Werk-Brau WERBR-LK24 User manual

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WERK-BRAU CO., INC.
PRODUCT AND
INSTALLATION MANUAL
Loader Coupler Hydraulic Kit
(WERBR-LK24 –12/24V Kit)
Serial No:
Model No:
Date Manufactured:
PROUDLY MANUFACTURED IN FINDLAY, OH
W erk-Brau.com

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TABLE OF CONTENTS
P.O. Box 545 Findlay, Ohio 45839-0545
1-800-537-9561 phone
419-422-7207 fax
W erk-Brau.com
TITLE PAGE
General Safety Guidelines for Kit Installation 3
Before Starting the Kit Installation 4
JIC 37° Flare Connections 5
O-Ring Face Seal Connections 6
Standard Tightening Torque 7
Precautions Before Welding 7
System Overview 8
Troubleshooting 8
Schematic 9
Loader Hoses 10
Control Valve 10
Finish and Test 11
If at any time in the future, you require additional information on this product or any aspects of its
use, please do not hesitate to contact Werk-Brau Co., Inc.

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General Safety Guidelines
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 the 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 welding instructions.
Use safety protection such as a hardhat, working gloves, safety shoes and safety glasses as
needed to safely do the job.
Lower the bucket or any attachment to the ground prior to any work being completed.
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, tubes and compartments 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 the machine.
Kit installation procedures outlined in this instruction manual have been arranged to keep
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.
Once installation is 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.

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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 the kit description. If there are any concerns or
discrepancies, please contact the kit manufacturer immediately.
Open crates/boxes to take inventory of parts prior to installation. 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
the kit manufacturer immediately.
Read the instructions manual to familiarize yourself with the installation kit.
For the purpose of this 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 for any spilled
fluids.
Disconnect the 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.

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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 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
Nominal
Size
3
Dash
Size
Torque Value
2
1
F.F.F.T
I b-in
N-m
1/4"
-4
130-150
15-17
2
3/8"
-6
235-265
27-30
1-1/4
1/2"
-8
525-575
59-65
1
5/8"
-10
600-700
68-79
1
3/4''
-12
950-1050
107-119
1
1"
-16
1400-1500
158-170
1
1-1/4"
-20
1900-2100
215-237
1
1-1/2"
-24
2250-2550
254-288
1
Note: 1. TheFlats 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.

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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 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.
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.

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Standard Tightening Torque
Precautions Before Welding
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): 1Nm = 0.102 kgm = 0.737 lb. ft.
NOTE: These techniques are a general guideline only. If the loader manufacturer has
published welding guidelines, use them instead.
Turn off 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.

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System Overview
Troubleshooting
This instruction manual describes the installation of the hydraulic kit that will operate the
Werk-Brau Loader coupler on a pilot operated Loader. This hydraulic circuit uses pilot
pressure
(Min. 300 PSI / Optimal 500 PSI / Max. 1,500 PSI) to lock and unlock the coupler.
The coupler attaches onto various designated coupler series. Examples: J416, 418, 420, A30,
60, ISO, Etc.
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 the 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.
Never lift an attachment off the ground until all steps have been completed to confirm a safe
and proper connection has been made.
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.
Coupler will not function at all from start.
-Double check hoses are routed correctly, most likely positions 2 & 4 are switched (shown on
page 9).
Coupler will not disengage.
-Double check valve. The solenoid may have been shorted out or does not have enough
power to actuate.
Coupler will not disengage.
-Double check the voltages on the machine and valve match.

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Schematic
Note: Number on valve match up
with numbers on diagram.
1 = Pilot Side
2 = A or base end of cylinder
3 = Tank
4 = B or rod end of cylinder
Pilot
Connect to manifolds on
coupler or cylinder jumper
connection.

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Loader Hoses
This kit contains varied pre-made lengths of hoses at 48, 72, 96 and 144 inches.
The figure on the previous page shows 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 manifold fittings and the other end of the hoses to the fittings on the block
assembly on the stick.
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.
Leave a small amount of slack in the hoses to allow for cylinder movement while locking and
unlocking.
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
neither the bucket cylinder nor do the linkages come in contact with the junction block.
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 loader arms. 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.
Control Valve
Locate a good mounting location for the coupler lock valve, near the pilot 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.
Locate an existing JIC 06 (3/8”) tank line. Disconnect the existing hose and install tee.
Reconnect the existing hose to one end of the tee. Measure the appropriate length of hose to
connect the “T” port on the valve to the tank line tee and cut to length. Install the hose ends
and connect the hose.
Measure the required length of hose to reach from the valve mounting location to the blocks
on the stick.