JARVIS. Model 50G Hydraulic Dehorner

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Hydraulic Dehorner EQUIPMENT SELECTION... Ordering No. TABLE OF CONTENTS... Page 50G Dehorner Electric Triggers Offset Blades... 4025011 Cup Blades... 4025047 Air Triggers Offset Blades.

1 Hydraulic Dehorner EQUIPMENT SELECTION... Ordering No. TABLE OF CONTENTS... Page 50G Dehorner Electric Triggers Offset Blades Cup Blades Air Triggers Offset Blades Cup Blades Hydraulic Power Unit Electric Triggers Air Triggers Balancer Safety Messages to Employer and Safety Director... 2 Safety Messages to Operators, Maintenance and Cleanup Personnel 3 Parts Diagram and List... 4 Installation and Wiring Diagram Specifications Installation Instructions Operation Instructions Maintenance Instructions... 13

2 safety messages to employer and safety director page 2 of 16 Keep hands clear. SAFETY MESSAGES TO EMPLOYER AND SAFETY DIRECTOR AVOID INJURY 1. Remove and repair any tool that malfunctions. All personnel must be instructed to remove any malfunctioning equipment. 2. Ensure that all employees who use this tool are trained in the proper use of this tool and are aware of the dangers that may arise if they do not follow procedures outlined in this brochure. 3. Enclosed are four (4) copies of NOTICE TO OPERATORS, MAINTENANCE AND CLEANUP PER- SONNEL. Post one copy on the employees bulletin board; give one copy to the operator(s); give one copy to the maintenance foreman; and give one copy to the sub -contract cleanup / internal cleanup foreman. Additional copies will be provided upon request. 4. The tool is designed and intended to be powerful. This fact should be obvious to your employees, but you must emphasize it to them. 5. Never make modifications or alterations to the tool. Replace any missing or illegible labels. 6. Ensure that proper procedures are established (in accordance with OSHA s lockout/tagout procedures ) to prevent accidental startup or release of stored energy. 7. Follow our installation and maintenance instructions for proper installation and care of the tool. 8. Avoid injury. Do not permit the tool to be misused. 9. If you resell or distribute a Jarvis product, you must provide the purchaser with the appropriate safety sheets and tool brochure. Additional copies of safety sheets and tool brochures will be provided upon request.

3 safety messages to operators, maintenance and cleanup personnel page 3 of 16 Keep hands clear. SAFETY MESSAGES TO OPERATORS, MAINTENANCE AND CLEANUP PERSONNEL REMOVE ANY MALFUNCTIONING TOOL FROM SERVICE REPORT ANY PROBLEMS TO YOUR SUPERVISOR 1. Disconnect all hydraulic and air hoses and shut the power off in accordance with OSHA s lockout/tagout procedures (29 CFR ) before sharpening blades. 2. Disconnect all hydraulic and air hoses and shut the power off in accordance with OSHA s lockout/tagout procedures (29 CFR ) before performing any repair or maintenance. 3. Disconnect all hydraulic and air hoses and shut the power off - or have all hydraulic and air hoses disconnected and the power shut off - in accordance with OSHA s lockout/tagout procedures (29 CFR ) before performing any cleanup. 4. Disconnect all hydraulic and air hoses and shut the power off when the tool is not being used. 5. Clean up any spilled or leaked hydraulic fluid. 6. Never put fingers, hands or other parts of the body on the cutting edge, in the cutting path or in the path of the moving blades. 7. Never operate the tool with its guards removed. Report or replace any damaged guards. 8. Test the tool prior to useor daily. Depresseach trigger separately andthe bladeshould not close. Depress one trigger, then pause one second and depress the other trigger and the blade should not close. Repeat this procedure reversing the triggers. Depress both triggers simultaneously and the blade should close. With the blade closed, release one trigger and the blade should open. Continue holding the depressed trigger and then depress the other trigger. The blade should not close. Repeat this procedure holding the other trigger. If the tool malfunctions, remove it from service and report or repair it immediately. 9. Never depress the triggers unless you want to use or test the tool. 10. Never make modifications or alterations to the tool. Report or replace any missing or illegible labels.

4 parts diagram and list page 4 of 16 Figure A J F F J J F J Torque to 200 lbf--ft F F Torque to 150 lbf--ft Not used in current tools Pin and Shackle Link Assy Hanger Hanger Bracket Hex Head Screw Right Blade Guard Hex Head Screw Rail Mounting Plate H Acorn Nut Elbow Hose Assembly Quick Connect Socket Quick Connect Plug 1 13 page 5 Hydraulic Cylinder Assembly Hex Head Screw Right Handle Bracket 1 16 page 5 Handle Assembly Hex Head Screw F Hex Head Screw Rail with items 27 and Left Blade Guard Socket Head Cap Screw Block, Self Aligning Block Shim Offset Blade, Moving (Flat) Rail with items 27 and Offset Blade, Fixed (Sharp) Pan Head Slotted Screw Name and Serial No. Plate F Hex Head Screw Spacer Left Handle Bracket Hex Head Screw Hex Head Screw Split Lock Washer Rail Mounting Plate Danger Label Castle Nut Cotter Pin Conduit 1 40 page 5 Electrical Assembly Conduit Cup Blade, Fixed or Moving Cup Blade Set ( 2 item 42) J

5 parts diagram and list page 5 of 16 Figures B Handle Assembly Electrical Assembly Male Twist Lock Plug Electrical Wire Strain Relief Connector Electrical Box Cover Gasket Connector Hex Head Screw Hex Head Screw Electrical Box Button Head Screw Hex Head Screw Spring Compression Spring Trigger Lever Plunger Retaining Ring Switch Handle Retaining Pin End Cap Pan Head Screw U--cup Seal O--ring Bushing U--cup Seal Piston Rod, Self Aligning Piston Rod O--ring Piston O--ring Piston Ring Seal Hex Lock Nut O--ring Cylinder Tube Blind End Cap Lock Ring Cylinder Tube Adaptor Fitting Seal Kit (includes items 22, 23, 25, 27, 29, 30 and 32) Hydraulic Cylinder Assy (includes items ) Handle Assy (items ) Wire and Plug Assembly (includes items 1 and 2) Trigger Lever Assembly (includes items 12, ) Not included in current tools Hydraulic Cylinder Assembly

6 parts diagram and list page 6 of Hex Head Screw Plastic Tubing 9 inch long Plastic Tubing 11 inch long Tube to Pipe Connector Flat Head Screw Handle Assembly (includes 2 items 5, 14-31) Handle Bracket Hex Head Screw Air Manifold Plastic Tubing 7.5 inch long Plastic Tubing 10 inch long Handle Bracket Gasket Valve Housing Compression Spring Valve Plunger with item O-ring O-ring Valve Bonnet Internal Retaining Ring Roll Pin Switch Handle with items 2 21 and Threaded Pin Handle Coupling Compression Spring Cylindrical Bearing Dowel Pin Trigger Lever with items 2 26, 27, Trigger Roller Roll Pin O-ring Gasket Connection Plate Tube to Pipe Connector O-ring Connection Housing Hex Head Screw with 2 item Strain Relief Connector Tubing Bundle, 20 ft Handle Assembly (includes items 1-31) Tubing Control Assembly (includes items 32-39) Air Trigger Conv. Kit, 115v Air Trigger Conv. Kit, 230v Figure C Air Triggers

7 parts diagram and list page 7 of 16 Figure D Electrical/Pneumatic Control Box (For Air Triggers) Not used in current tools Ring Tongue Terminal Tubing Connector Internal Lock Washer Socket Head Cap Screw Fork Tongue Terminal Washer Glass Fuse, 115v Hex Lock Nut Glass Fuse, 220v Socket Head Cap Screw Pigtail Fuse, 115v ATD Circuit Board, 115v Pigtail Fuse, 220v ATD Circuit Board, 220v Electrical Switch Control Box Enclosure Pneumatic Actuator Pan Head Screw Tubing Connector Mounting Plate Washer Locking Nut Hex Spacer Sealing Washer Washer Cord Connector Plastic Pan Head Screw Electric Cord, 3 ft Tee Fitting Wiring Diagram Label, 115v Air Bleed Fitting Wiring Diagram Label, 220v Air Filter Warning Label Quick Connect Plug Street Elbow 1 page 6 Tubing Control Assy Hex Nipple Complete Control Box, 115v Female Elbow Complete Control Box, 220v

8 parts diagram and list page 8 of 16 Figure E Electric Triggers Trigger Lever with item Bushing Spring Handle with item Switch Assembly O--ring Right Side Bracket Left Side Bracket Tube Connector Right Side Conduit Left Side Conduit Hex Head Screw Split Lock Washer Threaded Pin Roll Pin Handle Assemblies (includes items 1--13)

9 parts diagram and list page 9 of 16 Figure F Electrical Control Box (For Electric Triggers) Electrical Box Enclosure Fork Tongue Terminal Locking Nut Seal Ring Washer Strain Relief Female Twist Lock Outlet Electric Cord Electric Cord, 3 ft Wiring Diagram Label, 115v Wiring Diagram Label, 220v Electric Warning Label Ring Tongue Terminal Internal Lock Washer Glass Fuse, 115v Glass Fuse, 220v Not used in current tools Pigtail Fuse, 115v Pigtail Fuse, 220v Electrical Panel ATD Circuit Board, 115v ATD Circuit Board, 220v Washer Spacer Plastic Screw Pan Head Screw Socket Head Cap Screw Complete Control Box 115v Complete Control Box 220v 1

10 parts diagram and list page 10 of 16 Figure G or Electric Air Not used in current tools Filter Assembly with Element Filter Element only Electric Control Box, 115v Electric Control Box, 220v Elec/Pneu Control Box, 115v Elec/Pneu Control Box, 220v Return Tubing Sub Plate with item Supply Tubing, to Subplate Motor Half Coupling Spider Center Coupling Pump Half Coupling Supply Tubing, from Pump Hydraulic Gear Pump Directional Control Valve, 115v Directional Control Valve, 220v Rectangular din/iso Coil, 115v Rectangular din/iso Coil, 220v Round din/iso Coil for Round din/iso Coil for din/iso Connector, 115v din/iso Connector, 220v Socket Head Cap Screw Breather Filler Cap Elbow Reducing Bushing Pipe Nipple, 4 inch Pipe Nipple, 6 inch Relief Valve Cartridge Sandwich Relief Valve High Pressure Filter Assembly High Pressure Filter Element Hose Assembly Suction Strainer Oil Level Gage Drain Plug with Magnet Quick Connect Socket Quick Connect Plug Pressure Gage Motor, 460/230v, 60hz Motor, 440/380/220v, 50hz Motor, 575v, 60Hz Electric Danger Label 1

11 installation and wiring diagram page 11 of 16 Power Unit Installation for Models with Electric Triggers INSTALLATION AND WIRING DIAGRAM Installation for Models with Air Triggers Electrical Control Box To Directional Control Valve To AC Power Supply Cord to Handles Balancer To AC Power Supply Return Line Pressure Line 50G Air Supply Inlet Connect A Connect B Connect C Connect A Air Trigger Handle Assembly Connect C Connect B Electrical Wiring Diagram

12 specifications and installation instructions page 12 of 16 SPECIFICATIONS Dehorner Cutting Force 9900 lbf 44 kn Cutting Cycle Time with sec with sec Control Handles Electric or Air Dual Anti -tie Down Blade Opening 5.5 x 6.0 in 140 x 152 mm Overall Length 30 in 762 mm Weight 65 lbs 29.5 kg Hydraulic Power Unit Power hp 7457 W hp 7457 W Voltage 460/230 V, 3 phase, 60 Hz other voltages and 50 Hz available Hose Length 16 ft 5 m Oil Capacity 30 gal 114 L Oil Viscosity at 100 F/40 C 200 SUS 46 ISO Dimensions(lxwxh) 38x28x33in 965x711x838mm Weight (without oil) 380 lbs 172 kg INSTALLATION INSTRUCTIONS Refer to installation and wiring diagram on page 11 as a guide. IMPORTANT: ALWAYS DISCONNECT ALL HYDRAU- LIC HOSES AND SHUT THE POWER OFF IN ACCOR- DANCE WITH OSHA S LOCKOUT/TAGOUT PROCE- DURES(29CFR )BEFOREPERFORMINGANY MAINTENANCE OR REPAIRS. ALL WIRING MUST BE DONE IN ACCORDANCE WITH NATIONAL, STATE AND LOCAL ELECTRICAL CODES. 1 Install the 50G above the work station from a balancer. Jarvis part number is available. 1.1 The 50G should have sufficient travel to allow the operator to reach the entire work area. For best results mount the balancer on a rail inches away from and parallel to the beef rail. 2 Install the hydraulic power unit above the operator s station. 3 Fill the oil reservoir with a USDA H1 approved premium grade hydraulic fluid (viscosity: 200 SUS at 100 F/46ISOat40 C). 4 Make all necessary air connections (for models with air triggers). 4.1 The air inlet pipe should be 3/8 inch diameter minimum. 4.2 The required compressed air supply is 40 psi minimum and 50 psi maximum. 4.3 An air regulator must be installed to the quick connect plug (item 16, Figure D, page 7) before the air supply inlet to the air filter (item 15, FigureD,page7). 4.4 Connect the air hoses to the electrical control box and the air trigger handle assembly (Connections A, B and C on page 11). 5 Make all the necessary wiring connections. All wiring must be done in accordance with the national, state and local electrical codes. Refer to Figure D, page 7 for air triggers and to Figure F, page 9 for electric triggers. 5.1 Attach wires numbered 2, 3 and ground to the appropriate AC power supply. 5.2 Attach wires numbered 4, 5, 6 and ground to the directional control valve. 5.3 Connect the twist lock receptacle attached to wires numbered 8, 9 and 10 to the twist lock plug on the 50G (for models with electric triggers). 6 Make all necessary hose connections. 6.1 Connect the pressure and return line hydraulic hoses to the power unit and the 50G dehorner. 7 Adjust the cutter opening time. 7.1 Close the cutter. 7.2 Release the triggers. 7.3 Set the timer on the ATD board so that the valve on the hydraulic power unit is de-energized when the blades have fully opened. Older boards use a square potentiometer with a screw driver slot. Newer boards use a group of four rocker switches.

13 operation and maintenance instructions page 13 of 16 OPERATION INSTRUCTIONS 1 Connect all hydraulic hoses. 2 Connect all air hoses (for models with air triggers). 3 Turn on the power. 4 Each day, before you begin operation, go through the following checklist: 4.1 Make sure that the 50G moves freely on the balancer. 4.2 Make sure that the dual anti -tie down control handles are working correctly. Depress each trigger separately and the blade should not close. Depress one trigger, then pause one second and depress the other trigger and the blade should not close. Repeat this procedure reversing the triggers. Depress both triggers simultaneously (within one half second of each other) and the blade should close. With the blade closed, release one trigger and the blade should open. Continue holding the depressed trigger and then depress the other trigger. The blade should not close. Repeat this procedure holding the other trigger. If the tool malfunctions, remove it from service and report the problem to your supervisor immediately. 4.3 Make sure that both guards (items 5 and 20, Figure A, page 4) are in good condition and are installed on the tool. 5 Making the cut: 5.1 Place the 50G over the skull. 5.2 Depress both triggers simultaneously to close the blades. 5.3 Release either or both triggers to open the blades. MAINTENANCE INSTRUCTIONS Refer to Figure A on page 4 for referenced items unless otherwise noted. IMPORTANT: ALWAYS DISCONNECT ALL HYDRAULIC HOSES AND SHUT THE POWER OFF IN ACCORDANCE WITH OSHA S LOCKOUT/TAGOUT PROCEDURES (29 CFR ) BEFORE SHARPENING, INSTALLING OR REMOV- ING A BLADE. ALWAYS DISCONNECT ALL HYDRAULIC HOSES AND SHUT THE POWER OFF IN ACCORDANCE WITH OSHA S LOCKOUT/TAGOUT PROCEDURES (29 CFR ) BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS. 1 DAILY: 1.1 The 50G is equipped with dual anti -tie down control handles. Check for the correct operation of the dual anti -tie down control handles before each shift every day. Depress each trigger separately and the blade should not close. Depress one trigger, then pause one second and depress the other trigger and the blade should not close. Repeat this procedure reversing the triggers. Depress both triggers simultaneously (within one half second of each other) and the blade should close. With the blade closed, release one trigger and the blade should open. Continue holding the depressed trigger and then depress the other trigger. The blade should not close. Repeat this procedure holding the other trigger. If the tool malfunctions, repair or remove it from service immediately. Note: connect the hydraulic hoses and turn on the power to perform this operation only. 1.2 Inspect wire and plug assemblies (items 1-3, Figure B, page 5 and items 6-8, Figure F, page 9) over its full length for cuts or abrasions. Replace any abraded or damaged wire and plug assembly. 1.3 Inspect the hydraulic couplings, fittings and hoses (items 9-12) connected to the 50G dehorner. If there are any leaks, repair or replace the couplings, fittings or hoses. 1.4 Inspect the hydraulic couplings, fittings and hoses (items 15-18, 21, 25 and 26, Figure G, page 10) connected to the power unit. If there are any leaks, repair or replace the couplings, fittings or hoses. 1.5 Inspect the blade guards (items 5 and 20). Repair or replace if necessary. 1.6 Inspect all screws and nuts. Tighten if necessary.

14 maintenance instructions page 14 of 16 Figure 1 Figure 2 steel plate c--clamp 50G right angle plate grinding wheel cutting edge grinding table side view work bench 1.7 Loosen and remove hex head screws and split lock washers (items 33 and 34). 1.8 Loosen and remove hex head screws (items 18 and 29) or acorn nuts (item 8), as applicable. 1.9 Remove rail mounting plate (item 35) Loosen and remove hex head screws (item 17) Remove left guard plate (item 20) Loosen and remove socket head cap screws (item 21) Slide blades (items 24 and 26 or item 42) out of rails (items 19 or 25), as applicable Remove shim (item 23) Inspect all parts for wear and replace if necessary Inspect blades (items 24 and 26 or item 42, as applicable) for wear and sharpen or replace if necessary. Follow instructions in BLADE RE- CONDITIONING, section 3 or 4, as applicable. See note below Note: Do not sharpen blade (item 24). It is designed to have a flat side (offset blades only). 2 BLADE RECONDITIONING (Offset Blades) : 2.1 Place blade (item 26) on a surface grinder table against a right angle plate. Refer to Figures 2 and Place the flat end of the blade (opposite the cutting edge) on the table Place the flat side of the blade (the scalloped side) against the right angle plate. 2.2 Clamp the blade to the right angle plate. Refer to Figures 2 and 3. Figure 3 right angle plate end view grinding wheel c--clamp grinding table 2.3 Grind the cutting edge flat and parallel to the flat edge of the blade that is against the table Grind only enough blade to clean the surface. 2.4 Remove the blade from the right angle plate. 2.5 Place the blade on the surface grinder table against a sine plate set at a forty five degree angle. Refer to Figures 4 and 5. Figure 4 sine plate grinding wheel side view cutting edge grinding table Torque the hex head screws (items 18 and 29) to 150 lbf -ft or torque acorn nuts (item 8) to 200 lbf -ft, as applicable. 3 50G BLADE DISASSEMBLY: 3.1 Place the 50G on a flat piece of steel on a secure work bench.

15 maintenance instructions page 15 of Clamp the 50G to the work bench. Refer to Figure 1 on page Note: The piston rod (item 26, Figure B, page 5) should be extended out with the blades (items 24 and 26 or item 42, as applicable) in the closed position before disassembly. 4.3 First grind surface A parallel to surface B, removing any nicks or chips on the cutting edge. Refer to Figure 7 below. Figure 7 Figure 5 right angle plate c--clamp grinding wheel sine plate -- C -- end view 45 grinding table 3.3 Grind the inside face of the cutting blade until the cutting edge has a inch flat face. Refer to Figure 6 below. Figure Reinstall the blade. Refer to section 5 as a procedural guide, Note: If adequate surface grinding facilities are not available, return the blade to Jarvis for re -sharpening. 4 BLADE RECONDITIONING (Cup Blades) : 4.1 Place blade (item 42) on a surface grinder table against a right angle plate. Refer to Figures 2 and 3, page Place the flat end of the blade (opposite the cutting edge) on the table Place the flat side of the blade (the scalloped side) against the right angle plate. 4.2 Clamp the blade to the right angle plate. Refer to Figures 2 and 3, page Remove the blade from the right angle plate. 4.5 Place the blade on the surface grinder table against a sine plate set at a forty five degree angle. Refer to Figures 4 and Grind surface C at a forty five degree angle to surface A to achieve a inch flat on the end of the blade. 4.7 Repeat this procedure for the other blade (item 42) in the set. 4.8 Reinstall the blades. Refer to section 5 as a procedural guide. Note: If adequate surface grinding facilities are not available, return the blade to Jarvis for re -sharpening. 5 BLADE INSTALLATION: 5.1 Reverse steps and procedures outlined in section 2. See notes below Apply Jarvis 1315 White Grease to the sliding surfaces (top and bottom) of the moving blade (item 24 or 42, as applicable) and inside the track area of the rails (item 19 or 25, as applicable) Tighten acorn nut (item 8) to 200 lbf -ft, if applicable Tighten hex head screws (items 18 and 29) to 150 lbf -ft, if applicable.

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