User and Installation Manual Symmetrical Quick Couplers with Front pin lock S40-S70 Dok Nr: 700342ENB
User and Installation Manual Symmetrical Quick Couplers with Front pin lock S40-S70 Dok Nr: 700342ENB
4 User Manual Symmetrical Quick Couplers Introduction User and Installation Manual Symmetrical Quick Couplers with Front pin lock S40-S70 Published by: Steelwrist AB Bäckvägen 18 192 54 Sollentuna Sweden +46 8 626 07 00 www.steelwrist.com Translation of Original User Manual. Copyright 2015, Steelwrist AB. No part of this document can be reproduced.
User Manual Symmetrical Quick Couplers TOC 5 Contents 1. Introduction...7 1.1. EC Declaration of Conformity...8 1.2. Thank you for choosing a quick coupler from Steelwrist...9 1.3. Steelwrist Design Philosophy...10 2. Safety...11 2.1. Safety Levels...12 2.2. Safety regulations...12 2.3. Machine plate and decals...13 2.4. Type certificate for lifting hook...14 3. Product Description...15 3.1. Intended use...16 3.2. Function description...16 3.3. Technical data...19 3.3.1. Load table...19 3.3.2. Dimension tables...19 3.3.3. Recommended bucket sizes...20 3.3.4. Hydraulic connections...21 3.3.5. Hydraulic diagram...22 4. Environmental aspects...23 4.1. Environmental information...24 5. Installation...25 5.1. Unpacking/transport of the quick coupler...26 5.2. Install the quick coupler...26 5.3. Connect the hydraulics...28 5.4. Tightening torque...29 5.5. Remove the shaft pins...30 5.6. Check list for quick coupler installation...30 6. Operation...31 6.1. Connecting work tools...32 6.2. Disconnecting work tools...34 6.3. Using the lifting hook...35 6.4. Preparation before first use of the tool...36 7. Maintenance...37 7.1. Daily care and maintenance...38 7.2. Maintenance schedule...38
6 User Manual Symmetrical Quick Couplers TOC 7.3. Touch-up painting...39
Chapter 1 1. Introduction Topics: EC Declaration of Conformity Thank you for choosing a quick coupler from Steelwrist Steelwrist Design Philosophy
8 User Manual Symmetrical Quick Couplers 1. Introduction 1.1. EC Declaration of Conformity EC Declaration of Conformity according to Machinery Directive 2006/42/EC, Appendix IIA Steelwrist AB, Bäckvägen 18, 192 54 Sollentuna, Sweden, hereby certify as the manufacturer that: Table 1: Quick coupler Type: Serial number: Weight: Lifting hook (Yes/No): Oil type used when tested: Schematics - Part number: Delivery Date: The above machine meets the requirements of the Directive 2006/42/EC and the following parts of harmonized standards and technical specifications as stated below. SS-EN474-1:2006+A4:2013, SS-EN474-5:2006+A3:2013, SS-EN12100:2010, ISO/DIS13031.2. This declaration and Steelwrist guarantee is void if changes or other interventions are made without Steelwrist approval. The technical documentation for the quick coupler held at the above address. Questions are answered by the CTO or CEO. Stefan Stockhaus, CEO, Steelwrist AB
User Manual Symmetrical Quick Couplers 1. Introduction 9 1.2. Thank you for choosing a quick coupler from Steelwrist We would first like to thank you for the confidence in choosing a quick coupler from Steelwrist. We at Steelwrist work hard to design quick couplers that are well adapted to modern excavators and we will do everything to see that you are satisfied with your quick coupler. Steelwrist quick couplers follow the standard "Symmetrical Quick couplers for Excavators" which was developed by the Swedish trade association for suppliers of mobile machines - Maskinleverantörerna (revision 13.06.11). Steelwrist is one of the companies that take part in this standardizing work. To obtain the best performance and reduce the risk of accidents, it is essential that the quick coupler is installed, maintained and operated properly. Carefully read the user manual before starting to use your quick coupler. To ensure a long product life span, reliability and cost effectiveness, it is important to regularly inspect and maintain the product. This is part of the proper use of Steelwrist quick coupler. We as a manufacturer cannot be held responsible for accidents or accept complaints if the cause is due to inadequate inspection and maintenance or incorrect operation. Steelwrist products are CE marked. This means that they are designed, manufactured and described in accordance with current directives and requirements. However, it is important that all security requirements are considered in the installation, maintenance and use. This applies to the safety regulations in this user manual and in the excavator's manual and the local safety rules relating to the area where the machine is used. If the quick coupler is rebuilt or complemented in a way without Steelwrists written approval the CE marking and warranty ceases to apply immediately. Steelwrist reserves the right to make technical changes without prior notice. This manual is intended to provide the necessary information about the function, operation and maintenance of your Steelwrist. Ensure that the manual is always readily available in the machine's cabin. Yours sincerely, Stefan Stockhaus Steelwrist AB
10 User Manual Symmetrical Quick Couplers 1. Introduction 1.3. Steelwrist Design Philosophy Steelwrist s development work is aimed at giving you a quick coupler that is optimized for your excavator. To enable you to get the best digging geometry and best fuel efficiency, we have designed a quick coupler that is robust, low weight and has a low overall height. Over the excavator's lifetime, this optimization often results in savings larger than the quick coupler's total purchase price compared to other alternatives that may both be heavier or have higher building height. You will recognize our efforts by: Cast steel designs create strength and ensure a low weight Low building height retains the best digging geometry Shaft pins with expander cones for better distribution of excavation forces Shaft pins are used as part of the truss structure construction to take up lateral forces (especially important when the quick coupler is used with a tiltrotator) Large surface areas in grip and pin mountings distribute the excavation forces and reduce the wear on pins and bucket brackets Front pin lock for increased safety when changing work tool.
Chapter 2 2. Safety Topics: Safety Levels Safety regulations Machine plate and decals Type certificate for lifting hook
12 User Manual Symmetrical Quick Couplers 2. Safety 2.1. Safety Levels Most accidents occur as a result of carelessness or negligence to follow given safety instructions. For us at Steelwrist safety is very important and we will do our best to avoid risks with preventive measures. However no safety instruction or protection measure, no matter how good they are made, is better than a prudent machine operator. In order to classify risks we use the following safety standards and recommendations in this manual: Danger: Danger (Danger) indicates that an accident will occur if the regulation is not followed. The accident will result in serious injury or death. Read carefully the user's manual and understand the contents before the product is first installed and used. Avoid dangerous work situations. For questions, contact your dealer or Steelwrist. Warning: "Warning" indicates that an accident could occur if the regulations are not followed. The accident could result in serious injury or death. Read carefully the user's manual and understand the contents before the product is first installed and used. Avoid dangerous work situations. For questions, contact your dealer or Steelwrist. Caution: "Caution" indicates that an accident may occur if the regulations are not followed. The accident may result in serious injury or death. Read carefully the user's manual and understand the contents before the product is first installed and used. Avoid dangerous work situations. For questions, contact your dealer or Steelwrist. Note: "Note" could be something that we wish to draw your attention to that can increase or reduce the performance of the product or of your excavator. Carefully read the user manual for your excavator together with this manual to ensure best possible function and performance. 2.2. Safety regulations The quick coupler is intended to allow you to switch easily between different work tools on your excavator. The quick coupler must not be used for other purposes than those that it was designed for. The quick coupler is designed to handle a particular machine weight and certain break points in accordance with the Standard on Symmetrical Quick Couplers. Ensure that the quick coupler matches the performance of the excavator and is not overloaded. See: Technical data Warning: Never use tiltrotator or work tool to lift a person. Warning: Always follow safety instructions for the machine, tiltrotator and work tools. Warning: Do not stay near the work tools when the machine is in use and always stay clear from lifted work tools. Warning: When the tool is being connected or disconnected, the safety distance is three meters. (For some types of hydraulically powered tools the safe distance can be even higher, consult the user manual for the work tool.) Warning: Only authorized and trained personnel may use tiltrotator. Warning: Always turn off the machine for maintenance and repair work.
Warning: Never use the work tool grip to lift loads. Only use the lifting hook intended and never exceed the hook's lifting capacity. Warning: Do not exceed the machine s approved tip load! User Manual Symmetrical Quick Couplers 2. Safety 13 Warning: Exercise caution when handling long objects. Warning: The machine must be approved to lift goods in order to use the lifting hook (e.g. automatic shut-off valves, overload warning). Caution: Remember to relieve pressure in hydraulic systems before any maintenance or repair work is started. Be careful when searching for leaks as hot hydraulic fluid can cause skin burns, and hydraulic fluid under pressure can penetrate skin. Note: Remember that the machine operator is always responsible that safety procedures are observed during use. Note: The excavator geometry is changed with the quick coupler mounted. Compared with an excavator without a quick coupler the reach is extended while the weight increases. Choose the size of buckets and other work tools with this in mind. Note: Works with breakers can cause vibration damage to tiltrotator with accident and personal injury. Do not use larger breakers than specified in the machine manual. Note: Follow the recommendations in the chapter Maintenance to minimize the risk of personal injury and to ensure the lifetime of the coupler. Note: The indication for a locked or open quick coupler can differ from other couplers and tiltrotators. 2.3. Machine plate and decals The quick coupler s associated signs and warning decals must be visible and legible. Contact Steelwrist when ordering new signs and decals. Your quick coupler is marked with a machine plate as follows: The machine plate shows the quick coupler model, serial number, maximum lift weight with lifting hook, maximum hydraulic pressure, weight, year of manufacture, CE-marking and contact information for Steelwrist.
14 User Manual Symmetrical Quick Couplers 2. Safety 2.4. Type certificate for lifting hook The following type certificate is valid for lifting hooks used on Steelwrist products.
Chapter 3 3. Product Description Topics: Intended use Function description Technical data
16 User Manual Symmetrical Quick Couplers 3. Product Description 3.1. Intended use The quick coupler is designed to attach and switch between tools (e.g. buckets, tiltrotators, grapples, hydraulic breakers) on an excavator. The tool must be equipped with an coupling bracket that follows the symmetric standard of the same size as the quick coupler. The quick coupler should only be used on machines for which it is intended and which corresponds to the same weight class. The quick coupler may only be connected to machines with hydraulics and control electronics that meet current standards. The lifting hook must only be used for the max. lifting weight according to the machine plate, within the hook s lifting area and using approved lifting chains/lifting straps. 3.2. Function description The quick coupler consists of a cast quick coupler body, shaft pins, locking cylinder, locking pins, Front pin lock and lock indicators. The front grip is installed against the carrier machine, the locking pins and the rear grip point away from the machine. 1. Quick coupler body 2. Shaft pins 3. Locking cylinder with integrated spring 4. Check valve 5. Locking pins 6. Indicator bar red (for open quick coupler) 7. Indicator bar green (for locked/secured quick coupler) 8. Front pin lock 9. Cover Locking cylinder with check valve The quick coupler is equipped with a hydraulic cylinder that has an integrated pilot operated check valve with load maintaining function. This is a safety function which ensures that the coupler is still locked in the event of a hose
rupture. The maximum permissible working pressure is set out in the Technical data chapter in this manual. The piston side must be connected to the tank during operations. In addition to this, there is also a safety function in the form of an integrated spring in the locking cylinder that holds the locking pins in locked position even if the machine should lose oil pressure at the same time as the check valve does not function as it should. The locking lugs are driven by the locking cylinder and must always have hydraulic pressure (locking pressure) on the large area of the cylinder during operation. This means that the locking pins are forced out below the rear bracket pin of the work tool. The design of the locking pin means that the quick coupler can attach the work tool without any play and safely on the condition that the work tool bracket is manufactured in accordance with the Standard on Symmetrical Quick Couplers for Excavators. By pressurizing the piston side of the locking cylinder, the load maintaining pilot valve is opened, the cylinder is compressed and the quick coupler opens. The coupler may only be connected to machines where the hydraulics and its electrical components for control must be approved for its purpose. Indicator bars: When the quick coupler is locked, this is indicated by a green indicator bar (right) protruding at the front edge by the work tool shaft. If only the green indicator is visible the work tool is secured from coming loose from the quick coupler, provided the quick coupler is pressurised. User Manual Symmetrical Quick Couplers 3. Product Description 17 When the quick coupler is open, a red indicator bar (left) is visible. It can be seen whether the cylinder is in a withdrawn position (the quick coupler is open or locks against the rear pin of the work tool). The indicator bar is not visible if the cylinder is extended (the quick coupler is in the locked position). If both the red and green indicator bars are visible the quick coupler is incorrectly locked to the rear pin.
18 User Manual Symmetrical Quick Couplers 3. Product Description Front pin lock is a safety function and consist of two locking wings that automatically lock around the front bracket of the work tool and prevent the tool from coming loose, when the cylinder is in the pressurised and extended position. 1. 2. 3. Work tools can and should be connected when the green indicator is visible. When the tool needs to be disconnected the coupler must be opened so that the locking pins can release the rear bracket pin and so that the front bracket pin can pass the front pin lock. 1. 2. 3. The bucket lock switch and the hydraulic valve solution in the carrier machine must be approved for quick couplers for excavators. The switch must be the type that cannot be accidentally activated for example using an integrated lock mechanism that must be pushed to one side in order to use the switch.
User Manual Symmetrical Quick Couplers 3. Product Description 19 3.3. Technical data 3.3.1. Load table The Standard on Symmetrical Quick Couplers regulates shear forces, dimensions and tolerances. The designation S40 means that the quick coupler is based on two parallel bracket pins of 40 mm in diameter, S50 is based on pins of 50 mm in diameter etc. The standard also states what size of excavator the quick coupler is intended for as follows. Bracket type Pin diameter (mm) Max rec. machine weight (tons) Minimum positive excavation torque (knm) Minimum negative excavation torque (knm) S40 40 6 35 23 S50 (S45) 50 (45) 11 65 42 S60 60 18 150 75 S70 70 30 300 195 S80 80 40 600 390 S90 90 70 1000 650 Warning: Do not exceed the machine s approved tip load! Warning: Exercise caution when handling long objects. Warning: Check the quick coupler s compatibility with the machine's performance and do not exceed the recommended loads! 3.3.2. Dimension tables D C C W Pd E F C B A Table 2: Quick coupler dimensions Steelwrist quick couplers are manufactured in accordance with the Standard on Symmetrical Quick Couplers (can be retrieved from our website www.steelwrist.se). Quick coupler S40 S40w S45 S50 S60 S60w S70 S70w Machine weight (ton) 2-6 2-6 5-12 5-12 12-18 12-18 18-32 25-33 Weight Quick coupler (kg) 30 35 70 70 120 120 240 245 A Width (mm) 200 200 290 270 340 340 450 450
20 User Manual Symmetrical Quick Couplers 3. Product Description Quick coupler S40 S40w S45 S50 S60 S60w S70 S70w B Length (mm) 300 300 430 430 480 480 600 600 C. Overall height (mm) 100 120 120 120 135 170 175 200 D. Lifting hook 1 ton 1 ton 3 tons 3 tons 5 tons 5 tons 5 tons 5 tons E Height (mm) Max 50 Max 50 Max 65 Max 65 Max 80 Max 80 Max 100 Max 100 F. Diameter grip (mm) 40 40 45 50 60 60 70 70 Pd. Pin diameter (mm) 35-45 35-50 45-60 45-60 60-80 60-80 60-80, (80-90*) 70-90 W. Max width dipper arm (mm) 120-160 160-200 150-228 150-228 252-304 300-330 280-400 350-431 C/C. Shaft spacing (mm) 160-270 235-355 220-365 220-365 330-460 400-460 270-485, 470-565 (270-475*) J G I K H 1 0,5 Table 3: Bracket dimensions for work tools Bracket G H I J K S40 300.5±0.5 Min 55 Max 40 Max 100 202±1 S50 (S45) 430.5±0.5 Min 70 Max 45 Max 125 272±1 (292±1) S60 480.5±0.5 Min 85 Max 60 Max 150 342±1 S70 600.5±0.5 Min 115 Max 75 Max 250 452±1 S80 670.5±0.5 Min 135 Max 90 Max 250 592±1 S90 750,5±0,5 Min 155 Max 110 Max 250 752±1 3.3.3. Recommended bucket sizes Quick coupler S40 S40 S45 /S50 S45 /S50 S45 /S50 S60 S60 S60 S60 S60 S70 S70 Machine weight (ton) 2-4 4-6 5,5-7 7-9 9-12 12-14 14-15 15-16 16-18 17-20 18-22 22-26 Grading bucket Volume (litres) 175 240 300 400 550 700 750 750 900 900 1050 1250 Width (mm) 1100 1200 1200 1300 1500 1500 1600 1600 1600 1600 1800 1800
User Manual Symmetrical Quick Couplers 3. Product Description 21 Quick coupler S40 S40 S45 /S50 S45 /S50 S45 /S50 S60 S60 S60 S60 S60 S70 S70 Digging bucket Volume (litres) 150 250 280 350 500 600 650 700 850 850 1050 1250 Width (mm) 600 700 700 700 800 900 950 1000 1000 1000 1050 1200 Cable bucket Volume (litres) 105 160 160 190 280 330 330 330 360 360 360 550 Width (mm) 400 400 400 400 400 500 500 500 570 570 570 600 Utility bucket Volume (litres) - - - - - 450 450 450 550 550 700 850 Width (mm) - - - - - 700 700 700 800 800 900 900 Pallet fork Lyftkapacitet - - - 2 ton 4 ton 5 ton 5 ton 5 ton 5 ton 5 ton 5 ton 5 ton Width (mm) - - - 1000 1000 1500 1500 1500 1500 1500 1500 1500 Asphalt cutter Diameter (mm) 400 400 400 400 450 450 450 450 450 450 450 450 3.3.4. Hydraulic connections QCS40FPL + - + QCS45-QCS70FPL + - + -
22 User Manual Symmetrical Quick Couplers 3. Product Description Table 4: Technical data locking cylinder Quick coupler S40 S40w S45 S50 S60 S60w S70 S70w Pmin (bar) 50 50 50 50 50 50 50 50 Pmax (bar) 270 270 270 270 350 350 350 350 Thread G1/8" G1/8" G1/4" G1/4" G1/4" G1/4" G1/4" G1/4" 3.3.5. Hydraulic diagram See the hydraulic diagram for the quick coupler below. 2 + - 1. Locking cylinder 2. Pilot controlled check valve (integrated) For hydraulic pressure on + locks coupler. For hydraulic pressure on + opens coupler. + must be pressurised during operation. 1
Chapter 4 4. Environmental aspects Topics: Environmental information
24 User Manual Symmetrical Quick Couplers 4. Environmental aspects 4.1. Environmental information As part of Steelwrist environmental efforts, we strive to make products that over their life cycle have as little environmental impact as possible. Overall the usage of Steelwrist products on an excavator result in a more efficient work. This is achieved by fewer machine movements, higher machine utilization and also less machine transportations since a Steelwrist equipped excavator with appropriate work tools can do tasks that otherwise would require several different machines on the work site. All this has a positive impact on the environment compared with an excavator without Steelwrist products. Despite this, it is also important that Steelwrist products themselves are developed, produced, maintained and at the end of the product life cycle, recovered in a way that complies with regulatory requirements and reduces the environmental impact. The following applies to the disassembly and assembly work: All dismantling work shall be in accordance with applicable national laws regarding health, work safety and environment. This will include all labor, handling, sorting, transportation, storage and disposal of components, hydraulic oils, and other materials. Consideration must be given to soil and surface water in order to prevent contamination. Harmful substances and hazardous waste must be handled and stored in well ventilated areas in accordance with national laws and regulations. Local safety instructions should be well known and respected. Transportation of hazardous waste shall be made by approved forwarder. During dismantling, metals, hydraulic hoses, hydraulic oils, greases and other materials should be sorted and disposed of appropriately in accordance with laws and regulations. The following apply for recycling and waste management: Steelwrist products are manufactured with the purpose that as much as possible should be recycled. The majority of components are made from recyclable materials. Metals is the material that is easiest to recycle. Generally, we recommend that recyclable materials are handled through an approved recycling company. Metals are the largest part of the weight of Steelwrist products. Over 80% is made of steel but also aluminum bronze is used in the product. Most metals can be recycled. Steel and aluminum bronze should be separated from other metals before disposal for recycling. Oil is drained, cleaned and reused or burned for energy recovery. Make sure the oil is not poured down the drain! This can cause problems for wast water plants. Contact local authorities for information. Ensure the oil is not contaminated by other fluids such as water or solvents since contaminated oil is much more difficult and expensive to recycle. Plastics can be recycled either through mainly melting (thermoplastics) or burning (thermosets). Plastics should only be burned in approved incinerators. Electrical and electronic waste contains valuable and reusable components and a number of chemicals (PCBs, heavy metals, etc.) with environmental hazards. Other parts can be burned for energy recovery. Never dump hazardous electrical and electronic waste. Equipment for dismantling: The work of dismantling should be carried out in a well-ventilated room equipped according to health and safety protection laws and other laws and regulations. It is important that the dismantling work is done with appropriate tools from both the environmental and health and safety aspects. Personal protective equipment should be used where necessary during dismantling work. This includes protective clothing and footwear, goggles, gloves, ear protection, helmets and face masks.
Chapter 5 5. Installation Topics: Unpacking/transport of the quick coupler Install the quick coupler Connect the hydraulics Tightening torque Remove the shaft pins Check list for quick coupler installation
26 User Manual Symmetrical Quick Couplers 5. Installation 5.1. Unpacking/transport of the quick coupler The Steelwrist quick coupler with Front pin lock is supplied unassembled on a pallet. Warning: Before lifting, check the lifting capacity of the lifting slings, forklift, lifting tools, etc. The weight of the quick coupler is set out on the machine plate and in the Technical data chapter in this manual. Warning: Place the pallet on a stable, horizontal and non-slip surface. Examples of how the quick coupler can be lifted using lifting slings. Ensure that the shaft pins expander cones are tightened before lifting. 5.2. Install the quick coupler Before installing check that the quick coupler has not been damaged during transportation. Also check that the machine plate corresponds with the quick coupler and excavator in question. Warning: Installation of the quick coupler assumes that the excavator is equipped with the necessary locking hydraulics. If locking hydraulics are not installed on the excavator contact your dealer or Steelwrist. Warning: Check the limit values for loads with reference to the quick coupler weight and height to prevent personal injury and damage to the equipment. In certain cases it might be necessary to reduce the bucket volume. Caution: Observe cleanliness during the installation so that hydraulic oil does not get contaminated. Particles in the hydraulic oil are damaging to components such as valves, hydraulic motors etc. In the worst cases contaminated hydraulic oil can prevent the full functionality of the work tool and excavator. The procedure for installing the quick coupler is as follows: 1. Prepare the installation by positioning the excavator on a flat, clean and non-slip surface. Ensure that the quick coupler is aligned with the dipper arm and break link on the excavator. 2. Remove the original shafts from the excavator and the shafts supplied with the quick coupler. The shafts supplied with the quick-coupler must be used.
3. Install and shim the shaft pins as follows: User Manual Symmetrical Quick Couplers 5. Installation 27 a) Ensure that the excavator arm shaft bushings are clean and functional. b) Place any O rings around the shaft hub and lower the excavator dipper arm between the front shaft hubs on the quick coupler. c) Install the shaft through the quick coupler and the excavator dipper arm. Use the shims supplied so that the axial play between the quick coupler and the dipper arm is less than 1 mm. Shims are supplied with the quick coupler and can be used as necessary. Shims are available in different thicknesses to achieve the best possible shimming. d) Centre the shaft using a rubber mallet so that it protrudes equally on both sides of the quick coupler. e) Grease the cone and install on the shaft end. Install the cap and tighten the screws and locking washer loosely and then tighten alternately on both sides to a torque according to the table below Tightening torque 1 2 3 4 6 5 1. Shaft 2. Expander cone 3. Cap 4. Nordlock washer 5. Screw 6. Nut 7. Locking washer 2 4 7 4 5 4. Fold the bucket link down between the rear shaft hubs and install the shaft pin and bucket link in the same way as the previous procedure 5. Grease so that the bushings receive lubrication.
28 User Manual Symmetrical Quick Couplers 5. Installation Note: Important, the bolts for shaft pins with expandable cones must be retightened to the correct torque again after a period of use! Tightening torque 5.3. Connect the hydraulics It is important to have the right length for the hydraulic hoses. If they are too long there is a risk of them bending during work and if they are too short they will wear unnecessarily and result in unnecessary servicing. Warning: Installation of the quick coupler assumes that the excavator is equipped with the necessary locking hydraulics. If locking hydraulics are not installed on the excavator contact your dealer or Steelwrist. Caution: Observe cleanliness during the installation so that hydraulic oil does not get contaminated. Particles in the hydraulic oil are damaging to components such as valves, hydraulic motors etc. In the worst cases contaminated hydraulic oil can prevent the full functionality of the work tool and excavator. Note: The quick coupler s hydraulics and control must meet applicable requirements and standards e.g. ISO 474-1, App.B and ISO 13031. 1. Install the adapters on the hydraulic cylinder in the quick coupler, see the dimensions in the Technical data chapter. 2. In some cases the hydraulic hoses are supplied, if so, these should be fitted. Otherwise, manufacture the hoses. 3. Connect the locking hydraulics to the quick coupler. Ensure that the hoses are sufficiently long that they are not stretched when operating the work tool, while not hanging down too much. 4. Open any shut-off valves on the dipper arm. 5. Carefully run all movements of the machine. Check that the quick coupler does not hit any parts of the machine or that the hoses become trapped or rub during movement between limit positions.
User Manual Symmetrical Quick Couplers 5. Installation 29 6. Test run the hydraulic functions on the quick coupler and ensure these work correctly and that there is no leakage. 7. Then attach one work tool at a time in order to discover any limitations to free movements and to establish that all work tools can be attached correctly. Ensure that the quick coupler goes into the bracket of the tool and that the locking pins engage correctly with the rear bracket pin. The locking pins must move out at least half the shaft diameter in locked mode and the tool must not have any play at all in locked mode. 5.4. Tightening torque The following tightening torques apply to the bolts used for the quick coupler. Note: Important, the bolts for shaft pins with expander cones must be retightened with a torque and at intervals set out below: After 1 hr After 3 hrs After 1 day of use Last time after 4 days of use For recurring service Table 5: Tightening torque for shaft pins with expander cones Bolt/Nut size M12 M16 M27 M30 Torque [Nm] 128 311 300 350 Table 6: Tightening torque generally for bolts on the quick coupler Bolt size/ grade M8 12.9 M10 12.9 M12 12.9 M16 12.9 Torque [Nm] 38 75 128 311 Table 7: Tightening torque for the hydraulic adapter Thread 1/8" BSP 1/4" BSP Torque [Nm] 20 50
30 User Manual Symmetrical Quick Couplers 5. Installation 5.5. Remove the shaft pins The procedure for removing the shaft pins is as follows: 1. Place the quick coupler on flat ground. 2. Depressurise the locking hydraulics to the coupler. 3. Disconnect the hoses (cap sealing surfaces with plastic plugs). 4. Slacken off the screws, remove the locking washer and the cap on both sides of the shaft. 5. Use a round section bar or a drift between the rubber mallet and the shaft end to avoid damage to the threads. Hit first one side and then the other alternately until the cones loosen. Check that the round section bar does not come into contact with the cones. 6. Remove the cones and then remove the shaft. 1 2 3 4 6 5 1. Shaft 2. Expander cone 3. Cap 4. Nordlock washer 5. Screw 6. Nut 7. Locking washer 2 4 7 4 5 5.6. Check list for quick coupler installation After the installation is ready verify the following points to ensure durable and safe installation Table 8: Check list for installation of quick coupler Check that: OK? Check that the O rings around the shaft hub are positioned correctly and are not pinched. Check the shimming of the shaft pins so that the play is max 1 mm and that the locking screws are tightened. Check that the locking screws for the expander cones on the shaft pins are tight. Retighten the locking screws for the expander cones on the shaft pins after 1hr, after 3hr, and then again after 1 day of use and then a last time after 4 days of use. Check that all lubrication channels are unblocked and function properly, so that grease enters the shaft bushings around the shaft hub. Verify that all the shaft bushings are filled with grease. Check that the locking hydraulics are installed so that the quick coupling can move freely without the hoses catching. Check that the locking hydraulics are sealed. Run the lock mechanism and check that the indicator bars correctly indicate locked and unlocked. Ensure that the quick coupler can move through its maximum break angle without the hoses being trapped or without any mechanical interference anywhere.
Chapter 6 6. Operation Topics: Connecting work tools Disconnecting work tools Using the lifting hook Preparation before first use of the tool
32 User Manual Symmetrical Quick Couplers 6. Operation 6.1. Connecting work tools The quick coupler should be connected to the excavators hydraulic circuit for quick coupler locking, which shall have a constant pressure. The locking pressure should exceed 50 bar but be less than the recommended max. pressure. The hydraulics and its electrical components for control must be approved for its purpose. See: Technical data Caution: Ensure that tools and the excavator stands firmly on flat ground (recommended tilt max. ±5 ) and that nobody is within the working area. Note: The quick coupler s lock indicator can differ from other couplers and tiltrotators. 1. Ensure that the quick coupler is in the locked position before you start to attach i.e. switch off the bucket lock switch so that the lock pins move out. This is also indicated by the green indicator bar (right side) that is now visible. 2. Connect the front grip of the quick coupler to the front bracket of the work tool. Take care when attaching the work tool bracket pin so that no hydraulic hoses in the work tool (for example a tiltrotator) are close to the bracket and can be damaged if one is not careful. 3. Fold in the unit so that the quick coupler goes to the bottom of the bracket so that the work tool hangs from the front grip. Check that both the locking lugs for the front pin lock return to normal position when the bracket has been passed.
User Manual Symmetrical Quick Couplers 6. Operation 33 4. Activate the bucket lock switch so that hydraulic pressure is created and the locking pins are drawn back to the open position. A loud buzzer should sound and the bucket lock switch should also display visually that the quick coupler is now open, in an unsafe state. The work tool rear bracket pin must now be in position in the rear grip. The green (right) indicator bar is no longer visible, a red indicator bar (left) is visible instead and indicates that the quick coupler is open. 5. Deactivate the bucket lock control function and activate locking pressure according to the machine's instruction manual. The locking pins come out below the rear bracket pin and lock the bracket pin. This is also indicated the green indicator bar that is now visible again. The red indicator bar should not now be visible. If the red indicator bar (left) is visible the quick coupler is not correctly locked or secured. Repeat the locking procedure. 6. Make sure the quick coupler is securely locked and the work tool is fixed properly before use. Always perform the following test before using the work tool: 6 a) Place the work tool in an extended position and push the front end of the work tool to the ground. Pull in the dipper arm cylinder with the work tool pressed to the ground in order to ensure that the locking pins lock the rear bracket pin under load. 6 b) Lift the work tool and shake
34 User Manual Symmetrical Quick Couplers 6. Operation 6 c) Perform a full range of movement. 6 d) If it is not possible to determine if the quick coupler is locked using the above procedure, the operator should exit the machine and check that the quick coupler is properly locked before work is started. 6.2. Disconnecting work tools Disconnecting a work tool from the quick coupler is basically the reverse tasks compared to connecting a work tool in the quick coupler. Caution: Ensure that work tools and excavator is in a safe position and that nobody are within the working area. 1. Crowd in the tiltrotator so that the work tool hangs in the work tools front bracket pin The work tool should be on or near the ground. 2. Activate the bucket control function according to the machine instructions so that hydraulic pressure is created and the locking pins reverse and are in the open position. The buzzer should sound and indicate that the bucket lock control function even optically that the quick coupler is in the open position i.e. unsafe state. The green indicator bar is no longer visible, but a red indicator bar is visible instead. 3. Gently put the work tool on the ground. When the tool is placed on the ground, the bucket cylinder is retracted so that the quick coupler rear grip is released from the bucket adapter.
User Manual Symmetrical Quick Couplers 6. Operation 35 4. Lift the dipper arm so that the quick coupler is released from work tools front bracket pin. 5. Activate the quick coupler safety switch. The locking pins move out the maximum amount. This is also indicated by the green indicator bar being visible and the red indicator bar (left) disappearing into the quick coupler. 6. The quick coupler is now ready to pick up the next work tool. 6.3. Using the lifting hook The lifting hook must always be used with great care. Always check lifting equipment before every lift and always lift as low as possible. Warning: Only use approved lifting chains/lifting straps and never lift a greater weight than stated on the quick coupler machine plate. Warning: Ensure that nothing that can be damaged is within a safety radius of three meters plus the greater of the lifted object height or length. Warning: Never lift outside the hook s lifting range. The procedure for connecting a lifting shackle or lifting strap to the lifting hook is as follows. 1. Check that the lifting hook is intact and that the protective lugs function correctly. 2. Place the shackle/strap on the lifting hook so that the lift takes place within the marked area. 30 50 3. Ensure that no one is in the safety area or that there are objects there which could be damaged if the object being lifted should fall.
36 User Manual Symmetrical Quick Couplers 6. Operation 6.4. Preparation before first use of the tool Preparations before using Quick coupler or Tiltrotator with Front pin lock for symmetric standard. Warning: Check your Tiltrotator and other work tools before connecting a Quick coupler or Tiltrotator with Front pin lock! Incorrectly positioned reinforcement plates may reduce functionality or damage the Front pin lock s segment! * See symmetric standard (http://steelwrist.com). 1. Check your Tiltrotator and other work tools before connecting that there is sufficient space for the Front pin lock. No modifications will be necessary, if the work tool conforms to the symmetric standard. 2. The space needed for the Quick coupler or Tiltrotators with Front pin lock : A Quick Coupler/Tiltrotator QCS40 / X06 FPL QCS45/50 / X07 / X12 FPL QCS60 / X18 / X20 FPL QCS70 / X26 / X32 FPL A (mm) 37 37 53 62 3. Remove any. plates that may be in the way of the Front pin lock, see the figure above. Check with your equipment/work tool suppliers to ensure that no violations of the CE marking have been made. 4. Grind sharp edges and if necessary apply a surface finish.
Chapter 7 7. Maintenance Topics: Daily care and maintenance Maintenance schedule Touch-up painting
38 User Manual Symmetrical Quick Couplers 7. Maintenance 7.1. Daily care and maintenance To ensure that the quick coupler functions without problems during its entire service life, it is important to carry out regular inspections and maintenance. It is important that all safety instructions are followed in the daily maintenance work. Warning: Ensure that the machine is switched off and no unauthorized persons are in the machine or at the quick coupler when using or during maintenance work with or near the quick coupler. Warning: Always use the necessary protective equipment when carrying out maintenance work on the quick coupler. Note: Do not use the quick coupler if there is play or if there are damaged components. Note: Rectify all minor damage immediately. In event of more serious damage contact your dealer or Steelwrist. Recommended lubricant Multipurpose grease EP2/NLGI 2 is recommended for lubrication 7.2. Maintenance schedule Lubrication points Table 9: Maintenance schedule Daily Weekly Annually If necessary /Service Checkpoints X Check that no cracking has occurred in the construction. X X Cleaning the quick coupler X Make a check of the quick coupler locking pins, springs, and other mechanical components. X Check that all screws in the shaft pin end washers are secure and that the shaft pins do not slide out. X Check that the indicator bars are intact. X Check that the lock lugs for the front pin lock function correctly. / Check of the Front pin lock parts, function and visual check X Check that hydraulic hoses and connections are intact without oil leaks. X X Inspect the locking mechanism of the lifting hook before each use. X X Check that the locking bolt for lock cylinder is intact and tight
User Manual Symmetrical Quick Couplers 7. Maintenance 39 Daily Weekly Annually If necessary /Service Checkpoints X Lubricate the grease nipples on the locking pins bushings (2x) X Lubricate the shaft pins in accordance with the lubrication diagram for the machine if the quick coupler has lubrication through the shafts. X X Retighten the shaft pin bolts/nuts with a torque set out in the table in the Installation chapter X X Check that warning signs are present and legible 7.3. Touch-up painting Touch-up painting can be carried out on steel surfaces according the Steelwrist painting instruction 720008. Note: Do not paint contact surfaces, holes, threads, grips or bushes! Colour: RAL 9005 (Black) RAL 6018 (Green for lifting hooks)
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