MULTI-COUPLER OPERATIONS AND MAINTENANCE MANUAL

Transcription

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

2 CONTENTS 1.0 INTRODUCTION 1.1 WARRANTY REGISTRATION 1.2 TO THE OWNER 2.0 SAFETY INSTRUCTIONS 2.1 JB ATTACHMENTS MULTI COUPLER CAB OPERATION 2.2 SAFETY IDENTIFICATION LABELS 2.3 SERIAL NUMBERS 2.4 S.W.L - SAFE WORKING LOAD 2.5 S.W.L - LIFTING EYE 3.0 STANDARDS 3.1 QUALIFICATION OF OPERATING PERSONNEL 3.2 RISK ASSESSMENT WORKING WITH JB ATTACHMENTS MULTI COUPLER 3.3 RISK ASSESSMENT MULTI COUPLER PRE-START DAILY CHECK SHEET 4.0 INSTALLATION 4.1 FITTING MULTI COUPLER TO DIPPER ARM 4.2 FITTING HOSE FROM DIPPER TO MULTI COUPLER 4.3 (OPTIONAL) FITTING OF MANIFOLD BLOCK 4.4 MANIFOLD PARTS LIST 4.5 SOLENOID CONTROL VALVE 5.0 OPERATION 5.0 OPERATION GUIDE FOR ATTACHING BUCKET 5.1 OPERATION GUIDE FOR ATTACHING BUCKET 5.2 CONNECTION TEST 5.3 CHECKING ATTACHMENTS AND BUCKETS 6.0 GENERAL MAINTENANCE 6.1 WEEKLY CHECKS AND GREASE LOCATIONS hr PREVENTATIVE MAINTENANCE CHECK 6.7 MAINTENANCE AND REPAIR LOG 6.8 TORQUE SPECIFICATIONS 7.0 PARTS IDENTIFICATION FOR MULTI COUPLER 7.0 PARTS DRAWING AND LIST FOR MULTI COUPLER 7.2 PARTS DRAWING AND LIST FOR CYLINDER

3 introduction This manual contains important information about the installation, connection, maintenance and safe operation of the JB Attachments Multi Coupler. You can assist in this proactive safety approach by ensuring that all persons involved with the fitting or operation of the 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 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 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 Multi Coupler, and its advised safety procedures. 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 Multi Coupler. A logbook has been placed at the back of this manual for this purpose. 1.0

4 introduction CUSTOMER ACCEPTANCE AND WARRANTY REGISTRATION Upon delivery of your JB Attachments Multi Coupler, please complete and return this form immediately to your JB Attachments 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 the JB Attachments Multi Coupler. The Operator accepts that he/she is responsible for understanding safety and operation features of the JB Attachments 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 Limited PO Box 98979, Manukau City 2241, Auckland 1.1

5 introduction TO THE OWNER As the new owner and/or operator of the JB Attachments 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 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 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

6 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 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 Multi Coupler model. NOTE: The Multi Coupler has a maximum and minimum pin center travel range. Please refer to the attached badge on the Multi Coupler for this information. 2.0

7 SAFETY INSTRUCTION DECALS The JB Attachments Multi Coupler operation instructions are to be fitted inside the cab in clear view of the operator. MULTI COUPLER INSTRUCTIONS 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

8 SAFETY Identification labels Each JB Attachments 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. All attachments must be within the parameters of these measurements identified on the label. The label also identifies the slide hook type.! The badge also displays the SWL and data information. Note: The SWL is also stamped on the lifting eye All JB Attachments Multi Couplers have an identification label with the machine model recorded Coupler COUPLER Coupler Coupler Coupler 2.2

9 serial numbers Each JB Attachments Multi Coupler will have an identification label fitted. Each JB Attachments Multi Coupler has an identification label fitted. fitted. The Multi Coupler has the serial number stamped on the casting. This is situated on the top of the ears and also on the attached label. 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. Casting batch identification number. The slide hook will have numbering for identification of the type and model and this specifies pin range and pin diameters. 2.3

10 S.W.L - Safe Working Load JB Attachments Multi Coupler Lifting Restrictions Safe Working Load is stamped on top of lifting eye Only use certified lifting shackles Only lift from lifting eye situated on the rear of the Multi Coupler 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 - Safe Working Load is stamped on the lifting eye and the Multi Coupler is fitted with a label on the side that specifies maximum 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

11 S.W.L - lifting eye JB Attachments Multi Coupler Lifting Procedures! WARNING: Use correct lifting connection DO NOT LIFT FROM JAW DO NOT LIFT FROM BUCKET Only use the eye at the rear of the Multi Coupler for lifting. Do not lift with bucket or any attachment fitted to the Multi Coupler. Lifting must be carried out with the Multi Coupler in a vertical position so that the load can hang free without contacting the Multi Coupler 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 check (see Page 5.5). 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

12 STANDARDS Design, Installation, Maintenance and Operation Standards and OCCUPATIONAL SAFETY AND HEALTH Guidelines The standards and Occupational Safety and Health Guidelines for the JB Attachments Multi Coupler are as follows: AS Standards Australia. Australian standard for - Earthmoving Machinery - Multi Coupleres (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 Multi Coupler, 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 JB Attachments Multi Coupler (in agreement with JB Attachments). The crowd and breakout forces specified by the excavator manufacturer must not be exceeded. The JB Attachments Multi Coupler 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 JB Attachments Multi Coupler models have specific safety features, see those that relate to your purchase. 3.0

13 STANDARDS Qualification of Operating Personnel Only the following persons may work independently with the JB Attachments 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 JB Attachments 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 Multi Coupler system. Only give instructions to competent, skilled personnel. NOTE: FOR JB Attachments Multi Coupler SYSTEMS SUPPLIED TO OR MANUFACTURED IN COUNTRIES OTHER THAN NEW ZEALAND, THE RULES FOR PREVENTION OF ACCIDENTS AND SAFETY REGULATIONS FOR THE RESPECTIVE COUNTRY MUST BE STRICTLY ADHERED TO.! Some fittings - for connection to main pump test port and adapter for return oil to tank - will not be supplied due to the number of different types of connections. 3.1

14 Risk Assessment Working with Multi COUPLER 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 been adequately trained on the use of the Multi Coupler in general? Is the operator competent in using the specific Multi Coupler on the machine in use? Is there a system for checking that the attachments pins are in place on the Multi Coupler prior to work start every time a different attachment is fitted? Is the operator aware that they must not operate the machine unless they are satisfied that the Multi Coupler is secured in place? Is the view of the operator from inside the CAB able to visually see that the Multi Coupler is secured in place? Does the Multi Coupler have the approved labels stating and referring to Multi Coupler 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 Multi Coupler? Personal Protective Equipment - (PPE) Hard Hat Hi Vis Vest Safety Boots Gloves Ear Protection Safety Glasses Other Management Assessed By: Name: Date: Reported To: Name: Date: 3.2

15 Risk Assessment DAILY Multi Coupler PRE-START CHECK SHEET Operator s Name: JB Attachments Multi Coupler: 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 Multi Coupler 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 Multi Coupler Damage to 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 Multi Coupler body Wear on slide hook Wear and damage to bucket / attachment pins and retainers Security of mounting pins, locking bolts and nuts Is the Multi Coupler safe to use? YES or NO LUBRICATION Greasing in accordance with manufacturer s instructions Operator Signature Manager Signature 3.3

16 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 Multi Coupler models will require that the cylinder be removed to allow room to fit Banjo Bolt cylinder hose fittings. Before removing the hydraulic cylinder from the Multi Coupler, 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 4.0

17 INSTALLATION for JB Attachments factory fitted Multi Coupler kit on excavator STEP 2 Align JB Attachments Multi Coupler 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 JB Attachments Multi Coupler to dipper arm on excavator. Fit locking bolts and nuts to secure pins.! Check pins are original EQUIPMENT MANUFACTURer s PINS. 4.1

18 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 Multi Coupler to dipper arm piping via hoses (B) Fitting from 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 tilt Multi Coupler or tilt bucket. 4.2

19 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 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. 4.3

20 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 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 4.4

21 INSTALLATION CIRCUIT DIAGRAM SOLENOID CONTROL VALVE! WARNING: Important - check solenoid valve pressure. Please ensure that during installation of a JB Attachments Multi Coupler the pressure in the hydraulic circuit is checked and set at: kg/cm ( PSI) Pressure adjustment This is important for correct 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 4.5

22 operation and attaching Operation guide Attachment operation 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. SLIDE MECHANISM REAR SLIDE HOOK FRONT JAW LOCK FRONT PIN 2. Line up attachment and engage front attachment pin. STROKING THE PUMP METHOD: 3. Activate the quick-hitch switch ON. 4. Crowd Multi-Coupler - 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. 5. Turn the quick-hitch switch OFF. 6. Dump or Crowd Multi-Coupler -this will cause the sliding mechanism to extend and engage the rear slide hook onto the rear attachment pin. 7. Proceed with Connection Test + + REAR SLIDE HOOK ENGAGED FRONT JAW VISIBLY LOCKED 5.0

23 operation and attaching Operation guide Multi Coupler 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. FRONT JAW VISIBLY LOCKED 5. Flick the quick-hitch switch OFF. The sliding mechanism will extend Attachment and engage the rear operation slide hook onto the rear attachment pin. 6. Proceed with Connection Test. REAR SLIDE HOOK ENGAGED Releasing attachment From Multi-Coupler 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 Multi-Coupler away from attachment.. 5.1

24 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 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 5.2

25 operation and attaching Checking attachments and buckets! WARNING: Check pin centres of JB Attachments 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 B) Check the width of each attachment. Where there is an excessive gap (exceeding 10mm), spacers can be fitted to better suit the Multi Coupler 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. BASE WIDTH VARIABLE SPACER WIDTH 5.3

26 CHECK ATTACHMENTS & BUCKETS operation and attaching 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. 5.4

27 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 - Multi Coupler Condition! A defective Multi Coupler could injure you or others. Do not operate a Multi Coupler 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 Multi Coupler 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 Multi Coupler serial number stamped on the Multi Coupler data plate when ordering replacement parts. Daily checks 1) Complete Multi Coupler Pre-Start Check sheet on Page 3.3 of this Operation Manual. 2) Grease Multi Coupler regularly (minimum of once per week). It is important that all parts are greased. 3) Check lifting eye for damage. If in doubt do not use. 6.0

28 MAINTENANCE WEEKLY CHECKS It is recommended that the following procedures are carried out at least once per week. 1. Carry out all daily, checks (refer to Page 3.3 for guide). 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. the maintenance and repair log for the JB Attachments Multi Coupler IS ON PAGE 5.6 It is essential that this log is filled in at the time of carrying out maintenance or repair on the Multi Coupler. 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 Multi Coupler 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

29 500hr PREVENTATIVE MAINTENANCE CHECK Visual Stress Point on Multi Coupler 1. Visually check the cast Multi Coupler body for any cracks. Refer to the below steps to guide you through the appropriate methods to correctly analyze the cast Multi Coupler body 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 SIDE FRONT REAR TOP 3 4 LIFTING EYE REAR FRONT TOP INSIDE 5 6 FRONT JAW SAFETY LATCH 6.2

30 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. 6.3

31 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 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

32 SAFETY-LATCH MANUAL INSPECTION 500hr PREVENTATIVE MAINTENANCE CHECK Manual Safety- Latch InSPECTION Manual Inspection of JBA 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-and-tear assessments. Check movement of safety latch Connect JBA Multi-Coupler 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 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 Multi-Coupler model, it is safe to use.! If the Maximum Opening Distance is greater than the Maximum Allowable Opening value for that JBA Multi-Coupler model, safe operation of the JBA Multi-Coupler could be seriously impaired. Please contact JB Attachments service department for advice. 6.5

33 PREVENTATIVE MAINTENANCE CHECK Lifting eye InSPECTION! WARNING The Lifting Eye requires visual inspection every 6 months Figure 1.1 Product Code Minimum Lug Width (mm) (A) Maximum Lug Width (mm) (B) Wear Limits of Multi Coupler Minimum Lug Thickness (mm) (D) Maximum Lug Slot Depth (mm) (E) Minimum Lug Slot Width (mm) (F) Lug Thickness Wear Tolerance (mm) (G) (Cumulative) JB JB JB JB JB JB JB JB Visual check for cracking 2. Check for wear on the above chart 3. Damage to outer surface Figure 1.1 A, B, D, E, G must be with in the tolerances as to the chart 4. If the lifting eye is worn over the recommended ratings listed above Do not use the lifting eye Should you find any cracks anywhere on the lifting eye, contact your local JB Attachments Branch or authorised Service Centre immediately. 6.6

34 MAINTENANCE AND REPAIR LOG DATE FAULT / SERVICE DESCRIPTION MAINTENANCE / REPAIR EFFECTED BY WHOM 6.7

35 MAINTENANCE TORQUE SPECIFICATIONS 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 6.8

36 MUTLI COUPLER PARTS DRAWING 7.0

37 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 5 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 11 Label Range JB N/A 12 Label ID JB 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 Pin R Clip N/A N/A N/A N/A N/A N/A 4 COMPLETE HYD CYLINDER

38 CYLINDER PARTS DRAWING NOTE: Cylinder design is different for each model. 7.2

39 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

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

41 JB Attachments Australia 59 Magnesium Drive, Crestmead, Australia 4132 Ph: Web: JB Attachments New Zealand 49 McLaughlins Road, Wiri, Auckland 2104 Ph: Web: (P) PUBLISHED JULY 2011