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I-LOCK
INSTALLATION MANUAL
S P E C I A L N O T E
Your new Wedgelock Coupler fitted with the I-LOCK
the installation of a third hydraulic line - please follow the instructions carefully
NORTH AMERICA
MINI COUPLER
TM
Safety Device requires
TM
Dipper Arm
Hoses & Components
Boom Arm
Hoses & Components
Boom Base To Valve
Hoses & Components
Pump & Tank
Hoses & Components
Cabin Mounted
Components
Toll-free: 800 CASCADE (227.2233)
Telephone: 503-669-6257
cascadewedgelock@cascorp.com
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Summary of Contents for WEDGELOCK I-LOCK MINI COUPLER
- Page 1 MINI COUPLER INSTALLATION MANUAL S P E C I A L N O T E Your new Wedgelock Coupler fitted with the I-LOCK Safety Device requires the installation of a third hydraulic line - please follow the instructions carefully Dipper Arm Hoses &...
- Page 3 I-LOCK MINI COUPLER INSTALLATION REFERENCE CARD PLEASE READ INSTALL MANUAL THOROUGHLY BEFORE INSTALLATION Remove Bucket if attached to the excavator dipper arm. (8)*. Install Quick Coupler using the carrier machine’s original dipper and linkage pins (8, 9)*. Once mounted, rotate coupler through its full range of movement and check clearances around coupler and dipper arm (9)*.
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Page 4: Table Of Contents
CONTENTS NORTH AMERICA PAGE REFERENCE CARD SECTION 1: INSTALLATION GUIDELINES 1.0 CHECK LIST SECTION 2: PRECAUTIONS 2.0 SAFETY PRECAUTIONS 2.1 WELDING PRECAUTIONS SECTION 3: COUPLER INSTALLATION 3.0 SAFETY DURING COUPLER INSTALLATION 3.1 COUPLER ORIENTATION 3.2 REMOVING THE EXISTING BUCKET 3.3 FITTING THE COUPLER (LINK PIN) 3.4 FITTING THE COUPLER (DIPPER PIN) SECTION 4: HYDRAULIC KIT INSTALLATION 4.0 HOSE CLAMP BRACKET POSITION... -
Page 5: Check List
SECTION 1: INSTALLATION GUIDELINES NORTH AMERICA 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 components supplied. -
Page 6: Safety Precautions
SECTION 2: PRECAUTIONS NORTH AMERICA Please ensure you follow the stated precautions below while 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”... -
Page 7: Safety During Coupler Installation
DO NOT use standard attachment pins to connect the coupler to the machine. If unsure consult DO NOT use standard attachment pins to connect the coupler to the machine. If unsure consult your Wedgelock Dealer immediately. your Wedgelock Dealer immediately. -
Page 8: Removing The Existing Bucket
SECTION 3: COUPLER INSTALLATION NORTH AMERICA SECTION 3: COUPLER INSTALLATION NORTH AMERICA 3.2 REMOVE THE EXISTING BUCKET 3.2 REMOVE THE EXISTING BUCKET • Before you fit the coupler to the carrier machine you have to first remove any existing attachment from the dipper • Before you fit the coupler to the carrier machine you have arm. -
Page 9: Fitting The Coupler (Dipper Pin)
CAREFULLY CROWD THE COUPLER THROUGH FULL ROTATION TO CHECK CHECK CLEARANCES CLEARANCES IF THERE ARE ANY SIGNS OF INTERFERENCE STOP IMMEDIATELY AND IF THERE ARE ANY SIGNS OF INTERFERENCE STOP IMMEDIATELY AND CONTACT YOUR WEDGELOCK DEALER CONTACT YOUR WEDGELOCK DEALER Page 8... -
Page 10: Hose Clamp Bracket Position
SECTION 4: HYDRAULIC KIT INSTALLATION NORTH AMERICA There are three main sections to the hydraulic kit installation which consists of: • Fitting of the Hose Clamp Bracket to the dipper arm. • Fitting of the I-Lock Control Valve in the engine/pump compartment. • Routing the 3 Line Hydraulic Circuit to complete the hydraulic part of the coupler installation. -
Page 11: The I-Lock Control Valve
SECTION 4: HYDRAULIC KIT INSTALLATION NORTH AMERICA 4.2 THE I-LOCK CONTROL VALVE The I-Lock Coupler is designed to operate on the carrier machine’s MAINS PRESSURE supply. The I-Lock Control Valve controls the oil pressure and oil flow to the coupler for both the Primary Wedge function AND the Safety Knuckle function. The I-Lock Coupler Control Valve MUST BE USED for any installation of an I-Lock Coupler. •... -
Page 12: Hose Routing
SECTION 4: HYDRAULIC KIT INSTALLATION NORTH AMERICA 4.4 HOSE ROUTING Wedgelock Hose Kits have been designed to improve the speed and ease in which an installer can fit the hydraulic kit. The content of the hydraulic hose kit has been pre determined to ensure that, in most cases, the majority of fittings required to complete the install are provided. In some circumstances additional fittings may have to be sourced to complete the connection to the pump test port and tank return. For information regarding the port type at these locations please refer to the carrier machine service manual. -
Page 13: Hose Routing - Boom
SECTION 4: HYDRAULIC KIT INSTALLATION NORTH AMERICA 4.6 HOSE ROUTING – BOOM • Fit the nylon abrasive sleeve over the loose ends of the Dipper hoses. Using the GREEN color coded hoses for the Boom, connect these to the dipper arm hoses. (Fig 4.6.1) • Lay the Boom hoses along the top of the boom arm in preparation of Fig 4.6.1 Hose Joint determining the best hose clamp position for this part of the installation. -
Page 14: Hose Routing - Boom To Valve
“T” port to the other end of the tee. • Cable tie hoses to existing hoses where appropriate and coil any excess hose if required. Ensure that the hoses are not bound up or under any strain. • Tighten all hose joints and fittings between the control valve and the pump and tank. NOTE 1: When utilizing a “Pre-Crimped” or “Loose” hose kit supplied by Wedgelock we have endeavored to supply the majority of the fittings required to carry out a complete install of an I-Lock Coupler, however due to the vast array of different carrier machines, fitting types and port sizes, not all circumstances may be accounted for. In instances where the fittings supplied do not match the port size or the type of carrier machine that this install is being carried out on please contact your nearest machinery dealer or hydraulic fittings provider for the additional appropriate component(s). -
Page 15: Electrical Installation
SECTION 5: ELECTRICAL INSTALLATION NORTH AMERICA 5.0 ELECTRICAL INSTALLATION The I-Lock Coupler must be operated utilizing the I-LOCK CONTROLLER, DUAL SWITCH ASSEMBLY and SOLENOID LOOM. The proprietary electrical components have been designed in conjunction with the functionality and operation of the coupler safety features. The built in “Timer” and “Operational Sequences” controlling the solenoid valves are features which provide the operator and fellow co-workers a safe work environment during attachment change over. -
Page 16: Loose Hose Kit Assembly
SECTION 6: ASSEMBLIES NORTH AMERICA 6.0 LOOSE HOSE KIT ASSEMBLY HYDRAULIC COUPLER & I-LOCK SAFETY SYSTEM Dipper Arm Hoses Coupler Hoses Pump & Tank Hoses Boom Hoses I-LOCK SAFETY SYSTEM & COUPLER MACHINE CONTROL VALVE SPECIFIC CHECK 12V OR 24V SETTINGS VALVE Fig 6.0.1 Loose Hose Kit Assembly... - Page 17 SECTION 6: ASSEMBLIES NORTH AMERICA 6.2 ELECTRICAL ASSEMBLY I-Lock Controller Solenoid Loom Male / Female Connectors Earth Connection Din Plugs Fig 6.2.2 Electrical Assembly...
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Page 18: Finish & Test
SECTION 7: FINISH & TEST NORTH AMERICA 7.0 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). -
Page 19: In Cab Decals
SECTION 8: IN CAB DECALS NORTH AMERICA 8.0 IN CAB DECALS The following two “In Cab” Decals must be affixed in a suitable location within the operators working area. For replacement decals please call your nearest Wedgelock dealer. (Fig 8.0.1 Warning Decal & 8.0.2 I-Lock Coupler Oerating Decal) Fig 8.0.1 Warning Decal Fig 8.0.2 I-Lock Coupler Operation Decal... -
Page 20: Torque Chart - Metric Bolts
SECTION 9: TORQUE CHARTS NORTH AMERICA 9.0 TORQUE CHART – METRIC BOLTS The following chart gives the standard torque setting of the bolts used in this hydraulic kit installation. It is important to follow the chart when installing bolts and nuts. Failure to do so could result in premature failure, damage to components, or even serious injury. (Fig 8.0.1) Torque Setting of Metric Grade 8.8 Bolts &... - Page 22 NORTH AMERICA PO Box 20187 • Portland, OR 97294-0187 • USA • 800 CASCADE (227.2233) • Tel 503.669.6257 • www.wedgelockusa.com Cascade and Wedgelock are registered trademarks of Cascade Corporation. © Cascade Corporation 2013. All rights reserved. Form 6843145 150 GE 07/13...
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