Werk-Brau D-Lock Coupler User manual

Werk-Brau
D-Lock Coupler
Installation and Operation Manual
SERIAL NUMBER:
The D-Lock Coupler
(Fully Automatic with Dual Pin Locking)
International Patents pending
D-Lock Couplers are compliant ISO 13031
IMPORTANT:
The booklet should be kept with the machine at all times during and after quick coupler
installation. Machine operators must read and fully understand the operations manual before
use.

TABLE OF CONTENTS
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TITLE PAGE
Pre delivery check 3
Risk assessment 4
Important safety information 6
Product identification & decals 7
Installation 9
Operation 11
Maintenance 14
Parts List 21
Warranty policy 22
If at any time in the future, you require additional information on the D-Lock quick coupler or any aspects of its use,
please do not hesitate to contact:
WWW.DOHERTYDIRECT.NET

PRE DELIVERY CHECK
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Installation completed by:
Company:
Name:
Date:
Excavator make and model:
Coupler Serial #
End user name:
End user phone number:
End user address:
End user email address:
Lock circuit pressure checked at:
PSI
Unlock circuit pressure checked at:
PSI
Hose routings checked and abrasion free throughout full crowd movement:
All supplied attachments locked and unlocked from coupler:
All hydraulic connections, clean, tight and leak free:
Please specify type and brand of control valve fitted
NOTES:

RISK ASSESMENT
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This risk assessment form is supplied as a guide only. It is the responsibility of the owner / operator to ensure that this
equipment is operated in a safe manner and complies with all relevant compliance regulations.
Location of risk assessment:
Date:
Typical hazards associated with this
equipment
Personnel affected
Indicate in table below
Type
Operator
Site personnel
Service
personnel
General public
Changing Attachments
Is there a copy of the operations manual in the
machine cabin?
Has the operator been correctly trained for use
with this particular coupler and verified?
Is the operator aware they should not operate
this machine unless they are satisfied that the
coupler is in a safe condition?
Are all personnel aware that they must not
remain near attachments during attachment
changes?
Falling objects
Are all personnel aware that they must not
position themselves under attachments or
suspended loads?
Lifting equipment
Is the SWL rating of the equipment clearly
displayed?
Does all lifting equipment carry a current SWL
certification?
Warning devices and Decals
Are all safety and operations decals clearly
displayed?
Does the operator check that the equipment
warning devices are operational daily?
Equipment malfunction
Is there a checklist of daily, weekly, monthly
inspections?
Is there a record of all service / repair work?
Other hazards identified:
Plant & machinery movement
Warning devices on plant and equipment
Noise
Environment
Assessed by:
Reported to:
Name
Date
Name
Date

RISK ASSESMENT
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Daily pre start check list
Operators Name:
Date:
Coupler serial number:
S
M
T
W
T
F
S
Check all attachment pin retainer bolts and nuts for
tightness.
Check attachments for pin wear
Check all hydraulic hoses and fittings for any leaks or
wear
Clean away any material build up around cylinder guide
ways, spring apertures and the pin engagement
surfaces.
Weekly pre start check list
Thoroughly clean coupler
Week ending:
Check Coupler for evidence of fatigue, weld failure or
stress. Do not operate with a cracked weldment.
Repeat daily checks above.
Operators Name & Signature:
Managers Name & Signature:

IMPORTANT SAFETY INFORMATION
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The D-Lock range of Quick Hitch Couplers comply to AS4772-2008 standard for Earthmoving machinery –Quick
hitches (Couplers) for excavators and backhoe loaders AS4772-2008 Clause 2.1.4
Remember that on any job, YOU are the key to safety. Good safe practices not only protect the people around you;
they are also your own best protection. Study this section and any relevant manufacturer’s operation manuals
covering your equipment. Read all warning and caution instructions.
1. This manual must be READ and UNDERSTOOD before any installation and operation work begins. A copy must be
kept in the operator’s cabin for ongoing use.
2. Operators should note that the use of a quick coupler may affect the machine's breakout force and balance and may
result in attachments being able to come into contact with the boom set and or operator’s cabin.
3. Operators should note that the weight of the coupler is stamped on the ID Plate and this must be taken into account
which calculating the machine's lifting capacity.
4. Werk-Brau Engineered Attachments Couplers are designed for use with Werk-Brau Approved attachments only.
Approval must be obtained for use with non Werk-Brau attachments.
5. All D-lock couplers must be connected and installed in full compliance with this manual. Any variations may cause the
coupler to operate in an unsafe manner and/or void the warranty.
6. Due to the self-tightening and automatic wear compensation features of this coupler it is recommended that the locking
cylinder be disengaged at the end of each day.
7. The D-Lock Quick Coupler is designed to take up wear, however if mounting pin wear exceeds 5% of the original
diameter, immediately replace implement pins.
8. All excavator operators should familiarise themselves with all coupler/attachment combinations before attempting to
operate the coupler. This should include, but be not limited to, practicing engaging and disengaging each attachment.
Furthermore when new attachments are added to the machine’s fleet, the operators should proceed with the same
“familiarisation” process before it is used on the job site.
9. Never use the Coupler as a prying tool.
10. Never use the Coupler as a clamping device.
11. In the event of a loss of engagement failure, the Jaw Locking Pawls and compression units MUST BE
REMOVED AND REPLACED

PRODUCT IDENTIFICATION AND DECALS
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The locking system is based on the well proven sliding jaw design and incorporates a number of patented features to
ensure safe and secure operation. The most obvious of these are the instant automatic locking once the locking
cylinder is activated and the deliberate 4 digit pin required for unlocking activation which eliminates unintentional or
accidental loss of engagement.
Operator maintenance is restricted to weekly cleaning of the coupler to ensure no excessive build-up of material on the
interior or pin engagement surfaces.
All D-Lock Couplers are supplied with an ID plate attached as shown below. In addition, a serial # is stamped into the
top edge of the Left Hand mounting plate.
Serial # stamped here
It is recommended that a copy of these details be kept in the office for future reference.
Always quote these details when contacting Werk-Brau Engineered Attachments for Service or Parts.
In addition your Werk-Brau Engineered Attachments may be fitted with a number of SAFETY and MAINTENANCE
DECALS. These decals must be kept clean, in good condition and be visible from a distance of 3 meters.
Replacements for damaged decals may be obtained from your dealers parts department.
The D-Lock Coupler also requires that the following OPERATOR DECALS be fitted by the Installer in the machine's
cabin. These must be clearly visible from the operating position and maintained in a clean and legible condition. These
decals will be supplied in the same pouch as this manual –please check that all are included. Replacements for
damaged or missing decals may be obtained from the Werk-Brau parts department.
SWL stamped here

PRODUCT IDENTIFICATION AND DECALS
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Contact warning decal:
Operation decal:

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IMPORTANT INSTALLATION NOTES
Due to the large number of Excavator Makes and Models available, it is not possible to provide a rigid set of
installation instructions that will cover every situation. Modern Excavator control systems are complex and
sophisticated. Auxiliary connections must be carried out with care to ensure the manufacturer’s warranty is
not voided. It is therefore extremely important that only appropriately qualified and experienced persons
carry out the installation. It is STRONGLY RECCOMENDED that the excavator dealer be consulted to
ensure the auxiliary connections are correctly made.
Installation personnel must be competent and experienced in this type of work.
Best hydraulic practice will be used to ensure that all components remain clean and free of contamination
and that all hoses are suitably routed and armoured to prevent, crushing, pinching or chaffing damage.
The requirements detailed in this publication must be fully understood and complied with.
No changes to the host machine's control systems should be made without express agreement by the
manufacturer and or distributor.
All current Health and Safety Regulations pertaining to this installation and subsequent operation must be
complied with.
Contact Werk-Brau for additional assistance, if required.
Failure to comply with these guidelines may cause equipment damage and/or void any applicable warranty.
FITTING THE COUPLER
1. Remove any existing attachments from the machine. Some models of Werk-Brau couplers are supplied with purpose
designed hardened mounting pins. If these are not supplied, the coupler is mounted using the OEM pins which were
supplied with your machine.
2. NOTE Hardened pins MUST be used for this application do not use non hardened attachment pins.
3. CLEAN all bores and pin surfaces, pre-lubricate pins with grease and set aside on a clean surface.
4. Carefully align the link arm between the two bosses, which are furthest from the cab of the machine. Ensure the O-
rings are correctly positioned and fit one pin.
Lower link to
align bores
Raise arm and
retract link to
align dipper
arm and bore
link to align
bores

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5. You can now lift the coupler off the ground and use the crowd and arm controls to accurately line up the main dipper
arm bore. Position the O rings and fit the second pin.
6. Ensure the pin retaining bolts are fitted and tightened. Use nyloc lock nuts or supplied bolts for Werk-Brau supplied
pins.
7. Grease up both pivot points as required.
8. Using the excavator hydraulics, carefully crowd the quick coupler to the extremes of the crowd travel and check that
there is adequate clearance between the coupler and the dipper arm surfaces and linkages.
Note
Your coupler may be supplied with optional front clipper plate profiles. These are not essential but they can be
welded to either side plate to take up the gap between the coupler and attachment. Locate by offsetting
approximately 10mm from the front pin.
CONNECTING THE COUPLER LOCK CIRCUIT
ELECTRICAL & HYDRAULIC INSTALL
Refer to one of the following installation documents depending on the hose kit you received.
1. BR6-BR7**** for machine specific hose kit.
2. Any other hose kit must be approved in writing by Werk-Brau.
FINAL CHECK
1
Verify all fittings and fasteners are tight and secure.
2
Check the entire system for leaks.
3
Move the Coupler through its entire motion slowly checking for:
Hose chaffing
Proper hose lengths
Any type of mechanical interference.
4
Test the D-Lock switch, ensure alarm sounds and light flashes when in unlock
mode.
5
Attach and detach all attachments to be supplied with the machine and ensure
coupler locks securely.
6
Ensure that all product and cab decals are correctly fitted and visible.
7
Complete Warranty registration and Pre-delivery forms and return to Werk-Brau
Engineered Attachments to activate warranty.
8
Ensure the this manual (or a copy) is kept in the operator’s cab
Additional copies of this manual are available in hard copy or electronic form
from Werk-Brau Engineered Attachments.