FRONT & REAR LOCK OPERATION & MAINTENANCE MANUAL

Transcription

1 RAM-TILT COUPLER Imagery does not reflect actual product size FRONT & REAR LOCK OPERATION & MAINTENANCE MANUAL

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3 CONTENTS INTRODUCTION Owner Information 4 Warranty Registration 5 Key Features 6 Ram-Tilt Coupler Operation 7 To The Owner 8 SAFETY Safety Instructions 9 Safety Decals 10 Safety Identification Labels 11 W.L.L. Working Load Limit 13 Safety Standards 15 Pre-start Check List 17 INSTALLATION PROCEDURE Installation 19 Plumbing Overview 20 Plumbing Circuit Diagram 21 Hydraulic Requirements & Plumbing 23 Smart Valve Installation 24 Operating & Attaching 25 Connection Test 26 Checking Attachments 27 MAINTENANCE General Maintenance 28 Cylinder Mount Nut Tightening Procedure 29 Daily Greasing 30 Suggested Greasing Products Hour Preventative Maintenance 32 Latch Inspections 34 Lifting Eye Inspection 36 Shackle Table 37 Maintenance & Repair Log 38 Parts Diagram 39

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

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

6 INTRODUCTION KEY FEATURES Twin Displacement Cylinders proven, simple robust design Calibre Smart Valve protects Ram-Tilt from high pressure spikes, allowing for precise control and improves holding force Low Profile results in maximisation of break out force, improved fuel economy and less strain on your machine Integral pivot tube adds to pivoting mechanism strength Hard Pins all around for excellent load bearing and wear resistance Compliant Front & Rear Locking slide to AS4772:2008 and ISO 13031: 2016 Individually Certified & Tested (CPENG) with full manufacturing record 90 Degree Tilt allows tilting of Attachments 45 degrees each way, adding versatility to your attachments and your work environment 6

7 INTRODUCTION RAM-TILT COUPLER The patented Ram-Tilt system allows your Ram-Tilt to pick up a range of attachment pin centres with the same pin diameter.* The Ram-Tilt contains a fully compliant front and rear locking mechanism. Phase 1: With the slide fully extended, the front safety latch is opened to pick up the front pin of attachment. Phase 2: Retracting the slide fully engages the front safety latch onto the front pin of attachment and the rear safety latch becomes open. Phase 3: With the rear pin of the attachment in contact with the coupler, fully extending the slide wedges the slide onto the rear pin and engages the rear safety latch. Oil is locked in the cylinder by the check valve. RAM-TILT COUPLER OPERATING PRINCIPLE The single acting displacement cylinder design incorporates smart valve technology which locks the position of the tilt coupler once it is at the required angle. Hydraulic oil is trapped in both cylinders and is only released should the external load on the coupler 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 Ram-Tilt is subjected to, aiding its robust design. Ram-Tilt at horizontal position Ram-Tilt at 45 degrees position * Contact Calibre Contracting Equipment for pickup range 7

8 INTRODUCTION TO THE OWNER As the new owner and/or operator of the Ram-Tilt 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 Ram-Tilt 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 undertaken by persons not 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

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 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 Ram-Tilt 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 Ram-Tilt. NOTE: The Ram-Tilt base has a maximum and minimum pin centre travel range. Please refer to the attached badge on the Ram-Tilt for this information. 9

10 SAFETY SAFETY DECALS The Ram-Tilt operation instructions are to be fitted inside the cab in clear view of the operator to identify correct operation of our attachments. 10

11 SAFETY SAFETY IDENTIFICATION LABELS The pin centre range displays the minimum and maximum travel distance for each slide hook on the Ram-Tilt. All attachments must be within the parameters of these measurements identified on the label. The label also identifies the slide hook type. Pin Centre Range: Min Lifting Eye Capacity The badge also displays the W.L.L and data information. Note: The W.L.L is also stamped on the Lifting Eye. All Ram-Tilts have an identification label with the machine and model recorded. CALIBRE PART NO. 11

12 SAFETY Each Ram-Tilt will have numerous identification labels fitted as shown below: CALIBRE PART NO. Pin Centre Range: Min Lifting Eye Capacity The slide has numbering to identify the type, model, pin size and pin centre range The hydraulic cylinder has a serial number stamped to identify its model for servicing 12

13 SAFETY W.L.L. - WORKING LOAD LIMIT Your Ram-Tilt comes with an integrally designed Lifting Eye which has been individually pull tested and certified to meet and exceed current standards. Pin Centre Range: Min Lifting Eye Capacity W.L.L. is both stamped on Ram-Tilt and pickup pin centre range tag Stamping shows unique certification number and the W.L.L. e.g XXXX-XXX XXXXKG Lifting Eye 13

14 SAFETY The Certified Lifting Eye must be used accordingly to the following guidelines: Only use the Lifting Eye at the rear of the Ram-Tilt for lifting Do not lift with bucket or any other attachment fitted to the Ram-Tilt Ensure that the load to be lifted does not exceed the rated W.L.L. of the Ram-Tilt and Lifting Eye The Lifting Eye is to be used with certified Lifting Eye with the same or greater safe working load Lifting must be carried out with the Ram-Tilt in a vertical plane so that the load can hang freely without interfering with the Ram-Tilt body Lifting Eye must be visually inspected daily for defects and wear The below sticker MUST be permanently fixed to the operator s cab in a clearly visible location 14

15 SAFETY SAFETY STANDARDS The standards and Occupational Safety and Health Guidelines for the Ram-Tilt are as follows: AS4772:2008 Standards Australia. Australian standard for - Earthmoving Machinery Multi-Couplers (couplers) for excavators and backhoe loaders - AS4772:2008 section C AS Cranes (Including hoists and winches) Part 5: Mobile vehicle loading cranes European Standard EN474-5; Section /2 and 3 ISO 13031: 2016 Earthmoving Machinery Standard Operating Guidelines for Plant and Machinery 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 Ram-Tilt and its advised safety procedures. ASSOCIATED STANDARDS: AS 2954 Earthmoving Equipment - Rated Loads and Volumetric ratings AS 2954 Earthmoving Equipment - Tests and Measurements AS 2954 Earthmoving Equipment - Instrumentation and Control AS 2954 Earthmoving Equipment - Operation and Maintenance AS 2954 Earthmoving Equipment - Safety 15

16 SAFETY Only the following competent persons may work independently with any of type of Calibre earthmoving equipment. 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 Ram-Tilt system. 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 Ram-Tilt Only give instructions to competent and skilled personnel NOTE: For Ram-Tilt products supplied to or manufactured in countries other than New Zealand and Australia, the rules for prevention of accidents and safety regulations for the respective country must be strictly adhered to. 16

17 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 Ram-Tilt 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 Ram-Tilt 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 Ram-Tilt is secured in place? Does the view of the operator from inside the cab allow them to visually see that the Ram-Tilt is secured in place? Does the Ram-Tilt have the approved labels stating and referring to attachment specifications? Is there a risk assessment for the Ram-Tilt detachment? Is there a checklist of daily and weekly inspections? Is there cab instructions for the Ram-Tilt? 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 17

18 SAFETY Operator s Name: Calibre Serial No.: Calibre Model: Date: In Cab Ram-Tilt 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 Ram-Tilt Coupler 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 instructions Operator Signature Manager Signature 18

19 INSTALLATION PROCEDURE INSTALLATION Align Ram-Tilt to the rear link and insert the original hard pin Fit shims and O-ring seals as required CHECK PINS ARE ORIGINAL EQUIPMENT MANUFACTURERS PINS Align Ram-Tilt to the dipper arm and insert the original hard pin Fit shims and O-Ring seals as required. Fit locking bolts and nuts to each pin to secure pins 19

20 INSTALLATION PROCEDURE PLUMBING OVERVIEW Calibre suggest using a reversing manifold block mounted to the dipper arm for plumbing the Ram-Tilt to the machine. This should be carried out by a professional and experienced hydraulics installer. Hoses to machine Reversing block Connecting hoses to Ram-Tilt Smart Valve When plumbing Ram-Tilt to machine: 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 Check for tolerance between latch and machine Ensure that the connecting hoses will not be pinched or damaged through the entire crowd linkage movement 20

21 INSTALLATION PROCEDURE PLUMBING CIRCUIT DIAGRAM Ram-Tilt Side (Calibre Supply) Machine side (OEM or Hydraulic installer supply) 21

22 INSTALLATION PROCEDURE ITEM DESCRIPTION COMMENTS 1 Oil Reservoir - 2 Pump Must have min 3000 PSI & 50LPM **DO NOT USE PILOT PUMP** 3 Check Valve - 4 Coupler Cylinder Control Valve Can be OEM supply or Hydraulics installer supply 5 Pressure reducing **Must set between PSI** cartridge 6 Single Acting Solenoid - Control Valve 7 Connect Solenoid to - Coupler/Buzzer Alarm 8 Tilt Cylinder Control Valve Can be OEM supply Hydraulics or installer supply 9 Calibre Smart Valve Calibre Supply 10 Operational Flow See table for sizing Control Orifice 11 Calibre Tilt Cylinder - 12 Coupler Cylinder - Manifold 13 Pilot Operated Sun CKCB-XCN Check Valve 14 Coupler Cylinder

23 INSTALLATION PROCEDURE HYDRAULIC REQUIREMENTS & PLUMBING COUPLER CIRCUIT REQUIREMENTS Operating Pressure Hose Size PSI 1/4 Maximum TILT CIRCUIT REQUIREMENTS Machine Tonnage Unit 6T 8T 14T 20T 35T 45T Rod Size mm Stroke mm Displacement L Rotation Time * S Suggested Oil Flow L/min Operating Pressure PSI Port Connections 7/16 JIC (Calibre Supplied) Male Circuit Relief Pressure Hose/Tube Size (Minimum) PSI * Full 90 degree rotation i.e. stop to stop /16 JIC Male /16 JIC Male /16 JIC Male /16 JIC Male /16 JIC Male Inch 1/4 1/4 1/4 1/4 1/4 1/4 23

24 INSTALLATION PROCEDURE SMART VALVE INSTALLATION SMART VALVE The connection hoses connect to the Calibre Smart Valve located on the Ram-Tilt as shown: Quick Hitch (to machine) Quick Hitch (to machine) Tilt Cylinder Valve (to machine) Tilt Cylinder Valve (to machine) Quick Hitch (to cylinder) Quick Hitch (to machine) Quick Hitch (to cylinder) 24

25 INSTALLATION PROCEDURE OPERATING & ATTACHING Following the installation of the Ram-Tilt onto the machine, consult with the hydraulic installer as to the correct control operation of the Ram-Tilt and tilting cylinder circuits. Depending on the installer and the method used, controls can vary and it is important that the operator clearly understands how each circuit is operated Fully extend slide and ensure that front safety latch is fully open Line up attachment and engage front pin Fully retract slide and ensure that front safety latch is engaged over front pin Crowd the Ram-Tilt into the attachment so that the rear pin makes contact Fully extend slide to lock onto rear pin Check that both front and rear safety latches are engaged TO RELEASE ATTACHMENTS: 1. Place attachment on flat ground 2. Retract slide and crowd out of rear pin 3. Extend slide to release front safety latch 4. Lift Ram-Tilt away from attachment 25

26 INSTALLATION PROCEDURE CONNECTION TEST Check all attachments are fitted correctly. The safety latch is designed to work in closed position on the front pin. If the safety latch is not closed when attached to any attachment, check the rear jaw on the Ram-Tilt if fitted. If uncertain DO NOT USE THIS ATTACHMENT - call your local Calibre branch for assistance. Advise manufacturer of which attachment is not fitting and arrange modification before it is used. To ensure the Ram-Tilt has engaged securely to pins on attachment: Visually check the safety latch is engaged on the pin Test before operating through applying pressure to attachment by rotating against the ground and away from machine Do not proceed with work unless the safety latch is in closed position on the front pin If the safety latch on the front pin is open DO NOT OPERATE MACHINE SAFETY LATCHES IN CLOSED POSITION 26

27 INSTALLATION PROCEDURE CHECKING ATTACHMENTS WARNING: Check pin centre of Ram-Tilt for all attachments Label will indicate pin centre range (minimum - maximum) A) Check that each individual attachment s pin-centre fits the Ram-Tilt to confirm the range on the label B) Check the inner width of the Ram-Tilt. Width must be wider than the Ram-Tilt base C) Check Pin Diameter spacers can be fitted to either the base of the Ram-Tilt or between the inner side of the ears and the bosses of attachment. It is highly recommended to fit spacers in the case of heavier applications, particularly on machines that are 14 ton and above. DANGER: DO NOT USE ANY ATTACHMENT WITH THE SAFETY LATCH UP 27

28 MAINTENANCE GENERAL MAINTENANCE DAILY CHECKS 1) Complete Ram-Tilt Pre-start Checklist - refer to page 17 2) Grease Ram-Tilt regularly. It is important that all parts are greased. 3) Check Lifting Eye for damage. If in doubt do not continue to use - refer to page 36 4) Check dirt build up in rear safety latch WARNING - Maintenance Work Maintenance work must be completed by competent personnel or assistance from Calibre. WARNING - Ram-Tilt Condition A defective Ram-Tilt could injure you or others. Do not operate a Ram-Tilt if it is defective, please contact Calibre immediately. Replacement Parts We recommend that you fit genuine replacement parts. You will need to quote the Ram-Tilt serial number stamped on the Ram-Tilt data plate when ordering replacement parts. Refer to page for Parts Diagram information. 28

29 MAINTENANCE CYLINDER MOUNT NUT TIGHTENING PROCEDURE WHILE RAM-TILT COUPLER TIGHTEN NYLOCK NUTS ON UNTIL THERE IS NO GAP B WASHER & CYLINDER CAG ***DO NOT FORCIBLY TIGH WHEN HITCH IS TILTED IT I NUT & WASHERS. DIMPLE ON PIN IDENTIFIES GREASE EXIT POINT MUST FACE UPWARDS ATMOSPHERE HARD PIN GREA LIP SEAL INSTALLED BACK TO FRONT I.E. NUMBERING FACING INWARDS & LIP OUTWARDS. SO GREASE WILL BLOW SEAL OPEN & GREASE TO WASTE WHILE KEEPING DIRT OUT HARD PIN HARD BU SECTION SHOWING TYPICAL PIN & HARD BUSH SEALING ARRANGEME 29

30 MAINTENANCE DAILY GREASING It is recommended that the Ram-Tilt is thoroughly greased ONCE DAILY for all 8 grease points OR every 2 hours if operating under water. This will help prolong the service life of and help maintain smooth operation of the attachment. 1 2 & & 7 8 It is essential that the Maintenance and Repair Log (page 38) is filled in at the time of carrying out maintenance or repair on the Ram-Tilt In the unfortunate event of an accident, this log may be vital evidence as to show compliance with Occupational Safety and Health requirements Work carried out on this Ram-Tilt must only be by an authorised person 30

31 MAINTENANCE 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. 31

32 MAINTENANCE 500 HOUR PREVENTATIVE MAINTENANCE VISUAL STRESS POINTS CHECK: Visually check the entire Ram-Tilt 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. Cage Lifting Eye Ear to baseplate at front Front jaw and safety latch region Hook region on slide Body where rear attachment pin interfaces 32

33 MAINTENANCE The slide hook will have free movement when new. To gauge the wear of the cast body and slide hook place an allen key as in image 1 to test the space between the slide hook and cast body. Please see the table below to verify the maximum wear of the cast body. GUIDELINE FOR MAXIMUM WEAR 6,8,14T 5mm 20,35,45T 7mm Image 1 The slide should sit below the bearing surface of the rear attachment pin no less than 3mm The maximum permissible wear of the bearing surface where the rear pin wedges against is 3mm If the Ram-Tilt body becomes worn or damaged in this area contact your local Calibre branch or authorised service centre immediately. 33

34 MAINTENANCE LATCH INSPECTIONS Manual Inspection of both the Front & Rear Latch is to be carried out to ensure safety latch movement is within acceptable safety tolerances as specified below. This is in addition to a daily visual check of the safety latch and usual wear and tear assessments. The Maximum Opening Distance should be compared to the Safe Allowable Variation Table. If the Maximum Opening Distance is LESS than the Maximum Allowable Opening Distance for the Ram-Tilt model, it is safe to use. FRONT LATCH Must fully RETRACT slide to lock safety latch Must LIFT UP latch & measure gap in between Use a ruler to measure the distance between the bottom of the jaw to the tip of the Safety Latch whilst pulled up with hand This measurement (mm) is the Maximum Opening Distance Maximum Opening Distance Safe Allowable Variation Table LIFT UP Model Attachment Pin Diameter (mm) Maximum Opening (mm) If the Maximum Opening Distance is greater than the Maximum Allowable Opening value for that Calibre Coupler model. Please contact Calibre service department for advice. 34

35 MAINTENANCE REAR LATCH Must fully EXTEND slide to lock safety latch Must PULL DOWN latch and measure gap in between Use a ruler to measure the distance between the bottom of the jaw to the tip of the safety latch whilst pulled up with hand Maximum Opening Distance Safe Allowable Variation Table Model Attachment Pin Diameter (mm) Maximum Opening (mm)

36 MAINTENANCE LIFTING EYE INSPECTION WARNING: The Lifting Eye requires visual inspection monthly. Model (Tonnage) Minimum Lifting Eye Width (mm) A Minimum Lifting Eye Width (mm) B Minimum Distance to Edge (mm) C Maximum Lifting Eye Hole (mm) D Visual check for cracking or deformation 2. Check for wear on the above chart 3. Damage to outer surface (A, B, C, D) must be with in the tolerances in above chart 4. If the Lifting Eye has exceeded recommended ratings - immediately stop using attachment Should you find any deformation and cracks anywhere on the Lifting Eye, please get in touch with Calibre immediately. 36

37 MAINTENANCE SHACKLE TABLE Model # W.L.L. Pin Diameter Width Standard AS AS RR-C RR-C AS AS RR-C RR-C AS AS RR-C RR-C AS AS RR-C AS RR-C RR-C

38 MAINTENANCE MAINTENANCE & REPAIR LOG DATE FAULT REPAIR BY WHOM 38

39 MAINTENANCE PARTS DIAGRAM 39

40 40 MAINTENANCE

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