WEDGELOCK TenX Coupler User manual

OWNER’S MANUAL
Installation and Operation instructions
for both Standard and Tilt TenX Couplers

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CONTENTS
CONTENTS
CONTENTS...................................................................................................................................................................3
SECTION 1: INFORMATION........................................................................................................................................4
1.0 TENX SAFETY SYSTEM......................................................................................................................4
1.1 COMPLIANCE............................................................................................................................................4
1.2 COUPLER IDENTIFICATION...........................................................................................................4
1.3 SERIAL NUMBER  DATA LOCATIONS ...................................................................................5
1.4 CERTIFICATION .......................................................................................................................................5
INSTALLATION..........................................................................................................................................................6
2.0 INSTALLATION CHECK LIST.......................................................................................................... 6
2.1 SAFETY PRECAUTIONS.....................................................................................................................7
2.1 WELDING PRECAUTIONS................................................................................................................7
SECTION 2: SAFETY PRECAUTIONS...................................................................................................................7
SECTION 3: COUPLER INSTALLATION............................................................................................................. 8
3.0 STANDARD AND TILT COUPLERS........................................................................................... 8
3.1 COUPLER ORIENTATION................................................................................................................. 8
3.2 REMOVE THE EXISTING BUCKET............................................................................................. 9
3.3 FITTING THE COUPLER LINK PIN....................................................................................... 9
3.4 FITTING THE COUPLER DIPPER PIN.............................................................................10
SECTION 4: HYDRAULIC INSTALLATION .................................................................................................... 11
4.0 HYDRAULIC SUPPLY LINES....................................................................................................... 11
4.1 HYDRAULIC CIRCUITS................................................................................................................... 12
4.2 CONTROL SYSTEM............................................................................................................................ 13
SECTION 5: FINISH AND TEST.............................................................................................................................14
SECTION 6: DECALS..................................................................................................................................................... 15
OPERATION .............................................................................................................................................................16
SECTION 7: SAFE COUPLER USE........................................................................................................................17
SECTION 8: TERMINOLOGY...................................................................................................................................18
SECTION 8: TERMINOLOGY...................................................................................................................................19
SECTION 9: CHANGEOVER OPERATION.....................................................................................................20
SECTION 10: SAFE LIFTING PROCEDURE.................................................................................................22
MAINTENANCE.....................................................................................................................................................24
11.0 SERVICING SCHEDULE ................................................................................................................................24
WARRANTY .............................................................................................................................................................25
SECTION 13: WARRANTY .......................................................................................................................................26
SECTION 14: SERVICE RECORD.........................................................................................................................30
SECTION 15: MACHINE INFORMATION....................................................................................................... 32

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Congratulations on your purchase of the TenX Coupler.
You have just bought the SAFEST coupler in the world.
Wedgelock Equipment Limited
Established in New Zealand in 1994, Wedgelock are leaders in the design
and manufacture of world-class excavator attachments. With patented,
innovative safety features, Wedgelock couplers have enjoyed the enviable
reputation as being among the safest in the world.
1.0 TenX SAFETY SYSTEM
The TenX Coupler by Wedgelock must be installed correctly utilizing the
two hose circuit of the carrier machine. Correct installation ensures that the
TenX Coupler’s built in safety features operate in accordance with the way in
which the coupler has been designed.
1.1 COMPLIANCE
The TenX Coupler and TenX Tilt Coupler range complies with the following
standards/position papers: ISO 13031, AS4772-2008, EN474, NSW Quick
Coupler position paper, NZ WorkSafe Best Practices.
1.2 COUPLER IDENTIFICATION
All Wedgelock Couplers are fitted with an Aluminium Data Plate (Fig. 1.2.1).
Information pertains to the product code, the carrier machine the coupler
was designed to fit, product serial number, working load limit (for lifting
purposes) and the maximum operating pressure. If any of the cells are left
blank it means that the information is non applicable to this attachment.
1. INFORMATION
Fig. 1.2.1 Aluminium Data Plate

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1.3 SERIAL NUMBER / DATA LOCATIONS
If ordering parts, extras or accessories for your Wedgelock product, or making
a warranty claim, the most important piece of information you can have is
the SERIAL NUMBER.
Without a serial number, for warranty claims, we will need to know your
product type, model number, date of purchase and/or invoice number.
For the purchase of many parts this information is also a requirement –
unless you can supply your serial number.
You will find your serial number on the aluminium data plate fixed to the pin
retention side of the ear plate. Or if this is inaccessible or unreadable, there is
a serial number stamped on the top of the ear plate. See Fig. 1.3.1.
1.4 CERTIFICATION
Lifting Eye Certification and all relevant supporting documentation is
available for viewing on our website;
www.wedgelock.com/documentation
1. INFORMATION
Fig. 1.3.1 Serial Number Locations
SERIAL NUMBER
STAMPED ON TOP
OF EAR PLATE
ALUMINIUM
DATA PLATE
WLL WEIGHT
LIMIT (KGS)

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Please read this section of the MANUAL thoroughly before you
commence installation. Deviating from these instructions may
result in increased install time and/or damage to the hydraulic
components, carrier machine or attachment.
WARNING! Improper installation of this attachment
may void the manufacturer’s warranty
2.0 INSTALLATION CHECK LIST
Before you start, check the following;
• Check the contents of the installation components
supplied.
• Ensure that the components are correct for the
carrier machine to which the coupler is to be
installed. (NOTE: the carrier machine model will be
displayed on the aluminium data plate.)
• If the carrier machine does not allow for direct
two-line OEM fitment, ensure that you have the
additional components necessary for installation.
• 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.
INSTALLATION

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SECTION 2: SAFETY PRECAUTIONS
2.1 SAFETY PRECAUTIONS
• Please ensure that throughout the installation process you adhere to all
site, health and safety regulations applicable to your location.
• 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 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.
• 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
NOTE: It is possible to install the TenX Coupler without welding. But should
welding be necessary, please follow these 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.
Ensure parts and surfaces to be welded are clean and prepared properly for
welding.

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3.0 STANDARD AND TILT COUPLERS
These instructions pertain
to both STANDARD and
TILT couplers. Any specific
variations will be noted.
3.1 COUPLER ORIENTATION
The TenX Coupler has been designed and manufactured to fit
the dipper arm and linkage assembly of the carrier machine.
The TenX Coupler fits the carrier machine in one orientation only
with the C-Section facing the operator’s view (Fig 3.1.1)
Always use the original bucket pins to fit the coupler to
the machine. These pins are designed for the dipper arm
and linkage assemblies. DO NOT use non-hardened (soft)
attachment pins. If unsure consult your Wedgelock Dealer
immediately.
Always replace O-Rings to original positions and utilize pin
retention systems where applicable.
SECTION 3: COUPLER INSTALLATION
Operator View
Fig. 3.1.1 Coupler Orientation

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SECTION 3: COUPLER INSTALLATION
3.2 REMOVE THE EXISTING BUCKET
• Before you fit the coupler to the carrier machine you will have to remove
the bucket or existing attachment from the dipper arm. .
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.
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).
• Insert the main dipper pin through the coupler bosses & fit shims between
the dipper arm boss and the inside face of the coupler if required.
• Locate the O-Rings into the correct position (if fitted).
• 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.
IF THERE ARE ANY SIGNS OF INTERFERENCE,
STOP IMMEDIATELY
SECTION 3: COUPLER INSTALLATION
Fig. 3.4.1 Raise dipper arm to
take weight off coupler
Fig. 3.4.2 Retract crowd
cylinder to align dipper pin