Table of Contents General Information Safety Message Classifi cation...2 Safety Notes...3 Terminology...4 Coupler Lifting Lug...6 Assembly and Installation General Information...7 How it works...7 Component Installation...8 Electrical /Hydraulic Schematic For Hydraulic Kit...9 Hydraulic Installation...10 Electrical Installation...12 Installation Assessment...14 Operation Hydraulic Coupling of the Attachment...14 Hydraulic Uncoupling of the Attachment...19 Maintenance General Information...22 Daily Inspections (Static)...23 Daily Inspections (Dynamic)...25 Torque Chart...26 Parts Pages...27
General Information This section provides general information and recommendations required prior to installing, operating or maintaining your Hydraulic Quick Coupler. All safety messages and decals that are supplied in this manual, and in the Hydraulic Installation Kit, must be read and understood by all personnel installing, maintaining or operating the Hydraulic Quick Coupler. DANGER CAUTION NOTICE Safety Message Classification Indicates an imminently hazardous situation. If not avoided, this hazard will result in serious injury or death. Indicates a potentially hazardous situation. If not avoided, this hazard could result in serious injury or death. Indicates a potentially hazardous situation. If not avoided, this hazard may result in minor or moderate injury. Indicates a potentially hazardous situation. If not avoided, this hazard may result in damage to the attachment or machine. All personnel who are to operate the Hydraulic Quick Coupler must read and familiarize themselves with all sections of this manual prior to operating or maintaining the hydraulic quick coupler. The owner/operator of any equipment using a hydraulic quick coupler should review all additional materials including hazard assessments and operating manuals supplied by the manufacturer of the machine to ensure safe use and operation. Failure to comply with information contained within the Weldco-Beales Parts and Installation may result in injury, death, damage to property and/or damage to the Quick Coupler. Ensure that all personnel have read and understand the information contained in the before attempting to install, maintain and/or operate the Weldco-Beales Hydraulic Quick Coupler. The Weldco-Beales Hydraulic Quick Coupler has been designed to be installed using only the Hydraulic Installation Kit components provided. Inspect and ensure that all components of the Hydraulic Installation Kit are correct and are not damaged. Report all shortages or damaged components to Weldco-Beales Mfg. For product support contact your dealer, Weldco-Beales Service Department or Weldco-Beales Engineering Department. Weldco-Beales Manufacturing Page 8
Hydraulic Quick Coupler Read and understand operator s manual Attachment may fall if proper procedures are not followed A falling attachment may cause serious injury or death Engage and disengage attachment away from all personnel Always test connection before using attachment Stay clear of excavator during operation Visual inspection must be performed to ensure a proper connection and that safety pins are engaged each and every time an attachment is engaged Safety Notes 599-002-0413 Rev 0 Always utilize the Parts and Installation manual to ensure the recommended procedures have been followed. Only disengage the wedge bar to remove or engage an attachment. Never operate the machines hydraulic functions, or attachment, with the wedge bar disengaged. Ensure that all surrounding personnel and/or objects are at the recommended O.E.M (Original Equipment Manufacturer) safe working distance from the operating area of machine. Ensure that the attachment will be uncoupled in a safe, stable position to prevent unexpected or sudden movement that could cause damage, injury or death. Conduct a workplace hazard assessment prior to work commencing to address any dangers or potential dangers arising out of the use of the equipment and/or quick coupler and attachments. If the quick coupler is observed not properly engaging the attachment, the operator should immediately discontinue use. The quick coupler and attachment should be immediately secured and removed from operation. Perform a full assessment of any malfunction. All problems must be remedied by qualified personnel before returning quick coupler or attachment to service. Ensure the safety lock plate is correctly installed before every operation. Do not use any attachment which is not in the correct tonnage class. Cylinder rods do not have an internal stop. Do not operate cylinders if they are not installed in quick coupler. Cylinder rods do not have an internal stop. Do not operate wedge bar cylinder unless it is properly installed in the quick coupler with wedge bar in place. Failure to follow safe procedures may result in injury, death or damage to property or the quick coupler. Weldco-Beales Manufacturing Page 9
Hydraulic Quick Coupler Terminology Failure to utilize the components in the Hydraulic Kit results in an unauthorized installation. Unauthorized installations may result in impairing the function, performance or work life of the coupler or machine. Unauthorized installations may also result in injury or death to personnel, from which Weldco-Beales Mfg. disclaims all liability. Unauthorized installations void all warranty policies. Excavator Terminology STICK CYLINDER BOOM STICK OR ARM BUCKET CYLINDER STICK TO BUCKET PIN POWER LINK TO BUCKET PIN HYDRAULIC QUICK COUPLER Excavator Bucket REAR SADDLE ATTACHMENT LUG FRONT SADDLE WEDGE BAR SURFACE Weldco-Beales Manufacturing Page 10
Hydraulic Quick Coupler Hydraulic Quick Coupler Terminology FRONT BOSS SAFETY LOCK PLATE & PIN WEDGE BAR CYLINDER WEDGE BAR SPRING RETAINER WEDGE BAR SPRINGS REAR BOSS WEDGE BAR WEDGE BAR SPRING RETAINING PLATE AND COMPRESSION BOLT Weldco-Beales Manufacturing Page 11
Hydraulic Quick Coupler Coupler Lifting Lug LIFT RANGE Coupler Lifting Lug Series Rated Capacity 120 6 ton (5 450 kg) 200 12 ton (10 900 kg) 250 16 ton (14 500 kg) 300 20 ton(18 150 kg) 400 20 ton (18 150 kg) 650 20 ton (18 150 kg) 850 20 ton (18 150 kg) Not for overhead lifting devices. Never lift over personnel. Do not exceed rated capacity of lifting lug. Do not exceed rated capacity for rigging equipment. Do not side load lifting lug. Inspect lifting lug and rigging equipment before every lift. Perform NDT (Non Destructive Testing) inspection of lifting lug and all welds at least once a year. Weldco-Beales Manufacturing Page 12
Hydraulic Quick Coupler Assembly and Installation General Information How it works Installation of the hydraulic quick coupler is to be done by a qualified service technician. Ensure the technician has read and understands the manual before attempting installation. Failure to comply may result in property damage or serious injury or death. Large coil springs are used to provide engagement pressure for the wedge bar. This pressure is applied independently of the hydraulic system. The wedge bar is disengaged using hydraulic pressure. Full excavator hydraulic system pressure (approximately 5000 PSI) is used to disengage the wedge bar. System pressure is typically accessed via the hydraulic pump test port. WEDGE BAR WEDGE BAR SPRINGS WEDGE BAR CYLINDER WEDGE BAR SPRING RETAINER REAR BOSS Weldco-Beales Manufacturing Page 13
Hydraulic Quick Coupler Component Installation Always utilize the Parts and Installation manual to ensure the recommended procedures have been used for the installation of the hydraulic quick coupler. Failure to do so may result in injury, death or damage to property or the quick coupler. Locate the machine on level ground, in an area where all sides of the excavator can be accessed. Safely remove any attachments pinned to the excavator. Remove the attachment from the area and put aside any pins, some couplers will use the factory pins for installation. POWER LINK TO BUCKET PIN STICK STICK TO BUCKET PIN Install the hydraulic quick coupler using the factory pins or pins supplied with the quick coupler. Install the stick to attachment pin first, then the power link pin. STICK POWER LINK POWER LINK TO QUICK COUPLER PIN STICK TO ATTACHMENT PIN HYDRAULIC QUICK COUPLER LIFTING LUG (IF EQUIPPED) Weldco-Beales Manufacturing Page 14
Hydraulic Quick Coupler Electrical /Hydraulic Schematic For Hydraulic Kit Weldco-Beales Manufacturing Page 15
Hydraulic Quick Coupler Hydraulic Installation Mount the hydraulic quick coupler valve in the upper house area of the excavator, near the hydraulic pumps, hydraulic tank, and main hydraulic control valve. The quick coupler valve comes with a generic mounting plate and mounting bolts. You may need to fabricate a bracket or support to complete the installation, depending on the mounting area you have selected. Orient the valve in such a way to allow the easiest fit into the hydraulic and electrical systems of the excavator. The valve may need to be removed from the mounting plate for hose and adapter installations. Before loosening any excavator hydraulic connections make sure all hydraulic pressure is relieved from the circuit and the machine is locked out of operation. 1. Plug valve port 2 with supplied plug. 2. Connect the valve port 3 into the main pressure circuit of the excavator hydraulic system. TO COUPLER JUNCTION BLOCK VIA BOOM ARM (#8, RATED FOR 5000 PSI) DIRECTLY TO TANK (#8 100R16 TYPE AT) 4 2 3 1 FROM PRESSURE CIRCUIT OF THE EXCAVATOR HYDRAULIC SYSTEM KEY SWITCHED +24V ELECTRICAL POWER SOURCE THAT ONLY HAS POWER WHEN CONTROL BOX IS ACTIVATED (ENGAGED) AND SWITCH IS ACTIVATED PUMP TEST PORT 5000 PSI MAX (#4 HYDRAULIC HOSE) Weldco-Beales Manufacturing Page 16
Hydraulic Quick Coupler 3. Connect the valve port 4 to the main wedge bar cylinder. This connection will require you to: Mount the junction block to the arm or stick of the excavator near the attachment or tool end. It is to be centered across the width of the arm. Run one #8 size hydraulic line (rated for 5000 psi, hose not supplied) from the upper house of the machine, down the boom and arm of the excavator to the junction block on the arm. Run one #4 hose from the junction block on the arm to the junction block on the coupler (to connect to #4 hose attached to the cylinder). Clamp as needed to facilitate flexibility at the joints and secure fastening along the rest of the routing path. #4 HOSE RATED FOR 5000 PSI (STEP 7) JUNCTION BLOCK (SUPPLIED BY ) (STEP 5) #8 HOSE RATED FOR 5000 PSI (STEP 6) JUNCTION BLOCK (PART OF COUPLER) #4 HOSE (SUPPLIED BY ) WEDGE CYLINDER 4. Connect valve port 1 on coupler valve directly back to tank, with no restrictions. Weldco-Beales Manufacturing Page 17
Hydraulic Quick Coupler Electrical Installation 1. Install the hydraulic quick coupler control box in the cab, within reach of the seated operator. The control box can be installed using either the adhesive strips on the back side or, using screws or bolts, the mounting tabs on the sides. CAUTION The hydraulic quick coupler release switch, when flipped to the ON or release position, will sound the release buzzer and illuminate the indicator light on the control box. The Buzzer is very loud and hearing protection is recommended. 2. The control box has two wiring harnesses (16/2), one short and one long. Connect the short wiring harness to power and ground, see the next page for schematic. Connect the white wire to ignition power (must be fused and key switched). Connect the black wire to a suitable ground. Electrical power from the machine must run through the fuse or circuit breaker, before reaching the quick coupler release switch. Weldco-Beales Manufacturing Page 18
Hydraulic Quick Coupler ELECTRICAL SCHEMATIC 3. Run the long wire harness to the quick coupler control valve. Protect the wires from with an appropriate wire loom. Ensure the wires will not be pinched. Connect the long harness to the control valve using the supplied connectors. The hydraulic quick coupler release switch, when on, will sound the release buzzer and illuminate the indicator light on the control box. CAUTION The Buzzer is very loud and hearing protection is recommended. WEDGE BAR ENGAGED RELEASING WEDGE BAR LIGHT ON BUZZER ON Ensure wedge bar is properly engaged and safety lock is secured before operating attachment. Failure to follow all procedures in this manual may result in property damage, serious injury or death. Weldco-Beales Manufacturing Page 19
Hydraulic Quick Coupler Installation Assessment 1. Visually check that the hydraulic quick coupler is connected. 2. Ensure all the electrical wires and hydraulic lines have been secured and tightened. 3. Check the hydraulic oil level and top it up, if required. 4. With everyone clear of the machine s operating area, start up the machine and run at low idle. 5. Test all functions for proper operation. 6. Confirm clearance for the hoses. 6. Shut down the machine and then check for leaks or pinch points. Tighten or alter routing of hoses or wire as required. 7. Recheck hydraulic oil level and add if required. Operation Hydraulic Coupling of the Attachment 1. Prior to engaging another attachment, ensure that the attachment is in a safe position to be coupled. Engage or disengage attachments away from all personnel as the attachment may drop without warning. Failure to do so may result in injury, death or damage to property or the quick coupler. Use only style lugged excavator attachments on the style hydraulic quick couplers. Failure to do so may result in injury, death or damage to property or the quick coupler. Always ensure the wedge bar safety lock plate is used. Failure to do so may result in injury, death or damage to property or the quick coupler. Weldco-Beales Manufacturing Page 20
Hydraulic Quick Coupler 2. With the stick and boom positioned in an approximate 90 configuration, align the hydraulic quick coupler with the attachment lugs. Fully insert the front bosses of the coupler in the front saddles of the attachment. FRONT BOSS 90 FRONT SADDLE 3. Disengage the wedge bar (control switch ON). LIGHT ON BUZZER ON Weldco-Beales Manufacturing Page 21
Hydraulic Quick Coupler 4. Extend the machines bucket cylinder and linkage, rotating the rear bosses of the coupler into the rear saddles of the attachment lugs. Coupler rear bosses must be firmly seated in the rear saddle area, or the wedge bar will be too high to properly engage the lugs. REAR BOSS REAR SADDLE 4. Flip the quick coupler switch to the OFF or engage position. The quick coupler release light will go out, and the warning buzzer will stop sounding. This will engage the wedge bar into the attachment lugs. SWITCH GUARD WITH SWITCH IN ENGAGE (OFF) POSITION LIGHT OFF BUZZER OFF Wedge bar must fully engage attachment lugging. Always ensure the wedge bar safety plate is used. Failure to fully engage lugs and use the wedge bar safety lock plate may result in injury, death or damage to property or the quick coupler. Weldco-Beales Manufacturing Page 22
Hydraulic Quick Coupler 5. Wait for the wedge bar to be fully engaged in the attachment lugs. 6. Manipulate stick and/or boom cylinder hydraulics to perform a visual inspection from the operators cab to inspect the wedge bar engagement and ensure that the attachment is seated properly on the hydraulic quick coupler. SAFETY LOCK PLATE When performing inspections or tests with equipment in a fully operable condition ensure all personnel/objects are at the recommended O.E.M (Original Equipment Manufacturer) safe working distance from the operating area of the machine. Failure to comply may result in property damage or serious injury or death. Weldco-Beales Manufacturing Page 23
Hydraulic Quick Coupler Immediately discontinue use if the coupler is showing signs of excessive wear. The wedge bar contacting the front surface of the coupler indicates extreme wear and will cause premature failure. Failure to comply may result in property damage or serious injury or death. THE WEDGE BAR CONTACTING THE FRONT SURFACE, WHILE ATTACHMENT IS ENGAGED, IS A SIGN OF EXCESSIVE WEAR. EXCESSIVE WEAR REQUIRES IMMEDIATE SERVICE. FRONT SURFACE OF QUICK COUPLER WEDGE BAR 7. Test attachment for secure engagement with the hydraulic quick coupler by: Placing the attachment on the ground Apply down pressure by lifting the tracks Cycle the coupler on the attachment working the stick/bucket cylinder in and out trying to force the attachment from the bucket. 8. Lower attachment to the ground and install wedge safety lock. A visual inspection and secure engagement test must be completed after every attachment change to ensure proper engagement of the hydraulic quick coupler and installation of the safety lock has occurred. Failure to comply may result in property damage or serious injury or death. Weldco-Beales Manufacturing Page 24
Hydraulic Quick Coupler Hydraulic Uncoupling of the Attachment 1. Position the attachment to ensure that it will remain stable after uncoupling. At or near ground level is preferred, away from operations, and so it will remain in the intended position. Engage or disengage attachments away from all personnel as the attachment may drop without warning. Failure to do so may result in injury, death or damage to property or the quick coupler. Use only style lugged excavator attachments on the style hydraulic quick couplers. Failure to do so may result in injury, death or damage to property or the quick coupler. Always ensure the wedge bar safety lock plate is used. Failure to do so may result in injury, death or damage to property or the quick coupler. 2. Position the stick and boom in an approximate 90 configuration. Ensure the attachment will remain stable after uncoupling. 90 3. Confirm everyone is cleared from the operating area of the machine. Weldco-Beales Manufacturing Page 25
Hydraulic Quick Coupler 4. Remove the wedge bar safety lock plate so that the wedge bar can be disengaged. REMOVE WEDGE BAR SAFETY LOCK PLATE (STEP 4) DISENGAGE WEDGE BAR (STEP 6) 5. Curl the bucket until the bucket cylinder is fully extended, to build up hydraulic pressure in the circuit. 6. Raise the switch guard and flip the quick coupler switch to the ON position. The switch box light will illuminate and the buzzer will sound. This buzzer is very loud and hearing protection is recommended. This will hydraulically disengage the quick coupler wedge bar from the attachment. While the quick coupler switch is flipped to the ON position, the quick coupler cylinder will remain extended, holding the wedge bar in the released position. 7. Ensure the attachment is safely positioned and supported on the ground. Weldco-Beales Manufacturing Page 26
Hydraulic Quick Coupler 8. Retract the machines bucket cylinder and linkage, rotating the hydraulic quick coupler out of the rear saddle of the attachment lugs. FRONT SADDLE FRONT BOSS REAR BOSS REAR SADDLE 9. Once the hydraulic quick coupler has cleared the rear saddle, activate the stick cylinder to curl the stick towards the operator and allow the hydraulic quick coupler to release from the front saddle of the attachment lugs. 10. When the hydraulic quick coupler has cleared the attachment, switch the control box to OFF. Weldco-Beales Manufacturing Page 27
Hydraulic Quick Coupler Maintenance General Information Improper operation and maintenance of the Hydraulic Quick Coupler could result in serious injury or death. Read and understand this manual prior to operating and/or maintaining this equipment. Always ensure safety lock pins are engaged during operation. Failure to follow all safety precautions could result in serious injury or death. Read and understand this manual prior to operating and/or maintaining this equipment. Only qualified personnel should complete all maintenance and inspection operations. Prior to all maintenance or inspection operations ensure that the attachment is resting on the ground and is properly supported. Always wear the proper protective equipment when performing maintenance operations. All welds must be made in accordance with current CWB (Canadian Welding Bureau) or AWS (American Welding Society) Standards, by certified welders using moisture free E-7018 electrodes or equivalent wire unless noted otherwise. The attachment end of the excavator stick, the linkage and attachments contain several pinch points. Stay clear when bucket cylinder is in operation. Properly support all attachments and linkages before performing maintenance or inspections. Failure to do so may result in serious injury. Weldco-Beales Manufacturing Page 28
Hydraulic Quick Coupler Daily Inspections (Static) Disengage the attachment from the coupler and position the coupler for inspection. With any dirt removed and the machine off, perform the following daily inspections: Inspect all welds and components for cracks or damage. Contact for recommended welding procedures before repairing any welds. Check hydraulic components (hoses, hose ends, fittings, valves, cylinders) and connections for leakage or damage. Inspect quick coupler cylinder and anchor points for structural integrity, weld cracks or damage. Inspect wedge bar springs for cracks or damage. Operation of wedge bar should be smooth. Replace springs as a pair only. Check bolts for tightness and installation. Refer to bolt torque chart for values. Use Loctite 242 on all fasteners. When inspecting the hydraulic components for damage, ensure the proper Protective Equipment is being used and the machine s hydraulic engage function has been disengaged. Measure the diameter of the bosses on the quick coupler. Bosses that show signs of wear, which reduce the original boss diameter by more than 1/32, will require rebuilding or replacement. Measure all contact surfaces on the coupler and on the attachment. Any contact surface with wear grooves greater than 1/32 in depth require replacement or repair. There should be no movement between a correctly connected coupler and its respective attachment lugs. WEAR GREATER THAN 1/32 NEEDS REPAIR OR REPLACEMENT WEAR GREATER THAN 1/32 NEEDS REPAIR OR REPLACEMENT WEAR GREATER THAN 1/32 NEEDS REPAIR OR REPLACEMENT Weldco-Beales Manufacturing Page 29
Hydraulic Quick Coupler Measure wedge bar cylinder travel. Cylinder travel must be correct to ensure proper operation, and minimize damage to the cylinder. Fully extend the wedge bar cylinder. Verify that the wedge bar touches the rear of the wedge bar opening in the quick coupler frame on both sides before the wedge bar cylinder strokes out. There should be 1/16 to 1/8 of cylinder rod stroke remaining with the wedge bar fully contacting the quick coupler frame on both sides. If required, build up the frame as needed to ensure wedge bar cylinder rod travel of 1/16 to 1/8 remains. REAR OF WEDGE BAR OPENING WEDGE BAR Inspect wedge bar springs for cracks or damage. Operation of wedge bar should be smooth. Replace springs as a pair only. Installed wedge bar springs are under high pressure. Use appropriate practices, procedures and equipment when removing. Failure to follow safe removal practices may result in serious injury or death. Discontinue use and service immediately, if there is excessive wear on the attachment lugs, the wedge bar or the quick coupler frame. Failure to repair damaged or worn components may result in serious injury or death. Any cracking or component damage must be repaired; all worn components or missing parts must be replaced prior to any and all operation of the Hydraulic Quick Coupler. Failure to repair or replace damaged or worn components may result in equipment malfunction, serious injury or death. Weldco-Beales Manufacturing Page 30
Hydraulic Quick Coupler Daily Inspections (Dynamic) Dynamic Daily Inspections are done with: Machine rpm at low idle. Machine s hydraulic safety engage lever in the OFF position. The safety lock plate removed. The coupler disengaged from all attachments. Dynamic Daily Inspection Procedure: 1. Move the coupler such that the wedge bar can be seen from the cab. 2. Flip the wedge bar activation switch to the ON position (disengage the wedge bar). 3. Verify that the wedge bar is moving to the disengaged position. 4. Flip the wedge bar activation switch to the OFF position (engage the wedge bar). 5. Verify that the wedge bar is moving to the engaged position. 6. Repeat this procedure twice prior to engaging any attachment to ensure that the hydraulic quick coupler is functioning properly. If the hydraulic quick coupler is not functioning properly have it checked and/or repaired by a qualified service technician before attempting to use the quick coupler or any related attachments. Failure to comply may result in property damage or serious injury or death. When performing inspections with equipment in a fully operable condition ensure all personnel/ objects are at the recommended O.E.M (Original Equipment Manufacturer) safe working distance from the operating area of the machine. Conduct all inspections on flat, dry ground where the equipment and all attachments are properly supported. Failure to comply may result in property damage or serious injury or death. Any cracks or component damage must be repaired prior to any and all operation of the Hydraulic Quick Coupler. Failure to repair damaged or worn components may result in serious injury or death. All hydraulic leaks or damage must be repaired prior to any and all operation of the Hydraulic Quick Coupler. Failure to repair damaged or worn components may result in serious injury or death. Weldco-Beales Manufacturing Page 31
Hydraulic Quick Coupler Torque Chart All bolted connections and threaded hydraulic fittings or adapter connections must be done in accordance with the Torque Specifications listed below. Run in all tapped mounting holes with a thread chaser to remove paint from interfaces and ensure full clamping load. Torque Requirement For Capscrews (Gr 8 Bolts Using Fedalloy Flatwashers) Thread Size Torque ft lb (dry) N-m 5/8 195 260 3/4 330 440 7/8 530 720 1 759 1030 1-1/4 1100 1450 Torque Requirement For Hydraulic Hose Fittings And Adapters Thread Size Torque in lb (dry) N-m 9/16-18 250 30 3/4-16 500 55 7/8-14 720 80 1-1/16-12 960 110 Weldco-Beales Manufacturing Page 32