OPERATION & MAINTENANCE MANUAL

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1 THUMB Imagery does not reflect actual product size T2017A OPERATION & MAINTENANCE MANUAL 1

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3 CONTENTS INTRODUCTION Owner Information 5 Warranty Registration 6 Key Features 7 To the Owner 8 SAFETY Safety Instructions 9 Pre-Start Check List 10 INSTALLATION PROCEDURE Installation 12 General Maintenance & Servicing 16 Suggested Greasing Product 17 OPERATION Hydraulic Requirements & Plumbing 18 Plumbing Circuit Diagram 19 Operating and Procedure 20 Precautions 21 MAINTENANCE Maintenance & Repair Log 22 Parts Diagram 23 T2017A 3

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5 INTRODUCTION OWNER INFORMATION Thank you for choosing to purchase your new Calibre (Thumb) from Calibre Contracting Equipment s (Calibre) range of earthmoving products. This manual contains important information about the installation, maintenance and safe operation of your Thumb. You can assist in this proactive safety approach by ensuring that all persons involved with the fitting and operation of the Thumb, 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 Thumb 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 Thumb 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 Thumb 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 Thumb. T2017A 5

6 INTRODUCTION WARRANTY REGISTRATION Upon purchasing your Thumb 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 Thumb. The Operator accepts that he/she is responsible for understanding safety and operation features of the Thumb. NAME: POSITlON: COMPANY: SIGNATURE: THE PURCHASER SHALL: Follow the recommended installation, testing and maintenance and operating procedures Comply with safety and training guidelines for use of equipment (not totally exclusive) Keep an accurate maintenance, operation, malfunction and repair log of equipment Ensure that the equipment is used for the purpose it was intended for 6 T2017A

for additional stiffness Compact within parked

7 INTRODUCTION KEY FEATURES Smart Valve Technology incorporated into cylinder Reinforced base plate for additional stiffness Compact within parked position No parking pin required Adjustable Thumb arm 7 7

8 INTRODUCTION TO THE OWNER As the new owner and/or operator of the Thumb 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 Thumb is obliged to ensure that the equipment is always in safe working order in accordance with accident prevention regulations, Occupational Safety and Health or any other official instructions. WARRANTY REGULATION Calibre provides guarantees according to its sales and delivery conditions, extended to twelve months from delivery. The extended guarantee assumes proper operation and use as intended but will be nullified as a result of: Repairs or other intervention not undertaken by persons authorised by Calibre With use of accessories or replacement parts not approved by Calibre or which are not original replacement parts supplied by Calibre After the warranty period has expired, we strongly recommend the use of original replacement parts and manufacturer s replacement parts approved by Calibre. 8 T2017A

9 SAFETY SAFETY INSTRUCTIONS This safety alert symbol indicates important safety messages in this manual. When you see this symbol carefully read the message that follows and be alerted to the possibility of personal injury or death. WARNING: Incorrect operation of this machine can cause injury or death. Before using this machine make sure that every operator: Is instructed in safe and proper use of the attachment Reads and understands the manual pertaining to the attachment Reads and understands all safety decals and tags on the machine Clears the area of all other persons Learns and practices safely using attachment controls in a safe, clear area before operating this machine on a job site It is your responsibility to observe pertinent laws and regulations and follow Calibre instructions for operation and maintenance. T2017A 9

10 SAFETY PRE-START CHECK LIST Location: Date: Ref no: Hazards Identified: Work equipment Lifting devices Ergonomics Entanglement Crushing Access / exit Slip, trip and fall Plant movement Warning devices on equipment Noise Vibration Fumes Environmental People Affected YES NO N/A Involved in activity Close to activity Everyone on site Members of the public Expected Precautions YES NO N/A Has the operator been adequately trained on the use of the Thumb in general? Is there a checklist of daily and weekly inspections? Is there cab instructions for the Thumb? Personal Protective Equipment (PPE) Hard Hat High Visibility Vest Safety Boots Gloves Ear Protection Safety Glasses Other Management Assessed by: Name: Date: Reported to: Name: Date 10 T2017A

11 SAFETY Operator s Name: Calibre Serial No.: Calibre Model: Date: In Cab Operating Instructions (labels) Operating and Maintenance Manual M O N T U E W E D T H U F R I S A T S U N Hydraulic System Wear or damage to hoses or fittings Security of hoses Hydraulic oil leaks Thumb Coupler 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 T2017A 11

12 INSTALLATION PROCEDURE INSTALLATION STEP 1: CHECK EXISTING DIPPER SURFACE FOR DOUBLER PLATES/WEAR BARS Some machines have a doubler plate or wear bars welded to the inside of the dipper arm. Before fitting the thumb to the dipper arm these have to be modified. If your machine has a doubler plate (Fig 1.1), it may need to be extended by adding a doubler extension (Fig 1.2), this is to ensure a good weld all around the end of the Thumb baseplate. The doubler should be wider than the Thumb baseplate by 8-10mm to allow a good fillet weld (also refer step 3 for a positioning suggestion). Doubler extension Doubler Fig 1.1 Doubler Fig 1.2 If your machine has wear bars (Fig 1.3), you will need to remove these and grind the area smooth so the Thumb will sit flat on the dipper. Wear bars Fig T2017A

13 INSTALLATION PROCEDURE STEP 2: TRIM THUMB BASEPLATE WIDTH (IF NECESSARY) Because different machines have different dipper widths, the thumb baseplate provided is made to the widest known dipper width. This means that the baseplate may need to be trimmed in width to suit your machine. Depending on your machine you may need to trim the sides of the baseplate to: A) Line up with the welds that join the dipper arm top and side plates (Fig 1.4). Dipper Arm Welds aligned Thumb baseplate Fig 1.4-Section through Dipper Arm and Thumb B) Fit approximately 8-10mm within any doubler plate or extension welded to dipper (Fig 1.5). Doubler T2017A Fig

INSTALLATION PROCEDURE STEP 3: LAYOUT OF THUMB 1. Put the attachment with the greatest forward protrusion on the machine/hitch and fully crowd attachment towards machine. 2.

14 INSTALLATION PROCEDURE STEP 3: LAYOUT OF THUMB 1. Put the attachment with the greatest forward protrusion on the machine/hitch and fully crowd attachment towards machine. 2. Position the Thumb assembly so the closest point of the Thumb is approximately 50mm to the closest point of the equipment on the dipper (Fig 1.6). Note: this will also allow you to measure the distance you will need to increase the doubler by at the other end (refer Step 1). 20 TIP: Use a piece of 20mm to set the gap Fig 1.6 Once positioned, stitch weld (approx. 20mm stiches) each side of the Thumb baseplate to the dipper arm in locations shown in Fig 1.7. Standing clear of the Thumb and attachment, crowd the attachment in/out and open/close the Thumb to check the Thumb operates in the desired range. Stitch weld Fig T2017A

15 INSTALLATION PROCEDURE STEP 4: WELDING WARNING: Never weld straight across the dipper as this can cause the dipper arm to crack/fail along the weld. Always curve/angle plates running across the dipper arm. Make sure machine or batteries are isolated before welding. 1. Ensure that the earth lead is attached near the cylinder mount. DO NOT attach earth lead to the hydraulic cylinder. 2. Grind all surfaces that will be welded before welding. 3. The welds should be a well penetrated fillet of approximately 8-10mm all around. 4. Ensure to weld the baseplate to the dipper inside all plug welds provided. 8-10mm fillet weld all around Fig 1.8 T2017A 15

16 DAILY MAINTENANCE - Grease all grease points twice daily (see greasing tips) - Remove solid materials, stones etc from around moving parts - Check hoses and fittings for signs of leak or wear - Check all pin retainer bolts and nuts for tightness - Check hydraulic cylinder mounting bolts for tightness - Check for damage and cracks INSTALLATION PROCEDURE GENERAL MAINTENANCE & SERVICING GREASING Greasing must be carried out twice daily! We recommend before starting work, and before restarting after lunch. 16 T2017A

17 INSTALLATION PROCEDURE SUGGESTED GREASING PRODUCTS SUGGESTED REQUIREMENTS: NLGI Grade 2 Lithium Complex Base Better ones contain 3-5% Moly (MoS2/ Molybdenum Disulfide) additive Base Oil 40 degrees C exceeds 300 cst Exceeds 28kg on Timken OK Load Test Contains high tack / adhesive qualities / Resists water washout SUGGESTED PRODUCTS: Moreys BigFoot EP2 Moreys Moly Complex EP2 Moreys Super Red Premium Waterproof Cat Ultra 3Moly Grease NGI2 Trans Diesel Super Red Lith Tac EP2 Shell Gadus S3 V460D Mobil Grease XHP 462 Moly Any Mobil XHP 460 Grease Gulf Western Red Lith Tac GENERAL NOTE: Recommended greases are generally hard to pump because of their high viscosity. A quality 10000psi gun will give guaranteed results. T2017A 17

18 OPERATION HYDRAULIC REQUIREMENTS & PLUMBING THUMB CIRCUIT REQUIREMENTS Operating Pressure PSI Hose/ Tube Size 3/8 Minimum Flow Rate 15 LPM Min. 47 LPM Max. (must not be exceeded) Port Connecting (Calibre Supplied) 3/8 BSPP Female x3 *Ensure that the operating hydraulic pressure is set at a minimum of 206 Bar (3000PSI) on A and B line. Pressure and flow need to be checked at connecting hose to Thumb cylinder. 18 T2017A

19 OPERATION PLUMBING CIRCUIT DIAGRAM T2017A 19

20 OPERATION OPERATING AND PROCEDURE TO OPEN 1. Extend dipper arm close to horizontal 2. Extend SHS (square hollow section) arm fully until it stops 1. Retract cylinder slightly until it stops 1. Thumb should drop slightly over centre under its own weight 2. Extend the cylinder to move the Thumb outwards. Thumb is ready to use. Tip: If the thumb doesn t drop slightly under its own weight, pulse the cylinder controls open/closed. TO CLOSE 1. Tuck in dipper arm close to machine 2. Retract cylinder fully until it stops 1. Thumb should drop slightly over centre under its own weight. 1. Extend cylinder fully to close Thumb onto stops 2. Retract SHS (square hollow section) arm 20 T2017A

21 OPERATION PRECAUTIONS A Calibre Thumb is a medium duty piece of equipment not to be used for purposes where a heavy duty Power Claw or grab type attachments would otherwise be used. The Thumb is designed to be used in conjunction with a standard bucket and should only experience forces exerted by the opposing bucket as shown below. Care needs to be taken when the Thumb cylinder is fully extended, that the thumb does not experience any loading that tries to over extend the cylinder. (e.g. when the dipper is being moved towards the operator and the thumb catches onto an object). Failure to do so will result in evident damage to the cylinder end and will VOID ANY WARRANTIES. THE CALIBRE THUMB IS DESIGNED TO HOLD A LOAD AGAINST A SUITABLE BUCKET OR RIPPER: ü FORCE û FORCE Do not exert load on the back of the Thumb (e.g. Do not pull anything towards the cab with the Thumb) Do not exert load on the side of the Thumb (e.g. do not slew) Do not pull stumps or other items out of the ground with the Thumb Do not use with items longer than the machine width If fitted with tilting coupler, do not tilt coupler with Thumb extended Always ensure that any tilting hitches or buckets are locked in a horizontal position and cannot creep or tilt before using the Thumb Always ensure that the centre of gravity of the load is in line with the centre of the dipper and Thumb Always ensure that the ram and base are free from dirt or debris when extending or retracting the Thumb Always ensure that any people or property are well clear of your work area T2017A 21

22 MAINTENANCE MAINTENANCE & REPAIR LOG DATE FAULT REPAIR BY WHOM 22 T2017A

23 MAINTENANCE PARTS DIAGRAM T2017A 23

24 MAINTENANCE 24 T2017A

25 T2017A 25 January Version 2017

26 CALIBRE Contracting Equipment Australia 59 Magnesium Drive, Crestmead, Australia CALIBRE Contracting Equipment New Zealand 49 McLaughlins Road, Wiri, Auckland T2017A

FRONT & REAR LOCK OPERATION & MAINTENANCE MANUAL

RAM-TILT COUPLER Imagery does not reflect actual product size FRONT & REAR LOCK OPERATION & MAINTENANCE MANUAL CONTENTS INTRODUCTION Owner Information 4 Warranty Registration 5 Key Features 6 Ram-Tilt