HOA HDX S120 Installation & User Manual Download

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HDX™ Cast Coupler

Installation & User Manual

Summary of Contents for HDX S120

Page 1: ...HDX Cast Coupler Installation User Manual ...

Page 2: ...gene OR USA All rights reserved Any use of the editorial or pictorial content of this publication is strictly prohibited without express written permission from HOA Manufacturing Inc Printed in the USA 02 13 DCN HDX IUM 01 20130216 ...

Page 3: ...N INSTRUCTIONS Installation Preparation 14 15 Removing Attachment 16 Connecting Coupler to Excavator Arm 17 Installing Hose Brackets 18 19 Hydraulic Hose Assembly 20 Hydraulic Hose Routing 21 23 Control Valve Filter Switch Box 24 28 OPERATION MAINTENANCE Warnings Precautions 29 30 Switch Box Overview 31 Engaging Attachment 32 35 Disengaging Attachment 36 Lifting Loads with Coupler Installed 37 Mai...

Page 4: ... HDX coupler operates on the excavator s low pressure pilot system rather than the main high pressure system Engaging an attachment is easier and safer using the low pressure pilot system The attachment can remain on the ground and does not have to be curled in to take the machine over relief The HDX coupler is designed to allow the operator to switch the attachments on a hydraulic excavator in a ...

Page 5: ... products manufactured by HOA Manufacturing Products manufactured by others are covered only by the warranties extended to HOA Manufacturing by its suppliers Warranty claims must be made to HOA Manufacturing in advance of any repairs by submitting a Warranty Claim Number and Warranty Claim Form which can be obtained by contacting HOA Manufacturing Warranty claims made without a Warranty Claim Numb...

Page 6: ...ad this manual thoroughly before attempting to install operate or maintain your HDX coupler Before installing unpack the coupler and Coupler Installation Kit Inspect the shipper s bill of lading and the Coupler Installation Kit component list on pages 7 9 to ensure you received all items If items are missing contact your dealer Inspect all items for damage due to transit or handling If any items a...

Page 7: ...ct will not be damaged or made unsafe by the operation lubrication maintenance and or repair procedures you choose Other Recommendations Install a Safe Operation decal on cab inside right hand window near switch Always wear protective equipment during installation inspection and maintenance procedures Avoid oil spills Ensure you have an ample supply of rags and absorbent towels on hand for cleanin...

Page 8: ... Part Identification Charts This section provides diagrams for identification of the excavator the coupler and the Coupler Installation Kit These charts will also familiarize you with the terminology used in this manual HOA Manufacturing HDX Cast Coupler Installation User Manual ...

Page 9: ... to pick up multiple pin diameters Refer to this chart for the appropriate pin diameter to match your HDX coupler HDX Coupler Model Pin Diameter S120 60 65 70 mm S200 70 80 mm S250 80 90 mm S350 90 100 mm S450 100 110 mm Chart 4 HDX Coupler Pin Diameters HOA Manufacturing HDX Cast Coupler Installation User Manual ...

Page 10: ...ng Reference 6 Reusable Female Hose Ends Swivel BL06 06NJ 18 18 N 6 O Ring x 6 JIC Male 90 Degree 849FSO06X06 5 5 O 8 O Ring x 6 JIC Male 848FSO06X08 2 2 P 6 JIC Male x 6 JIC Male Straight Bulkhead Fitting 2700 06 06 2 2 Q 6 JIC Male x 6 JIC Male 45 Degree Bulkhead Fitting 2702 06 06 2 2 R Nut for Bulkhead Fittings 711BHSF06 4 4 S 6 O Ring x 6 JIC Male 6400 06 06 1 1 T Upper Lower Bulkhead Fitting...

Page 11: ...lter Head B Filter Element C 2 x 2 x 1 4 Angle Bracket 1 4 x 20 x 3 4 Hex Head Bolts w Washers D F 3 Light Switch Box Assembly E Buss 10 Amp Fuse G 8 x 1 2 x Mounting Screws H Hydraulic Control Valve 24V Vickers I Mounting Sub Plate 1 4 x 20 x 3 4 Sub Plate Mounting Screws J M Control Valve Mounting Bracket K 1025 Mounting Screws HOA Manufacturing HDX Cast Coupler Installation User Manual ...

Page 12: ...se Ends Swivel N O P 8 O Ring x 6 JIC Male Q 6 JIC Male x 6 JIC Male Straight Bulkhead Fitting 6 JIC Male x 6 JIC Male 45 Degree Bulkhead Fitting R S Nut for Bulkhead Fittings V 6 2500 psi Single Braid Hydraulic Hose X Wire Ties Y Tubular Hose Retainer Bracket T 6 O Ring x 6 JIC Male Protective Hose Sleeve W Upper Lower Bulkhead Fittings Brackets U HOA Manufacturing HDX Cast Coupler Installation U...

Page 13: ...cibel Rating 72 dBA Wiring Harness T4 2 SJT0W TPE 105 C FT2 water resistant Hydraulic Control Valve Part Number Vickers DG4V3S2CMU1H560 Power Rating 30W 24 VDC Fatigue Pressure 5000 psi 350 bar System Pressure Excavator pilot pressure control system Not to exceed 1000 psi Hydraulic Hose 6 Single Braid Hose Eastman HFS06 2500 psi or equivalent 4 Single Braid Hose Eastman E7 04 2750 psi or equivalen...

Page 14: ...ing to familiarize yourself with the coupler components Front Lever The HDX coupler features a cast front lever The geometry of the front lever along with the configuration and alignment of the other coupler components hold the front lever in the closed po sition without the assistance of the hydraulic cyl inder Lifting Eye The cast lifting eye on your coupler is durable and designed to handle the...

Page 15: ...fter the install any time a hose is removed as well as any time after the machine sits for any length of time Cylinder check valve is a cartridge type and separately serviceable Bleed Screw Hydraulic ports are positional for easy access Hardened ball and socket spherical self aligns and requires no lubrication Oversize solid chrome rod Shafts are machined from a solid block of steel eliminating cr...

Page 16: ...unhealthy gases when heated Preheat parts to be welded to a temperature of 300ºF to 400ºF 150ºC to 200ºC Run stringer passes minimize heat input and welding time by using short stringer beads to remove stress Cool slowly after welding If temperature is 50ºF 10ºC or below wrap with an insulation blanket A lo calized post weld heat treatment with a Rosebud torch should include at least two inches mi...

Page 17: ...ake sure you have the proper fittings needed to tie into the pilot pressure system and the hydraulic return system These fittings are not supplied with the Coupler Installation Kit Check to determine if the tubular hose bracket can be welded to the excavator s H link Determine the best route for running the hoses on the excavator The hoses should not interfere with other excavator components 14 DA...

Page 18: ...operly Always use the proper safety protection such as hard hats work gloves safety shoes and safety glasses when operating maintaining or installing this equipment HDX couplers are designed to be used only with a HOA Manufacturing Coupler Installation Kit Installing a coupler with anything other than components from a HOA Manufacturing Coupler Installation Kit results in an unauthorized modificat...

Page 19: ...osition the attachment securely on firm level ground 1 Make sure the throttle control is in the low idle position Start the engine 4 Remove the retaining bolts from the pins 5 Remove both the stick and link pin from the arm to bucket connection 6 Operate the excavator controls to remove the excavator arm from between the ears of the attachment 7 Rest the excavator arm securely on firm level ground...

Page 20: ...ch came with the excavator to connect the coupler to the stick Use a rubber mallet to drive the pin into place 5 Slowly operate the bucket cylinder on the excavator to align the excavator s pivot link hole with the link side of the coupler Insert the link machine pin Use the original link machine pin which came with the excavator to connect the coupler to the pivot link Use a rubber mallet to driv...

Page 21: ...e excavator arm in an extended position 6 Disconnect the negative cable from the battery terminal 7 Attach the lower bulkhead fittings bracket to the excavator arm Remove the fittings from the bracket and weld the bracket to the excavator arm using the recommended welding procedures on page 13 8 The location of the lower bulkhead fittings bracket will vary depending on your specific excavator arm ...

Page 22: ...ink and weld using the recommended welding procedures on page 13 Note The tubular hose retainer bracket may not work on all excavator H links The main objective for the bracket is to guide the hoses from the lower bulkhead fittings to the coupler cylinder and to prevent hose chaffing Some H links are made of materials not suitable for welding Other H links may allow the hoses to slip through them ...

Page 23: ...you need extra hose See the hose specifications listed on the Coupler Installation Kit component list on page 7 to determine if you will need extra hose A Place socket in a vise B Cut hose to length and dip into heavy oil D Hold hose with the vise E Dip hose end of nipple into heavy oil F Using a wrench screw nipple assembly completely into socket C Screw hose counter clockwise into the socket unt...

Page 24: ...ering with other lines and equipment Be sure to secure all hoses to the excavator 1 Before connecting any hoses be sure the hoses have been flushed completely with clean hydraulic fluid to prevent contamina tion 3 Route the hoses through the excavator s linkage as shown in the diagram below Make sure the hose has enough slack to move with the excavator linkage Allow for some flexibility Protect al...

Page 25: ...or controls so the coupler is curled in completely Pull the hoses tight to the lower bulkhead fittings bracket Release tension on the hoses allowing a small amount of slack Mark the hoses cut and then assemble the hose fittings on the cou pler 5 After installing the lower hose from the cou pler to the lower bulkhead fittings bracket begin routing the remaining hose sections Measure and install the...

Page 26: ...nt interference with other lines or equipment Secure the hoses to the ma chine using the plastic tie wraps supplied in the Coupler Installation Kit Repeat this procedure for both sides 7 Carry both of your hoses all the way into the engine compartment that houses the pilot pressure system Make sure you have plenty of slack where the line ends in the engine compartment You will tie these two hoses ...

Page 27: ...ies into the pilot pressure system and hydraulic reservoir tank in order to provide hydraulic flow to operate the coupler The 3 light switch box is mounted in the cab of the excavator and is used by the operator to control the action of the coupler The 3 light switch box connects to the control valve using the wiring harness provided The switch box and wiring harness leads are color coded for easi...

Page 28: ...he mounting bracket using the supplied sub plate mounting screws The mounting sub plate ports are marked as follows T Tank P Pilot Pump A Hose B Hose 3 Install three 90 degree 6 O ring x 6 JIC male fittings and one straight 6 O ring x 6 JIC male into the mounting sub plate 4 Connect the hoses to the mounting sub plate The two hoses that run from the cou pler cylinder into the mounting sub plate co...

Page 29: ...lation use care to keep the sealing surfaces of the filter sealing ring 7 After properly connecting your hoses you are ready to install the control valve onto the mounting sub plate You will use the four 1025 mounting screws to connect the valve and sub plate 6 Route hose from the mounting sub plate port P to the pilot pressure system Refer to the excavator s OEM service manual for connection poin...

Page 30: ...Performance Standard 8 Install the wiring harness onto the control valve The harness is marked for the lock side and the release side The lock side of the harness should be connected to the side of the control valve where the extend line comes into the sub plate The release side of the harness should be connected to the side of the control valve where the retract line comes into the sub plate The ...

Page 31: ...ch box is oper ating properly you have completed the installation of your coupler Before attempting to operate or maintain the coupler thoroughly read and familiar ize yourself with the Operation Maintenance section on pages 29 40 Note The lights on the switch box indicate switch position only The lights do not indicate the position of the levers You must allow the levers time to extend and retrac...

Page 32: ...nstalled Keep in mind the attachment can come in contact with the boom arm and or cab depending on the coupler attachment combination The excavator s attachment range of motion changes with the HDX coupler installed specifically the bucket dump angle and the bucket curl angle The operator may experience slow or unexpected movement when operating with cold hydraulic oil Likewise damage to the hydra...

Page 33: ...l excavator operators should familiarize themselves with all coupler attachment combinations before attempting to operate the coupler This includes but is not limited to practicing engaging and disengaging each attachment Furthermore when new attachments are added to the machine s fleet the operators should proceed with the same familiarization process before being used on the jobsite Only operate...

Page 34: ...erating the coupler In the neutral position hydraulic flow to the coupler is shut off Release Position The release position will retract the coupler cylin der In this position the buzzer alarm will sound and the red light on the switch box will glow The release position should be used only when chang ing attachments If the coupler is disconnected from an attachment for any length of time the se le...

Page 35: ... The attachment may drop without warning if the coupler is not properly engaged with the attachment Read this section carefully and perform the following steps each and every time you change attachments 1 Engage attachments completely clear of all personnel 2 Test connections away from all personnel 3 Never swing coupled attachments over workers heads The front lever engages in front of the attach...

Page 36: ...aging attachment Keep in release position while engaging attachment CAUTION All coupler attachment combinations should be checked for possible interference before operating the coupler Ensure the coupler engages and disen gages properly and easily with each attachment Keep in release while seating the coupler 3 Seat the coupler onto the attachment s link pin by curling the coupler in toward the ma...

Page 37: ...ing Attachment 4 After fully seating the coupler switch to the lock position to engage the link pin with the lock lever Switch to lock to engage link pin with lock lever DANGER The control switch should always remain in the lock position while operating the excavator with coupled attachments DANGER Connection tests must be performed every time you engage an attachment Failure to properly engage an...

Page 38: ...on by trying to disengage the attachment from the coupler using the machine s weight Dig the attachment in the ground lower the attachment against the ground and try to force the attachment off by lifting the excavator s tracks off the ground 8 After performing all connection tests you are ready to operate your machine with the coupled attachment DANGER The switch must remain in the lock position ...

Page 39: ...upled attachments over workers heads CAUTION When disengaging from an attachment turn the switch to the release position long enough to ensure the levers are completely open before curling the coupler out Do not force the coupler off of the attachment DANGER Always disengage attachments away from personnel The following details the proper steps for disengaging from an attachment with the HDX coupl...

Page 40: ...excavator Curl the coupler inward when lifting loads This is the preferred method for lifting 2 Do not use the attachment hook while coupled on an attachment and do not use the coupler s lifting eye while coupled to an attachment Follow these steps to properly lift loads with the HDX coupler HOA Manufacturing HDX Cast Coupler Installation User Manual ...

Page 41: ...plate and coupler indicate worn areas Those worn areas should be built up and then ground to fit the template After buildup is complete grind both sides smooth When a template is not available proceed as follows to rebuild the C casting Allow pin to rest at the bottom of the C casting Wedge pin to the back of the C casting Mark at the top of the pin approximately centerline of pin where the weld b...

Page 42: ...pect daily to make sure the springs are installed properly and are not damaged or missing Replace any damaged or missing springs immediately Both springs need to be replaced as a set annually regardless of their condition Only use springs supplied by HOA Manufacturing and designed for your HDX coupler Installing any other springs void the warranty and may result in injury death damage to property ...

Page 43: ...loose in C casting Bucket pin is severely worn Replace pin and build up C casting with weld per procedure outlined on page 38 Machine pressure is too low Check to make sure machine pilot pressure is at least 450 psi Rear lever will not extend far enough to engage the bucket pin Install yoke Make sure cylinder stroke extends 6 full retract to full extend Check for oversize pin spread dimension beyo...

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