Most coupler-related injuries are the result of an operator not properly securing the safety pin on semi-automatic or manual models. Numerous injuries, some resulting in fatalities, have occurred as a result of poor coupler connections and dropped buckets. According to a study conducted by the U.S. Occupational Health and Safety Administration (OSHA), there were 15 injury-related accidents between 1998 and 2005 in the U.S. involving the unanticipated release of excavator buckets from quick couplers on hydraulic excavators. Eight of those accidents resulted in fatalities.

Failure to properly engage and lock the coupler is likely the cause of accidents in most cases. According to OSHA, unintended Air Quick Coupler releases tend to happen because users may not be aware of changeout hazards, they fail to properly insert locking pins or they have insufficient training on installation and testing procedures. To decrease the likelihood of accidents, manufacturers developed solutions via hydraulic couplers to ensure proper engagement and minimize the possibility of injuries from operator error.

While a hydraulic coupler doesn’t eliminate all risk of dropped attachments, there are features that make them a safer option than mechanical couplers for preventing work site injuries.

To ensure operators engage the locking pin correctly, some systems feature red and green LED lights as well as a warning buzzer that let the user know whether or not the pairing was successful. This heightens operator awareness, helping them manage the system and prevent dangerous situations.

Since most serious accidents occur within the first five seconds of latching the attachment, some manufacturers have added features that make it virtually impossible for operators to unintentionally drop attachments.

One of these features is a wedge-locking principal that combats improperly locked pins. This requires the coupler to connect to the attachment in two separate places. This constantly applied working pressure continuously readjusts the wedge, keeping both pins firmly against the quick hitch and the attachment securely in place.

Advanced designs also offer a safety knuckle that securely latches instantly and automatically onto the first of two pins. This prevents the attachment from dropping, even if the operator forgets to complete the process. The safety knuckle works independently from the wedge that secures the second pin, preventing the release of the first pin even if the hydraulic system fails. Operators change attachments by first releasing the wedge, then placing the attachment in a secure position on the ground before releasing the safety knuckle.

For added safety, operators can look for a time-out feature offered by some manufacturers that automatically re-engages the safety knuckle. If the operator doesn’t fully detach the safety knuckle within the time-out window, the knuckle re-engages itself. This timing feature, which is customizable but usually occurs after 5 to 12 seconds, helps to prevent dangerous situations. Without this feature, there’s increased risk of the operator forgetting the attachment is unlocked and dropping it, either after lifting it off the ground or after unlocking it in the air.

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