Case TPV 600 FH SERIES TPV 700 FH SERIES Polyp Grab Operator's Manual - PDF DOWNLOAD

ORIGINAL INSTRUCTIONS

- according to Directive 2006/42/EC, Annex I, 1.7.4.1

TPV 600 FH SERIES TPV 700 FH SERIES Polyp Grab

OPERATOR’S MANUAL

Part number 51544749 1st edition English December 2018

Polyp Grab

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Table of Contents

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OVERVIEW

TABLE OF CONTENTS 0 OVERVIEW 1.

2.

3.

4.

5.

Purpose of the Instructions Manual How to read the Instructions Manual How to preserve the Instructions Manual Intended readers Glossary and symbols

1. GENERAL INFORMATION 1.

2.

3.

4.

Identification data and equipment plate Safety Regulations Preparations to be made by the customer General warranty conditions

4. INSTALLATION 1.

2.

3.

4.

5.

6.

Transport and handling Storage Coupling check Assembling the equipment Connections Stopping and disassembling the equipment

5. USE OF THE EQUIPMENT 1.

2.

3.

4.

5.

Starting the equipment Operation cycle Stopping the equipment Decommissioning the equipment Waste disposal 6. Dismantling the equipment

2. SAFETY 1.

2.

3.

4.

5.

6.

7.

General warnings Safety requirements Hazard zones Stickers on the equipment Pictogrammes related to safety Personal protective equipment (PPE) Residual risks

3. EQUIPMENT DESCRIPTION 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

Equipment description Intended use Contra-indications for use Environmental conditions Technical data Position of stickers Lighting Vibrations Noise emissions Standard supply

6. MAINTENANCE 1.

2.

3.

4.

5.

Isolating the equipment General instructions Ordinary maintenance Scheduled maintenance Supplementary maintenance 6. Diagnostics and troubleshooting

7. SPARE PARTS 1. Spare parts

8. DECLARATION OF CONFORMITY 1. Declaration of Conformity

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OVERVIEW

DESCRIPTION Purpose of the Instructions Manual

1. PURPOSE OF THE USE AND MAINTENANCE INSTRUCTIONS MANUAL This Manual is an integral part of the equipment, and it is intended to provide all the necessary information for: Properly making operators aware of safety problems; Handling the equipment, while it is both packed and unpacked, in safety conditions; Installing the equipment correctly; Deeply knowing its operation and its limits; Using it correctly in safety conditions; Performing maintenance operations, in a correct and safe manner; Dismantling the equipment in safety conditions and in compliance with the regulations in force related to the protection of health at the work place and of the environment.

The operators in charge of using this equipment, have the obligation, according to the regulations in force, to carefully read the content of this document, and to have it read by the drivers and maintenance engineers in charge, for the parts falling within their competence.

The time spent to such end will be largely rewarded by the correct operation of the equipment and by its use in safety conditions.

This document assumes that the safety and industrial hygiene regulations in force are observed in the places where the equipment is intended to be used. This Manual contains reserved technical instructions, drawings and documents that are the exclusive property of the manufacturer, and may not be reproduced in any way, in whole or in part.

The limits of this Manual are the following ones: The Manual may never replace the user’s suitable experience; For those operations that are particularly challenging, the Manual can constitute only a reminder of the main operations.

The Manual is to be considered a part of the equipment and it must be preserved for future reference up to the equipment final dismantling. The Manual must be available for consultation near the operating machine, and it must be correctly preserved. This Manual observes the state of the art at the time when the equipment was sold, and it must not be considered to be unsuitable only because it was subsequently updated according to new experiences. The manufacturer has the right to update production and the Manuals without the obligation to update production and previous Manuals.

CASE CONSTRUCTION shall be exempted from any possible liability in the main following cases: Improper use of the equipment; Use against the specific national regulations; Incorrect installation (in case the equipment has been installed by unauthorised personnel); Power supply defects; Serious deficiencies in the foreseen maintenance; Unauthorised changes and operations; Use of spare parts or materials not specific for the model; Failure to comply, in whole or in part, with the instructions given; Use of the equipment with a machine that is not compatible; Exceptional events.

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OVERVIEW

DESCRIPTION How to read the Instructions Manual

2. HOW TO READ THE INSTRUCTIONS MANUAL The Manual has been divided into independent chapters, each one of which is addressed to a specific type of operator (INSTALLER, USER AND MAINTENANCE ENGINEER), for whom the skills that are necessary to operate the equipment in safety conditions have been defined.

The sequence of chapters follows the time logic of the equipment service life.

To facilitate the immediate understanding of the text, certain terms, abbreviations and symbols are used, and their meaning is indicated on par. 6.

The Manual consists of a cover, a table of contents and a series of chapters (sections).

NUMBERING OF PAGES

Polyp Grab Company Logo

XXXXXXX

Machine Name

Model

XXXXX Chapter Name

NUMBERING OF FIGURES Each figure is numbered progressively.

Numbering is made up as follows:

Fig. X.Y.Z Fig: Abbreviation Figure X = Chapter Y = Paragraph Z = Progressive number

X Chapter No.

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Rev. No. Chapter Page No.

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NUMBERING OF TABLES Each table is numbered progressively.

Numbering restarts from “1” every time a new section begins.

Numbering is made up as follows:

Tab. X.Y.Z Tab: Abbreviation Table X = Chapter Y = Paragraph Z = Progressive number ABBREVIATIONS Sec. = section Chap. = chapter Par. = paragraph Pag. = page Fig. = figure Tab. = table UNITS OF MEASUREMENT The units of measurement present are those foreseen by the International System (SI).

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OVERVIEW

DESCRIPTION How to preserve the Instructions Manual

3. HOW TO PRESERVE THE INSTRUCTIONS MANUAL The Manual must be kept carefully and go with the equipment every time its property is transferred throughout its service life.

Its preservation must be aided by handling it carefully, with clean hands, and by not resting it on dirty surfaces.

Its parts may not be removed, torn away or arbitrarily modified.

The Manual must be kept in a place protected from humidity and heat, and near the equipment to which it refers.

CASE CONSTRUCTION, upon the User’s request, may provide additional copies of the Manual.

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OVERVIEW

PAR. 4

DESCRIPTION Intended readers

4. INTENDED READERS This Manual is addressed to: the Installer, the Operator and the Qualified Personnel in charge of the equipment maintenance.

It is specified that “OPERATOR” means the personnel in charge of operating, adjusting, cleaning, and performing the ordinary maintenance of the equipment.

“QUALIFIED PERSONNEL or QUALIFIED OPERATOR” mean those persons who have attended specialisation or training courses, and have experience related to the installation, start-up, maintenance, repair and transport of the equipment.

“EXPOSED PERSON” means any zone inside and/or near an operating machine in which the presence of a person constitutes a risk for the safety or health of such person.

The equipment is intended for industrial, and, therefore, professional use, and not for widespread use; consequently, it can be used by qualified persons, who must particularly: • • • • • • • • •

Have reached their majority; Be physically and mentally able to carry out works characterised by particular technical difficulty; Have been particularly trained on the use and maintenance of the equipment; Have been assessed as suitable by the employer to perform the task assigned to them; Be able to understand and interpret the Manual and the safety requirements; Know the emergency procedures and how to implement them; Be able to operate the specific type of equipment; Be familiar with the regulations specific for each case; Have understood the operating procedures defined by CASE CONSTRUCTION.

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OVERVIEW

DESCRIPTION Glossary and symbols

5. GLOSSARY AND SYMBOLS This paragraph explains the abbreviations used, and the meaning of the symbols used to indicate the operator qualification and the status of the equipment. It quickly and unequivocally provides the information that is necessary for using the equipment correctly and in safety conditions.

HAZARD ZONE: Zone inside and/or near the equipment in which the presence of a person constitutes a risk for the safety and health of such person (See the safety regulations indicated below).

EXPOSED PERSON: Any person that is either wholly or partially in a hazard zone (See the safety regulations indicated below).

OPERATOR: Person in charge of installing, operating, adjusting, performing maintenance operations on, cleaning, repairing and transporting the equipment (See the safety regulations indicated below).

MAN-OPERATING MACHINE INTERACTION: Any situation in which an operator interacts with the equipment in any of its operating phases at any time of its life.

OPERATOR QUALIFICATION: Minimum level of the skills that the operator must have in order to carry out the operation described.

NUMBER OF OPERATORS: Number of operators that is suitable for performing the operation described in the best way, and which has been obtained after a careful analysis carried out by CASE CONSTRUCTION; therefore, the use of a different number of operators could prevent achieving the expected result or jeopardize the safety of the personnel involved.

RESIDUAL HAZARD: Hazard that could not be eliminated or sufficiently reduced by means of design, and against which protections are not (or are not completely) effective; the Manual includes information about their existence and the instructions and warnings to be followed in order to overcome them.

SAFETY COMPONENT: A component used to guarantee a safety function. The failure or incorrect operation of any safety component affects the safety and/or health of exposed persons. Some examples of these components are: movement equipment; fixed or mobile adjustable protector; electrical, electronic, optical pneumatic or hydraulic device that interlocks a protector, etc.).

INTENDED USE: The use of the interchangeable equipment must comply with the information included in the instructions for use (Annex I, 1.1.1 Directive 2006/42/CE).

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The descriptions preceded by this symbol contain very important information / requirements related to safety. Failure to comply with them may entail: • Hazards for the safety of operators; • Loss of the contractual warranty; • Waiver by CASE CONSTRUCTION. SYMBOLS RELATED TO THE OPERATOR QUALIFICATION

Symbol

Description

General unskilled worker: an operator who does not have specific skills, and who is able to perform only simple tasks following the indications of qualified technicians.

Driver of transport vehicles: an operator who is qualified to use vehicles for transporting materials and machines (strictly following the instructions given by CASE CONSTRUCTION), in compliance with the legislation in force in the country in which the machine is to be used.

1st level machine driver: an operator who does not have specific skills, and who is able to perform only simple tasks, i.e. driving the machine by using the push-buttons on the push-button panel, loading and unloading the materials used during production, with the protections installed and enabled; these operators are not qualified to use the machine with operation having a control held down (JOG).

2nd level machine driver: personnel who are able to perform the tasks carried out by 1st level drivers and, in addition, who are able to operate the machine having a control held down (JOG), in order to typically perform simple operations related to production start or production resumption after a stop and adjustment.

Mechanical maintenance engineer: qualified technician who is able to drive the machine in normal conditions, to operate it having a control held down (JOG) with protections disabled, to perform operations on mechanical parts in order to carry out the necessary adjustments, maintenance works and repairs. These operators are not usually qualified to work on electrical installations with the presence of voltage.

CASE CONSTRUCTION technician: qualified technician made available by CASE CONSTRUCTION to carry out complex operations in particular situations or, in any case, as agreed with the user.

Skills are, depending on the cases, mechanical and/or electrical and/or electronic and/or software.

Tab.0.6.1

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GENERAL INFORMATION

PAR. 1

DESCRIPTION Identification data and equipment plate

1. IDENTIFICATION DATA AND EQUIPMENT PLATE Every piece of equipment is identified with a CE plate (Fig. 1.1.1) showing the reference data.

For any information with the CASE CONSTRUCTION authorised dealer, indicate these reference data accurately and completely.

Fig. 1.1.1 CAUTION! The plate is affixed to the equipment in a protected position that is easy to read. Its position may vary from one model to another one.

The identification plate contains the following data: 1. Type / Model 2. Serial number 3. Part number 4. Year of manufacture 5. Weight in Kg 6. Excavator oil flow 7. Excavator working pressure

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GENERAL INFORMATION

PAR. 2

DESCRIPTION Safety Regulations

2. SAFETY REGULATIONS The equipment has been manufactured in compliance with the safety regulations listed below: UNI EN ISO 12100

Safety of machinery - Basic concepts, general principles for design - Risk assessment and risk reduction

UNI EN ISO 13857

Safety of machinery - Safety distances to prevent hazard zones being reached by upper and lower limbs Safety of machinery - Minimum gaps to avoid crushing of parts of the human body

UNI EN 349:1993+A1:2008 UNI EN 474-1:2006+A3:2013

Earth-moving machines - Safety - General requirements

UNI EN 475-5:2006+A3:2013

Earth-moving machines - Safety - Requirements for hydraulic excavators

NOTE! The regulations specified in this Manual cannot provide protection from particular situations that may arise during the different work phases.

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GENERAL INFORMATION

PAR. 3

DESCRIPTION Preparations to be made by the customer /installer

3. PREPARATIONS TO BE MADE BY THE CUSTOMER/INSTALLER Without prejudice to any different contractual agreements, the Customer/Installer are usually in charge of: •

•

•

Preparing the work place/area and the work equipment in compliance with the specific Safety Regulations foreseen by the legal provisions in force in the country in which the equipment is to be used; Checking - in compliance with the specific Safety Regulations foreseen by the legal provisions in force in the country in which the equipment is to be used - the correct coupling with the operating machine; The hydraulic pressure supply of the equipment, in compliance with the Regulations in force in the country in which it is to be used and with the requirements indicated in this manual.

CAUTION! The customer/user shall be responsible for supplementing the instructions herein with those specified in the use and maintenance manual of the system/set, and for providing any additional information to the operator.

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PAR. 4

General Information

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GENERAL INFORMATION

DESCRIPTION General warranty conditions

4. GENERAL WARRANTY CONDITIONS For any complaints during the warranty period, please always indicate: - Model and serial number - Number of hours that the machine has worked and history of maintenance operations - Excavator - Installation: oil flow, working pressure, back pressure and drainage line pressure (if known) - Application

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SAFETY

DESCRIPTION General warnings

1. GENERAL WARNINGS Operators’ safety is one of the main concerns of CASE CONSTRUCTION. When making a new piece of equipment, all the possible hazard situations try to be anticipated, and, naturally, the suitable safety measures try to be adopted, paying a lot of attention to those operations that would be particularly hazardous. CASE CONSTRUCTION shall not be held responsible for the failure to comply with the safety and prevention regulations indicated in this Manual.

CAUTION! Before operating the equipment carefully read the instructions contained in this Manual and strictly follow the indications specified herein.

CASE CONSTRUCTION has fitted in the equipment all the protections and safety devices deemed necessary, and has also provided all the necessary information in order for the equipment to be used safely and correctly.

To such end, in each chapter, when necessary, for each man-equipment interaction, the following information has been indicated: Minimum qualification required for the operator; Number of operators that are necessary; Status of the equipment; Residual hazards; Personal protective equipment that is necessary or recommended; Prevention of human errors; Prohibitions / obligations related to reasonably foreseeable incorrect behaviours.

CAUTION! This information shall be strictly observed.

Whenever deemed suitable, the user may supplement the information provided by CASE CONSTRUCTION with additional work instructions, which must obviously not be opposite to the indications given in this Manual, in order to contribute to the safe use of the equipment.

A lot of attention must be paid to the clothes worn by anyone who performs operations on the equipment.

Avoid wearing of clothes with holds parts that may remain hooked to parts of the equipment.

Avoid wearing ties or other fluttering garments.

Avoid wearing voluminous rings or bracelets that could make your hands get entangled in parts of the equipment.

Whenever necessary, additional recommendations to be followed by the user regarding prevention measures, personal protective equipment, information on who to prevent human errors and on the prohibitions related to reasonably foreseeable inadmissible behaviours will be specified in the Manual.

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In any case, the following indications shall be strictly followed: It is absolutely prohibited to operate the equipment with its fixed protections removed; It is absolutely prohibited to disable the safety devices installed on the equipment; Washing operations must be performed with the hydraulic separation devices disconnected; Do not modify parts of the equipment for any reason whatsoever; In case of malfunction caused by the failure to comply with the indications specified above, CASE CONSTRUCTION shall not be held responsible for the consequences.

IMPORTANT! CASE CONSTRUCTION shall not be held responsible for any damage caused by the equipment to people, animals or things in case of: Use of the equipment by not properly trained personnel; Improper use of the equipment; Hydraulic pressure supply defects; Incorrect installation; Deficiencies in the foreseen maintenance; Unauthorised changes or operations; Use of non-original spare parts or spare parts not specific for the model; Failure to comply, in whole or in part, with the instructions; Use against national regulations; Disasters and exceptional events.

Controls and checks Checks must be carried out by an expert; they must be visual and functional, aimed at guaranteeing the safety of the equipment. These checks include: Checking all support structures, which should not have any crack, breakage, damage, deformation, corrosion, wear or alteration with respect to the original characteristics; Checking all mechanical parts; Checking all the safety devices installed on the equipment; Checking all the connections with bolts and screws; Checking the equipment operation; Checking the equipment status; Checking the hydraulic system sealing and efficiency.

CAUTION! If anomalies are detected, they must be eliminated before resuming the equipment operation.

If the person performing the check detects dangerous cracks or anomalies, an immediate communication shall be sent to CASE CONSTRUCTION. Decommission the equipment whenever operation anomalies are detected, and carry out all the necessary checks and/or repairs.

Make sure that there are no objects between the parts of the equipment.

After any maintenance operation, make sure that no objects are left between moving parts.

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To guarantee maximum safety when moving the equipment, it is PROHIBITED: • • • •

•

To alter any part of the equipment; To leave moving elements unattended; To use the equipment while it is working but not completely efficient; To modify the equipment in order to change the original intended use, without an explicit authorisation from CASE CONSTRUCTION or without taking on the full responsibility established by Directive 2006/42 EC (Machinery Directive); To move the mobile parts with manual operations in case there is no power.

2

SAFETY

PAR. 2

DESCRIPTION Safety requirements

2. SAFETY REQUIREMENTS While working above your head, fragments or blocks of material may fall down. Make sure that the machine on which the equipment is installed is fitted with the necessary protections to carry out the specific type of work, and that the cabin belongs to the FOPS type (Fig. 2.2.1).

Do not move closer than 20 metres from the radius of action of the operating machine working with the equipment.

Wear the suitable personal protective equipment (gloves, goggles, helmet, safety footwear) during both operating and maintenance phases.

The equipment may only be operated by a qualified operator who has read and understood the content of this Manual.

Do not let unauthorised personnel operate the equipment or perform any maintenance operation.

The operator must immediately relinquish the hold of the equipment in case of danger.

Fig 2.2.1 Do not use the equipment in case of anomalies.

The equipment may only be used as long as it is installed on an operating machine by means of the upper coupling and the suitable bolts.

The equipment may not be used for lifting or transporting people, animals or things.

Do not use the equipment to lift or remove parts embedded in the ground.

It is prohibited to climb onto the structure of the equipment.

Do not use the equipment to bump structures to be demolished.

•

The arm must be moved safely, with slow and accurate movements. Avoid sudden movements.

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Do not use the equipment to: pull, push frontally or laterally, bump, hit.

Make sure that the capacity of floors is enough to withstand the weight of the operating machine.

Do not move the operating machine less than 10 metres close to live overhead electric wires.

To avoid the generation and spread of dust during work phases, the work area must be kept constantly wet with jets of water.

All adjustment, maintenance, repair and cleaning operations must be performed when the motor is stopped, with the equipment stably resting on the ground and without any residual hydraulic pressure. The residual hydraulic pressure must be released by operating a few times the opening and closing controls of the equipment, while the motor is stopped and depressurising the oil tank.

The operation must be indicated by means of a sign in the cabin.

When performing the cleaning, assembling, disassembling, maintenance and transport operations, make sure that the equipment is placed perfectly stable, and that rotation is blocked with the suitable bolts. The movements of the different parts shall be blocked by means of external constraints (e.g. slings, supports).

Any operations on the swivel may only be performed by a specialised technician using a suitable torque wrench to tighten the screws.

For the hydraulic connections, use only and exclusively hydraulic pipes and connections in compliance with standard EN 856 for the pressures specified. Failure to comply with the indications above may compromise the safety of the equipment.

Always make sure that the pipes are in perfect condition and that there are no damages. If that is not the case, immediately replace them. Any leaks must be searched for with the aid of small pieces of paper or cardboard, never with your fingers in order to avoid possible subcutaneous injections of pressurised oil.

Oil may reach high temperatures. Before performing any operation on the external parts, wait until they cool down completely.

Use only original spare parts for replacing worn out parts.

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SAFETY

DESCRIPTION Hazard zones

3. HAZARD ZONES OPERATOR POSITIONING During the operating machine operation, the operator must pay special attention to his own position in order to prevent such machine from becoming a potential source of danger for himself and for the people near him.

The area close to the equipment has been divided into two zones: OPERATOR ZONES These are the zones in which the operator must work during the regular operation of the equipment. The

‘operator zones’ are to be considered potentially dangerous zones. In these zones, which are indicated in the drawing below, in order to protect the safety of the operator as well as of the people close to him, maximum attention must be paid during processing operations; and it is extremely important to comply with all the accident prevention regulations herein described.

HAZARD ZONES These are the zones to which access is strictly prohibited, during processing phases, for the personnel who are not in charge of the work.

OPERATOR POSITION MAP

1 = Control zone 2 = Person in safety zone 3 = Person in hazard zone 4 = Radius of action of the machine 5 = Safety zone limit

Fig.2.3.1

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DESCRIPTION Stickers on the equipment

4. STICKERS ON THE EQUIPMENT On the equipment some stickers indicating the main warnings and instructions to be taken into account during use have been applied.

Symbol

Description

Description

‘Read the Manual’.

Carefully refer to this Use and Maintenance Instructions Manual

‘Greasing spots’.

It indicates the spots to be lubricated.

‘Safety distance’.

Keep a safety distance from the radius of action of the operating machine.

‘Oil delivery’.

Power / rotation oil input.

‘Risk of burns’.

Surfaces that may reach high temperatures with risk of burns. Wait until the equipment before performing any operation.

Tab.2.4.1

Symbol

‘Oil return’.

Power / rotation oil output.

‘Risk of material being projected’.

‘Direction of rotation”.

Keep a safety distance from the radius of action of the operating machine.

Direction in which the equipment must rotate.

‘Risk of cutting’.

Do not move close to the operating machine during the work cycle.

In case of maintenance operations, wear the personal protective equipment.

‘Drainage’.

Point of excess oil drainage.

‘Risk of crushing’.

Do not move close to the operating machine during the work cycle.

‘Lifting points’.

Use the points indicated to move the equipment.

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SAFETY

PAR. 5

DESCRIPTION Pictogrammes related to safety

5. PICTOGRAMMES RELATED TO SAFETY The pictogrammes contained within a triangle indicate DANGER. The pictogrammes contained within a circle indicate PROHIBITION. Symbol

Name

Pay attention to your hands.

Crushing of limbs.

Entanglement.

Dragging.

General danger.

Do not remove the safety devices.

Do not clean, grease, repair or manually adjust moving parts.

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PAR. 6

DESCRIPTION Personal protective equipment

6. PERSONAL PROTECTIVE EQUIPMENT (PPE) The pictogrammes contained within a blue circle impose an OBLIGATION. Symbol

Name

Obligation to wear safety goggles.

Obligation to wear suitable work clothes.

Obligation to wear hearing protection.

Obligation to wear protective gloves.

Obligation to wear safety footwear.

Obligation to wear safety helmet.

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SAFETY

PAR. 7

DESCRIPTION Residual risks

7. RESIDUAL RISKS DEFINITION OF RESIDUAL RISK:

‘Hazard that could not be totally eliminated through design and protection techniques, i.e., potential hazard that is not evident."

Attention must be paid to the following residual risks that are present when using the equipment and which cannot be eliminated.

In order to work safely and maintain the equipment, the following general national safety regulations in force must be known and observed, and, in any case, the following indications must always be followed: Before starting up the equipment, the operator must have carefully read this Manual and must have acquired deep knowledge of the technical specifications and of the operating machine controls.

It is recommended for the operator to undergo a training period in order to use the equipment to the best advantage.

All maintenance operations must be performed only by qualified personnel.

Unauthorised and unqualified personnel may not start up, adjust, drive or repair the equipment.

Do not use your hands instead of suitable tools to work on the equipment.

In case of malfunctions of the equipment or damage to the components, contact the maintenance engineer, without making any additional repair operations.

Never perform hurried or makeshift repairs that could compromise the equipment correct operation. In case of doubt, always ask for the intervention of specialised personnel.

It is prohibited to perform control operations and/or replacements during the work phases.

All controls and maintenance operations that require the removal of safety protections are performed under the user’s full responsibility. It is therefore recommended to have these operations performed exclusively by specialised and authorised technical personnel.

In order to avoid personal risks, use only electrical tools that are correctly connected to the earth connection and comply with the national safety regulations.

In case of operations or repairs to be performed in positions that cannot be directly reached from the ground, use ladders or hoisting equipment that are safe and comply with the national safety regulations.

In case of repairs near or under the equipment, make sure that there are no moving parts that may start working, and that unstable items are not positioned over the equipment or near it; in any case, block them with suitable tools.

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Unless expressly specified in this Manual, avoid repairing or adjusting the equipment (or part of it) during the work cycle, in order to avoid being hooked by moving parts.

Pay maximum attention to the table (Tab. 2.6.1) with the indications on how to use the Personal Protective Equipment every time you get ready to work on the equipment or near it.

Excluding the operator, it is strictly prohibited to stand or work in the work area of the equipment when it is operating.

Before starting the equipment, inform all the people that may be near the machine at that time.

Do not remove the safety devices and the protection housings.

It is absolutely prohibited for anyone to use the equipment for any uses other than those expressly foreseen and documented. The equipment should always be used in the ways, times and places foreseen by good practice standards, and in accordance with the legislation in force in each country, even if there were not suitable standards to regulate the sector in the country.

CAUTION! These safety regulations supplement and do not replace the safety regulations in force at local level.

CAUTION! Any tampering by the user exempts CASE CONSTRUCTION from any liability, and the user thus remains solely responsible before the competent accident prevention authorities.

IMPORTANT! CASE CONSTRUCTION shall not be held responsible for any accidents or damages to people or things resulting from the failure to comply with either the general safety requirements or the regulations indicated herein.

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EQUIPMENT DESCRIPTION

DESCRIPTION Equipment description

1. EQUIPMENT DESCRIPTION The Series TPV 600 FH and Series TPV 700 FH Polyp Grabs are pieces of equipment that have been fully designed and manufactured to handle metal scrap and medium-consistency loose material in order to specifically select it and recycle it. The models belonging to the TPV 600 FH and TPV 700 FH series can be equipped with rotation systems (OR1S) in order to minimise movement operations and operate with maximum accuracy.

In addition to the large loading capacity and the reinforced body structure, the ranges of TPV 600 FH and TPV 700 FH polyp grabs can be customised depending on the customer’s needs by changing the type of blade: standard, full, medium and narrow, and the type of tip of the blade: standard and round.

The material grabbing and release function is performed by the 4 blades of the polyp grab, which - thanks to the action of 4 hydraulic actuators - simultaneously exert on the materials to be moved a closing action for grabbing (Fig.3.3.1) and an opening action for releasing (Fig.3.3.2). The material is moved in the polyp grab configuration with closed blades by means of the manoeuvres of the operating machine arm.

The equipment connection with the hydraulic control unit for the necessary supply is made possible thanks to the use of rigid pipes and connections.

The supporting structure and the blades are made of anti-wear steel with high elastic limit. This gives to the equipment high mechanical resistance.

Hinges are made of alloyed steel, and they rotate on cemented rectified bushes fitted with groves for internal lubrication.

The components of the equipment that are subject to wear include the possibility of greasing.

Equipment in closed configuration

Equipment in open configuration

Fig.3.3.1

Fig.3.3.2

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EQUIPMENT DESCRIPTION

DESCRIPTION Intended use 1st level machine driver: an operator who does not have specific skills, and who is able to perform only simple tasks , i.e. driving the machine by using the push-buttons on the push-button panel, loading and unloading the materials used during production, with the protections installed and enabled; these operators are not qualified to use the machine with operation having a control held down (JOG).

2. INTENDED USE The equipment described in this Manual has been designed to be fitted and used in machines for industrial movement (for information on the type, refer to the Technical Data chapter). The equipment must be used for grabbing, moving and releasing ferrous materials and loose materials having characteristics similar to those described in the Technical Data chapter.

3

PAR. 3

EQUIPMENT DESCRIPTION

DESCRIPTION Contra-indications for use

3. CONTRA-INDICATIONS FOR USE This equipment is exclusively intended for professional use. It is absolutely prohibited for anyone to use the equipment for any uses other than those expressly foreseen and documented. Any improper use of the equipment exempts CASE CONSTRUCTION from any liability for accidents affecting people or things, and renders any warranty condition null and void. The equipment should always be used in the ways, times and places foreseen by good practice standards, and in accordance with the legislation in force, even if there were not suitable standards to regulate the sector.

The equipment should not be used: For uses other than the ones indicated in 3.2, for uses not specified in this Manual or different from them; In explosive or corrosive atmospheres, or atmospheres with high concentration of powder or oily substances in suspension in the air; In atmospheres with fire risk; While safety devices are off or not working.

Polyp Grab

TPV 600 FH Series TPV 700 FH Series

3

PAR. 4

Equipment description

3

EQUIPMENT DESCRIPTION

DESCRIPTION Environmental conditions

4. ENVIRONMENTAL CONDITIONS The equipment does not require any particular environmental conditions.

CAUTION! The equipment is not suitable to operate in places with explosive or corrosive atmospheres.

The equipment is suitable to operate in environments with the following characteristics: Altitude not higher than 3000m a.s.l.; Temperature from - 20°C to + 50°C with average temperature of around 25°C; Relative humidity from 30% to 95%.

It is prohibited to use the equipment in environments with the following characteristics: In corrosive atmosphere; With fire risk; In explosive atmosphere.

3

PAR. 5

EQUIPMENT DESCRIPTION

DESCRIPTION Technical data

5. TECHNICAL DATA POLYP GRAB DIMENSIONS DIAGRAM

Fig.3.5.1

1.0

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TPV 600 FH Series TPV 700 FH Series

Equipment description

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POLYP GRAB TECHNICAL SPECIFICATIONS MODEL

CAPACITY

L

WEIGHT

BLADES

Kg without OR 1S

Kg with OR 1S

No.

DIMENSIONS (mm)

A

B

C

D

E

F

TPV 600 FH / 4

600

1130

1360

4

1470

1990

2230

1730

1450

310

TPV 700 FH / 4

700

1200

1430

4

1530

2130

2370

1800

1370

310

MODEL

CAPACITY

MAX. CAPACITY COUPLING UNDER POLYP GRAB

t

t

STATIC

DYNAMIC

TPV 600 FH / 4

10

7

1.5

TPV 700 FH / 4

10

7

MODEL

FORCE

bar

CLOSE

OPEN

3.0

330

300

1.5

2.8

330

300

OIL FLOW

TIMES

EXCAVATOR WEIGHT

L / min

sec

t

CLOSE

OPEN

CLOSE

OPEN

TPV 600 FH / 4

160

140

1.5

1

25 - 40

TPV 700 FH / 4

160

140

1.5

1

27 - 45

Tab.3.5.1

PRESSURE

NOTES

Polyp Grab

TPV 600 FH Series TPV 700 FH Series

Equipment description

3

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OR1S ROTATOR DIMENSIONS DIAGRAM

E

G

D

B

F

I Fig.3.5.2

ROTATOR TECHNICAL SPECIFICATIONS MODEL

WEIGHT

VERTICAL CAPACITY

DIMENSIONS (mm)

t

OR 1 S

MODEL

OR 1 S

Tab.3.5.2

Kg

STATIC

DYNAMIC

B

D

E

F

G

I

230

80

30

465

70

181

690

310

540

PRESSURE

MOTOR PRESSURE

OIL FLOW

RPM

MACHINE

MAX. BAR

MAX. BAR

l / min

Rpm

t

350

135

35

14

22 - 50

Polyp Grab 3

PAR. 6

TPV 600 FH Series TPV 700 FH Series

Equipment description

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EQUIPMENT DESCRIPTION

DESCRIPTION Position of stickers

6. POSITION OF STICKERS The positions of stickers may vary depending on the equipment model.

The instructions and warnings shown on the equipment and on the machine; the warning plates affixed to the equipment and in the service area are accident prevention signals, and they must be perfectly readable.

Fig. 3.6.1

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TPV 600 FH Series TPV 700 FH Series

3

PAR. 7

Equipment description

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EQUIPMENT DESCRIPTION

DESCRIPTION Lighting

7. LIGHTING The work area lighting must comply with the legislation in force in the country in which the equipment is used, and, in any case, it must guarantee good visibility in all points, it should not create dangerous reflections, and it must enable clear visibility of the controls and of the entire work area up to the safety limit also due to the possibility of objects being projected. Given the fact that the equipment does not have independent light sources, the area should be fitted with general lighting that can guarantee values from 250 to 400 lux at every point of the work area.

3

PAR. 8

EQUIPMENT DESCRIPTION

DESCRIPTION Vibrations

8. VIBRATIONS In conditions of use that comply with the correct indications for use, vibrations do not generate any hazard situations.

3

PAR. 9

EQUIPMENT DESCRIPTION

DESCRIPTION Noise emissions

9. NOISE EMISSIONS The equipment does not produce noise emissions (noise pollution).

Any phonometric analyses in the workplace shall be performed in accordance with the provisions of the regulations in force in the country in which the equipment is to be used.

3

PAR. 10

EQUIPMENT DESCRIPTION

DESCRIPTION Standard supply

10. STANDARD SUPPLY The equipment is supplied together with: Use and Maintenance Instructions Manual including Declaration of Conformity.

Identification plate with CE marking (Fig. 1.1.1).

Polyp Grab

TPV 600 FH Series TPV 700 FH Series

4

PAR. 1

Installation

4

1.0

1/7

INSTALLATION

DESCRIPTION Transport and handling

1. TRANSPORT AND HANDLING

Driver of hoisting equipment and transport vehicles: an operator who is qualified to use equipment and vehicles for hoisting and transporting materials and machines (strictly following the instructions given by CASE CONSTRUCTION), in compliance with the legislation in force in the country in which the machine is to be used.

The equipment can be dispatched on a pallet or in a box, depending on the destination and on the customer’s request.

Lifting the packed equipment with cables and gantry crane or with fork lift truck The equipment unloading, lifting and handling operations must be guided by personnel qualified to drive hoisting equipment.

Before starting the operations, identify and control the entire equipment handling area, including the means of transport parking area and the operating machine installation area, so as to detect possible dangerous points.

Fig. 4.1.1

Fig. 4.1.2 A = Lifting point of the equipment: use the lifting hook and sling the equipment with cables or chains at the indicated points.

It is prohibited to climb onto the equipment, to stand and/or walk below it while it is being moved.

Access to the transport and handling area is prohibited to anyone who is not in charge of the operation.

All operators must keep a safety distance in order to prevent being hit in case the equipment or its parts fall down.

The capacity of the equipment or vehicle to be used for lifting and transport must be suitable for the weight to be lifted.

If lifting cables are used, make sure that they are certified and that their label indicates the CASE CONSTRUCTION data and capacity data. Make sure that they are not damaged, and that they do not show any stripped threads or signs of wear.

The same warnings must be applied if chains are used.

If a gantry crane or a travelling crane are used as lifting equipment, position them in such a way that their length and capacity are suitable for the weight to be held.

Adjust the lifting equipment by moving it with short movements until reaching the ideal stability condition.

Perform the lifting operation slowly and with utmost caution, avoiding oscillations.

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CAUTION! Upon the equipment arrival, the user shall control it in order to check for possible damages (relevant breakages or bruises) in the transport phase or during movement for unloading. Should that be the case, the transport company shall be immediately informed, and “ACCEPTED UNDER PROTEST” shall be written on the delivery document. If damages are detected, report this fact to the transport company by means of a written document within the 8 following the receipt of the equipment. If at the time of the deliver, damages of considerable importance caused in the transport phase were detected, together with possible missing parts, this shall be immediately communicated to CASE CONSTRUCTION. In addition, the material received shall be compared with the material described in the detailed list of the transport document.

IMPORTANT! CASE CONSTRUCTION shall not be held responsible for the damages caused to people or things due to the use of lifting systems different from the ones described above.

4

PAR. 2

INSTALLATION

DESCRIPTION Storage

2. STORAGE In case of inactivity, the equipment should be stored, taking the following precautions: Store the equipment in a protected place; Grease the equipment in all its parts; Protect the equipment from impacts and stress; Protect the equipment from humidity and from high temperature ranges; Prevent the equipment from coming into contact with corrosive substances.

4

PAR. 3

INSTALLATION

DESCRIPTION Coupling check

3. COUPLING CHECK Preparations for assembly For the installation, a manoeuvre area suitable for the equipment dimensions and for the selected lifting equipment must be prepared.

Before assembling the equipment on the operating machine, the stability of the latter should be guaranteed: i.e., the lifting capacity (LC) of such operating machine should be enough to meet the essential safety requirements in order to prevent its overturn. To do so, you need to: 1. CHECK: the minimum value of the lifting capacity (LC) over 360° calculated according to standard ISO 10567:2007 indicated on the technical data of the operating machine.

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2. KNOW: the mass M of the equipment indicated on the identification plate.

3. APPLY: to the mass of the equipment a K correction factor that takes into account the equipment oscillation beyond the hinging point: K=1.2 CAUTION! This condition guarantees the operating machine stability only in working conditions on flat, horizontal, solid ground.

4

INSTALLATION

PAR. 4

DESCRIPTION Assembling the equipment

4. ASSEMBLING THE EQUIPMENT The assembling operations must be performed with the equipment stably resting on the ground, with the operating machine having its motor stopped and its parking brakes enabled. Whenever the equipment is supplied without machine couplings, the customer / operator shall be responsible for adding to it suitable connection couplings matching the operating machine characteristics.

The coupling for the connection between the equipment and the operating machine must be suitably chosen in order to guarantee the equipment lifting in total safety with full load (equipment weight plus maximum load that can be moved). It must also be oscillating, so as to be able to guarantee free oscillations with respect to the vertical axis of symmetry of the equipment.

Then, proceed as follows: • • •

Turn the coupling of the equipment Use a cloth to clean the internal surfaces of the coupling Accurately clean the bolts and the bushes of the equipment coupling, removing any impurities.

ASSEMBLING THE EQUIPMENT ON AN OPERATING MACHINE 1. Unscrew fixing nut 1 and take out washer 2 in order to remove bolt 3 of the OR (Fig.4.4.1).

2. Place the coupling inside the rotating OR of the equipment.

3. Insert bolt 3 for the connection between the OR and the coupling checking its alignment and securing it with its own safety system (nut, washer, etc.).

4. Remove the safety system of bolt 4 of the coupling and take out the bolt. (Fig. 4.4.2).

5. Move the operating machine close to the coupling directing the free end of the coupling towards the arm of the operating machine.

6. By moving the arm of the operating machine, make the holes on the side plates of the coupling match the hole at the end of the arm, and insert bolt 4, fixing it with the relative safety system.

IMPORTANT! In all assembling operations, never force the insertion of bolts, but rather check their correct alignment

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Fig. 4.4.2

If the polyp grab is supplied already equipped with coupling, only follow steps 4, 5 and 6.

Fig. 4.4.1

4

PAR. 5

INSTALLATION

DESCRIPTION Connections

5. CONNECTIONS

CASE CONSTRUCTION technician: qualified technician made available by CASE CONSTRUCTION to carry out complex operations in particular situations or, in any case, as agreed with the user. Skills are, depending on the cases, mechanical and/or electrical and/or electronic and/or software.

Hydraulic connections The hydraulic system is connection is performed by connecting the hydraulic connections present on the equipment with the corresponding connections present on the operating machine. Such operation must be performed for both the connections corresponding to the hydraulic rotation of the equipment (if present), and those related to the opening and closing of the equipment.

Insert the suitable flexible connection pipes between the operating machine and the equipment (in compliance with standard EN 856) and tighten the screws or the connections.

CAUTION! Any impurities (sand, gravel, dust) present on the connections may damage hydraulic system of the equipment.

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The hydraulic pressure supply of the equipment is received by means of hydraulic connections in the points indicated in the following diagram. The hydraulic connection of the OR motor is made by means of G1/2 connections.

The hydraulic connection of the blades is made by means of G 3/4 connections. (Fig.4.5.1) The operating data of the hydraulic parameters are included in Tab.3.5.1 and Tab.3.5.2.

The operations specified above must be performed by trained, authorised personnel, wearing the necessary Personal Protective Equipment, and they must be performed while the machine is off, in a suitably illuminated place free from other people or things.

Fig. 4.5.1

The ROTATION system is connected to a delivery pipe and to the corresponding return pipe.

The OPENING / CLOSING system is connected to a delivery pipe and to the corresponding return pipe.

Keep both hydraulic systems accurately separated.

HYDRAULIC DIAGRAM (TPV 600 FH/4 and TPV 700 FH/4)

Fig.4.5.2

Polyp Grab

TPV 600 FH Series TPV 700 FH Series

Installation

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TECHNICAL SPECIFICATIONS FOR CONNECTIONS

HYDRAULIC CONNECTIONS Equipment

A

B

Operating machine

Power

Rotation

Model

A

B

A

B

G 3/4 G 3/4

G1/2 G1/2

G 1/2 G 1/2

G 1/2 G 1/2

TPV FH 600 / 4 TPV FH 700 / 4

Tab. 4.5.1 The output pressure and capacity of the operating machine should always be those required for the equipment being used (see Tab. 3.5.1 and Tab. 3.5.2 Technical Data). Should that not be the case, the system must be equipped with reducing valves (contact the operating machine manufacturer or a specialised workshop).

Do not use the equipment without first having made sure that the pressure and oil flow of the operating machine are those required.

Before using the equipment start the operating machine and slowly pressurise the hydraulic circuit in order to avoid possible counterstrokes, until setting the maximum operating pressure, which shall comply with the characteristics indicated on the identification plate of the equipment. With the motor at idle speed, open the equipment up to 1/4 and close it back, then open it up to one half and close it back, then open it up to 3/4 and close it back, and finally open it completely and close it back. Perform the opening and closing operation of the equipment 5 or 6 times making sure there are no leaks along the hydraulic circuits.

CAUTION! Before using the equipment for the load movement operations, go to an open space free from obstacles and without people in the radius of action of the operating machine, and carry out some manoeuvres without load in order to become familiar with the equipment.

Now you can use the equipment in work operations.

4

PAR. 6

INSTALLATION

DESCRIPTION Stopping and disassembling the equipment

6. STOPPING AND DISASSEMBLING THE EQUIPMENT Once work is completed and before putting back the equipment, proceed as follows:

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By using the OPEN / CLOSE control of the operating machine, make all the rods of the equipment get in or out of the cylinders depending on the final position chosen for stopping the polyp grab: open polyp grab or closed polyp grab.(Fig 4.6.2 and Fig 4.6.2)

Fig 4.6.1: open polyp grab with cylinders ‘in’

Fig 4.6.2: closed polyp grab with cylinders ‘out’

•

Rest on the ground, on wooden supports the equipment and make sure it is stable by fixing it, if necessary, by means of cables or chains to a suitable support (pay attention mainly in case of closed polyp grab configuration).

•

Make sure there is no residual pressure in the hydraulic system. The residual hydraulic pressure must be released by operating a few times the OPEN / CLOSE controls of the equipment, while the motor is stopped and depressurising the oil tank.

•

Loosen the screws or the connections of the pipes and put the suitable protection covers.

•

Remove the safety system of the bolt of the coupling and take out the bolt. (Fig. 4.6.3)

Fig 4.6.3 •

Move the arm of the operating machine so as to take it out of the coupling of the equipment, making sure there are no people close to the work area. Turn the coupling of the equipment so as to put back the stop pin and the suitable split pin in the rotation blocking bolt (if present).

CAUTION! When disconnecting the pipes, make sure you collect any oil that may come out, by putting suitable containers beforehand. Do not throw away oil.

Polyp Grab 5

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USE OF THE EQUIPMENT

PAR. 1

DESCRIPTION Starting the equipment

1. STARTING THE EQUIPMENT

1st level machine driver: an operator who does not have specific skills, and who is able to perform only simple tasks, i.e. driving the machine by using the push-buttons on the push-button panel, loading and unloading the materials used during production, with the protections installed and enabled; these operators are not qualified to use the machine with operation having a control held down (JOG).

Before starting the equipment, the following operations must always be performed: • Check all safety systems; • Check protections and signs.

Before starting the machine, a series of checks and controls must be performed in order to avoid errors or accidents during the starting phase.

• • • •

Make sure that the equipment has not been damaged during the assembling phase; Check, with special care, the integrity of hydraulic pipes, valves and different components; Check that all mobile parts move freely and, if applicable, rotate freely; Make sure that the hydraulic connections are properly tightened so as not to cause dangerous leaks.

CAUTION! Carry out a thorough visual inspection of the entire equipment, and make sure that there are no people or materials that could constitute obstructions for regular operation, or objects that have been unintentionally left on top of it.

5

USE OF THE EQUIPMENT

PAR. 2

DESCRIPTION Operation cycle

2. OPERATION CYCLE • • •

•

Move close to the work area with the operating machine.

Make sure that there are no people in the radius of action of the operating machine or, in any case, in hazard zones.

Move the equipment - with its blades open - close to the material to be lifted, make sure that the material is correctly positioned in the equipment (if necessary, move the excavator arm or change rotation in order to optimise grabbing) and enable the blades closing control to perform the lifting operation.

During the operation, make sure that the force is enough to complete the material loading and lifting; otherwise, release the material by opening the blades and carry out another closing operation on a smaller amount of material to be moved.

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Once the movement operations have been completed, move the operating machine away from the work area, making sure there are no unstable items or pieces in positions potentially dangerous for the operators that will perform the material removal and/or loading operations.

5

PAR. 3

Use of the equipment

USE OF THE EQUIPMENT

DESCRIPTION Stopping the equipment

3. STOPPING THE EQUIPMENT The equipment is stopped by simply leaving the controls of the relative hydraulic distributors in rest position.

In normal conditions, if the controls are not operated, the equipment does not make any movement.

5

PAR. 4

USE OF THE EQUIPMENT

DESCRIPTION Decommissioning the equipment

4. DECOMMISSIONING THE EQUIPMENT In case of long periods of inactivity, the hydraulic pressure supply should be disconnected from the equipment.

5

PAR. 5

USE OF THE EQUIPMENT

DESCRIPTION Waste disposal

5. WASTE DISPOSAL The user shall be responsible - in compliance with the legislation in force in the relative country - for making sure that the waste generated by the equipment during operation is correctly disposed of. Lubricants and replaced parts must be disposed of in compliance with the regulations in force in the country of use of the equipment.

5

PAR. 6

USE OF THE EQUIPMENT

DESCRIPTION Dismantling the equipment

6. DISMANTLING THE EQUIPMENT During the dismantling operations, plastic parts must be separated and sent to separate collection in compliance with the regulations in force. As regards the metallic mass of the equipment, steel parts should be separated from other metals or alloys, in order to be correctly sent to recycling by fusion.

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MAINTENANCE

PAR. 1

DESCRIPTION Isolating the equipment

1. ISOLATING THE EQUIPMENT

General unskilled worker: an operator who does not have specific skills, and who is able to perform only simple tasks following the indications of qualified technicians

Before performing any type of maintenance and/or repair operation, the equipment must be isolated from the hydraulic pressure supply. The residual hydraulic pressure must be released by operating a few times the OPEN / CLOSE controls of the equipment, while the motor is stopped and depressurising the oil tank. The operation must be indicated by means of a sign in the cabin of the operating machine.

6

MAINTENANCE

PAR. 2

DESCRIPTION General instructions

2. GENERAL INSTRUCTIONS The type of maintenance operations suitable for this equipment can be divided into: Ordinary Scheduled Supplementary They include operations related to lubrication, cleaning, adjustment, replacement, inspection, tightening, etc.

When performing maintenance and/or repair tasks, the recommendations below should be followed: Before starting the works, put a sign reading “EQUIPMENT UNDER MAINTENANCE” in a well-visible position; Do not use solvents or inflammable materials; Pay attention so as not to throw away lubricating liquids; To access the highest parts of the equipment, use equipment that is suitable for the operations to be performed; Do not climb onto parts of the equipment, as they have not been designed to support people; Once the works have been completed, put back and correctly fix all the protections that had been removed and/or opened; Thoroughly clean the individual units with suitable degreasing products without using compressed air (as this only moves dirt); Determine the frequency of operations according to the specific needs in relation to the production cycle of the equipment; Before starting the equipment, the operator should daily perform a visual check on the general condition of the different components, and, in addition, request the intervention of maintenance personnel whenever strange noises or abnormal situations are detected; Make sure that the mechanical parts are always well lubricated (only the parts that need lubrication).

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CAUTION! CASE CONSTRUCTION shall not be held responsible for the failure to comply with the abovementioned recommendations and for any other improper use or uses not mentioned in these instructions.

6

MAINTENANCE

PAR. 3

DESCRIPTION Ordinary maintenance

3. ORDINARY MAINTENANCE

General unskilled worker: an operator who does not have specific skills, and who is able to perform only simple tasks following the indications of qualified technicians.

Ordinary Maintenance includes inspections and checks to monitor the equipment condition.

Maintenance and/or repair operations must only be performed by authorised, suitably trained personnel; Use tools and materials that are suitable for the type of operation; Maintenance operations must be performed with the machine stopped on flat ground, with the motor off and with the equipment without any load and resting on the ground; The operator in charge of maintenance must wear personal protective equipment suitable for the type of work to be done.

Ordinary Maintenance Table:

OPERATION Visual inspection of the equipment structure to detect possible anomalies (in particular, the assembly coupling between the equipment and the operating machine).

FREQUENCY

STATUS OF THE EQUIPMENT

Every day

Isolation for Maintenance

Check the clearance between bolts and bushes

Every day

Isolation for Maintenance

Make sure that no cracks have appeared in the welds.

Every day

Isolation for Maintenance

Visual check of the cylinders, the distributor, the fixing of connections and the integrity of hydraulic pipes.

Every day

Isolation for Maintenance

Every day

Isolation for Maintenance

Every day

Isolation for Maintenance

Make sure that the metal identification plate indicating the conformity of the equipment and its main technical characteristics is present.

Make sure that the stickers indicating hazard situations on the equipment are present and in good condition. Replace them in case they are missing or deteriorated.

Tab.6.3.1

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CAUTION! Failure to comply with these requirements exempts CASE CONSTRUCTION from any liability for the purpose of the Warranty.

6

PAR. 4

MAINTENANCE

DESCRIPTION Scheduled maintenance

4. SCHEDULED MAINTENANCE

Mechanical maintenance engineer: qualified technician who is able to drive the machine in normal conditions, to operate it having a control held down (JOG) with protections disabled, to perform operations on mechanical parts in order to carry out the necessary adjustments, maintenance works and repairs. These operators are not usually qualified to work on electrical installations with the presence of voltage.

Scheduled Maintenance includes inspections, checks and maintenance operations to guarantee that the equipment is constantly efficient Scheduled Maintenance Table: OPERATION

FREQUENCY

STATUS OF THE EQUIPMENT

Grease the hinges and the swivel, and replace any damaged grease nipples (see Fig. 6.4.2 and Fig 6.4.3).

Check the condition and the clearance between bolts and bushes; (if clearance is more than 0.6 mm, replace the bushes or the bolt).

Make sure that there are no cracks in the welds.

Every 8h

Isolation for Maintenance

Every 8h

Isolation for Maintenance

Every 8h

Isolation for Maintenance

Make sure that there are no cracks, breakages or deformations in the metal structure and in the stems of the jacks.

Check the tightening of the bolt-holding nuts and of the bolted joints.

Make sure that there are no deformations in the holes of flanges.

Check the condition of flexible and fixed pipes with the relative connections.

Check the sealing of the gaskets of cylinders and, if necessary, replace them.

Check the condition of flexible pipes and, if necessary, replace them.

Check the condition of the metal structure.

Every 8h

Isolation for Maintenance

Every 8h

Isolation for Maintenance

Every 8h

Isolation for Maintenance

Every 8h

Isolation for Maintenance

Every 3 months

Isolation for Maintenance

Every 3 months

Isolation for Maintenance

Every 3 months

Isolation for Maintenance

Every 3 months

Isolation for Maintenance

Check the tightening and condition of the boltholding nuts.

Tab.6.4.1

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OPERATIONS SHEET All overhaul and repair works performed on the equipment must be recorded on the operations sheet; the expert technician in charge must also write down any changes and/or deficiencies of the equipment.

Find below a sample sheet; make some photocopies to be kept in the use and maintenance manual.

Hours of operation

Date

Machine

Operation performed

Technical manager signature

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LUBRICATION The frequency of lubrications must be established according to the operating conditions. Before or after a long period during which the machined remained stopped, lubrication is absolutely necessary. This is particularly applicable to the winter break. Make sure that no detergent penetrates the rolling system or damages its sealing gaskets.

SWIVEL LUBRICATION Once the equipment has been assembled to the operating machine, lubricate the rolling system and the teeth (Fig. 6.4.1). For such operation, as well as for any subsequent lubrication, the only products that may be used are non-hygroscopic lubricants without acids or resin that are resistant to ageing and the temperature variation range of which is suitable for using the bearing, as specified in the table shown below (Tab. 6.4.2). Complete greasing is aimed at reducing friction, creating sealing and giving protection from corrosion. It is therefore recommended to perform the greasing operation in such a way that grease comes out of the bearing labyrinths or of the sealing gaskets. Some of the rolling bodies in the rolling tracks are spacers made of synthetic material: the use of aggressive product changes the grease properties, corrodes the rolling tracks and damages the spacers.

CAUTION! More frequent lubrications are recommended in tropical areas, as well as in places that are very humid, dusty, have impurities and are subject to marked temperature changes.

IMPORTANT! After having used the equipment under the water, remove the hinges in order to thoroughly clean bolts and bushes to eliminate any traces of oxidation, before performing a new lubrication.

●

CASE AKCELA MULTI-PURPOSE GREASE 251-H EP

▲ CASE AKCELA MOLY GREASE

(-20° up to + 120°)

(-20° up to + 120°)

Tab.6.4.2

● = Greases for rolling systems ▲ = Greases for teeth Grease NLGI class: NLGI 2 EP Fig. 6.4.1

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GREASING SPOTS Grease every 8 hours the spots indicated with letter G in the diagram below.

The operations specified above must be performed by trained, authorised personnel, wearing the necessary Personal Protective Equipment, and they must be performed while the machine is off, in a suitably illuminated place free from other people or things.

G = Greasing spots of the equipment signalled by specific stickers.

Fig 6.4.2 Greasing spots of the polyp grab

Fig 6.4.3 Greasing spots of the OR1S swivel TIGHTENING OF THREADED CONNECTION PARTS Tightening operations must be performed only and exclusively by specialised personnel using a torque wrench in compliance with the torque values indicated in the table below (Tab. 6.4.2).

Threaded connection parts may be re-tightened only once; then, they must be replaced.

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Tightening torques and tractive forces UNI 3740

6S

8.8-(8G)

10.9-(10K)

12.9-(12K)

Nominal diameter

Coarse pitch

Resistant section

Tightening torque

Tractive force on the screw

Tightening torque

Tractive force on the screw

Tightening torque

Tractive force on the screw

Tightening torque

Tractive force on the screw

d mm M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30 M33

p mm 0.8 1 1.25 1.5 1.75 2 2 2.5 2.5 2.5 3 3 3.5 3.5

s mm2 12.03 17.3 31.9 50.9 74.3 102 141 171 220 276 317 419 509 636

(M) Nm 5.10 8.73 21.58 42.2 73.6 116.7 178.5 245 348.5 471 598.5 888 1206.5 1628.5

(P) kN 5.3 7.5 13.7 21.8 31.8 43.7 60 73 93.9 117.3 135.4 178.1 215.8 269.8

(M) Nm 5.98 10.3 25.5 50 87.3 138.3 210.9 289.4 412 559.2 711.2 1049.7 1422.4 1932.6

(P) kN 6.3 8.8 16.2 25.8 37.7 51.7 71.2 86.5 111.3 139.3 160.4 210.9 256 319.8

(M) Nm 8.50 14.7 35.30 70.6 122.6 194.2 299.2 412 578.8 784.8 1000.5 1481 2011 2717

(P) kN 8.8 12.4 22.8 36.3 52.9 72.7 100 121.6 156.5 195.7 225.6 296.3 360 449.3

(M) Nm 10.20 17.6 42 85.5 147 235.5 358 490.5 696.5 942 1197 1776 2403 3267

(P) kN 10.6 14.9 27.4 43.6 63.6 87.3 120 146.1 187.8 234.5 271 356 432.6 539.6

Tab.6.4.2

6

PAR. 5

MAINTENANCE

DESCRIPTION Supplementary maintenance

5. SUPPLEMENTARY MAINTENANCE

Mechanical maintenance engineer: qualified technician who is able to drive the machine in normal conditions, to operate it having a control held down (JOG) with protections disabled, to perform operations on mechanical parts in order to carry out the necessary adjustments, maintenance works and repairs. These operators are not usually qualified to work on electrical installations with the presence of voltage.

Supplementary Maintenance includes maintenance operations, repairs and replacement of components in order to guarantee the equipment proper operation.

Supplementary Maintenance Table: OPERATION

FREQUENCY

STATUS OF THE EQUIPMENT

Replacement of cylinders in case of excessive wear or breakage.

Whenever necessary

Isolation for maintenance

Whenever necessary

Isolation for maintenance

Rotation or replacement of interchangeable blades in case of excessive wear or breakage.

Tab. 6.5.1

Polyp Grab

TPV 600 FH Series TPV 700 FH Series

Maintenance

6

1.0

8/10

CYLINDER REPLACEMENT To remove and replace the cylinders of the equipment blades, the operating machine must be turned off and suitable PPE (gloves, goggles, safety footwear and suitable clothes) must be worn.

DANGER! During the cylinder replacement operations, make sure that all people stand at a safety distance and that no damages are caused to things or people whenever that happens.

Carry out the cylinder replacement operation with the equipment stably resting on the ground and without any residual hydraulic pressure.

Before starting the replacement operation, make sure there is no oil inside the liner of the cylinder to be replaced or inside the hydraulic pressure supply pipes, see Chap.2 - Par.2: SAFETY REQUIREMENTS

•

•

•

•

•

•

• •

Disconnect the cylinder hydraulic pressure supply pipes, removing from the cylinder both the intake pipe and the delivery pipe.

Unscrew nut 1, remove bolt 2 that fixes the cylinder rod to the blade, and take out the head of the cylinder rod from its housing on the blade. (Fig. 6.5.1) Unscrew nut 3, remove bolt 4 that fixes the cylinder to the polyp grab body, and take out the cylinder from its housing on the polyp grab body.

Remove cylinder 5 to be replaced, and place the new cylinder in the same housing.

Insert the joint of the cylinder bottom in its housing on the polyp grab body, insert fixing bolt 4, and screw nut 3 applying the correct tightening torque.

Insert the head of the cylinder rod in its housing on the polyp grab blade, insert fixing bolt 2, and screw nut 1 applying the correct tightening torque.

Connect the cylinder hydraulic pressure supply pipes.

Start the equipment and make sure that the blade moves correctly checking its closing and opening.

Fig. 6.5.1

Polyp Grab

TPV 600 FH Series TPV 700 FH Series

Maintenance

6

1.0

9/10

BLADE REPLACEMENT To replace the cylinders of the equipment blades, the operating machine must be turned off and suitable PPE (gloves, goggles, safety footwear and suitable clothes) must be worn.

DANGER! During the blade replacement operations, make sure that all people stand at a safety distance and that no damages are caused to things or people whenever that happens.

Carry out the blade replacement operation with the equipment stably resting on the ground and without any residual hydraulic pressure.

Before starting the replacement operation, make sure there is no oil inside the cylinders or inside the hydraulic pressure supply pipes, see Chap.2 - Par. 2: SAFETY REQUIREMENTS Unscrew nut 1, remove bolt 2 that fixes the cylinder to the blade. (Fig. 6.5.2) Unscrew screw 3 at the end of the bolt that fixes the blade to the polyp grab body. (Fig. 6.5.3) Remove bolt 4 that fixes the blade to the polyp grab body.

Lift cylinder 5 making it turn around the bolt that connects it with the polyp grab body.

Remove blade 6 to be replaced and put it back in a safe position.

Insert the new blade aligning the holes for putting the connection bolts between blade and cylinder and between blade and polyp grab body.

Insert bolt 4 in the relative hole, insert and tighten screw 3 in order to fix bolt 4.

Align the joint of the cylinder rod with the bolt housing on the blade.

Insert fixing bolt 2 between the cylinder and the blade, and screw nut 1 with the suitable tightening torque.

Fig.6.5.2

Fig.6.5.3

The equipment has been designed to minimise supplementary maintenance; the operator shall be responsible for assessing its condition and suitability for use. It is recommended to stop the equipment and carry out maintenance operations every time that operation is not optimal; this will allow to keep maximum efficiency at all times.

Polyp Grab

TPV 600 FH Series TPV 700 FH Series

6

Maintenance

6

1.0

10/10

MAINTENANCE

PAR. 6

DESCRIPTION Diagnostics and troubleshooting

6. DIAGNOSTICS AND TROUBLESHOOTING General requirements In case of equipment malfunction, troubleshooting should only be performed by specialised personnel, or you may also contact CASE CONSTRUCTION technical service.

PROBLEM

One blade does not open

The blade does not remain closed

Cylinders leak oil

POSSIBLE FAILURE •

The operating machine does not supply suitable pressure to the equipment hydraulic circuit.

•

The equipment cylinder gaskets are damaged.

•

The operating machine does not supply suitable pressure to the equipment hydraulic circuit.

•

The equipment cylinder gaskets are damaged.

•

Damaged gaskets.

•

Loosened hydraulic pipes.

•

Oil leak on the operating machine distributor.

•

Oil leak on the cylinder.

•

•

Check the cylinder head gaskets.

•

Check the cylinder rod integrity.

•

Check the cylinder head gaskets.

•

Check the closing cap gaskets.

•

Check the valve calibration.

•

Make sure that there are no problems on the machine system.

Incorrect calibration of the operating machine pressure.

•

Adjust the operating machine pressure.

•

Rotation motor damaged.

•

Replace the motor.

•

Motor valve damaged.

•

Replace the motor valve.

•

Flow regulating valve closed.

•

Open the flow regulating valve.

•

Incorrect oil flow coming from

•

Adjust the oil flow coming from the operating machine.

•

the operating machine.

•

Flow regulating valve incorrectly calibrated

•

Calibrate the flow regulating valve correctly.

Blades do not hold tight

The equipment does not run

The equipment runs too slowly or too quickly

POSSIBLE SOLUTION

Tab.6.6.1 In case of defects or malfunctions of the equipment that have not been described in this Manual, please contact CASE CONSTRUCTION.

Polyp Grab

TPV 600 FH Series TPV 700 FH Series

1

Spare parts

7

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SPARE PARTS

PAR. 1

DESCRIPTION Spare parts

1. SPARE PARTS ALWAYS USE ORIGINAL SPARE PARTS CAUTION! CASE CONSTRUCTION shall not be held responsible for any breakage, malfunction or damage to people or things resulting from the use of non-original parts.

Non-original spare parts should not be used. And if they are actually used, the Warranty conditions shall become null and void (if they are still applicable) and CASE CONSTRUCTION shall not be held responsible.

When using the equipment and any damage caused to people and/or things.

In order to interact with our technicians as effectively as possible when ordering spare parts, please follow the procedure indicated below: •

Call CASE CONSTRUCTION Technical Service and indicate the type of failure found;

•

Indicate the equipment serial number specified on the identification plate;

•

Describe the item that is not working (also with the aid of pictures).

Polyp Grab

CE

PAR. 1

TPV 600 FH Series TPV 700 FH Series

Declaration of Conformity

CE

1.0

1/1

DECLARATION OF CONFORMITY

DESCRIPTION Declaration of Conformity

1. DECLARATIONS As it is not part of ANNEX IV of DIRECTIVE 2006/42/CE, the Manufacturer resorts to Self-certification for affixing the CE marking.

CE Declaration of Conformity for interchangeable equipment intended to be assembled to other operating machines, and which does not work independently

Dealer’s stamp

CNH Industrial Italia S.p.A. reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold.

Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication, but are subject to change without notice.

Availability of some models and equipment builds varies according to the country in which the equipment is being used. For exact information about any particular product, please consult your Case dealer.

© 2018 CNH Industrial Italia S.p.A. All Rights Reserved.

Case is a trademark registered in the United States and many other countries, owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates.

Any trademarks referred to herein, in association with goods and/or services of companies, other than owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates, are the property of those respective companies.