POWERTILT / MULTI-COUPLER

Transcription

1 POWERTILT / MULTI-COUPLER OPERATIONS AND MAINTENANCE MANUAL (P) PUBLISHED SEPTEMBER 2012

2 JB ATTACHMENTS - WHEN ONLY THE BEST WILL DO! INCREASE PRODUCTIVITY PROFITABILITY VERSATILITY

3 CONTENTS 1.0 INTRODUCTION Warranty Registration / Information about Technology 2.0 SAFETY INSTRUCTIONS Decals / Identification Numbers / SWL / SWL Lifting Eye 3.0 STANDARDS Standards / Risk Assessment 4.0 INSTALLATION Installation 5.0 OPERATION AND ATTACHING Connecting Attachment to PowerTilt 6.0 MAINTENANCE Maintenance 7.0 POWERTILT DRAWINGS / PARTS LIST Drawings / Part Identification 8.0 MULTI-COUPLER DRAWINGS / PARTS LIST Drawings / Part Identification 9.0 POWERTILT DISASSEMBLY Removing Parts POWERTILT ASSEMBLY Installing Parts 12.0 POWERTILT POST ASSEMBLY Testing and Greasing 13.0 WARRANTY / CONTACT INFORMATION Contact JB Attachments

4 INTRODUCTION Content in this Instruction, Service and Repair Manual applies to all current models, PT, PTA or PTB Series - Unless noted otherwise. For information on maintaining, servicing or repairing earlier product models - TT, TTB and TTB Series please contact JB Attachments Ltd. Ph: Australia Ph: New Zealand The JBA PowerTilt is a construction equipment attachment that is built using the Helac Actuator. The JBA PowerTilt increases the productivity, profitability and versatility of backhoes or excavators by simply tilting the attachment instead of moving the entire machine. JBA PowerTilt is ideal for performing everyday tasks, or completing jobs that haven t been tried. Thousands of contractors worldwide have come to rely on the PowerTilt, for cleaning ditches, clearing land, digging bevelled trenches, spreading rip-rap, and positioning brush cutters, mowers and hydraulic hammers. When the JBA PowerTilt is used in combination with the JBA PowerGrip Bucket (multi-purpose 4N1 bucket), operators can achieve unmatched, hand like manipulation and dexterity, dramatically maximizing productivity.

5 INTRODUCTION This manual contains important information about the installation, connection, maintenance and safe operation of JB Attachments PowerTilt Multi-Coupler. You can ensure a proactive approach to safety by ensuring that all persons involved with the fitting or operation of the PowerTilt Multi-Coupler read and understand these basic safety features and instructions. JB Attachments Ltd (JB Attachments) reserves the right of modification as a result of further technical developments with regard to the information and illustrations cited in this manual. JB Attachments and its suppliers have sole copyright of this manual. The manual is intended solely for the use of the JB Attachments PowerTilt Multi-Coupler System. No part of this manual may be reprinted, translated or reproduced by any means without prior written permission from JB Attachments. Utilisation for the purposes of competition is forbidden. The JB Attachments PowerTilt Multi-Coupler is designed for safe and dependable service if installed, maintained and operated correctly. We request that time be devoted to the study of installation and maintenance requirements. Users are also expected to familiarise themselves with the correct operation and use of the PowerTilt Multi-Coupler, and its safety features advised. IMPORTANT NOTE: To comply with Occupational Safety and Health requirements, a record must be made of all repairs, adjustments and regular maintenance events involving your PowerTilt Multi-Coupler. A logbook has been placed at the back of this manual for this purpose (refer to page 6.7). 1.0

6 INTRODUCTION CUSTOMER ACCEPTANCE AND WARRANTY REGISTRATION Upon delivery of your JB Attachments PowerTilt Multi-Coupler, please complete and return this form immediately to your JB Attachments PowerTilt Multi-Coupler distributor. DATE OF DELIVERY: SERIAL NUMBER: I confirm that the operator of the relevant excavator has read and understands the Operating Instructions and Warranty Terms, which relate to JBA PowerTilt Multi- Coupler. The Operator accepts that he/she is responsible for understanding safety and operation features of the JBA PowerTilt Multi-Coupler. NAME: POSITlON: COMPANY: SIGNATURE: THE PURCHASER SHALL: Follow the recommended installation, testing and maintenance and operating procedures. Comply with safety and training guidelines for use of equipment (not totally exclusive). Keep an accurate maintenance, operation, malfunction and repair log of equipment. Ensure that the equipment is used for the purpose it was intended for. The Purchaser is to sign this declaration with the understanding of the above and return this copy (also retaining a copy) to: JB Attachments Pty Ltd 59 Magnesium Drive, Crestmead, 4132 QLD, Australia. 49 McLaughlins Rd, Wiri, Auckland, NZ 1.1

7 INTRODUCTION TO THE OWNER As the new owner and/or operator of the JB Attachments PowerTilt Multi Coupler we would recommend that you take the time to read this Operation Manual carefully before commencing work. FOLLOW THE SAFETY INSTRUCTIONS: Carefully read all the safety information contained in this manual. Make sure all warning signs are legible. Immediately replace any signs which are missing or damaged. Before starting work make sure you are familiar with the equipment, and where necessary, with the machine and its control devices. INFORMATION FOR THE USER: The user of the JB Attachments PowerTilt Multi-Coupler system is obliged to ensure that the equipment is always in safe working order in accordance with accident prevention regulations, Occupational Safety and Health or any other official instructions. WARRANTY REGULATION: JB Attachments provides guarantees according to its sales and delivery conditions, extended to twelve months from delivery. The extended guarantee assumes proper operation and use as intended but will be nullified as a result of: Repairs or other intervention not undertaken by persons authorised by JB Attachments. With use of accessories or replacement parts not approved by JB Attachments or which are not original replacement parts supplied by JB Attachments. After the warranty period has expired, we further recommend the use of original replacement parts and manufacturer s replacement parts approved by JB Attachments. PLEASE COMPLETE THE CUSTOMER ACCEPTANCE AND WARRANTY REGISTRATION FORM LOCATED IN THIS MANUAL - FAILURE TO REGISTER MAY INVALIDATE YOUR WARRANTY CLAIM. 1.2

8 INTRODUCTION - OPERATION TECHNOLOGY The JBA PowerTilt uses the Helac Corporations innovative, sliding-spline operating technology to convert linear piston motion into powerful shaft rotation. Each actuator is composed of a housing and two moving parts - the central shaft and piston. Helical spline teeth on the shaft engage matching teeth on the pistons inside diameter. A second set of splines on the pistons outside diametre mesh with the gear in the housing. Starting Position The piston is completely bottomed out. Bars indicate starting positions of piston and shaft. Arrows indicate directions they will rotate. The housing with integral ring gear remains stationary. Ending Position When hydraulic pressure is applied to the piston, it moves axially, while the helical gearing causes the piston and shaft to rotate simultaneously. Applying pressure to the opposite port will return the piston and shaft to their original starting positions. JBA Multi-Coupler Quick Hitch Technology Unique patented* mechanical jaw locking system ensures the attachment is locked onto the coupler. The unique three-step engaging & disengaging system requires operators to follow a strict locking & unlocking safety procedure. Auto-lock mechanism improves operational safety - eliminates human error with no need for operator to leave excavator cab. Low profile, lightweight design improves breakout force, reducing fuel consumption. Greater versatility due to multi pick-up capability, which adjusts to different pin centres. *Australian Innovation Patent No and Australian Patent Application Nos and

9 INTRODUCTION - SAFETY GUIDLINES Cautionary Notices Before beginning disassembly of the PowerTilt, there are several cautionary notices that should be considered. If you are not comfortable with repair or maintenance of this product, contact your local dealer or Helac Corporation s Service Department for assistance. Other Safety Guidelines and Precautions 1. PowerTilt should only be used to perform tasks for which it was designed. Abusing the product and/or using it for purposes for which it was not intended can expose the operator and others to hazards as well as result in damage to the PowerTilt, carrier and/or other attachments. 2. Modification to the PowerTilt is done at the owner s risk and may void the Helac Corporation, Attachments division warranty. 3. PowerTilt is designed for a maximum bucket width as noted below. Applying the full force of the excavator or backhoe to the corner of a wide bucket (e.g. corner digging with a wide bucket) may cause premature wear and/or reduced equipment life. It is also recommended that the bucket widths are not exceeded. Maximum Recommended Bucket Width for Use with PowerTilt PowerTilt Model PT-6 PT-7 PT-8 PT-9 PT-10 PT-11 PT-12 Maximum Bucket Width 47 ( 1,200 mm ) 55 ( 1,400 mm ) 59 ( 1,500 mm ) 66 ( 1,700 mm ) 70 ( 1,800 mm ) 82 ( 2,100 mm ) 94 ( 2,400 mm ) 4. A decrease in breakout force may be experienced due to the increased tip radius and the added weight of the PowerTilt to the stick. 5. It is the owner s responsibility to be sure all safety equipment is in place and operating properly at all times. If safety decals fade, are damaged or become unreadable from a distance of 10 feet, they should be replaced immediately. 1.4

10 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS! WARNING This safety alert symbol indicates important safety messages in this manual. When you see this symbol carefully read the message that follows and be alerted to the possibility of personal injury or death. Improper operation of this machine can cause injury or death. Before using this machine make certain that every operator: Is instructed in safe and proper use of the attachment Reads and understands the manual pertaining to the attachment Reads and understands all safety decals and tags on the machine Clears the area of all other persons Learns and practises safely using attachment controls in a safe, clear area before operating this machine on a job site It is your responsibility to observe pertinent laws and regulations and follow JB Attachments instructions for operation and maintenance.! JB Attachments supplies a standard PowerTilt Multi Coupler to fit JB Attachments approved attachments. However, when fitting a non standard attachment check the operation fitting guide for the attachment s pin range and width to suit the PowerTilt Multi-Coupler model. NOTE: The PowerTilt Multi-Coupler base has a maximum and minimum pin center travel range. Please refer to the attached badge on the JBA PowerTilt for this information. 2.0

11 MULTI COUPLER INSTRUCTIONS SAFETY INSTRUCTIONS The JB Attachments Multi-Coupler operation instructions are to be fitted inside the cab in clear view of the operator to identify correct operation of PowerTlt with Multi-Coupler base. ATTACHMENT PICK UP: Rear Slide Hook needs to be fully extended to release front safety hook before front pin of attachment is engaged STEP 1: Fully extend slide hook STEP 2: Engage front attachment pin STEP 3: Retract slide hook to engage safety hook pin STEP 4: Curl into attachment STEP 5: Extend slide hook to lock rear pin STEP 6: Check safety hook engaged CHECK 1. Test apply pressure to attachment by rotating against the ground and away from machine before operating 2. Do not proceed to work unless safety hook is in the closed position on the front attachment pin ATTACHMENT RELEASE: 1. Place attachment on flat ground 2. Retract slide hook. Crowd out of rear pin 3. Pressurise hydraulics to extend slide hook and release safety hook at front pin DANGER! SAFETY WARNING! GREASE DAILY Do not lift with any attachment connected to the Multi Coupler and only from the lifting eye on the Multi Coupler Do not exceed lifting eye capacity on nameplate Do not exceed rated lift capacity of the machine (Ref to chart in cab) Use in a safe and proper manner at all times Read operators manual for the Multi Coupler Report damage or malfunction immediately Do not use Multi Coupler if damaged or malfunction has occured CONTACT NUMBERS AUST NZ Decal for inside cab. Part # JB Attachments

12 SAFETY INDICATION LABELS Each JB Attachments Powertilt Multi-Coupler will have an identification label fitted.! The pin centre range displays the minimum and maximum travel distance for each slide hook on the Multi-Coupler base. All attachments must be within the parameters of these measurements identified on the label.! The badge also displays the SWL and data information. All JB Attachments PowerTilt Multi-Couplers have an identification label with the machine model recorded 2.2

13 SERIAL NUMBERS Each JB Attachments PowerTilt Multi-Coupler will have an identification label fitted. Each JB Attachments PowerTilt Multi- Coupler has an identification label fitted. The hydraulic cylinder also has the serial number stamped on it. This is important for the serial number and identification of the model it is used for when referring to part numbers for future repairs. The slide hook will have numbering for identification of the type and model and this specifies pin range and pin diameters. 2.3

14 S.W.L - SAFE WORKING LOAD JB Attachments PowerTilt Lifting Eye Restrictions Only use certified lifting shackles Only lift from lifting eye situated on the rear of the PT Multi-Coupler base 1. Ensure that the load to be lifted does not exceed the safe working load of the lifting eye or the machine to which it is fitted. 2. The lifting eye is to be used with a certified lifting shackle with the same or greater safe working load. 3. S.W.L - PowerTilt base is fitted with a label on the side that specifies maximum Safe Working Load. 4. Lifting eye has to be visually inspected daily. SAFE WORKING LOAD BADGE S.W.L - Lifting Eye Capacity is stated on the Badge 2.4

15 S.W.L LIFTING EYE JB Attachments PowerTilt Lifting Procedures! WARNING: Use correct lifting connection Only use the eye at the rear of the JBA PowerTilt for lifting. Do not lift with bucket or any attachment fitted to the JBA PowerTilt. Lifting must be carried out with the JBA PowerTilt in a vertical position so that the load can hang free without contacting the JBA PowerTilt body.! WARNING - VISUAL INSPECTION OF LIFTING EYE The operator is required to carry out daily visual inspections of the lifting eye to check for defects and wear. This is on the pre-start checklist (see page 3.3) and 6 monthly / 500hr check (see page 6.6). Thorough lifting eye examination must take place every six months or as exceptional circumstances occur. (Exceptional circumstances are those that are likely to jeopardise the integrity and safety of the lifting eye). 2.5

16 STANDARDS Design, Installation, Maintenance and Operation Standards and OCCUPATIONAL SAFETY AND HEALTH Guidelines The standards and Occupational Safety and Health Guidelines for the JBA PowerTilt Multi-Coupler are as follows: AS Standards Australia. Australian standard for - Earthmoving Machinery - Multi- Couplers (couplers) for excavators and backhoe loaders - AS section C AS Cranes (Including hoists and winches) Part 5: Mobile vehicle loading cranes. European Standard EN474-5; Section /2 and 3. Electrical Interlocking for Safety in Industrial Processes. Standard Operating Guidelines for Plant and Machinery. We request that time be devoted to the study of installation and maintenance requirements. Users are also expected to familiarise themselves with the correct operation and use of the PowerTilt, and its advised safety procedures. Associated standards AS 2954 Earthmoving Equipment - Rated Loads and Volumetric ratings AS 2954 Earthmoving Equipment - Tests and Measurements AS 2954 Earthmoving Equipment - Instrumentation and Control AS 2954 Earthmoving Equipment - Operation and Maintenance AS 2954 Earthmoving Equipment - Safety Excavator and attachments must be suitable or converted for mounting the JBA PowerTilt (in agreement with JB Attachments). The crowd and breakout forces specified by the excavator manufacturer must not be exceeded. The JBA PowerTilt must not be used for impact work (only with attachments specified for this). Load hook rating must never be exceeded. Adherence to the specifications in this manual is part of the intended use. All JBA PowerTilt models have specific safety features, see those that relate to your purchase. 3.0

17 STANDARDS Qualification of Operating Personnel Only the following persons may work independently with the JBA PT Multi- Coupler system, and earthmoving machinery in general - Those who: Are over 18 years of age. Are physically and intellectually able. Have been instructed in the general regulations concerning operational safety and particularly accident prevention. Have been instructed in assembly, operation and maintenance of earth moving machinery and using the JBA PowerTilt Multi-Coupler system. They must understand these operating instructions and have proven to the contractor that they are capable of operating such machinery. Ensure that only authorised personnel work with the JBA PowerTilt system. Only give instructions to competent, skilled personnel. NOTE: FOR JB Attachments PowerTilt Multi-Coupler SYSTEMS SUPPLIED TO OR MANUFACTURED IN COUNTRIES OTHER THAN NEW ZEALAND And Australia, THE RULES FOR PREVENTION OF ACCIDENTS AND SAFETY REGULATIONS FOR THE RESPECTIVE COUNTRY MUST BE STRICTLY ADHERED TO. 3.1

18 RISK ASSESMENT Working with Powertilt Location: Date: Ref no: Hazards Identified: Work Equipment Lifting Devices Ergonomics Entanglement Crushing Access / egress Slip, trip and fall Plant Movement Warning Devices on Equipment Noise Vibration Fumes Environmental People Affected YES NO N/A Involved in activity Close to activity Everyone on site Members of the Public Expected Precautions YES NO N/A Has the operator beed adequately trained on the use of the PowerTilt in general? Is the operator competant in using the specific PowerTilt on the machine in use? Is there a system for checking that the attachment pins are in place on the PowerTilt prior to work start everytime a different attachment is fitted? Is the operator aware that they must not operate the machine unless they are satisfied that the PowerTilt is secured in place? Does the view of the operator from inside the Cab allow them to visually see that the PowerTilt is secured in place? Does the PowerTilt have the approved labels stating and referring to PowerTilt specifications? Is there a risk assessment for the bucket detachment? Is there a checklist of daily and weekly inspections? Is there cab instructions for the PowerTilt? Personal Protective Equipment (PPE) Hard Hat High Visibility Vest Safety Boots Gloves Ear Protection Safety Glasses Other Management Assessed By: Name: Date: Reported To: Name: Date 3.2

19 RISK ASSESMENT DAILY PRE-START CHECK SHEET Operator s Name: JB Attachments Hitch #: JB Attachments Model: Date: M O N T U E W E D T H U F R I S A T S U N In Cab Powertilt Operating Controls (Alarm, warning light, switch) Operating Instructions (labels) Operating Manual Hydraulic System Wear or damage to hoses or fittings Security of hoses Hydraulic oil leaks PowerTilt with Multi-Coupler Base Damage to Powertilt Multi-Coupler latch Correct functioning of safety latch device, rear slide hook and cylinder Build up of dirt and debris from around safety latch Build up of dirt and debris from rear slide hook Wear on PowerTilt Multi Coupler body and Lifting Eye Wear on slide hook Wear and damage to bucket / attachment pins and retainers Security of mounting pins, locking bolts and nuts Is the PowerTilt safe to use? YES or NO LUBRICATION Greasing in accordance with manufacturer s instructions Operator Signature Manager Signature 3.3

20 INSTALLATION Hydraulic Requirements The Typical PowerTilt Circuit Chart and the Tool Circuit Requirements Table (shown on this page) illustrate the control circuit requirements for the JBA PowerTilt. The hydraulic pressures and flow requirements must be observed or damage to the actuator can occur. The installer of the PowerTilt is responsible for selecting the control circuits that are compatible with the excavator and meet the tool circuit requirements. JB Attachments can be contacted for additional control circuits and methods for controlling the PowerTilt. Each PowerTilt model is manufactured with two ports, P1 and P2. This is done to assist in the hose routing. Refer to the suggested hose routing diagram for recommendations. Typical PowerTilt Circuit Tool Circuit Requirements for PT, PTA, PTB Series Model Sizes Displacement Required Oil Flow Port Connections* in³ (cm³ ) (525) gp m (liters/minute) ( 3-6) SAE BSPP 4 (1/4) 62 (1,060) (6-12) 4 (1/4) 89 (1,460 ) 3-5 (12-20 ) 6 (1/4) 118 (1,935 ) 6-7 (24-28 ) 6 (1/4) 159 (2,600 ) 6-8 (24-32 ) 6 (1/4) 215 (3,515 ) 8-11 (32-44 ) 6 (1/4) 277 (4,540 ) 9-13 (36-52 ) 6 (3/8) Hydraulic Hose and Tube S izing Hose, Tube (Optional ) in (mm) 3/8 (10) 3/8 (10) 3/8 (10) 1/2 (12) 1/2 (12) 5/8 (16) 5/8 (16) Whip Hose in (mm) 1/4 (6) 1/4 (6) 1/4 (6) 3/8 (10) 3/8 (10) 3/8 (10) 3/8 (10) Hydraulic Pressures Cross Port Relief Valve Pressure** Circuit Pressur e Maximum Circuit Back Pressure 3,200-3,300 psi ( bar) 3,650-3,750 psi ( bar) 580 psi (40 bar) *M ost PowerTilt models are manufactured with four ports: two ports (P1) and two ports (P2). The majority of all PowerTilts delivered to North American customers incorporate SAE port connections. PowerTilts delivered to customers outside of North America incorporate BSPP port connections. ** PowerTilts are equipped with factory-installed integral cross port relief valves. 4.0

21 INSTALLATION for JB Attachments factory fitted Multi-Coupler kit on excavator STEP 1 FITTING HOSES TO CYLINDER Remove plugs from cylinder Check surface is clean prior to connecting banjo fitting on hoses Banjo Washer Banjo Washer Banjo Banjo Bolt Banjo bolt Part# JB Attachments_Auto-c-cyl-015 Banjo washer Part# JB Attachments_Auto-c-cyl-016 Banjo Part# JB Attachments_Auto-c-cyl-022! WARNING: Some JBA PowerTilt Multi-Coupler models will require that the cylinder be removed to allow room to fit Banjo Bolt cylinder hose Before removing the hydraulic cylinder from the Multi-Coupler base, it is best to remove the check valve because the check valve will hold the pressure inside the cylinder and cause resistance. Follow the steps below to relieve the internal pressure in the cylinder: Step One: The grub screw on the base of the cylinder body will need to be removed to release any back pressure. Step Two: Remove check valve.! WARNING: Do Not Remove under hydraulic pressure Step Three: Check seals are centered correctly and look for damages prior to assembly. Step Four: Once check valve is fitted, tighten to the below specifications: - Check Valve Torque 30ft/lbs - 40Nm - Grub Screw Torque 15ft/lbs - 20Nm 4.1

22 INSTALLATION for JB Attachments factory fitted Multi-Coupler kit on excavator STEP 2 Align JBA PowerTilt to the dipper arm and fit o-ring seals and shims where required. STEP 3 Install original equipment manufacturer s harden fix spacing pins to attach JBA PowerTilt to dipper arm on excavator. Fit locking bolts and nuts to secure pins.! Check pins are original EQUIPMENT MANUFACTURer s PINS. 4.2

23 INSTALLATION for JB Attachments factory fitted Multi-Coupler kit on excavator STEP 4 OPTION (A) HOSES Hose POSITION Installation set up process can be done either using option (A) or (B) below: (A) Direct fitting from PT Multi-Coupler to dipper arm piping via hoses (B) Fitting from PT Multi-Coupler to manifold block to dipper arm piping Check hose lengths. The hose routing should be snug around the dipper arm but not too tight. It should be free to move 10mm to 20mm in both directions. Confirm both hoses will not be pinched or damaged by the crowd linkage in both directions. Tighten hose fittings in place (20ft/lbs / 27Nm) OPTION (B) DISTRIBUTION BLOCK The manifold block is an ideal way of keeping the hoses short and, with the hose in a reverse position, it has a natural spring movement pulling the hose away from contact with the crown linkage. Tighten hose fittings in place (20ft/lbs/ 27Nm) The manifold block is available with two extra ports for operation with a PT Multi- Coupler or Tilt bucket. 4.3

24 INSTALLATION for JB Attachments factory fitted Multi-Coupler kit on excavator STEP 4 Hose POSITION WARNING: Disconnect battery prior to welding. Failure to do so could result in damage to the machine s electronic system. Note: Protect hydraulic cylinder rod from weld spatter during welding operations. References to right and left are from the perspective of the operator in the cab of the machine. Measure up the distance specified for your machine from the center line of the stick pin and make a mark. This mark will locate the back side of the manifold block (no ports). Remove paint and weld the manifold block. Ensure it is centered on the top surface of the stick. Note: Only weld on the backside of the manifold block (no ports). Welding anywhere else may cause damage to the ports of the block. EXITING EXTEND HOSE Install jump hoses into two ports of PT Multi-Coupler cylinder. Make sure hoses are tight before proceeding. TO Multi Coupler CYLINDER PORTS EXITING RETRACT HOSE 240mm WELD THIS SIDE ONLY B = See instructions for your machine model! Note: This distance will vary to suit different machine, makes and models The length of the hoses are 300mm. Measurement may vary depending on different machine makes and models. 4.4

25 INSTALLATION for JB Attachments factory fitted Multi-Coupler kit on excavator STEP 4 Hose POSITION Install jump hoses to two center fittings. Hold back nut, secure with wrench and tighten down hoses. This will keep the jump hoses from turning and allow them to stay in the correct upright position. Connect existing hoses to the outer two ports of manifold block and route up-stick to solenoid valve. Use hose clamps to secure. Connect extend hose (right side) to port EXT of valve, and retract hose (left side) to port RET. Slowly cycle PT Multi Coupler and check for any interference. If interference exists, contact JB Attachments customer service immediately. EXITING EXTEND HOSE 2 TO Multi Coupler CYLINDER PORTS EXITING RETRACT HOSE WELD THIS SIDE ONLY 2 B = See instructions for your machine model ITEM QTY Part No. Description REVISION 1a 1 4 port kom weld block Manifold Block 4 Port A 1b 1 8 port kom weld block Manifold Block 8 Port A Adaptor A Plug A 4.5

26 INSTALLATION CIRCUIT DIAGRAM SOLENOID CONTROL VALVE! WARNING: Important - check solenoid valve pressure. Please ensure that during installation of a JB Attachments PT Multi-Coupler the pressure in the hydraulic circuit is checked and set at: Pressure adjustment kg/cm ( PSI) This is important for correct PT Multi-Coupler operation and must be set within the above parameters. Index Code Part No. Description Qty 20J Valve J Coil J Valve J Valve J Block 1 4.6

27 OPERATION AND ATTACHING MOUNTING AN ATTACHMENT TO POWERTILT (Std Base) To mount a bucket or attachment to the JBA PowerTilt with the Standard Pin-on coupler base, follow the steps below: 1. Activate the quick-hitch switch ON. 2. Line up attachment and engage front attachment pin. 3. Crowd PowerTilt - this will charge the quick-hitch lines to retract the cylinder to open the rear tongue. As you crowd around, rear pin will fit into rear jaw. 4. Turn Quick-Switch OFF to extend cylinder and this will engage tongue around rear pin. 5. Install the safety pin and retain properly - this will ensure tongue stays in place around rear pin. 6. Proceed with Connection Test Removing ATTACHMENT FROM POWERTILT (Std Base) To remove a bucket or attachment from the JBA Powertilt with the Standard Pinon coupler, follow the steps below: 1. Position the bucket or attachment so it is lightly supported by the ground where it will not move or fall when a pin is removed. Remove the coupler safety-pin. 2. Activate the quick-hitch switch ON. This will release tongue around rear pin. 3. Crowd JB PowerTilt from rear pin and then away from front bucket or attachment pin to disengage PowerTilt. Be careful not to damage the JBA PowerTilt hook while removing the bucket or attachment. 5.0

28 OPERATION AND ATTACHING Operation guide for POWERTILT Multi-coupler BEFORE ATTACHMENT, ENSURE SAFETY LOCK IS OPEN 1. With quick-hitch switch (located inside excavator cab) in OFF position, ensure slide is fully extended with front jaw safety lock open. 2. Line up attachment and engage front attachment pin. SLIDE MECHANISM REAR SLIDE HOOK FRONT JAW LOCK FRONT PIN STROKING THE PUMP METHOD: 3. Activate the quick-hitch switch ON. 4. Crowd PowerTilt - this will charge the quick-hitch lines to retract the slide mechanism and this will visibly lock the front jaw safety latch around front attachment pin. + FRONT JAW VISIBLY LOCKED 5. Turn the quick-hitch switch OFF. 6. Dump or Crowd Powertilt -this will cause the sliding mechanism to extend and engage the rear slide hook onto the rear attachment pin Proceed with Connection Test REAR SLIDE HOOK ENGAGED 5.1

29 OPERATION AND ATTACHING Operation guide for powertilt multi-coupler Attachment operation ELECTRONICALLY STROKED METHOD: 3. Activate the quick-hitch switch ON. This will retract the slide mechanism and this will visibly lock the front jaw safety latch around front attachment pin. 5. Flick the quick-hitch switch OFF. The sliding mechanism will extend and engage the rear slide hook onto the rear attachment pin. FRONT JAW VISIBLY LOCKED 6. Proceed with Connection Test. REAR SLIDE HOOK ENGAGED Removing Attachment from Multi-Coupler Base 1. Place attachment on flat ground 2. Activate quick-hitch switch ON to retract the slide mechanism. Crowd out of rear pin. 3. Turn quick-hitch switch OFF to extend slide hook and release red locking jaw around front pin. 4. Lift PowerTilt Multi-Coupler away from attachment.. 5.2

30 OPERATION AND ATTACHING Connection test important WARNING! Check all attachments are fitting correctly. The safety latch is designed to work in closed position on the front pin. If the safety latch is not closed when attached to any attachment, check the rear jaw on the Multi Coupler is fitting. If uncertain DO NOT USE THIS ATTACHMENT - call your local JB Attachments dealer for assistance. Advise manufacturer of which attachment is not fitting and arrange modification before it is used.! To ensure the PT Multi Coupler has engaged securely to pins on attachment: Visually check the safety latch is engaged on the front pin. Test before operating through applying pressure to bucket/attachment by rotating against the ground and away from machine. Do not proceed with work unless the safety latch is in closed position on the front pin. If the safety latch on the front pin is open DO NOT OPERATE MACHINE. SAFETY LATCH in closed position 5.3

31 OPERATION AND ATTACHING Checking attachments and buckets! WARNING: Check pin centres of JB Attachments PowerTilt Multi Coupler for all customer s attachments Label will indicate pin center range minimum - maximum MIN. MAX SAFETY LATCH - When the latch is in the lock position the jaw is ready and is in the range of the MULTI pin centers. A) Check that each individual attachment s pin-center fits the Multi Coupler to confirm that the Lock Jaw is locked down on the front pin.! DANGER: DO NOT USE ANY ATTACHMENT WITH THE SAFETY LATCH UP BASE WIDTH B) Check the width of each attachment. Where there is an excessive gap (exceeding 10mm), spacers can be fitted to better suit the PT Multi-Coupler base to the attachment. Spacers can be fitted to either the base of the Multi-Coupler or between the inner side of the ears and the bosses of attachment. It is especially advisable to fit spacers in the case of heavier applications, particularly on machines that are 10 ton and above. VARIABLE SPACER WIDTH 5.4

32 OPERATION CHECK ATTACHMENTS AND ATTACHING & BUCKETS Checking attachments and buckets Ensure the correct Attachments & Buckets are used with JBA Multi-Coupler in accordance with the specifications on the JBA Multi-Coupler / PowerTilt Serial Tag. Check pin diameter is correct image 1.0 Measure the diameter of the pin on attachment. (image 1.0) This should be the same as stated on the JBA Serial Tag. Check pin Centres are in range Use a ruler to check pin centres of all attachments being used. image 2.0 (image 2.0) This should be in the range specified on JBA Serial Tag. If Pin Diameter or Pin Centres do not match with the JBA Serial Tag, safe operation could be seriously impaired. You need to stop using the attachment until changes are made to match attachment to JBA Multi-Coupler. If you require assistance to resolve this issue, please call JB Attachments. 5.5

33 MAINTENANCE general maintenance!!!! WARNING - Maintenance Work Maintenance work must be completed by competent personnel or assistance requested from JB Attachments. DANGER - Hydraulic Fluid Never use hands to search for hydraulic fluid leaks, use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and can penetrate the skin and cause serious injury. If affected, see a doctor straight away. WARNING - PowerTilt Condition A defective PowerTilt could injure you or others. Do not operate a PowerTilt that is defective. WARNING - Hose Arrangement Ensure that the hoses are not too loose and do not come into contact with the spring mechanisms as this will prevent the safe operation of the blocking bar. Maintenance and Service To ensure that your PowerTilt works safely and to maximum efficiency it is imperative that it is properly maintained in accordance with the following service guidelines. Replacement Parts We recommend that you fit genuine replacement parts. You will need to quote the PowerTilt serial number stamped on the PowerTilt data plate when ordering replacement parts. Daily checks 1) Complete Daily Pre-Start Check sheet (page 3.3) 2) Grease PowerTilt Multi-Coupler regularly (minimum of once per week). It is important that all parts are greased. Grease the thrust washer at the two grease fittings with a high quality. Lithium-based grease. Apply grease until clean grease flows from the grease reliefs. Severe operating conditions such as abrasive dust or prolonged submersion in water may require more frequent grease applications. 2. Make sure the grease reliefs are functioning properly. Open or replace non-functional grease reliefs immediately. 3. Inspect the JBA PowerTilt for loose, worn or damaged components and replace or repair immediately. 4. Mounting pins should be greased upon installation and thereafter according to the equipment manufacturer s instructions.. 6.0

34 MAINTENANCE WEEKLY CHECKS It is recommended that the following procedures are carried out at least once per week. 1. Carry out all daily, checks 2. Lubrication points - Ensure that all grease points are greased regularly (at least once a week minimum). If damaged, replace and grease. It is important to follow the lubrication instructions in sequence i to v so that none of the grease nipples are overlooked. i. Release the bucket/attachment (refer to the operation instructions-section). ii. Retract the Multi Coupler cylinder. Switch off the engine. iii. Apply grease, via grease nipple (refer to image 1.1 and 1.2). iv. Apply grease via nipple to the hook (refer to image 1.1). v. Start the engine. Extend the bucket cylinder in order to position the Multi Coupler so that the cylinder grease nipples are accessible. Switch off the engine. Hydraulic fluid should be flushed through the JBA PowerTilt. Position the JBA Powertilt so that the hydraulic ports are facing downward. Swing the bucket to the end of rotation and then run the PowerTilt circuit over the cross port relief valve setting for one minute to completely flush out all hydraulic fluid and any containments which may have settled in the JBA Powertilt. Reverse the fluid direction and repeat so that both sides of the piston are purged. the maintenance and repair log for the JB Attachments PowerTilt IS ON PAGE 6.7 It is essential that this log is filled in at the time of carrying out maintenance or repair on the PowerTilt. In the unfortunate event of an accident, this log may be vital evidence as to compliance with Occupational Safety and Health requirements. Work carried out on this JB Attachments PowerTilt must only be by an authorised and competent person. Grease safety lock pin Image 1.1 Image 1.2 Rear slide hook Grease 6.1

35 MAINTENANCE Monthly checks CIRCUIT DIAGRAM Check shaft end play. When the end play exceeds (0.38mm), the end cap must be tightened according to the End Cap Torque Specifications. Tightening the end cap beyond 1/2 turn can cause the end cap to gall to the shaft. If excessive end play still exists, the thrust washers should be replaced. The end cap can be tightened using either of the methods outlined below. 1. Torque Wrench With the lock ring removed, torque the end cap according to the End Cap Torque Specifications Chart. 2. Hydraulic Pressure With the lock ring removed, torque by holding the end cap stationary and hydraulically pressurizing Port P2 according to the End Cap Torque Chart. This procedure will require the use of a pressure gauge mounted either in line or to one of the P2 ports on the PowerTilt. For more information, contact JB Attachments Ltd. 6.2

36 MAINTENANCE Problem Possible Cause Solution PowerTilt does not hold position Excessive down pressure applied by the excavator can cause buildup of pressure in the PowerTilt which is opening the cross port reief valve. this is normal. The integral cross port relief valve is designed to protect the PowerTilt from excessive internal pressures that can damage the unit. PowerTilt swings in only one direction. PowerTilt has spongy feel side to side. Forward and backward movement of shaft in the housing (shaft endplay) Side to side bucket movement PowerTilt will not accept grease at fittings. Control valve leaking oil. Faulty cross port relief valve. Seals leaking oil. Single directional control valve is being used. Cross port relief valve damaged. Both lines connected to either both P1 or P2 ports of PowerTilt. Air in PowerTilt or hydraulic circuit. Diameter of tubing/hoses larger or longer than recommended. Worn or missing thrust washers. Some movement is normal due to clearance required between internal spline teeth. Grease relief valve is not functioning, or it has been replaced with a grease fitting or plug. Test, repair or replace as needed. Remove the integral cross port relief valve and visually inspect for damage or debris. Check pressure setting of cross port relief valve: which can be found in the Tool Circuit Requirements Chart shown on page 4.0. Test and replace as needed. Replace with bi-directional control valve. Inspect, test and replace as needed. Refer to page 7.1 for proper port connection location. Bleed air from circuit and check for cause. Install new tubing/hoses with recommended diametres. Install pilot operated check valve in lines as close as possible to PowerTilt. Tighten end cap according to End Cap Torque Chart on Page Replace or install thrust washers if necessary. Normal movement is 1 to 1-1/2. If greater, check shaft end play; excessive end play can contribute to side to side movement. If shaft end play is not within acceptable limits, consult JB Attachments. Clean or replace Relief valves. 6.3

37 500HR PREVENTATIVE MAINTENANCE CHECK Visual Check Points on Slide Hook 2. Visually check the slide hook for any cracks. Refer to the below steps to guide you through the appropriate methods to correctly analyse the cast Multi Coupler slide hook for any defects. Should you find any cracks anywhere on the Multi Coupler body, contact your local JB Attachments Branch or authorised Service Centre immediately 1 2 Slide Hook Slide Hook 3 Minimum 5mm Clearance 4 Slide Hook Flat Base Multi Coupler Check the clearance of the slide hook The slide hook level should be below the main body line. The rear pin of the attachment will rest on the main body. Each coupler model will vary in the size of the gap but it must be a minimum of 5mm. 6.4

38 500HR PREVENTATIVE MAINTENANCE CHECK Wear Tolerance of the Cast Body and Slide 1 The slide hook will have free movement when new. To gauge the wear of the cast body and slide hook place an allen key as in image 1 to test the space between the slide hook and cast body. Please see the table below (Guideline for maximum wear) to verify the maximum wear of the cast body. GUIDELINE FOR MAXIMUM WEAR 2-4 Ton Multi Coupler 4mm 6,8,14 Ton Multi Coupler 5mm 20,35,45 Ton Multi Coupler 7mm Wear Tolerance of the Multi Coupler Base Maximum Wear 5mm If the Multi Coupler frame becomes worn or damaged in this area on the side frame (image 2), contact your local JB Attachments Branch or authorised Service Centre immediately

39 500HR PREVENTATIVE SAFETY-LATCH MAINTENANCE MANUAL INSPECTION CHECK Manual Safety- Latch InSPECTION Manual Inspection of PowerTilt Multi-Coupler Safety-Latch is to be carried out to ensure safety-latch movement is within acceptable safety tolerances as specified below. This is in addition to daily visual check of safety-latch and usual wear-andtear Check movement of safety latch Connect JBA PowerTilt to attachment with slide fully retracted to lock safety-latch. Use a ruler to measure the distance between the bottom of the jaw to the tip of the Safety-Latch whilst pulled up with hand - refer to image 3.0. This measurement (mm) is the Maximum Opening Distance. Maxiumum Opening Distance: Safe Allowable Variation Table image 3.0 PowerTilt Model Attachment Pin Diameter (mm) Maximum Allowable Opening (mm) PT4.5 (JB02) PT6 (JB03) PT6 (JB04) PT7 (JB06) PT8 (JB08) PT8 (JB08) PT8 (JB08) PT9 (JB14) This Maximum Opening Distance should be compared to the Safe Allowable Variation Table. If the Maximum Opening Distance is less than the Maximum Allowable Opening value for the PowerTilt model, it is safe to use. PT9 (JB14) PT10 (JB14) PT10 (JB20) PT10 (JB20) PT11 (JB20) PT11 (JB20) PT12 (JB35) PT12 (JB35) ! If the Maximum Opening Distance is greater than the Maximum Allowable Opening value for that JBA PowerTilt model, safe operation of the JBA PowerTilt could be seriously impaired. Please contact JB Attachments service department for advice. 6.6

40 500HR PREVENTATIVE MAINTENANCE CHECK Lifting Eye InSPECTION! WARNING The Lifting Eye requires inspection every 6 months Figure Visual check for cracking 2. Check for visible wear on the lifting eye. 3. Check wear and damage to outer surface of lifting eye. Refer to Figure 1.1 A, B, D, E, G Please contact JB Attachments for details of wear tolerances on lifting eye. Should you find any cracks anywhere on the lifting eye, contact your local JB Attachments Branch or authorised Service Centre immediately. 6.7

41 MAINTENANCE AND REPAIR LOG DATE FAULT / SERVICE DESCRIPTION MAINTENANCE / REPAIR EFFECTED BY WHOM 6.8

42 MAINTENANCE TORQUE The torque specifications are as follows: Check valve 30 ft/lbs 40 Nm B hose connection male (cylinder hose) 15 ft/lbs 20 Nm A hose connection male (cylinder hose) 26 ft/lbs 35 Nm Pressure hose connection female 20 ft/lbs 27 Nm Tank return hose connection female 55 ft/lbs 75 Nm Weld on block 20 ft/lbs 27 Nm Solenoid Valve A Line filter fitting o BSP M/M Adapter 25 ft/lbs 34 Nm B Line filter fitting 7/16 JIC x 7/16 UNF 15 ft/lbs 20 Nm P Line 9/16 JIC x 9/16 UNF 26 ft/lbs 35 Nm T Line 3/8 BSP M/M Adapter 55 ft/lbs 75 Nm Spool Valve 40.6 ft/lbs 54.2 Nm Check Valve 33.8 ft/lbs 40.6 Nm Electro-magnetic lock nut 5.4 ft/lbs 8.1 Nm Plug 9.3 ft/lbs 13 Nm 6.9

43 PTA ASSEMBLY DRAWING SEE PAGE

44 PTB ASSEMBLY DRAWING SEE PAGE

45 PT PISTON DRAWING * * * * * * * * * Service normally not required. 7.2

46 PT EXPLODED VIEW 7.3

47 TOOLS PARTS LIST PARTS Item Description quantity 1... Housing R ing Gear** Shaft Piston Sleeve End Cap Lock Ring Standard Pin-on Coupler...1 PT Series only Torque Foot** I dler Foot** Port Plug, Shaft S haft Mounting Screw* Model 6 M16 x Model 7 M20 x Model 8 M24 x Model 9 M24 x Model 10 M30 x Model 11 M30 x Model 12 M30 x Shaft Dowel Pin P late Washer G rease Relief Cover Lock Ring Screw* Model 6 M12 x Model 7 M12 x Model 8 M16 x Model 9 M16 x Model 10 M16 x Model 11 M16 x Model 12 M20 x P iston Dowel Pin G rease Fitting G rease Relief Port Plug J acking Bolt, Coupler...1 or J am Nut, Coupler...1 or Dowel Pin Retainer Lock Ring Set Screw C ross Port Relief Valve Hazard Warning Decal, for Product Hazard Warning Decal...1 For Cab * All shaft mounting screws are Grade 12.9 / All lock ring screws are Grade 10.9 SEAL KIT Sold as kit only. Item Description quantity Piston S eal...1 For model sizes 10, 11 and 12 only Piston S eal E nd Cap O-ring...1 or E nd Cap Back-up Ring Piston O -ring...0 or Piston B ack-up R ing...0 or Piston S eal Piston S eal...1 For model sizes 6, 7 and 8 only Exclusion S eal Pressure Seal Lock Ring O-ring...1 BEARING KIT Sold as kit only. Item Description quantity Shaft Bearing...2 or Shaft Bearing...1 or P iston Bearing P iston Bearing...1 or Thrust Washer...2 Order Your Spare and Replacement Parts Today Spare Spare or or replacement parts parts can can be be ordered from JB online Attachments at by the following methods: or by calling Helac sales@jbattachments.com Corporation s Service in NZ or Department brisbane@jbattachments.com at (U.S. in Australia. and Canada) Calling or our Service 802 department 1039 (Worldwide), between Monday the hours through of 8.30am Friday, pm. a.m. to 4 p.m. PST. NZ: When ordering AUS: +61 Spare 7 and 3803 Replacement 9400 Parts, When including ordering Seal Spare and and Bearing Replacement Kits, please parts have including Seal the and serial Bearing and/or Kits, model please number have the available. serial and/or model number available. These reference numbers These reference numbers are located on the are located on the PowerTilt ID Tag as noted on Page PowerTilt ID Tag as noted on Page ** These parts are not available for purchase. 7.4

48 MULTI-COUPLER BASE PARTS DRAWING 4 8.0

49 MULTI-COUPLER PARTS LIST PART NUMBERS Ref No. Description 2T 3T 6T 8T 14T 20T 35T 45T 2 Slide Type N/A 2 Slide Type N/A N/A N/A N/A 3 Latch N/A 4 Complete Hydraulic Cylinder Pin Latch TD Greasable N/A 6 Pin Cylinder Circlip Non Greasable N/A N/A N/A 7 Circlip N/A N/A N/A 8 Screw CSK N/A 9 Grease Nipple N/A 10 Pin Eye End N/A 15 Screw Grub N/A N/A N/A N/A N/A N/A N/A 16 Pin Safety N/A 17 Pin Lynch N/A N/A N/A 18 Pin Cylinder TD Non Greasable N/A N/A N/A N/A N/A N/A 19 Hydraulic Cylinder Hose 8.1

50 CYLINDER PARTS DRAWING NOTE: Cylinder design is different for each model. 8.2

51 CYLINDER PARTS LIST PART NUMBERS Ref No. Description 2T 3T 6T 8T 14T 20T 35T 45T 1 Cylinder Spear N/A Cylinder Piston N/A Cylinder Body N/A Cylinder Gland N/A Cylinder Check Valve Cylinder Plug N/A N/A N/A Cylinder Check Valve Seal Kit Cylinder Seal Kit COMPLETE HYD CYLINDER

52 DRAW PIN DRAWING AND PARTS PART NUMBERS Ref No. Description 2T 3T 11 Label Range JB Label ID JB Screw Cap Nut Nyloc DP Slide

53 DISASSEMBLY component identification The JBA PowerTilt is comprised of the following components: 1. Housing with integral ring gear 2. Shaft 3. Piston sleeve assembly 4. End Cap 5. Lock ring 6. Standard pin-on coupler base. 9.0

54 DISASSEMBLY Tools Required Several basic tools are required for th e disassembly and reassembly of the PowerTilt. The suggested tools are outlined below: 1. Brush 2. Customized end cap tool 3. Customized seal tools 4. Permanent marker 5. Flashlight 6. Hex driver 7. Hex wrenches 8. Large socket wrench 9. Plastic or rubber mallet 10. Plastic mandrel 11. Pry bar 12. Safety glasses 13. Threaded bolts 14. Torque wrench Making a Seal Tool The seal tool is merely a customized standard flat head screwdriver. 1. Heat the flat end with a torch until it glows. 2. Secure the heated end of the screwdriver in a vise and bend the heated end to a slight radius. 3. Round off all sharp edges of the heated tip to a polished finish. The tool may be modified slightly to your own personal preference. 9.1

55 DISASSEMBLY Product inspection Make sure the PowerTilt is thoroughly cleaned prior to disassembly. Continue to clean all machined parts in a wash tank and dry with compressed air. Inspect the PowerTilt for corrosion prior to disassembly. Severe corrosion can make it difficult to remove the lock ring screws or set screws and unthread the end cap. If corrosion is evident, soak the screws with penetrating oil for several hours before disassembly. Product inspection 1. Begin with removing the port fittings and plugs (124) to drain the hydraulic oil into a suitable container. 3. Secure the coupler using a hoist or similar device. 2. When removing the standard pin-on coupler or torque foot (6.1) and idler foot (6.2), remove the torque foot mounting screws (104). 4. Unthread and remove the lock ring screws (120). 9.2

56 DISASSEMBLY Standard Pin-on Coupler Removal 5. Tighten the two lock ring set screws (129) into the lock ring (05). Turn the set screws equally, backing the lock ring off the end cap (04) and idler foot (6.2). 7. Using a hoist or similar lifting device, lift off the standard pin-on coupler (06) or feet (6.1, 6.2). 6.I nsert threaded bolts into the lock ring (05) and pull straight out. There is an alignment dowel pin (105) between the shaft and the torque foot (6.1) to prevent sliding. 9.3

57 DISASSEMBLY End cap, lock ring and cross port releif valve 1. Unthread the port plug (101) on the end of the shaft to remove the cross port relief valve (413). 3. Unthread the end cap (04) from the shaft (02) using two bolts and a pry bar. 4. Remove the thrust washer (344) from the end cap (04) or the housing collar. 2. Remove the lock ring O-ring (239) from the shaft. 9.4

58 DISASSEMBLY SHAFT REMOVAL Do not remove the shaft (02) at this point. Component gearing is aligned for correct timing. Timing is critical for correct operation of the PowerTilt. If you are unable to locate the factory-made timing marks, use a paint stick or a permanent marker to mark the orientation between the housing ring gear, shaft and the piston sleeve assembly. 1. Rotate the shaft (02) completely clockwise, then slowly rotate the shaft counterclockwise while tapping the threaded end of the shaft to begin removing the shaft from the piston sleeve assembly (03). Stop when the shaft gearing becomes visible. 3. Remove the shaft (02) by rotating and sliding the shaft gear teeth out of engagement with the inside diameter gear teeth of the piston sleeve assembly (03). 2. Locate the timing marks on the housing ring gear (1.4), piston sleeve assembly (03) and shaft (02). Small punch marks are usually found on the face of the piston teeth and ring gear. The shaft timing marks may be located in the root or V of the helical gearing. Piston sleeve timing marks are best seen when the splined end of the piston sleeve is flush with the ring gear inside the housing. 9.5

59 DISASSEMBLY Piston sleeve assembly removal 1. Before removing the piston sleeve assembly (03), double check the timing marks of the housing ring gear (1.4) in relation to the piston sleeve assembly. 2. Using a rubber or plastic hammer and mandrel, gently tap the piston sleeve assembly (03) to disengage the O.D. gear teeth from the housing ring gear teeth inside the housing bore. 9.6

60 DISASSEMBLY Seal and Bearing Removal 1. Use the seal tools to remove all seals, wear guides and thrust washers (344) from the piston sleeve a ssembly (03), end c ap ( 04) and shaft (02). Note that several product models may not have wear guides on the I.D. and/or O.D. of the piston sleeve assembly (03). 2. Remove the grease fittings (122), grease relief covers (107) and grease reliefs (123). 9.7

61 DISASSEMBLY Component and timing mark inspection 1. Clean all machined components thoroughly in a wash tank and dry with compressed air. 2. Carefully inspect all critical areas: Seal grooves, wear guide grooves, thrust surfaces, shaft surfaces, housing bore and gear teeth for any wear, corrosion and any other signs of damage. 3. Locate the timing marks on the shaft (02), piston sleeve assembly (03) and housing ring gear (1.4). Re-mark with a permanent marker or paint stick if needed. 9.8

62 ASSEMBLY Dry Assembly In some cases, for repair personnel not familiar with the assembly process, it may be beneficial to perform a dry assembly. This will provide a better idea of how to properly align the gear teeth. A dry assembly is typically done without seals, yet requires the wear glides and thrust washers to be installed. Seal and bearing installation Before installing seals and bearings, coat the seals and machined surfaces with a high quality hydraulic oil. Note: All seals, bearings and thrust washers must be replaced whenever the PowerTilt is reassembled. Note: The exact location and number of seals or bearings used varies by product model. End Cap Seals and Bearing Installation Before installing the end cap seals and bearings in the below sequence, lay the end cap on the table with the inside facing up. Note orientation of all seals on assembly drawings before installing. 1. First Install the O.D. exclusion seal. 10.0

63 ASSEMBLY Seal and Bearing installation 2. Lightly coat both sides of the thrust washer (344) with lithium grease and install on the thrust face of the end cap (04). 5. Now install the O-ring (230) and backup ring (231) into the I.D. seal groove on the end cap (04). 3. Next install the O.D. pressure seal (238) with the lip facing inboard toward the hydraulic pressure. 4. Then install the wear guides (340, 341) in the wide groove of the end cap (04). 10.1

64 ASSEMBLY Seal and Bearing installation Piston Seal and Bearing Installation 1. Before installing the cup seals on some PowerTilt models, remove the energizer O-ring from one O.D. and one I.D. seal and install them nearest to the piston gearing. Failure to do so may cause premature seal wear and pressure trapping. 3. When used, install the wear guide(s) on the O.D. and/or I.D. (342, 343) 2. For product models with cup and/or T-seals, install the seals on the O.D. and I.D. (234, 235) of the piston sleeve assembly. Note that the lips are facing away from each other on models with cup seals. 10.2

65 ASSEMBLY Seal and bearing installation Shaft Seal and Bearing Installation 1. First install the exclusion seal (237) onto the shaft (02). 3. Then install the pressure seal (238) with the lip facing inboard, toward the hydraulic pressure. 4. Now install the wear guides (340, 341). 2. Lightly coat both sides of the thrust washer (344) with Lithium grease and install onto the shaft (02). 10.3

66 ASSEMBLY piston sleeve installation Piston Seal and Bearing Installation 1.B efore installing the piston sleeve assembly (03), coat the piston and housing bore with high quality hydraulic oil to reduce chance of seal damage. 3. Confirm proper timing by aligning the piston sleeve assembly (03) timing marks with the housing ring gear (1.4) timing marks. 4. Then using a plastic or rubber mallet and mandrel, engage the piston sleeve (03) into the housing ring gear (1.4). Continue tapping until the piston sleeve bottoms out against the housing ring gear. 2. Carefully slide the piston sleeve assembly (03) into the housing (01). Gently tap the piston to compress the seals through the housing chamfer. Continue tapping until the piston sleeve contacts the housing ring gear (1.4). 10.4

67 ASSEMBLY Shaft Seal and Bearing installation 1. Before installing the shaft (02), coat the shaft with high quality hydraulic oil. Temporarily cover the shaft threads with tape to prevent seal damage. Remove the tape after the shaft has been installed. 3. Verify timing marks before rotating the shaft all the way into the housing (01). 4. Use a pry bar to rotate the shaft (02) in until it is completely bottomed out in the housing (01). 2. Insert the shaft (02) into the piston sleeve assembly (03), carefully aligning the timing marks on the shaft with the piston (03). Take care not to damage the I.D. piston seals (204, 205) with the threaded end of the shaft. 10.5

68 ASSEMBLY end cap and lock ring installation 1. Before installing the end cap (04), coat the end cap and shaft threads with anti-seize grease. 4. Remove the two screws and tighten the end cap (04) using a torque wrench and customized end cap tool to the torque specifications shown on the End Cap Torque Chart on Page Install two screws into the end cap. Thread the end cap (04) onto the shaft (02) until the seal contacts the housing. 5. Then install the lock ring (05), trying different splines to find the best alignment between the lock ring splines and the end cap (04) holes. If the holes do not align, thread the end cap by no more than one spline tooth to align the holes. 3. Using a pry bar, continue to rotate clockwise and tighten until the thrust washer (344) makes contact with the housing (01) collar. 10.6

69 ASSEMBLY end cap and lock ring installation 6. Now make an alignment mark between the lock ring (05) and shaft (02) splines. Then remove the lock ring. End Cap Torque Specifications Model Torque ft-lbs Nm Hydraulic pressure psi bar 10.7

70 ASSEMBLY cross port releif valve installation 1. Reinstall the cross port relief valve (413) with new O-rings and back up rings and torque to 44 ft lbs (60 Nm). 2. Coat the shaft port plug (101) threads with Loctite 242 and install into the end of the shaft (02) and torque to 225 ft lbs or (305 Nm). Standard Pin-on Coupler I nstallation 1. Reinstall the lock ring (05), aligning the timing marks. Then install and tighten two screws into the lock ring (05) to lock the end cap (04) and shaft (02) together. 10.8

71 ASSEMBLY standard pin-on coupler installation 2. Then using a pry bar, rotate the shaft until the torque foot (6.1) mounting surface is horizontal. 4. Install the alignment dowel pin (105) into the torque foot (6.1) if it is not already in place. 3. Remove the two screws and lock ring (05). 5. Then install the coupler (06) onto the shaft (02). Align the dowel pin (105) on the shaft to the torque foot (6.1). 6. Coat the end of the shaft (02), the lock ring (05) and the outside of the end cap (04) with waterproof grease. 10.9

72 ASSEMBLY standard pin-on coupler installation 9. Coat the lock ring screw (120) threads with Loctite 242, install and torque per the Fastener Torque Chart on Page 42. Install the lock ring O-ring (239) onto the shaft. 10. Coat the lock ring set screws (129) with Loctite 545, thread until tight and torque to 30 ft-lbs. Next install the lock ring (05) using two threaded bolts as handles. 11.0

73 ASSEMBLY standard pin-on coupler installation 11. Coat the torque foot screw (104) threads with Loctite 242 and install. 12. Torque the fasteners to the specifications shown on the Torque Specifications Charts. Fastener Torque Specifications Torque values for Port Plugs Plug Size BSPP G1/4 SAE-4 SAE-6 SAE-20 Torque value - Hollow Hex Head Plugs Torque value - Hex Head Port Plugs ft-lbs Nm ft-lbs Nm 23 +/ / / / / / / / / / / / / / / /- 22 Torque values for Metric Fasteners Fastener Size M10 x 1.50 M12 x 1.75 M16 x 2.00 M20 x 2.50 M24 x 3.00 M30 x 3.50 Socket Head Bolt (grd 12.9) ft-lbs Nm 44 +/ / / / / / / / / / / /- 41 Hex Head Bolt (grd 10.9) ft-lbs Nm 32 +/ / / / / / / / / / / /- 34 ft-lbs 240 +/ / / / /- 15 Jam Nut (grd 12.9) Nm 27 +/ / / / /- 2 *A ll Shaft mounting screws are Grade 12.9 / All Lock Ring screws a re G rade

74 POST ASSEMBLY testing and greasing Testing and Greasing Attach the PowerTilt to either a hydraulic test bench or portable pump for greasing and testing. Make sure the PowerTilt is secured to prevent movement. Install the grease fittings, grease reliefs and covers. 1. After the PowerTilt is assembled but before it is put back into service, the exclusion seals and thrust washers must be packed with Lithium grease. Testing the Carrier's Hydraulic System If symptoms of poor performance develop, refer to the Troubleshooting Guide on Page 15 for general instructions. If you need help with more specific application issues, contact Helac Corporation s Service Department. 2. Locate the grease fittings (122) or ports on the end of the PowerTilt and using a grease gun, pack the exclusion seal and thrust washer with grease until it exhausts from the grease reliefs (123). It is the responsibility of your service technician to verify that the carrier and hydraulic circuit are operating correctly. Because the PowerTilt receives its power from the carrier, a thorough check of the carrier hydraulic system is mandatory before performing any PowerTilt service or adjustments. 3. Cycle the PowerTilt slowly and re-grease as necessary. During testing, it is recommended the PowerTilt be cycled 20 to 30 times to check for leaks and the proper degrees of rotation. 12.0