10-2014 BOX Use and...Dismantled tyre inflation cage, complete with screws and expansions plugs for securing it to the floor; screws, washers and U-bolts for securing the steel sheets

SECUR BOX

10-2014

USE AND MAINTENANCE MANUAL UK

EN

GLIS

H

BURST TYRE PROTECTIVE CAGE

MODEL: SECUR BOX NUMBER:CONSTRUCTION YEAR:

Constructor

CORMACH SRL Via A. Pignedoli, 2

Correggio (RE) Italy

Tel. +39 0522 631274 - Fax +39 0522 631284 www.cormachsrl.com

These use instructions refer to the cage offering protection against bursting tyres. The use instructions are an essential part of the product and must be available if it is transferred and/or sold. Each cage has an ID plate.

Authorised technical service Contact the manufacturer regarding all problems.

The guarantee period is 1 (one) year commencing from date of purchase. The guarantee covers any faulty spare parts and does not include labour costs and any shipping costs. Repairs under guarantee will be effected only if manufacturing faults or poor quality of material are recognised. The guarantee shall cease automatically if the fault is due to:

damage during shipment, tampering, repairs or modifications without the manufacturer’s approval, improper use, lack of maintenance, incorrect positioning during work, and bursting of a tyre.

CORMACH SRL - Via A. Pignedoli, 2 - 42015 Correggio (RE) - Italy – Tel. +39 0522 631274 - Fax +39 0522 631284 - [email protected]

3

INDEX

1. General information1.1 Introduction 1.2 Special signs 1.3 Composition of the supply

2. Description off SECUR BOX CAGEDeclaration of conformity

3. Transport, unpacking, fitting, installation, assembly and handling3.1 Transport 3.2 Unpacking 3.3 Installation

3.3.1. Place of installation 3.3.2. Securing appliance to floor

3.4 Assembly 3.5 Replacing parts of the structure deformed by a tyre burst 3.6 Shifting

4. Inflating4.1 Putting into service 4.2 Operation

5. Routing maintenance5.1 Screw check 5.2 Lubrication

6. Troubleshooting

7. Storage and restoring for further duty7.1 Storage 7.2 Restoring for further duty

8. Dismantling, and separation of materials into categories

9. Spare parts

10. Technical specifications

11. Drawing and drafts


4

1. GENERAL INFORMATION

1.1 INTRODUCTION

This manual was prepared to ensure the appliance is used in the best possible way. We urge you to read the manual to the letter before attempting to use the appliance.

If your read the following chapters carefully, you will obtain useful information on installation, use and maintenance. Knowledge and strict observance of current laws/standards both regarding prevention of accidents in the work place, and systems, is essential for correct use. Correct, reliable operation of the appliance depends on rational use and accurate maintenance. If faults or malfunctions occur, parts must be replaced with originals supplied by the manufacturer or by its service organisation.

We thank you for selecting our appliance, and assure you we shall always endeavour to provide both an increasingly efficient service and equipment of improved quality and performance.

1.2 SPECIAL SIGNS

BEFORE ATTEMPTING ANY JOB, CAREFULLY READ ALL THE INSTRUCTIONS. PAY SPECIAL ATTENTION TO BORDERED INSTRUCTIONS.

THIS SIGN INDICATES POTENTIAL DANGER – TAKE ALL PRECAUTIONS TO PREVENT DANGEROUS SITUATIONS OCCURRING.

1.3 COMPOSITION OF THE SUPPLY

Dismantled tyre inflation cage, complete with screws and expansions plugs for securing it to the floor; screws, washers and U-bolts for securing the steel sheets to the structure.

Operating and maintenance manual.

2. DESCRIPTION OF SECUR BOX CAGE

This appliance was built to enable safe inflation of tyres of the maximum dimensions and at the pressures indicated in the technical specifications;

USING THE APPLIANCE OR ITS PARTS FOR DIFFERENT PURPOSES IS FORBIDDEN.

The cage is supplied dismantled and includes complete installation instructions. The structure consists of a frame of press-formed steel tubes to which a perforated metal sheet is rigidly secured. Tyres can be inserted through an opening with door at the front end. The door is usually open, and is held open by appropriate hinges so that its non closed state is evident. The door can be closed only by drawing the bolt. The entire structure must be anchored to a concrete base by means of screws and expansion plugs.


5

Tyres are inflated by compressed air supplied by a compressor (not included in the supply) or electronic device (optional item that can be installed at any time). Compressor to tyre connection is achieved by approved pipes and appropriate regulators with pressure gauge.

If a tyre bursts at high intensity, part of the structure can be deformed; any deformed pats must be replaced with original spare parts. All cage parts can be replaced individually.

DECLARATION OF CONFORMITY

CORMACH SRL Via Mons. Pignedoli, 2 - CORREGGIO (RE) - ITALIA

declares, under its exclusive responsibility, that the safety device BURST TYRE PROTECTION CAGE

SECUR BOX

CONFORMS TO THE ESSENTIAL SAFETY REQUIREMENTS SPECIFIED IN DIRECTIVE 98/37/EC AND SUBSEQUENT AMENDMENTS

Correggio, 10/01/08

CORMACH SRL

3. TRANSPORT, UNPACKING, FITTING, INSTALLATION AND HANDLING

The operations described in the following chapter must be carried out by mechanical experts, with a knowledge of the capacities of the systems used to lift and handle the appliance, and the regulations concerning safety at work.

3.1 TRANSPORT

The cage is transported fully dismantled and, therefore, its overall dimensions are highly compact. There are no particularly specifications regarding temperature and relative humidity of the handling and storage place. Avoid violent impact. The weight of an individual cage including packing is shown in the technical specifications; use lifting and handling systems approved for capacities above the weight to be lifted. When the appliance is delivered, check the condition of the pack, both to note any damage occurring during transport, and also check that the goods received correspond to those indicated in the shipping documents. Anything out of order must be indicated on the accompanying documents. Regarding manual handling, do not exceed the weight a single person is permitted to lift as specified by law.


6

3.2 UNPACKING

Unpacking entails removing the film of plastic used to wrap the set of pieces making up the cage. To do this, place the pack on the floor, making sure that the cage cover, i.e. the formed, perforated steel sheet, faces upward. You may cut the plastic film with a sharp blade or scissors. Packing material must be disposed of according to law or local authority regulations.

3.3 INSTALLATION

3.3.1 PLACE OF INSTALLATION

� Installation must be carried out by trained personnel observing current laws/standards.

� The place of installation must be selected carefully according to the following conditions:

� The place must not be subjected to explosion hazard.

� The structure of the building or outdoor enclosure must not contain parts that could yield following bursting of a tyre.

� The structure must be particularly resistant, be of a minimum height of 3.5 m, and have ample openings toward the outside.

� THERE MUST BE NO OBJECTS THAT COULD BE PROJECTED, OR OBSTACLES OF ANY KIND OR CONSISTENCY WITHIN A 2M WIDE BELT COMMENCING FROM THE PERIMETER OF THE APPLIANCE (Page 12).

� THERE MUST BE NO OBJECTS WHICH COULD CAUSE PARTICULARLY DANGEROUS SITUATIONS IN A 16M WIDE BELT COMMENCING FROM THE PERIMETER OF THE APPLIANCE (e.g. Glass panels or other articles that could be dangerous following the shock wave caused by a burst tyre).

� THERE MUST BE NO OTHER WORK STATIONS APART FROM THE INFLATION OPERATOR WITHIN A 16M WIDE BELT COMMENCING FROM THE PERIMETER OF THE APPLIANCE

The same warnings apply to outdoor installations.

3.3.2. SECURING APPLIANCE TO FLOOR

The appliance must be installed on a reinforced concrete floor with minimum thickness of 15 cm, without any surface roughness and adequately levelled.

Procedure for drilling securing holes:

1. Locate the base (Fig. 1) in the selected installation point.

2. Mark the positions of the holes to be drilled to match the three holes on the two longer sides of the base(Fig. 5 Detail E)

3. Drill, using a concrete grade drill with diameter suitable for the supplied expansion plugs.

4. Re-position the base to check exact position of holes with respect to the holes on the base. If positionsare incorrect, do not widen the holes but re-drill them in other positions – this will ensure the expansionplugs are tight.

5. Fit the expansion plugs.


7

Before doing the fixing/securing jobs, do all the installation jobs described in the following paragraphs.

WARNING: THE CAGE MUST BE SECURED TO THE FLOOR.

3.4 ASSEMBLY

Drill the holes in the floor before attempting any installation jobs.

1. Lay the base on the floor.2. Fit tube 1(Fig. 1), complete with door and bolt, in the holes on the base.3. Do likewise with tube 3 (tube 3 differs from tubes 2 and 4 as it has screws secured at its ends) and tube

5.4. Rotate the cage axially with respect to one of the long sides in order to lift the opposite side, so that you

can then secure tubes 1,3 and 5 to the base with the supplied nuts (Fig. 1 Detail A).Before securing with the nuts, make sure the base is stable. If the base is not maintained stable, partscan overturn and crush arms or legs.

5. Secure the tubes on the other side as described in the previous point.6. Position the structure over the holes drilled in the floor, making sure all expansion plugs were fitted.7. Fit tubes 2 and 4 (Fig. 1) in the holes.8. Fit the U-bolts on the upper side and on the lateral sides, using the pertinent holes (Fig. 2 Details B).9. Fit the protective roof inside the cage, securing it to the U-bolts using the supplied screws and nuts (Fig.

3 Detail C), making attention to assemble the screws inside and the nuts outside the cage.10. Fit two safety walls in the cage, and securing them to the U-bolts with the relevant plates, repeat this

with the other two walls (Fig. 4 Detail D), making attention to assemble the screws inside and the nutsoutside the cage.

11. Secure the structure to the floor using the supplied screws (Fig. 5 Detail E).12. Fit the earth connection (Fig. 5 Detail E) and connect it to the earthing system of the building according

to current standards/regulations.

3.5 REPLACING PARTS OF THE STRUCTURE DEFORMED BY A TYRE BURST

If a particularly violent tyre burst occurs, parts of the structure could be permanently deformed. Deformed parts can be replaced individually; for dismantling and installation operations, observe the instructions in paragraph 3.4.

3.6 SHIFTING

The cage can only be shifted during installation. It cannot be shifted after installation, unless all securing screws are removed. Shifting operations must be done with lifting systems positioned under the base of the structure. Use the lifting points indicated on the labels. We recommend use of a transpallet

The structure cannot be lifted with hooks or other systems anchored to walls or tubes


8

4. INFLATING

BEFORE BEGINNING ANY OPERATION MAKE SURE NO DANGER SITUATIONS CAN OCCUR WHICH MIGHT HARM YOURSELF OR OTHERS.

4.1 PUTTING INTO SERVICE

This appliance does not require any adjustments or particular measures before being put into service.

Only the following checks are necessary: the condition of the appliance and, in particular, the door closing system; correct installation.

4.2 OPERATION

The operator must be a trained person, with knowledge of accident prevention laws and the recommendations in this manual. S/he must wear safety equipment suitable for the operations to be carried out; in particular, we recommend the following: Noise prevention head-sets to prevent damage to hearing caused by burst tyres. Safety goggles to protect the eyes against any chips. Safety gloves, shoes and clothing. S/he must have psycho-physical characteristics appropriate to the job s/he is doing.

� To use the cage, the operator must observe the following instructions to the letter: � Make sure there are no persons, or objects that could be projected, in the vicinity of the cage within the

limits shown in Page 12. � Do not inflate tyres to over 0.5. bar unless they are placed in the cage. � Place the tyre to be inflated in the cage. � Fit the Doyfe attachment � Close the door wit the appropriate bolt making sure it travels right to the end (Fig. 6 Detail F). � Begin inflating, taking care not to exceed the pressures recommended by the tyre manufacturer (in any

event, pressure must never exceed 12 bar). � While inflating, make sure no malfunctions occur to the tyre. Such malfunctions must be assessed by an

expert.

if malfunctions occur or in case of doubt, deflate the tyre before removing it from the cage.

� Open the door, by lifting the handle (Fig. 6 Detail G) . � Remove the tyre.


9

5. ROUTINE MAINTENANCE

5.1 SCREW CHECK

Check periodically if all securing screws are tight. INSUFFICIENTLY TIGHT SECURING SCREWS COULD CAUSE SERIOUS DAMAGE

5.2 LUBRICATION

Grease the following moving parts at least one a month or after long periods out of service: � hinges � bolt

6. TROUBLESHOOTING

TROUBLE CAUSE REMEDY PERSONNEL AUTHORISED TO ELIMINATE TROUBLE

Loose screws vibrations or other causes

Check all screws and, if necessary, tighten them

Personnel with a knowledge of mechanics

Door does not stay open when bolt withdrawn

hinges replace Qualifiedtechnician

Door not closing obstacles present

worn hinges

worn or deformed bolt

remove obstacles

replace

Operator

Qualified technician

Presence of rust which could weaken the structure

Impact, abrasions, burst tyres or other causes combined with humidity

paint with suitable rust-proofing paints and covering paints after checking condition of structure

Operator for superficial trouble

Qualified technician in other cases

ALL JOBS MUST BE CARRIED OUT BY QUALIFIED PERSONNEL OBSERVING SAFETY LAWS.


10

7. STORAGE AND RESTORING FOR FURTHER DUTY

7. 1 STORAGE

In the event of long out-of-service periods, store the equipment in a dry place accessible to authorised personnel only.

7. 2 RESTORING FOR FURTHER DUTY

Lubricate moving parts and check if screws are tight.

IF YOU NOTE ANY MALFUNCTIONS, REMEDY THEM BEFORE BEGINNING ANY JOB.

8. DISMANTLING, AND SEPARATION OF MATERIALS INTO CATEGORIES

Dismantling entail subdividing materials into categories. The appliance consists almost exclusively of ferrous materials, and to a small extent, plastic.

For separation, storage, recycling and disposal procedures of the above materials, observe current laws.

CORMACH SRL may improve or modify the supplied product without notifying such variations to clients. Information contained in these operating instructions are constantly updated; such modification will be included in successive editions of the instructions.

9. SPARE PARTS

For technical servicing and spare parts, also after the guarantee period, you must advise the manufacturer of the identification data shown on the ID-plates and the serial number stamped on the structure.

When ordering spare parts, quote the following information:

1. Type of appliance2. Serial number3. Part number (Fig. 1 and Fig. 2)4. Quantity


11

10. TECHNICAL SPECIFICATIONS

Overall dimensions for transporting the appliance

length 1750 mm

width 970 mmheight 500 mm

Dimensions of installed cage (Fig. 7)

length 1730 mmwidth 962 mmheight 1685 mm

Maximum tyre dimensions

diameter 1600 mmwidth 800 mm

Maximum permitted tyre inflation pressure : 12 bar Weight of appliance, packing included: 190 kg. Noise level: no parts of the cage produce noise during normal operation.

11. DRAWINGS AND DRAFTS

- Safety distances - Machine assembly draft (Fig. 1-6) - Overall dimensions (Fig. 7)


12

FIG. 1

12

34

5

- Fit tubes 1, 2, 3, 4, 5 in the holes on the base (see drawing) - Fit tubes 1, 3, 5 on the base with the nuts (see detail A)

DETAIL A

FIG. 2- Fit the U-bolts on the upper side on the lateral sides, using the pertinent holes (see detail B)

DETAIL B


13

FIG. 4

FIG. 3

- Fit the protective roof and securing it to the U-bolts using the supplied screws (see detail C), making attention to assemble the screws inside and the nuts outside the cage

DETAIL C

- Fit the safety walls and securing them to the U-bolts with the relevant plates (see detail D), making attention to assemble the screws inside and the nuts outside the cage

DETAIL D


14

FIG. 5

FIG. 6

- Secure the cage to the floor using the holes on the base, with the supplied screws and connect it to the earting system (see detail E)

DETAIL E

DETAIL F

DETAIL G


15

FIG. 7


16

CORMACH S.r.l. via A. Pignedoli, 2 42015 CORREGGIO (RE) ITALY Tel. +39 0522 631274 - Fax +39 0522 631284 e-mail: [email protected] www.cormachsrl.com

10-2014 BOX Use and...Dismantled tyre inflation cage, complete with screws and expansions plugs for securing it to the floor; screws, washers and U-bolts for securing the steel sheets

Documents