Miller GTX Series Installation Manual

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GTX

INSTALLATION

GUIDE

Date /

01.01.2023

Revision /

2nd Issue

Checked /

RP & RM

Miller Control Document

GTX Installation Guide Second Issue

Document No.

GTX-INS-EXT-FI

Table of Contents

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Questions and answers

glynn smith

May 1, 2025

We have a miller bug coupler on our 21t volvo what would be the weight please

1 comments:

Mr. Anderson

May 16, 2025

The weight of a Miller bug coupler for a 21-ton (21t) Volvo is 318 kg.

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Summary of Contents for Miller GTX Series

Page 1 INSTALLATION GUIDE Date / 01.01.2023 Revision / 2nd Issue Checked / Checked / RP & RM Miller Control Document GTX Installation Guide Second Issue Document No. GTX-INS-EXT-FI...
Page 2 If you have any challenges or queries – let us fix it by contacting our dedicated Technical Support Team on 01670 707 272. We trust that you will enjoy many trouble-free years with your Miller Coupler and hope to be of service to you again soon. IMPORTANT: This book should always be kept with the machine during and after coupler Installation.
Page 3: Table Of Contents
GTX Installation Guide CONTENTS Product Safety Hydraulic Install – Coupler to Solenoid Valve – Product Safety information 5 – Preparation & Safety Notes 26 – Product Specification Table 7 – Installation of Hydraulics 27 Hydraulic Install – Solenoid to Pressure & Tank –...
Page 5: Product Safety Information
Important: Indicates that equipment or property damage recommended by Miller is used; you must satisfy yourself that it is safe for you and for could occur if instructions are not followed. others. Please contact Miller at convenience if such a scenario occurs whereby we will be happy to assist.
Page 6 The GTX coupler hydro-pneumatic cylinder contains compressed gas and should not be disassembled or tampered with during the functional life of the quick your coupler unsafe and invalidate your warranty. Please call Miller for advice and coupler. The Miller hydraulic hydro-pneumatic cylinder (RAM) is designed to be tamper- service requirements.
Page 7: Product Specification Table
GTX Installation Guide PRODUCT SPECIFICATION TABLE GTX SERIES EXCAVATOR WEIGHT (T) COUPLER WEIGHT (KG) PIN DIAMETER (MM) PIN CENTRE (MM) PICK UP WIDTH (MM) Range 3 6 - 10T 280 - 317 290 - 320 Range 4 11 - 14T...
Page 8: In Cab Decal
To ensure the safe operation of the quick coupler you must place the coupler decal in the machine cab where it can be seen clearly. Replace unreadable or missing decals with new ones before operating the machine. ©Miller UK 2023.
Page 9: Coupler Identification
To ascertain the serial number, weight, and safe working load (SWL) of the coupler please refer to the data plate detailed below. The I.D plate can be located on the inside of the coupler frame. Series Miller UK Ltd, Bassington Lane, Cramlington, UK, NE23 8AD. Tel: +44 (0) 1670 707 272 www.millergroundbreaking.com COUPLER TYPE MASS SERIAL No.
Page 10: Pre-Install Information And Checks
DRAWING CHECKS Example shown opposite: GTX Coupler Components Drawing – please refer to the Miller GTX drawing guide for alternative drawings specific to your machine 2.2. INSTALL KIT & PARTS LIST Open the installation kit and cross check the items with the supplied picklist to familiarise yourself with the contents of this installation.
Page 11: Install Kit
Fitting requirements may vary depending on the make and model of the machine. Hydro-pneumatic cylinder Note: Spare parts and hydraulic hose kits suitable for most excavator types are available by contacting Miller or an authorised distributor. If in doubt, please ask.
Page 12: Ppe Requirements
Wear relevant personal protective equipment (PPE) such as a hard hat, safety glasses, safety shoes and oil resistant safety gloves along with a high visual jacket when operating or servicing the coupler or machine. ©Miller UK 2023.
Page 13: Preparation For Installation
3. Remove any protective covers, pipe routing and pipe clamps that may cause any interferences during phase three of the install. 4. Identify a suitable location on the machine to fit the solenoid valve. Miller Miller recommend the following checks would recommend mounting the solenoid bracket next to the main control in advance of the coupler installation.
Page 15: Preparation & Safety Notes
GTX Installation Guide PREPARATION & PARTS REQUIRED SAFETY NOTES (1) Coupler hose A (blue) Note: Please have on hand the coupler internal components (2) Coupler hose B (yellow) drawings located in the GTX drawings guide to assist with the identification of key components required for the installation of the coupler.
Page 16: Attaching Coupler Hoses
2. Once the coupler is reassembled manoeuvre the excavator stick in a horizontal position to allow for the marking out of the steel pipe position. Please use the template provided in the installation kit. ©Miller UK 2023.
Page 17: Coupler Install
GTX Installation Guide COUPLER INSTALL...
Page 18: Attaching The Coupler
1. Lower the excavator stick and align the link arm directly above the coupler – once in position manoeuvre both the dipper and link arm in line with the inside boss faces. ©Miller UK 2023.
Page 19 GTX Installation Guide ATTACHING THE COUPLER 2. Align the coupler with the end of the link arm and fit seals and shims where required. Please start with the linkage pin first which will be inserted in between the rear bosses. Whilst lowering the linkage into the rear boss, place lightly greased O-rings on either side of the link before fully aligning.
Page 21: Factory Fitted Vs Non Factory Fitted
GTX Installation Guide FACTORY FITTED Factory Fitted VS NON FACTORY FITTED Factory Fitted Machines (Coupler ready) – are machines that have had a quick coupler system installed onto the machine by the OEM. Quick coupler systems include: • Either a manifold block or steel pipes on the front of the dipper •...
Page 22: Connecting Coupler Hoses In Oem Systems
B. Once tight, start the machine and tip/crowd the coupler to ensure coupler hoses don’t foul and are not taut, contact Miller if you have any issues with this step. Once installed please turn to page 36.
Page 23: Attaching The Mounting Block
The installer will require a 6.8mm drill bit and an M8 tap. Note: Once the manifold block or clamp is fully welded make sure they will not interfere with the bucket RAM when fully extended or retracted. OPT 1 OPT 2 ©Miller UK 2023.
Page 24 GTX Installation Guide ATTACHING THE MOUNTING BLOCK 3. Clean the welds using a solvent and cloth and re-paint the affected areas with etch primer. Once the primer is dried, paint the area with the OEM machine specified paint. 4. Connect the hoses from the coupler RAM making sure both hoses are straight prior to tightening.
Page 25: Hydraulic Install - Coupler To Solenoid Valve
GTX Installation Guide HYDRAULIC INSTALL – COUPLER TO SOLENOID VALVE ©Miller UK 2023.
Page 26: Preparation & Safety Notes
GTX Installation Guide PREPARATION & PARTS REQUIRED SAFETY NOTES (1) Hydraulic hose A (blue) Note: To help with this phase of the install please refer to the solenoid drawing located in the GTX drawing pack. Important: Please refer to Appendix B for (2) Hydraulic hose A (yellow) torque specifications.
Page 27: Installation Of Hydraulics
B line are running parallel with the coupler hoses. Important: Ensure that the hydraulic pressure is set to a minimum 150 bar. Please use a pressure gauge to determine the pressure. Important: Please refer to Appendix B for torque specifications. ©Miller UK 2023.
Page 28 GTX Installation Guide INSTALLATION OF HYDRAULICS 2. Follow the natural curve of the existing excavator hydraulic hoses and steel pipes and clamp or cable tie where required up to the solenoid valve. Make sure that the hoses are not twisted. Important: The operator may need to remove top clamps already mounted on the...
Page 29: Hydraulic Install - Solenoid To Pressure & Tank
GTX Installation Guide HYDRAULIC INSTALL – SOLENOID TO PRESSURE & TANK ©Miller UK 2023.
Page 30: Preparation & Safety Notes
GTX Installation Guide PREPARATION & PARTS REQUIRED SAFETY NOTES (1) Pressure hose (red) (2) Tank hose (green) Note: Pre checks should take no longer than five minutes to complete prior to the installation of the secondary hydraulic system. Please adhere to the following preparation instructions to ensure a safe and timely installation.
Page 31: Installation Of Hydraulics
- a mounting bracket has been included in the installation kit if needed. We would advise bolting the solenoid/solenoid bracket to an existing hole inside the machine. A new hole may have to be drilled if an existing one is not available. ©Miller UK 2023.
Page 32 The location of the solenoid valve may vary from OEM. 3. Once secure, feed the hoses up to the valve ensuring there is adequate length on each hose to securely connect them to the A & B ports on the solenoid valve. ©Miller Groundbreaking 2021.
Page 33 The pressure needs to be a minimum of 150 bar. 6. Install the tank line (green) into the T port on the solenoid valve and route hose to the hydraulic tank. ©Miller UK 2023.
Page 34 GTX Installation Guide INSTALLATION OF HYDRAULICS 6. Install the tank line (green) into the machines hydraulic tank in the most suitable place. Please note: Removing fittings from the hydraulic tank can cause the tank to drain substantially. a drip tray, service bungs and oil spill mats are required in this stage.
Page 36: Installation Of The Pressure Switch System
GTX Installation Guide 1/4 Dowty washer Pressure switch INSTALLATION OF THE PRESSURE SWITCH SYSTEM 1/4 BSP female/female 90 The pressure switch kit will include: Male / male adaptor with 0.8mm internal orifice (snubber) 1 x pressure switch harness 1 x pressure switch 1 x pressure switch TEE piece or flange block 1 x Pressure switch adaptor kit Flange block...
Page 37 This is to try and prevent as much residual oil from coming back down the steel pipes on the boom. Once complete, turn to page 45. ©Miller UK 2023.
Page 39: Preparation & Safety Notes
(2) 12/24v Buzzer (3) ISO Toggle Switch Important: Ensure the battery is disconnected or isolated and machine is locked off and tagged. (4) 1 x Electric Connector Pack (5) 1 x Pack of Cable Ties ©Miller Groundbreaking 2021.
Page 40: Installation Of Electrical Harness
(This will ensure that the harness is refrained from touching any hot surfaces within the engine bay). Carefully move the wiring harness through the cab access point and into the cab. Fuel Tank Reserve ©Miller UK 2023.
Page 41 Connect the switch to the wiring harness using the shovel connection points on the back of the switch and then fix your switch into the control panel slot. 5. Secure wiring harness and all loose cables inside the cab with cable ties provided. ©Miller Groundbreaking 2021.
Page 42 USB cables. This increases the risk of damaging this socket which if it was to happen would lead to your coupler switch out of service until socket connection ISO Lockable where restored. Therefore, Miller recommend that you toggle switch locate your source point from another ignition live. Note: Ensure the switch is installed in an area where it cannot be accidentally activated.
Page 43 GTX Installation Guide INSTALLATION OF ELECTRICAL HARNESS Note: The solenoid is energised when the switch is in the release or off position. In normal working conditions, the solenoid should be electrically disconnected and the switch in attach or on position. 1.
Page 45: Commissioning
GTX Installation Guide COMMISSIONING 1. Turn on the machine ignition and activate switch, if the in-cab buzzer sounds then the coupler system is connected properly. 2. Turn on the machine and leave to idle, whilst machine is idling, check all hoses/fittings for any leaks. If leaks are present then turn off machine and rectify leak.
Page 46: Commissioning
RAM. Warning: Coupler RAM should only open if the bucket RAM is fully extended and begins to dead- end. If coupler RAM opens before this point, this could be caused by excess air in the hydraulic hoses. ©Miller UK 2023.
Page 47: Troubleshooting
GTX Installation Guide TROUBLESHOOTING...
Page 48 That no electrical wires are broken. • That the switch and/or buzzer is not broken. • That the voltage to the magnetic coil is correct (24 volts main line feed, to a 24 volt system). • Electrical wiring. ©Miller UK 2023.
Page 49 GTX Installation Guide HYDRAULIC Check for: Re-connect all hydraulic hoses to correct ports as detailed in the installation Warning: Always remove the electrical supply to the switch before commencing procedure. Ensure the pressure feed hose connects to the port marked P and work on the hydraulics (Remove machine key and disconnect battery).
Page 50: Operation
(RAM) is designed to be tamper-proof, disassembly should only be performed by Miller technical support. If you have the bucket. If the coupler does not hold firmly, this any issues, please contact Miller for support.
Page 51 GTX Installation Guide...
Page 53: Warranty Period
The warranty period is 36 months for the coupler frame and 12 months for Miller shall be liable only for repair or replacement of parts as described under ‘warranty coverage’, and Miller shall not be liable, whether under breach of warranty, negligence internals or 2,000 hours from date of delivery, whichever is the sooner.
Page 55: Torque Specifications
GTX Installation Guide TORQUE SPECIFICATIONS FITTINGS FITTINGS GTS 30lb.ft 40Nm (Fit Thread locking adhesive) A Line filter fitting ¼ BSP Non-return valve 30lb.ft 40Nm M/M Adapter 25lb.ft 34Nm B hose connection male B Line filter fitting 7/16 (Hydro-pneumatic cylinder hose) 15lb.ft 20Nm JIC x 7/16 UNF 15lb.ft 20Nm A hose connection male P Line 9/16 JIC x 9/16 UNF 26lb.ft 35Nm...
Page 56 INSTALLATION GUIDE Date / 01.01.2023 Revision / 2nd Issue Checked / Checked / RP & RM Miller Control Document GTX Installation Guide Second Issue Document No. GTX-INS-INT-v5...

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