WEDGELOCK I-LOCK COUPLER

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Summary

Introduction

Our Focus

Defines the primary user focus for safer work sites.

Our Purpose

States the mission to transform excavators into productive, safe tool carriers.

Our Values

Outlines the company's core principles: pioneering, committed, collaborative, courageous, family.

Our Mission

Describes the business goal of creating stronger human relationships and user-centric products.

Installation Guide Lines

Check List

Essential pre-installation checks to ensure the correct kit and machine readiness.

Precautions

Safety Precautions

General safety guidelines for operating machinery and handling hydraulic systems.

Welding Precautions

Specific safety measures and best practices for welding on the carrier machine.

Coupler Installation

Safety During Coupler Installation

Critical safety advice for handling attachments and ensuring personnel safety.

Coupler Orientation

Guidance on correctly orienting the I-Lock Coupler on the carrier machine.

Removing the Existing Bucket

Procedure for safely detaching the current attachment from the dipper arm.

Fitting the Coupler (Link Pin)

Steps for installing the coupler onto the machine using the link pin.

Fitting the Coupler (Dipper Pin)

Steps for installing the coupler onto the machine using the dipper pin.

Hydraulic Kit Installation

Junction Manifold Position

Determining the optimal location for the junction manifold block on the dipper arm.

Fitting the Junction Manifold Block

Procedure for attaching the manifold block to the dipper arm via welding.

The I-Lock Control Valve

Details the function, components, and port markings of the I-Lock control valve.

Installing the Control Valve

Steps for securely mounting the control valve in the engine compartment.

Hose Routing

General guidance and considerations for routing hydraulic hoses within the machine.

Hose Routing - Dipper Arm

Specific instructions for routing hoses on the dipper arm, including clamp placement.

Hose Routing - Boom

Specific instructions for routing hoses along the boom arm, including clamp placement.

Hose Routing - Boom to Valve

Instructions for routing hoses from the boom end to the control valve in the pump compartment.

Hose Routing Valve to Pump; Tank

Instructions for routing hoses from the control valve to the pump and tank return.

Electrical Installation

Steps for connecting the I-Lock Coupler's electrical components, including the control switch.

Schematics

Hydraulic Schematic

Diagram illustrating the complete hydraulic circuit connections for the I-Lock Coupler.

Electrical Schematic

Diagram illustrating the complete electrical circuit connections for the I-Lock Coupler.

Finish & Test

Procedures for final checks, system testing, and ensuring correct operation post-installation.

Torque Charts

Torque Chart - Metric Bolts

Specifies correct torque settings for metric bolts used in the hydraulic kit installation.

Torque Chart - JIC Connections

Specifies correct torque settings for JIC hydraulic connections to prevent leaks.

Install Kits

Hose Kit, I-Lock 130

Lists all components included in the I-Lock 130 weight class hose kit.

Hose Kit, I-Lock 170 - 210 - 270

Lists all components for I-Lock 170, 210, 270 weight class hose kits.

Hose Kit, I-Lock 320

Lists all components included in the I-Lock 320 weight class hose kit.

Hose Kit, I-Lock 450

Lists all components included in the I-Lock 450 weight class hose kit.

Hose Kit, I-Lock 750

Lists all components included in the I-Lock 750 weight class hose kit.

Hose Kit, I-Lock 1000

Lists all components included in the I-Lock 1000 weight class hose kit.

Warranty

Details the standard limited warranty policy, inclusions, and exclusions for Wedgelock products.

Warranty Registration

Warranty Registration Form

Form to be completed and returned to register the product for warranty coverage.

The I-LOCK Coupler is a quick coupler system designed for excavators, featuring an integrated safety device. This installation manual provides comprehensive instructions for fitting the I-LOCK Coupler and its associated hydraulic kit, emphasizing safety precautions and proper procedures.

Function Description:

The I-LOCK Coupler is an attachment for excavators that allows for quick and secure changes of buckets and other tools. Its primary function is to transform excavators into versatile tool carriers, enhancing productivity and safety on work sites. The system incorporates an I-LOCK Safety Device, which is a world-first in coupler safety, building upon the original features of a standard Wedgelock Hydraulic Coupler. This safety device is controlled by a dedicated I-LOCK Control Valve and Switch, ensuring secure operation during attachment changes. The coupler operates on the machine's mains hydraulic pressure, with the control valve managing oil pressure and flow for both the primary wedge function and the safety knuckle function. The control switch includes built-in "Timer" and "Operational Sequences" to control the solenoid valves, providing a safe work environment.

Important Technical Specifications:

Coupler Type: I-LOCK Coupler (Hydraulic Quick Coupler with Safety Device)
Hydraulic Circuit: Requires a third hydraulic line for installation.
Control Valve: I-LOCK Control Valve (twin solenoid valves, twin pressure reducing valves, 5 ports for hose routing).
- Solenoid Valves: SAFETY (safety knuckle solenoid), WEDGE (primary wedge solenoid).
- Ports: P (pressure supply), T (tank return), RET (primary wedge retract), EXT (primary wedge extend), SAFETY (safety knuckle release).
Control Switch: I-LOCK Control Switch (Rotary, Electronic) with "plug & play" wiring harness, designed for cab mounting. Features "Extend Wedge," "Retract Wedge," and "Release/Pick Up" positions, with a light indicator for "Release."
Junction Manifold Block: 9-port block (7/16" UNO x 9 PORT, 3 PLUG) for optimizing jumper hose routing on the dipper arm.
Hose Kits: Available for various I-LOCK Coupler weight classes (130, 170, 210, 270, 320, 450, 750, 1000), including pre-crimped hoses with color-coded cable ties.
Fittings: JIC (SAE 37º Flare) connections are common. Specific adapters and tees are included in the kits.
Torque Settings:
- Metric Bolts (Grade 8.8): M6 x 1.0 (9.9 Nm / 7.3 Lb.Ft) up to M20 x 2.5 (390.0 Nm / 287.4 Lb.Ft).
- JIC Connectors: 1/4" (-4) (15-17 Nm / 10.8-12.5 Lb.Ft) up to 1/2" (-8) (59-65 Nm / 45.5-47.8 Lb.Ft).
Electrical System: 12V or 24V machine battery, 10 AMP fuse, ignition switch connection.
Materials: Nylon abrasive sleeves for hose protection, Dowty seals for fittings.

Usage Features:

Simplified Installation: The manual provides a step-by-step guide, including a reference card and detailed sections for coupler, hydraulic kit, and electrical installation.
Clear Orientation: The coupler is designed to fit in one specific orientation, with the C-Section facing the operator's view, ensuring correct installation.
Optimized Hose Routing: The junction manifold block allows for multiple routing options to minimize jumper hose length and ensure free movement of hoses during operation. Color-coded hoses and cable ties aid in identification and secure routing.
Safety Interlocks: The I-LOCK Control Switch and Valve incorporate safety features like a timer and operational sequences to prevent accidental release of attachments. The "Release" function is time-limited, requiring the operator to act within a specific window to disconnect.
Visual Indicators: The control switch includes a light to indicate the "Release" status.
Clearances: The installation process emphasizes checking clearances during coupler rotation and hose routing to prevent pinching or crushing.
In-Cab Decals: Warning and operation instruction decals are provided for placement within the operator's cab to ensure easy access to safety and usage information.

Maintenance Features:

Regular Checks: The manual advises checking hose clamp assemblies, valve mounting bolts, and hose connections for tightness as part of the finish and test procedure.
Leak Detection: Instructions include running the machine at low RPM to check for leaks and immediate shutdown if detected.
Paint Touch-Up: After welding, components should be touched up with paint to match the carrier machine's color, protecting against corrosion.
Hose Protection: Nylon abrasive sleeves are used to protect hoses at pivot points, extending their lifespan.
Operator Manual Reference: For service details regarding the control valve and proper operation, users are directed to the I-LOCK Coupler Operators Manual.
Warranty: Wedgelock offers a limited warranty, covering defects in material and workmanship for 12 months/2000 machine hours for quick couplers and 6 months/1000 service hours for other attachments. Proper installation and maintenance according to the manual are required to maintain warranty validity.
Warranty Registration: A form is provided for installers and owners to register the product, ensuring warranty coverage.