Engcon SG09 User manual

User manual
STONE AND SORTING GRAB
SG03 | SG06 | SG09 | SG12 | SG19 | SG26 | SG33
Article 9000296 | Version 1.7
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. EU 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
4.4. On completion................................................................................................. 12
5. Operation
5.1. Before and during use.....................................................................................13
6. Maintenance
6.1. General............................................................................................................ 15
6.2. Daily inspections..............................................................................................16
6.3. Special maintenance....................................................................................... 17
6.3.1. EC-Oil.......................................................................................................17
6.3.2. Expander pin............................................................................................18
6.4. Lubricate every 16 operating hours.................................................................20
6.4.1. Grease recommendation......................................................................... 20
6.4.2. Lubrication, stone and sorting grab......................................................... 20
6.5. Tightening torque.............................................................................................20
7. Decals
7.1. Warning decals................................................................................................22
7.1.1. Warning decals in cab............................................................................. 22
7.1.2. Symbol legend......................................................................................... 22
8. Technical data
8.1. Stone and sorting grab....................................................................................24
9. Glossary
9.1. Designations.................................................................................................... 25
9.2. Abbreviations................................................................................................... 25
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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. EU Declaration of Conformity
Manufacturer: engcon Nordic AB - Industricentragatan 4, 833 93 Strömsund, Sweden
THE OBJECT OF THE DECLARATION DESCRIBED BELOW CONFORMS WITH
Directive: Machinery Directive 2006/42/EU.
Type designation:
Part no:
Serial No:
Max jacking point:
Max hydraulic pressure:
Date:
Other:
Harmonised standards
SS-EN ISO 12100:2010
SS-EN 474-1:2006+A5:2018
SS-EN 474-5:2006+A3:2013
The standards and regulatory directives have been applied and the product complies with the requirements for
CE marking.
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.
SIGNED FOR AND ON BEHALF OF
Krister Blomgren – Signatory, engcon Nordic AB
Strömsund, 2023-04-26
Qualified person authorised to compile the technical documentation:
Fredrik Jonsson, Head of R&D, engcon AB
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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
engcon’s stone and sorting grab is perfectly suitable for sorting waste. The tool has a bolt-
on gate/attachment point that allows the attachment points to be changed easily when
necessary.
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.
8

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.
The rating plate is located on the stone and sorting grab’s yellow body.
9

4 Installation
Ratin plate content:
Type designation
Serial number
Year of manufacture
Weight
Max hydraulic pressure
Max machine weight
Figure 2.
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.
10

4 Installation
4.3. Electrical and hydraulics
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.
Figure 3.
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4 Installation
4.4. On completion
Affix the warning decal supplied in a conspicuous place
that does not distract the operator.
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.
12

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.
Open and close the grab using the regular controls in the base machine.
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.
Before using your product, remove the yellow protective covers from the EC-Oil block.
If your product is equipped with a rotator, there are instructions for the
rotator section in the tiltrotator user manual.
The grab is not designed for lifting with chains, straps or similar.
WARNING
Use dedicated lifting equipment when lifting objects.
Risk of personal injury and damage to property.
The grab is equipped with a pressure accumulator. Be aware of the risks with pressurised
devices.
WARNING
The hydraulic system must be de-pressurised before
work on the system is begun. Risk of personal injury
and damage to property.
WARNING
Be aware of your surroundings when working with the
grab, as material can become loose and be thrown
clear. Risk of personal injury and damage to property.
WARNING
Take care when handling long objects. Take dynamic
load and the extended risk area into account. Risk of
personal injury and damage to property.
13

5 Operation
WARNING
Always make sure of a good grip when lifting objects.
Risk of personal injury and damage to property.
WARNING
Do not leave the base machine with the tool raised.
Risk of personal injury and damage to property.
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.
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6 Maintenance
6. Maintenance
6.1. General
Intervals for greasing and inspections to be performed by the user:
- Daily, carried out on all configurations before the machine is put into use for the working
day.
- Every 16 operating hours, grease according to the lubrication schedule.
If your product is equipped with a rotator, there are instructions for the
rotator section in the tiltrotator user manual.
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.
15

6 Maintenance
6.2. Daily inspections
The grab is equipped with a pressure accumulator.
WARNING
Be aware of the risks with pressurised devices. Risk
of personal injury.
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:
- No damage or cracks are present.
- Warning decals are present and legible.
- Check that the tool is properly attached to the quick hitch/machine hitch.
- There are no hydraulic leaks.
- Check that the product is clean. Clean the product. Be very sure to clean the hydraulic
components.
- That divisible bolted joints are tightened. If any bolted joint is loose, tighten it according
to 6.5. Tightening torque
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6 Maintenance
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
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
Replace damaged or illegible signs and decals before
using the machine. Risk of personal injury and
damage to property.
6.3. Special maintenance
6.3.1. EC-Oil
Cleanin
- 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
17

6 Maintenance
Guard
During transport and extended layups, use
the protection supplied on the EC-Oil block.
Figure 6.
6.3.2. Expander pin
The information in this section makes sure the expander pins are properly installed and
that the system is detachable in connection with service or joint bearing changes.
6.3.2.1. Recommended tightening and retightening torque
Torque recommendation
Screws
Unit
M12
M14
M16
M20
M24
M30
M36
M42
(Nm)
70
115
175
350
500
600
700
900
Table 1. Table text
Nuts: Standard hei ht
Unit
M12
M14
M16
M20
M24
M30
M36
M42
(Nm)
65
115
175
250
350
500
600
700
Table 2. Table text
Check tightening torque during scheduled maintenance Set the recommended torque
according to Table 1. and Table 2. . Apply torque to the torque wrench until the set the
value is achieved.
Reti htenin
Retightening the expander pins is crucial for successful installation.
Grease the joint between the expander pin and the attachment. We recommend grease
with 3-5% molybdenum sulphide to minimize shaft wear and increase the load-bearing
capacity of the hinge.
Reti htenin intervals
Operating hours
- After 1 hour
- After 3 hours
18

6 Maintenance
- After 10 hours or 1 day*
- After 40 hours or 4 days*
* If no additional torque is added when retightening the pins, the installation is successful.
If the expander sleeves have not bedded in after one week's operation, contact your
dealer.
6.3.2.2. Removal
1. Unscrew the fasteners on both sides and remove any washers.
2. Tap the shaft body until the sleeve on the impact side releases. Use a pipe as a drift
between the hammer and the shaft to prevent damage to the threads. Make sure the pipe
is not touching the sleeve, and that its internal diameter is slightly larger than the thread.
3. Remove the sleeves and the shaft.
6.3.2.3. Before installation
Do not try to install the expander pins with the wrong sleeve size or the pins will not work.
- Make sure there is no structural damage present (e.g. broken or severely deformed
lugs) that could affect attachment point alignment. If damage is present, the system
may not function as expected.
- Repair any damage.
- Check maximum and minimum wear in the attachment lug hole to make sure you have
the correct size expander sleeve for each side of the shaft. Each sleeve expands max
2 mm. If maximum wear exceeds this value, contact your dealer to order a suitable
oversize sleeve.
- Visually inspect the attachment lug hole. Remove
any sharp edges and other unevenness. If the
difference between maximum and minimum wear
is greater than 1.5 mm, the hole must be drilled out
or ground so that ovality is less than 1.5 mm.
MAX - MIN < 1.5 mm
In the case of extreme wear, contact your dealer.
Figure 7.
6.3.2.4. Installation
1. Grease the shaft and expander sleeves with bearing grease to make installation easier.
Start by installing the shaft body, followed by the sleeves, washers and fasteners. Take
care not to damage the threads or the conical parts in the expander pins.
2. Centre (normal) or position (inset versions) the shaft in the correct position and then
tighten the fasteners by hand.
3. See Table 1. and Table 2. before tightening the pins. Measure the pins or check the
delivery note to ascertain fastener thread sizes. Tighten the expander pins alternately to
the recommended torque to achieve even installation.
19

6 Maintenance
The sleeve must always protrude to ensure expansion. The washer (or fastener, for
variants without washers) must never come into contact with the end of the shaft body
or attachment lug. Should this occur, go to section 6.3.2.2. Removal and follow the
instructions under step 2. If the washer on either side comes into contact with the
attachment point lug or the end of the shaft body, the sleeve is the wrong size. The
expander pins must then be fitted with oversize sleeves.
4. Grease the joint with 3-5% molybdenum sulphide grease before putting the machine
into operation. Regular greasing extends the service life of the expander pins.
5. Start the base machine and move the joint back and forth. Retighten to the
recommended torque. This process makes sure the sleeves bed in.
6.4. Lubricate every 16 operating hours
engcon recommends greasing at 16 hour intervals. See chapter 6.4.2. Lubrication, stone
and sorting grab.
When working in water, the lubrication interval is reduced to 8 hours.
If your product is equipped with a rotator, there are instructions for the
rotator section in the tiltrotator user manual.
6.4.1. Grease recommendation
The tiltrotator’s worm gear is factory filled with the recommended lithium-based universal
grease (NLGI 2). This grease is often miscible with other greases of similar type.
Always check with your dealer to ensure miscibility. The use of inferior grease categories
will lead to increased consumption.
6.4.2. Lubrication, stone and sorting grab
The arrows show the location of the grease nipples.
Grease quantity: 3-4 pump strokes per nipple.
6.5. Tightening torque
Bolts and threaded holes must be thoroughly clean and the threads oiled.
20