TILT BUCKET Twin Cylinder

Transcription

1 TILT BUCKET Twin Cylinder Imagery does not reflect actual product size OPERATION & MAINTENANCE MANUAL TBT2017A 1

2 2 TBT2017A

3 CONTENTS INTRODUCTION Owner Information 4 Warranty Registration 5 Key Features 6 Tilt Bucket Connection 7 To The Owner 9 SAFETY Safety Instructions 10 Safety Identification Labels 11 Safety Standards 12 Pre-Start Check List 13 INSTALLATION PROCEDURE Tilt Bucket Hose Fittings 15 Plumbing Circuit Diagram 16 Hydraulic Requirements & Plumbing 17 Smart Valve Installation 18 MAINTENANCE General Maintenance 19 Cylinder Mount Nut Tightening Procedure 20 Daily Greasing 21 Suggested Greasing Products Hour Preventative Maintenance 23 Parts Diagram 24 Maintenance & Repair Log 26 TBT2017A 3

4 INTRODUCTION OWNER INFORMATION Thank you for choosing to purchase your new Tilt Bucket from Calibre Contracting Equipment s (Calibre) range of earthmoving products. This manual contains important information about the installation, maintenance and safe operation of your Tilt Bucket. You can assist in this proactive safety approach by ensuring that all persons involved with the fitting and operation of the Tilt Bucket, 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 Tilt Bucket 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 Tilt Bucket 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 Tilt Bucket 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 Tilt Bucket. A Maintenance & Repair Log has been placed at the back of this manual for this purpose, please refer to page TBT2017A

5 INTRODUCTION WARRANTY REGISTRATION Upon purchasing your Tilt Bucket 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 Tilt Bucket. The Operator accepts that he/she is responsible for understanding safety and operation features of the Calibre Tilt Bucket. 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 TBT2017A 5

6 INTRODUCTION KEY FEATURES Urethane Absorbers reduce shock loading Calibre Smart Valve Provides better performance, allowing for precise control and greater holding force Integral pivot tube and centre rib adds to pivoting mechanism strength Hard Pins all around for excellent load bearing and wear resistance 90 Degree Tilt allows 45 degrees tilt each way, adding versatility to your machine and your work enviroment Twin Displacement Cylinders. Simple, robust and proven design Tapered Sides for clean cutting Side Style Cutting Edges made from hard wearing plate for greater durability, better cutting finish and reduced force when cutting through the ground CALIBRE PRODUCT TONNAGE CLASS STANDARD WIDTH OVER STYLES (mm) WEIGHT WITH PINS (kg) STRUCK VOLUME (m3) SAE HEAPED VOLUME (m3) SIDE & BOTTOM WEAR STRIPS 450 BRINELL CUTTING EDGE STYLES YES YES YES YES YES YES TBT2017A

7 INTRODUCTION TILT BUCKET CONNECTION If you have purchased your new Calibre Tilt Bucket to be used with a Calibre coupler, then attach the bucket to the coupler as shown: Phase 1: With the slide fully extended, the front safety latch is opened to pick up the front pin of bucket Phase 2: Retracting the slide fully engages the front safety latch onto the front pin of bucket and the rear safety latch becomes open Phase 3: Crowding the coupler onto the rear bucket pin and fully extending the slide will wedge the slide onto the rear pin. The rear safety latch is then engaged. Oil is locked in the cylinder by the check valve Tips: - Connect Calibre Tilt Bucket hose ends together when not in use to prevent debris from entering hydraulic system - Always clean fittings prior to connecting to machine Connect quick-connect hoses to machine Carefully, fully crowd and tilt bucket to make sure all hoses are free and clear from obstructions through entire movement TILT - If storing bucket outside for long period, ensure it faces downhill to prevent build up of water TBT2017A CROWD 7

8 INTRODUCTION Removal of bucket is reverse of steps: 1. Disconnect hoses from machine and clip hose ends together to keep dirt from entering hoses 2. Place bucket on flat surface 3. Ensure area is clear from persons and objects when detaching bucket from coupler Operating Principle The single acting displacement cylinder design incorporates Smart Valve technology which locks the position of the Calibre Tilt Bucket once it is at the required angle. Hydraulic oil is trapped in both cylinders and is only released should the external load on the bucket be greater than the safe operating pressure of the cylinder. Urethane absorbers at the base of each cylinder allow them to move through the tilting range. The urethane also absorbs any shock loading that the Calibre Tilt Bucket is subjected to, aiding its robust design. 8 TBT2017A

9 INTRODUCTION TO THE OWNER As the new owner and/or operator of the Calibre Tilt Bucket 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 Calibre Tilt Bucket 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. TBT2017A 9

10 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 practises 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. Calibre supplies a standard Calibre Tilt Bucket to fit Calibre approved attachments. However, when fitting a non standard attachment check the operation fitting guide for the attachment s pin range and width to suit the Calibre Tilt Bucket TBT2017A

11 SAFETY SAFETY IDENTIFICATION LABELS TBT2017A 11

12 SAFETY SAFETY STANDARDS Only the following competent persons may work independently with any of type of Calibre earthmoving attachments. Operators must possess the following: Over 18 years of age Highly competent Have been instructed in the general regulations concerning operational safety and particularly accident prevention Have been instructed in assembly, operation and maintenance of earthmoving machinery and using the Calibre Tilt Bucket. They must understand these operating instructions and have proven to the contractor that they are capable of operating such machinery Ensure that only authorised personnel work with the Calibre Tilt Bucket Only give instructions to competent, skilled personnel NOTE: For Calibre products supplied to or manufactured in countries other than New Zealand and Australia, the rules for prevention of accidents and safely regulations for the respective country must be strictly adhered to TBT2017A

13 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 Calibre Tilt Bucket in general? Is the operator competent in using the specific attachment on the machine? Is there a system for checking that the attachment pins are in place on the Calibre Tilt Bucket prior to work starting everytime a different attachment is fitted? Is the operator aware that they must not operate the machine unless they are satisfied that Calibre Tilt Bucket is secured in place? Does the view of the operator from inside the cab allow them to visually see that the Calibre Tilt Bucket is secured in place? Does the Calibre Tilt Bucket have the approved labels stating and referring to attachment specifications? Is there a risk assessment for the Calibre Tilt Bucket detachment? Is there a checklist of daily and weekly inspections? Is there cab instructions for the Calibre Tilt Bucket? 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 TBT2017A 13

14 SAFETY Operator s Name: Calibre Serial No.: Calibre Contracting Equipment Model: Date: In Cab Tilt Bucket Operating Controls (Alarm, warning light, switch) Operating Instructions (labels) Operating & 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 Tilt Bucket Wear and damage to bucket / attachment pins and retainers Security of mounting pins, locking bolts and nuts Is the attachment safe to use? YES or NO Lubrication Greasing in accordance with Calibre Contracting Equipment instructions Operator Signature Manager Signature 14 TBT2017A

15 INSTALLATION PROCEDURE TILT BUCKET HOSE FITTINGS Calibre recommends using a Ball Valve mounted to each side the dipper arm for plumbing the Calibre Tilt Bucket to the machine. This should be carried out by a professional and experienced hydraulics installer. Ensure connecting hoses are long enough to be unobstructed and not stretched through out the buckets complete crowd and tilt movement. Quick-connect Connecting hose Hose loop (optional) Hose guide To Smart Valve TILT CROWD Important: - Disconnect battery prior to any welding. Failure to do so can result in damage to the machines electronics. - Protect hydraulic cylinder rods from weld spatter. - Ensure that the connecting hoses will not be pinched or damaged through the entire crowd and tilt movement. TBT2017A 15

16 INSTALLATION PROCEDURE PLUMBING CIRCUIT DIAGRAM 16 TBT2017A

17 INSTALLATION PROCEDURE HYDRAULIC REQUIREMENTS & PLUMBING TILT CIRCUIT TILT CIRCUIT REQUIREMENTS REQUIREMENTS Calibre Tonnage Unit 14T 20T8T 35T14T 45T20T 35T 45T Rod Size mm Stroke mm Displacement L Rotation Time* S Suggested Oil Flow L/min Operating Pressure PSI Port Connections (Calibre (JB Supslied) supplied) Circuit Relief Pressure Hose/Tube Size (Minimum) 7/16 JIC Male *Full 90 degree rotation i.e. stop to stop 7/16 JIC Male 7/16 JIC Male 7/16 JIC Male 7/16 JIC Male PSI /16 J Male Inch 1/4 1/4 1/4 1/4 1/4 1/4 TBT2017A 17

18 INSTALLATION PROCEDURE SMART VALVE INSTALLATION Optional hose loops Hose hole on base plate for 1/4 hose Valves (to machine) Valve 2 Valve 1 Cylinder 2 Cylinder 1 Tilt Cylinders 18 TBT2017A

19 MAINTENANCE GENERAL MAINTENANCE DAILY CHECKS 1) Complete Tilt Bucket Pre-start Checklist - refer to page 13 2) Grease Tilt Bucket regularly - refer to page 21 It is important that all parts are greased WARNING - Maintenance Work Maintenance work must be completed by competent personnel or assistance from Calibre. WARNING - Calibre Tilt Bucket Condition A defective Tilt Bucket could injure you or others. Do not operate a Calibre Tilt Bucket if it is defective, please contact Calibre immediately. Replacement Parts We strongly recommend that you fit genuine replacement parts. You will need to quote the Calibre Tilt Bucket serial number stamped on the data plate when ordering replacement parts. Refer to page 24 for Parts Diagram information. TBT2017A 19

20 MAINTENANCE CYLINDER MOUNT NUT TIGHTENING PROCEDURE While the Calibre Tilt Bucket is in the horizontal position, tighten nyloc nuts on both cylinders until there is no gap between nut, steel washer, urethane washer and mount plate. ***DO NOT FORCIBLY TIGHTEN OR URETHANE WASHER WILL EXTRUDE*** 20 TBT2017A

21 MAINTENANCE DAILY GREASING It is recommended that the Calibre Tilt Bucket is thoroughly greased DAILY for all 4 grease points OR every 2 hours if operating under water. This will help pro-long the service life and help maintain smooth operation of the attachment. Grease points shown are below: TBT2017A 21

22 MAINTENANCE SUGGESTED GREASING PRODUCTS SUGGESTED REQUIREMENTS: NLGI Grade 2 Lithium Complex Base Better ones contain 3-5% Moly (MoS2/ Molybdenum Disulfide) additive Base Oil Viscosity at 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 TBT2017A

23 MAINTENANCE 500 HOUR PREVENTATIVE MAINTENANCE VISUAL STRESS POINTS CHECK: Visually check the entire Calibre Tilt Bucket for any cracks, damage and excessive wear. The image below highlights major stress areas which particular attention should be given during checks. Should you find any cracks, damage or excessive wear, contact Calibre immediately. Front beam to styles Styles to cutting edge Bottom and side wear strips TBT2017A 23

24 MAINTENANCE PARTS DIAGRAM 24 TBT2017A

25 MAINTENANCE ITEM DESCRIPTION 14T PART NUMBERS 20T PART NUMBERS 35T PART NUMBERS 45T PART NUMBERS 1 TILT BUCKET WLDMT GREASE NIPPLE PIN PIVOT WLDMT SEAL OIL PIN GREASABLE HARD SEAL OIL BUSH HARD CYLINDER URETHANE BLOCK URETHANE WASHER WASHER FLAT NUT NYLOC BOLT HEX HEAD NUT NYLOC BOLT HEX HEAD NUT NYLOC SMART VALVE GREASE NIPPLE BUSH HARD TBT2017A 25

26 MAINTENANCE MAINTENANCE & REPAIR LOG DATE FAULT REPAIR BY WHOM 26 TBT2017A

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28 CALIBRE Contracting Equipment Australia 59 Magnesium Drive, Crestmead, Australia 4132 Ph: Web: CALIBRE Contracting Equipment New Zealand 49 McLaughlins Road, Wiri, Auckland 2104 Ph: Web: TBT2017A