ROZZI S.p.A.

ATTREZZATURE PER GRU IDRAULICHE

Via Barca, 7
ÉQUIPEMENTS POUR GRUES HYDRAULIQUES
25020 SENIGA (BS)
EQUIPMENTS FOR HYDRAULIC CRANES
TEL. 030/9955450
ZUSATZGERÄTE FÜR HYDRAULISCHE KRÄNE
S.p.A FAX 030/9955363
EQUIPOS PARA GRÚAS HYDRAULICOS
www.rozzi.it mail@rozzi.it
.

MANUALE USO E MANUTENZIONE

USE AND MAINTENANCE MANUAL

MANUEL D'UTILISATION ET ENTRETIEN

GEBRAUCHS- UND BETRIEBSHANDBUCH

MANUAL DE USO Y MANUTENCION

ER800 32294
2008 0,8
4000 2100
 INDEX
GUARANTEE .....................................................................................................................................................2
1) USE AND CARE OF THE "USE AND MAINTENANCE MANUAL" ...............................................................3
1.1 Cases which alleviate the manufacturer from responsibility.....................................................................3
1.2 Request for a new manual ........................................................................................................................3
1.3 Limits to manual’s use ..............................................................................................................................3
1.4 Updates to Manual....................................................................................................................................3
1.5 Additional information and explanations ...................................................................................................3
2) EQUIPMENT DESCRIPTION ........................................................................................................................4
2.1 Technical data...........................................................................................................................................4
2.2 Dimensions (see enclosed dimensional scheme).....................................................................................4
2.3 Functioning description of the electro hydraulic plant...............................................................................4
3) OPERATING CONDITIONS...........................................................................................................................5
4) GENERAL SAFETY PRECAUTIONS ............................................................................................................6
5) INSTRUCTIONS.............................................................................................................................................7
5.1 Specialised personnel...............................................................................................................................7
5.2 Transport instructions ...............................................................................................................................7
5.3 Assembly instructions ...............................................................................................................................7
5.4 Prohibitions and instructions for use .........................................................................................................8
6) MAINTENANCE .............................................................................................................................................9
6.1 Compulsory checks to be made by the operator before switching on ......................................................9
6.2 Ordinary maintenance...............................................................................................................................9
6.3 Extraordinary maintenance .....................................................................................................................10
6.4 Assistance service ..................................................................................................................................10
6.5 Hydraulic circuit trouble shooting ............................................................................................................11
6.6 Calibration and regulation .......................................................................................................................12
7) REGISTER ...................................................................................................................................................13
7.1 Installation card .......................................................................................................................................13
7.2 Inspections, periodical checks and extraordinary interventions card .....................................................13
7.3 Instructions for care ................................................................................................................................14
7.4 Writing up instructions.............................................................................................................................14
8) SECURITY SIGNALS...................................................................................................................................14
9) DISASSEMBLY, DISMANTLING AND DEMOLITION .................................................................................15

• Schemes – Enclosures – Optional

Manual version: ER 800

1
 GUARANTEE

Conditions of guarantee for ROZZI products:

• Every equipment produced is guaranteed for a period of twelve (12) months from the date of delivery;
• During the course of the guarantee, ROZZI S.p.A assures the substitution free of charge of any
accessory, component or part that, under the unobjectionable view of its technicians, shows defects to the
material and/or the workmanship;
• The inspection of accessories, components, or parts of equipment is to be carried out solely at the ROZZI
S.p.A premises.
• All items subject to guarantee must reach the ROZZI S.p.A. under “free port”, while the return of items
replaced under guarantee will be made without further costs;
• Any investigations in locus and labour costs relevant to the substitution of the defective items are
payable by the client;
• Not covered by the guarantee are all those components and accessories subject to normal wear and tear
through regular use of the equipment.

The guarantee is no longer valid under the following conditions:

1. Lack of observation, even if minimal, of the instructions contained in the “Use and Maintenance
manual” supplied with the equipment;
2. Improper use of the equipment;
3. Use of the equipment by untrained personnel;
4. Unauthorised interventions and modifications;
5. Use of non original spare parts;
6. Use of spare parts not in compliance with the type of equipment supplied;
7. Atmospheric and climactic conditions or exceptional events unforeseen during the planning stages.

2
1) USE AND CARE OF THE "USE AND MAINTENANCE MANUAL"
• The use and maintenance manual is intended for the attention of those responsible for installation,
transport, maintenance, overhaul and repair of the equipment as well as for all operators who use the
apparatus during its function. Especially important are those sections of the manual relevant to work
safety.
• The information contained in this manual serves to highlight the correct use of the equipment, according
to the anticipated purposes of design and construction.
• Furthermore, there are indications regarding handling, installation, maintenance, overhaul and problem
troubleshooting all of which respect the limits imposed by the manufacturer as mentioned in this manual.
• The use and maintenance manual is an integrative part of the equipment and must be kept until the latter
is dismantled.
• The manual must be kept in a secure place and always in the vicinity of the equipment, and
consequently, at the complete disposal of anybody requiring it for consultation.
• The manufacturer reserves the right to modify the machine and the manuals without any obligation to
up-date previous editions.
• The user may ask for information and adjournments which, when supplied, form an integral part of the
manual.
• The user is invited, in the event of sale of the equipment, to pass on the manual and to inform the
manufacturer about the new owner.

1.1 Cases which alleviate the manufacturer from responsibility

The manufacturer is relieved from any responsibility in the following cases:
1. Improper use of the equipment or its use by untrained personnel;
2. Improper use according to particular national norms;
3. Incorrect installation;
4. Feeding defects;
5. Serious absence in foreseen maintenance;
6. Unauthorised modifications or interventions;
7. Use of non original spare parts;
8. Total or partial disregard of instructions;
9. Missed up-dates to compilation/subscription of the intervention cards and of the relevant sheets;
10. Exceptional events.

1.2 Request for a new manual

Should the manual be lost or damaged the user may ask the manufacturer for a new copy
indicating the following data:
1. Model;
2. Part number;
3. Year of construction.

1.3 Limits to manual’s use

This manual is intended for professional use. For this reason the use and maintenance
manual may never substitute an operator’s appropriate, practical experience.

1.4 Updates to Manual

The manufacturer reserves the right to update his produce and thereby, the relevant manual
without any obligation to inform previous owners.

1.5 Additional information and explanations

Any owner of this manual may get in touch with the manufacturer to ask for additional
information and explanations regarding the correct use of the equipment as well as any information
regarding interventions and/or repairs and installation.
3
2) EQUIPMENT DESCRIPTION

The polyp-grab model ER 800 is a handling unit consisting in 6 tines of independent movement.
Each one is operated by a double acting hydraulic cylinder. The tines and cylinders are fixed onto a robust
frame-work.
The under pressure oil necessary for the cylinders functioning is supplied by an electro hydraulic
station equipped with a three positions distributor which, according to its position, opens, closes or stops the
grab.
The electric control console, mounted on the lifting means, allows the starting of the electric motor
and of the electro distributor.

2.1 Technical data

MODEL ER800 6S ER800

WEIGHT daN (kg) 2050 2100
VOLUME m³ 0.8 0.8
LIFTING POWER daN (kg) 4000 4000
TINE FORCE daN (kg) 2200 2200

MAX. WORKING PRESSURE 180 bar

No. OF CYLINDERS 6
OPENING TIME 7.5 sec.
CLOSING TIME 11.5 sec.
ELECTRIC MOTOR POWER 15 kW
ELECTRIC MOTOR VOLTAGE 380 Volt 50Hz
ELECTROVALVES VOLTAGE see enclosed electrical scheme
MAX. MOTOR ABSORPTION 32 A + 10%
LOWER LINKAGE (*)

(*) IT IS ABSOLUTELY FORBIDDEN TO USE THE LOWER LINKAGE TO LIFT LOADS.

2.2 Dimensions (see enclosed dimensional scheme)

2.3 Functioning description of the electro hydraulic plant

The electro hydraulic equipments belonging to the ER range are equipped with an axial pistons pump
having an inclined plate system with variable cubic capacity. The plate location allows a capacity variation.
The plate inclination is regulated by the X pilotage (see hydraulic scheme). A pressure control valve is
mounted on such a pilotage (pos. 4 hydraulic scheme) which, when the max. calibration pressure is reached,
discharges the pilotage oil into the tank. As a consequence there is a reduction of the pump's cubic capacity,
till when the uses require no more capacity, maintaining in such a way the plant at a steady pressure,
independently from the blow-by and from the leakages due to the drainages. When the uses require a bigger
capacity, there is a pressure reduction in the circuit. As a consequence the valve closes and takes the pump
back to the max. cubic capacity.
Because of the special configuration of the circuit, it is possible to put on discharge the X pilotage of
the pump also through the electrovalve (pos. 6 hydraulic scheme) only in the case this one is in the central
position, that is to say when the equipment is not in the opening or closing phase. In such way the oil
circulation is reduced to the minimum when the equipment is still, avoiding the danger of overheating.

4
 In this phase the motion control valve begins operating (pos. 10 hydraulic scheme). It maintains
under pressure the circuit downstream, by blocking the cylinders in the position where they are. The valve is
blocked till the moment in which the circuit pressure value upstream does not increase. The grab opening
and closing operate electro hydraulically. The under pressure oil produced by the pump is sent to the
distributor which, according to its position, sends the oil either to the part A of the cylinder (grab closes) or
to the part B (grab opens) (see scheme 1.1). The LP valve which limits the pressure avoids to have a too high
pressure in the circuit, in case of a breakdown into the control system. This valve is located between the
pump and the distributor. If the pressure value in the circuit exceeds the calibration value of the valve, this
one opens and sends the oil directly into the tank.

3) OPERATING CONDITIONS
DO NOT USE THE GRAB WITHOUT HAVING FULLY UNDERSTOOD THE
INSTRUCTIONS CONTAINED IN THIS MANUAL.

Polyp-grabs belonging to the ER range are capable of handling metallic scrap, chips, waste or loose
material in general, with a medium specific weight not higher than 3500 daN/m³. The equipment is available
in two versions: the standard range with half-closed tines and the "S" range with open tines (teeth). The
standard range is designed to handle material of a medium-small size, while the "S" range is designed to
handle material of a larger size (blocks, compressed scrap, etc.) or material that is compressible (eg. waste,
metal chips, etc.).

Warning: it is absolutely forbidden to handle beams and any other material which does
not grant a secure hold as such an operation may cause dangerous incidents and/or breakage
of the equipment.

WORKING AREA: The working area to which the equipment is destined is related to the range of
the machine on which it is mounted. The equipment, however, requires a sufficiently large enough space
granting a diameter, which is at least as large as the grab’s maximum size when fully open.

In case the material to be handled is crammed in ditches or containers which are closed at least on 2
sides, be sure that the access surface is superior to the double of the area occupied by the equipment when it
is completely open.

WARNING: Make sure that anybody who may be working in the vicinity, keeps a safe
distance of at least 20 metres from the equipment and from the machine on which it is mounted.

If the equipment is required for a use other than the one mentioned above it is advisable to consult
the manufacturer’s technicians for advice whereupon they will provide their binding opinion.

The operating of the lifting means is restricted to trained personnel. The crane operator is
liable for the correct use of the lifting means and of the equipment. He must respect the general safety
standards and the manufacturer’s instructions for use pertaining to the means of lifting and to the
equipment.

The equipment has been designed and built to operate both in the open air and in enclosed spaces: its
function and performance are not influenced by, or are liable to, atmospheric agents except for particularly
unfavourable environment and climactic conditions.

machine =lifting means on which the grab is mounted

interface =device employed for the connection of the grab to the machine hook
equipment =grab
electric accessories =every detail placed between the electric system and the equipment (cables, connectors,
cable reel, electric switchboard and eventual push-button panel)

5
4) GENERAL SAFETY PRECAUTIONS

PROHIBITIONS:

• IT IS ABSOLUTELY FORBIDDEN TO WALK WITHIN THE MACHINE’S AND THE

EQUIPMENT’S RANGE OF ACTION: KEEP A MINIMUM SAFETY DISTANCE OF 20
METRES;

• IT IS ABSOLUTELY FORBIDDEN TO USE THE EQUIPMENT BEFORE CLOSING OFF THE

AREA TO PEOPLE AND ANIMALS: TO OBTAIN SUCH A MEANS IT IS NECESSARY TO
ENCLOSE THE WORKING AREA AND TO TAKE ANY FURTHER MEASURES
CONSIDERED NECESSARY IN ORDER TO INCREASE THE SAFETY OF EACH WORKING
STAGE;

• IT IS ABSOLUTELY FORBIDDEN TO LIFT AND HANDLE MATERIALS WHICH,

BECAUSE OF THEIR NATURE, DO NOT ALLOW A SURE TAKING;

• IT IS ABSOLUTELY FORBIDDEN TO TRANSIT ABOVE PEOPLE OR THROUGH AREAS

OF WORK WITH THE LOAD;

• IT IS ABSOLUTELY FORBIDDEN TO LIFT OR CARRY PEOPLE;

• IT IS ABSOLUTELY FORBIDDEN TO USE THE LOWER LINKAGE TO LIFT LOADS.

DANGERS:

• DANGER OF FALLING OBJECTS;

• DANGER OF SHEARING;
• DANGER OF CRUSHING;
• DANGER OF IMPACT;
• DANGER OF ELECTRIC NATURE.

OBLIGATIONS:

• THE OPERATION OF THE LIFTING MEANS IS RESTRICTED TO TRAINED PERSONNEL;

• ALL SAFETY STANDARDS INDICATED FOR THE MACHINE ARE ALSO VALID FOR THE
EQUIPMENT. IN THE EVENT OF DIFFERENCES BETWEEN THE MACHINE SAFETY
STANDARDS AND THE EQUIPMENT SAFETY STANDARDS, THE MORE RESTRICTIVE
ONES SHOULD BE APPLIED;

• THE CONFORMITY OF THE EQUIPMENT WITH THE MACHINE’S GUIDELINES IS

VALID ONLY IF THE MACHINE ON WHICH IT IS MOUNTED CONFORMS TO SUCH
GUIDELINES;

• BEFORE CARRYING OUT ANY REPAIR, MAINTENANCE OR CLEANING OPERATION,

THE FOLLOWING STEPS MUST BE COMPLETED:
1. REST THE EQUIPMENT ON THE GROUND IN A STABLE POSITION;
2. SWITCH OFF THE EQUIPMENT AND INSULATE IT FROM THE ELECTRIC
NETWORK;
3. LOCK THE GENERAL SWITCH OF THE ELECTRIC ACCESSORIES FOR THE
EQUIPMENT FEEDING ON THE “O” POSITION BY MEANS OF A PADLOCK;
4. WAIT FOR THE MACHINE’S OIL TO COOL.

6
FURTHER:
• The equipment security is related to the efficiency of the machine's and of the electric accessories’ safety
systems;
• The machine must be equipped with an acoustic and visual signal to warn people of the machine's and
equipment's functioning;
• The crane operator is liable for the correct use of the lifting means and of the equipment. He
must respect the general safety standards and the manufacturer’s instructions for use pertaining
to the means of lifting and to the equipment.

5) INSTRUCTIONS

5.1 Specialised personnel

Installation, overhaul and repair must be carried out by specialised personnel trained in procedures
regarding hydraulic, electrical and mechanical characteristics. It is absolutely forbidden to allow
production personnel or unskilled personnel to use the equipment.

5.2 Transport instructions

Warning: Regarding the equipment’s mass, use adequate means during hoisting and
transportation.

The equipment is transported firmly fixed on the transport means through a suitable slinging with
ropes and textile belts.

• Hoisting: to be carried out through linkage to the upper attachment (see diagram 2).
• Storage: to be carried out with extreme care due to the equipment’s unstable structure. It has to be
placed completely open on the ground.
• Placing on the vehicular transport: proceed as indicated on diagram 2.

It is absolutely forbidden to handle the equipment if the lower linkage is deformed, worn or
crushed.

5.3 Assembly instructions

• The machine has to possess the necessary accessories for the power supply of the equipment and in
particular:
• Electric switchboard (see relevant documentation)
• Connectors, cables and eventual cable reels (see relevant documentation)
These accessories, if supplied by ROZZI S.p.A., are equipped with the relevant instructions for installation,
use and maintenance. They are built following the regulations in force and supplied with the conformity
declaration to such regulations.
• Verify that the lifting capacity of the machine is fit to the equipment model you’ve chosen;
• To connect the equipment to the machine’s hook use one or more chains having a safety factor which is
conform to the standards in force (we suggest chains having a length not inferior to 1.5 metres).
• Use only hooks with security devices and shackles with nut and cotter pin;
• Lay the equipment on the ground in a stable position;
• Take the machine hook in correspondence with the equipment, hook up the chain/s and fix all security
devices;
• Verify that the feeding voltage of the motor corresponds to the one which is really available on the
machine;
• Verify that the electric plant of the machine and the electric accessories are suitable to the motor
power (see technical characteristics);
• Connect the electric plant of the machine to the equipment as indicated on the relevant electrical
schemes;
7
• Mount an anti-tear device on the cable in such a way that this one forms a bend before the connection to
the equipment;
• The electric connection takes place with suitable material fit to support the max. absorption of the motor
and it has to be in conformity to the security regulations in force;
• Lubricate the "L" points as shown on the lubrication diagram (use the same grease as for the machine
joints);
• Replace the tank cap with the air filter (separately supplied) and check the oil level;
• WARNING: after having connected the parts, if the electric motor turns but the equipment does not open
nor close, invert the motor’s sense of rotation (the right sense of rotation is clockwise);
• do the idling test to verify the correspondence of the equipment movements with the controls indications.
In case invert the electrovalves’ electric connection.

5.4 Prohibitions and instructions for use

• Operator knowledge of the controls is compulsory to the use of the machine and the equipment.
• The security of our equipment is indirectly linked to the safety devices pertaining to the lifting
means on which the grab is mounted;
• The crane operator is responsible for the correct use of the equipment and must respect safety
precautions established for the machine, for the equipment and for the electric accessories;
• Use the equipment in a well-lit environment.
• The equipment has no own operating systems but it uses the controls of the electric instrumentation
(electric switchboard - push-button panel) mounted on the machine (see the relative use
instructions);
• it is possible to keep connected, for short times, the closing control to improve the taking, without
exceeding with such operation to avoid oil overheating;
• during manoeuvres without loads or where the equipment is completely closed or resting, avoid keeping
the open and closed drives inserted;
• The equipment is to be used specifically to lift and handle material with characteristics as
described in paragraph 3;
• Handle only when sure of a secure hold, respecting the indications given in diagram 5.

WARNING: the non-observance of the following instructions may provoke dangerous situations
and/or serious damage to the equipment making it unstable:
• It is forbidden to lift and handle loads with an estimated weight superior to the equipment's lifting
capacity or with characteristics varying from those as described in paragraph 3;
• Loads should be initially hoisted to a few centimetres to check the stability of the hold and subsequently
lifted to the minimum height necessary to pass over obstacles;
• Avoid allowing loads to swing during lifting and handling;
• Handling of loads must be carried out in avoidance of circumstances that may provoke dangerous
situations or that may result in damage to people or things;
• It is forbidden to make the load turning provoking impacts against stored materials or other structures;
• If taking is difficult, open and close the equipment before lifting;
• It is forbidden to use the equipment either closed or opened to compress material;
• It is forbidden to use the equipment to rip or drag any object.
• It is forbidden to leave the machine unattended whilst loads are suspended from the equipment;
• When the task is completed lay the grab on the ground completely opened.
• IT IS ABSOLUTELY FORBIDDEN TO USE THE LOWER LINKAGE TO LIFT LOADS.
• WARNING: for temperatures which are lower than the ones admitted from the hydraulic fluid, heat oil
for about 5 minutes by making the motor turning but without moving the tines.

8
6) MAINTENANCE

WARNING:
• during operations the oil may reach high temperatures: before carrying out any intervention allow
the oil to cool completely (about 2 hours).

WARNING:
• before carrying out any repair, maintenance or cleaning operation, the subsequent steps must be
followed:
1. Make sure that the designated area is suitable for such a purpose: its surface must be of a
diameter at least double the size of the grab when fully open;
2. Rest the equipment on the ground in a stable position;
3. Switch off the equipment and insulate it from the electric network;
4. Lock the general switch of the electric instrumentation of the equipment feeding on the “O”
position by means of a padlock;
5. Wait for the machine’s oil to cool.

6.1 Compulsory checks to be made by the operator before switching on

Check:
1. Bolts of the linkage plate;
2. Linkage plate and all its components (flanges, pin and bushes);
3. Chain, ring or shackles;
4. That parts of electric connection between the equipment and the machine are in perfect conditions.
5. The condition of the carpentry (wear, deformities, cracks, etc.);
6. The condition of the mechanisms (gaps in the housings, pins and bushes);
7. That no leakages into the hydraulic system are present and that the feeder hoses are in perfect condition
(very important).

6.2 Ordinary maintenance

(May be undertaken by non specialised personnel)
• Points marked “L”, as shown on the lubrication diagram, must be lubricated every 20 working hours
using the same grease as is used for the machine’s joints;
• Should the equipment be used on an irregular basis, lubricate the pins at least once a week;
• In case of heavy working conditions (presence of aggressive and/or abrasive substances, very damp
environment), make the interventions more frequent;
• With the same frequency as the operations of lubrication, check the condition of the equipment, of the
interface and in particular:
1. Check all those parts that connect the equipment to the machine hook,
2. Check the condition and the gaps between pins and bushes;
3. Check that there are no cracks in the weldings;
4. Check that there are no breakages, cracks or deformities in the metallic structure or in the shaft of any
cylinder;
5. Check the tightness of each pin blocking nut and of the bolted joints;
6. If present, check the conditions of screws, pins, seegers and cotter pins;
7. Check that there are no deformations in the flange holes;
8. Check that there are no leakages in the hydraulic system (hoses, connections, cylinder seals);
9. Check that the when the equipment is open, the oil reaches the level gauge;
10. Check, if present, the filter obstruction gauge;
11. Check the presence and condition of the plate certifying the conformity of our equipment to the
machine’s directive. The plate must be replaced should it become deteriorated or be lost;
12. Check the presence and the condition of the stickers, that warn of dangerous situations (see paragraph 9).
These must be replaced should they become deteriorated or be lost;
13. Check the condition of the fixed and flexible hoses as well as the relevant connections.

9
 WARNING: SHOULD THERE BE ANY IRREGULARITIES, CONTACT SPECIALISED
PERSONNEL TO SOLVE THE PROBLEMS.

WARNING: OPERATIONS MADE IN AN UNCORRECT WAY CAN MAKE THE

EQUIPMENT DANGEROUS.

6.3 Extraordinary maintenance

(May be carried out by specialised personnel with suitable machinery.)

WARNING:
• POSSIBILITY OF RESIDUAL PRESSURES WITHIN THE CIRCUIT. BEFORE ANY
INTERVENTION, RELEASE PRESSURE;
• REMOVAL OF THE PINS MAY PROVOKE UNFORESEEN MOVEMENTS OF THE
CARPENTRY. IMMOBILISE THE COMPONENTS BEFORE ANY INTERVENTION.

USE ONLY ORIGINAL SPARE PARTS:

For orders of spare parts specify: MODEL – N. OF RANGE – YEAR OF CONSTRUCTION.

Every 500 hours check carefully every piece connecting the equipment to the machine hook:
1. Bolts of the linkage plate;
2. Linkage plate, flanges, pin and bushes;
3. Chain, ring or shackles;
4. Immediately replace the parts which appear worn or deformed;
5. Check that the electric connections going between the equipment and the machine are in perfect
condition;
6. Replace the cartridge of the oil filter and check that when the equipment is open, the oil reaches the level
gauge;
7. Check there are no leakages within the hydraulic system and that the flexible hoses are in perfect
condition (very important);
8. Check that the gap between pin and bush is less than 0.6 mm. Should it be more, replace the worn parts;
9. Check the seals on the cylinders. If necessary replace them;
10. Check the condition of the metallic structure;
11. Check the tightness and the condition of the pin blocking nuts and of the bolted joints;
12. Check the function of the equipment.

Every 2000 working hours or at the latest once a year:

• Replace the hydraulic oil (use MOBIL DTE 16 or similar oils: see comparative oil table here enclosed).
WARNING: the oil must be disposed of in appropriate collection points.

6.4 Assistance service

For repairs and/or overhauls, contact ROZZI S.p.A., which has specialised personnel and suitable
machinery at hand. Technical assistance is available at our firm providing further explanations and advice.

10
6.5 Hydraulic circuit trouble shooting

Apparent phenomena Procedures for the problem’s solution

(To be carried out by specialised personnel)
The motor turns, but the equipment don’t open nor • Check that the motor turns clockwise
close • Check that the electrovalve receives the electric
signals for opening and closing
• Clean the drilled grub screw into the flanged
block between the electrovalve and the
distributor
• Replace the electrovalve
• Clean the LM valve of max.
It is necessary to clean frequently the drilled grub • Replace the filter cartridge
screw into the flanged block between the • Replace the oil and clean the tank
electrovalve and the distributor
The equipment can’t close •Check the working pressure (calibration of
CP valve)
• If necessary replace the CP valve
• Check the calibration pressure of the LP
valve of max.
• If necessary replace the LP valve of max.
• Check the gaskets tightness
• Check the pump condition
The equipment loses its load during operations • Check the pressure of the CM valve
• Replace the CM valve or the VB blocking
valve (if present)
• Check the gaskets tightness
The equipment’s noise increases and/or the oil • Check the oil level and replace the filter
reaches high temperatures cartridge
• Check the pump condition.

WARNING: it is absolutely forbidden to modify or tamper with machine parts that may influence
its safety.

11
6.6 Calibration and regulation

LP valve of max. Bar 230

CP pump control valve Bar 180
Motion control valve - opening Bar 80
Motion control valve – closing Bar 120

The calibration of all valves is carried out at the factory during the equipment’s testing. In case of
malfunction it is possible to check the valve calibration and in case to modify it, when this does not
correspond to the one suggested by ROZZI S.p.A, paying a lot of attention as a wrong calibration may
damage seriously and permanently the circuit.
To check the valves calibration pressure it is necessary to place two manometers (see scheme 1.1),
one on the hose A (grab closing) and one on the hose B (grab opening). By closing the grab completely and
insisting with this operation, the manometer on hose A will show the calibration pressure of the CP pump
pilotage valve , which corresponds to the equipment working pressure. Before doing the calibration of the
CP valve, we suggest to check the calibration of the LP max. pressure valve , by acting as follows: screw for
the main length the grub screw n. 4 of the CP valve (scheme 1.4) so that this one can not operate to reduce
the pump capacity and pressure. Calibrate the max. pressure valve 50 bars more than the wished working
pressure of the circuit (by operating on the grub screw n. 1 scheme 1.2).
After such calibration the CP pressure and capacity control valve can be regulated, by screwing off
the grub screw n. 4 (scheme 1.4) until the wished working pressure is reached (at least 30 bars lower than the
calibration of the LP valve).
After the CP valve calibration, the CM motion control valve can be calibrated (see scheme 1.3). This
valve is necessary to maintain the cylinders under pressure when there are no opening or closing phases.
Calibrate this valve so that at the end of the opening or closing phase the cylinders pressure is the same to the
one indicated into the calibration scheme.

WARNING: DURING THE CALIBRATION PHASE, TURN THE GRUB SCREW OR THE
HANDLE OF ANY VALVE LIGHTLY, AS SMALL ROTATIONS CORRESPOND TO
CONSIDERABLE PRESSURE VARIATION. WHEN THE CALIBRATION IS OVER, SCREW THE SET
SCREW CAREFULLY.

12
7) REGISTER

7.1 Installation card

DATE SHEET NR. SIGNATURE OF TECHNICIAN
RESPONSIBLE

7.2 Inspections, periodical checks and extraordinary interventions card

DATE EQUIPMENT'S SHEET NR. SIGNATURE OF

WORKING HOURS TECHNICIAN
RESPONSIBLE

13
7.3 Instructions for care
The present register is to be considered an integral part of the equipment and must remain with it as
long as it exists.

7.4 Writing up instructions

These instructions are supplied according to the standards that are valid on the date of sale of the
equipment. New standards may come into effect in the meantime modifying the user’s obligations.
The register is made so that the following events regarding the equipment’s useful life may be noted
according to the plans proposed:
• Transfer of property;
• Replacement of components regarding the hydraulic plant, electric motor, safety devices, structural
elements or mechanisms;
• Damages of a certain degree and relevant repairs.

8) SECURITY SIGNALS

- WARNING KEEP CLEAR OF

WORKING AREA
- BEFORE OPERATION REFER TO
MANUAL
- WARNING LONG LOADS

14
9) DISASSEMBLY, DISMANTLING AND DEMOLITION

Specialised firms must carry out the demolition of the equipment. Every function must be carried
out by specialised personnel that have read the instructions contained into this manual.
Each movement of the equipment within the disposal area must be carried out by way of vehicles
with a suitable device. These operations, even if in private areas, must be done by skilled personnel.
The operations of dismantling of the equipment must be done following environmental laws, it is
particularly important to avoid oil spillage from the hydraulic circuit into the environment.
These operations must be carried out in the following order:

1. Place the equipment on the ground completely open (this operation allows that a bigger quantity of oil
goes into the tank).
2. Remove the upper linkage.
3. Remove the feeding hoses of the cylinders.
4. Take away the power pack group by means of the suitable lifting hook.
5. Remove the tank cover.
6. Provide for the runout of the tank, paying attention to recover the oil they contain. This operation can be
done by putting a suction pump into the hole intended to the breather cap (placed into the upper part of
the tank), or removing the tank discharge cap placed into the lower part of the tank (see lubrication
scheme).
7. Remove all hydraulic components (filter, pump, etc.), paying attention to recover the oil they contain.
8. Dismantle the motor.
9. Remove the protection covers of the cylinders.
10. Remove the fixing pins of each cylinder. Warning: removal of the pins may provoke unforeseen
movements of the carpentry, immobilise the components before any intervention. During this
operation pay attention to the cylinders that, if not suitably supported, could fall.
11. Dismantle each cylinder, paying attention to recover the oil they contain.

Do not forget it is absolutely forbidden to disperse waste material from the dismantled equipment
into the environment. Such waste must be disposed of in appropriate collection points.

15
ER 800-1000L-1500L-1800L-2000L

IMPIANTO CON POMPA A PORTATA VARIABILE

“A10VSO28 DFR” “REXROTH”
BENNA A POLIPO ELETTROIDRAULICA
 Tavola 1

Descrizione - Description Q.ty N. Cod.

Pos Beschreibung Parts ver1
1.1 Boccola martinetto øi=35 øe=45 L=70 6 P03502
1.2 Stelo 6 FS008
1.3 Grano M8x10 6 B076
1.4 Guida 6 FG009
1.5 Rondella guida 6 FR010
1.6 Anello guida 6 FR011
1.7 Rondella pistone 6 FR012
1.8 Pistone 6 FP006
1.9 Spina elastica 6 Q046
1.10 Canna 6 FC008
1.11 Snodo SKF GE 35 ES 6 FN003
1.12 Seeger I 55 Uni 3654 6 Q044
1.13 Kit guarnizioni 6 K015

(*) Specificare Tensione e Frequenza di alimentazione

(**) Optionals
(***) Riferimento disegno: ER800-CA-02
 Tavola 2

2.1 Vite uni 5739 M10x30 8.8 3 B088

2.2 Carter filtro aria 1 ***
2.3 Attacco 1 ***
2.4 Vite uni 5739 M16x60 10.9 12 B351
2.5 Dado autob. Uni7473 M16 classe 10 12 C030
2.6 Vite uni 5739 M16x60 10.9 12 B351
2.7 Carter superiore 1 ***
2.8 Dado autob. Uni7473 M16 classe 10 12 C030
2.9 Sportelli 2 ***
2.10 Vite uni 5933 M8x25 8 B185
2.11 Dado autob. M30x2 6 C041
2.12 Distanziali øi=35 øe=45 L=12.5 2 X142
2.13 Perno ø=35 Lu=90 6 A03501
2.14 Castello 1 ***
2.15 Dado autob. Uni7473 M16 classe 10 3 C030
2.16 Vite uni 5737 M16x50 8.8 ZN 3 B340
2.17 Rondella rame ½” 24 M033
2.18 Vite forata ½” 12 H042
2.19 Tubo fless. ½” O FD lsr=325 12 -
2.20 Dado autob. M42x4.5 6 C044
2.21 Coccola carb. nitr.. ø=70 ø=60 L=70 12 P06001
2.22 Perno ø=60 Lu=283 6 A06010
2.23 Dado autob. M30x2 6 C041
2.24 Martinetto Al=75 St=45 C=294 6 I07501
2.25 Perno ø=35 Lu=134 6 A03502
2.26 Pala 6 ***

(*) Specificare Tensione e Frequenza di alimentazione

(**) Optionals
(***) Riferimento disegno: ER800-CA-02
SPACCAT0 RICAMBI ER800 - 1000L - 1500L - 2000L
05.03.03 TAVOLA 1-2 Ver: 1
 Tavola 3

3.1 Elettrovalvola 4WE6H-5X Rexroth 1 N075

3.2 Blocchetto derivazione bloccaggio pompa 1 -
3.3 Nipples ¼” 1 H054
3.4 Corpo valvola 4WEH16J-6X/ET 1 N058
3.5 Massello M087 1 N026
3.6 Valvola di max DBDS 10K1X/315 1 N024
3.7 Viti Uni5739 M10X30 8.8 3 B088
3.8 Nipples ¾” 3 H040
3.9 Nipples ¾” 1” 1 H041
3.10 Rondella in rame 3/4” 3 M034
3.11 Rondella in rame 1” 1 M035
3.12 Adattatore girevole curvo M F 1” 1 H101
3.13 Tubo flessibile pompa massello ¾” F90 F90 lsr=270 1 -
3.14 Viti uni 5739 M12X35 2 B109
3.15 Filtro LMP 250 1B AG1 1 N022
3.16 Nipples 1-1/2” 1” 2 H114
3.17 Tubo flessibile massello filtro 1” F90 FD lsr=360 1 -
3.18 Tubo flessibile massello pilota 1/4” F90 FD lsr=920 1 -
3.19 Tubo flessibile filtro serbatoio 1” F90 FD lsr=430 1 -
3.20 Tubo flessibile massello cm 3/4” F45 FD lsr=680 1 -
3.21 Tubo flessibile massello cm 3/4” F45 FD lsr=635 1 -
3.22 Tubo flessibile cm coll. inf. 3/4” F90 F90 lsr=530 1 -
3.23 Tubo flessibile cm coll. sup. 3/4” F90 F90 lsr=490 1 -
3.24 Tubo flessibile pilota P 1/4” F90 FD lsr=530 1 -
3.25 Tubo flessibile pilota T 1/4” F90 FD lsr=590 1 -
3.26 Rondella in rame ¾” 8 M034
3.27 Nipples ¾” 4 H040
3.28 Viti uni 5737 M10x70 8.8 ZN 2 B326
3.29 Valvola CM VBSO DE NA 34 1 N028
3.30 Nipples ¼” 3 H054
3.31 Valvola pilotaggio pompa DBDS 6G 1-X/315 1 N032
3.32 Vite uni 5737 M6x50 8.8 4 B150

(*) Specificare Tensione e Frequenza di alimentazione

(**) Optionals
(***) Riferimento disegno: ER800-CA-02
SPACCAT0 RICAMBI ER800 - 1000L - 1500L - 2000L
05.03.03 TAVOLA 3 Ver: 1
 Tavola 4

4.1 Tappo ¾” bsp 1 H121

4.2 Rondella di tenuta ¾” 3 M034
4.3 Tubo F90-FD 3/4” bsp Pompa-Campana 1 -
4.4 Nipplo ¾” bsp 1 H040
4.5 Rondella di tenuta 3/4” 4 M034
4.6 Flangia SAE ¾” +Viti +OR 1 N154
4.7 Pompa A10VSO28DFR “Rexroth” 1 N056
4.8 Vite TE M12x40 10 B331
4.9 Linguetta A 6x6x32 1 Q110
4.10 Rondella di tenuta ¼” 3 M030
4.11 Nipplo ¼” bsp 3 H054
4.12 OR Pompa 1
4.13 Giunto elastico ∅M=42 ∅P=22 L=181O.M.T.” 1 N057
4.14 Tubo FD-FD ¼” bsp Pompa-Campana 1 -
4.15 Tubo FD ¼” bsp Scarico pilotaggio 1 -
4.16 Tubo FD 1” bsp Scarico filtro 1 -
4.17 Campana Motore-Pompa *** 1 -
4.18 Nipples 1” 1 H112
4.19 Prolunga filtro aria M 1” - F ¾” bsp 1 -
4.20 Filro Aria SA 075 G2 663 “MP Filtri” 1 N112
4.21 Motore 160 L 4 poli B3-B5 “Marelli” * 1 N064
4.22 Vite uni 5739 M12x50 8.8 2 B332
4.23 Dado autobloccante M12 alto 2 C061
4.24 Dado autobloccante M5 alto ** 2 C069
4.25 Termostato Thermostat Kp78 “Danfoss” ** 1 -
4.26 Vite TE M5x20 ** 2 B198
4.27 Dado autobloccante M16 alto 7 C030
4.28 Vite TE M16x60 3 B105
4.29 Linguetta A 12x8x100 1 Q111
4.30 Guarnizione motore 1 -
4.31 Livellostato Elettrotec LM2 250 “O.S.C.” ** 1 -
4.32 Nipplo ¾” bsp 1 H040
4.33 OR serbatoio 1 -
4.34 Spia livello 1” bsp 1 H125
4.35 Serbatoio *** 1 -

(*) Specificare Tensione e Frequenza di alimentazione

(**) Optionals
(***) Riferimento disegno: ER800-CA-02
SPACCAT0 RICAMBI ER800 - 1000L - 1500L - 2000L
05.03.03 TAVOLA 4 Ver: 1