JARVIS. Model 30CL-1 and 30CL-3 Hock Cutter and Dehorner

Transcription

1 Model 30CL-1 and 30CL-3 Hock Cutter and Dehorner 30CL--1 Hock Cutter 30CL--1 Pistol Grip 30CL--3 Dehorner EQUIPMENT SELECTION... Ordering No. 30CL--1 Hock Cutter CL--1 Hock Cutter with Grabber CL--1 with Pistol Grip Handle Leg Grabber Kit CL--3 Dehorner Hydraulic Power Unit (one tool) Hydraulic Power Unit (two tools) Balancer TABLE OF CONTENTS... Page Notice to Employer and Safety Director... 2 Notice to Operators, Maintenance and Cleanup Personnel... 3 Parts Diagram and List... 4 Installation Diagram Installation Instructions Specifications Operation Instructions Maintenance Instructions Special Safety Notice PRODUCTS CORPORATION

2 noticetoemployer and safety director Model 30CL-1 and 30CL--3 page 2 of 16 Keep hands clear. NOTICE 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 PERSONNEL. 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 (29 CFR ) 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 6 notice to operators, maintenance and cleanup personnel page 3 of 16 Model 30CL-1 and 30CL--3 Keep hands clear. NOTICE 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, within the cutting path or within the path of the moving links. 7. Test the tool prior to use or daily. Depress one trigger, then pause one second and depress the other trigger and the blades should not close. Repeat this procedure reversing the triggers. Depress both triggers simultaneously and the blades should close. With the blades closed, release one trigger and the blades should open. Continue holding the depressed trigger and then depress the other trigger. The blades should not close. Repeat this procedure holding the other trigger. If the tool malfunctions, remove it from service and report or repair it immediately. 8. Never depress the triggers unless you want to use or test the tool. 9. Never make modifications or alterations to the tool. Replace any missing or illegible labels.

4 parts diagram and list Model 30CL-1 and 30CL--3 page 4 of 16 Figure A Cylinder Housing Assembly * * * * * * Not used in current tools Quick Connect Plug Nipple * Swivel Elbow Pipe Elbow External Lock Washer Hex Head Screw Cylinder Housing. w/item Piston Rod O--ring Locking Ring with item Internal Retaining Ring U--Cup Seal Bearing Cartridge O--ring Wiper Ring O--ring Spacer Hex Head Screw Yoke Pinch Point Guard Socket Head Cap Screw Washer Shackle and Pin Assembly Hanger Bracket Pinch Point Gd w/items 24 & Danger Label Flat Washer Pan Head Screw Clevis Housing with 1 items 3, 24, 26 and Drive Coupling Quick Connect Socket Hex Head Screw * Cylinder Housing * Cylinder Cap Piston Ring Piston Ring O--ring Drive Screw Name and Info Label Seal Kit (includes items 11, and ) Guard Kit (includes items 4, 5, , and 30)

5 6 parts diagram and list page 5 of 16 Model 30CL-1 and 30CL--3 Figure B Blade Assembly * * * * Standard Blades 30CL--1 Dehorner Blades 30CL--3 * ** * Not used in current blades ** Not used with leg grabber Hex Nut (Left Hand) Drive Pin Sleeve Bearing Connecting Link Connecting Pin * Sleeve Bearing Blade (30CL--1) * Sleeve Bearing Wear Plate Pivot Pin Hex Head Screw Split Lock Washer Blade Insert Blade Support Blade (30CL--3), 1 Piece Blade Set, (2) Blade Assy (items ) Blade Set, (2) Hex Nut ** Hex Jam Nut Acorn Nut Pin Pivot Bolt Washer Grabber Blade 2 Leg Grabber 30CL Split Lock Washer Hex Jam Nut Hex Slotted Nut Cotter Pin Plastic Tubing, 2.5 inch Spring Grabber Assembly (includes items )

6 parts diagram and list Model 30CL-1 and 30CL--3 page 6 of 16 Figure C Handle Assembly * Tubing Fitting 1 / 4 inch ** Tubing Fitting 3 / 8 inch *** Manifold, 5-port with item O--ring O--ring O--ring Plunger with (2) item Valve Body with item 70 & Valve Spring Trigger Button Handle Trigger Guard Socket Head Cap Screw Guard Clamp Cup Point Set Screw Cup Point Set Screw Flush Hex Plug Yellow Plastic Tubing 12 inch Grey Plastic Tubing 12 inch Manifold, 2-port with item Valve Assy. (includes items 70-75, 81 and 82) Control Handle Assy (2--port) (includes items 66, 67, , and 85) Control Handle Assy (5--port) (includes items and ) * quantities listed are per handle. ** 2-port control handle requires one (1) item port control handle requires three (3) item 65. *** 2-port control handle requires one (1) item port control handle requires two (2) item 67.

7 6 parts list and diagram page 7 of 16 Model 30CL-1 and 30CL--3 Figure D Pistol Grip Handle Assembly Used on Pistol Grip Hock Cutter and Dehorner Hex Head Screw Spacer Hex Head Screw Washer Guard with items 24 and Danger Label Flat Washer Pan Head Screw Tubing Fitting, 1 / 4 inch Yellow Plastic Tubing, 12 inch Grey Plastic Tubing, 12 inch Tubing Elbow 3 / 8 inch Tubing Elbow 1 / 4 inch Trigger Handle Dowel Pin Conical Spring O--ring Plunger with item O--ring Cartridge with (2) item Hex Head Screw Lock Washer Trigger Guard Trigger Lever Hex Head Screw Guard with items 26 and Danger Label Socket Head Cap Screw Tubing Elbow 3 / 8 inch Socket Head Cap Screw Hanger Pinch Point Guard Washer Trigger Guard Pistol Grip Handle Stick Handle Assy (includes items 26, and ) Pistol Grip Handle Assembly (items 66, 86, 87, , 98, 103, 108 and 109) Pistol Grip Handle Kit (items 5, 16, 17, , 66, 83, 84, and )

8 parts diagram and list Model 30CL-1 and 30CL--3 page 8 of 16 Figure E Electric/Hydraulic Power Unit (Vertical) Electric Motor Oil Breather Filler Cap Dir. Control Valve, 115V Dir. Control Valve, 220V Hard Wired Coil, 115V Hard Wired Coil, 220V Relief Valve Cartridge * Sandwich Relief Valve Oil Level Gage Hyd. Hose Assembly, 16 ft Quick Connect Plug Quick Connect Socket Return Tubing Electric Cord Hydraulic Pressure Gage 1 * Indicated items are available as spare parts for older, sandwich-type relief valves Cartridge Sub Plate 1 (includes item 5) * Sandwich Sub Plate Hex Nipple (2 inch) Hex Nipple (4 inch) Pipe Elbow Motor Half Coupling Spider Center Coupling Pump Half Coupling Pump Mounting Flange Hydraulic Gear Pump U-shaped Tubing Suction Strainer Filter Elec/Pneu Control Box Electrical Danger Label 1

9 6 parts diagram and list page 9 of 16 Model 30CL-1 and 30CL--3 Figure F Electric/Hydraulic Power Unit (Horizontal) * not used in current units Elec Motor, 460/230V--60Hz Elec Mtr, 440/380/220V--50Hz Mounting Bracket Return Tubing Assembly Coupling Half, Motor Coupling, Spider Center Coupling Half, Pump Hydraulic Gear Pump Adapter Elbow Triangular Filter Assy Filter Element only * Square Filter Assy * Filter Element only Supply Tubing Assembly Dir. Control Valve, 115V Dir. Control Valve, 220V din/iso Coil for 115V Valve din/iso Coil for 220V Valve din/iso Connector, 115V din/iso Connector, 230V * Hard Wired Coil, 115V * Hard Wired Coil, 220V Socket Head Cap Screw 4 13 page 10 Control Box Assembly Sub--Plate with item Hex Nipple (4 inch) Hex Nipple (2 inch) Elbow Cartridge Relief Valve Oil Level Gage Hose Assembly, 16 ft Suction Strainer Drain Plug with Magnet Quick Connect Plug Quick Connect Socket Filler Breather Cap Assy Pressure Gage Hex Nipple (1.5 inch) Reducer Bushing Pipe Tee Male Elbow Electrical Danger Label 1

10 parts diagram and list Model 30CL-1 and 30CL--3 page 10 of 16 Figure G Electric/Hydraulic Power Unit (Two Tools) Tandem Hydr. Gear Pump din/iso Connector, 115V Mounting Bracket din/iso Connector, 230V Coupling Half, Pump Hydr. Manifold w/o Valves Coupling, Spider Center Relief Valve Cartridge Coupling Half, Motor Filler Breather Cap Assy Motor, 460/230V--60Hz Hose Assembly, 16 ft Motor, 440/380/220V--50Hz Suction Strainer 1 7 page 11 Control Box Assembly Drain Plug with Magnet Pressure Gage Quick Connect Socket Filter Assy with element Quick Connect Plug Filter Element only Oil Level Gage Dir. Control Valve, 115V Hex Nipple (2 inch) Dir. Control Valve, 220V Elbow din/iso Coil for 115V Valve Hex Nipple (4 inch) din/iso Coil for 220V Valve Electrical Danger Label 1

11 6 parts diagram and list page 11 of 16 Figure H Electric/Pneumatic Control Box Model 30CL-1 and 30CL--3 * not used in current tools Socket Head Cap Screw Washer Hex Lock Nut Quick Connect Plug Tube to Pipe Connector Grey Tubing, 20 ft Air Filter Air Bleed Fitting Street Tee Yellow Tubing, 20 ft Plain Washer Tube to Pipe Connector Actuator Plastic Screw Hex Spacer Lock Washer Electric Switch ATD Circuit Board, 115V ATD Circuit Board, 220V Cylindrical Fuse, 115V Cylindrical Fuse, 220V Ring Tongue Terminal Electrical Warning Label, 115V Electrical Warning Label, 230V Wiring Diagram, 115V Wiring Diagram, 220V Sealing Washer Strain Relief Connector Electric Cord, 10 ft Locknut Panel Plate Electrical Enclosure * Pigtail Fuse, 115V * Pigtail Fuse, 220V Control Box Assembly, 115V Control Box Assembly, 220V

12 installation diagram Model 30CL-1 and 30CL--3 page 12 of 16 INSTALLATION DIAGRAM Hydraulic Power Unit Hydraulic Pressure Hose Hydraulic Return Hose Horizontal Vertical Air Supply Inlet To Directional Control Valve To AC Power Supply Dual Anti-Tie Down Electric/Pneumatic Control Box (Factory Installed on Hydraulic Power Unit) 30CL-1 and 30CL--3 Hydraulic Return Grey Hose Hydraulic Pressure Yellow Hose CL--1 Blades Shown Grey Hose Yellow Hose

13 6 installation instructions page 13 of 16 INSTALLATION INSTRUCTIONS Refer to the installation diagram on page 12. Refer to Figures A -D on pages 4-7 for referenced items unless otherwise noted. IMPORTANT: ALWAYS DISCONNECT ALL HYDRAULIC AND AIR HOSES AND SHUT THE POWER OFF IN ACCORDANCE WITH OSHA S LOCKOUT/TAGOUT PROCEDURES (29 CFR ) BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS. 1 Install the 30CL-1 or 30CL -3 above the work station from a balancer. Jarvis part number is available. Model 30CL-1 and 30CL The 30CL-1 or 30CL -3 should have sufficient travel to allow the operator to reach the entire work area. 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 S.U.S. at 100 For46ISOat40 C). 4 Make all the necessary air connections. 4.1 The air inlet pipe should be 3 / 8 inch diameter minimum. 4.2 An air pressure regulator must be installed ahead of the air filter (item 7, Figure H, page 11). Figure I Electric/Pneumatic Control Box Directional Control Valve

14 installation instructions, specifications and operation instructions Model 30CL-1 and 30CL--3 page 14 of 16 5 Make all necessary hose connections. 5.1 Attach one end of both yellow hoses (item 10, Figure H, page 11) to the tube fittings (items 66 or items 66 and 87) on the applicable handle assembly. 5.2 Attach the free ends of the yellow tubing to the tube to pipe connectors (item 12, Figure H, page 11) on the electric/pneumatic control box. 5.3 Attach one end of the grey tubing (item 6, Figure H, page 11) to the tube fitting (item 67 or item 86) on the applicable handle assembly. 5.4 Attach the free end of the grey tubing to the tube to pipe connector (item 5, Figure H, page 11) on the electric/pneumatic control box air filter (item 7, Figure H, page 11). 6 Make all the necessary wiring connections. All wiring must be done in accordance with the national, state and local electrical codes. 6.1 Adjust cutter opening Close cutter Release triggers Adjust the pressure into the control box to achieve the desired blade closing response time. This usually occurs between psi Set the timer (the group of four rocker switches on the ATD board (item 18, Figure H, page 11) so that the valve on the hydraulic power unit is de-energized after the blades have just fully opened. The older ATD boards have a timer that is a square potentiometer with a screwdriver slot. Refer to Figure H on page 11. SPECIFICATIONS Model 30CL-1 and 30CL -3 Blade Opening 4 in 102 mm Control Handles Air / Dual Anti-tie Down 50 psi 3.4 bar Cutting Force 9900 lb -f 44kN Cutting Cycle 1.5 sec Overall Length 30cl in 813 mm 30cl in 711 mm Weight 38 lbs 17.2 kg Hydraulic Power Units Voltage 460/230 V, 3 phase, 60 Hz other voltages and 50 Hz available Power 5 hp 3728 W 10 -hp 7457 W Hose Length 16 ft 5 m Oil Capacity 20 gal 76 L 30 gal 114 L Oil 100 F/40 C 200 SUS 46 ISO Dimensions ( ) 30 x 16 x 34 in (lxwxh) 762x406x864mm Dimensions ( ) 28 x 22.5 x 28 in (lxwx h) 711x572x711mm Dimensions ( ) 40 x 24 x 31 in (l x w x h) 1016 x 610 x 787 mm Weight (without oil) 178 lbs 81 kg Weight (without oil) 200 lbs 91 kg Weight (without oil) 500 lbs 227 kg OPERATION INSTRUCTIONS 1 Connect all hydraulic hoses. 2 Connect all air hoses. 3 Turn on the power. 4 Each day, before you begin operation, perform the following. 4.1 Make sure that the dual anti-tie down control handles (the front and the rear handles) are working correctly. Depress each triggerseparatelyand the blades should not close. Depress one trigger, then pause one second and depress the other trigger and the blades should not close. Repeat this procedure reversing the triggers. Depress both triggers simultaneously (within one half second of each other) and the blades should close. With the blades closed, release one trigger and the blades should open. Continue holding the depressed trigger and then depress the other trigger. The blades 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.

15 6 operation and maintenance instructions page 15 of Make sure that the compressed air supply is at the proper pressure. 4.3 Make sure that 30CL-1 or 30CL -3 moves freely on the balancer. 5 Making the cut. 5.1 For the 30CL-1, place the cutter around the hock of the carcass. For the 30CL -3, place the cutter blades around the horn of the carcass. 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 Figures A -D on pages 4-7 for referenced items unless otherwise noted. IMPORTANT: ALWAYS DISCONNECT ALL HYDRAULIC AND AIR HOSES AND SHUT THE POWER OFF IN ACCORDANCE WITH OSHA S LOCKOUT/TAGOUT PROCEDURES (29 CFR ) WHEN INSTALLING OR REMOVING A BLADE. AL- WAYS DISCONNECT ALL HYDRAULIC AND AIR HOSES AND SHUT THE POWER OFF IN ACCORDANCE WITH OSHA S LOCKOUT/TAGOUT PROCEDURES (29 CFR ) BEFORE PERFORMING ANY MAINTENANCE OR REPAIRS. 1 BEFORE EACH SHIFT EVERY DAY: 1.1 The 30CL-1 and 30CL -3 are equipped with dual anti-tie down control handles (the front and the rear 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 blades should not close. Depress one trigger, then pause one second and depress the other trigger and the blades should not close. Repeat this procedure reversing the triggers. Depress both triggers simultaneously (within one half second of each other) and the blades should close. With the blades closed, release one trigger and the blades should open. Continue holding the depressed trigger and then depress the other trigger. The blades should not close. Repeat this procedure holding the other trigger. If the tool malfunctions, repair or remove it from service immediately. Model 30CL-1 and 30CL--3 Note: connect the air hoses and hydraulic hoses and turn on the power to perform the above maintenance check only. 1.2 Add Jarvis 1315 White Grease to the grease holes in pins (items 39, 42 and 47). 2 BLADE & CONNECTING LINK DISASSEMBLY: 2.1 Remove pivot pin (item 47). 2.2 Remove wear plates (item 46). 2.3 Remove connecting pins (item 42). 2.4 Remove blades (item 44 from 30CL-1 or items or item 52 from 30CL -3). 2.5 Remove drive pin (item 39), left hand thread, from drive coupling (item 28). 2.6 Remove connecting links (item 41). 2.7 Inspect all parts for wear and replace if necessary. 2.8 Inspect blades (items 44, or 52) for wear and sharpen if necessary. Refer to diagram below for proper sharpening angle. 30CL--3 grind here to sharpen 3 CYLINDER DISASSEMBLY: 30CL--1 grind here to sharpen 3.1 Loosen locking ring (item 9). 3.2 Remove cylinder housing (item 6) from clevis housing (item 27). 3.3 Remove piston rod (item 7) from drive coupling (item 28). 3.4 Remove internal retaining ring (item 10) from clevis housing (item 27).

16 maintenance instructions and special safety notice Model 30CL-1 and 30CL--3 page 16 of Remove bearing cartridge assembly (items 11-14) from clevis housing (item 27). 3.6 Inspect the parts for wear and replace them if necessary. 4 30CL-1 AND 30CL -3 ASSEMBLY: 4.1 Reverse steps and procedures outlined in steps See notes below Push piston rod (item 7) into clevis housing (item 27) Piston rod must go straight through clevis housing in one motion. If it gets caught, back out the piston rod and repeat this step. 4.2 Fasten piston rod (item 7) to drive coupling (item 28) with a 1 / 2 inch ratchet wrench. Use Loctite The step on coupling should face the hole in clevis housing. Refer to Figures A and B on pages 4 and Line up drive coupling (item 28), connecting links (item 41), and drive pin (item 39) through hole in clevis housing (item 27). Be sure the links are installed as the diagram shows on page Fasten drive pin (item 39) and hex nut (item 38), left hand threads. Use Loctite Screw cylinder housing (item 6) into clevis housing (item 27) Turn cylinder housing until it is tight and then back off until the hydraulic inlet and the outlet holes are in line Use Jarvis 1315 White Grease on the threads of the cylinder housing. 4.4 Tighten locking ring (item 9). 4.5 Reverse steps and procedures outlined in steps See notes below Tighten hex nut (item 53) to eliminate play between blades (item 44), wear plates (item 46) and clevis housing (item 27). Then tighten jam nut (item 54) to secure setting. IT IS FUNDAMENTAL: DO NOT ATTEMPT TO BY -PASS A TRIGGER. DO NOT REMOVE A TRIGGER. DO NOT ATTEMPT TO MODIFY THE TOOL. HOSES ARE COLOR CODED AND SIZED FOR THIS SPECIFIC TOOL. IMPROPER CONNECTION AND SIZE OF FITTING COULD NEGATE THE ANTI -TIE DOWN FEATURE. BEFORE CLEANING OR WORKING ON THE TOOL ITSELF, SHUT OFF THE POWER AND FOLLOW PROPER LOCKOUT/TAGOUT PROCEDURES. Our representatives are willing to assist you in the use of our tools. They may make suggestions in an effort to improve the safe use of the tools. However, in the final analysis, the burden and responsibility rest with you and your employees to be alert. Do not expect Jarvis personnel to assume your duty to inspect and maintain the tool.