multi coupler jb
TRANSCRIPT
OPERATIONS MANUAL
JBA MULTI-COUPLER
CONTENTS PAGECustomer acceptance and warranty registration _________________________________ 2
To the owner ______________________________________________________________ 3
Safety instructions _________________________________________________________ 4
Introduction ______________________________________________________________ 5
Standards ________________________________________________________________ 6
Qualification of operating personal____________________________________________ 7
Installation of multi-coupler _______________________________________________8-14
Circuit diagram ___________________________________________________________ 15
Hydraulic installation ______________________________________________________ 16
Electrical installation ______________________________________________________ 17
Maintenance _____________________________________________________________ 18
Maintenance and repair log _________________________________________________ 19
Parts ___________________________________________________________________ 20
Parts List ______________________________________________________________21-22
CUSTOMER ACCEPTANCE AND WARRANTY REGISTRATION
Upon delivery of your JBA Multi-Coupler, please complete and return this form immediately to your JBA 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 JBA Multi-Coupler.
The Operator understands that he/she is responsible for upstanding all safety and operation features of the JBA 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 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 aboveand return this copy (also retaining a copy) to:
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AUCKLAND 49 McLaughlins Road, Wiri 2104, Auckland, New Zealand - PO Box 98979, Manukau City 2241
Phone: 0064 9 278 4863 - Phone: 0800 527 2537 - Fax: 0064 9 278 4864 - Email: [email protected]
BRISBANE 82 Chetwynd Street, Loganholme QLD 4129, Australia - Phone: 0061 7 380 60344 - Fax: 0061 7 380 60295
Email: [email protected]
MELBOURNE Unit 1, 15 Commercial Drive, Dandenong, Melbourne Vic 3175, Australia - Phone: 0061 3 9706 5239
Fax: 0061 3 9706 5213 - Email: [email protected]
TO THE OWNERAs the new owner and/or operator of the JBA Multi-Coupler we would recommend that you take the time to read this operator guide carefully before commencing work.
The JBA Multi-Coupler brings major advancements in safety to the construction attachment industry. It demonstrates JBs ongoing commitment to the development of safe and productive products that not only meet but surpass our clients requirements.
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 JBA 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 Ltd 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 Ltd.
• With use of accessories or replacement parts not approved by JB Attachments Ltd or which are not original replacement parts supplied by JB Attachments Ltd.
After the warranty period has expired, we further recommend use of original replacement parts and our replacement parts approved by JB Attachments Ltd.
We thank you for your choice and look forward to being of service to you now and in the future.
PLEASE COMPLETE THE CUSTOMER ACCEPTANCE AND WARRANTY REGISTRATION FORM LOCATED IN THIS MANUAL - FAILURE TO REGISTER MAY INVALIDATE YOUR WARRANTY CLAIM.
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SAFETY INSTRUCTIONSThis 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.
WARNINGImproper 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 safe use of 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 Ltd instructions on operation and maintenance.
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CAB DECALThe JBA Multi-Coupler operation instructions to be fitted inside the cab in clear view of the operator.
Decal for inside cab. Part # JBAUTO1467
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COUPLER IDENTIFICATION LABELEach JBA Multi-Coupler will have an identification label fitted which will also have the SWL and data information. There will also be a serial number stamped into the steel body with SWL stamp near the lift eye.
All cylinders will have an identification number and serial number stamped onto the cylinder. Please use this identification number when ordering parts to confirm the correct repair kits.
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INTRODUCTIONThis manual contains very important information about the installation, connection, maintenance and safe operation of the JBA Multi-Coupler. JB Attachments Ltd takes great care and pride in the manufacturing standards applied to this equipment and to ensure satisfactory and safe performance. You can also help in this positive safety approach, by ensuring that all persons who may be involved with the fitting or operating of the JBA Multi-Coupler read and understand these BASIC SAFETY FEATURES AND INSTRUCTIONS
JB Attachments Limited 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 Ltd has sole copyright of this manual.
• The manual is intended solely for the use of the JBA Multi-Coupler System.
• No part of this manual may be reprinted, translated or reproduced by any means without prior written permission of JB Attachments Ltd.
• Utilisation for the purposes of competition is forbidden.
• The JBA Multi-Couplers are 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. Also in the correct operating use of the 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 JBA Multi-Coupler.
A log book has been placed at the back of this manual for that purpose and your convenience.
STANDARDS OF DESIGN, INSTALLATION, MAINTENANCE & OPERATIONSTANDARDS AND OSH GUIDELINES
The standards and OSH Guidelines for the JBA Multi-Coupler are as follows:
• AS4772 Standards Australia. Australian Standard for - Earthmoving Machinery - Quick-hitches (couplers) for excavators and backhoe loaders AS4772 section C12.1.4
• AS 1418 5 1995 Cranes (Including hoists and winches) Part 5: Mobile vehicle loading cranes.
• European Standard EN474-5; Section 4.1.9.1/2 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. Also in the correct operating use of the 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 JBA Multi-Coupler (in agreement with JB Attachments Ltd).
• The crowd and breakout forces specified by the excavator manufacturer must not be exceeded.
• The JBA 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 JBA Multi-Coupler models have specific safety features, see those that relate to your purchase on Page 9.
PLEASE NOTE
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QUALIFICATION OF OPERATING PERSONNELOnly the following persons may work independently with the JBA Multi-Coupler systems and in general earthmoving machinery, those who:
• Are over 18 years of age.
• Are physically and intellectually suitable.
• Have been instructed in the general regulations concerning operational safety and accident prevention in particular.
• Have been instructed in assembly, operation and maintenance of the earthmoving machinery and how to use the JB Multi-Coupling system, who have understood these operating instructions and have proven to the contractor they are capable of operating such machinery.
Ensure that only appointed personnel work with the multi-coupler system.
Only give instructions to competent, skilled personnel.
NOTE: FOR JB MULTI-COUPLING 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.
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INSTALLATION KIT 1 x JBA Multi-Coupler
1 x Operation switch
1 x Warning buzzer
1 x Hydraulic hose kit and fittings
1 x Solenoid valve (12 or 24 volt)
6 x Clamps (weld on type)
1 x Cable ties (packet)
!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.
FITTING HOSES TO CYLINDER
Remove plugs from cylinder
Check surface is clean prior to connecting banjo fitting on hoses
INSTALLATION: JBA MULTI-COUPLER
STEP 1
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Banjo bolt Part# JB_Auto-c-cyl-015
Banjo washer Part# JB_Auto-c-cyl-016
Banjo Part# JB_Auto-c-cyl-022
INSTALLATION: JBA MULTI-COUPLER
Align JBA Multi-Coupler to the dipper arm fit oring seals and shims where required.
Install OEM harden pins to attach JBA Multi-Coupler to dipper arm on excavator and fit locking bolts and nuts to secure pins.
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CHECK PINS ARE ORIGINAL OEM PINS.!
STEP 2
STEP 3
INSTALLATION: JBA MULTI-COUPLER
FITTING MANIFOLD BLOCK ON DIPPER ARM AND WHIP HOSES TO THE COUPLER (follow step 5)
Manifold block
Whip hoses
OEM pins
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Whip hoses in this position will give the whip hoses a natural spring movement to keep hose snug and neat fitting close to dipper arm for protection
!WARNING!! PRIOR TO WELDING DISCONNECT BATTERY AND ANY ELECTRICAL OR COMPUTER CONNECTIONS - IF NOT CERTAIN CONTACT MACHINE SUPPLIER BEFORE WELDING.
MANIFOLD POSITIONSTEP 4
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Fig. A
MULTIPLE CONNECTOR
Fig. B
NOTE: THIS DISTANCE WILL VARY TO SUIT DIFFERENT MACHINE MAKES AND MODELS.
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NOTE: WHIP HOSE CAN HAVE SPIRALFLEx HOSE PROTECTION OR SPIRAL STEEL FITTED. KEEP IN MIND NATURAL HOSE HAS BETTER FLExIBILITY.
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Remove paint, tack weld manifold block on either end as in (Fig. B)
Whip hose position approx dimensions (Fig. C)
INSTALLATION: JBA MULTI-COUPLER
With coupler fully crowded in towards the cab, position the manifold block approx 240mm (Fig.A) from the dipper bucket pin center to manifold block on the dipper.
FITTING MANIFOLD BLOCK & WHIP HOSESSTEP 5
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Fig. C
Test whip hose position in the opposite position, the coupler crowd fully out in the (dump) position. Check clearance between the crowd cylinder and manifold block has clearance. Hose should be in neat tidy position that will not cause damage to whip hoses.
If not in correct position damage will occur, options are move the hose to a suitable position where the hoses are fitting freely or reposition manifold block or mark lengthen whip hose. Repeat the same procedure and check until the hoses are in a neat and tidy position and follow (Fig, A, B, C)
100-130mm (check hose is not too tight at hose end)
Manifold block
Whip hose
25-50mm distance from dipper arm
Coupler cylinder adjust banjo connection on cylinder can be directed at 10° angle facing outwards in a V angle to direct hoses away from the crowd linkage on the machine
INSTALLATION: JBA MULTI-COUPLER
FITTING WHIP HOSESSTEP 5 (CONTINUED)
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Fully weld block on outer sides RH/LH
Only weld parallel to dipper on each end of manifold block
INSTALLATION: JBA MULTI-COUPLER
FITTING WHIP HOSESSTEP 5 (CONTINUED)
STEP 6OPTIONAL USING STEEL TUBE OR HOSE
From the manifold block install hoses or tube up the dipper arm at the top clamp hose/tube to outer side allowing clearance when crowd cylinder clearance.
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Follow original pipe/hose on main boom where you can feed in between and existing clamps.
Optional outer hose sox can be used for extra protection.
Cable tie every 300-400mm to existing hose pipe work.
Position where appropriate. This may vary with different machine.
!NOTE: CHECK HOSES ARE CLEAN PRIOR TO CONNECTING.
INSTALLATION: JBA MULTI-COUPLER
STEP 7
INSTALLATION SOLENOID VALUE
MAINS PRESSURE SUPPLY TO SOLENOID VALVE Locate the main test port on the Excavators main hydraulic pump. Fit adapter or Tee adapter connect main hydraulic pump to the “P” port on the solenoid valve, (“P” is marked on valve for pressure in).
Mount the solenoid valve in convenient position near the main hydraulic pumps.
!CHECK MACHINE VOLTAGE. 12/24. CHECK SOLENOID IS CORRECT.
!CHECK THIS BY FITTING A PRESSURE GAUGE INTO THE PUMP PORT OPERATE MACHINE TO CONFIRM PORT IS FITTING. NOTE: CONNECTION ON CROWD OPERATION - AS MACHINE HAS TWO PUMPS IN SERIES, CHECK OPERATION PRIOR TO FITTING.
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INSTALLATION: JBA MULTI-COUPLER
STEP 8
!NOTE: THE JBA MULTI-COUPLER SOLENOID VALVE HAS A PRESSURE REDUCER FITTED. THIS WILL DECREASE PRESSURE FROM THE SOLENOID VALVE TO 2800-3000 PSI. THIS IS SUFFICIENT PRESSURE TO THE CYLINDER AND WILL PROTECT THE CYLINDER FROM SPIKE PRESSURES ON THE ExCAVATORS. ALSO WORKING AT THIS PRESSURE WILL GIVE MORE FLExIBILITY ON WHIP HOSES TO INCREASE THE LIFE OF HOSE TO COUPLER.
THE JB QUICK COUPLER HAS BEEN OPERATING THIS SYSTEM ON ALL COUPLERS FOR MORE THAN 12 YEARS.
INSTALLATION: JBA MULTI-COUPLER
STEP 9
Solenoid valve marked “T” Port, is returned to hydraulic tank.
Connect hose from solenoid valve to accessable, convenient position on the main hydraulic tank (NOTE: fitting is not supplied in the installation kit).
• Tee Connection fitted for return oil from the solenoid marked “T”
RETURN LINE FROM SOLENOID VALVE TO HYDRAULIC TANK
Hose connected to hydraulic tank
(Tee connection fitting can be used on existing connection on tank if required, if spare connections are not available)
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CIRCUIT DIAGRAM FOR DOUBLE ACTING INSTALLATION
CIRCUIT DIAGRAM
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HYDRAULIC INSTALLATION
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! SAFETY WARNING
Depending on electrical solenoid, valve supplied wiring is as follows:
A: Coil with two wires coming from it should be wired with one to earth and the other to the power source.
B: Coil has three points to wire to. You can use two of theses terminals, which are marked 1 and 2.
1. Wire 1 to earth on body of machine, wire 2 to switch which is mounted in the cab (terminal 3 not used).
2. Further information can be found in section 9.
NOTE
Buzzer Alarm
Solenoid Valve
Switch
Install Hitch Switch inside cab
ELECTRICAL INSTALLATION
INSTALLATION KIT CHECKLIST
REAR SLIDE HOOK
FRONT JAW LOCK
FRONT PINREAR PIN
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OPERATION AND ATTACHING
MULTI-COUPLER OPERATION
1. Activate JBA Multi-Coupler switch inside operators cab to ON position.
2. Crowd fully in towards cab to pressurise hydraulics.
3. Rear slide hook will be fully out which will release the front jaw lock.
1BEFORE ATTACHING ATTACHMENTS
ATTACHMENT OPERATION
1. Line up front jaw of the JBA Multi-Coupler to the attachments front pin. Curl into the front pin on the attachment and continue until the open jaw on the coupler fits into the front pin on the attachment.
2. Switch to OFF position, buzzer will sound. Curl/crowd the coupler towards the cab. The rear slide hook will slide forward to engage the front jaw lock on the pin.
3. With the attachment crowded towards the cab, activate the switch to ON. The buzzer will stop. The rear slide hook will lock on the rear pin.
4. The front jaw lock will be fully closed on the front pin. Proceed to connection test.
2PICK UP
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OPERATION AND ATTACHING
CONNECTION TEST IMPORTANT3
To ensure the Multi Coupler has engaged surely to pins on attachment:
Visual check Front Auto Jaw Lock is engaged on front pin.
Test apply pressure to bucket/attachment by rotating against the ground and away from machine before operating.
Do not proceed to work unless Jaw Lock is in closed position on the front pin.
If Jaw Lock on front pin is open DO NOT OPERATE MACHINE.
WARNING! Check all attachments are fitting correctly. Safety lock jaw is designed to work in closed position to suit all weight breaks to machine models makers of OEM design pins centers. If the safety lock is not closed when attached to any attachment DO NOT USE THIS ATTACHMENT. Advise manufacturer of attachment this it is not fitting and arrange modification before it can be used.
LIFTING WITH THE JBA MULTI-COUPLERWARNING! Always use the correct rated shackle and lifting equipment when lifting. Never use worn, damaged, undersized or under rated equipment.
The coupler has an integrated certified lifting eye. The safe working load of which can be found stamped into the coupler frame (next to the lifting eye). Do not lift over the SWL limit of the coupler. The lifting capability of the machine should also be checked prior to lifting with the coupler in a vertical position.
SAFETY LOCK JAW IN CLOSED POSITION
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OPERATION AND ATTACHING
TESTING HYDRAULIC INSTALLATION AND ELECTORAL SYSTEM
Check all hose and adapters fitted are tight. Check that hoses are not rubbing and all cable ties are secured. Ensure all bolts and nuts are tight
Ensure electrical insulation is in correct fuse, earth, switch is surer and alarm is working
NOTE ! Check alarm only works when coupler is in the release operation
Make sure all warning decals are fitted
Start machine crowd fully in hold crowd lever over and switch coupler switch on and off, Slide jaw will move to either release or attach position and hold lever over will pressurize the hydraulics hose and fittings do this in both directions and visually check all connections for leaks and operation
Grease all grease points on the coupler (Fig. D)
Move slide jaw with hydraulics in and out after greasing
PRESSURE TEST HYDRAULICS
Rear slide hook GreaseGrease safety lock pin
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MAINTENANCE
GENERAL MAINTENANCE
WARNING - Maintenance WorkMaintenance work must be completed by competent personnel or ask JBs to assist.
DANGER - Hydraulic FluidNever use your 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 - Coupler ConditionA defective coupler could injure you or others. Do not operate a coupler that is defective.
WARNING - Hose ArrangementEnsure that the hoses are not to slack and do not come into contact with the spring mechanisms as this will prevent the safe operation of the blocking bar.
Maintenance and ServiceTo ensure that your quick coupler works safely and to maximum efficiency it is imperative that it is properly maintained in accordance with the following service guidelines.
Replacement PartsWe recommend that you fit genuine replacement parts. You will need to quote the coupler serial number stamped on the coupler data plate.
DAILY CHECKS1. Thoroughly clean the coupler.
2. Check the coupler for cracked, bent or broken components, distressed welds, missing parts and oil leaks. Replace broken parts if required.
3. Check the security of the mounting pins, locking bolts and nuts.
4. Check the condition of the hydraulic hoses, fittings and hydraulic system generally. Replace any that are damaged.
OVERLEAF IS THE MAINTENANCE AND REPAIR LOG FOR THE JBA MULTI-COUPLER
• It is essential this log is filled in at the time of maintenance or repair to 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 Muti-Coupler must be by an authorised and competent person.
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MAINTENANCE
WEEKLY CHECKS
It is recommended that the following procedures are carried out at least once per week.
1. Carry out all daily, checks.
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 vii so that none of the grease nipples are overlooked.
I. Release the bucket/attachment. (Refer to the operation instructions- section)
ii. Retract the coupler cylinder. Switch off the engine.
iii. Apply grease, via grease nipple.
iv. Apply grease via nipple B to the hook.
v. Start the engine. Extend the bucket cylinder in order to position the coupler so the cylinder grease nipples are accessible. Switch off the engine.
MAINTENANCE AND REPAIR LOG
DATE FAULT / SERVICE DESCRIPTION MAINTENANCE / REPAIR EFFECTED BY WHOM
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MAINTENANCE
TORQUE SPECIFICATIONS The torque specifications are as follows:
Check valve 30 lb.ft 40 Nm
B hose connection male (cylinder hose) 15 lb.ft 20 Nm
A hose connection male (cylinder hose) 26 lb.ft 35 Nm
Pressure hose connection female 20 lb.ft 27 Nm
Tank return hose connection female 55 lb.ft 75 Nm
Weld on block 20 lb.ft 27 Nm
Solenoid Valve
A Line filter fitting o BSP M/M Adapter 25 lb.ft 34 Nm
B Line filter fitting 7/16 JIC x 7/16 UNF 15 lb.ft 20 Nm
P Line 9/16 JIC x 9/16 UNF 26 lb.ft 35 Nm
T Line 3/8 BSP M/M Adapter 55 lb.ft 75 Nm
Spool Valve 40.6 lb.ft 54.2 Nm
Check Valve 33.8 lb.ft 40.6 Nm
Electro-magnetic lock nut 5.4 lb.ft 8.1 Nm
Plug 9.3 lb.ft 13 Nm
PARTS
When ordering, state excavator size, make & Model & Coupler, Serial Number.
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PARTS LIST
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PARTS LIST
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www.jbattachments.com
AUCKLAND 49 McLaughlins Road, Wiri 2104, Auckland, New Zealand - PO Box 98979, Manukau City 2241
Phone: 0064 9 278 4863 - Phone: 0800 527 2537 - Fax: 0064 9 278 4864 - Email: [email protected]
BRISBANE82 Chetwynd Street, Loganholme QLD 4129, Australia - Phone: 0061 7 380 60344 - Fax: 0061 7 380 60295
Email: [email protected]
MELBOURNE Unit 1, 15 Commercial Drive, Dandenong, Melbourne Vic 3175, Australia - Phone: 0061 3 9706 5239
Fax: 0061 3 9706 5213 - Email: [email protected]