model 525--1 / 525--tb hock/tonguebonecuttermodel 525--1 / 525--tb cutting force 750 lbf 3.34 kn...

TABLE OFCONTENTS Page. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model 525--1 Hock CutterSingle Acting Dual Triggers 4025077. . . . . .Single Acting One Trigger “CE” 4025078. .Double Acting Dual Trigger 4025107. . . . . .

Model 525--TB CutterDouble Acting Dual Triggers 4025099. . . . .

Hydraulic Power UnitDouble Acting Dual Triggers, 115V 4027173Double Acting Dual Triggers, 230V4027214

Balancer 4042044. . . . . . . . . . . . . . . . . . . . . . .

PRODUCTS CORPORATION33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457--4926

UNITED STATES OF AMERICA E--MAIL. [email protected]

TEL. 860--347--7271 FAX. 860--347--6978 www.jarvisproducts.com

Model 525--1 / 525--TBHock / Tongue Bone Cutter

EQUIPMENTSELECTION Ordering No.. . . . . . . . . . . .

•Notice to Employer and Safety Director 2. . . . . .•Notice to Operators, Maintenanceand Cleanup Personnel 3. . . . . . . . . . . . . . . . . . .

•Parts Diagram and List 4. . . . . . . . . . . . . . . . . . . . .

•Installation Diagram 8. . . . . . . . . . . . . . . . . . . . . . .

•Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

•Installation Instructions 9. . . . . . . . . . . . . . . . . . . . .

•Operating Instructions 9. . . . . . . . . . . . . . . . . . . . .

•Maintenance Instructions 10. . . . . . . . . . . . . . . . . .

®JARVIS6225031:.

Model 525--1 / 525--TB page 2 of 12

JARVIS6225031:.

® PRODUCTS CORPORATION33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457--4926



notice to employerand safety director

1. Remove and repair any tool that malfunctions. All personnel must be instructed to remove anymalfunctioning equipment.

2. Ensure that all employees who use this tool are trained in the proper use of this tool and are aware ofthe 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 CLEANUPPERSONNEL.” Post one copy on the employees’ bulletin board; give one copy to the operator(s); giveone copy to themaintenance foreman; and give one copy to the sub-contract cleanup / internal cleanupforeman. 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, butyou 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 1910.147) 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 safetysheets and tool brochure. Additional copies of safety sheets and tool brochures will be provided uponrequest.

NOTICE TO EMPLOYER AND SAFETY DIRECTORAVOID INJURY

Keep hands clear.

Model 525--1 / 525--TBpage 3 of 12

JARVISPRODUCTS CORPORATION33 ANDERSON ROAD, MIDDLETOWN, CONNECTICUT 06457--4926


TEL. 860--347--7271 FAX. 860--347--6978 www.jarvisproducts.com6225031:.

®

notice to operators, maintenanceand cleanup personnel

1. Disconnect all hydraulic and air hoses in accordance with OSHA’s lockout/tagout procedures (29CFR1910.147) before sharpening blades.

2. Disconnect all hydraulic and air hoses in accordance with OSHA’s lockout/tagout procedures (29CFR1910.147) before performing any repair or maintenance.

3. Disconnect all hydraulic and air hoses - or have all hydraulic and air hoses disconnected - in accordancewith OSHA’s lockout/tagout procedures (29 CFR 1910.147) before performing any cleanup.

4. Disconnect all hydraulic and air hoses 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 pathof the moving links.

7. Test the tool prior to use or daily. 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 notclose. Repeat this procedure reversing the triggers. Depress both triggers simultaneously and theblades should close. With the blades closed, release one trigger and the blades should open. Continueholding the depressed trigger and then depress the other trigger. The blades should not close. Repeatthis procedure holding the other trigger. If the tool malfunctions, remove it from service and report orrepair it immediately

8. Never depress the triggers unless you want to use or test the tool.

9. Nevermake modifications or alterations to the tool. Report or replace any missing or illegible labels.

NOTICE TO OPERATORS, MAINTENANCE AND CLEANUP PERSONNELREMOVE ANY MALFUNCTIONING TOOL FROM SERVICE

REPORT ANY PROBLEMS TO YOUR SUPERVISOR

Keep hands clear.

Model 525--1 / 525--TB page 4 of 12

JARVIS6225031:.




parts diagram and list

QTY

1 1007321 Link Lock Nut 22 1028117 Link 23 1054158 Link Pivot Bolt 24 1054157 Blade Pivot Bolt 15 1023412 Blade 26 1007214 Blade Lock Nut 17 1032487 Wear Plate 28 1016522 Clevis Housing 19 1011329 Yoke 110 1010177 Link Pivot Pin 111 1035541 Rod Seal 112 1036246 Bushing 113 1035542 O--ring 114 1014163 Spring 115 1020286 Piston Shaft 116 1065066 Piston 117 1035540 Piston Seal 118 1016523 Cylinder with item 19 119 1017083 Danger Label 120 1050690 Adapter 121 1011330 Quick Connect Plug 122 1055134* Socket Head Cap Screw 2

ITEM PART NO. PART NAME QTY

ITEM PART NO. PART NAME23 1024035* Trigger Guard 124 1012033* Trigger Guard Clamp 125 1018020* Trigger Lever 126 1010235* Pin 127 1054153 Threaded Plug 1/2*28 1022211 Valve 1/2*29 1019192* “D” Handle with item 33 130 1055292* Hex Head Screw 131 1051161* Elbow 232 1061649* Plastic Tubing, 12 inch 133 1055043 Socket Set Screw 1/2*34 1029339* Spacer 135 1004073* Lock Washer 136 1007183* Lock Nut 137 1051160 Straight Tubing Connector 138 1051160 Straight Conn. 1 Trigger 1

1051161* Elbow Conn. 2 Trigger 139 1019186 Pistol Grip Handle with

items 33 and 47 140 1055026 Socket Set Screw 241 1010274 Threaded Pin 242 1018144 Lever 143 1018145 Trigger 144 1024199 Trigger Guard 145 1055001 Flat Head Screw 146 1024206** Blade Guard 147 1013263 Hanger Ring 3

3019196 “D” Handle Assembly(items 22--31 and 33--36)

3019197 Pistol Grip Handle Assy(item 27, 28, 33, 39--45, 47)

8039148 Linkage Positioning Tool 1(see page 11)

* For dual trigger model only.** For single trigger “CE” model only.

**

**

*****

*

*

*

**

**

Figure ASingle ActingHock Cutter

*

Model 525--1 / 525--TBpage 5 of 12




®


ITEM PART NO. PART NAME QTY48 1054157* Blade Pivot Bolt, 3/8 in. 1

1054195 Blade Pivot Bolt, 1/2 in.49 1023489* TBC Blade, 3/8 in. Pin 2

1023561 TBC Blade, 1/2 in. Pin50 1007214* Hex Lock Nut, 3/8 in. 1

1007181 Hex Lock Nut, 1/2 in.51 1032487* Wear Plate, 3/8 in. 2

1032638 Wear Plate, 1/2 in.52 1016522* Clevis, 3/8 in. 1

1016641 Clevis, 1/2 in.53 1013122 Internal Retaining Ring 154 1032604 Plate 155 1035483 U--Cup Seal 1

Figure BDouble Acting

Tongue Bone Cutter

For 4025107 use item 5 blades.* not used in current tools.

ITEM PART NO. PART NAME QTY56 1013282 Lock Ring 157 1036299 Bushing 158 1050783 Elbow 159 1011331 Quick Connect Socket 160 1065073 Piston 161 1035626 Piston Seal Set 162 1051201 Pipe “T” 163 1019226 Pistol Grip Handle with

items 33 and 47 13019196 “D” Handle Assembly

(items 22--31 and 33--35)3019268 Pistol Grip Handle Assy

(items 27, 28, 33, 40--4547 and 63)

Model 525--1 / 525--TB page 6 of 12

JARVIS6225031:.




parts list and diagram

Figure CHydraulic Power

Unit

1 1008193 Electric Motor, 460/230v 12 see page 7 Control Box 13 1034064 Filter Assembly 14 1034062 Filter Element only 15 1042361 Mounting Bracket 16 1061734 Return Tubing Assembly 17 1011324 Motor Half Coupling 18 1011326 Spider Center 19 1011325 Pump Half Coupling 110 1034013 Filler Breather Cap 111 3008065 Hydraulic Gear Pump 112 1050515 Elbow 113 1061733 Supply Tubing 114 1025022 Pressure Gage 115 1022042 Dir. Control Valve, 115v 1

1022175 Dir. Control Valve, 230v1063843 din/iso Coil for Valve, 115v


1063844 din/iso Coil for Valve, 230v16 1072135 din/iso Connector, 115v 2

1072136 din/iso Connector, 230v17 1055376 Socket Head Cap Screw 418 1022120 Sub Plate 119 1050090 Hex Nipple, 2 inch 120 1050462 Hex Nipple, 4 inch 121 1022119 Relief Valve Cartridge 122 1050126 Elbow 223 1050602 Reducer Bushing 224 1025045 Oil Level Gage 125 1059099 Hose Assembly 226 1034007 Suction Strainer 127 1054166 Drain Plug with Magnet 128 1011330 Quick Connect Plug 129 1011331 Quick Connect Socket 1


Model 525--1 / 525--TBpage 7 of 12




®


Figure D Electric/Pneumatic Control Box


* not used in current tools

1 1063079 Ring Tongue Terminal 22 1004022 Internal Lock Washer 13 1063502 Fork Tongue Terminal 134 1072091 Glass Fuse, 115v 1

1063862 Glass Fuse, 220v5 1063311* Pigtail Fuse, 115v 1

1063312* Pigtail Fuse, 220v6 1005059 Electrical Switch 27 1051065 Pneumatic Actuator 28 1051115 Tubing Connector 29 1004154 Washer 410 1029445 Spacer 411 1004244 Washer 412 1073072 Plastic Screw 413 1051063 Tee Fitting 214 1050773 Air Bleed Fitting 215 1034014 Air Filter 116 1051185 Tubing Connector 117 1051001 Quick Connect Plug 118 1055197 Hex Head Screw, 115v 2

1055198 Hex Head Screw, 230v

ITEM PART NO. PART NAME QTY19 1004206 Washer 220 1007355 Hex Lock Nut, 115v 2

1007359 Hex Lock Nut, 230v21 1072071 ATD Circuit Board, 115v 1

1072072 ATD Circuit Board, 220v22 1016347 Control Box Enclosure 123 1055010 Pan Head Screw 424 1032266 Mounting Plate 125 1007278 Locking Nut 326 1004211 Sealing Washer 327 1011240 Cord Connector 328 1001014 Electric Cord ft29 1017114 Wiring Diagram Label, 115v 1

1017153 Wiring Diagram Label, 220v 130 1017012 Warning Label, 115v 1

1017150 Warning Label, 230v

1061340 Tubing Bundle (3) 20ft 13063278 Complete Control Box, 115v3063349 Complete Control Box, 220v

Model 525--1 / 525--TB page 8 of 12

JARVIS6225031:.




installation diagram

Figure GTypical Installation

Air Supply Hose

Trigger 2 Signal

HydraulicPressure HoseConnection

HydraulicReturn HoseConnection

HydraulicReturn Hose

HydraulicPressure Hose

HydraulicPower Unit

To AC PowerSupply

To DirectionalControl Valve Coils

Control Box(Factory installed onHydraulic Power Unit)

Air SupplyInlet

Trigger 1 Signal

Model 525--TB

Model 525--1 / 525--TBpage 9 of 12




®

SPECIFICATIONS

Model 525--1 / 525--TBCutting Force 750 lbf 3.34 kNCutting Cycle 0.6 secControl HandlesAir / Single / Dual Trigger 100 psi 6.9 barAir / Dual Anti--tie Down 50 psi 3.4 barBlade Opening 525--1 1.5 in 38.1 mmBlade Opening 525--TB 1.73 in 43.9 mmOverall Length 525--1 15.3 in 389 mmOverall Length 525--TB 13.3 in 338 mmWeight 9 lb 4.1 kg

Hydraulic Power UnitVoltage 460/230 V -- 60 Hz -- 3 ph

other voltages and frequencies availablePower 5 hp 3728 WattsHose Length 16 ft 5 mOil Capacity 20 gal 76 LOil Visc. at 100° F / 40° C 200 SUS 46 ISOOverall Dimensions (l x w x h) 28 x 24 x 28 in

711 x 610 x 711 mmWeight (without oil) 235 lbs 107 kg

INSTALLATION INSTRUCTIONS

IMPORTANT: ALWAYSDISCONNECTALLHYDRAULICANDAIR HOSES IN ACCORDANCE WITH OSHA’SLOCKOUT/TAGOUT PROCEDURES (29 CFR 1910.147)BEFORE PERFORMING ANYMAINTENANCE OR REPAIRS.

Refer to FigureG, page 8 as a guide to your installation.

1 Suspend the 525--1 / 525--TB cutter from a balancer.Jarvis part number 4042044 is available.

1.1 The 525--1 / 525--TB should have sufficienttravel to allow the operator to reach the entirework area.

2 Install the hydraulic power unit above the operatorstation.

3 Fill the oil reservoir with a USDA H1 approvedpremium grade hydraulic fluid (viscosity 200 SUSat 100 ° F / 46 ISO at 40° C). Never run the powerunit without oil.

4 Make the necessary air connections.

4.1 The air inlet pipe should be 3/8 inch diameterminimum.

4.2 The required compressed air supply is 40 psiminimum to 50 psimaximum for toolswithdualanti--tie down triggers; or 100 psi for nonanti--tie down tools.

4.3 An air regulator must be installed before theinlet to the air filter (item 15, Figure D, page 7).

5 Make all necessary hose connections.5.1 For anti--tie down tools, attach plastic tubing in

bundle 1061340 from tubing connectors (items8 and 16, Figure D, page 7) on the side of theelectric/pneumatic control box to fittings ( items31, 37 and 62, Figure B, page 5) on the handlesof the tool.

5.2 Attach quick connect socket (item 29, Figure C,page 6) located on the hydraulic hose to thequick connect plug (item 21, Figure A, page 4)on back of 525--1 / 525--TB cutter.

5.3 Make sure that the compressed air supply is at theproper pressure (100--120 psi or 40--50 psi foranti--tie down tools). Adjust your air regulator asnecessary.

OPERATION INSTRUCTIONS

Refer to Figures A and B on pages 4 and 5 for referenceditems unless otherwise noted.

1 Connect all hydraulic hoses.2 Connect all air hoses.3 Each day, before you begin operation, go throughthe following checklist:

3.1 Make sure that the compressed air supply is at theproper pressure. Refer to installation instructionstep 4.2.

3.2 Make sure that the Model 525--1 / 525--TB cutteris working correctly. Check for the correctoperation of the trigger(s) prior to use or daily.3.2.1 For Model 525--1 equipped with a single

trigger, depress the pistol grip trigger (item43) and the blades should close. Release thetrigger and the blades should open. If thetool malfunctions, remove it from serviceand report the problem to your supervisorimmediately.

specifications, installationand operation instructions

Model 525--1 / 525--TB page 10 of 12

JARVIS6225031:.




3.2.2 For Model 525--1 equipped with dualtriggers and Model 525--TB, depress the“D” handle trigger lever (item 25) only andthe blades should not close. Depress thepistol grip trigger (item 43) only and theblades should not close. Depress onetrigger, then pause one second and depressthe other trigger and the blades should notclose. Repeat this procedure reversing thetriggers. Depress both triggerssimultaneously (within one half second ofeach other) and the blades should close.With the blades closed, release one triggerand the blades should open. Continueholding the depressed trigger and thendepress the other trigger. The blade shouldnot close. Repeat this procedure holdingthe other trigger. If the tool malfunctions,remove it from service and report theproblem to your supervisor immediately.

3.3 Make sure that the 525--1 / 525--TB cutter movesfreely on the balancer.

4 Making the cut:4.1 Place 525--1 / 525--TB cutter around the hock or

tongue bone of the carcass.4.2 Depress the trigger or both triggers

simultaneously, as applicable, to close the blades.4.3 Release the trigger(s) to open the blades.4.4 Set the timer on the ATD board so that the valve

on the hydraulic power unit is de--energizedwhenthe blades have fully opened. Older boards use asquare potentiometer with a screw driver slot.Newer boards use a group of four rocker switches.See Figure D on page 7.

MAINTENANCE INSTRUCTIONS

IMPORTANT:ALWAYS DISCONNECTALLHYDRAULICANDAIR HOSES IN ACCORDANCE WITH OSHA’SLOCKOUT/TAGOUTPROCEDURES (29 CFR 1910.147)WHENINSTALLING OR REMOVING A BLADE. ALWAYSDISCONNECT ALL HYDRAULIC AND AIR HOSES INACCORDANCE WITH OSHA’S LOCKOUT/TAGOUTPROCEDURES (29 CFR 1910.147) BEFORE PERFORMINGANY MAINTENANCE OR REPAIRS.

Refer to Figures A and B on pages 4 and 5 for referenceditems unless otherwise noted.1 DAILY:

1.1 Check for the correct operation of the trigger(s)prior to use or daily.

1.1.1 For Model 525--1 equipped with a singletrigger, depress the pistol grip trigger (item43) and the blades should close. Release thetrigger and the blades should open. If thetool malfunctions, repair or remove it fromservice immediately.

1.1.2 For Model 525--1 equipped with dualtriggers and Model 525--TB, depress the“D” handle trigger lever (item 25) only andthe blades should not close. Depress thepistol grip trigger (item 43) only and theblades should not close. Depress onetrigger, then pause one second and depressthe other trigger and the blades should notclose. Repeat this procedure reversing thetriggers. Depress both triggerssimultaneously (within one half second ofeach other) and the blades should close.With the blades closed, release one triggerand the blades should open. Continueholding the depressed trigger and thendepress the other trigger. The blade shouldnot close. Repeat this procedure holdingthe other trigger. If the tool malfunctions,repair or remove it from serviceimmediately.

1.2 Check that the blades are opening and closingsmoothly and that they are meshing properly. Ifthe blades do not have a smooth sliding contactduring cutting, the blade pivot bolt and bladelock nut (items 4 and 6 or 48 and 50) must beadjusted. Tighten until smooth operation is lost,then back off tension slightly. Do notover--tighten.

1.3 Apply Jarvis 1315 White Grease to sliding,mating surface of each blade (item 5 or 49).

2 BLADE REMOVAL:

2.1 Remove link pivot bolts (item 3) and link locknuts (item 1).

2.2 Remove blade pivot bolt (item 4 or 48), bladelock nut (item 6 or 50) and blade guard (item46), if applicable.

operation andmaintenance instructions

Model 525--1 / 525--TBpage 11 of 12




®

2.3 Remove blades (item 5 or 49) and wear plates(item 7 or 51).

2.4 Inspect all parts for wear and replace them ifnecessary.

2.4.1 Inspect blades (item 5 or 49) for wear andsharpen or replace as necessary. See Figure1 for proper sharpening angle.

Figure 1

3 BLADE ASSEMBLY:

3.1 Reverse steps and procedures outlined insection 2.

3.2 Apply Jarvis 1315 White Grease to the pivotarea sliding surfaces of the blades and bladeholes prior to insertion into clevis housing (item8 or 52).

3.3 Tighten blade lock nut (item 6 or 50) asdescribed in section 1, step 1.2.

4 LINK REMOVAL:

4.1 Remove the blades (item 5 or 49). Refer to stepsand procedures outlined in section 2.

4.2 Remove adapter and quick connect plug (items20 and 21). Thread Jarvis service tool 8039148into rear of 525--1 / 525--TB cutter. See Figure2.

Figure 2

4.3 Turn handle of service tool to position the links(item 2) by extending the piston shaft (item 15)until link pivot pin (item 10) and yoke (item 9)are aligned with the top and bottom holes in theclevis housing (item 8 or 52).

4.4 Use a 5 mm punch to drive the link pivot pin

(item 10) from the yoke (item 9).4.5 Remove the links (item 2).4.6 Inspect all parts for wear and replace them if

necessary.5 LINK ASSEMBLY:5.1 Reverse steps and procedures outlined in

section 4. See notes below.5.1.1 Apply Jarvis 1315 White Grease to link

pivot pin (item 10) and pivot area slidingsurfaces of links (item 2) before insertinginto clevis housing (item 8 or 52).

5.1.2 Use a pin punch through the bottom hole ofthe clevis housing (item 8 or 52) to align theyoke (item 9) and links (item 2) as you pressin link pivot pin (item 10). The pin shouldend up approximately flush with top ofyoke.

6 CYLINDER DISASSEMBLY:6.1 Remove the blades (item 5 or 49). Refer to steps

and procedures outlined in section 2.6.2 Remove the links (item 2). Refer to steps and

procedures outlined in section 4.6.3 Remove pistol grip handle assembly from

cylinder (item 18). Refer to steps 8.1--8.3outlined in section 8.

6.4 Remove the cylinder (item 18) from thebushing(item 12 or 57) by holding bushing in soft jawedvise and using wrench flats on cylinder toseparate the parts.

6.5 Unscrew the piston (item 16 or 60) from thepiston shaft (item 15) using Jarvis service tool8039093. See Figure 3.

Figure 3

6.6 Remove piston seal (item 17 or 61) from piston(item 16 or 60).

6.7 Remove the spring (item 14), if applicable, ando--ring (item 13).

6.8 Unscrew yoke (item 9) from piston shaft (item15).

maintenance instructions

Model 525--1 / 525--TB page 12 of 12

JARVIS6225031:.




6.9 Remove rod seal (item 11) from the bushing(item 12 or 57).

6.10 Inspect all parts for wear and replace ifnecessary.

7 CYLINDER ASSEMBLY:7.1 Reverse steps and procedures outlined in

section 6. See notes below.7.1.1 Place bushing (item 12 or 57) in soft jawed

vise and use wrench flats on back ofcylinder (item 18) to tighten cylinderassembly.

7.1.2 Install scalloped end of backup ring (item61) facing scalloped end of piston seal (item61). See figure 4.

Figure 4

Backup Ring Piston Seal

8 PISTOL GRIP HANDLE DISASSEMBLY:8.1 Loosen socket set screws (item 40).8.2 Remove flat head screw (item 45) and trigger

guard (item 44).8.3 Remove pistol grip handle (item 39 or 63) by

sliding over cylinder (item 18).

8.4 Unscrew threaded pins (item 41) to removetrigger (item 43) and lever (item 42).

8.5 Reach inside pistol grip handle (item 39 or 63)with a 5/16 inch (8 mm) nut driver to unscrewthreaded plug (item 27).

8.6 Remove valve (item 28) by grasping its stemwith needle nose pliers.


9 PISTOL GRIP HANDLE ASSEMBLY:9.1 Reverse steps and procedures outlined in

section 8.10 “D” HANDLE DISASSEMBLY:10.1 Remove lock nut (item 36), hex head screw

(item 30), lock washer (item 35) and spacer(item 34) to separate “D” handle from the 525--1/ 525--TB cutter.

10.2 Push out pin (item 26) and lift away trigger lever(item 25).

10.3 Unscrew threaded plug (item 27) and gentlygrasp stemwith pliers to removevalve (item28)from handle.


11 ”D” HANDLE ASSEMBLY:11.1 Reverse steps and procedures outlined in

section 10.

maintenance instructions

model 525--1 / 525--tb hock/tonguebonecuttermodel 525--1 / 525--tb cutting force 750 lbf 3.34 kn...

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