stability limit has been exceeded. Where fitted, ensure that bogie blocking cylinders are in use, and ensure that the maximum load is not exceeded. If, when lifting there is a tendency to slip or lean sideways or the vehicle is prevented from rolling backwards, release the lever, disengage the PTO, and pull forward SLOWLY to achieve a better situation. Then re-engage the PTO and continue. EVERY 3 MONTHS Check for free movement of the FRAME LOCKING HOOKS and lubricate as necessary, using the following procedure and referring to the attached drawing. 1. With the bin removed, retract the jib fully and observe that just before full retraction the locking hooks open. 2. Extend the jib and observe whether the hooks close positively onto the rear frame section. Ensure that the hook is fully latched onto the frame as shown. 3. If the hooks are sluggish or remain partly open, they will need to be lubricated. 4. Fully retract the jib and position the hook over the rear of the vehicle in the pick-up position. Put a chock underneath the rear frame for extra security. (see page 31) 5. Locate the proximity sensor alongside the normal jib position (see sketch). Tape a small metal plate over the sensor. This will allow the jib to be extended. Extend the jib a few inches to allow the latches to relax. 6. Remove the tension springs from the latch levers and test the levers for free movement. Use penetrating oil to free them up and then liberally coat in oil to lubricate. Finally wipe off the excess oil and smear in grease to protect from the elements. 7. Replace the springs and retract the jib fully. 8. Remove the plate from the sensor and confirm that the latches operate normally. Operate the jib-forward lever to move the jib as far as it will go. Disengage the PTO. 9. Continue to grease monthly. UNDER NO CIRCUMSTANCES SHOULD THE PROXIMITY SENSOR BE OVERRIDDEN IN NORMAL USE 13 34

16 WEEKLY/MONTHLY MAINTENANCE INSTRUCTIONS OPERATING INSTRUCTIONS IN THE FIRST FEW WEEKS OF OPERATION Check for oil leaks from hydraulic fittings and re-tighten where necessary. DO NOT OVER TIGHTEN. Change the return line filter cartridge after approximately two months use and thereafter every year when changing the oil. Check the torque settings of the chassis attachment bolts and retorque where necessary. For example for grade 8.8 bolts:- If manual body locks are fitted, close them. If applicable, raise the bogie blocking cylinders. Check that the rear facing locking prongs are fully engaged in the bin locking pockets. Check that the body locks have engaged securely on the bin and are not prevented from locking by the bin fabrication. Where fitted, do not drive with bogie blocking cylinders down. This may damage the vehicle or equipment. Diameter 10mm 12mm 14mm 16mm 20mm Torque 56Nm 98Nm 185Nm 240Nm 470Nm THE VEHICLE IS NOW READY TO DRIVE AWAY WEEKLY Check the hydraulic oil level when the equipment is fully tipped ensuring oil level lies between the two marks on the dipstick. Check for oil leaks from hydraulic fittings and re-tighten where necessary. MONTHLY OR EVERY 500 OPERATIONS Check the torque settings of all bolts and screws, re-torque where necessary. Check hydraulic hoses for signs of wear, replace where necessary

17 OPERATING INSTRUCTIONS HEALTH & SAFETY DURING MAINTENANCE TO DEMOUNT A CONTAINER Unload bin. Tip the main arm ensuring that the jib is fully forward. Position the body prop such that it stands on the first crossmember forward of the rear hinge. Ask a colleague to hold the prop in this position and guide the top lugs into the forward aperture in the underside of the rear frame. Position the vehicle to leave sufficient space to demount the con tainer. Apply the handbrake. Engage PTO. Where applicable, lower the bogie blocking cylinders. a warning buzzer will sound. Slowly lower the main arm down until the body prop is just trapped. Do not power the arm down because this can damage the equipment. Disengage the pto and switch of the engine. Remove the ignition key. If you are working on the hydraulic system, start by cracking open the pipe unions on either main lift cylinder. This will release any trapped oil pressure, but take care to guard against injury from high pressure oil. If manually operated body locks are fitted, open them Retract the jib fully

18 HEALTH & SAFETY DURING MAINTENANCE OPERATING INSTRUCTIONS To minimise the risk of accidents and injury it is essential to adopt safe practices during the repair of this equipment. Edbro recommend that for all servicing the hook is parked in the lift-on position as shown below. Operate body-off lever until the container just touches the ground. Then release the hand brake and continue to lower the container. Allow the vehicle to roll forward and steer straight until the container is on the ground. Apply the handbrake. Full width metal or wooden beam For additional security a suitable wooden or metal beam should be wedged between the rear tipping frame and the subframe. If the arm is left in the tipped position, a BODY PROP MUST BE FIT- TED. This must be placed between the subframe and the rear section of the tipping frame. An Edbro prop (part no. BWA 1086) is available and should be installed as below. If both sections of the arm lift together, the safety hooks have not disengaged. Lower the arm and ensure that the jib is fully retracted. If the vehicle is prevented from moving or the brakes have been left on and the bin cannot roll, the tipping frame will prematurely lift off the subframe. If allowed to continue this can damage the equipment. Ensure that the brakes are off and if necessary reverse the lever to lower the arm, disengage the PTO, and reposition the vehicle. The jib must remain fully retracted throughout. Operate body-off lever until the hook opening is in line with the hook bar. Disengage PTO. Edbro prop Drive clear of the container. Apply the hand brake

19 OPERATING INSTRUCTIONS SPECIAL OPERATING INSTRUCTIONS FOR STATIC CELL LOAD WEIGHING MEASURE THE LOAD READING WITH THE DISPLAY/PRINTER Engage PTO. Operate arm-down lever until main arm comes to rest on its frame. Note: Depending on the type of display or load cell manufacturer the reading must be interpreted as described in the operators instructions. Operate jib-out lever to its fully out travelling position. Disengage the PTO. Where applicable, raise the bogie blocking cylinders. The warning buzzer will switch off. Do not drive the vehicle until the arm is down on the subframe and the hook fully forward. Do not drive the vehicle with the bogie blocking cylinders down. This may damage the vehicle or equipment. 17 Fully retract the jib until the container is at its forward position. Lock the container in place using the cross-locks switch (XL). Check that the rear facing locking prongs are fully engaged into the container. Check that the body x-locks have engaged securely on the container and are not prevented in any way by the bin fabrication. THE VEHICLE IS NOW READY TO DRIVE AWAY FOR FURTHER INFORMATION REGARDING THE LOAD WEIGH SYSTEM PLEASE CONTACT THE LOCAL DEALER. AN INFORMATION PACK IS SUPPLIED IN THE DRIVERS CAB WITH A LIST OF DEALERS/TELEPHONE NUMBERS. 30

20 SPECIAL OPERATING INSTRUCTIONS FOR STATIC CELL LOAD WEIGHING OPERATING INSTRUCTIONS This load weighing system is for guidance purposess only. It cannot be guaranteed to prevent overloading nor can it be used for invoicing purposes unless agreed specifically with the customer. TO TIP A CONTAINER When jibbing back with a rear end heavy bin, care must be taken not to back too far otherwise the bin may have a tendancy to tip backwards causing an incorrect load reading. If unusual or unexpected readings are seen on the display, the operator should inspect the bin and/or loader to ensure that the bin is clearly in contact with the load cells. TO RECORD THE WEIGHT OF A CONTAINER USING STATIC CELL LOAD WEIGH SYSTEM (XL) Open the body cross locks. Drive to the position required to tip the load. Apply the hand brake. Engage PTO. Check and release the container tailgate / doors. If manually operated body locks are fitted, ensure that they are closed. Operate jib-back lever to move the hook to the rear of the vehicle, for approximately 600 mm. The jib is marked with a white line painted on the bottom. This area will have to be lined up with the corresponding white line on the front crossmember of the main subframe. When this area is reached stop the jib back movement. The main arm will then have to be 'powered-down' to ensure that the hook is well clear of the bale-bar thus avoiding any mis readings. 29 Operate body-tip lever until the tipping angle is enough to release the load. Disengage the PTO. Pull forward gently to clear the load at the rear. Take great care when tipping to ensure that the vehicle is stable. If at any point the vehicle starts to lean over, quickly lower the body and reposition the vehicle to a better site. 18

21 OPERATING INSTRUCTIONS SPECIAL OPERATING INSTRUCTIONS FOR RED FORGE LOAD WEIGHING Check that the body locks are closed. MEASURE THE LOAD READING WITH THE DISPLAY/PRINTER Do not shunt the vehicle to free sticky loads. Beware of frozen loads in cold conditions. Do not attempt to open the bin doors when tipped. Never retract the jib while tipping. Look out for falling loads that might damage the equipment or property. Lower the container back to the hooklift bed when complete. Operate the body-lower lever until the main arm comes to rest on its frame. Disengage PTO. Secure the container tailgate doors. Clear rear light clusters of any debris before driving off. Do not drive off with the body coming down. Fully retract the jib until the container is at its forward position. Lock the container in place using the cross-locks switch (XL). Check that the rear facing locking prongs are fully engaged into the container. Check that the body x-locks have engaged securely on the container and are not prevented in any way by the bin fabrication. THE VEHICLE IS NOW READY TO DRIVE AWAY 19 28

22 SPECIAL OPERATING INSTRUCTIONS FOR RED FORGE LOAD WEIGHING ADDITIONAL OPERATING INSTRUCTIONS FOR SHORT CONTAINERS This load weighing system is for guidance purposess only. It cannot be guaranteed to prevent overloading nor can it be used for invoicing purposes unless agreed specifically with the customer. When jibbing back with a rear end heavy bin, care must be taken not to back too far otherwise the bin may have a tendancy to tip backwards causing an incorrect load reading. If unusual or unexpected readings are seen on the display, the operator should inspect the bin and/or loader to ensure that the bin is clearly in contact with the load cells. TO RECORD THE WEIGHT OF A CONTAINER USING RED FORGE LOAD WEIGH SYSTEM (XL) Open the body cross locks. APPROX 600mm Operate body-off lever to move the hook to the rear of the vehicle, for approximately 600mm. Note a warning light in the cab will alight when it is safe to operate the load weighing system. For maximum safety, when working with short containers, only equipment with claw type body clamps should be used. It is also recommended that the Bail Back option is specified for maximum safety. If in doubt consult Edbro Sales. TO PICK UP A SHORT CONTAINER When pulling the bin forward, stop before the rear of the bin passes the rear rollers. Visually check that the body clamps have correctly secured the container. TO TIP A SHORT CONTAINER - VEHlCLE FITTED WITH A BAIL BACK OPTION Press the Bail Back button, which will illuminate. Check that the body clamps are open (dashboard light on). With the engine at tickover, jib back to the desired position. When the jib is about 150 mm from fully closed, the bail back inter lock will prevent further movement. When at the desired jib position, close the body clamps (light goes off) and tip as normal. Visually check that the body clamps have correctly secured the containers In normal use ensure that the Bail Back button is off (light off) otherwise this may prevent normal loading and unloading opera - tions. TO TIP A SHORT CONTAINER - VEHICLES NOT FITTED WITH A BAIL BACK OPTION Check that the body clamps are open. Jib back no further than 1000mm. At this position the front of the jib is approximately in line with the base of the lift cylinder. If this dimension is exceeded, there is a risk that the safety latches connecting the two frame sections will open and the frames may separate while tipping. Close the body clamps (light goes off) Operate load lifting system with seperate control switch supplied. The lifting cylinders will lift the container to the required height. Visually check that the body clamps have correctly secured the container 27 20

23 SPECIAL OPERATING INSTRUCTIONS FOR TRUCK/TRAILER APPLICATIONS SPECIAL OPERATING INSTRUCTIONS FOR TRUCK/TRAILER APPLICATIONS TO DEMOUNT A CONTAINER Continue operating the body-on lever until the container is fully onto the chassis/sub frame bed, and located correctly. (BB) Lower the bogie blocking pillars. (XL) Open the body cross locks. Fully retract the jib until the container is at its forward position. Lock the container in place using the cross-locks switch (XL). Reverse hook loader and couple up trailer to tow hitch. Fully retract the bogie blocking cylinders and uncouple the trailer from the tow hitch. Check that the rear facing locking prongs are fully engaged into the container. Retract the jib arm ready for unloading Check that the body x-locks have engaged securely on the container and are not prevented in any way by the bin fabrication. THE VEHICLE IS NOW READY TO DRIVE AWAY 21 26

24 SPECIAL OPERATING INSTRUCTIONS FOR TRUCK/TRAILER APPLICATIONS SPECIAL OPERATING INSTRUCTIONS FOR TRUCK/TRAILER APPLICATIONS Operate the body-off lever until the hook locates into the container bale-bar. If the hook/bale bar do not line up it may be necessary to extend the jib arm until the hook locates in the bale bar. Operate the body-off lever until the trailer rests on the trailer bed. Note it is the responsibility of the operator to manoeuvre the hook with great caution when extending and retracting the jib in this position. Continue unloading the container onto the trailer bed until the jib/arm assembly is fully over. Operate the body-on lever to lift the container from the trailer bed. When the container is fully located in the hook it may be necessary to fully retract the jib arm back to its normal operating condition. Note it is the operators responsibility to proceed with caution. The container may or may not be fully into the trailer bed stops. If not then extend jib arm carefully to push the container backwards onto the trailer bed until it locates in the stops. Note that although the jib is re-inforced it is the responsibility of the operator to use caution when extending the jib in this operation

25 SPECIAL OPERATING INSTRUCTIONS FOR TRUCK/TRAILER APPLICATIONS SPECIAL OPERATING INSTRUCTIONS FOR TRUCK/TRAILER APPLICATIONS TO PICK UP A CONTAINER FROM THE TRAILER BED When the container is full back and locked in place, retract the jib. (BB) Lower the bogie blocking pillars. (XL) Open the body cross locks. Reverse the hook loader towards the trailer and couple up the tow hitch. Operate the arm down lever until the main arm/jib assembly comes to rest on its frame. Retract the jib arm completely by operating jib-back lever. Operate the jib out lever until the jib is fully forward in the travelling position and raise the bogie blocking cylinders (BB). Uncouple the trailer from the tow hitch and return the beam to the travelling position. Operate the body-off lever to move the hook to the rear of the vehicle If both sections of the arm lift together, the safety locks have not disengaged. Lower the arm and ensure that the jib is fully retracted and then try again.

26 HOW TO SPREAD THE LOAD The specification details for your vehicle are shown below. CHASSIS TYPE REGISTRATION NUMBER ROLATIP TYPE ROLATIP SERIAL NUMBER BUILD DATE G/A DRAWING REFERENCE PUMP KIT REFERENCE MAXIMUM WORKING PRESSURE MAXIMUM WORKING LOAD INCLUDING SKIP bar Kg DATE IN SERVICE It is the operators responsibility to ensure that road regulations are adhered to. 9 For full details of the complete network of specialist spares and service agents visit our website at or call Edbro Service on