choose compose lift

Transcription

choose compose lift

choose compose lift
repairing instructions
2
GB Edition, 07/2006, Last Update 05/2007 - Amendments and errors reserved - Binotto ®
Repairing Instructions
Front-End (MFC, MF-RP and MF-RO ) Cylinder
1. Introduction..................................................................................................................................3
2. General remarks for safety ......................................................................................................4
3. Warranty........................................................................................................................................5
4. Cross section of front end cylinders.....................................................................................6
5. Position of inner parts...............................................................................................................7
6. Removing the cylinder from the chassis .............................................................................8
6.1. Dismantling Cylinder........................................................................................................10
6.2. Dismantling Cylinder: MFC&MF Cylinder ...................................................................13
6.3. Dismantling Cylinder: further dismantling of all cylinder types ..........................14
7. Assembling instructions ........................................................................................................16
7.1. Assembling Cylinder: MFC&MF Cylinder ...................................................................18
7.2. Assembling Cylinder: further assembling of all cylinder types ...........................18
8. Service points............................................................................................................................20
9. Contacts ......................................................................................................................................20
3
1. Introduction
Some inner parts of cylinders are subjected to wear.
Therefore sometimes it is necessary to dismantle the cylinder and replace these components (i.e. the sealkit)
This manual has been written to assist the repairing of the Binotto front-end cylinder.
The Binotto Front-end cylinder range includes cylinders with Outer Cover (MFC), with Eye (MF-RP) and with
Eye/Eye (MF-RO).
The cylinder description is on the type plate of the cylinder.
This manual is intended both for those experienced fitters that are new to Binotto hydraulic equipment
and also for those that are already familiar with Binotto products.
Always use original Binotto components when re-assembling the cylinder.
The warranty will be operative if:
- only original Binotto components are used;
- Binotto components are not modified;
- any maintenance or repairing operations is in accordance with Binotto instructions.
Please read some general remarks on safety and precautions to be taken before and during installation.
For further information or for checking operations, please contact our Sale&Service Point near you.
Explanation of guidance
Tip
There are suggestments to simplify future tasks or warns of potential problems.
Warning
Warning of danger to the operator or product.
The operator can be seriously hurt or the equipment severely damaged
if the recommended procedure is not followed.
Danger
There is a serious threat to the life of the operator.
4
2. General remarks for safety
Remove the cylinder from the chassis prior to dismantling.
For the MFC type, it is possible to leave the gimbal attached to the body.
Tip
Should the outer cover be the cause of the problem then it must be replaced.
Specification sheets are available for all Binotto cylinders; these sheets contain all relevant dimensional and
application details about your cylinder.
The Binotto cylinder is developed for lifting purposes only. It is prohibited to use the cylinder in any
other way. The cylinder is not to be used as a stabiliser and any kind of side-load must be avoided whenever
possible.
Warning
Applying side-load to any cylinder is dangerous.
The cylinder should be mounted with a minimum pull out of 15 mm and a maximum pull out of 35 mm (the
closed length of the cylinder on the Binotto specification sheet already includes 20 mm pull out).
Ensure there is enough free working space to mount the cylinder.
If the tipper body is on the truck chassis, lift the body using an overhead crane so that the cab protector is
well clear to mount the cylinder.
If the tipper body is raised to create working space, support the body using body props before mounting the
cylinder.
Danger
Working under an unsupported tipper body is a danger to life.
To avoid damage to the truck cabin, cover the rear of the cab with a tarpaulin.
If necessary tilt the vehicles cabin (see the truck manual for details).
Disconnect the vehicle’s battery leads before any welding.
While lifting a cylinder the other stages can extend, to avoid this use a sling around the cover or piston and
base tube (between the trunnion and anti-rattle ring).
Extend the cylinder until the sling is locked and transport the cylinder using a suitable lifting device (see
chapter 4.4).
Danger
Not using the appropriate equipment when lifting parts (such as the proper sling for a cylinder) is a danger to
life.
Ensure any oil, spilt during installation and testing, is disposed of in an environmentally friendly way.
For further questions concerning the application, installation, operation or repair of any Binotto product,
please contact your nearest Binotto Service Point.
Binotto cylinders are also compatible with biodegradable oils
such as the following synthetic ester based oils:
• BP - Biohyd SE-S
• Castrol - Carelube HES
• Texaco - Hydra
• Elf - Hydrelf Bio Safety
5
3. Warranty
Binotto Terms of Warranty
Binotto only issues warranty to products under agreed conditions.
This section is not complete or contractual, it is just an overview to the Binotto general terms of warranty.
For any problem with a Binotto product you should contact your nearest Binotto Sale&Service point.
The following products are covered by warranty:
1. Hydraulic Cylinder
2. PTO & Pump
3. Tipping valve & Air Control
4. Oil Tank
The warranty is only valid under the following conditions:
01. All Binotto products must be installed, operated, maintained and repaired in accordance with
the relevant Binotto guidelines.
02. For the parts listed above, the warranty period covering is valid 12 months from date of delivery or
up to a maximum, whichever comes first, of:
• 20.000 tipping cycles for the cylinder, tipping valve, control and body.
• 300 running hours for the PTO and pump.
• 100.000 km for the oil tank.
03. The warranty period does not cover:
• Wear of parts during normal operation (e.g. sealing set), parts made of rubber or
with limited lifetime.
• Paint coatings.
• Damage caused by forces beyond our control.
• Damage caused by incomplete or erroneous installation.
• Damage caused by abusive or inappropriate operation.
• Damage as a result of service not carried out in accordance with the Binotto
Operating & Maintenance Instructions.
04. This warranty is valid only in accordance with the Binotto General Terms unless otherwise
specified.
05. A completed Claim Report shall be delivered with every claim.
06. All broken parts shall be kept for inspection, these parts will be returned to Binotto Group or one of
his authorized Sale&Service point for inspection on request (transportation costs to be met by end
user).
07. Where warranty is granted, Binotto will meet the cost of the following:
• All necessary spare parts.
• A replacement part where the original cannot be repaired.
08. Binotto does not accept any liability for transport costs or travel expenses.
09. During the warranty period the equipment must be serviced at the appropriate periods (costs to be
met by the end user). Checks listed in the Binotto Operating & Maintenance Instructions must be
completed.
10. Drivers must be trained to operate the Binotto equipment with the appropriate operating
instructions made available.
11. Drivers should include the Binotto equipment in their daily vehicle inspection and arrange service
for the vehicle/equipment as described in the Maintenance Instructions.
Any variation from the conditions listed above must be agreed with Binotto prior to the operation of the
equipment.
6
4. Cross section of front end cylinders
These repairing instructions apply to 2 types of cylinders:
MFC, cylinder with outer casing;
MF, cylinder with eye piston.
-
MOUNTING CROSS SECTION – MFC CYLINDER
FIGURE 1
Cross section – MF Cylinder
7
5. Position of inner parts
FIGURE 2
8
6. Removing the cylinder from the chassis
1 - Remove the plastic cover
FIGURE 3
2 - Remove the top nut from the cylinder
FIGURE 4
3 - Raise the tipping body using the hydraulic system until the first moving stage is visible
Danger
Working under an unsupported tipper body is a danger for life.
Support the tipper body securely use of a body prop.
FIGURE 5 – BODY SUPPORT AND LIFTING DEVICE
9
4 - Place the lever of the air control valve in the lowering position.
5 - Secure the cylinder, using a proper rope or sling to a suitable lifting device to prevent cylinder from tipping
over.
FIGURE 6
6 - Disconnect one of the trunnion brackets from the cradle or sub frame and ease the cylinder from the
other bracket.
The cylinder can now be laid on bench ready for dismantling.
7 - Secure the cylinder, using a proper rope or sling to a
suitable lifting device to prevent the cylinder from tipping
over.
FIGURE 7
8 - Remove the split pin out of the pivot and tap the pivot pin out of the piston eye.
10
9 - Disconnect one of the trunnion brackets from the cradle or subframe and ease the cylinder from the other
bracket. The cylinder can now be laid on a bench ready for dismantling.
FIGURE 8 – REMOVAL OF THE MF CYLINDER
6.1. Dismantling Cylinder
1 - Lay a cylinder flat on a clean bench with the oil inlet
facing downwards and clamp securely to avoid any kind
of damage or injuries
A “V” block arrangement is usually the best.
Collect the oil.
Danger
The drained oil must be disposed
environmental way.
in a proper
FIGURE 9
11
2 - Use a ring spanner to unscrew the bolt of the bottom
plate and remove it.
FIGURE 10
3 - Push the bottom forward until the snap is visible on
the internal diameter of the base tube.
FIGURE 11
Warning
The snap ring is mounted under tension, it may jump out.
4 - The snap ring can be removed using a screwdriver.
FIGURE 12
12
5 - The bottom plate can now be removed using the
following method:
Strike the head of the piston with a mallet or mandrel.
FIGURE 13
This forces the bottom out of the base tube.
FIGURE 14
6 - When the bottom is free then remove its “O” ring
FIGURE 15
13
6.2. Dismantling Cylinder: MFC&MF Cylinder
1 - Push the bottom forward until the snap is visible
on the internal diameter of the next inner.
FIGURE 16
2 - The snap can be removed using a screwdriver.
FIGURE 17
Danger
Then snap ring is mounted under tension, it may jump out.
Tip
This piston can be removed through the bottom of the cylinder:
- if the piston diameter is smaller than top head diameter go to point 3;
if the piston diameter is larger than top head diameter go to point 4
3 - First remove the locking bolt in the top head.
After unscrewing the top head, the piston can be
removed through the bottom of the cylinder (see
point 4).
Remove the seal ring (“O” ring) from the top head.
FIGURE 18
14
4 - Strike the head of the piston with a mallet or
mandrel.
This forces the piston out of the next tube.
Warning
The “O” ring seal must not be reused
FIGURE 19
6.3. Dismantling Cylinder: further dismantling of all cylinder types
Before the next inner can be removed through the
bottom of the cylinder, the snap ring of the subsequent
inner must be removed.
1 - Push the inner forward until the snap ring in the
subsequent inner is exposed.
Remove the snap ring as described in figure aside.
Warning
The removed inner parts must be placed on a clean
safety surface in order to prevent scratches and other
damages.
FIGURE 20
2 - All the subsequent inners can be removed in this
way.
Warning
The seals, wipers and sliders must not be re-used.
FIGURE 21
3 - Remove the wiper, seal and slider from the internal
grooves at the top of each inner.
Do not remove the seals and wipers with a screwdriver
or other sharp instruments as this may damage the
grooves irreparably and lead inevitably to leaks.
The slider can be removed by use of a screwdriver.
15
Warning
Never remove a stop ring: if it seems to be damaged,
the whole stage must be replaced.
4 - Clean each inner carefully and check each groove
and the surface of the tube for any irregularities.
Check also the sliders on each tube; if these are
damaged, they should be replaced.
In this case, it is necessary to check the stop ring in
the subsequent tube for signs or damage or twisting.
FIGURE 22
5 - Checking stop shoulder.
Please check all stop shoulder surfaces for damage
and distortion, this should be carried out on lathe or
similar and re-machined if required.
16
7. Assembling instructions
1 - Clean each inner thoroughly and apply sufficient
grease to the pack set and the grooves.
The seals, wipers and sliders must not be re-used
FIGURE 23
2 - Apply a new pack set to each stage
For the mounting of the pack set proceed in this way:
-
Pu Seal (fig. 23);
-
upper slider (fig. 24);
-
Pu seal (fig. 25);
-
Wiper (fig. 26).
Always ensure that each ring is seated correctly in the
proper groove.
Incorrect fitting can lead to faults occurring.
FIGURE 24
FIGURE 25
17
FIGURE 26
3 - Slide the first outgoing inner almost fully into the
basic base tube; ensure that the tube is not damage by
scraping over the stop ring.
Some resistance will occur when passing through the
pack set.
FIGURE 27
4 - Place the slider at the end of the inner; use grease
enough.
5 - Slide the tube further home until the slider are in the
base tube
6 - Each of the subsequent inners can be mounted
similarly.
After mounting a inner, the snap ring should be placed
in the previous inner, with the exception of the cylinder
base.
FIGURE 28
18
7.1. Assembling Cylinder: MFC&MF Cylinder
1 – Fit a new O ring to the Piston eye, apply sufficient
grease and screw the head onto the piston.
Fitting the head onto the piston can be eased by
applying copper grease to the screw thread.
Danger
Not fitting the locking bolt is dangerous to life.
FIGURE 29
2 – The locking bolt should be placed on the same
height but not in the same existing hole:
3 – Drill a new hole and machine threading M8 into the
hole.
4 – Place the locking bolt in the new hole, apply locking
agent (i.e. Loctite) before mounting.
7.2. Assembling Cylinder: further assembling of all cylinder types
1 – Fit a new O ring to the bottom plate and slide the
bottom plate into the base.
Apply sufficient grease to prevent damage to the seal.
FIGURE 30
19
2 – Push the bottom forward until the groove of the
snap ring is visible and than mounting the snap ring.
FIGURE 31
FIGURE 32
After testing the cylinder, it can be refitted to the chassis.
See also the mounting instructions manual for the front mounted cylinders.
Warning
The top nut on the casing must not be reused.
During the first new tipping operations of the cylinder, some excess grease may spill out of the stages: please
note this doesn’t mean that the cylinder is leaking.
3 – Strike the head of the piston with a mallet or
mandrel, until the bottom come back in the correct
position.
4 – Use a ring spanner to screw the bolt of the bottom
plate and fix it.
FIGURE 33
20
8. Service points
A global and update overview of main (or national) service
agents to contact for checking your equipment is available
on the Binotto website (www.binotto.com).
Even if you are considerable distance from the agents listed,
you should still contact your nearest agent or contact the
supplier where you bought your hydraulic equipment..
Most agents maintain their own networks and can advise you of
the most convenient for your work.
CYLINDERS
WET KITS
SPARE PARTS
SERVICE
REPAIRS
9. Contacts
Binotto General Offices
Binotto srl
via Divisione Julia 7/B
36010 Dueville (VI)
tel. +39 0444593290
fax +39 0444593357
[email protected]
Marketing Office
[email protected]
Mariz General Offices
Mariz srl
Viale dell’Industria, 32
I-35014 Fontaniva (PD)
tel. +39 049 5942402
fax +39 049 5942212
[email protected]
Marketing Office
[email protected]
Web sites
www.binotto.com
www.mariz.com
www.binottouk.co.uk
www.binotto.co.uk
www.binottoiberica.es
www.binottoiberica.net
www.binotto.com.au
www.binotto.pl
www.binotto.be
www.binottochina.cn
www.binotto.ru
www.binotto.eu

choose compose lift

Transcription

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