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CONTENTS INTRODUCTION Owner Information 4 Warranty Registration 5 Safety Instructions Safety 6 Safety Decals 7 Safety Identification Labels 8 Safety Notice 10 Safety Standards 11 Risk Assessment 13 INSTALLATION Installation 15 Circuit Diagram 20 OPERATION AND ATTACHING Operation Guide 21 Connection Test 23 Checking Attachments and Buckets 24 MAINTENANCE General Maintenance 26 Weekly Checks 27 500hr Preventative Maintenance 28 Maintenance & Repair Log 33 Torque Specifications 34 Parts Drawing 35 Parts List 36 Cylinder Parts Drawing 37 Cylinder Parts List 38 Multi-Coupler Series 1C Specifications 39 3

INTRODUCTION OWNER INFORMATION Thank you for choosing to purchase your new Calibre Multi-Coupler (Multi-Coupler) from Calibre Contracting Equipment s (Calibre) range of earthmoving products. This manual contains important information about the installation, maintenance and safe operation of your Multi-Coupler. You can assist in this proactive safety approach by ensuring that all persons involved with the fitting and operation of the Multi-Coupler, read and understand these basic safety features and instructions. Calibre reserves the right of modification as a result of further technical developments with regard to the information and illustrations cited in this manual: Calibre and its suppliers have sole copyright of this manual The manual is intended solely for the use of the Multi-Coupler No part of this manual may be reprinted, translated or reproduced by any means without prior written permission from Calibre Utilisation for the purposes of competition is forbidden The Multi-Coupler is designed for safe and dependable service if installed, maintained and operated correctly We request that time be devoted to the study of installation and maintenance requirements. Users are also expected to familiarise themselves with the correct operation and use of the Multi-Coupler and its advised safety procedures. IMPORTANT NOTE To comply with Occupational Safety and Health requirements, a record must be made of all repairs, adjustments and regular maintenance events involving your Multi-Coupler. 4

INTRODUCTION WARRANTY REGISTRATION Upon purchasing your Multi-Coupler please complete and return this form immediately to your local Calibre branch. DATE OF DELIVERY: SERIAL NUMBER: I confirm that the operator(s) of the relevant excavator has read and understands the Operating Instructions and Warranty Terms, which relate to the Multi-Coupler. The Operator accepts that he/ she is responsible for understanding safety and operation features of the Multi-Coupler. NAME: POSITlON: COMPANY: SIGNATURE: THE PURCHASER SHALL: Follow the recommended installation, testing and maintenance and operating procedures Comply with safety and training guidelines for use of equipment (not totally exclusive) Keep an accurate maintenance, operation, malfunction and repair log of equipment Ensure that the equipment is used for the purpose it was intended for 5

SAFETY INSTRUCTIONS SAFETY Incorrect It is your responsibility to observe pertinent laws and regulations and follow Calibre instructions for operation and maintenance. Calibre supplies a standard Multi-Coupler to fit Calibre approved attachments. However when tilting a non standard attachment check the operation fitting guide for the attachment s pin range and width to suit the Multi-Coupler model. NOTE: The Multi-Coupler has a maximum and minimum pin centre travel range. Please refer to the attached badge on the Multi-Coupler for this information. 6

SAFETY DECALS SAFETY INSTRUCTIONS 7

SAFETY INSTRUCTIONS SAFETY IDENTIFICATION LABELS The pin centre range displays the minimum and maximum travel distance for each slide hook on the Multi-Coupler. All attachments must be within the parameters of these measurements identifed on the label. The label also identifes the slide hook type. CALIBRE PART NO. All Calibre Multi-Couplers have an identifcation label with the machine model recorded. 8

SAFETY INSTRUCTIONS Only lift from Lifting Eye situated on the rear of the Muti-Coupler 1. Ensure that the load to be lifted does not exceed the safe working load of the Lifting Eye or the machine to which it is fitted. 2. The Lifting Eye is to be used with a certi ed lifting shackle with the same or greater safe working load. 3. S.W.L - Safe Working Load is stamped on the Lifting Eye and the Multi-Coupler is fitted with a label on the side that specifies maximum working load. 4. Lifting Eye has to be visually inspected daily. 9

SAFETY NOTICE SAFETY INSTRUCTIONS The Certified Lifting Eye must be used accordingly to the following guidelines: Only use the Lifting Eye at the rear of the coupler for lifting Do not lift with bucket or any other attachment fitted to the Multi-Coupler Ensure that the load to be lifted does not exceed the rated W.L.L of the Multi-Coupler and Lifting Eye The Lifting Eye is to be used with a certified Lifting Eye with the same or greater safe working load Lifting must be carried out with the coupler in a vertical plane so that the load can hang free without interfering with the coupler body Lifting Eye must be visually inspected daily for defects and wear The below sticker MUST be permanently fixed to the operator s cab in a clearly visible location SAFETY NOTICE Display in the cab visible to the Operator at all times CORRECT OPERATION OF LIFTING EYE Lifting Eye must be in a VERTICAL PLANE with the shackle hanging free of all obstruction DO NOT lift if the chain & shackle interfere with the Coupler Lift in a vertical plane ONLY Shackle MUST hang freely DO: + Must comply with Approved Code of Practice for Cranes & all other regulations relating to the use of Cranes + Only use Lifting Eye on Coupler + Only uses associated with primary function of Excavator + Only use in accordance with Calibre Operating Manual (To be stored in cab at all times) DO NOT: + Exceed lifting capacity (specified in certificate & hard stamped on the Lifting Eye) + Use with any other Attachment on Excavator Note: Check Lifting Eye & Coupler structure for wear, cracks & damage daily in accordance with Calibre Operation Manual.. Calibre Operation Manual must be safely stored in cab at all times. 10

STANDARDS SAFETY STANDARDS Only the following competent persons may work independently with any of type of Calibre earthmoving attachments. Operators must possess the following: Over 18 years of age Highly competent Are physically and intellectually able Have been instructed in the general regulations concerning operational safety and particularly accident prevention Have been instructed in assembly, operation and maintenance of earthmoving machinery and using the Multi-Coupler system. They must understand these operating instructions and have proven to the contractor that they are capable of operating such machinery Ensure that only authorised personnel work with the Multi-Coupler Only give instructions to competent and skilled personnel NOTE: For Calibre products supplied to or manufactured in countries other than New Zealand and Australia, the rules for prevention of accidents and safety regulations for the respective country must be strictly adhered to. 11

STANDARDS STANDARDS AND OCCUPATIONAL SAFETY AND HEALTH GUIDELINES The standards and Occupational Safety and Health Guidelines for the Calibre Multi-Coupler are as follows: AS4772-2008 Standards Australia. Australian standard for - Earthmoving Machinery - Multi-Couplers (couplers) for excavators and backhoe loaders - AS4772-2008 section C12.1.4 AS 1418 5 1995 Cranes (Including hoists and winches) Part 5: Mobile vehicle loading cranes. European Standard EN474-5; Section 4.1.9.1/2 and 3. Electrical Interlocking for Safety in Industrial Processes. Standard Operating Guidelines for Plant and Machinery. We request that time be devoted to the study of installation and maintenance requirements. Users are also expected to familiarise themselves with the correct operation and use of the Multi-Coupler, and its advised safety procedures. ASSOCIATED STANDARDS AS 2954 Earthmoving Equipment - Rated Loads and Volumetric ratings AS 2954 Earthmoving Equipment - Tests and Measurements AS 2954 Earthmoving Equipment - Instrumentation and Control AS 2954 Earthmoving Equipment - Operation and Maintenance AS 2954 Earthmoving Equipment - Safety Excavator and attachments must be suitable or converted for mounting the Calibre Multi-Coupler (in agreement with Calibre). The crowd and breakout forces speci ed by the excavator manufacturer must not be exceeded. The Calibre Multi-Coupler must not be used for impact work (only with attachments specified for this). Load hook rating must never be exceeded. Adherence to the specifications in this manual is part of the intended use. All Calibre Multi-Coupler models have specific safety features, see those that relate to your purchase. 12

RISK ASSESSMENT Location: Date: Ref no: Hazards Identified: Work equipment Lifting devices Ergonomics Entanglement Crushing Access / exit Slip, trip and fall Plant movement Warning devices on equipment Noise Vibration Fumes Environmental People Affected YES NO N/A Involved in activity Close to activity Everyone on site Members of the public Expected Precautions YES NO N/A Has the operator been adequately trained on the use of the Multi-Coupler in general? Is the operator competent in using the specific attachment on the machine? Is there a system for checking that the attachment pins are in place on the Multi-Coupler prior to work starting everytime a different attachment is fitted? Is the operator aware that they must not operate the machine unless they are satisfied that Multi-Coupler is secured in place? Does the view of the operator from inside the cab allow them to visually see that the Multi-Coupler is secured in place? Does the Multi-Coupler have the approved labels stating and referring to attachment specifications? Is there a risk assessment for the Multi-Coupler detachment? Is there a checklist of daily and weekly inspections? Is there cab instructions for the Multi-Coupler? Personal Protective Equipment (PPE) Hard Hat High Visibility Vest Safety Boots Gloves Ear Protection Safety Glasses Other Management Assessed by: Name: Date: Reported to: Name: Date 13

RISK ASSESSMENT Operator s Name: Calibre Serial No.: Calibre Contracting Equipment Model: Date: In Cab Multi-Coupler Operating Controls (Alarm, warning light, switch) Operating Instructions (labels) Operating & Maintenance Manual M O N T U E W E D T H U F R I S A T S U N Hydraulic System Wear or damage to hoses or fittings Security of hoses Hydraulic oil leaks Coupler Wear and damage to bucket / attachment pins and retainers Security of mounting pins, locking bolts and nuts Is the attachment safe to use? YES or NO Lubrication Greasing in accordance with Calibre instructions Operator Signature Manager Signature 14

INSTALLATION Calibre_Auto-c-cyl-015 Calibre_Auto-c-cyl-016 Calibre_Auto-c-cyl-022-15

INSTALLATION Align Calibre Multi-Coupler to the dipper arm and fit o-ring seals and shims where required Install original equipment manufacturer s harden fix spacing pins to attach Calibre Multi-Coupler to dipper arm on excavator. Fit locking bolts and nuts to secure pins. 16

INSTALLATION - - Coupler or Tilt Bucket Tilt Multi- 17

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INSTALLATION - 19

CIRCUIT DIAGRAM INSTALLATION Please ensure that during installation of a Calibre Multi-Coupler the pressure in the hydraulic circuit is checked and set at: 20

OPERATION AND ATTACHING OPERATION GUIDE 21

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OPERATION AND ATTACHING OPERATION GUIDE 23

OPERATION AND ATTACHING WARNING: Check pin centres of Calibre Multi-Coupler for all customer s attachments centre pin-centre - B) Check the width of each attachment. Where there is an excessive gap - (exceeding 10mm), spacers can be fitted to better suit the Multi-Coupler to the attachment. Spacers can be fitted to either the base of the Multi-Coupler or between the inner side of the ears and the bosses of attachment. It is especially advisable to fit spacers in the case of heavier applications, particularly on machines that are 10 ton and above. 24

OPERATION AND ATTACHING Ensure the correct attachments and buckets are used with Calibre Multi-Coupler in accordance with the specifications on the Calibre Multi-Coupler / Power-Tilt Serial Tag. Measure the diameter of the pin on attachment (image 1.0) This should be the same as stated on the Calibre Serial Tag Use a ruler to check pin centres of all attachments being used (image 2.0) This should be in the range specified on Calibre Serial Tag If Pin Diameter or Pin Centres do not match with the Calibre Serial Tag, safe operation could be seriously impaired. You need to stop using the attachment until changes are made to match attachment to Calibre Multi-Coupler. If you require assistance to resolve this issue, please call Calibre. 25

MAINTENANCE GENERAL MAINTENANCE WARNING - Maintenance Work Maintenance work must be completed by competent personnel or assistance requested from Calibre DANGER - Hydraulic Fluid Never use hands to search for hydraulic fluid leaks, use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and can penetrate the skin and cause serious injury. If affected, see a doctor straight away. WARNING - Multi-Coupler Condition A defective Multi Coupler could injure you or others. Do not operate a Multi-Coupler that is defective. WARNING - Hose Arrangement Ensure that the hoses are not too loose and do not come into contact with the spring mechanisms as this will prevent the safe operation of the blocking bar. Maintenance and Service To ensure that your Multi-Coupler works safely and to maximum eficiency it is imperative that it is properly maintained in accordance with the following service guidelines. Replacement Parts We recommend that you fit genuine replacement parts. You will need to quote the Multi-Coupler serial number stamped on the Multi-Coupler data plate when ordering replacement parts. DAILY CHECKS 1) Complete Multi-Coupler Pre-Start Check sheet on Page 3.3 of this Operation Manual. 2) Grease Multi-Coupler regularly (minimum of once per week). It is important that all parts are greased. 3) Check Lifting Eye for damage. If in doubt do not use. 26

MAINTENANCE WEEKLY CHECKS It is recommended that the following procedures are carried out at least once per week. 1. Carry out all daily, checks (refer to Page 3.3 13 for guide). 2. Lubrication points - Ensure that all grease points are greased regularly (at least once a week minimum). If damaged, replace and grease. It is important to follow the lubrication instructions in sequence, so none of the grease nipples are overlooked. i. Release the bucket/attachment (refer to the operation instructions-section). ii. Retract the Multi-Coupler cylinder. Switch off the engine. iii. Apply grease, via grease nipple (refer to image 1.1 and 1.2). iv. Apply grease via nipple to the hook (refer to image 1.1). v. Start the engine. Extend the bucket cylinder in order to position the Multi-Coupler so that the cylinder grease nipples are accessible. Switch off the engine. It is essential that this log is filled in at the time of carrying out maintenance or repair on the Multi- Coupler. In the unfortunate event of an accident, this log may be vital evidence as to compliance with Occupational Safety and Health requirements. Work carried out on this Calibre Multi-Coupler must only be by an authorised and competent person. 27

MAINTENANCE - - - Should you find any cracks anywhere on the Multi-Coupler body, contact your local Calibre branch or authorised Service Centre immediately. 28

MAINTENANCE - Should you find any cracks anywhere on the Multi-Coupler body, contact your local Calibre branch or authorised Service Centre immediately. 29

MAINTENANCE - - - - If the Multi-Coupler frame becomes worn or damaged in this area on the side frame (image 2), contact your local Calibre branch or authorised Service Centre immediately. 30

MAINTENANCE Manual Inspection of Calibre Multi-Coupler Safety-Latch is to be carried out to ensure safety-latch movement is within acceptable safety tolerances as specified below. This is in addition to daily visual check of safety-latch and usual wear-andtear assessments. Connect Calibre Multi-Coupler to attachment with slide fully retracted to lock safety-latch. If the Maximum Opening Distance is greater than the Maximum Allowable Opening value for that Calibre Multi-Coupler model, safe operation of the Calibre Multi-Coupler could be seriously impaired. Please contact Calibre Service department for advice. 31

MAINTENANCE - C02 C03 C04 C06 C08 C14 C20 C35 Should you find any cracks anywhere on the Lifting Eye, contact your local Calibre branch or authorised Service Centre immediately. 32

MAINTENANCE MAINTENANCE & REPAIR LOG DATE FAULT REPAIR BY WHOM 33

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MAINTENANCE 35

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MAINTENANCE NOTE: Cylinder design is different for each model 37

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MAINTENANCE 39

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CALIBRE Contracting Equipment Australia 59 Magnesium Drive, Crestmead, Australia 4132 +61 7 3803 9400 CALIBRE Contracting Equipment New Zealand 49 McLaughlins Road, Wiri, Auckland 2104 +64 9 278 4863 41