OPERATOR MANUAL Premium Root/Cereal Bucket m³ & m³

Transcription

1 1 OPERATOR MANUAL Premium Root/Cereal Bucket m³ & m³ The Workshops Main Street Garton-on-the-Wolds Driffield, YO25 3ET Tel: Fax: sales@agriweld.co.uk

2 2 Contents Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 Page 17 Page 18 Page 19 Page 20 Page 21 Page 22 Page 23 Page 24 Page 25 Page 26 Page 27 Page 28 User Information & Getting Started Spout Fitting Instructions Safety, Qualification & Training & General Safety Important Safety Instructions Connection & Attachment to the Forklift/Loader Chain Tension Phase Operation Cross Line Relief Valve Maintenance Technical Data Sheet Full Assembly Main Drive Parts Main Drive Parts List Auger Assembly Auger Assembly Parts List Parts Parts List Spout and Stone Trap Open Chute Open Chute Parts List Hydraulic Stone Trap Assembly Parts List Forklift Brackets Stickers Warranty C E Declaration of Conformity

3 3 USER INFORMATION Before using your Root/Cereal Bucket for the first time it is IMPORTANT that all operators make themselves familiar with the unit and must read this OPERATORS MANUAL and SAFETY INSTRUCTIONS attentively. GETTING STARTED Your Root/Cereal Bucket will be fitted and delivered with the correct brackets to suit the fork-lift/loader it is intended to fit. SEE BOLT ON BRACKETING INSTRUCTIONS AND BOLT SPECIFICATIONS SECTION FOR FULL INFORMATION (PAGE 16). If for any reason the fittings are lost or damaged, or if the bracketing is removed for any reason, please refer back to this information in order to refit the brackets and/or replace any lost fittings with the correct specification. Please see SPOUT FITTING INSTRUCTIONS on page 4 before starting use! Your Root/Cereal Bucket will also be fitted with the correctly swaged hydraulic pipes and fittings applicable to your forklift/loader and as per your request. If these pipes are damaged they must be replaced immediately with NEW pipes and fittings. DO NOT ATEMPT TO REPAIR HYDRAULIC PIPES OR ALLOW ANY ONE ELSE TO REPAIR THEM. Any replacements can be ordered from us and sent to you overnight if required. Your Root/Cereal Bucket is a low maintenance machine, and requires minimum mechanical attention as such, other than greasing. WEIGHT 5 = 405kgs including brackets m³ = 535kgs including brackets m³ = 610kgs including brackets Your Root/Cereal Bucket is not to be used for any other purpose than for which it is intended - that is the collection, discharge and chopping of root feed and discharging cereals. Damage as a result of use for other purposes will not be covered under warranty. The specifications, descriptions and illustrations in this manual are accurate at the time of publication but may be subject to change. This bucket can be used to discharge cereals/nuts/minerals via an open stone trap.

4 4 SPOUT FITTING INSTRUCTIONS Spout requires fitting to stone trap before operation. 1. Push spout shaft fully in to nylon bush located on end of auger shaft. 2. Spout will turn freely on shaft to enable alignment of yellow markers. 3. Locate fixing bolts (M10 x 30mm cup head square) x 6 into flanges, and ensure flange edges are flush and level and tighten bolts using washers (on nylock side only) and nylock nuts. Ensure these are tight.

5 5 SAFETY All operators of the buckets forklift/loader must hold the appropriate forklift licence or certificate of competence to do so. All operators must be familiar with the Root/Cereal Bucket Operators Manual and forklift/loader operations prior to use. If safety instructions are not observed and complied with it can lead to the risk of injury to the operator and others as well as damage to the machine, property and the environment. Non-compliance to the safety instructions can lead to claims for damages/injury becoming invalid. QUALIFICATION & TRAINING Only personnel with the appropriate forklift/loader licence are authorised to use this machine. Statutory minimum age limits must be observed and reliable personnel only should perform maintenance/work on this machine. Persons undergoing training or instruction or taking part in a general training course should only use this machine under direct supervision of an experienced and trained person. Agriweld shall not be responsible for any damage/injury caused by the use of parts/repairs not supplied and/or approved by Agriweld. GENERAL SAFETY Any warning signs/instructions on the machine provide important information and must be observed. Ensure that you are familiar with the machine before starting work. Check round the machine for any noticeable damage, or missing parts before starting work. It is advisable that the operator does not wear jewellery and baggy clothing to avoid the risk of snagging and trapping.

6 6 Ensure that you are working in an area clear of obstructions and watch out for wandering individuals (particularly children!). Ensure that you are working in an area clear of obstructions and watch out for wandering individuals (particularly children!). IMPORTANT SAFETY INSTRUCTIONS Take extra care when attaching the Root/Cereal Bucket to the forklift/loader to ensure that it is attached correctly via the bracketing and hydraulic fittings. (See page 7 Connection to the forklift/loader). Ensure that the forklift/loader and its hydraulic system is in full working order. Never allow any person to stand between the forklift/loader and the Root/Cereal bucket during connection or at any time. Ensure that the brackets are connected fully before operation. Take into account the protrusions of the Root/Cereal Bucket from the forklift carriage when manoeuvring around and take particular care when approaching junctions and negotiating corners. The driving characteristics of the forklift/loader are influenced and altered by the attachment of mounted machines and it is important to ensure adequate steering and braking ability as required. Never allow any person to ride on or in the bucket at any time Never perform any adjustments to the bucket whilst mounted, unless the forklift/loader is stopped, turned off and the bucket is resting on the ground where possible. Ensure that the forklift/loader cannot roll away by use of a park brake or wheel chocks. Never allow any person to stand or work beneath a suspended load. It is forbidden to allow persons to ride on the bucket or the forklift/loader it is attached to, at any time.

7 7 CONNECTION TO THE FORKLIFT/LOADER Your Root/Cereal Bucket will be delivered already fitted with the correct bolt-on bracketing, hydraulic fittings and hydraulic hose to fit your forklift/loader. If for any reason the fittings are lost or damaged they must be replaced with the following specification of fitting; QUICK-HITCH brackets or LOADER BRACKETS require the following U Bolt fittings; 8 X M16 X 120mm U Bolts 16 X M16 Nylock nuts/washers For your own safety and the safety of others, always use the correct fittings to attach bolt-on bracketing to the rear of the unit. Always place the unit on the ground and turn off the forklift/loader before attempting any changes. CREATING OFFSET (Before Attachment to Forklift) The bracketing on a 1.7m³ bucket will be offset at the point of manufacture, however if you need to change the offset for any reason the procedure is as follows; 1. Remove all 16 nylock nuts and reposition the bracket. It is important to maintain the correct spacing between the brackets and that on tightening up the bolts make sure that the brackets remain square to the bracket mounting frame. REPLACE THE M16 NYLOCK NUTS EACH TIME THE BRACKETS HAVE BEEN REPOSITIONED AND ENSURE THEY ARE ALL THOUGHERLY TIGHTEND. ATTACHMENT Stand the Root/Cereal Bucket in an area free from obstruction to allow you to drive the forklift/loader towards the bracketing. For Quick Hitch bracketing, connect as you would with any other attachment and the type of bracketing fitted to the rear of the bucket. Attach the hydraulic hoses via the pipes and fittings supplied to fit your forklift/loader whilst it is TURNED OFF. For eased the hoses are marked FEED and RETURN. FEED is to drive the auger forwards to discharge.

8 8 RETURN will reverse the auger. YOU ARE NOW READY FOR OPERATION. ON FIRST USE (CHAIN TENSION PHASE) Your Root/Cereal Bucket is run and tested prior to delivery, however it is important to check the chains tensions and taper lock grub screws for tightness after first use and adjustment may be necessary. Please follow instructions on how to tension the chain and tighten grub screws below; Chain HOW TO TENSION CHAIN 1. Partly unscrew (about ½ turn) the tensioner nut. 2. Using the tensioner spacer as the levering point, push the spacer along the slider to tighten the chain as required and re-tighten the nut. DO NOT OVER TIGHTEN CHAIN APPROX 6mm of movement is recommended. Remember to replace the guard after any alterations. TIGHTNESS OF GRUB SCREWS Please ensure the 4 x grub screws are tight after first use and weekly thereafter. Grub screws are located 2 on each bracket.

9 9 OPERATION Once the Root/Cereal Bucket is attached to the forklift/loader correctly you can begin operation. The following step by step procedure will take you through the basic operation of the machine; 1. Shovel into heap to fill bucket with root feed. 2. Back bucket and drive to desired location. 3. When ready start the flow of hydraulic oil to the bucket by operating the lever inside the forklift cab. 4. Position the forklift/loader so that on discharge, the product will fall as required. As standard the bucket will discharge to the left (from the driver s seat of your forklift/loader). 5. If you decide not to empty the whole bucket fully, stop the flow of hydraulic oil and the auger will stop, enabling you to move to another location. 6. Repeat the process. The speed is pre-set before delivery and you do not need to worry about feathering the controls as the bucket will operate at a steady speed without jarring. MANUAL STONE TRAP TO REMOVE A BLOCKAGE All feed should be as clean and free from foreign bodies such as stones for the health of your animals and the lifespan of your bucket. However if you experience a blockage due to a stone; 1. Stop flow of oil ASAP. 2. Release pressure or back up auger ½m to free stone, which should drop into the trap. 3. Turn off forklift/handler before leaving cab. 4. Open stone trap. 5. Release foreign object. 6. Close stone trap. 7. Re-start forklift and continue operation.

10 10 IF HYDRAULIC STONE TRAP 1. Reverse auger as soon as blockage discovered. This automatically opens the stone trap and the stone should fall from bucket. 2. Run auger as normal to discharge and the stone trap will automatically close first and the bucket will continue operation. CROSS LINE RELIEF VALVE The Cross Line Relief Valve is fitted to the top of the hydraulic motor on your feeder bucket as additional protection for the motor and cutting die against damage from stones or other foreign bodies. TO SET THE CROSS LINE RELIEF VALVE The Valve is pre-set to 150 bar prior to delivery in the event that you do not make any adjustments yourself to give your motor protection against major blockages. We recommend that you re-set the Valve in accordance to your own requirements and feed type as follows; Before beginning, HALF fill your bucket with clean feed. That means NO stones or foreign bodies at all while setting up. The adjustments are made via an Allen (Hex Key) socket that is easily visible on the Valve. (Not the one underneath). Follow the steps below to set the sensitivity of your Cross Line Relief Valve; this can be set as keen as you like. 1. Start your loader and begin cutting the half bucket of feed. 2. Turn the Allen Key adjuster (whilst the bucket is cutting) anti clockwise until the auger stops. 3. Proceed to turn the adjuster clockwise again until the auger re-starts and you are happy with the cut. This is setting the sensitivity of the Valve. 4. Depending how sensitive this is set will depend if the valve allows small stones/ obstructions through or stops the flow of oil with any small/minor obstruction. 5. Re-adjust as required if you find it is too sensitive. It may be that the valve also requires adjustment for different types of feed. If you require any assistance with setting up the Cross Line Relief Valve, please do not hesitate to telephone and we will be pleased to assist you.

11 11 MAINTENANCE IMPORTANT: See page 8 for maintenance after 1 st use. WEEKLY MAINTENANCE 1. Grease main bearing (Number 10) from the remote greasing point located on the right hand side of the bucket above the chain guard and marked with a grease sticker, BEARING FAILURE MAY OCCUR AND REQUIRE REPLACEMENT IF THIS GREASING IS IGNORED. 2. Check auger drive and discharge end for wear. You are looking for play on the shaft in both the horizontal/vertical axis. There should be minimum movement. The main bearing (number 10) may be wearing if you notice more movement. If this is the case, increase the greasing routine and monitor. When play reaches significant movement the bearing requires replacement. 3. Grease chain as required. It should NOT be allowed to run dry. 4. Non drive end of the auger is fitted with a nylon bush which does not require greasing, but it would prolong the lifespan of the bush if given a squirt of freeing oil like WD40 or similar each week. 5. Straw sometimes evident in root feed can clog up the cutting die blades and cause excess pressure to be applied on the main bearing, motor and chain assemblies. It is requested that you keep the cutting dies/blades free of straw at all times to prevent this. SAFETY PLEASE NOTE THAT THE CUTTING BLADES ARE SHARP. PLEASE ENSURE THE FORKLIFT/ LOADER IS SWITCHED OFF PRIOR TO PERFORMING ANY MAINTENANCE. GREASING Greasing the bucket is very important in your weekly maintenance, the next page states the technical details of the grease we recommend and recommend you should use, or its equivalent.

12 12 Technical Data Sheet PRODUCT NAME : LITHOSHIELD EP2 PRODUCT CODE : 251/0295 A premium quality multi-purpose grease for use in all anti-friction and plain bearings subjected to high load conditions. Used extensively for applications throughout industry and the automotive sector. FEATURES Excellent extreme pressure and anti-wear performance High degree of corrosion protection Highly versatile multi purpose grease METHOD OF APPLICATION LITHOSHIELD EP2 can be applied manually, or by using a standard grease gun (400gm cartridges available), or via a central lubricating system designed for and capable of pumping an NLGI No.2 grease; consult a qualified centralised lubrication systems engineer before installation. As with all greases used for the first time, check compatibility with the grease applied previously and if necessary purge bearings prior to application. Likewise, as a general rule, take care not to over-lubricate and apply the quantity of grease recommended by the bearing manufacturer. Properties Specification Appearance - Smooth grease Colour - Dark brown NLGI classification - 2 Thickener - Lithium soap Base oil - Blend mineral oils Base oil 40 C (cst) IP Worked penetration IP to 295 Dropping point ( C) IP min. Oil separation (%) IP121 5 max. Copper corrosion IP112 Pass Resistance to corrosion Emcor (a) IP 220 0:0 Water 39 C % ASTM D Four Ball Weld Load (kgs) IP Timken OK load (lbs) IP Oxidation 100 C IP142 Pressure drop after 100 hrs psi 400 hrs psi 4 14 Operating temperature range C to +140 C Solids % - 0 The information in the table above is believed to be accurate and given in good faith but without warranty. It is the users responsibility to determine the suitability of the product. (Sept 2012)

13 13 Full Assembly Auger Bucket Edge Strip Stone Trap Detachable/ movable forklift brackets Cutting Spout Hydraulic Motor Chain Guard

14 14 Main Drive Parts (See Page 15 for Details)

15 15 Item Number Part Number Description Quantity per Machine 1 AW_GUARD Chain Guard 1 2 AW_SMT_400 Motor 1 3 AW_SE128TL_SP 28 Tooth Sprocket 1 4 AW_SWE011320_T Tensioner 1 5 AW_SE116TL_SP 16 Tooth Sprocket 1 6 AW_1I_S_CH / AW_1SL 1 Simplex Chain/ 1 Split Link -/1 7 AW_SR_0423 Guard Tab 2 8 AW_SR_0655 Offset Guard Tab 1 9 M12 x 30 Bolt 3 10 M12 Flat Washer M12 Nylock Nut AW_2517_45TL Taper Lock 1 13 AW_2012_40TL Taper Lock 1 14 M12 x 50 Motor Bolt 4 15 M12 x 60 Bearing Flange Bolt 4 16 M20 Cup Square Tensioner Bolt 1 17 M20 Washer Tensioner Washer 2 18 M20 Nylock Nut Tensioner Nuts 2 19 AW_ADB Auger Drive Bearing 1 20 AW_1SL 1 Split Link 1

16 16 Auger Assembly 1 12

17 17 Auger Assembly Parts List Item Number Part Number Description Quantity per Machine 1 Auger M16 nut M16 nut 4 3 M16 Washer M16 Washer 4 4 KOYO_50_FX10 Drive end bearing 1 5 AW_1509 Auger Drive End Spacer 1 6 AW_2012 Spacer plate 1 7 B_1265 Auger flange 1 8 JS_WK_03 Bearing housing 1 9 M16 Washer M16 Washer 4 10 M16X90 M16 Nut 4 11 Grease_Bearing Grease bearing 1 12 Nylon_Bearing Nylon Bearing 1

18 18 Parts

19 19 Parts List Item Number Part Number Description Quantity per Machine 1 Auger AW_TP Bucket Edge Strip 1 3 AW_80/80_EC 80 x 80 Plastic End Cap 3 4 M10 x 30 CHS Cup Head Square Bolt 4 5 M10 Flat Washer Hydraulic Bracket Washer 6 M10 Nylock Hydraulic Bracket Nut 4 7 AW_SR0577 Hydraulic Bracket 1 8 AW_SP110APPDPAS Full Pipe Clamp Set 1 4

20 20 Spout and Stone Trap Item Number Part Number Description Quantity per Machine 1 AW_SP 8, 10 or 12 Blade Spout 1 2 AW_ST Manual Stone Trap 1 3 PH_4550_50 Oilite Bush (Inserted in Auger tube) 1 4 M10 x 30 CHS Cup Head Square Bolt 10 5 M10 Flat Washer M10 Nylock Nut 10 7 AW_STH Stone Trap Handle 1 8 AW_STD Stone Trap Door and Hinge 1

21 21 Open Chute

22 22 Open Chute Parts List Item Number Part Number Description Quantity per Machine 1 AW_OC Open Chute with Manual Lid 1 2 AW_ST Manual Stone Trap 1 3 AW_OCL Chute Lid 1 4 AW_STD Stone Trap Door, Hinge and Hook 1 5 AW_STH Stone Trap Handle 1 6 M10 x 30 CHS Cup Head Square Bolt 10 7 M10 Flat Washer M10 Nyloc Nut 10 9 M16 x 110 Chute Lid Hinge Bolt 1 10 M16 Flat Washer M16 Nyloc Chute Hinge Lid Nut 1 12 AW_SLP Chute Lid Pin 1 13 AW_LP6Z Chute Lid Lynch Pin 1

23 23 7 Hydraulic Stone Trap Assembly

24 24 Parts List Item Number Part Number Description Quantity per Machine 1 AW_RB_11_ST_Hydro Hydraulic Stone Trap 1 2 AW_11_HYD_Flap Stone Trap Flap 1 3 AW_700_05 Stone Trap Ram 1 4 AW_16_100 Ram Base Bolt 1 5 AW_16_160 Ram Rod Bolt 1 6 AW_16_130 Flap Pivot Bolt 1 7 AW_16W M16 Washer 10 8 AW_16N M16 Nut 3

25 25 Forklift Brackets Example bolt on Euro Hook brackets. Item Number Part Number Description Quantity per Machine 1 80x80_M16_UBolt Bracket Bolt 8 2 M16 Flat Washer Bracket Washer 16 3 M16 Nylock Bracket Nylock Nut 16

26 26 Stickers Sticker Part number Description Quantity per Machine AW_SRB_WS (80mm x 80mm) Warning Sticker 4 AW_SRB_AS (185 mm x 85mm) Agriweld Sticker 1 AW_SRB_GB (85mm x 50mm) Great Britain Sticker 1 AW_SRB_ALS (460mm x 90mm) Agriweld Sticker 2 AW_SRB_CC Check Sticker 3 (80mm x 80mm)

27 27 AW_MRB_OF Do Not Over Fill Bucket Sticker 1 WARRANTY Your Root/Cereal Bucket is covered for a period of12 months from the date of delivery (which is recorded on our files) against faulty components and/or bad workmanship. The machine should be checked over at time of delivery for transport damage. All damage claims must be reported to Agriweld upon delivery and noted on the Disclaimer. Any claims not reported at this time are invalid. All our welders are coded to the relevant standard to manufacture your equipment, and all products are checked for quality prior to delivery/collection. WARRANTY EXCLUSIONS: Hydraulic hoses, fittings, and wearing parts such as wearing edges and cutting die blades are not covered. Damage as a result of incorrect setting or non-use of the Cross Line Relief Valve is not included. We cannot be responsible for claims arising from ignorance, occurrences outside our control, such as accidents, malicious damage and non-maintenance. Damage resulting from failure to report a fault may not be covered by warranty. WARRANTY CLAIMS FOR DAMAGE DURING TRANSIT Damage occurred during transit via an external haulier must be reported immediately upon unloading and signing for the item. The limit of our liability to undertake repairs to products damaged during transit is dependent on signing for any damaged product upon delivery as DAMAGED. IT IS IMPORTANT TO READ THE MAINTENANCE SECTION OF THIS MANUAL. IT IS VERY IMPORTANT TO USE YOUR BUCKET IN ACCORDANCE WITH ITS CAPABILITIES.

28 28 CE DECLARATION OF CONFORMITY The equipment which accompanies this declaration is in conformity with EU Directive(s):- 2006/42/EC Machinery Directive Manufacturer Name: Manufacturer Address: Product: Product Options: Agriweld Ltd Main Street Garton-on-the-Wolds Driffield East Yorkshire YO25 3ET Root Bucket All Individual Serial Number: Product Description: AGRIWELD Root Bucket Date of Last Load Test Report: N/A Supplementary Information: Authorized Signatory on Behalf of Manufacturer: Name of Signatory: Dawn Foster Position in Company: Director Date of Issue: