WEDGELOCK TenX Coupler User manual

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

Parts & Service 16/10/2019 902-001-46 Rev 1 Page 3
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

Parts & Service 16/10/2019 902-001-46 Rev 1 Page 7
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

Parts & Service 16/10/2019 902-001-46 Rev 1 Page 9
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

Parts & Service 16/10/2019 902-001-46 Rev 1 Page 11
SECTION 4: HYDRAULIC INSTALLATION
4.0 HYDRAULIC SUPPLY LINES
The Wedgelock TenX Coupler requires two hydraulic lines to be routed to
ports on top of the primary cylinder. The TenX Tilt Coupler requires four lines
to be routed to the bulk head at the rear of the coupler.
Tilt Coupler functionality requires connection to the carrier machine auxiliary
circuit. The installation of additional control mechanism(s) may be necessary.
Jumper hoses should be long enough to allow full rotation of
the coupler without stressing the hoses. (Fig. 4.0.1.)
Fig. 4.0.1 Jumper Hose Connections
Jumper Hoses
Primary Cylinder
Bulkhead
Fig. 4.0.2 Standard Coupler
primary cylinder ports
Fig. 4.0.3 Tilt Coupler
bulkhead ports
Ports Ports

Page 12 902-001-46 Rev 1 Parts & Service 16/10/2019
SECTION 4: HYDRAULIC INSTALLATION
Fig. 4.1.1 Standard Coupler hydraulic circuit
PRESSURE SOURCE
SOLENOID
VALVE
PRESSURE
REDUCING
VALVE
120 -180 BAR
RETRACT (R) EXTEND (E)
PILOT CHECK
VALVE
PUMP (P) TANK (T)
PRESSURE RELIEF VALVE
FIXED VALUE: 300BAR
3
2
1
1 2
WEDGE CYLINDER
I-LOCK CYLINDER
OEM 4/2 VALVE
COUPLER
POWER TO COIL
3
2 1
PILOT CHECK
VALVE
B
2
3
4
1
SURFACE
CARTRIDGE VALVE CAVITY CONVENTION:
PORT 1 IS ALWAYS AT THE BOTTOM
AND NUMBERING INCREASES TO THE SURFACE
NOTE THAT NUMBERS ARE NOT SHOWN ON
FACTORY 4/2 VALVE, AS THEY WILL VARY BY
MANUFACTURER
PRV WAS 120 BAR, NOW 120-180 BAR 15/10/19 AR AR B
DRG: 910-200-20-D
SCHEMATIC, HYDRAULIC, C5
IF IN DOUBT ASK!
REV.
w w w . w e d g e l o c k . c o m
e-mail: [email protected]
Phone: +
64 4 526 3901
B
A
FIRST ISSUE
REV
DESCRIPTION
ECN DATE DRN CHK
AA AR
PART: 910-200-20
13/09/17
-
PRESSURE SOURCE
SOLENOID
VALVE
PRESSURE
REDUCING
VALVE
120 -180 BAR
RETRACT (R) EXTEND (E)
PILOT CHECK
VALVE
PUMP (P) TANK (T)
PRESSURE RELIEF VALVE
FIXED VALUE: 300BAR
3
2
1
1 2
WEDGE CYLINDER
I-LOCK CYLINDER
OEM 4/2 VALVE
COUPLER
POWER TO COIL
3
2 1
PILOT CHECK
VALVE
B
2
3
4
1
SURFACE
CARTRIDGE VALVE CAVITY CONVENTION:
PORT 1 IS ALWAYS AT THE BOTTOM
AND NUMBERING INCREASES TO THE SURFACE
NOTE THAT NUMBERS ARE NOT SHOWN ON
FACTORY 4/2 VALVE, AS THEY WILL VARY BY
MANUFACTURER
PRV WAS 120 BAR, NOW 120-180 BAR 15/10/19 AR AR B
DRG: 910-200-20-D
SCHEMATIC, HYDRAULIC, C5
IF IN DOUBT ASK!
REV.
w w w . w e d g e l o c k . c o m
e-mail: [email protected]
Phone: +
64 4 526 3901
B
A
FIRST ISSUE
REV
DESCRIPTION
ECN DATE DRN CHK
AA AR
PART: 910-200-20
13/09/17
-
4.1 HYDRAULIC CIRCUITS

Parts & Service 16/10/2019 902-001-46 Rev 1 Page 13
4.2 CONTROL SYSTEM
To operate the functions of the coupler will require a control system. This will
either be pre-installed in the carrier machine (OEM fitment) or if not present,
will need to be installed separately.
SECTION 4: HYDRAULIC INSTALLATION
Fig. 4.1.2 Tilt Coupler hydraulic circuit

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5.0 FINISH & TEST
Before starting this section, position the machine in the “Oil
Level Check” position as suggested by the excavator machine
manufacturer. Check the oil level sight gauge on the hydraulic
tank. Add hydraulic oil if necessary (refer to the carrier machine
service manual for further information).
• Clear all personnel and all obstacles from the swing radius area and
working parameter of the machine.
• From the seat of the excavator, start the machine and lower the excavator
arm to near the ground. In a very slow motion, using the excavator levers,
raise the dipper arm and crowd the coupler through full rotation. Then
raise the boom of the excavator and motion the dipper arm cylinder to
full extension. Now motion the dipper arm cylinder to full retraction,
lowering the boom arm in unison.
• Activate the coupler circuit several times to ensure that the system is
working correctly – refer to SECTION 9 of this manual.
• Affix “In Cab” Decals in a suitable location within the operators working
area. (Fig 6.0.1 & 6.0.2)
SECTION 5: FINISH AND TEST

Parts & Service 16/10/2019 902-001-46 Rev 1 Page 15
6.0 IN CAB DECALS
The following two “In Cab” Decals must be affixed in a suitable
location within the operator’s working area. For replacement
decals please call your nearest Wedgelock Dealer. (Fig 6.0.1
Warning Decal & 6.0.2 TenX Coupler Operating Decal)
Fig. 6.0.1 Warning Decal
NOTE: Supplied
decals may
differ from
the examples
depicted on
this page
Fig. 6.0.2 TENX Coupler
Operation Decal
THIS MACHINE IS FITTED WITH A QUICK COUPLER.
LENGTH OF THE DIPPER ARM HAS INCREASED.
ATTACHMENTS MAY HIT THE CABIN AND OR BOOM.
THE QUICK COUPLER OPERATING MANUAL MUST BE
REFERRED TO BEFORE COMMENCING OPERATION.
WARNING
# 903-002-3
DETACH
ATTACH
PREPARATION
Position coupler for operation
Lock-out switch ON
Build Pressure
Lock-out switch OFF
Build Pressure
Lift coupler AWAY
from attachment
Note:
knuckle resets
automatically
ENGAGE first pin & LOWER
coupler to second pin
POWER
ON
POWER
OFF
FINISH
Shake test the attachment
12
12
NOTE THAT SOME BRANDS OF EXCAVATOR MAY HAVE A SLIGHTLY DIFFERENT SEQUENCE TO THAT DEPICTED HERE.
FOR FULL INSTRUCTIONS REFER TO OPERATION MANUAL OR SCAN THE QR CODE (TOP OF DECAL) TO WATCH THE VIDEO. 903-002-26
INSTRUCTIONS
for your TenX COUPLER watch the video
SECTION 6: DECALS

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OPERATION
7.0 SAFE COUPLER USE
Your TenX Coupler will extend the overall length of
the dipper arm.
ATTACHMENTS MAY HIT THE CABIN AND OR BOOM
Your TenX Coupler may enable the operator to
use buckets and attachments for which it is not
designed, i.e. oversized buckets or attachments.
ONLY USE ATTACHMENTS THAT ARE DESIGNED
SPECIFICALLY FOR THE HOST MACHINE.

Parts & Service 16/10/2019 902-001-46 Rev 1 Page 17
Never place your hands inside the coupler or
anywhere near the linkage mechanism whilst
the hydraulic system is pressurized or the carrier
machine is turned on.
Never use the Primary Locking Wedge or TenX
Safety Knuckle as a lifting device.
FOR INFORMATION RELATING TO “SAFE LIFTING
PROCEDURES” REFER TO SECTION 10 OF THIS
MANUAL.
Always fully engage the coupler to the bucket or
attachment even if you just want to lift or move the
attachment to a different position on your work
site.
Any damage deemed by Wedgelock to have been
caused by operator misuse will invalidate the
manufacturers warranty.
SECTION 7: SAFE COUPLER USE

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8.0 TERMINOLOGY
Coupler Components
The terminology listed below is referenced throughout this manual, and is
helpful to know when dealing with Wedgelock for instruction or future part
replacement.
Reset TRIGGER
Safety KNUCKLE Safety ARM
Lifting EYE
Primary WEDGE
Front/Back of Coupler
To avoid confusion the following is the standard definition of front and back
of excavator attachment(s).
SECTION 8: TERMINOLOGY

Parts & Service 16/10/2019 902-001-46 Rev 1 Page 19
OEM Pins
Attachment or bucket pins are constructed of a different grade of steel
than OEM or Excavator pins. It is vital that the correct pins are used in the
appropriate places or excessive wear can occur.
Lock Out Switch
The Power-On/Power-Off switch for the attachment changeover sequence
must be have ‘lock-out’ capability, which prevents accidental deactivation
during the operation. This switch may be the standard fitment switch pre-
installed in the carrier machine, or a third party Lock-Out switch installed
with the coupler. Note that in some carrier machines this switch may be a
‘missile’ switch with a cover (see Fig. 8.0.1 for examples). For the purposes of
this manual we will call it the Lock Out switch, and it refers to the Power On/
Power Off in-cab switch that operates the coupler control system.
BUCKET or
ATTACHMENT
pins
OEM or
EXCAVATOR
pins
SECTION 8: TERMINOLOGY
Fig. 8.0.1 LOCK OUT SWITCHES
Left: Third party switch (example). Centre: OEM carrier machine
switch (example). Right: OEM ‘Missile’ switch (example).

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PREPARATION
Position coupler for operation
Lock-out switch ON
Build Pressure
POWER
ON
1
Lift coupler AWAY
from attachment
Note:
knuckle resets
automatically
2
OPERATOR
ACTION
COUPLER
ACTION
IN-CAB
DECAL
DETACH
Instructions for attachment changeover
(Remove Attachment)
SECTION 9: CHANGEOVER OPERATION
Position excavator &
attachment so pins
are not loaded against
wedge & knuckle.
Position excavator to
allow pump pressure
to raise in later steps.
Turn the LOCK OUT
switch ON.
Build hydraulic
pressure.
Place attachment on
level ground (if not
already placed) and
lift coupler away from
attachment pins.
The Safety KNUCKLE
will retract (visible
from the cab).
The Primary WEDGE
will retract.
As the front pin leaves
the C cavity, the Reset
TRIGGER ensures that
the Safety KNUCKLE
automatically resets
to the READY (SAFE)
position.
* NOTE that in some brands of excavator, a secondary operation is required
to ensure that the Lock Out switch or auxiliary circuit system remains
activated throughout the changeover process.
Refer to your carrier machine operation manual for operation of auxiliary circuits.