Engcon PC3200 User manual

User manual
COMPACTOR
PC3200 | PC6000 | PC9500
Article 9000514 | Version 1.3
Original Instructions

Preface
Preface
Dear Customer,
Thank you for choosing a product from engcon.
engcon is the market leader in tiltrotators and tools for excavators. We represent
innovation, knowledge and experience, and we develop our products with a focus on the
customer's needs. Please visit our website for contact information and details about the
rest of our product range.
www.engcon.com
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Table of Contents
Table of Contents
1. Introduction
1.1. General............................................................................................................ 4
1.2. Scrapping and recycling.................................................................................. 4
1.3. Warranty.......................................................................................................... 5
1.4. Technical support and spare parts.................................................................. 5
1.5. Product approval............................................................................................. 6
1.5.1. EC Declaration of Conformity.................................................................. 6
2. Safety
2.1. General............................................................................................................ 7
3. Design and function
3.1. General............................................................................................................ 8
3.2. EC-Oil.............................................................................................................. 8
4. Installation
4.1. Identification.....................................................................................................9
4.2. Mechanical.......................................................................................................10
4.3. Electrical and hydraulics..................................................................................11
4.3.1. Installing hydraulic hoses.........................................................................11
4.4. On completion................................................................................................. 12
5. Operation
5.1. Before and during use.....................................................................................13
5.1.1. Operation................................................................................................. 13
6. Maintenance
6.1. General............................................................................................................ 15
6.2. Daily inspections..............................................................................................16
6.3. Special maintenance....................................................................................... 17
6.3.1. EC-Oil.......................................................................................................17
6.4. Oil change....................................................................................................... 17
6.5. Tightening torque.............................................................................................17
7. Decals
7.1. Warning decals................................................................................................19
7.1.1. Warning decals in cab............................................................................. 19
7.1.2. Symbol legend......................................................................................... 19
8. Technical data
8.1. Compactor....................................................................................................... 21
9. Glossary
9.1. Designations.................................................................................................... 22
9.2. Abbreviations................................................................................................... 22
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1 Introduction
1. Introduction
1.1. General
This user manual contain important information about your product's functions and
characteristics, and how to use it in the best way. Before you begin using the product, it is
important that you read and understand the content of these instructions, especially the
sections that address safety.
In addition to these instructions, you must study and understand the applicable safety
information for the relevant base machine as well as any other equipment involved.
The user manual is supplied with supplementary documentation providing more detailed
descriptions of the installation, fitting, operation and maintenance of control systems and
custom modifications for your specific product.
Information, images, illustrations and specifications used in the instructions are based
on product information that was available at the time of going to press. Images and
illustrations used in the instructions are typical examples and not intended to be exact
depictions of various part of the product. We reserve the right to make changes without
prior notice.
Always store the user manual together with any other supplementary information in a safe
manner and such that it is always available.
1.2. Scrapping and recycling
engcon makes constant efforts to reduce its environmental impact. engcon's products
comprise at least 99 per cent recyclable material. All assembly and service work must
take place in compliance with legislation and ordinances governing the environment,
health and occupational safety. This refers to all work with residual materials including
handling, storage and processing. To prevent contamination of soil and water, spillages
must be avoided. Should a spillage occur, it must be dealt with.
Hazardous waste may only be disposed of by those authorised to do so. All waste
produced must be disposed of in compliance with applicable legislation and ordinances:
- Metal and plastics to be recycled.
- Hydraulic hoses are normally used for energy recovery (sort as hazardous waste).
- Oils and greases are normally used for energy recovery (sort as hazardous waste).
- Electronic components to be recycled for materials (sort as hazardous waste).
- Packaging to be sorted at source and recycled for materials.
- Paper to be sorted at source and recycled for materials.
If in doubt, contact the environmental manager at engcon.
4

1 Introduction
1.3. Warranty
This product was designed, dimensioned and manufactured by engcon. It is forbidden
to modify, alter or convert this product such that it no longer corresponds to the
manufacturer's specifications. When replacing parts or making repairs, contact an
authorized workshop.
Warranty: One (1) year providing the product has not been subjected to abuse or other
abnormal operation.
1.4. Technical support and spare parts
Contact information for support and spare parts can be found at www.engcon.com.
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1 Introduction
1.5. Product approval
1.5.1. EC Declaration of Conformity
Manufacturer:
engcon Nordic AB
Address:
Box 111
Postal address:
SE-833 22 STRÖMSUND
Country:
SWEDEN
Telephone:
+ 46 670 178 00
Telefax:
+ 46 670 178 28
Email:
[email protected]
Hereby declare that:
Description of the machine
Type designation:
Part no:
Serial No:
Date of delivery:
Other:
has been manufactured in accordance with the EC Machinery Directive 2006/42/EC
-SS-EN ISO 12100:2010, SS-EN 474-1:2006+A5:2018 and SS-EN 474-5:2006+A3:2013
The following standards and directives have also been applied and complies with:
This declaration and engcon's warranties will cease to be valid immediately if spare parts other than engcon
original spare parts are used, or if any changes or other interventions are made without engcon's permission.
Title: CEO
Name: Stig Engström
Date:
Signature:
Qualified person authorised to compile the technical documentation:
Johan Johansson, Construction Manager, Poland Sp. Z. oo.
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2 Safety
2. Safety
2.1. General
It is important that you read and understand all warnings prior to installation work on this
product or before you use it and any accessories supplied. The warning texts highlight
potential risks and describe how to avoid them. The following warning levels are used in
this user manual:
DANGER
Indicates that an accident will occur if the regulation is
not followed. Risk of personal injury or death.
WARNING
Indicates that an accident may occur if the regulation
is not followed. Risk of personal injury or death.
CAUTION
Indicates that an accident may occur if the regulation
is not followed. Risk of personal injury.
IMPORTANT
Indicates that an accident may occur if the regulation is
not followed. Risk of damage to property, process or the
surroundings.
REMARKS
Specifies additional information that may make performance or
understanding of specific operations easier.
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3 Design and function
3. Design and function
3.1. General
The engcon compactor is intended for the compaction of soil. The tool has a bolt-on
gate/attachment point that allows the attachment point to be changed easily when
necessary. The compactor consists of a vibrating plate and body connected to each other
via vibration dampers. As a safety measure, two chains are fitted between the plate and
frame. Vibration is created by a hydraulic motor acting on the compactor plate via an
eccentric shaft located in the body.
DANGER
Do not exceed tipping load limits. The weight of the
product and the increased reach may impair stability.
Risk of personal injury and damage to property.
3.2. EC-Oil
engcon’s system for more efficient tool changes. It provides the ability to switch hydraulic
tools without leaving the cab. The system is designed for maximum reliability in harsh
environments. It is a fully hydraulic system that handles the connection of tools under full
system pressure.
Figure 1.
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4 Installation
4. Installation
It is important to check the necessary additional documentation before installation. At time
of delivery, your product and supplementary documentation are as far as possible adapted
to your base machine.
WARNING
Never attempt to increase the maximum capacity
of the equipment by modifications not approved by
the supplier. Risk of personal injury and damage to
property.
WARNING
If you have any doubts concerning the safety aspects
of your knowledge, the equipment or work, contact
a dealer or engcon Nordic AB. Incorrect installation
affect safety.
WARNING
Welding is not permitted. It can have a negative
impact on safety. Risk of personal injury and damage
to property. For welding, contact your dealer or
engcon Nordic AB.
WARNING
Beware of moving parts. A lack of awareness may lead
to crush injuries. Risk of personal injury.
IMPORTANT
Ensure miscibility with the base machine's hydraulic oil
prior to installation. If you are in any doubt, contact your
lubricant supplier. An incorrect mixture could damage hydraulic
components.
4.1. Identification
Check that your product's rating plate matches the information on the EC Declaration
of Conformity. If there is any deviation, contact the supplier before you begin initial
installation.
9

4 Installation
Rating plate content:
Type designation
Part number
Serial number
Year of manufacture
Weight
Max hydraulic pressure
Figure 2. Bildtext
4.2. Mechanical
If the product is installed on a machine hitch, tiltrotator or rotator, use
the user manual for connecting tools.
DANGER
Do not exceed tipping load limits. The weight of the
product and the increased reach may impair stability.
Risk of personal injury and damage to property.
WARNING
If you have any doubts concerning the safety aspects
of your knowledge, the equipment or work, contact
a dealer or engcon Nordic AB. Incorrect installation
affect safety.
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4 Installation
4.3. Electrical and hydraulics
4.3.1. Installing hydraulic hoses
1. Make sure the tool is level and resting stably.
2. Connect the base machine’s machine hitch/tiltrotator to
the tool.
3. Stop the engine and depressurise the base machine's
hydraulic outlet by operating the tool's functions.
WARNING
The hydraulic system
must be de-pressurised
before work on the
system is begun. Risk
of personal injury and
damage to property.
4. Connect the hydraulic hoses to the base machine's
hydraulic outlets. Make sure the correct hydraulic outlets
are used.
Use free return to tank. The back pressure in the return
line may not exceed 1 MPa (10 bar).
Figure 3.
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4 Installation
4.4. On completion
1. Affix the warning decals supplied in a conspicuous
place in the operator's cab, without obscuring operator
visibility.
WARNING
Replace damaged or
illegible signs and
decals before using
the machine. Risk of
personal injury and
damage to property.
2. Carry out function checks:
Figure 4.
- Run all the tool functions a few times to remove any air
from the system. Important for preventing uncontrolled
movement.
- Make sure the tool operates when the hydraulics are
running.
- Check that the hoses are not subjected to pinching,
cutting or stretching.
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5 Operation
5. Operation
5.1. Before and during use
Check your base machine manufacturer's recommendations for calculating tipping loads,
and be sure to include the increased weight and reach the product entails.
DANGER
Do not exceed tipping load limits. The weight of the
product and the increased reach may impair stability.
Risk of personal injury and damage to property.
Soil is compacted through the compactor's floating motion on top of the ground. Soil
compaction is not increased by pressing the compactor against the soil with the base
machine. This will instead increase wear on the compactor thereby reducing service life.
Before using your product, remove the yellow protective covers from the EC-Oil block.
WARNING
Beware of moving parts. A lack of awareness may lead
to crush injuries. Risk of personal injury.
WARNING
Do not leave the base machine with the tool raised.
Risk of personal injury and damage to property.
WARNING
Make sure no one is present under a raised tool. Risk
of personal injury.
IMPORTANT
Check the base machine's specified max capacity. Any use
of the product in excess of base machine max capacity may
damage the machine.
5.1.1. Operation
1. Place the tool on the ground.
2. Connect the extra hydraulics to start compactor vibration.
3. Move the tool over the area intended for compaction. The compactor must "float" over
the ground.
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5 Operation
4. Finish off work by disconnecting the extra hydraulics and raising the compactor from
the ground.
5. Empty out any soil and stones that have entered between the compactor plate and the
body.
WARNING
Pay attention to the surroundings when gravel, dust
and other objects can cause inconvenience, personal
injury or harm to property.
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6 Maintenance
6. Maintenance
6.1. General
- Daily, carried out on all configurations before the machine is put into use for the working
day.
- Lubricate according to the lubrication schedule every 40 operating hours.
Intervals for greasing and inspections to be performed by the user:
DANGER
Check the attachment points regularly and be alert for
the formation of cracks. Risk of personal injury and
damage to property.
WARNING
Make sure that service and maintenance is carried out
according to the manufacturer's recommendations.
Inadequate maintenance may cause defects on the
base machine and its equipment.
WARNING
When changing hoses, only hoses with press
couplings may be used. Screw connections may
not be used. Risk of personal injury and damage to
property.
IMPORTANT
Review the personal and environmental risks of hydraulic oil
and grease by reading the safety data sheets for the hydraulic
oil and grease in use. Risk of personal injury and damage to
surroundings.
IMPORTANT
Be sure to keep your product clean. Inadequate cleaning can
cause damage to your equipment.
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6 Maintenance
6.2. Daily inspections
WARNING
Avoid contact with hydraulic oil. Risk of burns.
WARNING
Never use your hands to search for leaks in the
hydraulic system. Use the necessary protective
equipment. Pressurised hydraulic oil can penetrate
the skin. Risk of personal injury.
WARNING
Beware of moving parts. A lack of awareness may lead
to crush injuries. Risk of personal injury.
WARNING
The hydraulic system must be de-pressurised before
work on the system is begun. Risk of personal injury
and damage to property.
Check daily:
- that there are no cracks or damage present
- Check that the rubber dampers are intact.
- that warning decals are in position and legible
- Check that the tool is properly attached to the quick hitch/machine hitch.
- that there are no hydraulic leaks; replace worn or damaged hydraulic hoses.
- Check that the product is clean. Clean the product. Be very sure to clean the hydraulic
components.
WARNING
Always make sure the latches protrude as specified
for the quick hitch concerned. The tool may only be
used if locking is correctly completed.
WARNING
Replace damaged or illegible signs and decals before
using the machine. Risk of personal injury and
damage to property.
16

6 Maintenance
WARNING
Welding is not permitted. It can have a negative
impact on safety. Risk of personal injury and damage
to property. For welding, contact your dealer or
engcon Nordic AB.
6.3. Special maintenance
6.3.1. EC-Oil
Cleaning
- Clean oil connections, electrical
connectors, grease connections and
dirt guards before and after use in order
to avoid oil or grease leakage and
safeguard EC-Oil function.
- If oil or grease leakage occurs despite
cleaning, we recommend face seal
replacement.
- Clean electrical connectors daily and
spray with water repellent.
Figure 5. Bildtext
Guard
During transport and extended layups, use
the protection supplied on the EC-Oil block.
Figure 6.
6.4. Oil change
Change the generator oil annually with 10w/30 mineral oil. Oil quantity: 0.2l.
6.5. Tightening torque
Top bracket
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6 Maintenance
Type
Dimension
Quality
Quantity
Torque
PC3200
M16
8.8
12
197 Nm
PC6000
M16
8.8
8
197 Nm
PC9500
M24
8.8
8
665 Nm
Table 1.
EC-Oil hydraulic connectors
Type
Fastener
Quantity
Torque
ECO45/50/60/70
Hydraulic connector
ECO
2
60 Nm
Table 2.
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7 Decals
7. Decals
Machine instructions, decals and warning signs must be kept clearly legible. Contact your
supplier to order replacements.
WARNING
Replace damaged or illegible signs and decals before
using the machine. Risk of personal injury and
damage to property.
7.1. Warning decals
The decals are usually placed to the right of the operator in clearly visible locations.
7.1.1. Warning decals in cab
7.1.1.1. 9000157
Figure 7. Warning decal to the right of operator.
7.1.2. Symbol legend
Take care when handling long objects. Bear in mind inertia and the
extended risk area when handling long objects.
Never stand under or pass beneath a raised tool.
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7 Decals
Leave room for rotating, tilting and sideways-moving tools. Risk area 3
metres.
Crushing hazard from moving parts.
Never exceed the base machine's approved tipping load.
Read the user manual.
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