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1. WERK BRAU CO INC Generic Quick Coupler Lock Kit Installation Instructions For Pilot Operated Loaders 12V System Technical Support Hotline 800 537 9561 TABLE OF CONTENTS GENERAL SAFETY GUIDELINES FOR INSTALLING THE KIT 3 BEFORE STARTINGTHERKITINSTALLATION Ah IL eg DARE E ENEE ORING PACE SEAL CONNEC TIONS E STANDARD TIGHTENING TORQUE e PRECAUTIONS BEFORE WEDDING Eeer Eegen CONTROL V AL V E DT 11 ENTREE 22 Hydraulic Schematic and Electrical Wiring Diageram 13 APPENDIX B REUSABLE HOSE AND HOSE ENDS 19 CUSTOMER FEEDBACK FORM REENEN Total Number of Pages 20 Page 2 GENERAL SAFETY GUIDELINES FOR INSTALLING THE KIT e Read the instruction manual thoroughly to familiarize yourself with the kit before installing it Deviating from the drawings and or instructions in this manual may result in increased installation time and or damage to hydraulic kit machine or attachment e Follow proper procedures as specified in the Service Manual for your machine In case of discrepancies in guidelines between the Service Manual and our kit instructions the manufacturer safety instructions take precedence especially regarding the welding instructions e Use safety protection such as hardhat working gloves safety shoes and safety glasses as needed to do the job e2. OTM POA OTM Jg anm ong 2908 8 poSeSug Ajamnoog st quouypeny sey roodsuy AIIEnSIA pow Sut8eSu st Q ONIDVONASIA LAVIS aBeure urqogl 10 Amnfuy song gea ur MSY ABW Og oq 0 amje asn ag enuey sJorerodg 1 ldnoO ur suononnsuT Sunerodo peoy SuTure AX XO8 TOALNOD YH1dNOO xog Jomuod TT 10 90 ALVA ZI ANN AM ON Sud weIgerq ZUM pue 10023 oneIpAH HA WRG anm ong Page 13 FINISH AND TEST e Before starting this section position the machine in the oil level check position as suggested by the loader manufacturer Check the oil level sight gauge on the hydraulic tank to ensure that the machine has enough hydraulic oil Add hydraulic oil use only loader manufacturer recommended grade if necessary e Check again for proper hose movement and routing then tighten all clamps hoses and fittings e Paint brackets and clamps to match the excavator e Make sure the hoses are connected to the coupler lock cylinder e Run the machine at idle or at a low engine rpm setting to supply a low volume of oil through the circuit and also to keep the noise levels low Activate the circuit and check for any leaks Be ready to shut down machine immediately in case of leaks When shutting down the machine it is important to turn the engine rpm dial setting to idle and shift the pilot safety lock lever to the lock position Tighten fittings and hoses as necessary e Clear all personnel from the area and all obstac
3. Always clean parts in a well ventilated area Cover the cylinder rods and glass for protection against welding spatter Protect any wiring harnesses in the vicinity e Clean welding areas of any combustible materials like dried leaves hydraulic oil etc e Clamp the ground cable from the welder directly to the component that will be welded If this is not achievable place the clamp as close as possible to the weld Make sure the electrical path from the ground cable to the component does not go through a bearing Page 8 SYSTEM OVERVIEW e This instruction manual describes the installation of the hydraulic kit that will operate the Werk Brau coupler on a pilot operated Loader This hydraulic circuit uses pilot pressure 500 600psi to lock and unlock the coupler e The coupler attaches onto various tools by hooking the front pin and then rotating a locking device under the rear pin of the attachment The lock is self adjusting so no adjustments are needed While engaged the lock is securely held in place by the cylinder and dual extension springs In the event of hydraulic failure the coupler s safety lock will enable the coupler to hold the attachment e To disengage unlock the coupler position the machine as described in the Operation and Maintenance manual also supplied with this coupler Remove the safety pin and turn the toggle switch in the unlock position Follow the steps to safely remove the attachment e Wi
4. Lower the bucket or any attachment to the ground e Itis very important to relieve the hydraulic tank pressure before loosening any connections or hoses Follow proper procedures as specified in the Service Manual for your machine e Be careful while handling hot parts on machines that have just been shut down The hydraulic fluid in the lines tubes and components are very hot and could cause severe skin burns It is advisable to allow hydraulic oil to cool down before removing any lines fittings tubes or plugs on machines e Kit installation procedures outlined in this instruction manual have been arranged to keep the hydraulic oil spills to a minimum However during kit installation oil spills are unavoidable and should be contained using rags absorbent towels or containers buckets Dispose of all waste oils fluids lubricants and other hazardous waste properly If there is an oil spill on the floor use liberal amounts of oil dry to avoid slippery conditions e Once installation in complete check and tighten all fittings and hoses before activating the circuit e Use a piece of cardboard to check for oil leaks in the circuit in order to prevent contact with high pressure oil Page 3 BEFORE STARTING THE KIT INSTALLATION Check to make sure this installation kit is correct for your excavator and or attachment Check the excavator information against kit description If there are any concerns or discrepancies please contac
5. the line big enough to tap 1 4 NPT Remove the fitting tap the hole and clean the piece thoroughly Reinstall the fitting and install NPT adapter 3 e Measure the required length of hose 1 to reach from the valve mounting location to the blocks on the loader arms Page 11 Lock Note Use hose 1 with reuseable ends 11 as necessary to connect ports A amp B to the coupler cylinder Existing Tank Hose Unlock Coupler Ports Note Use hose 1 with reuseable ends 11 as necessary to connect ports A amp B to the coupler cylinder A 4 T ZZ a B Er Existing Pilot Hose To Pilot Pressure Output This is the property of hydraulic kit manufacturer and shall not be altered copied used for manufacturing General Overview or duplicated to any other person or company without our written permission Dwg No WB UNVLDRPL12 D DATE 12 29 11 Drawing By AK Approved By B M B Mount the Coupler Lock Valve 1 in the control valve compartment See Figure 2 Appendix C for details iv Ag poaoiddy HD Ag Surmeiq uorssruu d upm INO jnoyjim Auedwos Jo uosiod 19440 Aue o poyeorjdnp Jo SuLMovsnueUl Joy p sn pordoo posae aq jou gus pue Jomnjovjnuewl yy ornespAy Jo Ayrodord oy st sty
6. ER HOSES e Install the straight adapters 14 or 4 and 90deg swivel 12 if required to the ports on the coupler lock cylinder e Measure the required length of hose 1 to reach from the cylinder fittings to the loader arms There will be blocks 2 with adapters 14 welded to the loader arms to act as a junction block and support for the hoses The block location should be determined by moving the arms throughout the full range of motion Watch the hoses curl and fall and then use the blocks to support and route the hoses to keep them out of harms way Use reusable hose ends 11 with cut length of hose Refer to Appendix B for details on hose assembly e This may require adjustments so clamp or tack weld the blocks 2 in place Do not finish weld until all hoses have been checked for pinching or binding e Leave a small amount of slack in the hoses to allow for cylinder movement while locking and unlocking e The remaining hoses connections will use the hose 1 with reusable hoses ends 11 e Measure the required length of hose to reach from the blocks to the valve mounting location near pilot pump as described in the next section of this manual e Connect the hoses to the blocks and route them up the loader arms Be sure to allow enough hose in the pivot areas of the machine Use the hose clamps 9 and wire ties 8 to secure the hoses to the machine existing blocks tubes and hoses e Ifusing the clamps 9 first tack weld the bases
7. ER LOCK KIT BOM NUMBER WB UNVLDRPL12 D REV DESCRIPTION Werk Brau Pilot Loader 12V Item Part No Description Qty 0016 M 4703 A Y1 2552 M10H Mount 1 0017 M 4438 WH HE1 CB 1 0018 Z 5026 Shipping Crate No Runners 1 Refer to Appendix A Page 16 APPENDIX A Use Appendix A to help determine whether a metal retaining ring should be used around the o ring when installing BSPP British Standard Parallel Pipe adapters BSPP o ring ports are made to either British BS or Japanese JIS standards Both feature a 55 flank angle and British Whitworth thread profile but use different sealing methods BSPP Ports to JIS Standards These ports have an o ring gland as shown in the picture below The o ring on the adapter seals in the o ring gland In this case it will be necessary to remove the metal retaining ring around the o ring on the adapter before installing it to the port in order to ensure proper seal O ring Gland E BSPP PORT TYPE 1 DO NOT USE RETAINING RING Figure 1 Cut Section of BSPP Port Type 1 Appendix A Page 17 BSPP Ports to BS Standards These ports do not have an o ring gland The o ring on the adapter seals on the port surface or spotface as shown in the picture below In this case it will be necessary to use the metal retaining ring around the o ring on the adapter before installing it to the port in order to ensure proper seal BSPP PORT TYPE 2 REQUIRES RETAIN
8. ING RING Figure 2 Cut Section of BSPP Port Type 2 Appendix A Page 18 APPENDIX B Step One Identify the overall length OAL of the hose assembly and subtract 25mm 1 inch to account for the hose end Properly measure mark and cut the hose to the desired length using a fine tooth hacksaw or a cut off machine Finish Step One by dipping the hose end into heavy oil Step Three Dip the hose end of the nipple into a heavy oil up to the hex Step Two Place the socket in a vice and screw in the hose counter clockwise CCW until the hose bottoms Back the hose out L of a turn Step Four Screw the nipple assembly into the socket using a wrench on the nipple hex until the nipple hex shoulders against the socket Page 19 WERK BRAU CO INC Reference 237046 Customer Feed Back Form At WERK BRAU we continually strive to provide the highest quality product We feel there is no better opinion than that of the customer This is why we ask that you take a few minutes to complete the form below and fax it back to us at 770 692 6978 Thank you for your time and effort in helping us provide the highest quality product possible Purchaser User Name Address Phone Fax Customer Feedback Did all components and or parts fit well Did the kit fit well overall Was the installation easy simple Were any modifications necessary Were the in
9. h resistance is reached Tighten further to the appropriate F F W R value shown in Table 1 Using a Torque Wrench is the preferred and suggested method and should be used whenever possible Page 6 STANDARD TIGHTENING TORQUE The following Table gives the standard tightening torques of bolts This applies to mounts tube clamps split flange clamps and any other bolts provided with this kit It is important to follow this chart when installing bolts and nuts Failure to do so could result in premature failure damage to components or even serious injury NOTE Nm Newton meter INm 0 102 kgm 0 737 Ib ft Standard Tightening Torque Of Metric Bolts Bolt O D x Pitch mm Metric Class 10 9 kgm Nm lb ft M6x1 1 3 0 15 13 54 1 5 10 1 M8x1 25 3 2 0 3 32 2 3 5 24 2 6 M10x1 5 6 5 0 6 63 6 5 47 4 8 M12x1 75 11 1 108 11 80 8 M14x2 17 5 2 172 18 127 13 M16x2 27 3 268 29 198 22 M18x2 5 37 4 366 36 270 26 Page 7 PRECAUTIONS BEFORE WELDING e NOTE These techniques are a general guideline only If the excavator manufacturer has published welding guidelines use them instead e Turn off the engine and disconnect the battery e Protect all areas in on and around the machine with a flame resistant covering during grinding and welding operations Use proper solvents to clean parts for welding
10. in place Once the location is finalized remove the hoses and finish weld the bases e Install hoses and check for correct alignment and routing Operate the machine and observe hose movement throughout the whole range of motion of the loader arms There must be no binding or strain in any of the hoses Make adjustments as necessary Page 10 CONTROL VALVE e Locate a good mounting location for the coupler lock valve 6 near the pilot pump outlet line The mount 16 can be bolted or welded in place If welding first tack weld the mount 16 Remove the valve 6 before finish welding the mount as welding heat will damage the valve seals e Locate a hose at the pilot pump outlet port Disconnect the hose at the pump and install the tee 10 Reconnect the existing hose to one end of the tee Measure the appropriate length of hose 1 to connect the P port on the valve 6 to the pilot line tee and cut to length Install the hose ends and connect the hose Refer to Appendix B for details on hose assembly e Locate an existing JIC 06 3 8 tank line Disconnect the existing hose and install tee 10 Reconnect the existing hose to one end of the tee 10 Measure the appropriate length of hose 1 to connect the T port on the valve 6 to the tank line tee and cut to length Install the hose ends and connect the hose Refer to Appendix B for details on hose assembly e NOTE If the tank line is not 3 8 JIC locate a fitting in
11. les in the path of the machine Operate the machine only when seated in the host machine Keep the coupler close to the ground e Activate the lock and unlock circuits several times to ensure that the system locks and unlocks with ease Follow the instruction booklet manual supplied with the coupler attachment for using different work tools e It is advisable to join the two sides of the circuit together at the end of the stick and activate the LOCK and UNLOCK circuits for a couple of minutes to flush the system off any contaminants introduced during kit installation e In order to reduce the risk of serious injury it is advised to follow any and all safety procedures as specified in the coupler operation and safety manual Page 14 COUPLER LOCK KIT BOM NUMBER WB UNVLDRPL12 D REV DESCRIPTION Werk Brau Pilot Loader 12V Item Part No Description Qty 0001 Z 3990 SAE100R2 3 8 ID Hose 100 0002 M 4694 1 5x1 5x1 5 DT 06 2 0003 Z 2343 90 degree adapter 1 0004 Z 2104 Straight Adapter 2 0005 Z 5067 Logic Control Box QCL 1 0006 Z 5593 4 Port PL 12V Valve 1 0007 D 0018 WB Warning Decal 1 0008 Z 1152 Wire tie 25 0009 Z 5073 Twin Hose Clamp 3 0010 Z 1746 Tee 2 0011 Z 3991 3 8 FJIC Reusable End 302 14 0012 Z 1730 90 degree swivel elbow 2 0013 Z 1992 45 degree swivel elbow 2 0014 Z 1703 Straight Adapter 6 0015 INSTALLATION INSTRUCTIONS 1 Refer to Appendix A Page 15 COUPL
12. ns These specs must be followed to prevent damage to the threads and flare seat Page 4 JIC 37 FLARE CONNECTIONS The 37 JIC Voint Industrial Council flare is a reliable straight thread flare design that is used world wide It is popular in many applications and environments because it is compact and easy to assemble Since it is a metal to metal seal it can be reliably connected and reconnected multiple times The assembly may or may not include a sleeve Figure 1 Female Swivel without Sleeve EON WU Sleeve i a Figure 2 Female Swivel with Sleeve Nominal Dash Torque Value See Size Size Ib in N m A 4 130 150 15 17 2 38 6 235 265 27 30 4 1 4 4 2 8 525 575 59 65 1 5 8 10 600 700 68 79 1 3 4 42 950 1050 107 119 1 4 46 1400 1500 158 170 1 4 1 4 20 1900 2100 215 237 1 4 1 2 24 2250 2550 254 288 1 Note 1 The Flats From Finger Tight F F F T method counts the number of hex flats past the finger tightened position a Visually inspect the threads to make sure they are clean b Hand tighten the female swivel nut onto the male thread c Make alignment marks on the nut and fitting d Proceed to tighten to F F F T value 2 These torque values are given for components without lubrication Do not use oil on the threads before tightening 3 Dash number represen
13. structions clear and concise Were the drawings clear and concise Do you have any suggestions to improve the installation of this kit YES NO YES NO YES NO YES NO YES NO YES NO Comments Comments Kit Number WB Base Machine Make Model Serial Number Installation Time hours Comments Comments Comments Comments Comments Rev 051608 Page 20
14. t the kit manufacturer immediately Open crates boxes to take inventory of parts Compare them with the Bill of Materials to make sure no parts are missing Please note that to reduce installation time some components are pre assembled before shipping In case of any discrepancies contact kit manufacturer immediately Read instructions manual to familiarize yourself with the installation kit For the purpose of kit installation it is a safe practice to have the machine on a level surface Swing the machine housing to get access to the panels under the cab for installing the pilot circuit components Jr will be necessary to remove the panels under the cab for this purpose Shut off engine If the machine has just completed work then allow sufficient time for cooling before opening any lines Make sure there are enough rags absorbent towels and or containers available Disconnect battery Remove the negative ground terminal connection Release pressure from the hydraulic tank Flow meter and pressure gauges will be required to complete the Finish and Test section of this installation Steel brackets mounts are protected from corrosion using primer or optional powder coating It may be necessary to paint these to match the excavator color after completing installation and checking all hoses for binding pinching Ensure there is enough factory paint available to do so Refer to the following pages for the proper specifications for all connectio
15. th the toggle switch still in the unlock position position the machine to pick up the next attachment Follow the steps to safely connect to the new attachment Turn the switch to the lock position and wait several seconds for the lock to fully engage Now install the safety lock pin with lynch pin in the rear of the coupler to fully lock the attachment in place e THE SAFETY LOCK PIN MUST BE INSTALLED AT ALL TIMES DURING USE OF THE COUPLER Failure to install the safety pin could result in severe injury or death Once installed it insures the operator that the lock is properly seated under the pin because the safety pin lock cannot be installed if the lock is only partially engaged The Safety Lock Pin will also prohibit inadvertent disengagement e Before operating a machine with a Werk Brau coupler visually check that the lock is properly positioned with the rear pin and the safety lock pin is properly installed e To confirm that the coupler and attachment are properly connected set the attachment on the ground and rotate in a dumping motion until the tracks come off the ground Do this EVERY time an attachment is changed e Never lift an attachment off the ground until all steps have been completed to confirm safe and proper connection e NOTE Pictures and diagrams throughout this manual may not be your exact Werk Brau coupler The pictures represent an action or a setup required for installation and operation Page 9 LOAD
16. ts the size in sixteenths of an inch Compiled on 03 04 2005 Rev A Page 5 O RING FACE SEAL CONNECTIONS The O ring Face Seal connection is one of the most reliable leak free connections available on the market today for mobile hydraulic applications The use of an elastomeric seal o ring as apposed to a metal to metal connection has many advantages It is very resistant to vibrations or pulsations in the system The connection can be assembled and dismantled many times without compromising the integrity of the connection It is important to note that because the connection is dependent on the o ring some simple precautions must be taken The o ring and fitting must be visually inspected before the connection is made If the o ring or o ring groove is nicked bent warped cut or otherwise damaged it must be replaced immediately Use a minimal amount of grease to install the o ring into the groove paying careful attention that it is seated properly Take care not to get grease on threads The o ring will be permanently damaged if it is not seated properly and the connection will leak 4 1 2 to 3 4 1 2 to 3 4 1 2 to 3 4 1 2 to 3 4 1 3 to 1 2 1 3 to 1 2 1 3 to 1 2 1 3 to 1 2 Table 1 ORFS Torque Specifications Note 1 If a Torque Wrench is not available an alternate method of assembly is the Flats From Wrench Resistance F F W R Tighten the nut onto the fitting body until light wrenc
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