Read 8Cust_Serv_Guide_Hydr_RotoLoc.pdf text version

®

HYDRAULIC ROTOLOC® COUPLER

REPAIR AND PREVENTATIVE MAINTENANCE GUIDE

800-428-2538 l www.paladinbrands.com JRB: 820 Glaser Parkway, Akron, OH 44306, United States of America

HYDRAULIC ROTOLOC®

CONTENTS

WARNING/INSTRUCTIONAL DECALS ............................................................................... ...... 3 DECAL AND SERIAL TAG PLACEMENT ............................................................................ ...... 4 TOOLS REQUIRED ........................................................................................................ ...... 5 OPERATION - SUPPLEMENTAL LOCK .............................................................................. ...... 5 Locking Coupler to Attachment ........................................................................................ ...... 6 COUPLER INSTALLATION ............................................................................................... ...... 6 COUPLER OPERATION ................................................................................................... ...... 6 Unlocking Coupler from Attachment ................................................................................. ...... 7 MAINTENANCE .............................................................................................................. ...... 8 VISUAL INSPECTION ..................................................................................................... ...... 9 OPERATION/TRAVEL PRECAUTIONS................................................................................ ...... 9 RotoLoc® LIFT EYE USAGE ............................................................................................. .... 10 TROUBLESHOOTING ...................................................................................................... .... 10 WARRANTY POLICY........................................................................................................ .... 11 RETURNED GOODS POLICY ............................................................................................ .... 13 ROTOLOC® COUPLER COMPONENTS AND SPECIFICATIONS............................................ .... 14 PARTS LIST ................................................................................................................... .... 14 COUPLER ASSEMBLY ..................................................................................................... .... 15 OVERVIEW ..................................................................................................................... .... 16 TOOLS REQUIRED ......................................................................................................... .... 16 HYDRAULIC KIT............................................................................................................. .... 16 TESTING THE SOLENOID WITH AN OHMMETER .............................................................. .... 17 SOLENOID VALVE ........................................................................................................... .... 17 LOW PRESSURE HYDRAULIC SYSTEM TESTING ............................................................. .... 19 THEORY OF OPERATION ................................................................................................. .... 22 POST INSTALLATION TESTING ....................................................................................... .... 22 HYDRAULIC CIRCUIT .................................................................................................... .... 22 MAINTENANCE .............................................................................................................. .... 23 JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

CONTENTS - Continued

TROUBLESHOOTING ...................................................................................................... ....23 SERVICEABLE PARTS ..................................................................................................... ....24 HYDRAULIC KIT INSTALLATION ...................................................................................... ....26 ELECTRONICS INSTALLATION ........................................................................................ ....27 ELECTRICAL PARTS LIST ............................................................................................... ....27 ELECTRICAL SCHEMATIC AND ASSEMBLY ...................................................................... ....28 ATTACHMENT PICK UP CHART ....................................................................................... ....29 PREVENTATIVE MAINTENANCE OR REPAIR PROCEDURE ................................................ ....36

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

WARNING/INSTRUCTIONAL DECALS

OPERATOR'S HANDBOOK Part Number A44435 READ MANUAL Part Number A44486 CLEARANCE HAZARD Part Number A43401

DO NOT touch coupler when machine is running. Failure to comply could result in death or serious injury.

PI N CH POI N T !

A45759

PINCH POINT Part Number A45759

partially

a

IMPROPERLY LOCKED Part Number A44485

COUPLER OPERATION Part Number A44487

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

DECAL AND SERIAL TAG PLACEMENT

SERIAL NUMBER TAG

2

5

REAR OF COUPLER (MOVING HOOK)

Warning Decal Placement

FRONT OF COUPLER (FIXED HOOK)

Note: Locate item 2 and 5 on both sides of coupler. Locate items 1, 2, 3, and 4 inside of machine cab. Operators Handbook also is to be located in cab.

ITEM QTY.

* * * 1 2 3 4 5 6 1 1 1 1 3 1 1 1 1

PART NUMBER

91V 0768 91V 0769 A 44435 A 44486 A 44485 A 44487 A 43401 A 45759 A 55521

DESCRIPTION

Decal Kit, RotoLoc Coupler (Includes 2 of item 2 & 1 of item 5) Decal Kit, RotoLoc Cab (Includes 1 each items 1, 2, 3, 4, & 6 Operator's Handbook, (in cab) Decal, Read Manual, (in cab) Decal, Improperly Locked Attachment, (1in cab & 2 on coupler) Decal, Coupler Operation, (in cab) Decal, Clearance Hazard, (in cab) Decal, Pinch Point, (on coupler) Decal, Ground Test, (in cab)

rotodec1

Warning/Instructional Decals

CRUSH HAZARD!

GROUND TEST REQUIRED!

Before using the attachment, perform a ground test to verify it is properly locked to the coupler. Place attachment flat on the ground. While applying slight down pressure, attempt to uncurl the attachment. The attachment should remain in tight contact with the coupler with minimal or no movement. Failure to perform this test could result in the unexpected release of the attachment, causing serious injury or death.

GROUND LINE

A55521

GROUND TEST Part Number A55521 JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

· · · · · Standard socket wrench set Phillips and flat screwdriver sets Sledge-hammer or mallet Wrench Set Grease and grease gun Keep attachment close to the ground during all lock and unlock operations. Clear debris from hook areas of coupler prior to engaging attachment. Assure the supplemental lock is properly secured and the coupler is fully engaged to the bucket before use. Failure to follow these steps could cause the attachment to disengage. Serious injury or death could occur.

Your JRB RotoLoc® Coupler is equipped with a mechanical supplemental lock that prevents the accidental unlocking of the coupler if the primary locking mechanism is not properly functioning.The supplemental lock is designed to work in conjunction with the coupler primary locking mechanism. The supplemental lock is not intended to be used as the primary locking system for the coupler.

Do not operate the coupler if the supplemental lock is the only locking mechanism.

SmartLoc Arm

Hydraulic Cylinder Cam lock

Supplemental Lock

Cam Lock Visible from Cab

Unlocked Position

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

COUPLER INSTALLATION

· Remove existing attachment from the machine linkage and place the OEM pins back into the attachment. · Install coupler onto stick using the supplied JRB coupler pins. The pins which come with the coupler must be used to pin the coupler to the machine. Use of pins either too large or too small a diameter will not allow proper hook engagement. Attachment may drop without warning if not properly attached. Failure to do so could result in serious injury or death.

Locking Coupler to Attachment

STEP 1 Position machine and coupler to pick up desired attachment by moving stick and coupler close to the cab. Curl coupler under to full extension of bucket cylinder. Move toggle switch to the UNLOCK position. Note: A safety light will turn on and a buzzer will sound warning the operator anytime the toggle switch is in the unlock position. Move the joystick to curl the coupler and hold over relief. NOTE: Secondary locking jaw must be in the fully retracted position. STEP 2

Engage front attachment pin (closest to cab) with the fixed hook on coupler. With the Hydraulic RotoLoc® engaged to this pin on the attachment, rotate, curl and lift the attachment slightly off the ground.

Curl coupler under to full extension of bucket cylinder. Move toggle swithc to the LOCK position. (light and buzzer will turn off, indicating the coupler is in the LOCKED position. position).

NOTE: Secondary locking jaw must be in the fully extended position, completely enclosing the

pin. Visually check the coupler to verify it is securely attached. Verify the attachment is properly locked by performing a ground test before using. Place the bucket (attachment) on the ground and apply slight pressure and attempt to uncurl to ensure the attachment is secured to the coupler.

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

Unlocking Coupler from Attachment

NOTICE

STEP 1: Position machine to unlock attachment by moving stick and coupler close to the cab. NOTE: Keep the coupler and attachment close to the ground. Curl coupler under to full extension of bucket cylinder. Move toggle switch to the UNLOCK position. Note: A safety light will turn on and a buzzer will sound warning the operator anytime the toggle switch is in the unlock position. Move the joystick to curl the coupler and hold over relief. NOTE: Secondary locking jaw must be in the fully retracted position. STEP 2:

Disengage the fixed hook on coupler from front attachment pin. After the Hydraulic RotoLoc® is disengaged from this pin, uncurl and lift the coupler away from the attachment.

If the following steps are not followed properly the machine stick and/or jrb coupler may be damaged.

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

MAINTENANCE

The following maintenance procedure should be performed in order to maintain proper operation of the Hydraulic RotoLoc® Coupler. In order to keep the RotoLoc® Coupler operating freely, follow the below maintenance procedure for the coupler. Failure to do so could result in binding of the coupling mechanism causing it to become very difficult to unlock the coupler. The RotoLoc® Coupler works best when it is maintained and lubricated properly. The moving parts of the coupler must be kept well lubricated and clean at all times to prevent corrosion and binding. Please refer to the lubrication diagram for lubrication points on the coupler. The RotoLoc® Coupler should be cleaned of all debris, particularly in the lock area, at all times. FAILURE TO PROPERLY MAINTAIN THE COUPLER COULD RESULT IN SERIOUS INJURY OR DEATH OR EQUIPMENT OR PROPERTY DAMAGE.

PR OC ED U R E Remove debri s from coupler Inspect locki ng mechani sm Grease zerk fi tti ngs on movi ng hooks Unlock coupler mechani sm Grease C yli nder assembly Grease RotoLoc zerk fi tti ngs on b o sse s IN TER VAL a t e a ch i nterchange a t e a ch i nterchange dai ly dai ly weekly weekly N OTES P r i m a r i l y i n m o vi ng ho o k a r e a p r i o r t o e ng a g i ng attachment. Both pri mary and supplemental. See locati on "A". T prevent bi ndi ng of coupli ng mechani sm. o Place grease gun ti p on all zerks to grease. See locati on "B". See locati on "C ".

mtnce2

Maintenance Procedures

REAR (STATIONARY HOOK)

B B

B C C

A A

FRONT (MOVEABLE HOOK)

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

VISUAL INSPECTION

Visually inspect the coupler for any structural or weld cracks on a daily basis. If a crack is found in either the steel structure or the welds, immediately take the coupler off the stick and contact JRB Attachments, Inc. at 1-800-428-2538 ask for Customer Service Department. Check to make sure that the pin retaining bolts are properly attached on the coupler pins on a daily basis. If a bolt is missing, replace it immediately with another JRB supplied bolt. FAILURE TO REPLACE A MISSING BOLT WILL CAUSE THE PIN TO EXTRACT AND COULD CAUSE SERIOUS INJURY OR DEATH AND DAMAGE TO THE COUPLER AND OTHER PROPERTIES.

· UNDERSTAND GEOMETRY OF MACHINE

The addition of the RotoLoc® Coupler to the backhoe/excavator will change the geometry of the machine. This change should be taken into consideration during operation and travel.

· UNDERSTAND EFFECTIVE REACH OF ATTACHMENTS

The coupler increases the distance between the stick and the attachment. The effective "reach" of the attachment will be increased.

· DETERMINE INTERFERENCE POTENTIAL PRIOR TO USE

Depending on the specific coupler and attachment combination, it may be possible for the attachment to come in contact with the upper structure of the machine (cab, boom, cylinders, etc.). The operator should familiarize themselves with any potential interference locations prior to use.

· MEASURE TRAVEL HEIGHT AND LENGTH PRIOR TO TRANSPORTING

The overall travel height and/or length of the machine may be increased if the coupler and attachment are installed. Do not rely on original machine specifications to determine overall dimensions. Actual dimensions will be affected by specific coupler and attachment combination.

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JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

ROTOLOC® LIFT EYE USAGE

A chain or other device for lifting should never be used on any part of the jrb rotoloc® coupler except the lift eye. Failure to follow this instruction may result in severe injury or death. The JRB RotoLoc® coupler is equipped with a lift eye for moving and placing material. It is designed for the convenience of the operator. It should not be used at the same time as an attachment. Consult your prime mover manufacturers specifications for lifting procedures and capacities. Incorrect applications and uses and failure to follow these instructions may result in severe injury or death. The JRB RotoLoc® is designed with a lift eye that may be used to assist in the lifting and placing of material when properly and safely attached. In order to use the lift eye correctly and safely the attachment must first be removed from the coupler. Not only is this the safe method, it also increases the lifting capacity of the machine. When an attachment is in use with the coupler, the chain, cable or other lifting device can contact it and may cause interference, damage or potential for unexpected release. The lifting device must always be removed when changing attachments. If the device is in the area of the coupler or attachment during coupling, it may cause an incomplete locking of the coupler to the attachment or damage to the coupler and/or the attachment.

TROUBLESHOOTING

PROBLEM Coupler cylinder will not retract. CAUSES Supplemental lock is engaged. SOLUTIONS Lock coupler. Position coupler close to cab to allow the supplemental lock to disengage. Unlock coupler. No hydraulic pressure directed With coupler close to cab. to coupler cylinder. Move control lever to the full curl position and hold until cylinder retracts Loss of electrical current to Check electrical connections. solenoid valve. Check ground connection at solenoid valve. Improper plumbing Check hose connections. Insure that connections are correct according to manual. Debris in coupler cylinder area. Remove debris from coupler and keep clean. Lack of lubrication. Grease all fittings according to maintenance instructions. Cold hydraulic oil. Warm hydraulic oil according to manufacturers recommendations. Cycle coupler several times to allow warm into the system.

Coupler mechanism moves slow.

Troubleshooting

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

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HYDRAULIC ROTOLOC®

WARRANTY POLICY

1

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

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HYDRAULIC ROTOLOC®

RETURNED GOODS POLICY

JRB.

820 Glaser Parkway Akron, OH 44306 1-800-428-2538 RETURNED GOODS POLICY - PARTS/SALES Items shipped in error JRB., will accept returned items, with prior approval of JRB. (see RGA Paragraph below), within thirty (30) days after shipment without a restocking charge, freight collect. Items ordered in error When current parts are incorrectly ordered and returned to JRB., the Customer is responsible for freight costs and a 15% restock fee. When current parts are purchased without a serial number and returned, the Customer is responsible for freight costs and a 15% restock fee. When current parts with a 90 day + shelf life are purchased and returned, the Customer is responsible for freight costs and a 25% restock fee. Non-current and Special Parts items JRB. will not accept returned items, which are special order or used on non-current machines. Service Parts JRB. will accept returned service parts items, which were ordered in error, with prior approval of JRB. (see RGA), within thirty (30) days after shipment with a 25% restocking charge, freight prepaid. RGA - Returned Goods Authorization All return items must have the prior approval of JRB. and be assigned an RGA (Return Goods Authorization) number by either the JRB Sales or Parts Department and must be returned within (30) days of request.

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JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

ROTOLOC® COUPLER COMPONENTS AND SPECIFICATIONS

This section of the manual contains information on the JRB Hydraulic RotoLoc® Coupler based on the manufacturer's specific model. Any questions related to the coupler and its components should be directed to JRB Customer Service at 1-800-428-2538. Attachments operated with the JRB coupler are required to use standard oem pin sizes and pin spacings. Attachments with longer pin centers or smaller pin sizes will result in excessive coupler wear and will void the coupler warranty. Refer to page 20 of this manual to obtain the correct pin spacer information. Using attachments with pin to pin dimensions not within the specifications of this coupler could result in the attachment becoming disengaged. Serious injury or death could result if these instructions are not followed properly

PARTS LIST

ITEM QTY.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 1 1 1 1 1 1 1 1 2 2 2 2 5 1 2 1 1 1 1

PART NUMBER

®

DESCRIPTION

Hydraulic RotoLoc Assembly RotoLoc® Coupler Hydraulic Cylinder Kit Cam Assembly Cam Pin Assembly Hydraulic Cylinder SmartLoc® Arm Grease Zerk Dowel Pin, Pin Kit,, RotoLoc® Pin, Bolt, Nut, Hex, Grease Zerk Serial Number Tag Drive Screw Pin, Moving Hook Pin, Main, Dowel Pin Dowel Pin,

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

1

HYDRAULIC ROTOLOC®

COUPLER ASSEMBLY

9

15 3 14 7 17 6 5 16

2

10 8

3 4 1

9

11 13 12

1

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

HYDRAULIC KIT OVERVIEW

To install the JRB Excavator RotoLoc® Hydraulic Kit correctly, the following basic steps will be taken. · Read instructions thoroughly and heed all cautions contained in this manual. · Install coupler to stick using the pins supplied with the coupler. The original OEM attachment pins must be used in the attachment. · Weld manifold block to stick (if applicable). · Install jump hoses. · Install extend and retract hoses. · Weld hose clamps in place. · Weld solenoid valve mounting plate in place. · Install solenoid valve. · Install supply and return hoses. · Install electrical box in cab. · Route electrical wires to the machine and solenoid valve. · Install warning decals and operator's handbook in a highly · visible location inside the machine cab · Test operation.

TOOLS REQUIRED

· · · · · · · · Standard and metric wrench sets Phillips and flat screwdriver sets Allen wrench sets Grinder for weld preparation Welding machine capable of 7018 low hydrogen process or equivalent Wire crimpers Drill 1/8" Drill Bit

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

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HYDRAULIC ROTOLOC®

SOLENOID VALVE

Valve Assembly:

The valve is comprised of the manifold, spool, check valves, solenoid, shuttle valve, and connector. If necessary, the connector and the solenoid can be purchased separately as replacement items. Position stick so the coupler is resting flat on the ground. With the machine off, move both hydraulic control levers in the cab in such a manner as to relieve pressure in the system. A relaxing of the arm and boom should be noticeable. High pressure hydraulic fluid can cause serious injury or death if not relieved prior to disconnecting hoses or fittings. Note: When handling any hydraulic component, it is important to maintain cleanliness of the component in order to prevent possible contamination of the hydraulic system.

TESTING THE SOLENOID WITH AN OHMMETER

STEP 1: · Remove solenoid from valve assembly and inspect for damage. STEP 2: · Use an ohmmeter to check the resistance of the coil, set meter for low resistance. · Connect positive lead to terminal #1 and negative lead to terminal #2. · The coils resistance should be approx. 30 ohms. · If reading is zero, coil is shorted - replace solenoid. · If reading is infinity, coil is open (broken) - replace solenoid.

ALTERNATIVE METHOD FOR TESTING THE SOLENOID

STEP 1: · Energize the coil by placing switch into the unlock position. STEP 2: · Using a screwdriver or a pocketknife, check for magnetism on the end of the solenoid tube. · If there is no magnetic pull, there is either a wiring problem or the coil is bad.

NOTICE

Damaged seals or incorrect placement could allow valve to malfunction.

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JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

SPOOL ASSEMBLY: Most problems related to the valve are caused by contamination of the

spool assembly. The spool assembly can be removed and cleaned.

SOLENOID VALVE

CLEANING THE SPOOL ASSEMBLY

STEP 1: · Unplug the connector assembly from the solenoid and remove the solenoid from the spool. · Unscrew the spool assembly from manifold and inspect it for contamination and seal damage. NOTE: Any time the valve is serviced, a new spool seal kit should be installed. · Energize the spool with coil outside of body. This should cause the internal spool to shift and is operating properly. STEP 2: · If the internal spool does not shift, use a Phillips screwdriver to push against the internal spool and check for movement (approx. 1/8"). · Loosen the coil retaining nut and retighten to 5 ft. lbs. (a little more than finger tight). · Clean spool and blow out with air and energize spool. · If spool still does not operate properly, replace the spool.

NOTICE

Do not over tighten spool assembly or cap when reinstalling. Torque to 25 ft. Lbs. Maximum. Overtightening can damage spool assembly

Manifold: With the spool and check valves removed, inspect the manifold for contamination.

Flush out the manifold and blow out with air.

COIL VALVE SOLENOID COIL ASSEMBLY

VALVE

RE

CT2

T EX P T

FEMALE PIN HOUSING FROM CABLE ASSEMBLY

T

CT1

Solenoid Valve Assembly DESCRIPTION

ITEM · 1 2 3 4

QTY PART NUMBER 1 1 1 1 1 A32470 A42116 A42117 HM00109 A32811

SOLENOID VALVE ASSEMBLY, 24 VOLT, (Includes all items) Cartridge, 4000 psi, (CT1) Cartridge, 3250 psi, (CT2) Coil Seal Kit

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

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HYDRAULIC ROTOLOC®

LOW PRESSURE HYDRAULIC SYSTEM TESTING

THEORY OF OPERATION: Lock Position

The PR1 cartridge closest to the P port makes sure the inlet pressure into the valve is at a minimum of 4000 PSI . The PR2 cartridge reduces this inlet pressure to 3250 PSI, this fluid is transferred through Solenoid Valve (SV) to the EXT. port of the valve body, to the EXT port of the coupler cylinder. (Note: Each time machine pressure rises over 4000 PSI. the EXT circuit is charged. This maintains a positive force on the locking wedge.) Oil is returned from the RET. Port in the cylinder to the RET port in the valve, through the Solenoid Valve (SV) to the T port then on to the machine oil tank.

Unlock Position

With a minimum of 24 Volts supplied to the coil, the Solenoid Valve is now energized and the spool shifted. The PR1 cartridge closest to the P port makes sure the inlet oil into the valve is at least 4000 PSI. The PR2 cartridge reduces this inlet pressure to 3250 PSI this fluid is transferred through Solenoid Valve (SV) to the RET. port of the valve body, to the RET port of the coupler cylinder. Oil returned from the EXT. Port in the cylinder to the EXT port in the valve, through the Solenoid Valve (SV) to the T port then on to the machine oil tank.

JRB System Test Procedure #1. Electrical

· Turn ignition key to the on position. ( Do not start ). · Move control box switch to the UNLOCK position · The Buzzer and warring light should be on. If the buzzer & light are not on, check the fuse at the control box & wiring to the box. Replace buzzer and light if necessary. · Disconnect the connector for the coils at the JRB control valve. · Using a Volt Meter, check for proper Voltage at the machine side of connector. · Voltage should be a minimum of 24 VDC. · If the Voltage is low or zero check battery condition and repair or replace wiring from control box. · If Voltage is OK, proceed to Coil Test Procedure.

Coil Test Procedure

· · · · Remove Coil from valve assembly and inspect for damage. If the coil housing is cracked or lead wires are broken replace the coil assembly. Use an ohm meter to check the resistance of the coil, set meter for low resistance. Connect positive to terminal #1 and negative to terminal #2. The coil resistance should be approx. 39 ohms. If reading is zero, coil is shorted ­ Replace If there is no reading the coil is open ­ Replace 0 JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

LOW PRESSURE HYDRAULIC SYSTEM TESTING - CONTINUED

Alternate coil test.

· Turn ignition key on (Do not start). · Energize the coil by moving the switch to the unlock position. · Using a small screwdriver, check for a magnetic pull at the end of the solenoid valve at the coil retaining nut. · If there is no magnetic pull, check wiring or replace coil.JRB System Test Procedure #2.

HYDRAULIC ROTOLOC®

Hydraulics

· Position coupler flat on the ground with No attachments. · Turn ignition key on (engine not Running). · Move control box switch from lock to unlock several times. This will help remove most of the trapped pressure in the EXT & RET lines. · Disconnect Ext & Ret lines at the manifold block, Install gauge's between the manifold block and hydraulic Lines using run tee's. (Minimum of 6000 psi gauges). Note: Sitting in operator's seat, the right side is Extend and the left side is Retract. · Start engine and move control lever so that the coupler is in the full curl position. · With the machine at high idle hold the control lever over fully so that the machine is over relief. · Read gauges. EXT. Gauge should read 3250 psi. RET. Gauge should read 0 psi. · If EXT. pressure is lower or higher than 3250 psi. Check upper valve cartridge (PR2) for missing or damaged seals. Replace PR2 Cartridge if necessary. · If EXT pressure is 0 psi Check hose routing per. Owners manual Check Pressure at P port of JRB control valve.(minimum of 4000psi) Check lower valve cartridge (PR1) for missing or damaged seals. · If there is pressure is present at RET. Remove Solenoid Valve, Inspect & clean. Replace if necessary. · Move switch to the unlock position. · With the machine at high idle hold the control lever over fully so that the machine is over relief. · Read gauges. EXT. Gauge should read 0 psi. RET. Gauge should read 3250 psi. · If RET pressure is lower or higher than 3250 psi. Check upper valve cartridge (PR2) for missing or damaged seals. Replace PR2 Cartridge if necessary. Remove Solenoid Valve, Inspect, check for debris & clean. Replace if necessary. · If RET pressure is 0 psi : Check hose routing per. Owners manual Check Pressure at P port of JRB control valve.(Minimum of 4000psi) · If there is pressure is present at EXT. Remove Solenoid Valve, Inspect & clean. Replace if necessary

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HYDRAULIC ROTOLOC®

LOW PRESSURE HYDRAULIC SYSTEM TESTING - CONTINUED

Cylinder & Cylinder Check Valve Test

· Position coupler flat on the ground with No attachments. · Turn ignition key on ( engine not Running ). · Move control box switch from lock to unlock several times. This will help remove most of the trapped pressure in the EXT & RET lines. · Disconnect Retract line at the manifold block, Install gauge between the manifold and hydraulic Line using a run tee. ( Minimum of 6000 psi gauges ). Note: Sitting in operator's seat, the left side is Retract. · Disconnect Extend jump hose at manifold block & cap fitting in manifold. · Route Extend hose end out between coupler and linkage into a container suitable to catch oil. Pressurized oil will escape through open hose end into container while coupler cylinder rod is moving · While holding the Extend hose in the container, have an operator slowly rotate coupler to the full curl position and stop. Make sure that gauge and hose are clear of linkage during coupler movement. · Move the control box switch to Unlock. Have operator slowly move control lever to the full curl position and over relief. · The Retract gauge should read 3250 psi. · After the coupler cylinder rod has fully retracted, there should be no oil present at Extend hoses end. · If oil is flowing out of the Extend hose.Remove and inspect check valve in the cylinder. Inspect seals, back up rings and plunger for debris. Repair or replace as required. High pressure oil may be trapped behind check valve, use caution when removing. · Coupler cylinder packing worn or damaged. Cylinder has internal damage. Repair or replace as required.

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

HYDRAULIC SCHEMATIC ROTOLOC® COUPLER

HYDRAULIC RESERVOIR

+V

RET

F012504K

SWITCH R

COUPLER CYLINDER

MAIN PUMP

CT4 CT1 CT2 CT3 SOLENOID VALVE

EXT E

SYSTEM SHOWN IN "LOCKED" POSITION SOLENOID IS NOT ACTIVEATED.

The JRB hydraulic circuit schematic drawing shown is in the LOCKED position (no electrical power to solenoid). System pressure is applied to the valve by the machines main hydraulic pump, the bucket circuit is also pressurized through the main control valve. System pressure is transferred through valve port "P" to sequence valve CT1. CT1 remains closed until the bucket cylinder pressure reaches 4000 PSI or over. At 4000 PSI CT1 opens and allows a maximum of 3250 PSI to be transferred through sequence valve CT2, valve CT3 and charges the head end of the coupler cylinder. The system maintains a positive force on the locking plate at all times while the bucket cylinder is pressurized. With the switch in the UNLOCK position (electrical power applied CT3). Pressure is transferred through CT1, CT2, CT3 and energizes the rod-end of the coupler cylinder to retract the coupler locking plate. Hydraulic fluid from the head end of the coupler cylinder moves through the "EXT" port back through CT3 and drains into the hydraulic reservoir. Note: The RotoLoc® Coupler is designed to be locked when there is no electrical power. In other words, the coupler is locked by default. Electrical power is required to unlock the coupler.

THEORY OF OPERATION

· For the circuit to operate correctly there must be certain hydraulic oil pressure through the

POST INSTALLATION TESTING

system. In order to verify there is correct pressure a gauge with a minimum of 6,000 psi rating must be used to: · First test the pressure of the machine before it enters into the coupler system. Each OEM has a predetermined operating pressure that JRB has used to make the coupler function. If the machine pressure is not within the range given by the OEM then the coupler could potentially not work or malfunction. Always run the machine at the OEM suggested pressure.

· Test the pressure in the extend line of the lock cylinder, with control box in lock position and

the bucket cylinder fully extended to over-relief condition. The operating pressure of the coupler circuit should be 3250 psi. JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

MAINTENANCE

The following maintenance procedure should be performed in order to maintain proper operation of the JRB excavator coupler hydraulic kit. PROCEDURE

Remove debris from coupler

INTERVAL

At each interchange

NOTES

Primarily in lock area prior to engaging attachment. Also clear debris from the Supplemental lock arm area. Both primary and supplemental

Inspect Locking Inspect hoses for leaks Grease zerk fittings Unlock coupler mechanism Check Supplemental lock mechanisms for wear or broken spring, (SmartLoc®). Tighten pin hardware Replace seals in valves Maintenance Procedures

At each interchange Daily Daily Daily Weekly

To prevent binding. During normal operation, the SmartLoc® arm may become worn. Replace when worn. If the bolt is out, the pin can slide out of one side of the coupler and cause the pin-on-rib to break.

Weekly 1500 hours

TROUBLESHOOTING

CAUSES Supplemental lock is engaged. SOLUTIONS Lock coupler. Position coupler close to cab to allow the supplemental lock to disengage. Unlock coupler. No hydraulic pressure directed With coupler close to cab. to coupler cylinder. Move control lever to the full curl position and hold until cylinder retracts Loss of electrical current to Check electrical connections. solenoid valve. Check ground connection at solenoid valve. Improper plumbing Check hose connections. Insure that connections are correct according to manual. Debris in coupler cylinder area. Remove debris from coupler and keep clean. Lack of lubrication. Grease all fittings according to maintenance instructions. Cold hydraulic oil. Warm hydraulic oil according to manufacturers recommendations. Cycle coupler several times to allow warm into the system.

PROBLEM Coupler cylinder will not retract.

Coupler mechanism moves slow.

Troubleshooting

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

SERVICEABLE PARTS

It may be necessary in some applications that use of a gauge port block is required for hydraulic"tiein". This chart provides dimensions and JRB part numbers for ordering purposes if your kit requires such a component.

3000 SERIES PIPE - CODE 61 - GAUGE PORT ADAPTER

PIPE DASH JR B SIZE NUMBER NUMBER

1/2 3/4 1 1-1/4 1-1/2 2 01 02 03 04 05 06 46107-01 46107-02 46107-03 46107-04 46107-05 46107-06

A

1.50 1.75 2.00 2.50 2.75 3.25

B

2.12 2.62 2.82 3.19 3.75 4.00

C

1.00 1.00 1.00 1.00 1.00 1.00

D

1.50 1.875 2.062 2.312 2.75 3.062

E

.688 .875 1.031 1.188 1.406 1.688

F

.50 .75 1.00 1.25 1.50 1.94

G

.34 .41 .41 .47 .53 .53

L

1.00 1.25 1.75 2.50

"O" RING

46117-11 46117-12 46117-14 46117-16

1.562 46117-13 2.125 46117-15

3000 Series Pipe Specifications

6000 SERIES PIPE - CODE 62 - GAUGE PORT ADAPTER

PIPE DASH JR B SIZE NUMBER NUMBER

1/2 3/4 1 1-1/4 1-1/2 2 12 13 14 15 16 17 46107-12 46107-13 46107-14 46107-15 46107-16 46107-17

A

1.75 2.00 2.25 2.75 3.25 4.00

B

2.22 2.81 3.19 3.75 4.50 5.25

C

1.00 1.00 1.00 1.00 1.00 1.00

D

1.594 2.00 2.25 2.625 3.125 3.812

E

.718 .937 1.093 1.25 1.437 1.75

F

.50 .75 1.00 1.25 1.50 1.94

G

.34 .41 .47 .53 .66 .78

L

1.00 1.25 1.562 1.75 2.125 2.50

"O" RING

46117-11 46117-12 46117-13 46117-14 46117-15 46117-16

6000 Series Pipe Specifications

Note: All o-rings must have a 90 durometer hardness.

A E .44 G

(5) .44 DIA. THRU 1/4-NPTF

F

.155 .175

B

D

L

C

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

SEAL-LOK AND SAE FITTINGS

DASH SIZE -4 -6 -8 -10 -12 -16

O-ring Table

O-RING (SEAL-LOK) 46161-01 46161-02 46161-03 46161-04 46161-05 46161-06

O-RING (SAE) 46117-01 46117-03 46117-04 46117-05 46117-06 46117-07

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

HYDRAULIC KIT INSTALLATION

Read and follow all safety and precautionary notes included in this text. Read all installation instructions before beginning actual installation. Any questions related to the installation of this kit should be directed to JRB Customer Service at 1-800-428-2538. Coupler Installation: (see Coupler Manual) · · Install coupler onto stick using original equipment pins and pin lock hardware. The pins which come with the coupler must be used in the attachment. Extend stick and lower boom to position the coupler flat on the ground. Failure to position coupler flat on the ground may allow movement of the bucket cylinder during installation which could cause dangerous spray and loss of hydraulic fluid. Escaping fluid could cause serious injury or death. Preparation: · · · · Relieve tank pressure prior to "tie-in" to hydraulic system. Disconnect positive lead from battery terminal. Unplug the computer, not all machine models are equipped with a computer. Check all new hoses and make sure they are not plugged by any debris which may have entered during manufacturing or shipping.

NOTICE

Position coupler and attachment prior to battery disconnection failure to disconnect battery terminal and computer could result in damage to the electronic system during welding operations. Do not allow spatter from welding operations to damage hydraulic cylinder rods. The JRB excavator must not be used with any hydraulic kit other than the one provided by JRB. The JRB hydraulic kit has been extensively studied and tested, for both efficiency and safety, using the JRB excavator coupler. The hydraulic kit has not been studied or tested using any other coupler. Since couplers vary in aspects, JRB cannot know whether the JRB hydraulic kit may be operated safely with a coupler that is not its own. Because of the unknown characteristics of any other hydraulic system, JRB takes no responsibility for the safety of a JRB hydraulic kit if it is operated with a coupler other than the one provided by JRB. The JRB hydraulic kit should be operated only with the JRB excavator coupler. JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

ELECTRONICS INSTALLATION

PREPARATION: · First test the pressure of the machine before it enters into the coupler system. Each OEM has a predetermined operating pressure that JRB has used to make the coupler function. If the machine pressure is not within the range given by the OEM then the coupler could potentially not work or malfunction. Always run the machine at the OEM suggested pressure. · Test the pressure in the extend line of the lock cylinder, with control box in lock position and the bucket cylinder fully extended to over-relief condition. The operating pressure of the coupler circuit should be 3250 psi. Disconnect positive lead from battery terminal. · Unplug the computer, not all machine models are equipped with a computer. Failure to disconnect battery terminals and computer could result in damage to the electrical system during welding operations. · The switch box should be mounted in a location of the cab where the operator can conveniently work the switch and see the light. Although a locking style toggle switch is used, the box should be mounted where the switch will not be inadvertently hit. Check all hydraulic fittings and electrical connections for tightness prior to NOTICE initial operation.

NOTICE

ITEM QTY PART NUMBER 1 A28827 · 1 A28828 1 A28829 1 A22113 1 A18182 1 A25945 1 EM00016 1 A25940 2 106003480038 2 162003000000 2 143003480000 1 A28843 1 148006320000 4 216060320038 1 A22114 1 A28842

ELECTRICAL PARTS LIST

DESCRIPTION ELECTRICAL BOX ASSEMBLY (includes Items 1-15) Front Cover Rear Cover Light Assembly, Red Indicator, 24V Toggle Switch Assembly Fuse Holder, Panel Mount Fuse, 3 AMP AGC 1/4"x 1-1/4" Buzzer, 24V-400Hz Screw, SHCS 3-48 x 3/8" Lock washer, #3 Hex Nut, 3-48 Bridge Rectifier, 15A Locknut, 6-32 Machine Screw, Metric, 6-32 x 3/8" lg. Decal (Lock / Unlock) Wire Harness Assembly, Internal Screw, Hex Head CTNG, #10-24 x 3/4, Electrical Bracket Mounting Bracket, Electrical Box Cable Assembly Pin Housing, Female Pin, Female Connector Seals, Rubber Grommet

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

ELECTRICAL SCHEMATIC AND ASSEMBLY

+V

BUZZER LAMP WHITE TOGGLE SWITCH

HYDRAULIC ROTOLOC®

GND

FUSE 3 AMP

BLACK BLACK

BLACK BLACK

CONNECTOR (2 POSITION)

BLACK RED

AC

BRIDGE RECTIFIER

WHITE

WHITE WHITE

RED RED

TOGGLE SWITCH DIODE

AC

RED RED

LAMP

FUSE ASSY. RED BLACK

BUZZER

BLACK

SOLENOID

ELECTRICAL BOX

SCHEMATIC

WIRING DIAGRAM

T va o ma lve le so plu len g o oid f co il a sse

19

mb ly

20

21

10 9 7 8 15 5

2

13

WH ITE BL AC K

(cable assembly) 18

D RE

D RE

15

BL

AC

F012511a

SPLICE CAP

WHITE WHITE

CONNECTOR (3 POSITION)

SPLICE CAP

K GR

B

4 1 12 11

CK LA ITE WH

5

RE

6

D

TO TO

OU

ND

+V

T OL

BL AC K

RE D

14

LO CK JR UN LO CK B CO UP LE R

SEE DETAIL "B"

3

Standard 24 v light bulb Unscrew cover for bulb access

LO CK

NL OC K RB CO UP

LE R

DETAIL "B"

Bulb Replacement

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

ATTACHMENT PICK UP CHART

ROTOLOC® WHEEL LOADER/BACKHOE CLASS SPACER CHART

MANUFACTURER MODEL 310E, 310G 310SE, 310SG 315SG 410E, 410G WB140, WB150

John John John John

Deere Deere Deere Deere

STICK PIN DIAMETER 1.75" 2.15" 2.15" 2.15" 1.57"

LINK PIN DIAMETER 1.50" 1.95" 1.95" 1.95" 1.57"

SPACER PART NO. A39485 A39486 A39486 A39486 N/A

Komatsu Komatsu Case Case Caterpillar Caterpillar Caterpillar JCB JCB JCB New Holland New Holland Ford

580L, 580M 890L, 590M 416C, 416D 420D 426D 214E, 214SE 215E 217 SERIES 555E LB75, B 555D

1.75" 1.75" 1.97" 1.97" 1.97" 1.75" 1.75" 1.75" 1.77" 1.77" 1.77"

1.50" 1.50" 1.77" 1.77" 1.77" 1.75" 1.75" 1.75" 1.77" 1.77" 1.77"

N/A N/A A39487 A39487 A39487 N/A N/A N/A A40470 A40470 A40470

0

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

ATTACHMENT PICK UP CHART

ROTOLOC® 20000 CLASS SPACER CHART

MANUFACTURER MODEL 80LC EC55 CS75SR 9007B SK60-IV SK70SR SK80CS 307, 307B, 307C 308C E70, E70B JS70 PC60 PC80 PC90 PC95 PC95R-2 LS1600Q SPACER REQUIRED YES NO SPACER PART NO.

John Deere Volvo Case Case Kobelco Kobelco Kobelco Caterpillar Caterpillar Caterpillar JCB Komatsu Komatsu Komatsu Komatsu Komatsu Linkbelt

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

1

HYDRAULIC ROTOLOC®

OEM ATTACHMENT PICK UP SPACER CHART

ROTOLOC® 25000 CLASS SPACER CHART

MANUFACTURER MODEL CX130 CX135, 9010B 110 120LC 12C LC EX 110 EX 120 SK115SR SK120-4 SK130IV SK135SR ED150 PC100 PC120 PC128 PC138 PC158 2550C II LC2650Q SE130 EC130 EC140 X X X A44482-18 X X X X X X X A44482-18 SPACER REQUIRED YES NO X X X X X X X X X X X X A44482-38 A44482-38 A44482-38 A44482-38 A44482-38 A44482-19

SPACER PART NO.

Case Case John Deere John Deere John Deere Hitachi Hitachi Kobelco Kobelco Kobelco Kobelco Kobelco Komatsu Komatsu Komatsu Komatsu Komatsu Linkbelt Linkbelt Samsung Volvo Volvo

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

OEM ATTACHMENT PICK UP SPACER CHART

ROTOLOC® 35000 CLASS SPACER CHART

MANUFACTURER MODEL CX160, 9020B CX210, 9030B 315L, 316 320 "B", 322 "B" 160LC, CLC EX150, EX160 JS160 JS200 SK150 SK200 SK210 SK235SR PC150, 170 PW170 PC200 PC220 PC250 PC270 PC290 2700Q 210LX 2800Q X X X X X X X X X X X X X X X X X X X SPACER REQUIRED YES NO X X X A44482-23 A44482-22 A44482-22 A44482-20 A44482-22 A44482-21 A44482-25 A44482-25 A44482-25 A44482-24 A44482-24 A44482-25 A44482-25 A44482-25 A44482-25 A44482-25 A44482-20 A44482-22 A44482-22 SPACER PART NO. A44482-20 A44482-22

Case Case Caterpillar Caterpillar John Deere Hitachi JCB JCB Kobelco Kobelco Kobelco Kobelco Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Komatsu Linkbelt Linkbelt Linkbelt

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

OEM ATTACHMENT PICK UP SPACER CHART

ROTOLOC® 45000/55000 CLASS SPACER CHART

MANUFACTURER MODEL 9030B, CX210 9040B, 9040B, CX240 318B 320B, 322B, 322S 324DL "CB" 320C, 325C, 330C 325B 330D Solar 225-5 200LC, 690E 230LC, 270LC, 790E R210LC-7 R290LC-3 JS200 SK200, SK210, SK235SR SK220, SK250, SK270 PC200, PC220, PC250 PC270, PC290 PC300 2800Q, 210LX EC240LC SE200, SE210 SE210-3 SE240LC-3 EC210 EC240BLC EC290BLC X X X X X X X X X X X X X A44482-37 A44482-5 A44482-33 A44482-2 A44482-33 A44482-2 A44482-1 X X X X A44482-33 A44482-36 A44482-33 A44482-33 A44482-4 X X X X x X A44482-1 A44482-20 A44482-29 SPACER REQUIRED YES NO X X X X A44482-6 A44482-3 A44482-3 A44482-2 A44482-20 SPACER PART NO. A44482-36 A44482-3

Case Case Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Caterpillar Daewoo John Deere John Deere Hyundai Hyundai JCB Kobelco Kobelco Komatsu Komatsu Komatsu Linkbelt New Holland Samsung Samsung Samsung Volvo Volvo Volvo

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

OEM ATTACHMENT PICK UP SPACER CHART

ROTOLOC® 70000 CLASS SPACER CHART

MANUFACTURER MODEL CX330, 9050, 9050B CX450, CX460 9060, 9060B 330D 330E 230LC 270LC 330LC 790E JS330 JS450 SK300 I, II, III SK300, IV SK330-6 PC300LC-5 PC400LC-5 330LX, LS4300Q LS5800Q SE240LC-3 EC240B LC, EC360B X X X X X SPACER REQUIRED YES NO X X X X X X X X X X X X X X X A44482-10 A44482-8 A44482-31 A44482-7 A44482-32 SPACER PART NO. A44482-8 A44482-31 A44482-31 A44482-6 A44482-12 A44482-9 A44482-9 A44482-11 A44482-9 A44482-8 A44482-31 A44482-7 A44482-7 A44482-7

HYDRAULIC ROTOLOC®

Case Case Case Caterpillar Caterpillar John John John John JCB JCB Kobelco Kobelco Kobelco Komatsu Komatsu Linkbelt Linkbelt Samsung Volvo Deere Deere Deere Deere

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

OEM ATTACHMENT PICK UP SPACER CHART

ROTOLOC® 100000 CLASS SPACER CHART

MANUFACTURER MODEL 9060, 9060B CX450, CX460 345, 350 "F" 350G 450LC JS450 SK400-IV, SK480-6 LS5800Q SE450LC-3 EC460B X X X X X X X SPACER REQUIRED YES NO X X X A44482-17 A44482-15 A44482-14 A44482-39 A44482-14 A44482-16 A44482-16

SPACER PART NO. A44482-14 A44482-14

Case Case Caterpillar Caterpillar John Deere JCB Kobelco Linkbelt Samsung Volvo

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

HYDRAULIC ROTOLOC®

PREVENTATIVE MAINTENANCE OR REPAIR PROCEDURE

PREVENTATIVE MAINTENANCE OR REPAIR PROCEDURE RotoLoc® COUPLER REMOVE AND REINSTALL

RotoLoc® Assembly

SERVICE TIME (HOURS)

Rotolocrepair

JRB CUSTOMER SERVICE MAINTENANCE AND REPAIR GUIDE

Information

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