OPERATIONS AND MAINTENANCE

Transcription

1 HELITILT OPERATIONS AND MAINTENANCE

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

3 CONTENTS 1.0 INTRODUCTION SAFETY INSTRUCTIONS STANDARDS INSTALLATION OPERATION AND ATTACHING MAINTENANCE HELITILT DRAWINGS / PARTS LIST MULTI-COUPLER DRAWINGS / PARTS LIST HELITILT DISASSEMBLY HELITILT ASSEMBLY HELITILT POST ASSEMBLY WARRANTY / CONTACT INFORMATION

4 INTRODUCTION

5 INTRODUCTION IMPORTANT NOTE: 1.0

6 INTRODUCTION CUSTOMER ACCEPTANCE AND WARRANTY REGISTRATION THE PURCHASER SHALL: 1.1

7 INTRODUCTION TO THE OWNER FOLLOW THE SAFETY INSTRUCTIONS: INFORMATION FOR THE USER: WARRANTY REGULATION: PLEASE COMPLETE THE CUSTOMER ACCEPTANCE AND WARRANTY REGISTRATION FORM LOCATED IN THIS MANUAL - FAILURE TO REGISTER MAY INVALIDATE YOUR WARRANTY CLAIM.

8 INTRODUCTION - OPERATION TECHNOLOGY and

9 INTRODUCTION - SAFETY GUIDLINES Cautionary Notices d t are t are not r or o or t Other Safety Guidelines and Precautions 1. to t was t t or w t was not t and o to as as damage to e o a 2. to t s done at e and may warranty. 3. s or a m as noted t or to o a e.g. d w a may wear It a t w are not Maximum Recommended Bucket Width for Use with PowerTilt PowerTilt Model Maximum Bucket Width n may e to t r and t added w o to 5. It t o to n and g at are damaged or a o 10 s

10 SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS! WARNING! NOTE: 2.0

11 SAFETY INSTRUCTIONS Decal for inside cab. Part # JB Attachments

12 SAFETY INDICATION LABELS!! 2.2

13 SERIAL NUMBERS 2.3

14 S.W.L - SAFE WORKING LOAD JB Attachments HeliTilt Lifting Eye Restrictions SAFE WORKING LOAD BADGE 2.4

15 S.W.L LIFTING EYE JB Attachments HeliTilt Lifting Procedures! WARNING: Use correct lifting connection! WARNING - VISUAL INSPECTION OF LIFTING EYE 2.5

16 STANDARDS Design, Installation, Maintenance and Operation STANDARDS AND OCCUPATIONAL SAFETY AND HEALTH GUIDELINES ASSOCIATED STANDARDS 3.0

17 STANDARDS NOTE: FOR JB ATTACHMENTS HELITILT 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 HELITILT Location: Date: Ref no: People Affected YES NO N/A Expected Precautions YES NO N/A Personal Protective Equipment (PPE) Management Date 3.2

19 RISK ASSESMENT DAILY PRE-START CHECK SHEET M W D R I In Cab Hydraulic System PowerTilt with Multi-Coupler Base LUBRICATION Operator Signature Manager Signature 3.3

20 INSTALLATION HYDRAULIC REQUIREMENTS 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 in (mm) 8 (10) 8 (10) 8 (10) 2 (12) 2 (12) 8 (16) 8 (16) e in (mm) 4 (6) 4 (6) 4 (6) 8 (10) 8 (10) 8 (10) 8 (10) Hydraulic Pressures e ( bar) ( bar) (40 bar) s to to o 4.0

21 INSTALLATION FOR JB ATTACHMENTS FACTORY FITTED MULTI-COUPLER KIT ON EXCAVATOR STEP 1 FITTING HOSES TO CYLINDER! WARNING: 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 Step Two:! WARNING: Step Three: Step Four: - 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 STEP 3! CHECK PINS ARE ORIGINAL EQUIPMENT MANUFACTURER S PINS. 4.2

23 INSTALLATION FOR JB ATTACHMENTS FACTORY FITTED MULTI-COUPLER KIT ON EXCAVATOR STEP 4 HOSE POSITION 4.3

24 INSTALLATION FOR JB ATTACHMENTS FACTORY FITTED MULTI-COUPLER KIT ON EXCAVATOR STEP 4 HOSE POSITION 240mm! 4.4

25 INSTALLATION FOR JB ATTACHMENTS FACTORY FITTED MULTI-COUPLER KIT ON EXCAVATOR STEP 4 HOSE POSITION 2 2 ITEM QTY Part No. Description REVISION 1a

26 INSTALLATION CIRCUIT DIAGRAM! WARNING: 2 Index Code Part No. Description Qty

27 OPERATION AND ATTACHING MOUNTING AN ATTACHMENT TO HELITILT Connection Test REMOVING ATTACHMENT FROM HELITILT (STD BASE)

28 OPERATION AND ATTACHING OPERATION GUIDE FOR HELITILT MULTI-COUPLER BEFORE ATTACHMENT, ENSURE SAFETY LOCK IS OPEN Connection Test 5.1

29 OPERATION AND ATTACHING OPERATION GUIDE FOR POWERTILT MULTI-COUPLER ATTACHMENT OPERATION Connection Test. REMOVING ATTACHMENT FROM MULTI-COUPLER BASE

30 OPERATION AND ATTACHING CONNECTION TEST IMPORTANT WARNING!! DO NOT OPERATE MACHINE. 5.3

31 OPERATION AND ATTACHING CHECKING ATTACHMENTS AND BUCKETS!! 5.4

32 OPERATION CHECK ATTACHMENTS AND ATTACHING & BUCKETS CHECKING ATTACHMENTS AND BUCKETS CHECK PIN DIAMETER IS CORRECT image 1.0 CHECK PIN CENTRES ARE IN RANGE image

33 MAINTENANCE GENERAL MAINTENANCE!!!! WARNING - Maintenance Work DANGER - Hydraulic Fluid WARNING - PowerTilt Condition WARNING - Hose Arrangement Maintenance and Service Replacement Parts serial number DAILY CHECKS 6.0

34 MAINTENANCE WEEKLY CHECKS It is recommended that the following procedures are carried out at least once per week. THE MAINTENANCE AND REPAIR LOG FOR THE JB ATTACHMENTS HELITILT IS ON PAGE 6.7 Image 1.1 Image

35 MAINTENANCE MONTHLY CHECKS CIRCUIT DIAGRAM 1. Torque Wrench 2. Hydraulic Pressure 6.2

36 6.3 MAINTENANCE Problem Possible Cause Solution - -

37 500HR PREVENTATIVE MAINTENANCE CHECK Attachments Branch or authorised Service Centre immediately Check the clearance of the slide hook 4 6.4

38 500HR PREVENTATIVE MAINTENANCE CHECK 1 4mm 5mm 7mm 2 6.5

39 500HR PREVENTATIVE SAFETY-LATCH MAINTENANCE MANUAL INSPECTION CHECK MANUAL SAFETY- LATCH INSPECTION - wear-and-tear assessments. CHECK MOVEMENT OF SAFETY LATCH Maximum Opening Distance: image 3.0 Safe Allowable Variation Table PowerTilt Model Attachment Pin Diameter (mm) Maximum Allowable Opening (mm) ! 6.6

40 500HR PREVENTATIVE MAINTENANCE CHECK LIFTING EYE INSPECTION! 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 AND REPAIR LOG DATE FAULT / SERVICE DESCRIPTION MAINTENANCE / REPAIR EFFECTED BY WHOM 6.8

43 MAINTENANCE TORQUE SPECIFICATIONS Solenoid Valve 6.9

44 PTA ASSEMBLY DRAWING 7.0

45 PTB ASSEMBLY DRAWING 7.1

46 PT PISTON DRAWING * not r 7.2

47 7.3 PT EXPLODED VIEW

48 TOOLS PARTS LIST PARTS Item Description Quantity R I or or C g 9 SEAL KIT Item Description Quantity nd C...1 or nd C R or R...0 or R...1 BEARING KIT Item Description Quantity or or or Order Your Spare and Replacement Parts Today or r an e ordered at or e or o and R arts and e r are on t ID as noted on

49 DRAW PIN DRAWING AND PARTS

50 MULTI-COUPLER PARTS LIST (Optional)

51 MULTI-COUPLER BASE PARTS DRAWING

52 CYLINDER PARTS LIST

53 CYLINDER PARTS DRAWING 8.4

54 DISASSEMBLY 9.0

55 DISASSEMBLY TOOLS REQUIRED e and r t e t are end t 3. t s 4. m s 8. w 9. or m t 10. mandre g w Making a Seal Tool t s a standard. 1. t end w a t 2. end o a v and t end to a r 3. o a edges o to a t may e d to own 9.1

56 DISASSEMBLY PRODUCT INSPECTION PRODUCT INSPECTION 1. r t and to o nto a. 3. a or. 2. r t standard or oot and oot remove t oot m. 4. and remove t r s 9.2

57 DISASSEMBLY 5. t two r set nto r set t r end and. 7. a or e standard or 6 6.I nsert nto r and. an t and t oot to s 9.3

58 DISASSEMBLY END CAP, LOCK RING AND CROSS PORT RELEIF VALVE REMOVAL 1. t on end o e to remove t ross. 3. t end t two and a ry. 4. Remove t t w e end or t 2. Remove t r m 9.4

59 DISASSEMBLY SHAFT REMOVAL Do not remove t at or t or. are to a m to t o n t r and s 1. Rotate t s rotate t e t t t end o to t s w t g v. 3. Remove t y and s g gear t o engagement w e d gear t t. 2. m on r g gear and m are on t o t and r gear. m may e n e root or t m are seen w t end o s s w gear t 9.5

60 DISASSEMBLY PISTON SLEEVE ASSEMBLY REMOVAL 1. r t y t t t r gear n to a 2. a r or and m t t to t.d. gear t gear t t 9.6

61 DISASSEMBLY SEAL AND BEARING REMOVAL 1. t to remove a wear and t w a end and. m may not wear on I.D..D. t s. 2. Remove t grease grease r and grease r. 9.7

62 DISASSEMBLY COMPONENT AND TIMING MARK INSPECTION 1. a m a t and dry w a. 2. a a wear g t and gear teet any w and any o s damage. 3. m on s and r g gear R w a anent m or s needed. 9.8

63 ASSEMBLY DRY ASSEMBLY SEAL AND BEARING INSTALLATION 10.0

64 ASSEMBLY SEAL AND BEARING INSTALLATION 2. o w w grease and on t o end. 5. and nto I.D. groove on e end. 3. w toward t 4. wear n e groove o end. 10.1

65 ASSEMBLY SEAL AND BEARING INSTALLATION Piston Seal and Bearing Installation 1. on some remove t one.d. and one I.D. and nearest to to do so may wear and. 3. wear on e I.D. 2. m on t.d. and I.D. t ote t are away o on s 10.2

66 ASSEMBLY SEAL AND BEARING INSTALLATION Shaft Seal and Bearing Installation 1. onto e. 3. w toward 4. wear. 2. o w w grease and onto e. 10.3

67 ASSEMBLY PISTON SLEEVE INSTALLATION 1 s y t and o to o damage. 3. t a t n t t r gear t 4. a or m and engage t nto e r gear t s t r gear. 2. s s t t t to t t C t t n r gear. 10.4

68 ASSEMBLY SHAFT SEAL AND BEARING INSTALLATION 1. t t o t r 3. t way t. 4. a to rotate t n t n. 2. Insert nto s a t t g on t t not to damage t I.D. w end o 10.5

69 ASSEMBLY END CAP AND LOCK RING INSTALLATION 1. end t end and w grease. 4. Remove t two and t t end a t w and end t to n 2. two t end t end onto t 5. r to t a t r and t end do not a t t end y no more one to a e. 3. a to rotate e and t t t w m w 10.6

70 ASSEMBLY END CAP AND LOCK RING INSTALLATION 6. an m t and remove r End Cap Torque Specifications Model Torque ft-lbs Nm Hydraulic pressure psi bar 10.7

71 ASSEMBLY CROSS PORT RELEIF VALVE INSTALLATION 1. w new and and t to Coat t t w 242 and t end o t and t to 225 or 305 Standard Pin-on Coupler I nstallation 1. r a t g and t two to t end and t. 10.8

72 ASSEMBLY STANDARD PIN-ON COUPLER INSTALLATION 2. a ry rotate t s e oot m s. 4. nto e oot s not a n 3. Remove t two and r. 5. onto. on to t oot 6. Coat t end o r and t o o end grease. 10.9

73 ASSEMBLY STANDARD PIN-ON COUPLER INSTALLATION 9. Coat t r t w and t t C on age 42. r onto 10. r two as 11.0

74 ASSEMBLY STANDARD PIN-ON COUPLER INSTALLATION t asteners to t on t C. Fastener Torque Specifications Torque Values for Port Plugs Plug Size Torque Value - Hollow Hex Head Plugs Torque Value - Hex Head Port Plugs ft-lbs Nm ft-lbs Nm Torque Values for Metric Fasteners Fastener Size M M M M M M Socket Head Bolt (grd 12.9) ft-lbs Nm Hex Head Bolt (grd 10.9) ft-lbs Nm Jam Nut (grd 12.9) ft-lbs Nm are 12.9 R g a re rade

75 POST ASSEMBLY TESTING AND GREASING Testing and Greasing t to a test or and t M s to movement. grease grease r and 1. s nto t s and t w e w grease. Testing the Carrier's Hydraulic System r to on age 15 need more C s D. 2. grease or orts on e end o and a grease t and t w r grease e t grease. It t r t to t and are t r a o e system s mandatory e any or 3. s and re-grease as D t r e 20 to 30 to and t degrees o 12.0

76 POST ASSEMBLY TESTING AND GREASING Testing for Internal Leakage 1. a test nto to ort t end o and e e.g. t or t oot or. not y e 2 at a v. 2. Remove and t to ort. 1 to or at 2 and and end. 3. t to ort and as n 1 4. or at 1 and a t m n and end as n 2 Testing the Cross Port Relief Valve ross vents t t at to 210 to 230 test t 1. a test nto to ort t t t end o and e.g. t or oot or. 2. to 2 and d t and t. 3. a to t end o vented to an. ross s set at and e 4. 1 e at w o r d vent at to 210 to at 2 t same 6. test does not meet t m e r test are e 12.1

77 WARRANTY INFORMATION JB ATTACHMENTS LTD Helac Corporation warrants its products to be free from defective material and factory workmanship for a period of one (1) year or 1000 service hours, whichever occurs first, for Helac Corporation approved applications, defined as medium duty service on the machine for which the Helac Attachment (PowerTilt or PowerGrip ) was originally designed and with cross port or work port relief valves installed according to Helac Corporation s recommendations. The warranty period shall begin when the Helac Attachment is first placed into service as documented by the return of the Warranty Registration Card to the factory. If the Registration Card is not returned, the warranty period will commence from the date the Helac Attachment was originally shipped from the factory. For products delivered from authorized dealer inventories, the warranty period shall commence no more than one (1) year from date of shipment from the factory. This warranty shall be voided as to any products which have been repaired, worked upon, or altered by persons not authorized by Helac Corporation, or which have been subject to misuse, misapplication, negligence, accident, overload, field alteration, severe use or service applications beyond what the Helac Attachment was designed to perform. In no event shall Helac Corporation be liable for any incidental or consequential damages or claims including, but not limited to, the application in which the product was placed, field travel, freight charges, oil samples, downtime, etc. Warranty related repair and/or replacement issues will be satisfied according to how the product was originally purchased: Direct Sales to End Users This warranty covers repair or replacement of product or parts, which under normal use and service disclose defective material and/or factory workmanship. Only repairs completed at the Helac factory or factory replacement (at Helac s option) will satisfy claims under this warranty. Products under warranty shall be returned to the Helac factory for evaluation and repair. The customer shall contact the Helac Warranty Department for a Return Authorization Number prior to shipping the product in question. The factory will not accept products returned without a Return Authorization Number. Transportation shall be prepaid by the purchaser. On receipt, Helac factory personnel will inspect the product for warrantable issue(s).upon warranty acceptance, Helac Corporation will repair the warranty issue(s)of the product at no cost to the customer and return the product freight prepaid. If it is determined that the issue(s)are not covered by the warranty, the product (repaired or not) will be returned COD to the customer. Sales Through Equipment Dealers This warranty covers labor at predetermined, fixed flat rates and repair or replacement of products or parts, which under normal use and service disclose defective material and factory workmanship. Claims under this warranty will be satisfied only by repair or replacement of the unit or any defective part there of. Products under warranty shall be returned to a factory authorized dealership location, transportation prepaid by the purchaser, for inspection by the dealer with factory consultation. Warranty repairs are only to be made at the selling dealer s location according to time maximums and at rates pre-established by Helac Corporation. Helac Corporation reserves the right to make changes in the design or construction of any of its products at any time without incurring any obligations to make changes or alterations to products previously sold. Helac Corporation reserves the right to alter this warranty and/or its terms at any time. This warranty is in lieu of all other and/or prior warranties, expressed or implied, and no other company or person is authorized to represent or assume for Helac Corporation any liability in connection with the sale of Helac Corporation products other than set forth herein. 13.0

78 SERVICE OFFERING TECHNICAL SUPPORT REPAIR SERVICE CONTACT US 13.1

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80 JB Attachments Australia JB Attachments New Zealand