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Hendrix Quick Change Coupler Gen I and Gen II User Manual (PDF

1. N WARNING N Maintenance work should be performed by experienced and qualified personnel Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 PI 2 3 BRIX OPERATIONS amp MAINTENANCE SECTION Il SWITCH BOX OVERVIEW This section provides an overview of the function of the Switch Box The Hendrix Quick Coupler is controlled by the provided 3 Position Switch Box that mounts in the cab of the excavator The Switch Box functions as follows A RELEASE POSITION C LOCK POSITION When the switch is placed in the Release Position The Lock Position will extend the Coupler cylinder the Coupler cylinder will retract In the Release When the Coupler cylinder extends the locking lever Position the buzzer alarm will sound and the RED will rotate and engage the attachment link pin The light on the Switch Box will glow The Release GREEN light will glow and the buzzer alarm will stop Position should be used ONLY when changing when the switch is placed in the lock position THE attachments If the coupler is disconnected from SWITCH MUST BE PLACED AND REMAIN IN THE an attachment for any length of time the selector LOCK POSITION WHILE OPERATING THE switch may be returned to the lock position to EXCAVATOR WITH A COUPLED ATTACHMENT silence the alarm B NEUTRAL POSITION The Neutral position is used ONLY in the event of a hydraulic leak in the coupler system i e Couple Hose Breakage In this position the buzzer alarm will sound and th
2. Z 4 Kit AB 4 Kit 8 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 MESS NORD QUICK COUPLER USER MANUAL GENERAL INFORMATION SECTION llli RECOMMENDED WELDING PROCEDURES This section lists the recommended welding procedures to follow when installing or maintaining your Coupler HENDRIX High Strength Low Allow Steels require greater than normal precautions when welding All areas to be welded should be cleaned and properly aligned if a fit is involved Minimize heat input and welding time by using short stringer beads and weaving not over three 3 times the electrode diameter Remove slag after each pass and peen the bead to relieve stress Preheat the part s to be welded to 300 degrees F 150 degrees C to 400 degrees F 200 degrees C Cool slowly after welding wrapping with insulating blanket if necessary in cold weather A localized post weld heat treatment with a Rosebud torch should include at least two 2 inches minimum of the adjacent base metal and the weld This heat treatment should raise the temperature of the area heated to 400 degrees F 200 degrees C to 500 degrees F 260 degrees C Control of this step is critical to avoid embrittling the steel Remove paint from any surface to be heated or welded Painted surfaces give off unhealthy gases when heated or welded Use a mask and proper skin protection when removing paint from any surface When removing paint by sanding do not breath the
3. dealer to obtain the proper caps and plugs used on your model excavator CAUTION Make sure you use the ORIGINAL machine pins from your excavator to connect the coupler to the arm of the excavator DO NOT use the attachment pins that shipped with the coupler to connect to the arm of the excavator N WARNING N Avoid oil spills Use containers rags and or absorvent towels to contain any oil leakage Dispose of all waste oils fluids lubricants and other hazardous waste properly N WARNING N Always use the proper safety protection such as hard hats work gloves safety shoes and safety glasses when operating maintaining or installing this equipment CAUTION DO NOT CONNECT THE HENDRIX QUICK COUPLER TO HYDRAULIC PRESSURES EXCEEDING 1000 PSI The Hendrix Quick Coupler is designed to operate off of the excavator s low pressure pilot system Only connect the coupler to the excavator s low WARNING pressure pilot system Hendrix Hydraulic Quick Couplers are designed to be used only with a Hendrix Installation Kit Installing a coupler with anything other than components from a Hendrix Installation Kit results in an unauthorized modification to the coupler Any unauthorized modifications may impair function affect performance and affect the life of the coupler the excavator and or the attachment Unauthorized modification may result in injury or death to personnel Hendrix disclaims any liability and
4. B HENDRIX II COUPLER The Hendrix Il Coupler is locked into place by engaging the attachment s stick pin with the Front Lever and the attachments link pin with the Back Lever To engage these pins with the Hendrix 11 levers place the Control Box Switch to the LOCK position see Fig 37 1 Placing the switch in the lock position will extend the coupler s cylinder in turn rotating the levers The lever that rotates first depends on the angle of the attachment ears However generally the Front Lever will engage the attachment s stick pin first The Front Lever engages over and around the stick pin see Fig 37 2 The Back Lever will then engage under and around the attachment s link pin see Fig 37 3 N DANGER N IMPORTANT The Back Lever is the locking device for the coupler The purpose of the Front Lever is to act as a backup in case of some type of failure to the Back Lever You must ensure that the Back Lever along with the Front Lever is properly engaged before attempting to operate the excavator with a coupled attachment DANGER A After the Front Lever engages allow time for the Back Lever to engage DO NOT assume that the Back Lever is engaged just because the Front Lever is engaged You must allow the back lever time to engage the attachment s link pin A 37 Hendrix ll Fig 37 2 Front Lever engages over and around the attachment Hendrix ll Chie Back
5. ji Male Fittings Chart 5 AA mim into the cylinder s extend and 1st Generation Coupler N e pole If you Hendrix II Coupler that uses a 4N 212 Kit install the 90 degree 4 O Ring X 4 JIC Male ITA ZU aa Fittings Chart 5 AE into ESQ inder ed N ir 1 i the cylinder s extend and CS retract ports Hendrix II Coupler 18 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AES HENDRIX QUIGK COUPLER USER MANUAL INSTALLATION SECTION VI HYDRAULIC HOSE ROUTING Continued 3 In order to determine the proper hose length cut 5 Next you will need to route the hoses from Upper two pieces of hose and allow plenty of extra hose Bulkhead Fittings Bracket all the way back to the Install the hose fittings on one end only Connect engine compartment Install a hose fitting on one the hoses to the coupler cylinder Route the end and route the hose to the excavator s bucket hoses through the excavator linkage see Fig 18 cylinder and then down the boom Route the 1 Slowly operate the excavator controls so that hoses in a manner that will prevent interference the coupler is curled in completely see Fig 19 1 with other lines or equipment Secure the hoses Pull the hoses tight to the Lower Bulkhead Fittings to the machine using the plastic tie wraps supplied Bracket Release tension on the hoses so that in the coupler kit Repeat this procedure for both you allow the hoses
6. Filter Element 20101 Flow Rating 32 Gpm 121 L min Temp Range 45 degrees F to 225 degrees F 43 degrees C to 107 degrees C Element change clearance 2 50 inches 65mm FILTER CROSS REFERENCE CHART Hendrix Filter Cross Reference Puralator 20101 Parker 921999 Baldwin BT839 10 Stauff ZSF6620 HYDRAULIC CONTROL VALVE Vickers DG4V 3S 2C M U1 H5 60 Power Rating 30W 24VDC Fatigue Pressure 5000 psi 350 bar System Pressure Excavator Pilot Pressure Control System Not to exceed 1000 psi SWITCH BOX ASSEMBLY Voltage Rating 24VDC Alarm Decibel Rating 72 dbA Wiring Harness T4 2 SJTOW TPE 105 degrees C FT2 water resistant HYDRAULIC HOSE 6 Hose Eastman HFS06 2500 psi Single Braid Hose or equivalent 4 Hose Eastman E7 04 2750 psi Single Braid Hose or equivalent 1 0 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 eio 11 QUICK COUPLER USER COUPLER INSTALLATION INSTRUCTIONS The following section will guide you through the necessary steps to install your Hendrix Quick Coupler Please review the information provided in the General Information Section before attempting to install your coupler Pay close attention to all Safety Messages in the manual The Coupler Installation will require you to do the following basic steps You will connect the coupler to the end of the excavator s arm You will route the hoses from the coupler up the excavator arm and boom and down to the e
7. HENDRIX MANUAL 1ST GENERATION HENDRIX HYDRAULIC QUICK COUPLER PART UMCP 0902 KENOR QUICK COURYER USER MANUAL Congratulations on your purchase of the Hendrix Hydraulic Quick Coupler The Hendrix Coupler you have purchased is a high quality well engineered product that will provide you with many years of good service The Hendrix Coupler will enhance the productivity and flexibility of your excavator Please read this manual and any accompanying materials thoroughly before installing operating or maintaining your Hendrix Hydraulic Quick Coupler If you have any questions please contact your authorized Hendrix dealer The Hendrix Quick Coupler brings you the design quality and workmanship you expect from a Hendrix product Please pay particular attention to your personal safety while installing operating or maintaining this unit and remember to follow all applicable standard safety precautions The advantages of the Hendrix Coupler become apparent when a bucket or attachment change is necessary These advantages include 1 A rotating locking mechanism with a locking lever that engages under and around the machine pin minimizing the chance of jamming unlike other trouble prone wedge lock systems that sometimes have to be hammered open 2 The positive locking system pushes against the back machine pin and away from the front pin keep
8. The High Strength lifting eye is made from a Low Alloy Cast steel and designed to handle the machines lifting capacity It is important to mention that the excavator gains additional lifting capacity in both weight and height and better visibility when the coupler is used to lift the load without the attachment The closed lifting eye should not be cut open or altered An approved lifting shackle is recommended for attaching cables or other safety hoisting products Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 Mere PENORD QUICK GOURLER USER MANUAL OPERATIONS 8 MAINTENANCE SECTION IV HENDRIX Il COUPLER FAMILIARIZATION Continued F CYLINDER CHECK VALVE Hendrix Il The Hendrix features a cylinder with an external check valve allowing for easier access Should a END OF SECTION hose break the check valve will maintain constant pressure on the attachment link pin Once the attachment is engaged the locking lever can only be retracted by applying positive pressure to the retracting port This is done by placing the control box switch to the Release position MECHANICAL LOCK PIN Hendrix II All Hendrix Il Couplers use a mechanical locking pin that inserts through the C Casting lt Mechanical Lock Pin 34 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 p 2 Lm N DANGER Failure to properly engage an attachment can result in serious injury or death THE ATTACHMENT MAY DROP WITHOUT
9. 3 U6N 412 CHARTS P 1 CONTROL VALVE COMPONENTS PARTNUMBER 44212 6 3 U N 412 CHARTS MouningSubplate TApossPsess 3 3 3 TUD CIL FITTINGS amp HOSES PARTNUMBER 44212 6 3 WON 412 CHART 46 O Ring X 6 JIC Male 90 degree 8495006 06 5 5 5 o 8 O Ring XH6 JIC Mae e4sFsooexos 2 2 2 P 6 Male 6 JIC Male Straight Bulkhead Fino 2700 06 86 2 2 2 Q 6 Male X 6 JIC Male 45 degree Bulkhead Fiting 27020606 2 2 2 R 04026010 10 TubuarHoseRelamerBracet 1 1 1 CAD IMPORTANT Hendrix makes every attempt to supply you with the fittings to install your quick coupler However due to the variety of excavators you will be required to provide the brand specific fittings needed to tie into the pilot pressure system and the hydraulic reservoir tank Please see your excavator dealer to obtain these fittings Additionally certain machines may require adaptation of connectors Please see your excavator dealer for any appropriate fittings 6 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 j Kd 3 S e ras BERI QUICK COUPLER USER MANUAL U NN 2 N 7 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 z Kel aj Sy ras GENI QUICK COUPLER USER MANUAL
10. to the operator s console to inform users that the machine is inoperable See your excavator dealer for the appropriate Lock Out tag 5 Release the hydraulic tank pressure by operating release valve on the hydraulic tank 15 6 Disconnect the negative cable from the battery terminal Review the Recommended Welding Procedures in the General Information Section You are now ready to attach the Lower Bulkhead Fittings Bracket to the excavator arm Remove the fittings from the bracket before welding the bracket to the excavator arm The location of the Lower Bulkhead Fittings Bracket will vary depending on your specific machine For a general guideline install the Bracket 9 from the center of the excavator arm s idler pin The angle of the bracket should be at the 9 point approximately see Fig 15 4 amp 15 5 Remember this is only a guideline and your requirements may vary depending on your specific excavator arm combination Weld the bracket securely onto the excavator arm using E7016 or E7018 welding rod or equivalent Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AES QUIEK COUPLER USER MANUAL INSTALLTION SECTION IV INSTALL HOSE BRACKETS CONTINUED 9 You are now ready to attach the Upper Bulkhead 12 Install the bulkhead fittings into the Upper Fittings Bracket to the excavator arm Remove Bulkhead Fittings Bracket This bracket uses the the fittings from the bracket before we
11. B LIFTING EYE 1st Generation The High Strength lifting eye is made from a Low Alloy Cast steel and designed to handle the machines lifting capacity It is important to mention that the excavator gains additional lifting capacity in both weight and height and better visibility when the coupler is used to lift the load without the attachment The closed lifting eye should not be cut open or altered An approved lifting shackle is recommended for attaching cables or other safety hoisting products C PIN SUPPORT CASTING 1st Generation The pin support casting is located in the rear mounting area of the coupler see Fig 31 1 This area of the coupler was strengthened to better accommodate most demolition tools such as hydraulic hammers concrete pulverizers hydraulic thumbs and other tools CAUTION All coupler attachment combinations should be checked for possible interference before operating the coupler Insure that the coupler engages and disengages properly and easily with each attachment D LOCKING LEVER 1st Generation The cast high strength locking lever rotates under the attachment link pin in the rear mounting area of the coupler The rotating mechanism is designed to minimize the chance of jamming When the pin is seated properly in the lever pressure from the springs and cylinder locks the attachment link pin between the pin support and the hexagon contact points in the lever Because the locking syst
12. ILLUMINATES NO BUZZER YELLOW LIGHT ILLUMINATES BUZZER SOUNDS RED LIGHT ILLUMINATES BUZZER SOUNDS CYLINDER ROD ON THE COUPLER EXTENDS HYDRAULIC FLOW TO THE COUPLER IS SHUT OFF CYLINDER ROD ON THE COUPLER RETRACTS ALWAYS OPERATE COUPLER IN LOCK POSITION Earlier versions of the Switch Box have a White Light for the Neutral Light Once you verify that the Coupler Switch Box is operating properly you have completed the installation of your Coupler Before attempting to operate or maintain the coupler thoroughly read and familiarize yourself with the following Operation and Maintenance Section of this manual Please Note The lights on the Switch Box indicate switch position ONLY The lights DO NOT indicate the position of the lever You must allow the lever time to extend and retract after placing the switch in the respective position Before operating the machine with coupled attachments always verify that the lever s are properly engaged by following the steps listed in the Engaging the Attachement section of this manual 26 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AES PEON QUICK GOURUER USER MANUAL OPERATION amp MAINTENANCE INSTRUCTIONS The following section will provide you the necessary information to operate and maintain your Hendrix Quick Coupler Please review the information provided in the General Information Section before attempting to operate and maintain your coupler Pay close attention to all Safe
13. Rev 1 GBH4 09 02 AES HENDRIX QUIGK COUPLER USER MANUAL INSTALLATION SECTION VI HYDRAULIC HOSE ROUTING This section details the necessary steps to route the hydraulic hoses needed for your coupler installation The hoses must be routed from engine compartment where they will tie into the pilot pressure system to the coupler CAUTION The exact manner in which you need to route your hoses will vary depending on the specifics of your excavator Please use the 2 Install the 90 degree 6 O Ring X 6 JIC Male fittings Chart 5 O into the Extend and Retract Ports on the cylinder Route the hoses through the excavator s linkage as shown in Fig 18 1 Make sure the hose has enough slack to move with the excavator linkage Allow for some flexibility Protect all moving hoses with the supplied hose guard sleeves Chart 5 W The next step offers a procedure for determining the proper length of the hose from the coupler to the Lower Bulkhead Fittings following steps as a guideline only Always route all hoses in a manner that will prevent interfering with other lines and equipment Be sure to secure all hoses to the excavator 1 Before connecting any hoses be sure the hoses PLEASE NOTE If you have been flushed completely with clean hydraulic have a 1st Generation fluid to prevent contamination Hendrix Coupler that uses a 4N 212 Kit install the 45 P degree 4 O Ring X 4 Fig 18 1 g 18
14. Subplate Mounting Screws Chart 5 J Please note the Mounting Subplate ports are marked as follows to assist you with your T Tank P Pilot Pump Hose Hose 6 Mount the Filter Assembly in area that provides easy access to the hydraulic reservoir tank but does not interfere with other equipment in the engine compartment The Filter is mounted in line between the Mounting Subplate and the Tank 4 Install three 90 degree 6 O Ring X 6 JIC Male fittings Chart 5 O and one straight 6 O Ring X 6 JIC Male Chart 5 T into the Mounting Subplate Chart 5 1 as shown in Fig 22 2 22 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AES HENDRIX QUIGK COUPLER USER MANUAL INSTALLATION SECTION VII CONTROL VALVE FILTER SWITCH BOX INSTALLATION Continued 7 23 IMPORTANT Hendrix makes every attempt to supply you with the fittings to install your quick coupler However due to the variety of excavators you will be required to provide the brand specific fittings needed to tie into the pilot pressure system and the hydraulic reservoir tank Please see your excavator dealer to obtain these fittings Additionally certain machines may require adaptation of connectors Please see your excavator dealer for any appropriate fittings Route a hose from the Mounting Subplate port P to the pilot pressure system Refer to the excavator s OEM hydraulic system diagram for connection po
15. coupler in toward the machine extend the machine s bucket cylinder as shown in Fig 36 2 o 0 36 Exes HENDRIX QUICK COUPLER USER MANUAL Continued Note The Control Box switch should still be in the RELEASE position while seating the coupler The coupler must be fully seated on the attachment s link pin for the locking lever to properly engage under and around the link pin After seating the coupler on the link pin you are ready to lock the coupler in place A 1ST GENERATION COUPLER The 1st Generation Coupler is locked into place by engaging the attachments link pin with the coupler s locking lever To engage the attachment s link pin place the Control Box switch to the LOCK position see Fig 36 3 Placing the switch in the LOCK postion will extend the coupler s locking lever see Fig 36 4 The lever should engage under and around the attachment s link pin Please allow the locking lever time to fully engage the pin If the locking lever does not engage under and around the link pin then you have NOT properly engaged the attachment Fig 36 3 FEMORIS o ar Switch to LOCK position after fully seating coupler to engage the link pin with the locking lever 1st Generation Fig 36 4 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 OPERATIONS amp MAINTENANCE SECTION V THE ATTACHMENT Continued
16. generated dust Protect yourself at all times When using chemical compounds to remove paint make sure to use plenty of soap and water to rinse the surface to be welded since such chemicals will generate unhealthy gases when heated or welded Be sure to perform this work in a well ventilated area The electrode to be used is E7018 SMAW or E7OT 1 FCAW Follow the manufacturer s recommendations about electrode storage and avoidance of moisture and other contaminants The electrode manufacturer can also recommend shielding gases Persons performing welding should follow Government guidelines for personal protective equipment Place the welding ground cable within 3 feet 1 m of the area to be welded Use proper welding protection NOTE CAUTION Have a Fire Extinguisher and First Aid Kit ready for emergencies Know how to operate the fire extinguisher p sureto disconnect the and know where the First Aid Kit is located in case of batteries Failure to do so any emergency Qi could result in extensive machine damage to the electronic system 9 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 REBRI n SNR AE QUIGK COUPLSR USER MANUAL GENERAL INFORMATION SECTION IV HYDRAULIC amp ELECTRICAL SPECIFICATIONS This section lists the specifications for the hydraulic and electrical components of the Coupler Installation Kit HYDRAULIC FILTER UNIT Purolator Filter Assembly Max Pressure 200 psi 13 8 bar
17. in this User Manual before attempting to install maintain and or operate the Hendrix Quick Coupler Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 INSTALLATION SECTION INSTALLATION PREPARTION This section lists necessary preparation steps before beginning the coupler installation 1 12 Place the excavator coupler and all tools and supplies needed in an open unencumbered work area Make sure that the machine and coupler are on flat secure ground Inspect the coupler and all coupler kit components for signs of damage Insure that the coupler kit is not missing any components If any components are damaged or missing notify your dealer Familiarize yourself with the components of the coupler see Chart 5 in the General Information section The coupler ships with a set of attachment pins REMOVE these attachment pins from the coupler These attachment pins are NOT case hardened pins and are designed to be used in the ears of the bucket or attachment DO NOT connect the coupler to the machine with the attachment pins that shipped with the coupler You will use the original pins that came with the excavator to connect coupler to the excavator You are now ready to begin the coupler installation CAUTION Never allow a hydraulic line or component to become contaminated Contamination in the hydraulic system can cause severe system damage Contact your excavator
18. not conform to OEM specifications and or have structural interferences are solely the responsibility of the end user HENDRIX WARRANTY POLICY AND PROCEDURES FOR QUICK COUPLERS Hendrix Manufacturing Co Inc Hendrix warrants all quick couplers against defects in material and workmanship for a period of 6 months or 1000 hours whichever comes first after delivery to an end user This warranty is valid only with the original purchaser and proof of delivery date to the original purchaser is required Warranty claims must be made to Hendrix in advance of any repairs via a warranty claim number and warranty claim form which can be obtained by contacting Hendrix Warranty claims without a warranty claim number will be rejected Any product requested by Hendrix to be returned for inspection must be done so with freight charges prepaid This warranty does not apply to any quick coupler that has been subjected to misapplication and or abuse or modified in any way without written authorization from Hendrix This warranty covers only new and unused products manufactured by Hendrix Products manufactured by others are covered only by the warranties extended to Hendrix by it s suppliers All products are wearable and expendable and as such Hendrix assumes no responsibility for normal wear Further it is the responsibility of the customer to follow normal maintenance and operating procedures including but not limited to daily inspection for routine ha
19. the excavator s low pressure pilot system Additionally mounting these components in the engine compartment offers protection from the elements The Switch Box is installed in the cab of the excavator and is used to operate the coupler COUPLER CYLINDER MOUNTING SUBPLATE LEGEND P PILOT PUMP TANK MOUNTING SUBPLATE SOLENOID WIRING HARNESS RELEASE LOCK N HYDRAULIC RESERVOIR SWITCH BOX 2 Bod TO EXCAVATOR S 24 VDC SYSTEM E 10 AMP FUSE LINKED 3WIRE N 2WIRE LEAD LEAD B TOSYSTEM WIRING LEGEND GROUND B BLACK W WHITE G GREEN 1 Figure 21 1 shows the electrical and hydraulic schematic for the quick coupler Please remember that the following steps are a general guideline since all excavators are different The objective for this section is to mount the control valve solenoid valve and the 3 light switch box The control valve ties 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 what the excavator operator uses to control the action of the coupler The 3 light switch box connects to the control valve via the provided wiring harness The switch box and wiring harness leads are color coded to ease installation CAUTION DO NOT CONNECT THE HENDRIX QUICK COUPLER TO HYDRAULIC PRES
20. 39 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 MESS MENDRE QUICK COUPLER USER MANUAL adm OPERATIONS 8 MAINTENANCE SECTION Vi DISENGAGING THE ATTACHMENT This section will detail the proper steps for disengaging from an attachment with the Hendrix Quick Coupler 1 Place the attachment on SECURE flat ground as shown in Fig 40 1 Remove the mechanical lock pin Clear all personnel from around the N ETN US o Jc attachment Place the control box switch to the RELEASE position The buzzer will sound and the Make sure to keep the control box switch on the Release position while unlatching the bucket 104 enpr 1 N Place the bucket on the ground and set the control box switch on Release D me A ALWAYS DISENGAGE ATTACHMENTS AWAY FROM PERSONNEL THE RELEASE POSITION ON THE SWITCH MUST NEVER BE USED WHEN THE COUPLED ATTACHMENT IS OFF OF THE GROUND NEVER SWING COUPLED ATTACHMENTS OVER WORKERS HEADS 2 Unlatch the attachment link pin by curling the coupler out retract the machine s bucket cylinder and simultaneously lift the boom to completely disengage the coupler from the attachment as shown in Fig 40 2 CAUTION When disengaging from an attachment turn the Switch to the RELEASE position long enough to ensure that the lever s are completely open before curling the coupler out DO NOT FORCE THE COUPLER OFF OF THE ATTACHMENT 40 He
21. Lever engages under and around the attachment o After placing the switch in the lock position and engaging the attachment you are ready to test the connection to the coupler by performing the following connection tests DANGER A The Switch should remain in the LOCK position ALWAYS while operating the excavator with coupled attachments Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 PERE AMHENDRIX AUG GOVI USER OPERATIONS 8 MAINTENANCE SECTION V ENGAGING THE ATTACHMENT Continued 7 CONNECTION TEST TWO DANGER Perform away from all personnel Test the connection by fully cycling the coupled attachment at CONNECTION TESTS MUST BE least twice see Fig 38 2 PERFORMED EACH AND EVERY TIME YOU ENGAGE AN ATTACHMENT FAILURE TO PROPERLY ENGAGE AN ATTACHMENT CAN RESULT IN SERIOUS INJURY OR DEATH THE ATTACHMENT MAY DROP WITHOUT WARNING IF THE COUPLER IS NOT PROPERLY ENGAGED WITH THE ATTACHMENT ENGAGE ATTACHMENTS COMPLETELY CLEAR OF ALL PERSONNEL TEST ALL CONNECTIONS AWAY FROM ALL PERSONNEL 8 CONNECTION TEST THREE NEVER SWING COUPLED ATTACHMENTS Perform away from all personnel Test the OVER WORKERS HEADS coupler connection 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 to lift the excavator s tracks off the ground and try to force the attach
22. OVE ANY ATTACHMENTS BEFORE TESTING THE SWITCH BOX INSTALLATION Please Note The Hendrix Coupler is equipped with a mechanical lock pin Be sure to remove the mechanical lock pin before performing this test DANGER A CONDUCT ALL TESTS AWAY FROM ALL PERSONNEL REMOVE ANY ATTACHMENTS WHEN TESTING THE SWITCH BOX INSTALLATION 14 With the machine power on and no attachment connected to the Coupler place the Switch Box Selector switch to the LOCK position The Green light on the Switch Box should illuminate and the Coupler cylinder rod should extend If the cylinder rod retracts then your connections are installed in reverse To rectify this situation reverse the wiring harness DIN connectors Retest the installation by repeating this step Verify that the Switch Box and the Coupler Cylinder operate according to Fig 26 1 If the Switch Box and Coupler Cylinder do not operate in accordance with Fig 26 1 recheck the installation of all electrical and hydraulic components and insure that they are installed in accordance with the instructions in this manual If the problem persists please contact your dealer Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AERE QUICK Gre USER MANUAL INSTALLATION SECTION VII CONTROL VALVE FILTER SWITCH BOX INSTALLATION Continued LOCK NEUTRAL RELEASE GREEN LIGHT
23. Quick Coupler is built with a low profile design It uses high strength castings in critical wear areas The Hendrix Il Coupler is built to accept multiple pin spacing Please review the following section to familiarize yourself with the Hendrix Il components HENDRIX II COUPLER Front Lever Cylinder w Integrated Spring Back Lever A FRONT LEVER Hendrix ll The Hendrix Coupler features a Front Lever The geometry of the Front Lever along with the configuration and alignment of other coupler components hold the Front Lever in the closed position even without the assistance of the hydraulic cylinder BACK LEVER Hendrix Il The cast high strength back lever rotates under the attachment link pin in the rear mounting area of the coupler The rotating mechanism is designed to minimize the chance of jamming Because the locking system pushes away from the front pin the coupler remains tight even as it begins to wear C REPLACEABLE WEAR PADS Hendrix Il The Hendrix Il Coupler features replaceable wear pads on the coupler frame where the back lever engages the attachment pin These wear pads are made of Hardox 400 material 33 C Casting Replaceable Wear Pads ifting Eye D CYLINDER W SPRING Hendrix Il The double acting cylinder on the Hendrix Il coupler features an integrated compression spring The spring is included solely as a backup to the cylinder E LIFTING EYE Hendrix Il
24. SURES EXCEEDING 1000 PSI The Hendrix Quick Coupler is designed to operate off of the excavator s low pressure pilot system Only connect the coupler to the excavator s pilot system 21 CAUTION BEFORE CONNECTING ANY HOSES FLUSH COMPLETELY WITH CLEAN HYDRAULIC FLUID TO PREVENT CONTAMINATION Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AES HENDRIX QUIGK COUPLER USER MANUAL INSTALLATION SECTION VII CONTROL VALVE FILTER SWITCH BOX INSTALLATION Continued 40 J 2 In the engine compartment that houses the low pressure pilot system of the excavator mount the Control Valve Mounting Bracket Chart 5 L You should weld the bracket in a place that does not interfere with other excavator components but allows easy access to the pilot pressure system Follow standard welding procedures when mounting the bracket CAUTION Protect all hydraulic hoses and electrical wires while welding inside the engine compartment f SS Ww NN Connect the Hoses to the Mounting Subplate You will connect the two hoses that run from the coupler cylinder into Mounting Subplate ports A amp B You need to run a hose from Mounting Subplate port P to the Pilot Pressure Pump You installation will route a hose from Mounting Subplate port T to the Hydraulic Reservoir Tank see Fig 22 3 3 Mount the Mounting Subplate Chart 5 1 to the 5 Mounting Bracket Chart 5 M using the supplied
25. 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 Release before ENGAGE ATTACHMENTS COMPLETELY engaging attachment CLEAR OF ALL PERSONNEL TEST ALL CONNECTIONS AWAY FROM ALL PERSONNEL NEVER SWING COUPLED ATTACHMENTS OVER WORKERS HEADS 1st Generation Fig 35 3 ATTACHMENT PARTS IDENTIFICATION Attachment Link Pin Attachment Stick Pin Hendrix ll G CAUTION Do not hit the coupler s locking lever or force 1 Open the coupler lever by placing the control box the coupler on the attachment pin while in the switch in the RELEASE position see Fig 35 RELEASE mode Always allow the lever s 2 3 amp 4 The buzzer alarm will sound and the red time to fully retract light will glow Allow the lever s time to retract fully 35 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 2 Operate boom arm and bucket cylinders to position the coupler at approx a 45 angle on the attachments stick pin Fully seat the coupler s C casting on the stick pin as shown in Fig 36 1 lexan Keep in Release while engaging the attachment Make sure to seat the stick pin on the cou pler C casting before curling in the coupler 3 Seat the coupler onto the attachments link pin by curling the
26. e attachment Unauthorized modification may impair the safety of personnel and can cause serious injury or death Hendrix assumes no responsibility for any unauthorized modifications to the coupler and or coupler components Unauthorized modification voids the coupler s warranty N DANGER N TEST ALL CONNECTIONS AWAY FROM ALL PERSONNEL NEVER SWING COUPLED ATTACHMENTS OVER WORKERS HEADS Read these instructions and safety precautions thoroughly before operating or maintaining the coupler Inspect the coupler and all coupler components before beginning operation Perform any necessary repairs before operating the coupler Make sure the attachment is resting on the ground and properly supported before performing any work on the coupler Under normal conditions all machine hydraulic circuits are under extreme pressure When inspecting for leaks use a small piece of cardboard wood or metal to locate leakages Small pinhole leaks can be dangerous if contact with skin or eyes is made Wear approved safety glasses and or face shields gloves hard hat safety shoes and work clothes during all inspection and maintenance procedures Always wear protective equipment when performing maintenance All coupler attachment combinations should be checked for possible interference before using Any interference problems should be corrected before using the coupler Ensure that the coupler engages and disengages properly a
27. e Yellow light will glow Under no circumstances should this position be used for Coupler operation In the neutral position hydraulic flow to the coupler is shut off 4 DUR sl 41 sl NEUTRAL NEUTRAL NEUTRAL LOCK RELEASE LOCK RELEASE LOCK RELEASE Fig 30 1 LOCK NEUTRAL RELEASE GREEN LIGHT ILLUMINATES NO BUZZER YELLOW LIGHT ILLUMINATES BUZZER SOUNDS RED LIGHT ILLUMINATES BUZZER SOUNDS CYLINDER ROD ON THE COUPLER EXTENDS HYDRAULIC FLOW TO THE COUPLER IS SHUT OFF CYLINDER ROD ON THE COUPLER RETRACTS ALWAYS OPERATE COUPLER IN LOCK POSITION Earlier versions of the Switch Box have a White Light for the Neutral Light Please Note The lights on the Sw
28. e the pin into place see Fig 14 2 1 4 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AERE NORD QUICK Grote USER MANUAL INSTALLATION SECTION IV INSTALL HOSE BRACKETS The Coupler Installation Kit includes several brackets to help you neatly route your hoses These brackets include 2 Bulkhead Fittings Brackets and the Tubular Hose Retainer Bracket One Bulkhead Fittings Bracket Lower mounts on the excavator arm near the arm idler connection point and helps to route the hoses from the end of the excavator arm to the coupler cylinder The other Bulkhead Fittings Bracket Upper mounts on the top portion of the excavator arm underneath the excavator s bucket cylinder and helps to route the hoses up the arm of the excavator The Tubular Hose Retainer Bracket mounts on the inside of the excavator s bucket linkage and helps to guide the hoses going from the Lower Bulkhead Fittings Bracket to the coupler s cylinder The following steps will guide you through the process of installing these brackets to the excavator 1 With the excavator still sitting securely on firm level ground rest the excavator arm in an extended position see Fig 15 1 2 Place the throttle control in the low idle position and turn the ignition key off see Fig 15 2 Fig 15 2 3 Place the safety lever in the locked position before leaving the cab Fate lever in the lock position 4 Secure DO NOT OPERATE
29. em pushes away from the front pin the coupler remains tight even as it begins to wear E CYLINDER CHECK VALVE 1st Generation The internal check valve is another safety feature that backs up the compression springs in the unlikely event of a hydraulic failure Should a hose break the check valve will maintain constant pressure on the attachment link pin Once the attachment is engaged the locking lever can only be retracted by applying positive pressure to the retracting port This is done by placing the control box switch to the Release position Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 HENDRIX Bice MENDRE QUICK COUPLER USER MANUAL a n a OPERATIONS amp MAINTENANCE SECTION Ill 1ST GENERATION COUPLER FAMILIARIZATION Continued 32 E MECHANICAL LOCK PIN 1st Generation Later model 1st Generation Hendrix Quick Couplers are equipped with a mechanical locking pin This pin is inserted behind the Locking Lever and is secured in place using lynch pins on each end of the pin If you have a coupler that does not have a mechanical locking pin Hendrix recommends that you obtain and install the mechanical locking pin Please contact your Hendrix dealer for details Fig 32 1 LOCKING LEVER LOCKING PIN END OF SECTION Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 PI 2 Lm OPERATIONS amp MAINTENANCE SECTION IV HENDRIX Il COUPLER FAMILIARIZATION The Hendrix
30. es smooth after all welding is complete Please contact your Hendrix Dealer to obtain the appropriate buildup template for your Coupler Please provide your coupler Serial Number and or the Coupler part number when ordering Arm Pin Template C Casting Hook Plate After Build up is complete grind both sides smooth VIEW B B Gaps between the template and the coupler indicate worn areas These worn areas should be built up and then ground to fit the template NOTE 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 as indicated in the upper part of Fig 43 2 Wedge pin to the back of the C casting Mark at the top of the pin Appox centerline of pin where the weld buildup should begin Weld 3 beds side by side through the entire width of the C casting Grind the weld smooth and check the pin fit Repeat the welding process until the desired pin fit is achieved Remember to use E7018 or equivalent welding material If the C casting is severely worn proceed as indicated above but also weld on bottom side of the C casting as shown in the lower part of the figure SEVERELY WORN CASTING Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AES ENDR QUICK GOURYER USER MANUAL OPERATIONS amp MAINTENANCE SECTION VIII MAINTENANCE PROCEDURES Continued 4 Zu 44 LINK PIN FRAME BUILDUP 1
31. g I Control Valve Filter amp Switch Box Installation LLL lt OPERATION amp MAINTENANCE INSTRUCTIONS Warnings amp Precautions 28 owitch Box Overview 1st Generation Coupler Familiarization V Hendrix Il Coupler Familiarization Engaging the Attachment g 5 O e qM gt lm O O 5 P Lifting Loads with the Coupler Installed Maintenance Procedures WARNING Read understand and follow all safety precautions and procedures found in the machine s operator s manual before attempting any operation inspection or maintenance of this machine its attachments and or systems Hendrix Mfg Co cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this document and on the product are therefore not all inclusive If a tool procedure work method or operating technique not specifically recommended by Hendrix Mfg Co is used you must satisfy yourself that it is safe for you and others You should also ensure that the product will not be damaged or made unsafe by the operation lubrication maintenance and or repair procedures you choose Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 QUICKSCOUDIERIUSERIVIATN UA GENERAL INFORMATION DANGER Failure to comply with information in this Hendrix Quick Coupler User Manual may result in injury death damage to property and or damage to the Quick Coupler Insu
32. he attachment pins that shipped with the 5 Slowly operate the bucket cylinder on the coupler are still in the coupler remove these pins excavator to align the excavator s pivot link hole You will NOT use these attachment pins to with the link side of the coupler Insert the link connect the coupler to the excavator arm These machine pin USE THE ORIGINAL LINK attachment pins are to be used in the ears of the MACHINE PIN THAT CAME WITH THE bucket or attachment You will use the original MACHINE TO CONNECT THE COUPLER TO pins that came with the excavator to connect the THE PIVOT LINK Use a rubber mallet to drive coupler to the excavator arm the pin into place A pry bar may be necessary to help adjust the pivot link in order to ease installation see Fig 14 3 3 If your machine requires bucket o rings install these onto the coupler bosses at this time see Fig 14 1 Roll O rings onto coupler bushings 6 Secure the stick and link pins in place by installing their respective retaining bolts and nuts 4 You are now ready to connect the coupler to the 7 Your coupler has now been connected to the excavator arm With the throttle control in the low excavator arm idle position slowly operate the excavator controls to align the stick pin hole to the stick side of the coupler Insert the stick machine pin USE THE ORIGINAL STICK MACHINE PIN THAT CAME WITH THE MACHINE TO CONNECT THE COUPLER TO THE STICK Use a rubber mallet to driv
33. ing the coupler always tight 3 High strength compression spring s maintain constant pressure on the locking lever for protection against a pressure loss in the hydraulic system 4 Acheck valve that backs up the compression spring s and helps to prevent the possibility of an accidental release of the attachment 5 The Hendrix Coupler is equipped with a lifting eye This lifting eye allows you to operate the machine as a lifting device without the attachment thereby gaining increased lifting power without bucket interference The Hendrix Hydraulic Quick 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 instead of a system that uses pressure from the bucket cylinder of the excavator The attachment can remain on the ground and does not have to be curled in to take the machine over relief The Hendrix Coupler is designed to allow the operator to switch the attachments on a hydraulic excavator in a minimum amount of time The Coupler is mounted between the excavator arm and the excavating attachment Realization of the Hendrix Coupler s full potential will depend upon the following factors 1 Acareful examination and execution of the installation operation and maintenance instructions provided in this manual 2 Adesignation of responsibility by the user of the equipment for the appropriate training in the
34. installation operation and maintenance of the coupler and its systems 3 The equipment owner and or operator should lock out tag out the machine to prevent accidental startup before installation of the Hendrix Coupler is attempted 4 All users should completely read this manual before attempting to install operate or maintain this coupler Thank you for purchasing our product We are confident you will be pleased with its performance Hendrix Manufacturing Company Inc P O Box 919 Mansfield LA 71052 Phone 318 872 1660 Fax 318 872 1508 www hendrixmfg com IMPORTANT NOTES Hendrix Manufacturing Company Inc builds its hydraulic quick couplers to OEM attachment specifications The coupler is designed to work only with attachments that are also built to OEM attachment dimensions The critical dimensions are the Pin Center to Pin Center dimensions the Stick Width and the Pin Diameters You should insure that your attachments are built to these specifications before attempting to operate the coupler Additionally you may encounter some attachments that have structural interferences that prevent the coupler from properly engaging the attachment You should resolve any interference issues before attempting to operate your quick coupler Hendrix assumes no responsibility or liability for attachments that are not built to OEM specifications and or have structural interference problems Any costs incurred to modify attachments that do
35. ints Figure 23 2 provides an example of one method of tying into the pilot pressure system Newer excavator s may provide auxillary ports for connections from aftermarket attachments Contact your excavator dealer s service department if you need additional guidance e 2 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AES QUIGK COUPLER USER MANUAL INSTALLATION SECTION VII CONTROL VALVE FILTER SWITCH BOX INSTALLATION Continued 8 After properly connecting your hoses from the Mounting Subplate to the Coupler cylinder the pilot pressure pump and the hydraulic reservoir tank you are now ready to install your solenoid control valve Chart 5 onto the Mounting Subplate You will use the four 1025 Mounting Screws Chart 5 to connect the valve and subplate see Fig 24 1 9 Install the Wiring Harness Chart 5 L onto the control valve see Fig 24 2 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 subplate The Release side of the harness should be connected to the side of the Control Valve where the Retract line comes into the subplate Please note that the Wiring Harness has 3 color coded leads Black Ground White Release amp Green Locked 24 10 Inside the cab of the excavator mount the 3 Light Switch Box in an area
36. irline cracks Any cracks should be repaired before further propagation occurs Warranty claims are subject to credit on the dealer s account Hendrix reserves the right to pass judgement on time allowed for repairs and the rate charged for repairs Repairs done by an outside source will be subject to warranty one time only subsequent failure of repairs by an outside source is non warrantable Hendrix shall not be liable for down time by the customer mileage costs damaged equipment or loss of productivity incurred by the dealer or customer Hendrix specifically disclaims all warranties express or implied including but not limited to implied warranties of merchantability and fitness for any particular purpose with respect to Hendrix products 2002 Hendrix Manufacturing Company Inc Mansfield LA USA All rights reserved Any use of the editorial or pictorial content of this publication is strictly prohibited without express written permission from Hendrix Manufacturing Company Inc Mansfield LA USA Printed in the USA 09 02 Rev 1 Issued 09 02 TABLE OF CONTENTS PAGE 2 GENERAL INFORMATION Parts ID Charts 4 Recommended Welding Procedures 9 Hydraulic amp Electrical Specifications 7 10 INSTALLATION INSTRUCTIONS Installation Preparation 712 Connect the Coupler to the Excavator Arm 14 V_ install Hose Brackes 145 18 221 Hydraulic Hose Assembly Hydraulic Hose Routin
37. itch Box indicate switch position ONLY The lights DO NOT indicate the position of the lever You must allow the lever time to extend and retract after placing the switch in the respective position Before operating the machine with coupled attachments always verify that the lever s are properly engaged by following the steps listed in the Engaging the Attachement section of this manual 30 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 fal OPERATIONS 8 MAINTENANCE SECTION 1ST GENERATION COUPLER FAMILIARIZATION The 1st Generation Hendrix Quick Coupler is built with a low profile design It uses high strength castings in critical wear areas The 1st Generation Coupler is built to OEM specifications Please review the following section to familiarize yourself with the coupler components 31 1ST GENERATION COUPLER Pin support casting Lifting eye A SPRINGS 1st Generation Constant pressure is maintained on the locking lever by two compression springs These springs assist the hydraulic cylinder in keeping the locking lever secured Inspect daily to make sure that the springs are set to their proper pre load dimension see Page 42 After the pre load dimension is properly set ensure that the adjusting bolt lock nut is tightened so that it jams to the spring hanger Any broken or missing spring should be replaced immediately In addition it is recommended that the springs are replaced annually
38. lding the 45 degree bulkhead fittings Chart 5 R and the bracket to the excavator arm fittings are secured by the bulkhead nut Chart 5 S See Fig 16 3 10 The location of the Upper Bulkhead Fittings 13 Install the bulkhead fittings into the Lower Bracket Chart 5 U will vary depending on your Bulkhead Fittings Bracket This bracket takes the specific machine For a general guideline install straight bulkhead fittings Chart 5 Q and the the Bracket approximately 20 to 24 from the fittings are secured by the bulkhead nut Chart 5 S See Fig 16 3 If you have a 4N 212 kit you center of the bucket cylinder connection pin see Fig 16 1 Remember this dimension is only a will need to install the 6 X 4 Tube End Reducer guideline and your requirements may vary and Nut Chart 5 Y amp Z onto the end of the bulkhead fittings depending on your specific excavator arm combination Weld the bracket securely onto the excavator arm using 7016 E 018 welding rod or equivalent N f S u 11 You now ready to mount the optional Tubular 14 You have now mounted the necessary brackets Hose Retainer Bracket Chart 5 AD This and are ready to route the hydraulic hoses piece of tubing mounts to the inside of the bucket H Link It is designed to guide the hoses and help prevent hose chaffing Position the tubing in the center of the link and weld it securely using E7016 o
39. lter Cross Reference Puralator 20101 Parker 921999 After build is Baldwin BT839 10 r complete grind Hook Plate Stauff SF6620 O D of hook plate smooth Back Plate VIEW A A Gaps between the template and the coupler indicate worn areas These worn areas should be built up and then ground to fit the template Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02
40. ment 6 CONNECTION TEST ONE off see Fig 38 3 Perform away from all personnel Test the connection to the attachment by completely curling the couper inward see Fig 38 1 38 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 Mere ENDR QUICK GOURLER USER MANUAL a n i OPERATIONS amp MAINTENANCE SECTION V ENGAGING THE ATTACHMENT Continued 9 After performing all connection tests rest the B HENDRIX II COUPLER attachment SECURELY on the ground see Fig 39 1 1229 Locking Pin Front Lever 10 Insert the mechanical lock pin Fig 39 2 3 4 5 A 1ST GENERATION COUPLER Fig 39 2 LOCKING PIN oecure the mechanical lock pin by inserting the lynch on both ends of the mechanical lock pin Be sure to close each lynch pin s locking ring NOTE When the locking lever is properly engaged under and around the link pin you will be able to insert the mechanical lock pin LOCKING PIN THE SWITCH MUST REMAIN IN THE LOCK POSITION WHEN OPERATING THE EXCAVATOR WITH COUPLED ATTACHMENTS NEVER SWING COUPLED ATTACHMENTS OVER WORKERS HEADS LYNCH PIN oecure the mechanical lock pin by inserting the 11 After you have successfully performed the lynch pin on both ends of the mechanical lock pin connection tests and inserted the mechanical lock Be sure to close each lynch pin s locking ring pin you are now ready to operate your machine with the coupled attachment
41. nd easily All excavator operators should familiarize themselves with all Coupler Attachment combinations before attempting to operate the coupler This should include but not be 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 they are used on the jobsite Never use the coupler without an attachment except when used for lifting Review all information in the General Information section of this manual Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 OPERATIONS 8 MAINTENANCE SECTION WARNINGS amp PRECAUTIONS Continued WARNING Avoid oil spills Use containers rags and or in the LOCK position The green light indicator will Only operate the Coupler with the control box switch illuminate when the switch is placed in the LOCK position absorvent towels to contain any oil leakage Dispose of all waste oils fluids lubricants The buzzer alarm indicates a potential unlock and other hazardous waste properly condition in the coupler Do not attempt to operate the attachment if this condition is present Always verify visually that the attachment is properly locked Make sure that the buzzer alarm functions properly N WARNING N at all times Use safety protection such as hard hats working gloves safety shoes and safety glasses when
42. ndrix Quick Coupler User Manual Rev 1 GBH4 09 02 Mere ENDR QUICK GOURLER USER MANUAL OPERATIONS 8 MAINTENANCE SECTION VII LIFTING LOADS WITH THE COUPLER INSTALLED This section will detail the proper steps for lifting loads using the Hendrix Quick Coupler 1 Always disengage the attachment when lifting 2 DO NOT use the attachment hook while coupled to loads with a Hendrix Quick Coupler installed on an attachment See Fig 41 2 the excavator Curl the Coupler inward when lifting loads see Fig 41 1 3 DO NOT use the Coupler s Lifting Eye while coupled PREFERRED METHOD FOR LIFTING to an attachment See Fig 41 2 1st Generation Coupler Pictured UNACCEPTABLE LIFTING PRACTICES 41 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 Ker HENDRIX QUICK COUPLER USER MANUAL OPERATIONS 8 MAINTENANCE SECTION VIII MAINTENANCE PROCEDURES This section will detail several maintenance procedures for the coupler 1 LUBRICATION You should lubricate all three pivot points of the s s ADJUSTING Coupler at least daily Certain applications may BOLT require more frequent lubrication If the Coupler is Ail working under water you should lubricate the Coupler approximately every four hours Use EP2 Lithium base grease to lubricate the coupler See Fig 42 1 for better reference SPRING application 1st Generation Coupler Pictured 2 SPRING PRELOAD ADJUSTMENT 1st Generation NOTE The Hendri
43. necting them to the system 3 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AERE psp QUIGK COURLER USER MANUAL This section provides Diagrams and Charts to help you identify the components of the Coupler the Coupler Installation Kit and the Excavator as well as to help familiarize you with the terminology used in this manual CHART 1 Excavator Parts ID Chart Excavator Boom Excavator Arm Cylinder Excavator Idler Link CHART 2 Coupler Attachment Parts ID Chart Excavator Idler Link Excavator Linkage V Excavator Arm Stick Link Side Original Machine Pin Stick Side Original Machine Pin Link Side Attachment Pin Stick Side Attachment Pin 4 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AES HENORD QUICK COUPLER USER MANUAL Continued CHART 3 1st Generation Coupler Parts ID A Cylinder A Locking Lever Low y Spring End Cap Springs Mechanical Lock Pin Cast Lifting Eye 5 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 GENERAL INFORMATION SECTION TWO PARTS ID CHARTS Continued CHART 5 COUPLER KIT COMPONENT LISTINGS amp DRAWINGS FILTER COMPONENTS PARTNUMBER 411 212 ON 3 6 412 CHARTS dott ja 1 ja 174 X 20 X 3 4 Hex Head Bolts with Washers 1 4X20X34 2 2 2 D 2 21 4442 SWITCH BOX COMPONENTS PARTNUMBER 44212 6
44. needed to perform this job Make sure to lubricate the Coupler daily with 2 CAUTION Lithium base type grease Lubricate every 4 hours if the coupler works under water The operator may experience slow or unexpected movement of functions when Never use the Coupler asa prying tool operating with cold hydraulic oil Likewise damage to the hydraulic components may result Never use the Coupler as a clamping device due to the cold oil Make sure to warm up the hydraulic system before operation inspect the Coupler and all components each day Make any necessary repairs before operating CAUTION Do not use the Coupler if it is severely worn Make sure to repair wear before resuming operation Never allow a hydraulic line or component to become contaminated This could cause severe e system damage Contact an authorized machine distributor to obtain proper caps and plugs to be used on this machine Perform all connection tests before attempting to operate the coupler Check the spring preload daily on the 1st Generation Coupler Refer to Page 42 for spring preload dimensions Do not pre load springs more or less than the specification values Also inspect the locknut on the spring adjustment for tightness each CAUTION DO NOT CONNECT THE HENDRIX QUICK COUPLER TO HYDRAULIC PRESSURES HIGHER THAN 1000 psi The Hendrix Quick Coupler is designed to operate on the low pressure pilot system only
45. ngine compartment that houses the pilot pressure system The Hendrix Quick Coupler operates off of the low pressure pilot system You will install the control valve and filter in the engine compartment This will provide easy access to the low pressure pilot system as well as protection from the elements Your Hendrix Quick Coupler comes with a 3 Light Switch Box that will be mounted in the cab of the excavator HELPFUL HINTS BEFORE BEGINNING INSTALLATION A Read through the entire installation section before beginning the installation B Determine where you will need to mount the control valve and filter these components are mounted in the main engine compartment near the excavator s pilot pressure system C Determine where you will need to mount the switch box this item mounts in the excavator cab D Make 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 E Check to determine if the Tubular Hose Bracket can be welded to the excavator s H Link F Determine the best route for running the hoses on the excavator the hoses should not interfere with other excavator components DANGER Failure to comply with information in this Hendrix Quick Coupler User Manual may result in injury death damage to property and or damage to the Quick Coupler Insure that all personnel have read and understand the information
46. r E7018 welding rod or equivalent see Fig 16 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 that are not suitable for welding Other H Links may allow the hoses to slip through them Find a method that will properly guide the hoses and prevent chaffing Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 16 AES COUPLER USER MANUAL INSTALLATION SECTION V HYDRAULIC HOSE ASSEMBLY This section details the processes of making the hydraulic hoses required for the coupler installation Please refer to the next section for installation procedures for the hoses Hendrix makes every attempt to provide adequate lengths of hoses for your coupler installation However depending on your excavator you may find you need extra hose Please see the hose specifications listed on the coupler kit component listing in the event you need extra hoses A Place socket in a vise D Hold hose with the vise B Cut hose to desired length and dip tip into heavy oil E Dip hose end of nipple into heavy oil C Screw hose counterclockwise into the socket until it bottoms out then back hose out 1 2 turn F Screw nipple assembly completely into socket using wrench 1 7 Hendrix Quick Coupler User Manual
47. re that all personnel have read and understand the information in this User Manual before attempting to install maintain and or operate the Hendrix Quick Coupler 2 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AES KITA QUICK COUPLER USER MANUAL a l ad GENERAL INFORMATION SECTION WARNINGS RECOMMENDATIONS amp PRECAUTIONS This section provides general information and recommendations needed before attempting to install operate or maintain your Quick Coupler SAFETY MESSAGE CLASSIFICATION Safety Messages in this Manual are classified as follows DANGER Indicates an imminently hazardous situation If not avoided this hazard will result in death or serious injury WARNING Indicates a potentially hazardous situation If not avoided this hazard could result in death or serious injury CAUTION Indicates a potentially hazardous situation If not avoided this hazard may result in minor or moderate injury and or damage to the coupler or machine Read these instructions thoroughly before Route all hoses and wires in a neat and orderly attempting to install operate or maintain your manner Secure the hoses and wires to other Hendrix Quick Coupler machine components Before installing unpack the Coupler and Coupler Do not force any parts during assembly If the Kit Inspect the Shipper s Bill of Lading to parts are properly aligned the pins will go in easily determine that all items have been recei
48. responsibility resulting from unauthorized modification Unauthorized modification voids all warranties Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 59 HENDRIX QUIEK COUPLER USER MANUAL INSTALLATION SECTION Il REMOVE THE BUCKET OR ATTACHMENT This section details the necessary steps to remove any existing attachment from the excavator before beginning the coupler installation 1 Make sure the throttle control is in the low idle 5 Remove both the stick and link pin from the arm to position Start the engine see Fig 13 1 bucket connection see Fig 13 5 6 Operate the excavator controls to remove the excavator arm from between the ears of the attachment 3 Operate the attachment controls on the excavator 7 Rest the excavator arm securely on firm level to position the bucket or attachment securely on ground firm level ground see Fig 13 3 END OF SECTION 13 4 1 3 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 TO lO QUICK GOUPLSR USER MANUAL INSTALLATION SECTION Ill CONNECT THE COUPLER TO THE EXCAVATOR ARM 1 Insure that the coupler is resting securely on firm level ground No pins should be in the coupler CAUTION Make sure you use the ORIGINAL machine pins from your excavator to connect the coupler to the arm of the excavator DO NOT use the attachment pins that shipped with the coupler to connect to the arm of the excavator 2 If t
49. st Generation 9 LINK PIN FRAME BUILDUP Hendrix Il When play exists between the link pin and the The Hendrix Coupler features a replaceable wear frame casting disengage the attachment and pad in the frame of the Coupler in the link pin area place the template at the link pin frame casting as This wear pad is made of Hardox 400 material shown in Fig 44 1 Measure across complete width of link pin location and mark areas of coupler that do not match the link pin template as indicated in the figure Preheat frame casting area to be rebuilt to 400 F 205 C Use E7018 equivalent welding material to weld across complete width of link pin location Clean excess weld to match profile of link pin template Grind outer diameter of hook plates smooth after all welding is complete Please contact your Hendrix Dealer to obtain the appropriate buildup template for your Coupler Please provide your coupler Serial Replaceable Wear Pad Number and or the Coupler part number when ordering 5 FILTER REPLACEMENT A hydraulic oil filter is provided for your Hendrix Quick Coupler This filter should be replaced at regular intervals such as when replacing the other filters on your excavator This filter is a Purolator brand filter Part 20101 and can be obtained from your Hendrix dealer Alternatively a cross reference to several other brands is provided below FILTER CROSS REFERENCE CHART AU Link Pin Template Hendrix Fi
50. that allows for easy access but does not interfere with the operation of the excavator Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 Ma did INSTALLATION SECTION VII CONTROL VALVE FILTER SWITCH BOX INSTALLATION Continued 11 12 13 25 The Switch Box has two cables The first cable has 3 leads Black White and Green and is approximately 20 feet in length Route this cable back to the engine compartment containing the control valve Connect the 3 leads of the switch box to the 3 leads on the Control Valve Wiring Harness You should match the color coded wires Black to Black White to White Green to Green You should make all wiring connections in accordance with standard electrical practices Refer to SAE Standard J2030 Heavy Duty Electrical Connections Performance The second cable on the Switch Box is approximately 6 feet in length and has 2 leads Black and White Connect the White lead to the excavator s 24VDC system Link with the supplied 10 AMP fuse Chart 5 F Fused circuits on the excavator should be utilized where applicable Connect the Black lead to the system ground You should make all wiring connections in accordance with standard electrical practices Refer to SAE Standard J2030 Heavy Duty Electrical Connections Performance After making all switchbox connections test the installation of the coupler DO NOT CONDUCT THE TEST WITH AN ATTACHMENT ON THE COUPLER REM
51. to have a small amount of sides slack even in the fully curled in position Mark the hoses cut and assemble the hose fittings on that end N WARNING N Be sure to eliminate any twisting of the hoses before tightening the connections Do not put hands into moving excavator 4 After installing the lower hose running from the coupler to the Lower Bulkhead Fittings bracket begin routing the remaining hose sections Measure and install the hose between the Lower Bulkhead Fittings Bracket and the Upper Bulkhead Fittings Bracket see Fig 19 2 Remember to route the hoses in a manner that will not interfere with other lines and equipment 1 9 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 AES HENDRIX QUIGK COUPLER USER MANUAL INSTALLATION SECTION VI HYDRAULIC HOSE INSTALLATION Continued 6 20 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 into the control valve which will be installed in the next section END OF SECTION Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 p BRIX IM INSTALLATION SECTION VII CONTROL VALVE FILTER SWITCH BOX INSTALLATION The Control Valve and the Filter Assembly for the coupler are installed in the engine compartment of the excavator These components will tie into
52. ty Messages in the manual DANGER Failure to comply with information in this Hendrix Quick Coupler User Manual may result in injury death damage to property and or damage to the Quick Coupler Insure that all personnel have read and understand the information in this User Manual before attempting to install maintain and or operate the Hendrix Quick Coupler 27 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 OPERATIONS amp MAINTENANCE SECTION I WARNINGS amp PRECAUTIONS This section provides warnings and precautions to be taken before operating and or maintaining the Hendrix Quick Coupler 28 Improper operation and maintenance of this equipment could result in serious injury or death Read this operator s manual thoroughly before operating and or maintaining this equipment The excavator s effective reach as well as the attachment tip radius are increased with the Hendrix Quick Coupler installed Keep in mind that the attachment can come in contact with the Boom Arm and Cab depending on the Coupler Attachment combination Be aware that the excavator s attachment range of motion changes with the Hendrix Quick Coupler Installed gt gt Increase Decrease bucket dump angle gt gt bucket curl forward angle Unauthorized modification to the coupler and or any coupler components may impair function affect performance and affect the life of the coupler the excavator and or th
53. ved and the fittings will screw into the valves without undue force inspect all items for any damage or missing items Lubricate all pins Always use the original due to transit or handling If some items are machine pins that came with the excavator to damaged or missing please contact your dealer attach the coupler to the dipperstick insure that all items listed on the Coupler Kit hoses should have enough slack to move when Component list see Chart 5 in General powering the dipperstick or attachment Information section are included Verify that the coupler machine number on the serial Number ID Tag Fig 3 1 matches the E machine you are attempting to install the coupler on ENDRIX Sort out all Coupler Kit Material and group the components together by component type Be sure QUICK COUP LER to group all bolts with their respective washers SERIAL NO MACHINE Familiarize yourself with the Coupler and Coupler HENDRIX MANUFACTURING COMPANY INC Kit components before installing operating or MANSFIELD LOUISIANA USA 71052 maintaining your Hendrix Quick Coupler see Parts ID charts insure that you have an ample supply of rags and absorbent towels on hand for cleaning purposes Fig 3 1 Coupler Serial Number ID Tag Tighten all fittings securely and properly Insure that all hoses lines and fittings are clean open and clear before con
54. x II Coupler features a cylinder The springs on the Hendrix Quick Coupler have to With an integrated spring that does not require regular be pre loaded to ensure proper operation To adjustment obtain the correct spring pre loading set the dimension A accordingly from underneath the spring hanger bracket to the top of the spring cap see Fig 42 2 Once the dimension is set tighten the lock nut against spring hanger to ensure dimension A will not change during operation It is recommended that you replace the springs annually SPRING PART NO DIMENSION MD140 1 1 1 8 inch 25 4 28 5 mm MD240 5 8 3 4 inch 15 9 19 0 mm C245 1 1 1 8 inch 25 4 28 5 mm 42 Hendrix Quick Coupler User Manual Rev 1 GBH4 09 02 FENDRIX QUICK COUPLIR USER MANUAL OPERATIONS amp MAINTENANCE SECTION VIII MAINTENANCE PROCEDURES 3 43 FRONT C CASTING BUILDUP When play exists between the arm pin and the C casting disengage the attachment and place the template at the arm pin C casting as shown in Fig 43 1 Measure across complete width of arm pin location and mark areas of coupler that do not match the arm pin template as indicated in the lower part of the figure Preheat C casting area to be rebuilt to 400 F 205 C Use E7018 or equivalent welding material to weld across complete width of arm pin location Clean excess weld to match profile of arm pin template Grind outer diameter of hook plat

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