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1. WERK BRAU CO INC WERBR DLOCK Generic Quick Dual Lock Coupler Kit Installation Instructions For 12 24V Pump Operated Excavators This is a Generic kit meaning the goal is to supply 95 of what you need but you may need to supply purchase a hose fitting or etc to complete this kit Technical Support Hotline 800 537 9561 File WERBR DLOCK Page 1 12 GENERAL SAFETY GUIDELINES FOR INSTALLING THE KIT 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 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 Use safety protection such as hardhat working gloves safety shoes and safety glasses as needed to do the job Lower the bucket or any attachment to the ground It is 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 Be careful while handling hot parts on machines that have just been shut down The hydraulic fluid in the lines tub2. 9090 06 06 06 Z 24 20 HOSE sk 4R16 6FJX 6FJX 120 2 25 INSTRUCTIONS AND STICKERS DUAL LOCK INSTRUCTIONS DER DER USE AS NEEDED
3. 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 It 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 connections These specs must be followed to prevent damage to the threads and flare seat File WERBR DLOCK Page 3 12 JIC 37 FLARE CONNECTIONS The 37 JIC Joint Industrial Council flare is a reliable straight thread flare design that is used world wide It is popular in many applications an
4. advised to follow any and all safety procedures as specified in the coupler operation and safety manual File WERBR DLOCK Page 11 12 RE DATE CHANGE DESCRIPTION BY CHECKED A 00 1014 RELEASED TO PRODUCTION SJF GJS WERBR DLOC K24 WERBR DLOC K1 2 B 09 11 14 ADDED EXTRAS TO KIT C17 19 20 21 22 23 SJF GJS C 09 25 14 H ADDED HOSE CLAMPS TO KIT S GJS ami Aa sted n perma r a P DESCRIPTION PART av l 48 HOSE w GUARD AR16 6F JX 6F JX45 48 w PWLD 2 2 96 HOSE 4R1 6 6F JX 6F JX 96 2 SS 3 72 HOSE 4R16 6F JX 6FJX 72 2 4 144 HOSE AR 16 6F JX 6F JX 144 4 5 WIRE TIES 11 75 UV 1000 30 6 O6JIC MALE O40RB MALE 6400 06 04 6 7 O6JIC MALE O60RB MALE 90 6801 06 06F 6 8 O6JIC MALE O60RB MALE 6400 06 06 4 9 O6MJ 06MJ STRAIGHT 2403 06 06 6 0 OBJICMALE O6JICFEMALE 90 SWIVEL 6500 06 06 l l BRACKET 15019049 l 2 1 4 20x1 3 4 BOLT 0115010 2 3 4 WASHER 1133004 2 4 174 20 NYLOCK NU 1137183 2 J ANT FOLD 15019050 or MN 2 J 6 24 VOLT 12 VOLT VALVE SV58 40 61D P 24DS or 1205 7 WB CONTROL BOX SWITCH E 3CS 1 8 HOSE CLAMP T2004H S 4 9 OBJIC MALE 06JIC FEMALE 9220 06 06 2 20 O6JISMALE O6JISMALE O6JISFEMALE SWIVEL 929 1 06 06 06 2 21 O6JIC MALE O6BSPP MALE 9002 06 06 2 22 O6JICMALE O6JICMALE O6JICFEMALE SWIVEL 6602 06 06 06 2 23 O6BSPPMALE OGBSPPMALEB OGBSPPFEMALE SWIVEL
5. ant 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 Nominal Size a Assembly Torque ft lb N m 1 2 to 3 4 30 40 1 2to3 4 40 55 1 2to3 4 60 8 Z1 2to3 4 34 2 8 15 1 3to12 x 4 e 110 150 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 wrench 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 File WERBR DLOCK Page 5 12 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 installi
6. ble check valve solenoid may have been shorted out or not enough power to eCoupler will not disengage gt Double check voltages match on valve and machine File WERBR DLOCK Page 7 12 TYPICAL DUAL LOCK CONTROL CIRCUIT Coupler Cylinder Note Numbers on valve match up with numbers on diagram So PCO1 Check J 1 Pump Side Unlock 2 Aor base end of cylinder 3 Tank 2 A 4 B or rod end of cylinder AAA V W l V Control a sities I Must be linked to bkt cyl circuit gt o I Pump TANK STICK AND BOOM HOSES This kit contains varied premade lengths of hose at 144 96 72 and 48 Figure show a generic installation for illustration purposes only Install the straight adapters to the ports on the coupler lock cylinder Connect the 48 hoses to the coupler lock cylinder fittings and the other end of the hoses to the fittings on the block assembly on the stick Install the live swivel and the adapter to the ports on the block The block is located close to the end of the stick Let the hoses dictate the best mounting location Curl the bucket in as far as possible and let this suggest the mounting location of the blocks This may require adjustments so clamp or tack weld the block in place Do not finish weld until all hoses have been checked for pinching or binding File WERBR DLOCK Page 8 12 Leave a small amount of slack in
7. d 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 mil as Figure 1 Female Swivel without Sleeve Figure 2 Female Swivel with Sleeve ra Sat eee ee Tr a se o momo ra 1 HACI e e ioo 198170 oo ea eooo zear tam ar aoaea assaee _ 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 represents the size in sixteenths of an inch File WERBR DLOCK Page 4 12 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 opposed 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 import
8. es 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 Kit installation procedures outlined in this instruction manual have been arranged to keep the hydraulic oil spills to a minimum However during kit installation o1l 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 Once installation in complete check and tighten all fittings and hoses before activating the circuit Use a piece of cardboard to check for oil leaks in the circuit in order to prevent contact with high pressure oil File WERBR DLOCK Page 2 12 BEFORE STARTING THE KIT INSTALLATION e 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 contact 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
9. h hydraulic oil Add hydraulic oil use only excavator manufacturer recommended grade if necessary Clear all personnel from the area and all obstacles in the path of the machine Operate the machine only when seated in the host machine Keep the coupler close to the ground Check again for proper hose movement and routing then tighten all clamps hoses and fittings 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 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 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 In order to reduce the risk of serious injury it is
10. le WERBR DLOCK Page 9 12 CONTROL VALVE Locate a good mounting location for the coupler lock valve near the pump outlet line The mount can be bolted or welded in place Locate the hose at the pump outlet port Disconnect the hose at the pump and install the tee Reconnect the existing hose to one end of the tee Measure the appropriate length of hose to connect the P port on the valve to the pilot line tee e Locate the 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 Measure the required length of hose to reach from the valve mounting location to the blocks on the stick Use sections of E 3CS Control Box Switch Locate E 3CS switch box and install in a safe place inside the cab preferably window Run wires accordingly 1 Hitch Valve Cail red 2 Hitch Valve Coll black R use 5 amp 4 Ignition Switch red orange 3 Earth black File WERBR DLOCK Page 10 12 FINISH AND TEST Before starting this section position the machine in the oil level check position as suggested by the excavator manufacturer Check the oil level sight gauge on the hydraulic tank to ensure that the machine has enoug
11. ng 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 Metric Class 10 9 Bolt O D x Pitch mm kgm tbat MOxt 1 3 0 15 13 5 1 5 PRECAUTIONS BEFORE WELDING e NOTE These techniques are a general guideline only If the excavator manufacturer has published welding guidelines use them instead Turn off the engine and disconnect the battery 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 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 Clean welding areas of any combustible materials like dried leaves hydraulic oil etc 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 File WERBR DLOCK Page 6 12 SYSTEM OVERVIEW This instruction manual describes the installation of the hydraulic kit that will operate the Werk Brau Dual Lock coupler on a pump operated excavator This hydraulic circuit uses pilo
12. t pressure Optimal 3 500 PSI Min 2000 PSI Max 4 500 PSI to lock and unlock the coupler The coupler attaches onto various tools by hooking the front pin and then sliding 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 In the event of hydraulic failure the coupler spring check valve and ratchet system will keep the coupler engaged To disengage unlock the coupler position the machine as described in the Operation and Maintenance manual also supplied with this coupler Before operating a machine with a Werk Brau coupler visually check coupler for any issues such as cracking missing bolts leaks etc 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 Trouble Shooting e Coupler will function at all from start gt double check hoses are routed correctly most likely 2 and 4 a switched e Coupler will not disengage gt Dou
13. the hoses to allow for cylinder movement while locking and unlocking e Next move the bucket to its fully dump position to ensure that the hoses don t bind or pinch This is a good time to cycle the bucket throughout its full range of motion to ensure that bucket cylinder nor do the linkages come in contact with the junction block e NOTE It is important to understand that some rubbing on the top and sides of the stick will be unavoidable Measure the required length of hose to reach the valve mounting location as described in the next section of this manual Unions have been provided to prevent the need to have one long hose from the stick to the valve This is an installer preference only and will not affect the function of the circuit Connect the hoses to the blocks and route them up the stick Continue routing the hoses up the boom and over the gooseneck section Be sure to allow enough hose in the pivot areas of the machine Use the hose clamps and wire ties to secure the hoses to the stick boom and existing hoses If using the clamps first tack weld the bases in place Once the location is finalized remove the hoses and finish weld the bases Install hoses and check for correct alignment and routing Operate the machine and observe hose movement throughout the whole range of motion of the stick and the boom There must be no binding or strain in any of the hoses Make adjustments as necessary Fi
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