Agriweld - 130C - Box Rotator User Manual

1 Operator Manual 130C Box Rotator www.agriweld.co.uk The Workshops Main Street Garton-on-the-Wolds Driffield, YO25 3ET Tel: 01377 259140 Fax: 01377 259141 Email: sales@agriweld.co.uk 2 Contents Page Page 3 User Information & Getting Started Page 4 Safety, Dangers, operating errors and exemption from liability, Qualification & Training Page 5 General Safety Page 6 Important safety instructions Page 7 Connection to the forklift/loader Page 8 Adjustment Page 9-10 Rules of conduct of Operation and Operation Page 11-12 Maintenance Page 13 Acquiring spare parts and disposing of replaced parts Page 14 Full assembly Page 15 Back plate Page 16 Carriage Page 17 Parts list Page 18 Main shaft and hub assembly Page 19 Top arm Page 20 Side arm Page 21 Rams, pallets forks and bolt on brackets Page 22 Forklift brackets Page 23 Hydraulic lid (if applicable) Page 24 Lid pitch adjustment Page 25 Stickers and warranty Page 26 C E Declaration of Conformity 3 User information Before using your 130C Box Rotator for the first time it is IMPORTANT that all operators make themselves familiar with the unit and must read this OPERATOR MANUAL and SAFETY INSTRUCTIONS attentively. Getting started The 130C Box Rotator will be fitted and delivered with the correct Bolt-On brackets/carriage blocks to suit the fork-lift/loader it is intended to fit. SEE BOLT ON BRACKETING INSTRUCTIONS AND BOLT SPECIFICATIONS SECTION FOR FULL INFORMATION. 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. The 130C Box Rotator 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 ATTEMPT 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. The 130C Box Rotator is a low maintenance unit, and requires little mechanical attention as such, other than greasing the main shaft, radius arm and hydraulic ram/rod ends at the greasing points located and visible at these areas and by following a general basic care routine. Your 130C Box Rotator weighs 425kg excluding bracketing and has a max loading of 2.0 tonnes NOTE: During use, please be aware of increased weight due to shock loading. This includes performing manoeuvres such as driving down a rough field, at some speed, with a full box. The resulting bouncing effect is known as shock loading and the weights can be significantly magnified to the point of overload. The 130C Box rotator is not to be used for any other purpose than for which it is intended - that is the lifting and rotating of one box containing free flowing product at a time. It is not to be used as a forklift. Damage to the unit resulting from overload will not be covered under a warranty or liability claim. The specifications, descriptions and illustrations in this manual are accurate at the time of publication but may be subject to change. 4 Safety All operators of the 130C and forklift/loader must hold the appropriate forklift license or certificate of competence to do so. All operators must be familiar with the 130C Operator 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. Dangers, operating errors and exemption from liability 1. No responsibility will be accepted for possible dangers arising from operations complying with the designated use. 2. Damage to agricultural produce particularly vulnerable to damage during processing cannot be entirely ruled out. Weather conditions, the quality of the produce and many other circumstances beyond our or the operator’s control have an influence on the vulnerability to damage of the produce being processed. For example, when processing potatoes the submerged weight of the potatoes, the manuring (nitrogen content) of the potatoes, the degree of maturity (firmness of the skin) of the potatoes, the temperatures during processing and many other circumstances can have an influence on the vulnerability to damage. These examples do not claim to be exhaustive. 3. To avoid damage to agricultural produce the user must adapt the machine to the respective operating conditions. The results produced by the machine must be constantly monitored and checked. 4. Agriweld shall not be liable for any damage to agricultural produce and other items, which occurs as a result of normal operating, adjustments errors or other incorrect usage. 5. Agriweld accepts no liability for any damage caused as a result of operations not complying with the designated use of the machine. This also applies to damage to agricultural produce caused by certain external influences, which cannot be avoided with the current state of the art. Qualification & training Only personnel with the appropriate forklift/loader license are authorised to use this machine. Statutory minimum age limits must be observed and reliable personnel only should perform maintenance/work on this machine. 5 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 loose-fitting clothing to avoid the risk of snagging and trapping. Ensure that you are working in an area clear of obstructions and watch out for wandering individuals (particularly children). 6 Important safety instructions Take extra care when attaching the 130C 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 are in full working order. Never allow any person to stand between the forklift/loader and the 130C during connection or at any time. Never exceed the permissible weight of the box and its contents for handling. Ensure that the side and top arms are set in accordance with the OPERATOR INSTRUCTIONS in relation to the sizes of box being handled at the time and NOTE that this may need adjustment for different sized boxes. Take into account the protrusion of the 130C pallet forks (a further 1200mm from the carriage of the unit) 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 sit or ride on the 130C at any time. Never perform any adjustments to the 130C whilst mounted, unless the forklift/loader is stopped, turned off and the 130C 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 130C or the forklift/loader it is attached to, at any time. Keep clear of unit discharge to avoid being hit by stray produce. 7 Connection to the forklift/loader The 130C 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 CARRIAGE BLOCKS require the following fittings; 8 X M20 X 50mm counter sunk socket head setscrew BZP - high tensile 10.9 8 X M20 high tensile grade 8.8 Nylock nuts 8 X M20 good quality washers (fitted nut side.) IMPORTANT NOTE (FOR YARD TRUCKS - Excludes telehandlers) CARRIAGE BLOCKS ONLY REQUIRE THE TOP BLOCK FITTING WITH “LOCKTITE” Top blocks are pre LOCKTITED before dispatch but will require LOCKTITE again if removed and re-fitted at any time. 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. Attachment Stand the 130C up the correct way using the lifting eye on the top catcher arm, 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 box rotator. For Carriage blocks, drive forward and locate the forklift carriage with the top block ensuring the centre castellation is lined up with the notch inside the top block to prevent unwanted movement left or right. Lift the unit off the ground enough to give access to bolt the bottom blocks in position, (remember to LOCKTITE). Attach the hydraulic hoses via the pipes and fittings supplied to fit your forklift/loader whilst it is TURNED OFF. YOU ARE NOW READY FOR OPERATION. 8 Adjustment The 130C requires immediate adjustment of the top and side arms and pallet forks in relation to the size of boxes you will be handling. This will require repeating when you change to different size boxes. Set the pallet forks using the latches located on the top of the fork to the maximum width your boxes can take for stability. Set the top arm 50mm or so higher than the height of the box and the same for the side arm to allow for driving in and out of the box. The arms are adjusted simply via a pin system at 100mm increments. Ensure the pin is fully located and the lynch pin is replaced to prevent the pin working loose. The 130C is a high visibility unit and the pallet forks can be seen below the rotators carriage and back plate to guide you into the box. The side arm will also enable you to gauge access to the box. The adjustment range of the 130C arms/forks are as follows: TOP ARM (taken from top of pallet fork to underside of arm) MINIMUM HEIGHT: 913mm MAXIMUM HEIGHT: 1213mm SIDE ARM (taken from centre of carriage) MINIMUM WIDTH: 709mm MAXIMUM WIDTH: 909mm PALLET FORKS (outside to outside) MINIMUM WIDTH: 811mm MAXIMUM WIDTH: 1211mm 9 Rules of Conduct for Operation The following points must always be observed before the machine is started up and during operation: - Never leave the machine unattended. - Check the machine regularly for oil leakage. Replace defective components immediately. - The user is responsible for damage to the produce caused by oil leakage. - Check the machine for dirt accumulation and clean it on a regular basis. Rules of conduct when handling the hydraulic system DANGER The hydraulic system is under high pressure Fluids escaping under high pressure can penetrate the skin and cause serious injuries If such injuries occur, call a doctor immediately as otherwise there is a risk of serious infection Consequently: Work only on the hydraulic system when the hydraulic system is depressurized and the drive is switched off. Note All components of the machine are driven hydraulically. Replace defective hose connections immediately. The user is responsible for damage to the produce caused by oil leakage. Speed Restriction Your box rotator is fitted with 2mm restrictors in the hydraulic system to set the speed. As a personal preference if you require rotation speeding up or slowing down these restrictors can be changed simply, please contact us to discuss your requirements and we can supply the relevant restrictors and instructions how to change them yourself. Operation Once the 130C is attached to the forklift/loader correctly and adjusted for the correct box size you can begin operation. The following step by step procedure will take you through the basic operation of the machine; 10 The 130C is a high visibility unit and the pallet forks can be seen below the rotators carriage and back plate to guide you. The side arm will also enable you to gauge access to the box. Drive in to collect a full box until it touches the 130C’s carriage (as far back as it will sit) Ensure that the 130C is not tilted forwards on the forklift/loader as the box could slide off. Pick up the box, and tilt the rotator back slightly to keep the load against the carriage and drive to the desired tipping point. Position the forklift/loader so that on rotating the box the product will fall as required. As standard the 130C will tip to the left (from the driver’s seat of your forklift/loader). Begin rotation. Ensuring that the forklift carriage and 130C is NOT tilted forwards to prevent the box sliding off. The speed is pre-set before delivery and you do not need to worry about “feathering” the controls as the rotator will rotate at a steady speed without jarring. Once the box is empty, rotate the box fully back. It will return to level. Drop the box off where required. On leaving the box it is easier to slightly tilt the forklift carriage forwards to aid exit from the box. If you decide not to empty the box fully, the 130C will return to level if required with a part full box. Repeat the process. REMEMBER TO ADJUST THE BOX ROTATOR SIDE AND TOP ARMS FOR DIFFERENT BOX SIZES. TOO MUCH SPACE BETWEEN THE BOX AND ARMS OF THE ROTATOR IS DANGEROUS AS EXCESSIVE FREE MOVEMENT COULD RESULT IN LOSING THE BOX OFF. 11 Maintenance Regular maintenance is a prerequisite for good operational reliability. The following safety advice is to be observed before starting any maintenance, cleaning or repair work. Trained personnel may only execute maintenance activities. Inform operating personnel before beginning special operations and maintenance work Delegate a supervisor If necessary, ensure that the maintenance area is adequately secured. Use suitable tools and wear gloves when working on the machine Switch off the machine completely for maintenance and repair work and ensure that it is protected against inadvertent starting by: - Locking the principal controls and removing the ignition key and/or - Detaching the hydraulic supply. Carry out maintenance and repair work only when the machine is positioned on stable and level ground and has been secured against involuntary movement and toppling. To avoid the risk of accidents, individual parts and larger subassemblies being moved for replacement purposes should be carefully securely attached to lifting tackle. Use only suitable hoisting and lifting gear with adequate load capacity, which is in proper working condition. Never work or stand under suspended loads The securing of loads and the instruction of crane operators should only be entrusted to experienced persons. A signaller giving instructions must be within sight of the crane operator or must be provided with a radio link. For carrying out overhead work, always use specially designed facilities or safe ladders/ platforms. Never climb on the machine itself Wear a safety harness when carrying out maintenance work at greater heights. Clean the machine, especially connections and threaded unions, of any traces of oil, fuel or preservatives before carrying out maintenance/repairs Never use aggressive detergents. Use lint-free cleaning cloths. Before cleaning the machine with water or steam jets (high-pressure cleaners) or other cleaning agents, cover or tape all openings which – for safety and operational reasons – must be protected against ingress of water, steam or cleaning agents. 12 After cleaning, examine all fuel, lubricant and hydraulic oil lines for leaks, loose connections, scuffing marks and damage. Any defects found must be rectified without delay. Always retighten any screwed connections that have been unscrewed during maintenance and repairs. Any safety devices removed for setting-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work and prior to operation. We recommend greasing using a good quality general purpose grease weekly whilst working under normal conditions, and twice weekly under extreme use and or very dry/dusty conditions. Instructions ? Whilst connected to the Forklift/loader grease all parts (main pivot, radius arm, hydraulic cylinders) using 3 pumps from the gun. ? Being aware of your own safety/safety of others, rotate the machine through 130° and repeat the process. ? Rotate machine on forklift/loader back and forth several times to work the new grease in. ? You are now ready to use the machine again. It is important to follow the recommended greasing routine to protect your 130C from damage and prolong the lifespan of its main operating parts. Failure to carry out this maintenance may result in your warranty becoming invalid due to non-maintenance. 13 Acquiring spare parts Please quote the details on the type plate(s) as well as the machine’s serial no. on every order for spare parts or accessories, or enquiries of a technical nature. The use of spare parts supplied by others shall only be permitted after consultation with the manufacturer. Original spare parts and accessories authorised by the manufacturer ensure safe and reliable operation. The use of other parts may invalidate the liability of the manufacturer for any consequences arising from such use. Disposing of replaced parts The following points should be observed before replacing or disposing of parts. - Replaced parts, which still function, should be cleaned and stored in an orderly manner. - Machine parts, which cannot be repaired should only be disposed of at appropriate collecting points or be collected by a scrap metal dealer. - So-called “valuable” materials should be disposed of in a proper way, i.e. plastics, rubber, scrap metal, etc. should be recycled. - Collect and dispose of old oil in accordance with the current regulations. 14 Full assembly Total Weight (Including Brackets) – 425KG This is an approximate weight due to different types of bracketing. Forklift Brackets (Example) Back Plate Top Arm Adjustable Box Support Side Arm Box Support Side Arm Socket Ram Carriage Pallet Tynes 15 Back plate Item Number Part Number Description Quantity per Machine 1 AW_130_301 Back plate 1 2 WK_130_005 Main Shaft 89.9mm Diameter 1 3 WK_180_200 Top Ram Pin 30mm Diameter 1 4 M20 x 80 Counter Sunk Bolt 10.9 High Tensile Strength 8 5 M20 Flat Washer - 8 6 M20 Nyloc Nut - 8 7 M30 Flat Washer - 1 8 LP6Z Linch Pin 1 1 2 3 4 5 6 7 8 16 Carriage 1 2 3 4 5 7 8 9 6 10 11 12 13 14 15 16 17 18 17 Parts list Item Number Part Number Description Quantity per Machine 1 AW_130_302 16” Carriage 1 2 WK_130_003 Main Hub with a Phosphor Bronze centre. 1 3 AW_130_020 Side Arm Socket (30mm) 1 4 AW_130_021 Side Arm Socket (30mm) 1 5 AW_130_145 Side Arm Socket (6mm) 1 6 AW_130_130 Side Arm Socket (12mm) 1 7 AWARGI017_130 Top Arm Socket (6mm) 1 8 AWARGI016_130 Top Arm Socket (6mm) 1 9 AW_130_135 Top Arm Socket (12mm) 1 10 AW_130_110 Tyne Stop (12mm) 1 11 WK_130_001 Carriage Pin 1 12 M30 Flat Washer - 1 13 LP6Z Holds ram in place. 1 14 LP11Z Linch Pin 2 15 Z319.075 Side and top arm pin 2 16 M12 x 50 Bolt 2 17 M12 Flat Washer - 4 18 M12 Nyloc Nut 2 18 Main shaft and hub assembly Item Number Part Number Description Quantity per Machine 1 M6 Straight Grease Nipple Set in main shaft 1 2 D1400-090 (EXT 90mm) Circlip 1 3 130_Washer 1 1 2 3 19 Top arm Item Number Part Number Description Quantity per Machine 1 Solid_100x50_130 Top arm height adjustment 1 2 Box_100x50_130 - 1 3 AWARGI011A Top arm length adjustment 1 4 AWARGI013 - 1 5 AW_130_100 8mm Strengthener profile 1 6 AW_130_115 12mm Pipe holder and lifting point profile 1 7 M16 Flat Washer - 1 8 M16_LN Lock Nut 1 9 M16 x 40 Bolt 1 1 2 3 4 5 6 7 8 9 20 Side arm Item Number Part Number Description Quantity per Machine 1 SOLID_100x50 Side Arm 1 2 Box Section_100x50 Side Arm 1 3 100x50 End Cap - 1 4 AWARGI012A Box Support 1 5 AW_130_125 Strengthener Plate 1 6 AW_130_140 Strengthener 1 7 M12 x 140 Bolt 2 8 M12 Nyloc Nut 2 9 M12 Flat Washer - 4 1 2 3 4 5 6 7 8 9 21 Rams and pallet forks and bolt on brackets Item Number Part Number Description Quantity per Machine 1 CY_705_4_(40_80) Back plate to Carriage Ram 1 2 Class 2B Pallet Fork 2 1 2 22 Forklift brackets Bolt on brackets for a JCB example. 23 Hydraulic lid (if applicable) 24 Lid pitch adjustment It helps access to the box if the lid pitch is set higher at the front. Adjust using bolt (1) ITEM NUMBER PART NUMBER DESCRIPTION QUANTITY PER ASSEMBLY 1 M24X100 BOLT 2 2 M 24 WASHER FORM C 2 3 M24 NUT NYLON INSERT 1 4 M24 NUT PLANE LOCKING NUT 1 1 2 3 4 25 Stickers Warranty Your Agriweld 130C is covered for a period of 24 months from the date of delivery (which is recorded on our files) against faulty components and/or bad workmanship. Our welders are coded to BS EN 287-1and our welding procedures are approved in accordance with: BS EN ISO 15614-1 to manufacture your equipment and all products are checked for quality prior to delivery/collection. We cannot be responsible for claims arising from ignorance, occurrences outside our control, such as accidents, and malicious damage. Damage occurred during transit must be reported on signing for the item from the haulier to enable us to make a claim for damages caused during transport. Sticker Part number Description Quantity per Machine AW_130C 180C Sticker 2 AW_130_AS (185 mm x 85mm) Agriweld Sticker 2 AW_130_GB (85mm x 50mm) Great Britain Sticker 2 AW_130_GNS Grease nipple Sticker 2 26 CE DECLARATION OF CONFORMITY The equipment which accompanies this declaration is in conformity with EU Directive(s):- 2006/42/EC Machinery Directive Manufacturer Name: Agriweld Ltd Manufacturer Address: Main Street Garton-on-the-Wolds Driffield East Yorkshire YO25 3ET Product: 130C Box Rotator Product Options: All Individual Serial Number: Product Description: AGRIWELD 130C Box Rotator Date of Last Load Test Report: N/A Supplementary Information: Authorised Signatory on Behalf of Manufacturer: Name of Signatory: Dawn Foster Position in Company: Director Date of Issue: