Case Wheel Compactor for Skid Steer & Compact Track Loader Operator's Manual 48092964 - PDF DOWNLOAD

OPERATOR’S MANUAL

WHEEL COMPACTOR

Lec - 48092964 Issue date July 2019 EN

0 - INDEX

0 - INDEX 0.INDEX.............................................................................................................................................................0-1 1.GENERAL INFORMATION............................................................................................................................1-1 WARRANTY .................................................................................................................................................1-1 DECLARATION OF CONFORMITY.............................................................................................................1-2 DESCRIPTION .............................................................................................................................................1-3 MAIN PARTS................................................................................................................................................1-4 2.SAFETY INFORMATION ...............................................................................................................................2-1 SYMBOLS ....................................................................................................................................................2-1 SAFETY DECALS ........................................................................................................................................2-2 GENERAL PRECAUTIONS FOR USE ........................................................................................................2-5 ENVIRONMENTAL CONDITIONS ...............................................................................................................2-6 PERMITTED USES ......................................................................................................................................2-6 RESIDUAL RISKS........................................................................................................................................2-6 SAFETY DISTANCE ....................................................................................................................................2-7 SAFETY DEVICES.......................................................................................................................................2-7 EMERGENCY STOPS .................................................................................................................................2-8 3.CONTROLS ...................................................................................................................................................3-1 LEVER CONTROLS.....................................................................................................................................3-1 CONTROLS PANEL.....................................................................................................................................3-2 4.OPERATING INSTRUCTIONS ......................................................................................................................4-1 EQUIPMENT - PRIME MOVER COUPLING................................................................................................4-2 EQUIPMENT - PRIME MOVER HYDRAULIC COUPLING..........................................................................4-3 EQUIPMENT - PRIME MOVER HYDRAULIC DISCONNECTION ..............................................................4-5 EQUIPMENT - PRIME MOVER DISCONNECTION ....................................................................................4-6 5.TRANSPORT OPERATIONS ........................................................................................................................5-1 DELIVERY AND UNLOADING.....................................................................................................................5-1 HANDLING, TRANSPORTATION AND LIFTING ........................................................................................5-2 6.WORKING OPERATION ...............................................................................................................................6-1 OPERATING PRINCIPLE ............................................................................................................................6-1 GENERAL OPERATING CONDITIONS.......................................................................................................6-2 SIDE MOVEMENT ADJUSTMENT ..............................................................................................................6-4 STARTING UP FOR THE FIRST TIME........................................................................................................6-4 POSITIONING THE SUPPORT FEET .........................................................................................................6-5 STOPPING IN NORMAL CONDITIONS ......................................................................................................6-6 PARKING .....................................................................................................................................................6-6 7.MAINTENANCE .............................................................................................................................................7-1 ROUTINE MAINTENANCE SCHEDULE......................................................................................................7-1 TORQUE CHARTS ......................................................................................................................................7-2 REPLACING EXTENSION PADS ................................................................................................................7-3 ADJUSTING VIBRATOR BELT TENSION...................................................................................................7-3 ADJUSTING THE FLOW CONTROL VALVES ............................................................................................7-5 LUBRICATING WHEEL HUB .......................................................................................................................7-6 LUBRICATING THE DEPTH AND SIDE TILT HYDRAULIC CYLINDERS ..................................................7-7 MACHINE CLEANING..................................................................................................................................7-7 STRUCTURAL INTEGRITY ASSESSMENT................................................................................................7-7 NUT AND BOLT TIGHTNESS TEST ...........................................................................................................7-7 HOSES INSPECTION ..................................................................................................................................7-8 STORAGE INSTRUCTIONS ........................................................................................................................7-8

0-1

0 - INDEX RECOMMISSIONING...................................................................................................................................7-8 DISPOSAL....................................................................................................................................................7-8 8.TROUBLESHOOTING ...................................................................................................................................8-1 9.TECHNICAL SPECIFICATIONS....................................................................................................................9-1 OVERALL DIMENSIONS .............................................................................................................................9-1 TECHNICAL DATA.......................................................................................................................................9-2 PADS............................................................................................................................................................9-2 SOUND POWER LEVELS DETECTED .......................................................................................................9-2

0-2

1 - GENERAL INFORMATION

1 - GENERAL INFORMATION Dear Customer, Thank you for choosing our product! We are pleased to give you this manual, which we hope will help you get the most out of our product and enhance your work.

Inside this manual the user will find all the information required to use the wheel compactor correctly. The trade name of the wheel compactor is stated on the front cover of this manual. You are advised to follow all the instructions contained in this handbook exactly and to store it carefully in an appropriate, accessible place. The manual must be kept for future reference until the wheel compactor is scrapped. If the wheel compactor is sold, the vendor is required to pass on the manual to the new owner.

The information in the manual is arranged into topic-based chapters.

Þ DANGER The contents of this manual may be altered without prior notice, with no further duties ensuing, in order to include changes or upgrades made to the units already despatched.

Please note that, for reasons of visibility and clarity, certain figures may show the equipment arranged in ways which do not correspond to the correct set-up for use.

No part of this handbook may be reproduced or translated without the manufacturer’s permission.

WARRANTY When submitting a warranty claim, always remember to quote: - Model and serial number - Number of working hours and maintenance history - Carrier - Installation: oil flow, working pressure, counter pressure and drain line pressure (in known) - Application.

1-1

1 - GENERAL INFORMATION

DECLARATION OF CONFORMITY The declaration of conformity is filled in and signed and attached to this manual. Following an example of the declaration of conformity.

Dichiarazione di Conformità “originale”

DICHIARAZIONE DEL FABBRICANTE (Secondo l’Allegato II A della Direttiva Macchine 2006/42/CE) SIMEX s.r. l.

Via Newton, 31 40017 San Giovanni in Persiceto (BO) Italy Tel 051/6810609 – fax 051/6810628 ________________________________________________________________________________________________________________________ _____

DATI DI IDENTIFICAZIONE: Denominazione: Attrezzatura Intercambiabile Modello: XXXXXXXXXX Tipo: XXXXXX Numero matricola: XXXXXXXXXXX X Anno di costruzione: XXXX Massa (kg): XXXX Pressione Max di funzionamento mento (bar): XXX XX E, il sopraccitato sop Ai sensi della Direttiva Macchine 2006/42/CE, costruttore

DICHIARA SOTTO LA L PROPRIA RESPONSABILITA’ - che la macchina indicata è conforme nforme alle disposizioni della: x x

Direttiva Macchine 2006/42/CE hine 2006/42/ Direttiva EMC MC - Compatibilità Compatibili Elettromagnetica 2014/30/UE

- che la macchina alle norme tecniche EN 12100: 2010 na indicata è conforme con - che il responsabile della costituzione del Fascicolo Tecnico è il Responsabile Ufficio Tecnico c Simex s.r.l, Via Newtonn 31, 3 40017, San Giovanni in Persiceto, (BO), Italy ________________________________________________________________________________________________________________________

IDENTIFICAZIONE DEL FIRMATARIO Nome: MIRCO RISI Posizione: legale rappresentante Data emissione: 01/01/2017 FIRMA …………..............................

COD. SXMD032A17

1-2

1 - GENERAL INFORMATION

DESCRIPTION The wheel compactor (hereinafter referred to as "equipment") has been designed to compact the section trench bottom. The wheel compactor guarantees a solid, homogeneous and well compacted bottom, which does not give up over time, thus providing maximum safety to road traffic.

Perfect insulation from the prime mover thanks to the double vibrating and counter-rotating shaft, located at the centre of the wheel, the vertical forces are added while the horizontal ones are cancelled for greater operator’s comfort.

The width of the sectors can be changed by means of bolted sectors that can be easily replaced on site.

Available in two versions: - Fixed.

- With shifting, that allows to work at the side of the road, near walls or footpaths.

1-3

1 - GENERAL INFORMATION

MAIN PARTS 3

7

5

2 8 1

6 4 F0007680

1 2 3 4 5 6 7 8

1.1

Wheel compactor Vibrating unit Vibrating driver motor Support feet Fitting plate Flow control valve (sealed) Fixed support with fitting plate Pressure relief valve

1-4

1 - GENERAL INFORMATION

5

1

13

12

8

7

2

6

4

9 10

11

3

F0007690

1 2 3 4 5 6 7 8 9 10 11 12 13

1.2

Load bearing frame Extension pads (on request) Wheel compactor Vibrating unit Vibrating driver motor Flow control valve Hydraulic cylinder for lateral movement Side shift with prime mover adapter plate Valves for electro-hydraulic controls Support feet Control panel Transversal tilt hydraulic cylinder Hydraulic cylinder for planing depth adjustment

1-5

1 - GENERAL INFORMATION

1

5

2

6

3

7

4

1 2 3 4 5 6 7

1.3

Model/Type Serial number Part number Year of manufacture Weight Operating oil flow Operating pressure

1-6

2 - SAFETY INFORMATION

2 - SAFETY INFORMATION SYMBOLS The chart below outlines the symbols used in this handbook (those considered the most important).

Þ DANGER This term is used in safety messages in the manual and on the plates when there is a significant chance of severe injury if the danger is not avoided.

NOTE This term is used for sentences supplying useful information on the operation in progress.

IMPORTANT This term is used for precautions which must be taken to avoid operations which can shorten the lifetime of the equipment or its components.

OPERATOR: This is the appropriately trained staff member who is authorised to install, operate, adjust, clean and transport the equipment.

MAINTENANCE ENGINEER: This is the person(s) trained and authorised to work on the equipment for routine maintenance and the replacement of certain components.

EQUIPMENT: This is the interchangeable equipment.

PRIME MOVER: This is the vehicle on which the interchangeable equipment is fitted.

NOTE Left and right refer to the equipment viewed by the operator sitting in the working position.

2-1

2 - SAFETY INFORMATION

SAFETY DECALS Location of the data plate and the safety and hazard decals on the equipment.

1

2 6

5

4

3

1

F0007700

2.1

Decal key (Fig. 2.1) Pos.

Decal

Description

1

Warning: NO WORK MAY BE CARRIED OUT ON THE EQUIPMENT UNTIL DRUM ROTATION HAS BEEN STOPPED

2

Warning: RISK OF CRUSHING DECAL; DO NOT ACCESS THE AREA OF RISK

2-2

2 - SAFETY INFORMATION Pos.

Decal

Description

3

Warning: READ THE MANUAL CAREFULLY

4

Warning: READ THE MANUAL CAREFULLY AND REMOVE THE KEY FROM THE CONTROL PANEL BEFORE MAINTENANCE OR REPAIRS

5

Requirement: YOU ARE REQUIRED TO WEAR APPROPRIATE PERSONAL PROTECTION EQUIPMENT

6

Warning: KEEP CLEAR OF THE EQUIPMENT (MIN. 10 m)

2-3

2 - SAFETY INFORMATION

7

8

F0007701

2.2

Decal key (Fig. 2.2) Pos.

Decal

Description

7

Lifting decals: Hook up point for lifting purposes

8

DATA PLATE

Þ DANGER Always heed the warnings on the plates and transfers/stickers. Failure to do so may result in death or serious injury. Make sure the plates and transfers/stickers are always in place and legible. If this is not the case, affix or replace them, obtaining the materials required from the manufacturer.

2-4

2 - SAFETY INFORMATION

GENERAL PRECAUTIONS FOR USE •

The operator is directly accountable for the equipment’s safe operation.

•

Read this manual carefully before proceeding with installation, start-up, use or any servicing of the equipment.

•

The aim of this handbook is to familiarise the operator, through the figures and explanations, with the basic rules and criteria to follow during equipment use and maintenance.

The following procedures are essential to warranty safe operation: •

Check that the equipment has not suffered any damage during transportation and if it has, advise the manufacturer or area agent straight away.

•

Make sure the equipment is only used by authorised adults with appropriate training.

•

Make sure the prime mover due to be used has all the dead-man’s controls fitted and that they are in perfect working order.

•

Ensure all non-members of staff are kept clear of the equipment when it is in use (safety distance of at least 10 metres). Cordon off the work area. This operation is to be done by the operator.

•

Stop working if anyone or any animals should enter the work area.

•

Clean the equipment regularly, removing all foreign matter which could impair operation or cause injury to the operator.

•

Before using the equipment, make sure all the safety devices are correctly in place and in good condition; if any broken devices are found, replace them immediately.

•

Make sure all the hoses and fittings are properly attached.

•

Do not carry out any maintenance work until you have read the instruction manual, and always remove the ignition key from the prime mover before starting.

•

Any repairs needed must be carried out solely by authorised personnel using original spare parts. If this rule is not applied, the user could be exposed to serious risks.

•

All inspections of the hoses and fittings must be carried out using suitable personal protection equipment (goggles, gloves and clothing to protect against contact with the skin).

•

Do not leave the equipment installed on the prime mover when the prime mover is unattended in the work area.

•

Do not wear anything which might get caught in the moving parts, such as unsuitable clothing, shoes, shirts etc. You are recommended to wear garments approved for accidentprevent purposes, e.g. helmets, non-slip shoes, headphones, and safety goggles and gloves. Check with your employer as to the safety regulations in force and the accidentprevention devices required.

•

Do not wear rings, bracelets, necklaces, watches, or scarves.

•

If you have long hair, keep it tied back.

2-5

2 - SAFETY INFORMATION

ENVIRONMENTAL CONDITIONS With working temperatures below -10 °C, let the prime mover idle before beginning work, and wait until the hydraulic circuit reaches and exceeds 40 °C. The use environments must comply with the regulations in force concerning hygiene and safety in the workplace.

Þ DANGER •

No naked flames and suchlike near the equipment.

•

Do not use the equipment in areas where there is a risk of explosion or fire. This equipment is not built to be use in the explosion environment (ATEX).

PERMITTED USES The equipment is designed to be mounted on a prime mover in order to compact the section trench bottom.

Use of the equipment is only permitted if mounted on a prime mover carrying a declaration of conformity with directive 98/37/EC and/or 2006/42/EC and the legislation in force, and if it meets the technical requirements of the equipment to be mounted.

Any other use than that expressly provided for herein should be considered mishandling and therefore not permitted.

When working in tunnel or during night time or with low visibility due environmental conditions, the working are has to be illuminated (min 200 lux) either by the prime mover or by working area fir o mobile lights.

Þ DANGER •

Any use of the equipment which does not comply with the uses specified in this installation, use and maintenance manual is strictly prohibited.

•

Do not stand, move or work on floors or any non-bearing structures.

RESIDUAL RISKS When the equipment is in use, the following risks may arise: - Electric shocks from contact with underground power lines.

- Fire and explosions through contact with underground gas lines.

- Explosion of explosive devices buried in the area as a result of wars/conflicts that may have occurred in the past.

Anyone standing in the vicinity of the equipment may be exposed to the following risks: - Risks originating from blows, catching or shearing - Risk of crushing between the equipment and the prime mover.

- Risk of rubble (stones, blunt objects, etc.) being thrown out.

- Risk of falling spoil (when working on uneven ground or on surfaces at different heights).

2-6

2 - SAFETY INFORMATION

SAFETY DISTANCE Respect safety distances.

F0007710

2.3

SAFETY DEVICES

Þ DANGER •

The safety guards must NEVER be tampered with.

•

The equipment must NEVER be used without the safety guards fitted.

•

Use always suitable PPE for any maintenances’ operation.

1 - Guard for the motor hoses (pressure, return and drain).

1

2 - Eccentric masses and pulleys inspection cover. To open the cover the fixing bolts need to be unscrewed.

2 F0007702

2.4

2-7

2 - SAFETY INFORMATION

EMERGENCY STOPS To stop the equipment in an emergency, the operator can use the following controls on the prime mover: - Press emergency stop button (when this control is featured).

- Get up from driver’s seat (when the dead-man’s switch is featured).

- Lift up the operator’s armrest (when the dead-man’s switch is featured).

- Switch off the diesel engine with the ignition/OFF key.

NOTE For further details on how to stop the equipment, see the prime mover's instruction manual.

2-8

3 - CONTROLS

3 - CONTROLS LEVER CONTROLS The controls on the prime mover control levers can be used to activate the equipment adjustment as per below instructions: Turn the switch (1) to centre position Do not activate HF or HP function (a + b).

1

a b

3.1

LEFT CONTROL LEVER

D

RIGHT CONTROL LEVER

H E

J

F

G C

C: Press to activate the hydraulic cylinder to shift the equipment to the RIGHT. D: Press to activate the hydraulic cylinder to shift the equipment to the LEFT. E: Press to activate the right hydraulic cylinder to INCREASE the planing depth.

F: Press to activate the right hydraulic cylinder to DECREASE the planing depth.

H: Press to activate the hydraulic cylinder to tilt the wheel COUNTER-CLOCKWISE. G: Press to activate the hydraulic cylinder to tilt the wheel CLOCKWISE. J: To activate the vibration.

3-1

3 - CONTROLS

CONTROLS PANEL 1 2 3 4

Two-position switch (ON-OFF) which allows the motor of the vibrating unit to be activated.

Depth regulation Turn the selector (A) on position (2).

To increase the depth, turn the switch (B) to the right.

To increase the depth, turn the switch (B) to the left.

Tilt adjustment Turn the selector (A) on position (3). To tilt clockwise, turn the switch (B) to the left. To tilt counter-clockwise, turn the switch (B) to the right.

Lateral regulation Turn the selector (A) on position (4).

To shift to the right, turn the switch (B) to the right. To shift to the left, turn the switch (B) to the left.

B

F0007910

3.2

3-2

4 - OPERATING INSTRUCTIONS

4 - OPERATING INSTRUCTIONS Before proceeding with the connection to the equipment, the prime mover must undergo checks to ensure: •

That all the featured safety devices work properly.

•

That all the quick couplings and other components related to the coupling to the prime mover are in good condition.

4-1

4 - OPERATING INSTRUCTIONS

EQUIPMENT - PRIME MOVER COUPLING The equipment must be mounted on the prime mover’s arm instead of the standard bucket, using any of a number of connection types. Apart from the general instructions given below, the procedures outlined in the prime mover’s manual (see specific section on the application of equipment) must also be followed.

Example of the operations that must be carried out for a standard coupling: 1 - Position the equipment on flat, compact ground, in the nonoperative position, and away from ditches, stores of fuel or any other substances, and electrical substations. (Fig. 4.1).

2 - Slowly bring the arm of the prime mover towards the equipment in order to position the attachment plate below the upper lip of the equipment coupling. Move forwards until it is resting on the lip.

3 - Operate the prime mover hydraulic controls in order to bring the support plate (1) towards you until it is completely resting on the coupling area of the equipment.

F0007661

4.1

4 - Turn off the engine of the prime mover, remove the key from the ignition and push the two levers to engage the quick coupling lock pins. Check that the levers are locked in the retaining position and that the pins are fitted properly inside the slots on the equipment's coupling.

F0007070

F0007060

5 - Lift support feet (3). Block the pins (2) with the safety pin (1) to prevent the pin coming out (Fig. 4.3).

4.2

3 1

Þ DANGER Do not lift the equipment off the ground until you have completed the operations described above.

2 F0007740

4.3

4-2

4 - OPERATING INSTRUCTIONS

EQUIPMENT - PRIME MOVER HYDRAULIC COUPLING To connect the hoses, proceed as follows: 1 - Release the pressure in the hydraulic system (see prime mover instructions).

2 - Connect the hoses using the quick coupling fittings; it is compulsory to fit the drain line first (A).

3 - Connect the equipment’s power cable to the prime mover arm cable (B).

4 - Check for oil leaks: a) Get on the prime mover and start the engine. b) Activate the hydraulic system. c) Switch off the engine, remove the ignition keys, and get off the prime mover; now check for signs of leaks near the hosing fittings.

Example of hydraulic and electrical connection on HF prime mover

A

B F0007080

Example of hydraulic and electrical connection on EHF prime mover

4.4

F0007380

4.5

4-3

4 - OPERATING INSTRUCTIONS

Þ DANGER The machine is connected to the prime mover via hydraulic hoses; make sure the hoses are not tangled together, as this could prove hazardous, and are not likely to be crushed or exposed to tension during work manoeuvres.

Residual risk of burns: the hydraulic oil, hoses and fittings can all reach extremely high temperatures whether the equipment is fitted or not. Use appropriate personal protection equipment.

The operation must be carried out by one person (operator) only.

IMPORTANT • When connecting the hoses to the prime mover, the drain line featured must be connected first of all.

•

If screw quick couplings are used, check closely that they have been completely and correctly screwed down. If possible, we recommend the use of flat-faced quick couplings with safety ring nut.

If using flat-faced quick couplings, proceed as follows (Fig. 4.6): 1 - Fit the male section (7) into the female section (8) until you hear it click into place in the ring nut (9).

8

7

2 - Turn the ring nut (9) so that the notch (10) is not aligned with the spherule (11), thereby preventing accidental disconnection.

10 11

8

9

7

F0000222

4.6

NOTE Figure 4.6 shows flat-faced quick couplings with a snapfastening safety ring nut.

Þ DANGER Before connecting up, carefully clean all the quick couplings on the equipment and the prime mover.

If, for some reason, there is residual pressure in the prime mover’s hydraulic system, you will not be able to fit the male section of the coupling into the female section. Follow the instructions given by the prime mover’s manufacturer to relieve the pressure.

4-4

4 - OPERATING INSTRUCTIONS

EQUIPMENT - PRIME MOVER HYDRAULIC DISCONNECTION

Þ DANGER Before leaving the operator’s seat on the prime mover, make sure the equipment is resting on flat ground, the prime mover is stabilised and the key has been removed from the ignition.

Residual risk of burns. The hydraulic oil and hoses can reach extremely high temperatures whether the equipment is fitted or not. Use appropriate personal protection equipment.

IMPORTANT Always disconnect the drain line last of all.

To disconnect the hosing, proceed as follows: 1 - Stop the engine.

2 - Release the pressure in the system.

3 - Get off the prime mover and disconnect the quick coupling fittings (see specific section below).

4 - Disconnect the electrical cable.

If using flat-faced quick couplings, proceed as follows (Fig. 4.7): 1 - Turn the ring nut (9) so that the notch (10) is aligned with the spherule (11), and then push it towards the ball to disengage the joint.

8

7

10 11

8

9

7

F0000222

4.7

4-5

4 - OPERATING INSTRUCTIONS

EQUIPMENT - PRIME MOVER DISCONNECTION IMPORTANT Make sure the hydraulic connections between the equipment and the prime mover have been disconnected and that the power cable has been disconnected.

Operations that must be carried out for a standard coupling type: •

Position the equipment, compact ground, in the non-operative position, and away from ditches, fuel stores, electrical substations or any other hazard risk (Fig. 4.1).

•

Slip off the support feet (Fig. 4.8).

•

Once you have turned off the diesel engine, removed the ignition key, and stabilised the prime mover (e.g.: with the parking brake, stabiliser feet, parking wedges, etc.), leave the driver’s seat.

•

Pull the two levers (Fig. 4.3), to slide out the lock pins.

Get back on the prime mover, start the engine and use the hydraulic controls on the prime mover as if to perform a forward tipping manoeuvre with the equipment, lowering the loader forearm at the same time, until the prime mover adaptor plate disengages from the lips. Reverse the prime mover slowly to release it from the equipment.

3 1

2 F0007750

4.8

4-6

5 - TRANSPORT OPERATIONS

5 - TRANSPORT OPERATIONS DELIVERY AND UNLOADING The equipment is normally transported and delivered securely fastened to a pallet, in a stable position, and duly wrapped in plastic sheeting. The type of packing, though, may vary according to the desired means of transport and the destination. For carriage by air, the equipment is packed inside a suitable wooden crate. All the equipment despatched is checked prior to delivery to the customer.

NOTE On receipt of the equipment, check it for any damage (major breakages or dents) caused during transportation. If any are found, the carrier must be alerted immediately and the statement “Accepted conditionally” must be added to the delivery note.

In the event of damage, give notice of the fact to the carrier in writing within 7 days of receipt of the equipment.

If, upon delivery, major damage caused during transportation is noted, or any parts that should be included are found to be missing, CNH INDUSTRIAL must be notified of the situation promptly.

It is also essential to check the equipment delivered against the information given in the itemised shipping document.

Þ DANGER •

The packed unit must be unloaded with the utmost care using lifting means with a suitable capacity (e.g. fork lift truck or other appropriate means). Next, the entire unit must be placed on a flat, stable surface.

•

All load handling operations must be carried out in compliance with the regulations in force concerning safety in the workplace.

5.1

IMPORTANT! Dispose of the packing in compliance with the regulations in force in the country of use; do not fly tip it.

5-1

5 - TRANSPORT OPERATIONS

HANDLING, TRANSPORTATION AND LIFTING

Þ DANGER If the type approval of the prime mover to travel on normal roads does not extend to the equipment, it must be removed before transportation on open roads.

Only small movements may be performed on the worksite when the equipment is mounted on the prime mover. During these movements, shifting must be carried out at low speeds with the equipment located close to the ground and the prime mover arms as closed up as possible; all people and things must be kept a safe distance away.

The equipment must always be removed from the prime mover before the vehicle is driven up loading ramps. The equipment must not be operated during handling.

Handling over short stretches (in the workplace): •

Use the prime mover, leaving the equipment attached.

•

Secure the equipment to a pallet, and handle it with a fork lift truck or a transpallet.

Handling over long stretches: •

Secure the equipment to a pallet, using a fork lift truck or a transpallet for handling, then load it onto the means of transport (lorry, train, etc.).

Lifting from one surface to another (e.g. to load it onto a lorry): •

Use a lifting crane or truck with a suitable capacity for the weight specified on the “EC” plate. Connect the cables or chains at the four points shown with the relative decals. When lifting, use hooks with the “EC” marking.

Þ DANGER •

Check that the capacities of the cables, chains and lifting and transportation means in general are compatible with the equipment weight specified on the “EC’’ data plate.

•

When attached to the prime mover, keep the equipment close to ground level (safety height: 0.5 m) during handling.

•

Shifting is only permitted on flat, or slightly loose ground, and as long as stability is never jeopardised.

Check that the pallet on which it will be stored is in suitable condition.

F0007760

5.2

5-2

6 - WORKING OPERATION

6 - WORKING OPERATION OPERATING PRINCIPLE The equipment is produced in two versions: a first version with a fixed compacting wheel unit, and a second version equipped with side translation unit and hydraulic adjustments.

To start the basic version, the operator has a control on the prime mover for supplying oil to the vibrating unit.

This is the only control capable of activating or deactivating the equipment, which will compact the backfill. This action is done by pushing forward the wheel that turns freely (neutral).

To start the version with hydraulic version, the operator has a control on board the prime mover for supplying oil to the electro-hydraulic control unit; therefore the equipment will be able to work. Once the adjustments have been made and the vibrating unit has been activated, the operator can start processing by pushing forward the equipment with the prime mover.

The hydraulic power is transmitted by the prime mover to the equipment via hoses.

All the equipment functions are controlled using the prime mover controls.

Sometimes, the equipment is backed up with a electric panel to be mounted on the prime mover.

A

B

C

D0004070

6.1

A = Maintenance of grip on ground B = Wheel rotation direction C = Direction of work

6-1

6 - WORKING OPERATION

GENERAL OPERATING CONDITIONS 1 - Bring the equipment onto the working area.

Þ DANGER Move the prime mover keeping the equipment no more than a few centimetres off the ground.

IMPORTANT! While positioning on the work line, try to keep the equipment in the centre of the translator, to allow the entire apparatus to be better balanced.

2 - Using the control on board the machine, supply oil to the trench compactor.

IMPORTANT! Inspect the work area to check for any obstacles, manhole covers or similar.

3 - Move forward and, if necessary, back.

Þ DANGER Before starting up the equipment, ensure that there is no one in the equipment's range of motion.

IMPORTANT! Before beginning processing, check that the wheel can operate without touching the walls of the excavation.

IMPORTANT! In the basic version once the vibrating unit is started, the wheel is lowered into the excavation via the prime mover arms. Still with the basic version trench compactor, the prime mover arms should be tilted to exert greater pressure on the wheel. The load exerted on the equipment should not exceed 400 kg.

6-2

6 - WORKING OPERATION NOTE: If the trench compactor is assembled on a prime mover, in order to exert greater pressure on the wheel, lift the front wheels of the prime mover slightly.

In the version with translator and hydraulic adjustments, if the type of job allows, it is always advisable to stay above the excavation; otherwise, the prime mover will be sideways on to the excavation.

F0007770

6.2

Þ DANGER Move the wheel beyond maximum stroke only when already in work position, as it may cause dangerous imbalances. Adapt the work position of the wheel to the conditions of the excavation, using the hydraulic jacks (depth, tilt and translation).

NOTE: During processing, keep the prime mover arms as close to the ground as possible, modifying the wheel adjustments accordingly. Equipment wheel may be of fixed width or have interchangeable extension soles.

F0007780

6.3

IMPORTANT! With pads between 100 mm and 200 mm in width, penetration in the excavation of approximately 350 mm is possible, whereas with wider pads penetration of up to 750 mm is possible.

6-3

6 - WORKING OPERATION

SIDE MOVEMENT ADJUSTMENT This adjustment is obtained using the hydraulic cylinder on the translator (1).

Þ DANGER Operation to be performed with the equipment stationary and slightly lifted off the ground. Ensure no one is present near the equipment during the translation, to prevent risk of crushing.

NOTE: If there are no particular requirements in the work area, it is advisable to keep the wheel in the centre while working.

2

1

F0007790

6.4

STARTING UP FOR THE FIRST TIME Start the wheel and slowly, with the diesel motor at the low idle for about 20 minutes. Figure, hydraulic diagram and equipment motor rotation and (Fig. 6.5).

1

F0007800

6.5

IMPORTANT! Each time the equipment has been stopped for a few minutes, or has been disconnected, start it slowly with the diesel motor on minimum. Accelerate slowly and gradually.

6-4

6 - WORKING OPERATION

IMPORTANT! The equipment motor is very sensitive to the back pressure on the drainage unit. This value must never exceed 3 bar.

IMPORTANT! During the winter, ensure the oil in the prime mover’s hydraulic circuit is suitably heated (possibly by making some idle movements with the arm hydraulic cylinder), before supplying oil to the equipment to start the compact operations.

POSITIONING THE SUPPORT FEET 1 - After to have connected the equipment to the prime mover, extract the safety pin (1) and extract the pin (2). (Fig. 6.6)

3 1

2 - Raise the equipment a few centimetres off the ground.

2 F0007810

6.6

3 - Raise the foot (3) and re-insert the pin (2) in the new hole to block the foot in the raised position.

3

4 - Insert the securing safety pin (1) again to push out the pin. (Fig. 6.7)

1

2 F0007820

6.7

6-5

6 - WORKING OPERATION

Þ DANGER Before leaving the operator position on the prime mover and approaching the equipment, you must do the following: - stop the prime mover motor; - remove the starter key from the dashboard; - block the prime mover using the hand brake.

STOPPING IN NORMAL CONDITIONS In normal conditions, the prime mover controls must be used to stop the equipment (by slowing down to idling speed, then cutting off the hydraulic oil flow). This way, the equipment will stop completely and immediately.

PARKING Lower the equipment to the ground, stop the prime mover’s diesel engine, engage the brake or any other parking devices (when featured) and remove the ignition key.

6-6

7 - MAINTENANCE

7 - MAINTENANCE

Þ DANGER •

All maintenance work on the equipment, as well as inspections and cleaning, must be carried out with the equipment detached from the prime mover and positioned on the ground (for designated worker, see the maintenance schedule).

•

Maintenance operations must be carried out in a suitable place, in compliance with the safety regulations in force.

•

Clean all the equipment’s parts thoroughly before beginning any maintenance work on it.

•

Appropriate personal protection equipment must be used throughout maintenance.

ROUTINE MAINTENANCE SCHEDULE Maintenance interval

Operation

Designated worker

When required

REPLACING EXTENSION PADS

Operator

When required

ADJUSTING THE FLOW CONTROL VALVES

Operator

Every 4 hours

LUBRICATING WHEEL HUB

Operator

MACHINE CLEANING

Operator

LUBRICATING THE DEPTH AND SIDE TILT HYDRAULIC CYLINDERS

Operator

HOSES INSPECTION

Operator

STRUCTURAL INTEGRITY ASSESSMENT

Operator

NUT AND BOLT TIGHTNESS TEST

Operator

ADJUSTING VIBRATOR BELT TENSION

Operator

Every 50 hours

Every 100 hours Every year

IMPORTANT! During machine maintenance, if you are in any doubt as to the parts required or complicated work is needed, contact your authorised dealer.

Þ DANGER All load handling operations must be carried out in compliance with the regulations in force concerning safety in the workplace.

7-1

7 - MAINTENANCE

TORQUE CHARTS MAXIMUM SCREW TIGHTENING TORQUES Screw class

Screw diameter - Torque (nm) - Friction coefficient 0.10

ISO

DIN

M4

M5

M6

M8

M10

M12

M14

M16

M18

M20

M22

M24

M27

M30

8.8

8G

2.4

4.9

8

20

40

69

110

170

235

330

446

570

840

1150

10.9

10K

3.3

7

12

28

56

98

155

240

330

465

620

800

1200 1600

12.9

12K

4

8

14

34

67

116

185

285

395

560

750

960

1400 1950

FITTING ADVICE - The screws must be lubricated with engine oil.

- For parts fastened with two or more screws, the screws must be tightened progressively and alternately until the prescribed torque is reached; - If flat washers are needed, steel washers with a minimum resistance of 80 kg/mm² must be used.

TIGHTENING TORQUES FOR HOSE FITTINGS ‘’GAS’’ Diameter

1/4”

3/8”

1/2”

3/4”

1”

1” 1/4

1” 1/2

Torque (Nm)

35

70

100

190

300

330

400

“W’’ (inch) Diameter

9/16”

3/4”

7/8”

1” 1/16

1” 3/16

1” 5/16

1” 5/8

1” 7/8

Torque (Nm)

30

50

70

100

130

145

190

240

TIGHTENING TORQUES FOR HOSES With ORFS fittings “W’’ (inch) Diameter

9/16”

11/16”

13/16”

1”

1” 3/16

1” 7/16

1” 11/16

2”

Torque (Nm)

25

40

55

86

125

165

200

245

“W’’ (inch) Diameter

9/16”

3/4”

7/8”

1” 1/16

1” 3/16

1” 5/16

1” 5/8

1” 7/8

Torque (Nm)

30

50

70

100

130

145

190

240

With JIC 37° fittings

with GAS fittings “W’’ (inch) Diameter

1/4”

3/8”

1/2”

5/8”

3/4”

1”

1” 1/4

1” 1/2

Torque (Nm)

15

28

60

70

110

140

190

245

7-2

7 - MAINTENANCE

REPLACING EXTENSION PADS

Þ DANGER •

Before leaving the operator’s seat on the prime mover, make sure the area is flat, the prime mover is stabilised, the equipment is resting on the ground, and the keys have been removed from the ignition.

To vary the width of the area to be compacted, it is possible to replace the pads (1) by removing the screws (2).

After disassembly, insert the new extension pads and fasten them with the relative screws (2).

2

1

F0007830

7.1

ADJUSTING VIBRATOR BELT TENSION

Þ DANGER •

Before leaving the operator’s seat on the prime mover, make sure the area is flat, the prime mover is stabilised, the equipment is resting on the ground, and the keys have been removed from the ignition.

Þ DANGER These adjustments involve working on parts that may be highly dangerous. As such only specialised and qualified personnel must make such adjustments.

7-3

7 - MAINTENANCE To adjust the tension of the vibrator belt, proceed as follows: 1 - Unscrew the screws (A), then remove the safety guard (B).

2 - Loosen the nut (C) that locks the tightener.

3 - Loosen the nut that locks the hub of pulley (E) from the opposite side of the body side.

A

4 - Tension the belt by turning the tightener screw (D).

5 - Afterwards, tighten the nut that locks the hub of pulley (E), and the nut (C) of the tightener.

A

B

F0007840

7.2

3-

4m

m

D

C

E F0007850

7.3

IMPORTANT! Check the belt is correctly tensioned after having turned the vibrating unit for a few minutes; the belt must be able to flex by approximately 3-4 mm with a 4 or 5 kg load.

After checking, refit the safety guard (B).

7-4

7 - MAINTENANCE

ADJUSTING THE FLOW CONTROL VALVES

Þ DANGER •

Before leaving the operator’s seat on the prime mover, make sure the area is flat, the prime mover is stabilised, the equipment is resting on the ground, and the keys have been removed from the ignition.

The task of the flow control valves (A) in the complete version and (B) in the basic version, is to limit the quantity of oil supplied to the motor for rotating the vibrating masses.

D A

F0007860

7.4

NOTE: The basic version also has a pressure relief valve (C), whose regulation pressure must be 140 bar.

C

B

F0007870

7.5

Þ DANGER Valves (C) and (D) are terned. If the flow rate must be changed for any reason, the operation must be performed by authorised personnel.

NOTE: The shafts with the vibrating masses must turn at a speed of 2000-2200 rpm.

7-5

7 - MAINTENANCE

IMPORTANT! In the complete version, given that the vibrating unit motor uses approx. 32 l/min, when it is running no other function may be used at the same time unless the prime mover supplies a further 32 l/min (in any case, no more than 55 l/min must be supplied).

LUBRICATING WHEEL HUB

Þ DANGER •

Before leaving the operator’s seat on the prime mover, make sure the area is flat, the prime mover is stabilised, the equipment is resting on the ground, and the keys have been removed from the ignition.

The wheel hub must be lubricated at least twice a day using the appropriate lubricators (A).

A

F0007880

7.6

7-6

7 - MAINTENANCE

LUBRICATING THE DEPTH AND SIDE TILT HYDRAULIC CYLINDERS

Þ DANGER •

Before leaving the operator’s seat on the prime mover, make sure the area is flat, the prime mover is stabilised, the equipment is resting on the ground, and the keys have been removed from the ignition.

Periodically lubricate the hydraulic cylinders for the side tilt (1) and depth (3) using the appropriate lubricators (A) and (B).

1

A F0007890

7.7

B

2 F0007900

7.8

MACHINE CLEANING

Use approved, neutral detergents. Clean the equipment with a high pressure jet of water.

STRUCTURAL INTEGRITY ASSESSMENT

Clean the equipment carefully prior to the inspection. Inspect the bearing framework visually to check its integrity, focusing particularly on the welding. If you notice any weakening or small cracks, contact an authorised dealer to have it examined more closely.

NUT AND BOLT TIGHTNESS TEST

Check all the nuts and bolts are securely fastened and, if any parts have worked loose, tighten them. For tightening torques, see the chart.

7-7

7 - MAINTENANCE

HOSES INSPECTION

Check the condition of the hoses and the crimping of the fittings. If a hose shows signs of leaks, breakages, swellings, abrasions, etc., it must be replaced.

Warnings concerning hose replacement 1 - Clean the working area to avoid dirt entering the hydraulic circuit.

2 - The hose must be replaced by a maintenance engineer, who should use the necessary accident-prevention equipment.

3 - The new hose must have the same features and dimensions as the previous one.

IMPORTANT! The new hose must be built to withstand the pressure indicated on the “CE” plate.

STORAGE INSTRUCTIONS

If you are not planning on using the equipment for some time, it must be stored in a sheltered area, where it cannot get knocked or hit.

Position the equipment on a pallet (making sure it is stable), then proceed as follows: - Wash it carefully.

- Check for and fix any oil leaks.

- Check for and replace any damaged parts.

- Place a sheet over the equipment to protect it from dust.

- Cordon off the area where the equipment is located to prevent anyone accidentally knocking against its corners, sharp edges or blunt parts.

RECOMMISSIONING

Before starting up the equipment again after a long period of disuse, the following checks must be carried out: - Grease all the parts subject to lubrication.

- Check for and fix any oil leaks.

- Check integrity of the hoses.

- Check that there are no badly fastened, worn out or missing parts.

- Nut and bolt tightness test

DISPOSAL IMPORTANT! When disposing of the equipment or its parts (oils, hoses, plastic parts, etc.), always comply with the laws in force in the country in which it is located.

7-8

8 - TROUBLESHOOTING

8 - TROUBLESHOOTING This section aims to provide the user with solutions to the most commonly experienced problems (malfunctions).

Do not carry out any maintenance or repairs which would effect equipment safety.

•

The remedies marked with the letter D require the intervention of the authorised dealer.

•

The remedies marked with the letter P require the intervention of qualified personnel.

•

The remedies marked with the letter O can be carried out by the operator.

Fault

Fault likely

Remedy

Low performance levels

Low flow and/or hydraulic pressure

Ensure you have correctly made all connections necessary for machine operation with equipment. Contact the prime mover’s service department, as the flow and hydraulic pressure depend on the prime mover.

Equipment hydraulic motor noisy or jammed.

Problems inside the motor

Contact an authorised service

D

Vibrations

Loose or missing screws/bolts

Check the tightening torques of the screws/bolts (wheel, hydraulic motor, etc.).

Replace the missing screws.

P

No hydraulic flow and/or pressure

Check the prime mover’s hydraulic system

P

Inversion of the delivery and return lines in the connections with the prime mover

Invert the delivery and return connections with the prime mover

Problems inside the hydraulic motor

Contact an authorised service

D

The belt is broken

Contact an authorised service

D

No current for the dashboard electric brake control

Check that current is supplied to the control panel. Check that the safety fuses in the control panel are not damaged.

P

No current arrives to the solenoid valve on the equipment

Check the electrical system and the relative connection

P

There is no hydraulic flow

Check that the prime mover capacity and pressure are correct

P

Quick-fit couplings inverted

Invert the quick-fit couplings for the applications on the equipment hoses

P

There is dirt in the valves

Check that the oil used is not dirty and clean the valves

P

Contact an authorised service

D

The vibratory unit does not work

The equipment does not carry out the adjustments

-

8-1

D

8 - TROUBLESHOOTING

Fault

External oil leaks

Fault likely

Remedy

Fittings are loose

Tighten fittings

Hosing damaged

Replace hosing

Coupling damaged

Replace coupling

Leaks from the hydraulic motor oil seals

Contact an authorised service

8-2

O P D

9 - TECHNICAL SPECIFICATIONS

9 - TECHNICAL SPECIFICATIONS OVERALL DIMENSIONS 84515687

D

B E

A C 84515688 84515689

C

D

B E

A F

D0004080

9.1

Part number 84515687

84515688 84515689

A

1335

1555

B

1155

1215

C

1340

1740

D

750

750

E

200-390

200-390

F

N.A.

1100

9-1

9 - TECHNICAL SPECIFICATIONS

TECHNICAL DATA Models

Unit of measureme nt

84515687

84515688 84515689

Vibration frequency

Hz

37

37

Vibration amplitude

mm

1 - 1.2

1 - 1.2

Compact force

kN

17.5

17.5

Max. weight without accessories

kg

554

772

Operating pressure

bar

200

200

l/min

30 - 35

30 - 35

Technical specifications

Oil flow

Accessories

Models

Unit of measureme nt

84515687

84515688 84515689

degree

N.A.

18°

kg

737

955

Horizontal tilting Max weight with accessories

PADS Description

Dimension (mm)

Weight (kg)

84515693

Pads kit

200

126

84515694

Pads kit

250

142

84515695

Pads kit

300

145

84515696

Pads kit

350

167

84515697

Pads kit

390

183

Part number

SOUND POWER LEVELS DETECTED The sound power levels (LwA) measured according to EN ISO 3744 are given below.

Part number

Value

84515687

LwA 87 dB (A)

84515688

LwA 87 dB (A)

84515689

LwA 87 dB (A)

9-2