Operation and Maintenance Manualtranscend-cat.netexpress.net/.../operators_manuals/cwt021983.pdf · GEBJ1139-01 July 2012 Operation and Maintenance Manual Connect’o’maat® Quick

GEBJ1139-01

July 2012

Operation and Maintenance Manual

Connect’o’maat® Quick Coupler System CW DEW1-Up (CW-05) DEP1-Up (CW-10) DEL1-Up (CW-20/30/40) DEJ1-Up (CW-20/30/40 S) DEE1-Up (CW-45) DEH1-Up (CW-45 S) DEG1-Up (CW-55) DEK1-Up (CW-55 S) DEF1-Up (CW-70)

NOT in SIS Produced by CWTS-EAME

© Copyright Caterpillar Work Tools B.V. All rights strictly reserved. Reproduction

to third parties in any form whatever is not permitted without written authority from the proprietor.

Connect’o’maat® CW-series

07.12 all rights reserved 1

DEAR USER, CATERPILLAR's Connect'o'maat® quick coupler system (CW series) is a multifunctional tool carrier for excavators. The Connect'o'maat® is deliverable in a mechanical or a hydraulic version. With both versions attachments can be exchanged quickly and easily. You are urgently requested to read the operating manual and to carefully execute the instructions when working with the equipment. CATERPILLAR-products bear the CE mark and comply with all the relevant EC safety requirements. However, it remains necessary to make sure that the safety requirements are met for all operations, maintenance or repair works. This refers to the safety regulations mentioned in this manual, in the operating manual of the machine and in the local safety regulations valid for the area in which the CATERPILLAR-product is being used, maintained or repaired. Modifying the CATERPILLAR-product is only allowed with the permission of your

supplier! Only then the warranty conditions and CE liability apply. Warnings Only qualified persons are permitted to operate the excavator with the Connect’o’maat® fitted to it. Maintenance or repair jobs can only be carried out by well qualified technical personnel. Prevent unsafe work situations. Keep distance from moving parts. Make sure there are no persons within reach of the excavator with the Connect’o’maat® fitted to it. Stop the engine before starting maintenance or repair operations. Make sure the safety precautions are met! Defective parts must be replaced by original CATERPILLAR-parts. In this product mineral oil is used. When applying other types of hydraulic oil problems may arise. In case of questions, first contact your supplier.


all rights reserved 07.12 2

Warranty and service The warranty obligation of the supplier depends on the correct installation of the product. Check the working pressure of your machine first. Should there be any questions, contact your supplier. Unless otherwise agreed upon, the terms of warranty drawn up by ORGALIME in the publication of October 1992 apply to this product. Some of the clauses from these terms can be found at the back of this manual. CATERPILLAR is continually improving its products. It reserves the right to change its products without prior notice. Apart from supplying a complete range of equipment, CATERPILLAR can also supply the following service: - Supplying (spare) parts for the equipment.



C O N T E N T S

Page

1. PRODUCT IDENTIFICATION .................................................................................................................. 4

2. LIFTING THE CONNECT’O’MAAT® ....................................................................................................... 6

3. PRODUCT OVERVIEW AND TECHNICAL DATA .................................................................................. 7

3.1 CONSTRUCTION OF THE CONNECT’O’MAAT® .......................................................................................... 8 3.2 OPTIONS AND IDENTIFICATION ............................................................................................................. 10 3.3 TECHNICAL DATA ................................................................................................................................ 11 3.4 TORQUES FOR CONNECT’O’MAAT® (TYPE D) ........................................................................................ 13 3.5 TORQUES FOR CONNECT’O’MAAT® (TYPE H) ........................................................................................ 14 3.6 CALCULATING THE HYDRAULIC EXCAVATOR/CW COMBINATION ................................................................ 15

4. INSTALLATION OF THE CONNECT’O’MAAT® ................................................................................... 17

4.1 HYDRAULIC CONTROL SYSTEM ............................................................................................................. 18 4.2 HYDRAULIC CONNECTIONS .................................................................................................................. 19 4.3 MOUNTING THE CONNECT’O’MAAT® ON THE EXCAVATOR ...................................................................... 19 4.4 MOUNTING THE CONTROL SYSTEM ....................................................................................................... 20 4.5 AIR PURGE THE HYDRAULIC SYSTEM .................................................................................................... 20

5. OPERATION ........................................................................................................................................... 23

5.1 SAFETY PRECAUTIONS FOR COUPLING .................................................................................................... 24 5.2 COUPLING THE ATTACHMENT ................................................................................................................ 24 5.3 UNCOUPLING THE ATTACHMENT ............................................................................................................ 34 5.4 HOISTING HOOK .................................................................................................................................. 36 5.5 LIFTING OBJECTS ................................................................................................................................ 37

6. CONNECT’O’MAAT® CONVERSION .................................................................................................. 37

7. DISMOUNTING THE CONNECT'O'MAAT® FROM THE EXCAVATOR ............................................... 38

8. MAINTENANCE AND REPAIR ................................................................................................................ 39

8.1 SAFETY PRECAUTIONS ......................................................................................................................... 40 8.2 DAILY MAINTENANCE ............................................................................................................................ 41 8.3 MAINTENANCE EVERY 200 HOURS OF OPERATION ................................................................................. 42 8.4 MAINTENANCE EVERY 750 HOURS OR QUARTERLY ................................................................................ 45

8.4.1. Lifting Hook – Inspect ........................................................................................................ 46 8.5 WELDING THE CONNECT'O'MAAT® ....................................................................................................... 49 8.6 TORQUE SETTINGS ............................................................................................................................. 49

9. SPARE PARTS ....................................................................................................................................... 50

9.1 SAFETY CRITICAL COMPONENTS .......................................................................................................... 50

10. DECOMMISSIONING AND DISPOSAL ............................................................................................... 51

WARRANTY CONDITIONS ........................................................................................................................ 52



1. Product identification

Caterpillar Work Tools B.V. Sigarenmakerstraat 9 NL-5232 BJ ‘s-Hertogenbosch The Netherlands

ITEM No. / MODEL :

SERIAL No. :

CUSTOMER No. :

G.E.T SIZE :

MAX LOAD TORQUE [kgm] :

MACHINE TYPE :

/

YEAR :

MASS [kg] :

VOLUME [m³] :

p max. [bar] :

VOLTAGE [V] :

Connect’o’maat® serial number plate a. Connect’o’maat® model : ..................................... b. serial number : ........................ c. year of manufacture : ........................ d. weight [kg] : ........................ The CE mark is located on the serial number plate.

d

c

b

a



1.1 Dimensions

This operating manual applies to the Connect'o'maat® with the following dimensions in mm: T1 : . . . . . . . . . T2 : . . . . . . . . . T3 : . . . . . . . . .

Figure 1.1.1.

The distance C depends on the excavator mounting. The dimensions given in the table are the standard dimensions for the Connect'o'maat®.

type B [mm] L [mm] CW 05 175 200 CW 10 310 300 CW 20 550 475 CW 20 S 420 475 CW 30 550 475 CW 30 S 420 475 CW 40 550 475 CW 40 S 420 475 CW 45 690 570 CW 45 S 550 570 CW 55 830 650 CW 55 S 560 650 CW 70 840 875



2. Lifting the Connect’o’maat® Lifting of the Connect'o'maat® is permitted with the use of a lifting strap only. Guide the lifting strap through the mounting holes of both mounting plates. See Figure 2.1. It is not permitted to use a steel cable or lifting hooks. This would damage the mounting eyes.

Figure 2.1.

Check the lifting capacity of the lifting strap. The weight of the Connect'o'maat® is shown on the serial number plate and in chapter 1 of this manual.



3. Product overview and technical data Page

3.1 CONSTRUCTION OF THE CONNECT’O’MAAT® .......................................................................................... 8 3.2 OPTIONS AND IDENTIFICATION ............................................................................................................. 10 3.3 TECHNICAL DATA ................................................................................................................................ 11 3.4 TORQUES FOR CONNECT’O’MAAT® (TYPE D) ........................................................................................ 13 3.5 TORQUES FOR CONNECT’O’MAAT® (TYPE H) ........................................................................................ 14 3.6 CALCULATING THE HYDRAULIC EXCAVATOR/CW COMBINATION ................................................................ 15



H D

3.1 Construction of the Connect’o’maat® The Connect'o'maat® quick coupler system makes it possible to attach a wide range of attachments to the excavator in a simple manner. The Connect'o'maat® is mounted on the excavator. The attachment, which is fitted with Connect'o'maat® adapter plates, is suspended from the Connect'o'maat® journals. The attachment is secured to the Connect'o'maat® by a wedge. The Connect’o’maat® is available in two types. See figure 3.1.1. One version has a hydraulic wedge control, type H, and one has a wedge with spindle fastening that must be fastened manually, type D. The mechanical type can be simply converted to the hydraulic type.

Figure 3.1.1.



For the identification of the most important parts of the Connect'o'maat®, with hydraulic wedge control type H see Figure 3.1.2.

Figure 3.1.2. Connect’o’maat® with hydraulic wedge control type H

1. mounting plate 4. wedge 2. front pivot 5. mounting bolts 3. rear pivot 6. cylinder

For the identifications of the most important parts of the Connect'o'maat®, with spindle mounting type D see Figure 3.1.3.

Figure 3.1.3. Connect’o’maat® with spindle mounting type D

1. mounting plate 4. guide shaft 2. front pivot 5. locking bolt 3. rear pivot 6. spindle

7. wedge



3.2 Options and identification

Meaning of the Connect’o’maat® type identification: Example: CW 20S-H 4

hoisting hook

wedge control

class

Class: Indication of the excavators for which the

Connect’o’maat® has been designed. Type S: small model

Wedge control: H : hydraulic D : manually, with spindle mounting Hoisting hook: 2 : with hoisting hook 4 ton 4 : with hoisting hook 10 ton 5 : with hoisting hook 14 ton 6 : with hoisting hook 20 ton 7 : with hoisting hook 2 ton



3.3 Technical data

CW 05 CW 10 CW 20 CW 20Smaximum permissible load* [kgm] 750 2750 6000 6000

hydraulic wedge control**

p max. [bar] 350 350 350 350

p min. [bar] 150 150 150 150

connection to DIN 3853 8 S 8 S 8 S 8 S

excavator weight [tons] 1 - 3,5 3,0 - 10,5 7,5 - 16 7,5 - 16

Max. SAE break-out force (kN) <27,5 <60 <100 <100

CW 30 CW 30S CW 40 CW 40S

maximum permissible load* [kgm] 10500 10500 13750 13750


p max. [bar] 350 350 350 350

p min. [bar] 150 150 150 150

connection to DIN 3853 8 S 8 S 8 S 8 S

excavator weight [tons] 14 - 21 14 - 21 19 - 27 19 - 23

Max. SAE break-out force (kN) <135 <135 <175 <150

CW 45 CW 45 S CW 55 CW 55S CW 70

maximum permissible load* [kgm] 20000 20000 28000 28000 37250


p max. [bar] 350 350 350 350 350

p min. [bar] 150 150 150 150 150

connection to DIN 3853 8 S 8 S 8 S 8 S 8S

excavator weight [tons] 25 - 45 25 - 45 40 - 65 40 - 65 62 - 90

Max. SAE break-out force (kN) <240 <240 <300 <280 <400

The weight of the Connect'o'maat® is shown on the serial number plate, and given in chapter 1 of this manual. * Including operating load on the coupled attachment (see Figure 3.3.1). ** Only applicable for the Connect'o'maat® with hydraulic wedge control. The CW 70 is only available with hydraulic wedge operation (model H). Note: The specified maximal acceptable load moment applies when Connect'o'maat® is used on a flat and sturdy surface. For all other uses, consideration must be taken of a reduced stability. See also chapter 5.1.



L

G

Figure 3.3.1. G = total weight of attachment including operating load L = distance between pivot axes of the Connect'o'maat® and the operating load



3.4 Torques for Connect’o’maat® (type D)

In the Connect’o’maat with manual wedge operation with spindle fastening (model D) the bolts (see Figure 3.4.1) must be tightened with the torques as per the table below.

Torques [Nm]

Posnr CW 05 CW 10 CW 20/30/40 (S) CW 45 (S) CW 55 (S)

1. 8510 11010 25025 36035 36035 2. 8510 11010 25025 36035 36035

3. 8510 8510 29530 58060 58060 4. 253 424 14515 14515 14515 5. - 505 8510 8510 8510 6. - 61 101 253 253

7. - 505 - - - 8. - 8510 41040 71070 71070

= fasten with Loctite 243 = only fasten with Loctite 243 at CW 05

Figure 3.4.1



3.5 Torques for Connect’o’maat® (type H)

In the Connect’o’maat with hydraulic wedge operation (model H) the bolts (see Figure 3.5.1) must be tightened with the torques as per the table below. For CW 05 see Figure 3.5.1. For CW 10/20(S)/30(S)/40(S)/45(S)/55(S)/70 see Figure 3.5.2.

Mounting instructions posnr. 1, see figure 3.5.2. Put bolt (A) in place. Tighten nut (B) by hand. Tighten nut (C) against nut (B)

Torques [Nm]

Posnr CW 05 CW 10 CW 20/30/40 (S) CW 45 (S) CW 55 (S) CW 70

1. 505 - - - - -

2. 8510 12010 29520 58050 58050 1000100 3. - 707 12012 12012 12012 29530

4. - 12010 29520 41040 41040 71070 = fasten with Loctite 243.

Figure 3.5.1. CW 05

Figure 3.5.2. CW 10/20(S)/30(S)/40(S)/45(S)/55(S)/70



3.6 Calculating the hydraulic excavator/CW combination

A Connect'o'maat® quick coupler system is sold for a certain application. If the technical specifications of the hydraulic excavator and the intended use are known then it is checked that the combination of hydraulic excavator/Connect’o’maat®/ attachments is 'safe'. A combination of hydraulic excavator and attachment is safe if the combination is stable enough and if the performance of the hydraulic excavator is not too high for the Connect'o'maat® quick coupler system and attachment. If, upon commissioning Connect’o’maat® quick coupler system is attached to an hydraulic excavator with different specifications, then it should be checked first that the new combination is safe. For further information about how to calculate a combination of hydraulic excavator Connect’o’maat®- quick coupler system and attachment, please contact your supplier. Note: If a hydraulic excavator and attachment with Connect’o’maat® quick coupler system combination is not safe, then the Connect’o’maat® quick coupler must not be connected to the hydraulic excavator. In an unsafe hydraulic excavator/Connect’o’maat® quick coupler system combination the warranty obligations and CE-liability for CATERPILLAR become null and void.





4. Installation of the Connect’o’maat® Installation of the Connect’o’maat® can only be carried out by well qualified technical personnel.

Page

4.1 HYDRAULIC CONTROL SYSTEM ............................................................................................................. 18 4.2 HYDRAULIC CONNECTIONS .................................................................................................................. 19 4.3 MOUNTING THE CONNECT’O’MAAT® ON THE EXCAVATOR ...................................................................... 19 4.4 MOUNTING THE CONTROL SYSTEM ....................................................................................................... 20 4.5 AIR PURGE THE HYDRAULIC SYSTEM .................................................................................................... 20



4.1 Hydraulic control system

The Connect'o'maat® wedge cylinder must be controlled through the excavator's hydraulic system. There are legal safety requirements applicable for the control systems of quick coupler systems. The Connect'o'maat® with hydraulic wedge control is therefore supplied with a hydraulic control system that meets all the requirements. For an explanation of this system and the hydraulic/electrical diagrams see the operating manual for the CATERPILLAR SB operating system.

When the Connect'o'maat® system is purchased without the CATERPILLAR control system, the user must himself ensure that the control system meets the requirements. The control system must meet the following requirements: The control of the wedge must be protected against 'unintentional' operation; for

example, by the fitting of a two-handed control. When connected there should be no pressure build up on line b, see Figure 4.1.1.

Otherwise disconnecting during operation is possible.

Note: Some excavators may have pressure in either of the outgoing ports from the control valve when the control valve is in the middle position. When pressure exists in either of the outgoing ports, make sure that the pressure line is connected to line a.

The system must be designed so that after unlocking, the wedge ram remains driven fully out for at least 30 seconds, against the spring pressure.

The maximum operating pressure in the cylinder is 350 bar, the required oil flow is approximately 15 l/min.

For further information concerning modifications to the excavator, contact your supplier. Use of a hydraulic function without the above-mentioned safety provisions is not permitted. The CE mark is then no longer valid.

Figure 4.1.1. (2 example connection diagrams) 1a, 1b: control valve, extra hydraulic function 3: Connect’o’maat® wedge cylinder 2: ball valve 4: connection for extra hydraulic function 5: discharge valve



Note: Valve 1a (Figure 4.1.1.) requires the discharge valve to be mounted in line b!

4.2 Hydraulic connections The hydraulic hoses are connected directly onto the Connect'o'maat® cylinder. Note: For safety and environmental reasons it is necessary for the excavator jib to be fitted with ball valves and/or speed couplings! In order to be able to mount the hydraulic hoses, a screw-in coupling must be fitted on the cylinder. The figure 4.2.1. below, shows the right screw-in coupling.

D1 = G ¼“ D2 = M16 x 1,5 d = 8 mm Figure 4.2.1.

4.3 Mounting the Connect’o’maat® on the excavator The Connect'o'maat® may only be fitted to the excavator indicated on the serial number plate. The Connect'o'maat® is adjusted for the capacity of that type of excavator and, more importantly, is fitted with an excavator-dependent mounting plate. All Ce-liability on the part of CATERPILLAR may become null and void if the Connect’o’maat® is used in conjunction with an excavator with other specifications without prior written permission from your supplier. Proceed according to the following instructions for mounting on the excavator: 1. Position the Connect'o'maat® on the ground in front of the excavator. The wedge

must point away from the excavator. 2. Install the mounting pins. (See the excavator manual). Warning: Never put your fingers in the mounting bores to check the alignment of the bores! 3. Lock the pin in accordance with the excavator instructions. 4. Lubricate the mounting points (also see the operators’ manual for the excavator). 5. Connect the hydraulic lines to the Connect'o'maat® (if equipped). 6. Before you operate the Connect'o'maat®, you must purge the air from the hydraulic

system. See chapter 4.5.

24

D2 d D1



4.4 Mounting the control system For mounting a CATERPILLAR control system carry out the instructions mentioned in the operating manual for the CATERPILLAR SB operating system. Carry out the following instructions for mounting another control system: 1. Position the control and operating console in the cabin so that:

the operator can see the display. the knobs can be operated from the seat.

2. The hydraulic hoses are not supplied with the Connect’o’maat®. Use only hydraulic

hoses with the specification given in the table below. Ensure that the hoses are long enough and that they cannot become trapped by a movement of the excavator or the Connect’o’maat®. Fit the hoses that run from the arm to the wedge cylinder with protective springs.

3. Mount the ball valves on the excavator arm.

Caution: Clean the oil connections before connecting the hoses. Dirt in the hydraulic system can result in damage! After uncoupling the Connect'o'maat® system: connect the hoses to one another or seal off the connections with blanking plugs! Use the following hose specification:

CW-serie

Interior hosediameter 1/4"

hose specification DIN 20022-2 SN

4.5 Air Purge the hydraulic system

After mounting the Connect'o'maat® on the excavator, or after working on the Connect'o'maat® hydraulic system, it is necessary to purge all the air from the cylinder and the control system. If there is air in the cylinder and the oil in the cylinder is placed under a high pressure, as a result of dieselling the oil can spontaneously ignite. This will inevitably cause damage to the cylinder. Only for use with hydraulic wedge operation Proceed according to the following instructions for bleeding the wedge cylinder and the control system: 1. Loosen the fastening bolts of the wedge (no. 5 in figure 3.1.2) 2 cm. 2. Start the excavator engine.



3. Send the cylinder, 3 x in a row, fully in and out. Do not use any extra pressure! The

air is taken up by the oil and is discharged in this way. 4. Tighten the fastening bolts at the correct torque. For this see chapter 3.5. 5. Check that the shoulder of the spring shafts is against the wedge. Correct if

necessary.





5. Operation Only qualified persons are permitted to operate the excavator with Connect’o’maat®.

Page

5.1 SAFETY PRECAUTIONS FOR COUPLING .................................................................................................... 24 5.2 COUPLING THE ATTACHMENT ................................................................................................................ 24 5.3 UNCOUPLING THE ATTACHMENT ............................................................................................................ 34 5.4 HOISTING HOOK .................................................................................................................................. 36 5.5 LIFTING OBJECTS ................................................................................................................................ 37



5.1 Safety precautions for coupling

Before using the Connect'o'maat®, first carry out the daily maintenance. See Section 8.2. Before the attachment may be coupled, first determine whether the combination of excavator and attachment is safe. This is easily determined by filling the calculation sheet. The calculation sheet is available from your supplier.

5.2 Coupling the attachment Check that the attachment is fitted with original CATERPILLAR Connect'o'maat® adaptor plates.. Note: The CATERPILLAR's CE liability is void if an attachment is coupled with imitation adaptor plates!

Figure 5.2.1. Before connecting first carry out the safety measures in chapter 5.1. For coupling the attachment to the Connect'o'maat®, follow the instructions given in the operators manual for the attachment. Also follow the instructions given below: A. Connect’o’maat® with hydraulic coupling 1. Verify that the wedge is in the uncoupled position. If the wedge is not extended,

extend the dump cylinder. Then, extend the wedge. See Figure 5.2.2. 2. Ensure that the mounting bracket is in line with the excavator. The attachment must

be facing the excavator. The mounting bracket must be at the top of the attachment. See Figure 5.2.2.



Figure 5.2.2. Coupling a bucket 1. Hook the forward pivot of the Connect'o'maat® into the hooks of the mounting

bracket. See figure 5.2.3.

Figure 5.2.3. 3. Tilt the Connect'o'maat® against the attachment by extending the dump cylinder.

Position the attachment so that the wedge can be seen from the cab. 4. Engage the wedge. Ensure that the wedge locks into the attachment. 5. Verify the engagement of the Connect'o'maat® and the attachment.

a. Place the attachment on the ground. b. Apply pressure to the attachment against the ground. c. Drag the attachment backward.



Coupling a hammer or shear

Note: avoid contacting the ground with the wedge. Damage to the wedge can occur.

Figure 5.2.4.

1. Hook the forward pivot point of the Connect’o’maat® into the hooks of the mounting bracket. See figure 5.2.5.

Figure 5.2.5.

2. Lift the attachment from the ground. See figure 5.2.6.

Figure 5.2.6.



3. Tilt the Connect'o'maat® against the attachment by extending the dump cylinder.

Position the attachment so that the wedge can be seen from the cab. See figure 5.2.7.

Figure 5.2.7. 4. Engage the wedge. Ensure that the wedge locks into the attachment.

5. Verify the engagement of the Connect'o'maat® and the attachment. a. Place the attachment on the ground. b. Apply pressure to the attachment against the ground. c. Drag the attachment backward.

Coupling a grapple 1. Hook the forward pivot of the Connect'o'maat® into the hooks of the mounting



See figure 5.2.8.



Figure 5.2.9. 3. Engage the wedge. Ensure that the wedge locks into the attachment. 4. Verify the engagement of the Connect'o'maat® and the attachment.


B. Connect’o’maat® with spindle coupling 1. Ensure that the mounting bracket is in line with the excavator. The attachment must

be facing the excavator. The mounting bracket must be at the top of the attachment. See Figure 5.2.2.

2. In order to move wedge (1) to the unclamped postion, perform the following steps:

a. Loosen lock bolt (3) until you can turn spindle (2). b. Turn spindle (2) until the bolts (4) lightly contact the coupler (5).

Figure 5.2.10.



3. Position the wedge in an upward position. Coupling a bucket 1. Hook the front pivots into the hooks of the mounting bracket on the attachment. See

figure 5.2.11.

Figure 5.2.11. 2. Tilt the Connect’o’maat® against the attachment by extending the dump cylinder. Stop

the engine of the excavator.

Figure 5.2.12. 3. Turn the spindle inward. Tighten the spindle. Refer to paragraph 3.4 for the correct

torque value for your Connect’o’maat®. Note: If necessary, tighten the spindle until the next notch is aligned with the locking bolt.

4. Tighten the locking bolt. Refer to paragraph 3.4 for the correct torque value for your

Connect’o’maat®.



5. Ensure that there is a visible space between the wedge and the Connect'o'maat®

frame. See paragraph 8.3. figure 8.3.1. If f there is not a space, the mounting bracket or the Connect'o'maat® may be damaged.

6. Verify the engagement of the Connect'o'maat® and the attachment.


Coupling a hammer or shear Note: avoid contacting the ground with the wedge. Damage to the wedge can occur.

Figure 5.2.13. 1. Hook the forward pivot point of the Connect’o’maat® into the hooks of the mounting


Figure 5.2.14. 2. Lift the attachment from the ground. See figure 5.2.15.




Position the attachment so that the wedge can be seen from the cab. See figure 5.2.16.




Connect’o’maat®. 6. Ensure that there is a visible space between the wedge and the Connect'o'maat®






Coupling a grapple 1. Hook the forward pivot of the Connect'o'maat® into the hooks of the mounting



See figure 5.2.18.




Connect’o’maat®. 5. Ensure that there is a visible space between the wedge and the Connect'o'maat®








5.3 Uncoupling the attachment For uncoupling the attachment, follow the instructions given below: 1. Disconnect any auxiliary hoses from the work tool (if equipped). 2. Ensure that the attachment is clear of the ground. 3. Fully extend the bucket cylinder and send the stick cylinder so far out that the

wedge points straight down. See Figure 5.3.1. The load is now released from the wedge.

Figure 5.3.1. A. Connect’o’maat® with hydraulic coupling 1. Drive the wedge ram out. In the case of the CATERPILLAR SB operating system the

two lamps on the control and operating console light. 2. Drive the bucket ram in while the wedge ram remains out. The attachment then

remains suspended from the Connect'o'maat® front pivot. 3. Lay the attachment on the ground. 4. Unhook the Connect'o'maat® front pivot from the mounting bracket.



B. Connect’o’maat®-wedge with spindle mounting 1. Switch of the excavator engine. 2. Loosen the locking bolt until it hangs loose in the screw thread. Attention: Do not

remove bolt. 3. Turn the spindle with wedge outward, until the guide shafts just touch. If necessary

tap with a hammer in the middle of the wedge to loosen it. See figure 5.3.2.

Figure 5.3.2. Connect’o’maat® with spindle mounting type D

4. Retract the bucket cylinder. The attachment is still hanging from the front shaft of

the Connect’o’maat®. 5. Place the attachment on the ground. 6. Unhook the Connect’o’maat® from the mounting bracket.



5.4 Hoisting hook The Connect'o'maat® is deliverable with a hoisting hook. See Figure 5.4.2. The hoisting hook is certified. A copy of the certificate is available on request.

Note: As soon as the excavator will be used to lift loads of more than 1000 kg, the excavator must comply with the requirements for lifting machinery. These are given in standard EN 474-5. If necessary, consult your excavator dealer.

For the use of a hoisting hook of the Connect’o’maat® follow the instructions given below:

1. When using the hoisting hook, no piece of equipment must ever be fastened to the Connect'o'maat®.

2. Never stand under the Connect’o’maat* in order to attach the load! To attach the load to the hoisting hook, hang the Connect’o’maat* just above the load.

3. The load to be hoisted must never be heavier than the permissible hoist capacity of the machine.

4. Never exceed the maximally permissible hoist capacity of the hoisting hook. See table 5.4.1.

5. Check the lifting capacity of the chain, cable or lifting strap.

6. Before using the hoisting hook first fully extend the bucket cylinder. Note: Only lift straight up. The hoisting hook of the Connect'o'maat® must not be

loaded sideways. During hoisting the bucket cylinder must not be used. Make sure that the wedge is pressed in (in type H) or has been removed. While

hoisting prevent the chain, cable or hoisting sling from pressing against the wedge. See Figure 5.4.1.

Figure 5.4.1. Note: Lifting with the Connect'o'maat® hoisting hook is only permitted when there is no attachment mounted on the Connect'o'maat®.



7. Fasten a chain, cable or lifting strap to the hoisting hook. If the safety beam is missing or is

damaged, stop all work and contact your supplier.

Figure 5.4.2.

type max. load [kg] type max. load [kg] CW 05 2.000 CW 45 14.000 CW 10 4.000 CW 55 20.000 CW 20-40 10.000 CW 70 20.000

Table 5.4.1.

5.5 Lifting objects

Warning: To prevent injury, do not exceed the rated load capacity of the machine. If the machine is not on level ground, load capacities will vary.

1. Refer to the load charts in the Operation and Maintenance Manual of the host machine. Use the load charts and account for the mass of the work tool. Calculate the load capacity relative to the location of the lifting point on your specific host machine.

2. The lifting point has a maximum capacity. The capacity is marked on the lifting point or near the lifting point. Do not exceed the maximum capacity.

3. Use a sling or a shackle to attach to the lifting point and lift the object. The sling or the shackle must have a rated capacity that is greater than the mass of the load.

4. If the machine is equipped with the CE plate per requirements for the European Union, used to lift objects, then the machine must be equipped with the optional boom lowering control valve and an overload warning device.

5. A fit for purpose test was completed in order to confirm that a properly equipped machine meets the requirements of the European Union Machinery Directive "2006/42/EC" for lifting objects.

6. The overload warning device (if equipped) must be adjusted for the bucket linkage and bucket size that is installed on the machine. Adjust the overload warning device for proper operation.

7. The setting for the overload warning device (if equipped) should be checked by an authorized dealer.

6. Connect’o’maat® conversion

The Connect’o’maat® with mechanical spindle control type D is simple to convert to type H, the model with hydraulic wedge control. For further details contact your supplier.



7. Dismounting the Connect'o'maat® from the excavator Dismounting the Connect’o’maat® from the excavator can only be carried out by well qualified technical personnel. Follow the instructions given below for dismounting the Connect'o'maat® from the excavator: 1. Lay the Connect'o'maat® flat on the ground (Figure 7.1.).

Figure 7.1. Warning: There is a pressure of 80 bar in the hoses of the Connect'o'maat® with hydraulic wedge control and the CATERPILLAR SB operating system, even when the engine is off. When releasing the pressure from the hydraulic lines, please take care of the security measures in chapter 8.1. 2. Blank off the hoses or connect them to one another (if applicable). The connections

on the fork must be sealed off with blanking plugs. Prevent oil being released into the environment!

3. Remove the fastening pin from the Connect'o'maat® pressure piece. 4. Drive the bucket ram in. Switch off the excavator engine. 5. Remove the mounting pins from the Connect'o'maat®.



8. Maintenance and repair Warning: Maintenance and repair can only be carried out by well qualified technical personnel. Before starting any maintenance or repair on the Connect'o'maat®, it is necessary for safety precautions to be taken first! See Section 8.1.

Page

8.1 SAFETY PRECAUTIONS ......................................................................................................................... 40 8.2 DAILY MAINTENANCE ............................................................................................................................ 41 8.3 MAINTENANCE EVERY 200 HOURS OF OPERATION ................................................................................. 42 8.4 MAINTENANCE EVERY 750 HOURS OR QUARTERLY ................................................................................ 45

8.4.1. Lifting Hook – Inspect ........................................................................................................ 46 8.5 WELDING THE CONNECT'O'MAAT® ....................................................................................................... 49 8.6 TORQUE SETTINGS ............................................................................................................................. 49



8.1 Safety precautions Warning: Carry out maintenance or repair only when the engine is switched off! Inspection of the Connect'o'maat® with the excavator engine running must be done by two authorized persons. The person at the excavator controls must be able to see the person who carries out the check. Keep your hands away from moving parts! Before maintenance or repair to the Connect'o'maat® is started, always carry out the following instructions: 1. With a coupled attachment, always lay the attachment on the ground. 2. Switch the excavator engine off. 3. Carry out the maintenance or repair. For work on the hydraulic system only 1. Uncouple the attachment from the excavator. Warning: Never work on the hydraulic system while it is under pressure! For the Connect’o’maat® with the CATERPILLAR SB operating system only: In the hose to the piston side of the wedge ram there is a minimum pressure of approximately 80 bar. Even when the engine is switched off! Therefore follow the instructions given below before starting maintenance or repair: 2. Drive the wedge ram out. 3. Stop the engine and turn off the ignition. 4. Release the pressure in the excavator's hydraulic tank. See also the operator's

manual for the excavator. 5. Switch on the excavator's ignition. The hoses to the wedge cylinder are now

practically pressure free. The Connect'o'maat® ram will be moved inwards by the Connect'o'maat® wedge springs.

6. Switch off the excavator ignition. 7. Close the ball valve on the fork. 8. Carry out the maintenance or repair.



8.2 Daily maintenance

Carry out the following daily check and maintenance activities: 1. Take the safety precautions described in Section 8.1. 2. Check the hydraulic system for leaks and damage (Connect'o'maat® type H only).

Repair or replace as necessary. 3. Check the pin locking at the hinge position on the stick of the host machine. 4. Check the steel material of the Connect'o'maat® for cracks. If cracks are found,

stop work, contact your supplier. Weld only with the written permission of your

supplier! 5. Check if the wedge bolts are secure. If necessary tighten the bolts with the proper

torque. See paragraphs 3.4. and 3.5. CW model D: See no. 1 and 3 in figure 3.4.1. CW model H: See no. 2 in figure 3.5.1. and 3.5.2.

6. Check if the check nut see no. 1 in paragraphs 3.4. figure 3.5.2. is secure. (only

Connect’o’maat® model H). If necessary tighten the nut (A) figure 3.5.2. finger tight against the wedge. Tighten the check nut (C) against the nut and hold onto the nut (A) while tightening it.

7. Check if the locking bolt of the spindle is secure (only Connect’o’maat® model D). If

necessary secure the bolt with the proper torque. See no. 2 in figure 3.4.1. If it is damaged replace the locking bolt.

8. Check, if present, the hoisting device for damage. In case of damage, stop working

on or with the installation and contact your supplier. 9. Check that the warning sticker is readable. If not, clean or replace it.

10. Execute a uncouple- and couple cycle of the wedge, to provide a smooth operation

of the wedge (Connect'o'maat® type H only).



8.3 Maintenance every 200 hours of operation Every 200 hours of operation carry out the following maintenance: 1. Take the safety precautions described in Section 8.1. Warning: The maintenance described in the following two steps is only to be carried out with a coupled attachment. 2. Check that there is a space (A) between the wedge (B) and the frame (C) at both

ends. See Figure 8.3.1. If not, stop work, contact your supplier.

Figure 8.3.1. 3. Check whether there is any play between the forward pivot of the Connect'o'maat®

and the attachment adapter plates. See Figure 8.3.2. Stop work if any play is detected. Contact your supplier.

A B

Figure 8.3.2. A. good B. wrong



4. Uncouple the attachment and visually check that the spring pivots are straight (type

H only). If not, replace with original CATERPILLAR spring pivots. See Figure 8.3.3. Note: Tighten the bolts right up to the end of the screw thread.

Figure 8.3.3. D. Connect’o’maat® with spindle mounting 1. Spring pivot S. grease points 2. Bolts

5. In type D fully turn in the spindle and grease the spindle at both grease points until the

grease becomes visible.





8.4 Maintenance every 750 hours or quarterly

Page

8.4.1. Lifting Hook – Inspect ........................................................................................................ 46



8.4.1. Lifting Hook – Inspect

Type 1

Type 2

Type 3

Figure 8.4.1.1.



Dimensions of Lifting Hook

Part Number of Lifting Hook

173-9955 173-9956 173-9957 173-9958Part Number of

Lifting Hook 41009900

Type Hook 1 2 2 2 Type Hook 3

Working Load Limit (WLL)

4000 kg 10000 kg 14000 kg 20000 kg Working Load Limit (WLL)

2000 kg

8819 lb 22046 lb 30865 lb 44093 lb 44093 lb

A: Maximum diameter of bar

30 mm 40 mm 60 mm 60 mm A: Maximum diameter of bar

25 mm

1,2 inch 1,6 inch 2,4 inch 2,4 inch 1,0 inch

B1: Nominal width of bottom

40 mm 60 mm 60 mm 60 mm B: Nominal width of bottom

35 mm


B2: Nominal height of bottom

38 mm 67 mm 77 mm 90 mm B1: Nominal width of hook

27 mm


C1: Nominal width of front

40 mm 60 mm 60 mm 60 mm D: Actual throat clearance

25 mm


C2: Nominal height of front

36 mm 67 mm 77 mm 90 mm E: Required weldheight (a)

4 mm


E: Actual throat clearance

32 mm 42 mm 62 mm 62 mm F: Required weldheight (a1)

6 mm


F: Full throat clearance

47 mm 62 mm 100 mm 95 mm L: Total length of hook

130 mm


G: Required weldheight (a)

6 mm 8 mm 8 mm 10 mm L1: Nominal length of hook

83 mm


H: Nominal height of hook

132 mm 210 mm 260 mm 272 mm H: Nominal height of hook

93 mm


L: Nominal length of hook

120 mm 179 mm 226 mm 239 mm -

-

4,7 inch 7,0 inch 8,9 inch 9,4 inch -

Table 8.4.1.1.



Note: Designate a person in order to inspect the hook frequently. The designated person should inspect the hook prior to operation and during operation. The designated person will determine if the conditions that are found are a hazard. The designated person will determine if a more detailed inspection is required. 1. Inspect the hook for any distortion such as bends in the hook or twists in the hook. 2. Inspect the dimensions of the throat (E) and (F) of type 1 and 2, (D) of type 3. An

increase in the dimensions of the throat must not exceed 5% of the original dimensions of the throat. Refer to Figure 8.4.1.1. and Table 8.4.1.1. for the dimensions of the throat.

3. Inspect the hook for wear. An increase in the nominal dimensions (B1), (B2), (C1),

(C2), (H), and (L) of type 1 and 2, (B), (B1), (H) and (L1) of type 3 of the hook must not exceed 10% of the original nominal dimensions of the hook. Refer to Figure 8.4.1.1. and Table 8.4.1.1. for the nominal dimensions of the hook.

4. Inspect the hook for cracks, nicks, or gouges. 5. Ensure that the latch properly engages. Inspect the latch for any damage. Ensure

that the latch is not malfunctioning.

Note: Before continuing to operate the hook, the hook must be repaired or replaced if any of the above conditions exist. Refer to Special Instruction, Media Nr.: GEBI0310 “Installation or Replacement Lifting Hook/ Lifting Yoke on Certain Quick Couplers” for additional information.



8.5 Welding the Connect'o'maat® It is not permitted to carry out any welding on the Connect'o'maat® without the written permission of your supplier.

8.6 Torque settings

torque (+/- 10%) [Nm]

bolt size

boltquality 8.8

boltquality 10.9

boltquality 12.9

M10 50 70 80

M12 85 120 145

M14 135 190 230

M16 210 295 355

M20 410 580 690

M24 710 1000 -

M27 1050 1500 -

M30 1450 2000 -



H D

9. Spare parts The correct and safe operation of CATERPILLAR products is only warrantyd if the faults that arise are corrected. The repair of defective components is only permitted with the written permission of your supplier, unless the repair is described in this manual. For safety reasons, defective components should only be replaced with original spare parts. For the list of spare parts, refer to the spare parts manual for the Connect'o'maat® CW series.

9.1 Safety critical components Safety critical components have also been used in the construction of the Connect'o'maat®. Safety critical components are components that can affect the safe operation of the Connect'o'maat®. See Figure 9.1.1. When a defect is detected in a safety critical component, work with the Connect'o'maat® should be stopped. The defective component must be replaced with an original CATERPILLAR component. The component may not be repaired. For queries, contact your supplier. The lists given below consist of the Connect'o'maat® safety critical components.

Figure 9.1.1.



Note: All hexagonal bolts : use material quality 10.9 All hexagonal screws : use material quality 12.9 Bolts and screws must be tightened to the correct torque. See Section 3.4 and 3.5. Connect’o’maat® type H Pos No. Qty. Article No. Nomenclature Notes

1 1 see parts manual wedge see Figure 9.1.1. 2 2 see parts manual spring pivot “ 3 2 see parts manual spring “ 4 1 see parts manual cylinder “

Connect’o’maat® type D Pos No. Qty. Article No. Nomenclature Notes

1 1 see parts manual wedge see Figure 9.1.1. 2 2 see parts manual spindle “ 3 1 see parts manual spindle housing “ 4 1 see parts manual lock bolt “

10. Decommissioning and Disposal When the product is removed from service, local regulations for the product decommissioning will vary. Disposal of the product will vary with local regulations. Consult the nearest CATERPILLAR dealer for additional information.



Warranty conditions Unless confirmed otherwise, the guarantee conditions apply as stated in the general conditions of delivery as laid down by ORALGIME. The clauses below are extracted from the ORGALIME General Conditions, issued October 1992. The supplier shall remedy any defect resulting from faulty design, materials or

workmanship. The supplier's liability is limited to defects which appear within a period of one year

from delivery. Defective parts which have been replaced shall be made available to the supplier and shall be his.

The supplier is liable only for defects which appear under the conditions of operation

provided for in the contract and by proper use of the product. The purchaser shall without undue delay notify the supplier of any defect which

appears. If the defect is such that it may cause damage, the purchaser shall notify the supplier immediately.

The supplier's liability does not cover defects which are caused be faulty

maintenance, incorrect erection or faulty repair by the purchaser, or by alterations carried out without the supplier's consent in writing. Finally the supplier's liability does not cover normal wear and tear or deterioration.



©2012 CATERPILLAR Work Tools B.V. All Rights Reserved Printed in The Netherlands

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Operation and Maintenance Manualtranscend-cat.netexpress.net/.../operators_manuals/cwt021983.pdf · GEBJ1139-01 July 2012 Operation and Maintenance Manual Connect’o’maat® Quick