WEDGELOCK I-LOCK User manual

THIS OPERATORS MANUAL MUST BE KEPT WITH THE CARRIER MACHINE AT ALL TIMES
Toll-free: 800 CASCADE (227.2233)
Telephone: [phone]
[email protected]
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PAGE
SECTION 1: SAFETY
1.0 I-LOCK™ SAFETY SYSTEM 3
1.1 INTEGRATED DESIGN FEATURES 4
1.2 SAFE COUPLER USE 5
SECTION 2: OPERATION
2.0 CONNECTING TO THE FIRST PIN 6
2.1 CONNECTING TO THE SECOND PIN 6
2.2 TO DISENGAGE THE SECOND PIN 7
2.3 TO DISENGAGE THE FIRST PIN 7
2.4 READY TO RE-CONNECT 8
2.5 NORMAL OPERATING PROCEDURE – FLOW DIAGRAM 9
SECTION 3: MAINTENANCE
3.0 COUPLER IDENTIFICATION 10
3.1 SERVICING SCHEDULE
SECTION 4: TROUBLE SHOOTING
4.0 TROUBLE SHOOTING GUIDE 11,12
SECTION 5: SAFE LIFTING PROCEDURE
5.0 SAFE LIFTING PROCEDURE 13
SECTION 6: WARRANTY
6.0 WARRANTY 14,15
SECTION 7: WARRANTY REGISTRATION
7.0 WARRANTY REGISTRATION FORM 16
CONTENTS

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Congratulations on your purchase of the I-LOCKTM coupler. You have just bought the SAFEST
coupler in the world.
1.0 I-LOCK™ SAFETY SYSTEM
The I-LOCKTM Coupler by Wedgelock must be installed correctly utilizing our 3 hose circuit
technology. Correct installation ensures that the I-LOCK™ Coupler’s built in safety features operate
in accordance with the way in which the coupler has been designed.
INSTANT SAFETY
Most accidents occur in the rst 5 seconds of latching an attachment. Your coupler is tted with the
I-LOCKTM SAFETY SYSTEM which ensures that your attachment is locked the INSTANT that it is
latched (see gure 1.0.1). This means there is no danger of dropping the attachment if the primary
lock is not engaged completely. The I-LOCKTM SAFETY SYSTEM operates independently of the
primary lock.
MOST SERIOUS ACCIDENTS HAPPEN IN
THE FIRST 5 SECONDS OF LATCHING
THE WEDGELOCK ADVANTAGE
SAFETY
100%
50%
0%
1 2 3 4 5 6
ATTACHMENT CHANGE TIME IN SECONDS
ENGAGE FIRST
PIN with OTHER
COUPLER
ENGAGE PRIMARY
LOCK of OTHER
COUPLER
ENGAGE
SECONDARY LOCK
of OTHER COUPLER
NORMAL
OPERATION
ENGAGE FIRST
PIN with I-LOCK
NORMAL
OPERATION
ENGAGE PRIMARY
LOCK of I-LOCK
COUPLER
DANGER ZONE!
Key
I-Lock
Other
SECTION 1: SAFETY
(Fig 1.0.1)

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OPERATOR CONTROLLED SAFETY KNUCKLE
The attachment can only be disconnected completely from the I-LOCK™ Coupler after the
intentional activation of the SAFETY KNUCKLE by the operator. The release switch has a built in
time delay. To retract the safety knuckle the operator manually activates the switch which allows
a 10 second timeframe to disengage the attachment. After 10 seconds the safety knuckle in the
I-LOCK™ mechanism will automatically reset. If the attachment has not been removed completely
the automatic reset of the safety knuckle will render the attachment into a safe situation again. If the
attachment has been removed the automatic reset of the safety knuckle ensures that the coupler is
ready to reconnect to the next attachment.
WEDGE LOCKING PRINCIPLE
Another safety feature of the I-LOCK™ Coupler is the Wedge Locking Principle. The locking
principle of the primary wedge provides at least 2.5 times the locking force compared with a swinging
jaw coupler. This assures that both attachment pins are locked rmly to the coupler body minimizing
the wear in the locking area of your coupler.
1.1 INTEGRATED DESIGN FEATURES:
Integral with the solenoid operated directional control valve are 2 pressure reducers set to: Locking
Pressure - 2100 PSI (145 BAR) and Unlocking Pressure - 3750 PSI (260 BAR). These ensure that
the hydraulic circuit is not over pressurized.
The solenoid valve is only energized to release the attachment. This will ensure that in the event of
an electrical failure the primary locking mechanism will stay in the locked position.
The electrical circuit is protected by a 10 Amp fuse.
Operation is by a dual rocker switch arrangement complete with warning buzzer. The warning
buzzer is present to alert the operator that the electric circuit is still live and the attachment can be
released.
The unique one piece hydraulic cylinder body eliminates port welding and potential feeder tube
damage. Integrated into the cylinder is a ‘Pilot Operated Safety Check Valve” which locks the
pressure in the extend side of the cylinder in the event of hose failure anywhere in the coupler
circuit. In addition, on the larger models, an internal pressure relief valve is tted to the cylinders to
protect against the potential of mechanically induced pressure spikes.
SECTION 1: SAFETY

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Your I-LOCKTM Coupler will extend the overall length of the dipper arm.
ATTACHMENTS MAY HIT THE CABIN AND OR BOOM
Your I-LOCKTM 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.
Never place your hands inside the coupler or anywhere near the linkage
mechanism while the hydraulic system is pressurized or the carrier machine is
turned on.
Never use the Primary Locking Wedge or I-LOCK™ Safety Knuckle as a lifting
device.
FOR INFORMATION RELATING TO “SAFE LIFTING PROCEDURES” REFER
TO SECTION 5 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 set out in section 6.0 of this manual.
1.2 SAFE COUPLER USE
SECTION 2: OPERATION

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2.0 CONNECTING TO THE FIRST PIN (Front Pin)
Switch Mode
The Lock-Out Switch is ON
The Momentary Switch is OFF
(Fig 2.0.1)
Buzzer Mode
The Audible Buzzer is sounding
(once every second)
I-Lock™ Coupler Mode
The Primary Wedge is retracted
The Safety Knuckle is in the safe position
(Fig 2.0.2)
Operator Action
Using the excavator arm control levers move front jaw of
the coupler over the rst pin (front pin) of the attachment.
Seat the rst pin into the front jaw. The I-LOCKTM Safety
Knuckle will instantly lock the coupler to the rst pin of the
attachment.
(Fig 2.0.3)
2.1 CONNECTING TO THE SECOND PIN (Rear Pin)
Operator Action
Using the excavator arm control levers simultaneously lift
and crowd the attachment until the second pin (rear pin)
is seated in the rear jaw section. Deactivate the Lock-Out
Switch – continue to activate the crowd lever, extending
the crowd cylinder - this will extend the Primary Wedge,
locking the second pin.
(Fig 2.1.1) RATTLE TEST TO CONFIRM CONNECTION
Switch Mode
The Lock-Out Switch is OFF
The Momentary Switch is OFF
(Fig 2.1.2)
Buzzer Mode
The Audible Buzzer is OFF
I-Lock™ Coupler Mode
The Primary Wedge is extended
The Safety Knuckle is in the safe position
(Fig 2.0.1)
(Fig 2.0.2)
(Fig 2.0.3)
(Fig 2.1.1)
(Fig 2.1.2)
SECTION 2: OPERATION
CONNECTION AN ATTACHMENT

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2.2 TO DISENGAGE THE SECOND PIN (Rear Pin)
Operator Action
Using the excavator arm control levers position the
attachment slightly above the ground so the second
pin (rear pin) is lower than the rst pin (front pin).
Activate the Lock-Out Switch, this will retract the
Primary Wedge, unlocking the second pin.
(Fig 2.2.1)
Switch Mode
The Lock-Out Switch is ON
The Momentary Switch is OFF
(Fig 2.2.2)
Buzzer Mode
The Audible Buzzer is sounding
(once every second)
I-Lock™ Coupler Mode
The primary wedge is now retracted
The safety knuckle is in the safe position
The second pin is disengaged from the rear jaw
2.3 TO DISENGAGE THE FIRST PIN (Front Pin)
Operator Action
*Depress the Momentary Switch for more than one
second to activate the release of the Safety Knuckle.
Using the excavator arm control levers crowd the
I-Lock™ Coupler away from the rst attachment pin.
(Fig 2.3.1)
Switch Mode
The Lock-Out Switch is ON
The Momentary Switch is ON
(Fig 2.3.2)
Buzzer Mode
The Audible Buzzer is sounding
(twice every second)
I-Lock™ Coupler Mode
The Primary Wedge remains retracted
The Safety Knuckle is in the release position
(Fig 2.3.3)
After 5 to 10 seconds** the safety knuckle will reset to the
safe position and the Audible Buzzer will continue to sound
once every second (Fig 2.3.4)
(Fig 2.2.2)
(Fig 2.2.1)
(Fig 2.3.1)
(Fig 2.3.2)
(Fig 2.3.4)
DISCONNECTING AN ATTACHMENT
(Fig 2.3.3)
SECTION 2: OPERATION

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PLEASE READ CAREFULLY
*Depressing of the Momentary Switch to activate the release of the
Safety Knuckle requires the operator to press down the rocker for
at least ONE second. After ONE second remove your nger from
the rocker to allow the Momentary Switch to reset. (the rocker will
automatically return to the rest position)
**The resetting of the Safety Knuckle is controlled by a timer, factory
set at 10 seconds. To adjust the timer refer to 2.5 Normal Operating
Procedure - (Flow Diagram)
2.4 READY TO RE-CONNECT
NOTE – Please read carefully
As soon as the Safety Knuckle automatically resets to the
safe position the Audible Buzzer will return to sounding
once every second. (Fig 2.4.1)
The I-Lock™ Coupler is ready to be re-connected to the
next attachment. (Fig 2.4.2)
To re-connect to your next attachment refer to:
SECTION 2.0 CONNECTING TO THE FIRST PIN
(Fig 2.4.1)
(Fig 2.4.2)
SECTION 2: OPERATION

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2.5 NORMAL OPERATING PROCEDURE - (FLOW DIAGRAM)
SECTION 2: OPERATION
Normal Operation
Power Off
Turn Power ON
using LOCK OUT
SWITCH
Wedge retracts
Safety unlocks
Press
MOMENTARY
SWITCH more
than 1 second
Remove
Attachment
5-10 second
window
Safety Resets Automatically
Connect
Attachment
Turn Power OFF
using LOCK OUT
SWITCH
Wedge extends
Timer Adjustment
Power Off
Press and hold
MOMENTARY SWITCH
Count beeps / second
Release MOMENTARY
SWITCH between 5 & 10
seconds to set timer
Turn Power ON using
LOCK OUT SWITCH
4 short beeps
4 short beeps
then 1 beep /
second
1 beep /
second
1 beep /
second
2 beeps /
second

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All Wedgelock Couplers are tted with
an Aluminum Data Plate (FIG 3.0.1).
Information pertains to the product code,
the carrier machine, 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
3.0 COUPLER IDENTIFICATION
SECTION 3: MAINTENANCE
WARNING: Wedgelock Quick Couplers that incorporate a factory tted lifting eye
will be labeled and marked with a Working Load Limit (WLL). The lifting eyes are
designed in accordance with BS-2573:Part1. It is highly recommended that a Bow
Type Shackle be used to connect to the lifting eye. See page 13.
3.0 SERVICING SCHEDULE
Maintenance Required Daily Weekly
Check all pin retainers, bolts & nuts for tightness on the quick coupler and
the attachments. ✓
Lubricate all greaseing points – the attachment will have to be removed to
access all grease points. ✓
Check hydraulic hoses and ttings for any leaks or wear – replace
immediately if required. ✓
Check the quick coupler switch audible warning buzzer and lights are
operating properly. ✓
Check the full operation of all the moving parts within the quick coupler –
repair or replace immediately if required. ✓
Check the hydraulic cylinder mounting bolts for tightness – remedy if
required. ✓
Thoroughly clean the quick coupler and ensure there is no material build
up around locking cylinder, wedge or I-Lock™ safety system. ✓
Thoroughly clean the quick coupler and ensure there is no material build
up around locking cylinder, wedge or I-Lock™ safety system. ✓
(Fig 3.0.1)
PRODUCT
MACHINE
CAP.
GET
MAX PRESSURE
SERIAL
W T.
WLL.
www.wedgelockusa.com Made in USA
EXAMPLE
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PROBLEM CHECK REMEDY
1. I-Lock™ Safety Knuckle
will not retract when
activated
Check hydraulic line to I-Lock™
Safety Knuckle
If damaged or leaking repair or
replace
Check operating pressure of
hydraulic line to I-Lock™ Safety
Knuckle
Adjust operating pressure on
solenoid pressure reducer if
required
Check electrical circuit between
solenoid and I-Lock™ Controller
Repair connections or replace
loom if required
Check function of solenoid
spool valve for I-Lock™ Safety
Knuckle circuit
Remove spool valve, clean and
clear any debris. Replace spool
if necessary
Check mechanical function of
solenoid coil for I-Lock™ Safety
Knuckle circuit
Replace solenoid coil if required
Check in-cab I-Lock™
Momentary Switch is functioning
See instructions below
2. I-Lock™ Safety Knuckle
remains in retracted (up)
position
Check Safety Knuckle &
housing for damage
Repair or replace parts if
necessary
Check Safety Knuckle and
housing for lodged debris
Remove debris
Check hydraulic lines Repair or replace if required
Check I-Lock™ spring assembly
for damage
Replace if required
Check I-Lock™ shaft assembly
for damage
Replace if required
3. The I-Lock™ Safety
Knuckle is slow to or partially
activates.
Check the system pressure
being supplied to the I-Lock™
piston during operation
Crowd the bucket cylinder
while activating the Momentary
Switch to overcome low idle
pressure
Check un-lock pressure of
I-Lock™ Safety Knuckle circuit
Adjust the pressure reducing
valve if required
Check condition of wiring loom
between the in-cab I-Lock
Controller and the solenoid
Replace or repair as necessary
NOTE: Should this problem occur it must be investigated and
remedied immediately
4.0 TROUBLE SHOOTING GUIDE
SECTION 4: TROUBLE SHOOTING

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4.0 TROUBLE SHOOTING GUIDE – cont’d
PROBLEM CHECK REMEDY
3. The I-Lock™ Safety Knuckle
is slow to or partially activates.
(cont’d)
Check for damage to Knuckle
blade or Knuckle damage
Replace parts if required
Check grease around I-Lock
piston
Grease liberally
Check I-Lock™ spring assembly
for damage
Replace if required
4. There is oil leaking around
the I-Lock™ piston assembly
Check the hose connection on
the I-Lock™ piston
Tighten as necessary
Check seals, rod and bore of
piston assembly for damage
Remove the I-Lock™ piston
assembly and dismantle.
Replace parts where necessary
and re-assemble.
5. The primary wedge is
operating slower than normal
Check that the operator is
crowding the cylinder to create
machine pressure
Crowd the bucket cylinder to
overcome low idle pressure
Check the operating pressure
that extends the Primary Wedge
Adjust the pressure reducing
valve if required
Check the inlet port on coupler
directional control valve
Clean and clear any debris that
is present from the orice
6. There is oil leaking around
the main cylinder in the coupler
Check hoses and connections
to the main cylinder
Tighten and replace as
necessary
Check cylinder for damage Remove main cylinder and
dismantle. Replace any
damaged parts
7. Primary Wedge will not
retract
Check coupler any debris
that maybe lodged behind the
Wedge plate
Clear the debris
Check the retract Wedge
pressure at the cylinder
Adjust the pressure reducing
valve if required
Inspect Pilot Operated Safety
Check valve in main cylinder
Remove, clean and replace if
necessary
Check in-cab I-Lock™ Lock-Out
switch is functioning
See previous instructions
Check mechanical function of
solenoid spool valve for the
Primary Wedge circuit
Remove spool valve, clean and
clear any debris. Replace spool
if necessary
SECTION 4: TROUBLE SHOOTING

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Your Wedgelock Quick Coupler may have been manufactured with an incorporated
lifting eye as part of the side plate of the coupler or it may have a welded lifting eye
tted to the rear plate of the coupler. Either of these two options offers the operator a
safe lifting point that can be used to lift loads suspended from the coupler body.
Before suspending any loads from the lifting eye you must rst do the following:
1. Remove any attachment or bucket that is currently tted to the coupler.
2. Understand and verify the maximum suspended load that the carrier machine can lift
taking into account the mass weight of the coupler.
3. Understand and verify the safe working load of the coupler lifting eye by referring to the
coupler aluminum data plate afxed to the coupler body.
4. Ensure that you use the correct lifting rigs and lifting procedures for the loads that are to
be suspended.
5. Ensure that co-workers KEEP WELL CLEAR at all times during the lifting procedure.
The following diagram indicates the safe working loads of the certied lifting eyes that are either
part of the side plate or welded to the rear plate of your Wedgelock Coupler. If you can’t identify the
working load limit from either the aluminum data plate that is stamped on the coupler or the chart
below please contact Cascade Corproation immediately for further assistance.
5.0 SAFE LIFTING PROCEDURE
SECTION 5: SAFE LIFTING PROCEDURE
contactCascadeCorporationforfurtherassisstance.

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6.0 WARRANTY Standard Limited Warranty Policy
WARRANTY INCLUSIONS
Cascade Corporation warrants all Wedgelock Quick Couplers to be free from defect in material and
workmanship for a period of 12 months (365 days) or 2000 machine hours, whichever occurs rst,
from the date of delivery to the End User or Dealer (“the Customer”).
If, during the warranty period, any quick coupler, attachment or part manufactured by Cascade
Corporation upon receipt of supporting evidence and inspection by Cascade Corporation, is proven
to be defective in material and/or workmanship, Cascade Corporation shall repair or arrange for
the repair and/or full or partial replacement of such attachment or part, providing said attachment
or part was installed and operated in accordance with Cascade Corporation’s currently published
instructions.
Any attachment or part repaired or replaced under the terms of the warranty policy shall retain the
warranty period pertaining to the product’s original date of purchase.
WARRANTY EXCLUSIONS
This policy does not cover machinery, parts or accessories that are warranted directly to the end
user by third party manufacturers, for example hydraulic cylinders, hoses, valves, or any other
portions of hydraulic kits used in Cascade Corporation products but not manufactured directly by it.
Failure to follow Cascade Corporation's or the third party manufacturer's recommendations for oil
pressure and ow ratings on hydraulic components will invalidate all warranty claims relating to both
the attachment and the hydraulic components of the attachment.
Cascade Corporation shall not be responsible for any problems associated with hose ttings,
damage or malfunction after installation regardless of cause.
This policy does not extend to those attachments or parts that have been altered or repaired by
others without the express written authorization of Cascade Corporation. Nor does it apply to
any Cascade Corporation products or parts, which in Cascade Corporation's opinion, have been
subjected to or adversely affected by operator misuse, accident, negligence, improper installation,
maintenance, or storage.
Cascade Corporation accepts no responsibility whatsoever for the suitability or otherwise of the
carrier machine of other equipment to which a Cascade Corporation attachment may be mounted
upon or tted to.
Cascade Corporation shall not be held liable for injury or damage caused to any persons, place
or machine by reason of the installation, use or mechanical failure of any Cascade Corporation
attachment.
General product wear and tear or pins and bushings wear and tear are not eligible for warranty
claims.
SECTION 6: WARRANTY

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WEDGELOCK OBLIGATIONS
At its option, Cascade Corporation may repair or arrange for the repair and/or full or partial replacement
of a defective part or attachment. Any repair work may be carried out at Cascade Corporation's own
premises, at the location of an authorized Service Agent/Dealer Workshop, on the site at which
the part or attachment is being used, or at any other location that Cascade Corporation considers
appropriate under the circumstances.
Under the terms of this warranty, Cascade Corporation's obligations are limited to the repair or
full or partial replacement of the defective item(s) and do not include any costs, direct or indirect,
associated with the removal or reinstallation of the attachment or part on the carry machine. This is
the responsibility of the Customer.
Cascade Corporation warrants that any repair work carried out by it directly shall be conducted
in a timely and professional manner. Where a third party is engaged to carry out repair work in
connection with a Cascade Corporation warranty claim, Cascade Corporation's obligation and
liability shall be limited to a refund of the authorized reimbursable costs charged in connection with
the provision of such work.
CUSTOMER OBLIGATION
The Customer is responsible for the proper and normal installation, operation and maintenance of
a Cascade Corporation-supplied attachment or part, including any hydraulic components or ttings.
The Customer is also responsible for notifying Cascade Corporation as soon as it identies a defect
or problem that may potentially be subject to a claim under this policy and for following Cascade
Corporation's published warranty claim procedure.
PLEASE COMPLETE AND REFER TO THE INFORMATION BELOW WHEN MAKING ENQUIRIES
FOR PARTS AND SERVICE:
Purchased From:______________________________________
Make & Model:________________________________________
Product Serial Number: _________________________________
Date of Manufacture:___________________________________
Date of Purchase:______________________________________
SECTION 6: WARRANTY

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7.0 WARRANTY REGISTRATION FORM
Once you have read and understood both the INSTALLATION and OPERATORS manuals
please complete and return this form by email to Cascade Corporation to ensure that your product
purchase is registered and covered under our standard warranty terms.
Send to: [email protected]
INSTALLER TO COMPLETE
I acknowledge that I have read and understood the Installation & Operator Manuals
MAKE AND MODEL OF CARRIER MACHINE
DATE OF INSTALLATION (DD/MM/YY)
PRODUCT SERIAL NUMBER
NAME OF INSTALLER
INSTALLER’S SIGNATURE
INSTALLER’S / CUSTOMER NAME AND ADDRESS
I acknowledge that I have read and understood the Installation & Operator Manuals
NAME OF OWNER / OPERATOR
OWNER / OPERATOR’S SIGNATURE
CUSTOMER NAME AND ADDRESS (if different from
above)
OWNER / OPERATOR TO COMPLETE
SECTION 7: WARRANTY REGISTRATION

PO Box 20187 • Portland, OR 97294-0187 • USA • 800 CASCADE (227.2233) • Tel [phone] • www.wedgelockusa.com
Cascade and Wedgelock are registered trademarks of Cascade Corporation.
© Cascade Corporation 2013. All rights reserved. Form 6827659 150 GE 2/12
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