PosiGrab Hydraulic Coupler. Installation and Operation Instructions

Transcription

1 PosiGrab Hydraulic Coupler Installation and Operation Instructions For PosiGrab Couplers Shipped Prior to April 15, 2015

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3 Table of Contents PosiGrab Hydraulic Coupler Installation Instructions Installation Safety 5 General Safety Information 5 Signal Words 5 Personal Safety 5 Installation Procedures 1. Visual Inspection 6 2. Read the Instruction Manual 6 3. Remove Attachment 6 4. Coupler Pins 6 5. Remove the O-Ring Seals 6 6. Mount the Coupler to the Stick 7 7. Install the OEM Pins 7 8. Safety Check 7 9. Positioning the Machine Arm Connect the Hydraulic Hoses to the Coupler Locate the Hose Clamps Manifold Attachment (Optional) Corrosion Protection Installation of Stick Hoses Locate the Solenoid Valve Assembly Hose Connections to the Solenoid Valve Connection to Port X Hose Connections to the Machine Pump Control Box Installation Control Box Harness Installation Grease the Coupler Lifting Check Coupler Operation 11 PosiGrab Hydraulic Coupler / Hydraulic and Electrical Schematic Control System A 12 Electrical Connection 13 3

4 Table of Contents PosiGrab Hydraulic Coupler Operation Instructions Operation Safety General Safety Information 14 Signal Words 14 Personal Safety 14 PosiGrab Coupler Safety Procedures 14 Introduction 16 Operating Instructions 17 Pickup Bucket/Attachment Procedure 17 Bucket/Attachment Release Procedure 20 Daily Inspection and Maintenance 21 Maintenance Schedule 22 Maintenance Log 23 Parts List Ordering Spare Parts 24 Troubleshooting Guide 25 Important: For questions regarding installation or operation of the ESCO PosiGrab coupler, call the ESCO Tech Line

5 Safety General Safety Information The safety practices described in this manual are meant as guidelines for safe operation under most conditions and are meant to supplement any safety rules and/or laws that may be in force in your area. Your safety and the safety of others results from putting into practice the correct operating procedures. Read this entire manual prior to conducting the maintenance procedures described in this manual. Signal Words Throughout this manual are statements preceded by a special attention symbol:. The symbol is used with the following signal words to attract your attention to information of special priority. Read the paragraphs carefully and make sure you understand their significance, especially the possible causes of injury or death. WARNING: A statement preceded by WARNING is information that should be acted upon to prevent serious injury or death. CAUTION: A statement preceded by CAUTION is information that should be acted upon to prevent machine or equipment damage. Safety Procedures WARNING: To guarantee satisfactory and safe operation of the equipment, the ESCO PosiGrab Hydraulic Coupler must be installed and fitted by trained personnel only. Installation of the coupler must be in accordance with the instructions provided in this manual. Any deviation from the instructions given here needs to be authorized by ESCO. WARNING: Any difficulty or doubt with interpretation of the installation instructions in this manual should be resolved between the technician and ESCO before proceeding any further. WARNING: Never attempt to modify the ESCO PosiGrab Coupler or the attachment which it will be used with without receiving approval from ESCO. Unauthorized modification of the coupler or the host machine can seriously impair the performance of the equipment and could cause serious injury or death. WARNING: The following precautions must be taken prior to any work on the coupler. Failure to follow these precautions could cause serious injury or death. Ensure the engine of the excavator is off before proceeding with installation. Welding Ensure area is ventilated and battery is disconnected from machine. Proper personal protection equipment (PPE) suitable for welding must be worn at all times. Environmental Safety Please take precautions to avoid any accidental spillage of hydraulic fluids. Additional signal words that are not preceded by the attention symbol are: IMPORTANT: A statement preceded by the word IMPORTANT is information that possesses special significance. Tip: A statement preceded by Tip is information that is handy to know and may make your job easier. Personal Safety WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 5

6 PosiGrab Hydraulic Coupler Installation Procedures IMPORTANT: The following tools are required for the installation of the ESCO PosiGrab Hydraulic Coupler. A. Lifting gear that includes a suitably sized hoist, chains and straps to maneuver the coupler during installation to the host machine. B. A complete set of technician tools. IMPORTANT: The installation of the PosiGrab Hydraulic Coupler is a job for at least two people. One should be a fully qualified technician. 1. Visual Inspection Visually inspect the PosiGrab Coupler and its accessories. Check the packaging for any damage which might have occurred in transit. Check that all items have been delivered. If you encounter anything that appears to be damaged, missing or incorrect, contact ESCO before you proceed any further. 2. Read the Instruction Manual If you have NOT done so already, READ THIS MANUAL in full before proceeding with any part of the installation. WARNING: Failure to read and understand the full contents of this manual may result in improper installation, operation or maintenance of the of the PosiGrab coupler that could lead to serious injury or death. 3. Remove Attachment Before starting with the installation of the coupler you must remove the existing attachment (e.g., bucket) from the machine by removing the OEM pins. IMPORTANT: Set the OEM pins aside, including the bolts and lock nuts that hold the pins in place, for use to attach the coupler to the machine in Step 7. Ensure the joint area of the machine stick and the bucket are thoroughly cleaned. 4. Coupler Pins Remove pins which have been installed in the PosiGrab coupler prior to delivery. IMPORTANT: These pins are to be saved for installation in the bucket or attachment that will be attached by the coupler. 5. Remove the O-Ring Seals Remove the O-ring seals from the existing attachment. Check to ensure they are in good condition and replace if necessary. Clean them and temporarily place them over the coupler bushings as shown in Figure 1. Figure 1 WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g., OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 6

7 6. Mount the Coupler to the Stick Position the coupler with the stick so the pin holes are properly aligned to allow installation of the pins as shown in Figure 2. CAUTION: It may be necessary to use some spacer shims between the stick and/or linkage and the inside of the coupler to eliminate any gaps that would cause excess movement. Shims are NOT included in the kit provided by ESCO. 7. Install the OEM Pins Install the OEM pins previously removed in Step 3. Grease the pins and bushings and secure the pins with the bolts and lock nuts removed earlier. Move the O-rings to position them between the machine bushings and the coupler bushings. Double-check to ensure they fit correctly. 8. Safety Check Check that the coupler is fitting correctly by maneuvering it with the machine (curling the coupler both fully inwards and outwards) and at the same time watching for any interference or resistance to movement (see Figure 3). WARNING: If there are any concerns with the smooth functioning of the PosiGrab coupler, including but not limited to, interference with the hoses, stick attachments or other components, DO NOT attempt any modifications. Contact ESCO for instructions on how to proceed. 9. Positioning the Machine Arm Extend the machine arm to its full length, and position it as low to the ground as possible while extending the bucket cylinder. The coupler should be set level with the ground. WARNING: Before attempting any of the following steps the machine s hydraulic system must be depressurized. Excavator hydraulic systems operate under very high pressure. Failure to take precautions could result in serious injury or death. Consult the machine manual for instructions to relieve the pressure in the hydraulic tank with the pressure relief valve similar to the one shown in Figure 4. IMPORTANT: A complete schematic of the hydraulic system required by the PosiGrab coupler is shown on page 12 of this manual. Refer to this schematic for clarification of connections as needed. Figure 2 Figure 3 Figure 4 7

8 10. Connect the Hydraulic Hoses to the Coupler Connect the three short hoses, one each to the coupler cylinder ports marked A and B, and then port marked C on the small rear lock cylinder as shown in Figure 5. Also refer to the Hose Kit Installation Instructions. IMPORTANT: Connect the hoses at the coupler locations first and work back to the pump housing. 11. Locate the Hose Clamps The short hoses coming off of ports A, B and C of the coupler will connect to the longer hoses on the machine stick just above coupler. IMPORTANT: The standard method uses hose clamps on either side of the coupling between the short hoses and the ones that run the length of the machine stick. An optional method is the use of a manifold attached to the stick. All hydraulic hoses for the coupler are connected using the manifold. Step 12 provides instructions for this option. The hydraulic hoses need enough length to extend when the bucket is in full curl. Fully curl the coupler when positioning the hose clamps and mark the location on the hoses where they will pass through the clamps to allow enough length of hose. Please note that excessive length can lead to abrasion of the hoses or allow the hoses to extend into pinch points. Check for excessive length with the coupler fully extended. Once the correct length of the hoses is determined and properly secured, tie-wrap the hoses together for additional protection. CAUTION: Failure to properly adjust the length of the hydraulic hoses and check for pinch points may lead to severe damage to the hoses or the coupler cylinders. Space the clamps evenly on the top face of the stick just above the coupler on either side of the hose connections. Using the clamp bases as a template, mark the area where the clamps will be attached. Remove paint and other foreign material from the area where weld will be applied to mount the clamps in place. Weld the clamp bases to the machine. Refer to Figure 6. CAUTION: Isolate the machine's electrical system prior to any welding. Failure to do so could lead to serious damage to the machine s on-board computer system. CAUTION: Weld applied perpendicular to the length of the machine stick should be in short segments and should never be applied closer than 50mm/2.00in. to the edge of the stick. Weld applied near the edge of the stick must be applied parallel to the length of the stick. Weld applied perpendicular to the stick near the edge could weaken it and lead to cracking or failure. Port B: Main cylinder retract Port A: Main cylinder extend Figure 5 Figure 6 Port C: Rear lock cylinder 8

9 12. Manifold Attachment (Optional) If it is decided to use a manifold to connect the hoses, locate the manifold where it will be attached. Using the manifold base as a template, mark the area where the base will be attached. Remove paint and other foreign material from the area where weld will be applied to mount the base. Weld the manifold base to the machine and attach the manifold to the base with the bolts supplied. Refer to Figure 7. CAUTION: Weld applied perpendicular to the length of the machine stick should be in short segments and should never be applied closer than 50mm/2.00in. to the edge of the stick. Weld applied near the edge of the stick must be applied parallel to the length of the stick. Weld applied perpendicular to the stick near the edge could weaken it and lead to cracking or failure. CAUTION: Isolate the machine's electrical system prior to any welding. Failure to do so could lead to serious damage to the machine s on-board computer system. 13. Corrosion Protection Use an appropriate paint to protect all welded areas from corrosion. 14. Installation of Stick Hoses Connect the long hoses marked Hoses on Boom to the short hoses between the clamps installed in Step 11, or using the optional manifold installed in Step 12. The hoses are color-coordinated. If the clamps were used, a clamp should be on either side of the union connection. If the manifold is used, all the hoses need to be connected by attaching them to the manifold. With the hoses attached, tie-wrap the remaining length of hose to the machine s existing hydraulic hose all the way to where the stick attaches to the machine. Refer to Figure 8. Figure 7 Figure 8 WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g., OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 9

10 15. Locate the Solenoid Valve Assembly Noting the length of hose left at the end of the stick, select a location to mount the solenoid valve assembly where the hoses can reach it easily. The valve assembly is mounted by drilling two suitably sized mounting holes and securing it in place with two bolts. IMPORTANT: Position of valve assembly will vary depending on the machine. Two example locations of valve assemblies are shown in Figure 9. The appearance of the valve assembly valve may vary from one manufacturer to another but the basic instructions are the same. 16. Hose Connections to the Solenoid Valve Once the valve is attached, the hoses extending from ports A, B and C of the coupler cylinder and along the machine stick, should be connected to the A, B and C ports of the solenoid valve. The A, B and C ports on the valve are marked. Refer to the installation instructions provided with the Hose Kit. 17. Connection to Port X Connect the brown-banded hydraulic hose to the port marked X on the solenoid valve. Route the end of the brown-banded hose to the line to extend the bucket. Use the elbow fitting as provided in the Hose Kit. Disconnect the extend line and fit the adapter tee. Connect the elbow end of the brown line to the side of the bucket extend line adapter. The configuration varies by machine. Refer to Figure 10 for some examples. 18. Hose Connections to the Machine Pump Connect the red-banded hose between the ports marked P on the Valve Assembly and to the pressure test port on the machine hydraulic pump shown in Figure 11. The appearance of the test port may vary from one manufacturer to another. Connect the green-banded hose to the port marked T on the solenoid valve to a suitable outlet on the machines hydraulic tank. It may be necessary to "TEE" into an existing feed from the tank. A separate drain line is preferred for best performance. Figure 9 Figure 10 Test port Figure 11 WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g., OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 10

11 19. Control Box Installation The control box for operation of the coupler, shown in Figure 12, can now be installed in the machine cab. Select a suitable position for mounting the control box for easy operator access. Attach the control box using the adhesive pad provided. 20. Control Box Harness Installation The control box is supplied with a pre assembled harness which has three cables that attach to the control box. Refer to the schematic on pages 12 and 13 for connection locations to attach the harness to the machine s electrical system. 21. Grease the Coupler Grease the coupler at all designated greasing points. Refer to the PosiGrab Coupler Operating Instruction portion of this manual for location of the greasing points. Figure Lifting Check The technician must check that the machine complies with the lifting regulations. Refer to the machine owner s manual for lifting information and the Safe Working Load (SWL). WARNING: Always check the excavator manual for the machine SWL as this determines the lifting capacity of the machine. This SWL must never be exceeded under any circumstance which may lead to serious injury or death. 23. Coupler Operation Prior to initial use of the coupler, check all systems and connections, and make adjustments as needed. Refer to the PosiGrab Coupler Operating Instruction portion of this manual for use on the coupler to pick up, operate and release attachments. CAUTION: Prior to operation of the PosiGrab coupler, be sure the hydraulic pressure relief valve is closed, and reconnect the machine s electrical system. The coupler will not operate properly and system damage may occur. WARNING: Prior to operation of the PosiGrab coupler, check all hydraulic connections for leaks and repair as needed. Hydraulic fluid leaks under high pressure may lead to serious injury or death. WARNING: Do not operate the PosiGrab coupler without completely reading the owner s manual. Improper use of the coupler may lead to serious injury or death. Important: For questions regarding installation or operation of the ESCO PosiGrab coupler, call the ESCO Tech Line

12 PosiGrab Hydraulic Coupler Hydraulic and Electrical Schematic Control System A FOR DETAILED ELECTRICAL CONNECTIONS, REFER TO PAGE

13 Electrical Connection Ensure all work is carried out in accordance with applicable standards and by suitably qualified personnel. Power IN: Brown: Positive Input (12-24 Volts DC) Blue: 0V Solenoid Valve: Green: Solenoid Positive Input Blue: Solenoid 0V (Connect to Terminal G1 on DIN Connector) CAUTION: Ensure input supply voltage matches the coil voltage of the solenoid value. Failure to do so may lead to damage to the electrical system or other equipment components. Control Function Following are the basic control functions. Refer to the PosiGrab Coupler Operating Instructions portion of this manual. On the unit power up (Vehicle Power Up) buzzer will sound continuous for two seconds. While the system is idle the power indicator flashes slowly GREEN. At any time the POWER key can be pressed to turn the system OFF and return it to its idle state. To turn the system ON press the POWER key. The power LED will illuminate green and remain lit, and an audible alarm will sound continuously for five seconds. The unit will automatically Lock-Out if no further action is taken within five seconds, and return to its idle state, where the power LED flashes slowly. Press the CONTROL key within five seconds of pressing the POWER key. The output to the solenoid will be activated (ON), the Control LED will flash Red and an audible alarm will sound intermittently. The power LED will remain continuously illuminated green. After one minute the unit will return to its idle state, unless the CONTROL key is pressed again within the last five seconds. The audible alarm and visual indicator will turn to continuous mode to indicate the approaching end of action time. To cancel the operation and make the unit safe, press the POWER key again. Note: This will remove the power supply to the solenoid valve, silence the audible alarm and switch off the power LED. 13

14 PosiGrab Hydraulic Coupler Operation Instructions Safety General Safety Information The safety practices described in this manual are meant as guidelines for safe operation under most conditions and are meant to supplement any safety rules and/or laws that may be in force in your area. Your safety and the safety of others results from putting into practice your knowledge of the correct operating procedures. Signal Words Throughout this manual are statements preceded by a special attention symbol:. The symbol is used with the following signal words to attract your attention to information of special priority. Read the paragraphs carefully and make sure you understand their significance, especially the possible causes of injury or death. WARNING: A statement preceded by WARNING is information that should be acted upon to prevent serious injury or death. CAUTION: A statement preceded by CAUTION is information that should be acted upon to prevent machine damage. Additional signal words that are not preceded by the attention symbol are: IMPORTANT: A statement preceded by the word IMPORTANT is information that possesses special significance. Tip: A statement preceded by Tip is information that is handy to know and may make your job easier. Personal Safety WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g, OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. PosiGrab Coupler Safety Procedures 1. As a new owner and operator of the PosiGrab Hydraulic Coupler, it is very important to take time to acquaint yourself with the main features of the coupler and the requirements for its safe operation and maintenance. WARNING: It is very important to study the contents of this booklet very carefully and be fully familiar with its contents before putting the coupler to work. Improper use of the coupler could cause serious injury or death. IMPORTANT: This manual should be kept in the host excavator at all times after the installation of the ESCO PosiGrab Coupler. Operators should be fully trained with regards to all aspects of this type of coupler. 2. Great care must be taken when working on or with the PosiGrab coupler. Never attempt to work on, or conduct maintenance to this product without first ensuring that it has been made safe, and that the machine to which it is attached is switched off and locked out. 3. In the case of a hydraulically operated coupler, even with the machine switched off, the hydraulic circuits may remain pressurised so care must be taken when connecting or disconnecting hydraulic hoses. Bleed off to OEM specifications per the machine owner s manual. 4. While the PosiGrab coupler is designed to work with most available buckets and other attachments, ESCO DOES NOT approve the use of mechanical pulverizers, mechanical shears, mechanical stump grinders and similar attachments with this coupler. Breakers and hammers can cause serious issues with the coupler. They should be used with caution at all times. CAUTION: Breakers and hammers used in excess of 50 percent should be used with direct connection to the machine. The warranty will be void if such attachments are used with the coupler. 5. All buckets and attachments being used with the coupler must be used in strict accordance with individual's manufacturer guidelines and instructions. 6. In order to ensure the best performance from the PosiGrab coupler, recommended service and maintenance checks are detailed in this manual. These should be carried out on a regular basis and any damaged parts should be replaced immediately. 7. Never attempt to modify either the coupler or equipment that is to be attached to without first receiving approval from ESCO. WARNING: Unauthorized modification of the PosiGrab coupler or the host machine can seriously impair the performance of the equipment and could cause serious injury or death. 14

15 8. If you have any concerns with the PosiGrab coupler that is not addressed in this manual, contact ESCO immediately. 9. Although every effort has been made to optimize the strength and durability of the PosiGrab coupler, it should be noted that the typical working environment can be extremely harsh and detrimental to all types of equipment. For this reason, ESCO highly recommends that, in addition to the regular maintenance checks, certain components be replaced after reaching a pre specified number of working hours as noted in the back of this manual. Intermittent problems can be symptoms of imminent failure. If intermittent problems are experienced with key control components such as the control box or solenoid valve, these components should be replaced immediately. Details of specific components and their expected normal working life can be found in the Maintenance section of this manual. Please take the time to become acquainted with these components and to monitor their working age. CAUTION: Only genuine ESCO parts are to be used to service the PosiGrab coupler. ESCO reserves the right to waive liability if non genuine parts are fitted to this coupler. 10. It is important to note that if you or your representative are responsible for the initial installation of the coupler, especially in regard to the hydraulic and electrical systems; you must take the full responsibility to make sure the installation is carried out in strict accordance with ESCO S instructions. WARNING: Any failure to follow the instructions as provided may allow the unsafe operation of the coupler and could result in serious injury or death. 11. In addition to the structural integrity of the coupler, the most important components in this coupler are the two hydraulic cylinders, and the front and rear pin locking mechanisms. 12. In order to provide a safer, more durable and effective product to work in a typically harsh environment, it is the responsibility of the owner and user to keep the system serviced and in good working order. CAUTION: To ensure the continued safe and effective use of the PosiGrab coupler, a daily check must be conducted to monitor wear, blockages and other damage that may affect performance. 13. Continued safe operation of the coupler requires that along with regular maintenance checks and services carried out on the coupler, close attention be paid to the presence and legibility of all the decals in the operator s cab. If one or more of these decals become damaged or lost, it is essential that they be replaced immediately. ESCO has supplied an extra set of decals with this manual for that purpose. If you have not received these decals, contact your dealer immediately. If you have further need for decals, contact your ESCO representative to request new ones. IMPORTANT: Please make sure that the in-cab operation instruction decals are mounted in the machine cab in an easily visible location convenient to the operator and that this manual is available in the machine cab. 14. Always use approved lifting shackle and chains in conjunction with the lifting eye. Always remove the attachment on the coupler prior to using the lifting eye. No other part of the coupler may be used for lifting other than the lifting eye. WARNING: If the coupler is fitted with a lifting eye, please inspect daily before use for wear, cracks and fatigue. If damage is detected or suspected, do not use the eye. WARNING: Check the SWL (Safe Working Load) that is stamped on the coupler and ensure the lifting equipment is compatible. WARNING: Always check the excavator manual for the machine SWL as this determines the lifting capacity of the machine. This SWL must never be exceeded under any circumstance. WARNING: The lifting eye on the coupler has been tested and stamped. This test is valid for 12 months from first date of purchase, and thereafter it is the responsibility of the machine owner to insure the lifting eye remains compliant to the applicable national standard. 15

16 15. The PosiGrab coupler should only be fitted to the machine referenced on the Serial Number Plate or the declaration of incorporation. If the model is different than what is on the plate, contact ESCO for permission before installation. 16. Sequence of the PosiGrab Coupler opening: Rear Lock Hydraulically Opens, Latching Hook Retracts Hydraulically, Front Locking Mechanism Mechanically Opens. 17. The operating instructions contained in this manual are a guideline for use with the supplied Control Box. If another system has been used, please contact a qualified technician or the manufacturer of that system for proper operation. WARNING: The working range of the machine can change with the incorporation of a hydraulic coupler. Following are areas of the working range to be familiar with: The bucket is more liable to interfere with the dipper arm and possibly the cab. Break out force is reduced at the tip of the bucket due to the longer distance from teeth to the pivot point. As shown in Figure 1, there is a danger zone that follows a 360-degree axis to the machine from the centerline of swing. In addition, the working radius of the machine increases Figure 1 due to the extra distance between the bucket and the excavator arm. Maximum operating capacity is limited with the use of a hydraulic coupler. Refer to the excavator owner s manual for further information on maximum operating loads. Introduction Thank you for purchasing the ESCO PosiGrab Hydraulic Coupler. This coupler was designed and manufactured with ease of use and operator safety in mind. This product has undergone extensive testing and benchmarking against similar competitor products and we believe the PosiGrab coupler product is unique and is the best available in today s marketplace with safety first. The PosiGrab coupler features the ability to hydraulically release the front and rear pins independently; both front and rear pins are independently locked through the full working cycle. The PosiGrab coupler can operate with a wide range of buckets and attachments within the same pin size range and can be fully operated from the comfort and safety of the machine cab. The PosiGrab coupler, when used correctly and with proper OEM (Original Equipment Manufacturer) matched excavator buckets and attachments, will provide safer and more reliable attachment and change-over of various implements, allowing the user to get maximum productivity from the machine. WARNING: For optimal and safe operation of the equipment, only experienced and qualified personnel should install and operate the product. Failure to follow the procedures in this manual could result in serious injury or death. ESCO accepts no responsibility or liability for equipment installed or operated other than in full accordance with the information provided in this manual. WARNING: The bucket is more likely to interfere with the stick and/or the cab which could result in serious injury or death. WARNING: Under no circumstances is the PosiGrab coupler to be used to transport people. Such action could result in serious injury or death. 16

17 Operating Instructions The operating instructions contained in this manual are a guideline for use with the supplied Control Box. If another system has been used, please contact a qualified technician or the manufacturer of that system for proper operation. Installation of the PosiGrab coupler must be in accordance with the instructions provided in this manual. Any deviation from the instructions given here must be authorized by ESCO. WARNING: The PosiGrab coupler must be installed and fitted by trained personnel only. WARNING: Any difficulty or doubt with interpretation of the installation instructions in this manual should be resolved between the technician and ESCO, before proceeding any further. WARNING: Before attaching to a bucket or any other attachment it is important to ensure the following. A. The attachment is fitted with the correct pins at the correct center distances and that they are secured properly in place. B. The area within the maximum machine swing radius must be clear of all personnel and obstacles. C. The sequence and function matches the sequence outlined in this manual. If the in-cab control system is not supplied by ESCO, this may affect the performance and safety of the coupler. D. The PosiGrab coupler must be left in a safe position after previous use or operation. Pickup Bucket / Attachment Procedure Step 1 From the operators seat in the machine cab the PosiGrab coupler must be fully curled inwards to the transport position in order to disengage the automatic latching system (see Figure 2). Fully extend the bucket cylinder and hold over relief. Figure 2 IMPORTANT: Keep holding over relief until the cylinder fully opens. Step 2 Press the POWER button on the in-cab Control Box and the LED light will pulsate GREEN and activate an audible buzzer (continuous tone) in the machine cab (see Figure 3). IMPORTANT: If no further action is taken within five seconds, the unit will automatically LOCK OUT, the indicators will stop, and the LED light will return to a constant green. Figure 3 WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g., OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 17

18 Step 3 To activate the cylinders hold the bucket lever over relief during this operation. Then press the CONTROL button within five seconds from POWER on (see Figure 4). IMPORTANT: Be sure to maintain the lever over relief until the cylinder fully opens. The status indicator light will illuminate to a flashing red signal and the buzzer will also change from a continuous tone to a pulsating tone. This indicates that a positive supply is being sent to the Valve Assembly, which in turn operates both lock cylinders. The back lock will open allowing the cylinder to retract. When the cylinder retracts, this will open the front lock. Now you are ready to connect the coupler to an attachment. Figure 4 Step 4 Maneuver the PosiGrab coupler to line it up with the bucket or attachment to be picked up (see Figure 5). CAUTION: After the CONTROL button is pressed, the system will activate a warning signal at 55 seconds, and after 60 seconds the coupler will reset to a closed position. Step 5 Lower the coupler downward and slide forward to engage the front jaw of the coupler over the bucket pin nearest to the cab. Curl the coupler inward to line up with the bucket pin furthest from the cab (see Figure 6). Figure 5 Figure 6 18

19 Step 6 When both attachment pins are seated in the coupler jaws, rotate the attachment fully inwards using the excavator bucket cylinder (see Figure 7). This maneuver will ensure that the attachment is fully seated in the coupler jaws. Step 7 Press the POWER button. The indicator light will go out and audible buzzer will stop sounding in the excavator cab. The main cylinder will extend and lock the latching hooks over the attachment pin. Step 8 As a final confirmation that this procedure has been carried out correctly, the following checks are to be performed in the order listed: 1. Visually confirm the rear lock is engaged (see Figure 8). 2. Complete bump test to ensure that the rear lock is properly secured. 3. Visually confirm the front lock is engaged (see Figure 9). With confirmation of these checks, the machine is now ready for use with the attachment. Figure 7 Rear lock is engaged Figure 8 Front lock is engaged WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g., OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. Figure 9 19

20 Bucket/Attachment Release Procedure WARNING: Before attempting the release of a bucket or attachment: A. Ensure that the area within the maximum machine swing radius is clear of all personnel and obstacles. B. Put attachment on level ground to ensure that it does not roll over (see Figure 10). Step 1 Lower the PosiGrab coupler and attachment to the ground with the coupler rotated fully inwards towards the machine in order to disengage the automatic latching system. Step 2 Press the POWER button on the in-cab Control Box, the LED light will pulsate GREEN and activate an audible buzzer (continuous tone) in the machine cab (see Figure 11). IMPORTANT: If no further action is taken within five seconds, the unit will automatically LOCK OUT, the indicators will stop, and the LED light will return to a constant green. Figure 10 Step 3 To activate the cylinders, hold the bucket lever over relief during this operation. Then press the CONTROL button within five seconds from POWER on (see Figure 12). IMPORTANT: Be sure to maintain the lever over relief until the cylinder fully opens. IMPORTANT: If no further action is taken within five seconds the unit will automatically LOCK OUT, the indicators will go out and the green LED light will return to a constant green light. The status indicator light will illuminate to a flashing red signal and the buzzer will also change from a continuous tone to a pulsating tone. This indicates that a positive supply is being sent to the solenoid valve, which in turn operates both cylinders used to lock the bucket or attachment. CAUTION: After CONTROL button is pressed, the system will activate a warning signal at 55 seconds, and after 60 seconds the hitch will reset to a closed position. Step 4 Maneuver the PosiGrab coupler rearwards and away from the machine. This will disengage the coupler from the bucket or other attachment (see Figure 13). Step 5 Set the switch to the OFF position. The indicator light will go out and the audible buzzer will stop sounding in the machine cab. The PosiGrab coupler cylinder will extend and lock the coupler latching hooks. This maneuver will also activate the automatic locking system. 20 Figure 11 Figure 12 Figure 13

21 Daily Inspection and Maintenance WARNING: The following inspection and maintenance are to be conducted on the PosiGrab Hydraulic Coupler on a daily basis. Any conditional concerns with the coupler must be addressed prior to putting the coupler back in service. Failure to follow the inspections and checks listed, and any corrective action, could result in serious injury or death. Check attachment pins for damage or wear Check main frame for cracks or weld failure 1. Check the coupler main frame for cracks or weld failure. 2. Check the coupler components for damage or for signs of wear. 3. Check the attachment pins for damage or undue wear. 4. Check for any sign of damage to or clogging of both automatic locking mechanisms. 5. Check for oil leaks from the hydraulic cylinders and hose connections. 6. Check that all nuts and bolts used to secure the pins are locked tight. 7. Grease the coupler daily. All pins and bushings should be greased. Grease nipples are provided at cylinder bushings and at the latching hooks to simplify greasing. 8. Clean coupler of all dirt and debris, and ensure all labels are clean and legible at the end of each shift. 9. Inspect the lift eye for wear, damage or cracks. Check that all nuts and bolts used to secure the pins are locked tight IMPORTANT: Refer to the Maintenance Schedule in the back of this manual. Important: For questions regarding installation or operation of the ESCO PosiGrab coupler, call the ESCO Tech Line WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g., OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 21

22 Maintenance Schedule The table below is to be used as a guideline in the maintenance program of the PosiGrab coupler. The maintenance log on the next page should be updated and signed off at the recommended hourly interval. Description Hourly Intervals LATCHING HOOK ASSEMBLY 1,000 2,000 3,000 4,000 5,000 6,000 INSPECT INSPECT INSPECT INSPECT INSPECT REPLACE BUCKET PINS ( INSPECT INSPECT INSPECT REPLACE INSPECT INSPECT HYDRAULIC CYLINDER - LARGE INSPECT INSPECT INSPECT INSPECT INSPECT INSPECT HYDRAULIC CYLINDER - SMALL INSPECT INSPECT INSPECT INSPECT INSPECT INSPECT FRONT LOCK INSPECT INSPECT INSPECT INSPECT INSPECT INSPECT CYLINDER PIN INSPECT INSPECT INSPECT INSPECT REPLACE INSPECT HOOK ASSEMBLY PIN INSPECT INSPECT INSPECT INSPECT REPLACE INSPECT CYLINDER AND HOOK PIN INSPECT INSPECT INSPECT INSPECT INSPECT INSPECT REAR LOCK INSPECT INSPECT INSPECT INSPECT INSPECT INSPECT CHECK VALVES INSPECT INSPECT INSPECT REPLACE INSPECT INSPECT SEAL KITS INSPECT INSPECT INSPECT REPLACE INSPECT INSPECT PUSH BAR INSPECT INSPECT INSPECT INSPECT REPLACE INSPECT FRONT LOCK PIN KIT INSPECT INSPECT INSPECT INSPECT REPLACE INSPECT 22

23 Maintenance Log Description Hourly Intervals 1,000 2,000 3,000 4,000 5,000 6,000 23

24 Parts List Ordering Spare Parts All PosiGrab couplers are labelled with a unique serial number. The serial number is located on the main body of the frame. At the time of ordering spare or replacement parts, you will be required to provide the serial number and a description of the parts you require. Please see below reference illustration of spare parts for the coupler Item Tonnage 10 ton 15 ton 20 ton 25 ton 30 ton 40 ton No. Range Main Hydraulic Cylinder Cylinder -Finger Hook - Latch Lock kit-front Lock kit-back Front Lock Linkage Kit Main Cylinder Pin Kit Hook and Cylinder Pin Kit Front Lock Pin Kit Front Lock Spring Kit Back Lock Spring Kit Coupler Pins Control Panel

25 Troubleshooting Guide PROBLEM ACTION NO 1. Coupler will not pick up attachment Check if attachment measures to OEM Spec. (Pin sizes, centers and width, bucket rib height). Check if coupler bottom section matches OEM Spec. Check for damage to bucket pins, i.e., bent, concrete debris, etc. NO YES Check for damage to bucket pins, i.e., bent, concrete debris, etc. Check if attachment hanger contacts top of coupler. NO YES Coupler not suitable. Contact ESCO. Contact ESCO to discuss if modification to attachment or coupler is necessary Clean/repair attachment 2. Coupler will not release attachment Check that procedure is being followed correctly as per ESCO Manual i.e., coupler crowded in fully. Check for debris preventing hook/prop retracting. Clean if necessary NO Is rear latch hook retracting during release cycle? NO 1) Check if rear latch hook interferes with linkage as it moves. Is rear front prop retracting during release cycle? 2) Check if bolt has come loose from end of slide rod which runs through slide block. Is slide linkage damaged (bent/ worn) preventing front prop opening? YES YES NO Refer to Operator s Manual 3. Electrical/hydraulics problem Replace/repair damaged/worn parts 3) Check if 2 parts of slide linkage run parallel to each other as they move. 4) Check if slide linkage interferes with body of couples as hook moves. 3. Electrical/hydraulics problem Check if buzzer sounds and light signals when attach/release cycle is activated. YES Check if oil is getting to correct hose during cycle. Hold hose firmly. It should be apparent if hose is energized when rear hook movement is attempted. Check if control box is getting power? Fuse OK? Connections OK? Wiring integrity OK? YES YES NO - Likelihood of solenoid damage/ failure NO Check solenoid is getting power at correct time. YES - Likelihood of cyclinder valve or cyclinder damage/ failure Repair/replace affected worn or damaged parts. Contact ESCO 25

26 NOTES 26

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