WEDGELOCK I-LOCK COUPLER User manual

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*(Refers to Installation Manual page reference)
1 Remove Bucket if attached to the excavator dipper arm.
2 Install Quick Coupler using the carrier machine’s original dipper and linkage pins (8, 9, 10)*.
3 Once mounted, rotate coupler through its full range of movement and check clearances around
coupler and dipper arm (10)*.
4 Begin routing hoses from coupler to the dipper manifold on the dipper arm to determine hose
routing and dipper manifold positioning (11, 13)*.
5 Position dipper arm hoses, install hose clamps and connect hoses to dipper manifold as labelled
(11, 13)*.
6 Position boom hoses, install hose clamps and join unions. Ensure all moving joints are fitted with
abrasive sleeve supplied (14)*.
7 After hose routing is completed, it will be easy to determine the best/final mounting location for
the coupler control valve (12, 15)*.
8 Route hoses from valve ports to labelled hoses on boom and join with unions (15)*.
9 Locate and connect pressure line from test port on pump to “P” port on valve (15)*.
10
Locate and connect hose form tank to return line to “T” port on valve (15)*.
11
Locate mounting position for I-LOCK control switch in cab (16)*.
12
Route electrical harness from DIN connectors on valve to switch harness and attach positive and
negative leads (16)*.
13
Test coupler to ensure all functions are working properly. (Please refer to Operators Manual)*.

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PAGE
FRONT COVER / REFERENCE CARD 1
CONTENTS 3
INTRODUCTION 4
CONTACTS 5
SECTION 1: INSTALLATION GUIDE LINES
1.0 CHECK LIST 6
SECTION 2: PRECAUTIONS
2.0 SAFETY PRECAUTIONS 7
2.1 WELDING PRECAUTIONS 7
SECTION 3: COUPLER INSTALLATION
3.0 SAFETY DURING COUPLER INSTALLATION 8
3.1 COUPLER ORIENTATION 8
3.2 REMOVING THE EXISTING BUCKET 9
3.3 FITTING THE COUPLER (LINK PIN) 9
3.4 FITTING THE COUPLER (DIPPER PIN) 10
SECTION 4: HYDRAULIC KIT INSTALLATION
4.0 JUNCTION MANIFOLD POSITION 11
4.1 FITTING THE JUNCTION MANIFOLD BLOCK 11
4.2 THE I-LOCK CONTROL VALVE 12
4.3 INSTALLING THE CONTROL VALVE 12
4.4 HOSE ROUTING 13
4.5 HOSE ROUTING – DIPPER ARM 13
4.6 HOSE ROUTING – BOOM 14
4.7 HOSE ROUTING – BOOM TO VALVE 15
4.8 HOSE ROUTING VALVE TO PUMP / TANK 15
SECTION 5: ELECTRICAL INSTALLATION
5.0 ELECTRICAL INSTALLATION 16
SECTION 6: SCHEMATICS
6.0 HYDRAULIC SCHEMATIC 17
6.1 ELECTRICAL SCHEMATIC 17
SECTION 7: FINISH & TEST
7.0 FINISH & TEST 18
SECTION 8: TORQUE CHARTS
8.0 TORQUE CHART – METRIC BOLTS 19
8.1 TORQUE CHART – JIC CONNECTORS 19
SECTION 9: INSTALL KITS
9.0 HOSE KIT, I-LOCK 130 20
9.1 HOSE KIT, I-LOCK 170, 210, 270 21
9.2 HOSE KIT, I-LOCK 320 22
9.3 HOSE KIT, I-LOCK 450 23
9.4 HOSE KIT, I-LOCK 750 24
9.5 HOSE KIT, I-LOCK 1000 25
SECTION 10: WARRANTY
10.0 WARRANTY 26
SECTION 11: WARRANTY REGISTRATION
11.0 WARRANTY REGISTRATION FORM 28
CONTENTS

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INTRODUCTION
OUR FOCUS IS….
THE OPERATOR, because operators and their co-workers deserve safer work sites.
OUR PURPOSE....
Transforming the world’s excavators into highly productive, safe and user-friendly tool carriers.
OUR VALUES….
PIONEERING, we are continually pushing in new directions. We are building a reputation as the
industry innovators through constantly looking for ways to make excavator operators’ lives better.
And we look to new opportunities in new markets, reaching customers that others don’t.
COMMITTED - we are committed to our customers, our people, our community and New Zealand.
We are committed to the cause of simple, user-centric design and we are committed to safety,
without compromise.
COLLABORATIVE - we maximize the value we add to our customers’ business by working in
active, collaborative partnerships.
We are onside: we take time to listen, we encourage honest dialogue, we look for opportunities on
their behalf, we think proactively as well as responsively.
COURAGEOUS - we are bold and intrepid in our quest for earth-moving innovation. We do not turn
back at the first hurdle. We are determined (the earth wasn’t moved in a day!) Our attitude is robust
and our product testing rigorous. We honor the Kiwi pioneering spirit and are proud to uphold it.
FAMILY - we believe people need to be treated as they are family. We look to build long-term
relationships both internally and externally through an honest, down-to-earth approach. We believe
business success is crucial – but not at the expense of people.
OUR MISSION….
CREATING HUMAN ATTACHMENTS
A business that builds stronger, more enduring human relationships
A business that creates uniquely user-centric products
The Wedgelock Quick Coupler was originally developed by Graham Calvert at Waikanae Engineering, NZ
in 1987. The company and its reputation have since grown into a global leader in the design, manufacture
and distribution of excavator attachments
Over the years Wedgelock has developed a complete range of excavator attachments to cater for
machines from 1 tonne to 100 tonne. Spearheading the range is the I-Lock™ Coupler.
Changes in law and safety standards have piloted the design and development of the I-Lock™ Coupler, a
world first in coupler safety. The I-Lock™ Coupler incorporates all the original features of a standard
Wedgelock Hydraulic Coupler but with the added I-Lock™ Safety System.
INTRODUCTION

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Please take the time to read and understand the information presented to you in this operation manual to ensure
you get the full benefit and life expected of your I-Mcoupler.
WEDGELOCK EQUIPMENT LTD
NEW ZEALAND
Toll-free: 0800 424 482
Telephone: [phone]
Fax: [phone]
[email protected]
WEDGELOCK EQUIPMENT INC
USA
Toll-free: 888 418 3311
Telephone: [phone]
Fax: [phone]
[email protected]
WEDGELOCK
UNITED KINGDOM
C/- Harford Attachments Ltd
Telephone: [phone]
Fax: [phone]
[email protected].uk
WEDGELOCK
AUSTRALIA
C/- Equipment Component Holdings Pty Ltd
Telephone: [phone]
Fax: [phone]
[email protected]u
REST OF WORLD
WEDGELOCK EQUIPMENT LTD
NEW ZEALAND
Toll-free: 0800 424 482
Telephone: [phone]
Fax: [phone]
[email protected]
CONTACTS

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Please read this Installation Manual thoroughly before you commence installation of
the I-Lock Coupler. Deviating from these instructions may result in increased install
time and / or damage to the hydraulic kit, carrier machine or attachment.
1.0 CHECK LIST
Before you start check the following
•Check the contents of the installation kit against the Bill of Materials. Ensure that the kit supplied is
the correct one for the carrier machine that the coupler is to be installed.
•Check that the carrier machine is positioned on level ground.
•Check that you have absorbent materials available to soak up any fluid spills. Dispose of any used
materials in a safe and environment friendly manner.
•Power off the carrier machine. If the machine has been working ensure that it has cooled down
adequately prior to commencing any part of the installation procedure.
•Before carrying out any welding on the carrier machine disconnect the battery. Refer to the carrier
machine operator / maintenance manual.
•Ensure that the pressure in the hydraulic system is relieved before opening any hydraulic lines.
SECTION 1:
INSTALLATION GUIDELINES

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Please ensure you follow the stated precautions below whilst carrying out the coupler and hydraulic kit
installation procedure.
2.0 SAFETY PRECAUTIONS
•Always use PPE (Personal Protective Equipment) when servicing, operating or maintaining plant,
machinery and its components.
•Refer to the carrier machine “Service Manual” for correct procedures when carrying out work on the
machine. The machine service manual takes precedence over any discrepancies between that and
this installation manual.
•Allow for hydraulic oil to cool adequately before opening or accessing any hydraulic lines. Hydraulic
lines, fittings and components can be hot which can be harmful causing severe burns.
•Relieve the hydraulic tank pressure before accessing hydraulic lines. Refer to the carrier machine
service manual for proper procedures.
•Ensure that the stick of the carrier machine is resting on the ground at all times – do not leave
attachments suspended in the air during service / installation.
•Check and tighten all fittings, hose connections and joints within the hydraulic quick coupler circuit
prior to activating the machine.
•Visually inspect for oil leaks tighten and adjust accordingly. Avoid contact with hydraulic fluids
and high pressure oils – use cardboard or similar as a backing when checking for leaks.
•Oil spills are sometimes unavoidable. Contain all fluid spills with appropriate absorbent materials and
dispose accordingly. Immediately clean affected areas to minimize safety risks.
•When operating plant and machinery keep people and property well out of harms way. Evaluate the
working environment and identify hazards. Ensure that all people involved in the installation
understand the hazards associated with this procedure.
2.1 WELDING PRECAUTIONS
•Before commencing any welding procedures on the carrier machine ensure that the engine is turned
off and the battery supply is disconnected (refer to the carrier machine service manual)
•Ensure all surrounding areas are protected with a flame resistant covering. Clear surrounding areas
of combustible materials. Ensure you have a fire extinguisher at hand.
•Cover highly susceptible surfaces like cylinder rods, glass windows, electrical components and
plastics to prevent spatter or heat damage.
•Connect the ground cable (earth lead) from the welder to the component to be welded to the carrier
machine.
•Ensure parts and surfaces to be welded are clean and prepared properly for welding.
•Use appropriate PPE (Personal Protective Equipment) when carrying out any welding procedures.
SECTION
2
:
PRECAUTIONS

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3.0 SAFETY DURING COUPLER INSTALLATION
•Always use the correct PPE when removing attachments from carrier machines.
•Stand well clear of machinery that is in motion at all times.
•NEVER place hands or fingers near pin holes or recesses.
•Always use correct tools when carrying out removal and installation of attachments on the carrier
machine.
•Use correct lifting techniques and lifting equipment when maneuvering heavy objects
•Attachments may roll or tip during removal when placed on the ground – place with extreme caution
•Always use assistance when installing and removing attachments pinned to the carrier machine
3.1 COUPLER ORIENTATION
The I-Lock Coupler has been designed and manufactured to fit the dipper arm and
linkage assembly of the carrier machine. The I-Lock Coupler fits the carrier machine in
one orientation only with the C-Section facing the operators view (see fig 3.0.1)
•Always use the original bucket pins to fit the coupler the machine. These pins are designed for
the dipper arm and linkage assemblies.
•Always replace o’rings to original positions and utilize pin retention systems where applicable.
•DO NOT use standard attachment pins to connect the coupler to the machine. If unsure consult
your Wedgelock Dealer immediately.
•If a THUMB is / will be fitted to the carrier machine utilizing the main dipper pin position refer to
the THUMB Installation Guide for reference.
Correct Incorrect
FIG 3.1.1 Coupler Orientation
SECTION
3
:
COUPLER INSTALLATION
Dipper Arm
(Operator View)
Coupler C-Section
Coupler C
-
Section


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3.2 REMOVING THE EXISTING BUCKET
Before you fit the coupler to the carrier machine you have to firstly
remove any existing attachment from the dipper arm. (Fig 3.2.1)
•Place the bucket or attachment in a safe position on the ground.
•Undo the pin retention systems holding the dipper pin and link
pin in their position.
•Gently raise the bucket off the ground and crowd the cylinder
until the weight is off the dipper pin.
•Remove the dipper pin and place in a clean area.
•Lower the bucket to the ground with the crowd cylinder until
there is no longer weight on the link pin.
•Remove the link pin and place in a clean area.
3.3 FITTING THE COUPLER (Link Pin)
•Ensure the coupler is sitting on a flat surface in the correct
orientation.
•Align the dipper arm of the carrier machine with the coupler.
•Position the o’rings for the linkage boss assembly on the linkage
boss (if fitted).
•Using the crowd cylinder lower the linkage into position on the
rear boss of the coupler (Fig 3.3.1)
•Align the coupler if necessary using a bar or lever.
•Insert the linkage pin through the coupler boss and linkage boss.
•Align pin retention system and fix linkage pin into place.
•Locate the o’rings into the correct position (if fitted).
•NOTE – ORIGINAL OEM LINKAGE PIN MUST BE USED.
SECTION
3
:
COUPLER INSTALLATION
Fig 3.2.1 Remove Bucket
Fig 3.3.1 Lower linkage into coupler

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3.4 FITTING THE COUPLER (Dipper Pin)
•Place o’rings over ear plates of coupler to hold in position until ready for final placement.
•Carefully raise the dipper arm of the carrier machine so that the weight of the coupler is off the
ground. Ensure that the dipper arm is in a vertical position. (Fig 3.4.1).
•Retract the crowd cylinder until the coupler front boss aligns with the dipper pin hole. The coupler will
balance allowing an easy insertion of the main dipper pin (Fig 3.4.2).
•Align pin retention system and fix dipper pin into place.
•Grease both the dipper pin and the linkage pin.
•Crowd coupler through full rotation to check clearances.
•NOTE – ORIGINAL OEM DIPPER PIN MUST BE USED.
CAREFULLY CROWD THE COUPLER THROUGH FULL ROTATION TO CHECK
CLEARANCES
IF THERE ARE ANY SIGNS OF INTERFERENCE STOP IMMEDIATELY AND
CONTACT YOUR WEDGELOCK DEALER
Fig 3.4.1 Raise dipper arm to
take weight off coupler
Fig 3.4.2 Retract crowd cylinder
to align dipper pin
SECTION
3
:
COUPLER INSTALLATION