Home

MSD Saber Series User Manual

1. 1 2 een ee PM EE 1 3 Attachment Decals REM 1 5 SECTION 2 ABOUT THE ATTACHMENT ID CS CHO ua asan a ta one meet coral Gonna LI TIU 2 2 i e M 2 2 Attachment ua 2 3 2 4 Flow and Pressure Requirements sss 2 7 SECTION 3 INSTALLATION Shear NIGu ti g sab 3 2 Mobile Shear Start Up Procedure 3 4 Shear Removal Procedure u uu uuu uusauisaskaswaswaauaqasaakaspaaqsakaqsaspastasqhaqskawkaqakaykayaphnssasqiphiqak aa 3 5 Shear 0 de 0 2 Wa 3 5 Internal Rotation Control System Installation if 3 6 Electrical Installation Internal Rotation Control 3 6 Electrical Schematic Internal Rotation Control System 3 7 Hydraulic Return Line Installation Instructions Internal Rotation Control System 3 8 Hydraulic Schematic Internal Rotation Control 3 9 SECTIO
2. llla OLA LOM E ER ERE E T x E Torque Values for Turntable Torque Values Tor Rotation Assembly Planetary Gearbox Lubrication if equipped n enne Lubiieant Change out PI ODGGUEG erie net Planetary Gearbox LUDTICANTS RM a TET Synthetic SS CG AION uu REED Gearbox Fill Capacities JT rtitable BEAMING m fa ors D st Turntable Bearing Lubricants Hydraulic teer roto tot etti pachi Cox reto punt Rotation Control Valve ERR C Se mun na apamama CL TABLE OF 5 SECTION 6 ROTATOR MAINTENANCE continued Rotation Control Valve Assembly Schematics and 6 8 Internal Rotation Control System if equipped 6 9 Accumulator Control Valve Assembly if 6 10 Maintenance Intervals for Internal Rotation if 6
3. FIGURE 5 40 FIGURE 5 42 2 Lubricate the o ring and ensure that it is properly installed so as to prevent damage during installation 3 Push the flange clamps toward the flange head and screw fasteners into flange pad Continue to screw the fasteners until their heads just meet the split flange surface see Figure 5 41 FIGURE 5 41 Maintenance Section 5 Page 39 MSD SABER SERIES SHEARS CYLINDER GAP CHECK FIGURE 5 43 RE x Periodically check minimum once per week the gap between the rod eye shoulder and head face X with the cylinder fully retracted see Figure 5 43 If the gap exceeds the dimensions given in the table below by more than 06 it could be an early indication of required maintenance Stop shear operations and call the LaBounty Service Department 218 834 6901 Page 40 Section 5 Maintenance em MSD SABER SERIES SHEARS HYDRAULIC SCHEMATIC STANDARD ROTATING SHEARS EXCAVATOR L EU SPEED VALVE ASSEMBLY HYDRAULIC LA MANIFOLD BLOCKS SHEAR 4 TEST PORT VALVE CASE DRAIN LINE 75 ASSEMBLY 1 AH Y SIZE lt TEST PORT TO EXCAVATOR 1 i I MOTOR FIGURE 5 44 HYDRAULIC SCHEMATIC STANDARD NON ROTATING SHEARS SHEAR CYLINDER __
4. 2 See Figure 5 10 For the second blade edge rotation when edges have rounded to a 1 4 radius remove and discard the lower blades Next remove the two upper blades swap end forend and install in the lower seats Now install two new blades in the open upper seats 3 Whenever you rotate or replace cutting blade edges make sure all blades are seated properly and use a new set of blade bolts and torque according to the Dry Bolt Torque Chart in this section Always use the same size and class of bolts Refer to your Parts Catalog to order replacement bolts from your authorized Stanley LaBounty dealer 4 Cross blade and guide blade maintenance should be performed when lower blades are being rotated Keep track of all parts and their positions as you remove them to make reinstallation easier Page 18 Section 5 Maintenance 1 Remove each blade 2 Turn end for end 3 Reinstall in same seat 4 Replace Saber Tip as required FIGURE 5 9 SECOND BLADE EDGE ROTATION d LY E P DISCARD 1 Discard lower blades 2 Rotate upper blades to lower blade seats 3 Install two new blades in upper seats FIGURE 5 10 MSD SABER SERIES SHEARS CUTTING BLADE ROTATION continued NOTICE The holes in the front of the cross plate can be useq to dislodge the cross blade from its seat Place a soft metal punch or pin through these holes and up against the blade Strike the punch with a mallet to
5. c Crossover relief valve is leaking excessively d Crossover relief valve set too low ii Check cartridge valve seals for damage i Rebuild or replace the motor i Check base machine hydraulic system i Check base machine hydraulic system i Check base machine hydraulic system i Check base machine hydraulic system i Adjust flow control to decrease flow to rotation group i Check base machine hydraulic system i Replace crossover relief valve i Replace flow control valve i Check base machine hydraulic system i Replace electric solenoid i Rebuild or replace gearbox i Disassemble motor from gearbox and inspect to determine cause of binding i Check base machine hydraulic system i Check base machine hydraulic system i Check base machine hydraulic system i Check base machine hydraulic system i Replace crossover relief valve i Replace crossover relief valve MSD SABER SERIES SHEARS INTERNAL ROTATION CONTROL SYSTEM TROUBLESHOOTING GUIDE if equipped The information contained in this guide provides for troubleshooting the Internal Rotation Control System only Any references to the attachment or the base machine will be made only to give some guidance as to where a problem may exist Any specific maintenance or troubleshooting information for the attachment or base machine will need to be obtained from its respective maintenance manual To properly troubleshoot the Hydraulic Rotation Circuit t
6. CONDUIT N gt JUNCTION Wa BOX NA ig GAUGE PORT rd RELIEF VALVE S 27 UNLOADING DIRECTIONAL VALVE SOLENOID VALVE FIGURE 6 6 Page 10 Section 6 Rotator Maintenance MSD SABER SERIES SHEARS MAINTENANCE INTERVALS FOR INTERNAL ROTATION it equipped A program of regular service should be established for the shear including maintenance of the Internal Rota tion Control System Use the base machine hour meter to determine service intervals The 8 Hour Inspection Checklist in this manual includes the rotation system and should be used daily to check for wear loose hose connections or components and other signs of potential failure There are three maintenance items within the Internal Rotation Control System that should be checked every six months or 1000 hours of operation 1 Accumulator Precharge Pressure 2 Operating Flow 3 Operating Pressure Keeping these three items adjusted to the specifications provided in this section will ensure that the rotator is operating efficiently and safely ACCUMULATOR MAINTENANCE There is a bladder inside the accumulator that is precharged with nitrogen gas when the shear leaves the fac tory When the accumulator is filled with hydraulic fluid this nitrogen bladder compresses and pressurizes the accumulator When the rotator function is operated the pressurized accumulator sends the fluid to the hydrau lic motor to rotate the shear If the accumulator is not proper precharged
7. CROSSHATCHAREA FIGURE 5 20 Section 5 25 MSD SABER SERIES SHEARS CRITICAL WEAR AREAS continued CROSSHATCH HARDSURFACING See Figure 5 21 A In some applications this area can be built up for added wear resistance Taper and blend the top edge of the weld procedure B Maintain build up in this critical area Area to be built up flush with the top edge of the blade Use E 7018 or E 70 series wire C Maintain profile and build up in this area Blend the bottom edge This area must be maintained to prevent wear into the Saber Tip reverse edge which rests just behind it D Use E 7018 or E 70 series wire Apply hardsur face allowing 1 16 space in from the edge both sides Do not apply hardsurface directly on an edge E Apply the crosshatch pattern using 1 50 spacing F Build up this area so that the bottom edge pro trudes 1 16 beyond the end of the blade Taper and blend the top edge use E 7018 or E 70 series wire BUILD UP TEMPLATE Apply hardsurfacing on top of the underlayment beads DO NOT APPLY HARD SURFACE DIRECTLY TO THE PARENT MATERIAL t is important to use an air operated slag peener on each pass of weld to J relieve stress NOTICE Figure 5 22 15 not to scale it has been enlarged for the purpose of illustration e Apply hardsurfacing on top of the underlayment beads DO NOT APPLY for all build up and welding procedures use E 7018 welding
8. Safety Operation amp Maintenance Manual MSD Saber Series hears INTELLECTUAL PROPERTY PATENT INFORMATION This product is covered by one or more of the following patents U S PATENT NUMBERS 5 474 242 7 240 869 5 531 007 7487930 5 992 023 7 578 461 4922 2 3 7 832 130 8 146 256 8 104 384 EPO Patent Numbers 435 702 737107 1 682 299 1 789 225 This manual contains information for the safe and proper operation and maintenance of MSD Mobile Shears Read the entire manual before the initial start up of the attachment It is important to know the correct operating procedures of the attachment and all safety precautions to prevent the possibility of property damage and personal injury The LaBounty attachment has been designed and manufactured with high quality materials and care in workmanship The instructions in this manual have been prepared to ensure that when followed properly the attachment will provide efficient and reliable service Continuing product development and improvement may have caused changes in the attachment that are not reflected in this manual If a question arises regarding the operation or maintenance of the attachment contact a LaBounty dealer for the most current information available COPYRIGHT 2012 TABLE OF CONTENTS SECTION 1 INTRODUCTION TO SAFETY R 1 2 Understand Signal Words uu
9. 10 9 metric flat head cap screws and class 12 9 metric socket head capscrews 2 Make sure bolts nuts and bolt holes are free of dirt oil grease and other contaminants 3 If necessary use the Capscrew Size Guide on this page to help determine the size of the bolt being in stalled 4 The torque values in this manual are for use with non plated fasteners with clean dry threads These val ues are suitable for use with or without thread adhesives such as Loctite products Please note that proper torque values may vary depending on the specific area of the shear METRIC CAPSCREW SIZE GUIDE CAP SCREW SOCKET HEAD SIZE KM 083 16 0 94 24mm 0 94 24mm 1 18 30mm 1 18 80mm M20 FIGURE 5 2 42 Gomm umm 177 emm Always replace bolts and nuts with the same size and class of fastener Inferior fasteners can fail and cause injury or death and damage to the equipment Page 10 Section 5 Maintenance La County MSD SABER SERIES SHEARS TORQUE VALUES FOR METRIC FASTENERS IMPORTANT Please note that some parts of the shear require special torque values These parts are listed below with the page number where the proper torque values for that area can be found They include Blade Bolts Page 5 15 e Hydraulic Connection Bolts split flange connections Page 5 40 e Speed Valve Bolts Page 5 44 55 8 26 Turnta
10. After blade rotation use the following instructions to shim to the proper blade gap Shimming is necessary if the gap exceeds 0 030 0 75 mm For most shearing applications this gap should be maintained at 0 010 to 0 020 0 25 to 0 50 mm but see the table below for the specific gap for your shear The gap may be shimmed down to 0 005 0 13 mm if jamming becomes a problem especially when processing thin mate rials Shim only the lower blades 1 To check for blade gap close the shear until the secondary blades in the upper and lower shear begin to bypass see Figure 5 18 Start with the thickest shims and check to see how many shims can be slipped between the blades and record this amount Another method is to use a feeler gauge to check the blade gap and record it 2 Ihe whole shim set adds up to 0 125 3 2 mm If all shims can be slipped between the blades it will be necessary to replace the blades Do not shim the lower blades out more than 0 125 3 2 mm This may cause structural damage to the shear 3 Close the shear further until the primary blades begin to bypass see Figure 5 19 Again check to see how many shims can be slipped between the blades or use the feeler gauge Record this gap also If the blades have been rotated properly at the correct intervals the blade gap should be even over the entire span of the blades If the gap is not even contact your Stanley LaBounty dealer 4 Once the blade gap is checked and reco
11. BRAKE VALVES FIGURE 6 4 Page 8 Section 6 Rotator Maintenance em MSD SABER SERIES SHEARS INTERNAL ROTATION CONTROL SYSTEMI if equipped The optional Internal Rotation Control System is designed to provide a medium pressure low flow hydraulic power source for rotating the shear The system is factory installed inside the rotating head of the shear and consists of the following major components Accumulator accumulator control valve assembly and foot switch The circuit taps into the shear s hydraulic supply manifolds to draw only enough fluid to charge the accumula tor This fluid is held in reserve until the control valve is actuated which sends the fluid to the rotation motor to drive the rotator The diagram below Figure 6 5 represents a typical Internal Rotation Control System The layout of the system that has been installed in your shear may vary slightly but the main components among shear models are generally the same FOOT SWITCH ELECTRICAL SUPPLY RETURN LINE ELECTRICAL CORD ACCUMULATOR CONTROL VALVE ASSEMBLY lt me gt of ACCUMULATOR LINE SUPPLY LINES LINE HYDRAULIC MANIFOLD ACCUMULATOR 2 PLACES FIGURE 6 5 7 Rotator Maintenance Section 6 9 MSD SABER SERIES SHEARS ACCUMULATOR CONTROL VALVE ASSEMBLY it equipped ADJUSTMENT SCREW b PRESSURE REDUCING MANIFOLD BLOCK VALVE CHECK VALVES FLOW CONTROL VALVE M ADJUSTMENT KNOB
12. Build up and Eardsu Taclbit usu l Saa asan Weld in Maintenance a III n Ime emn nnn enne nnn sss s sess ss ss sss sss sss s ss sssiis Weldin Tip REPIACEMOEN Front Wear Plate Lower Wear Plate Lower Shear Build up and Hardsurfacing Hydraulic System Blaine susto ncs asaakuqhayaqhaykaqysasssaqiysahaqyayqakaykayqawahuqsawkaqayau Flange Type Hose 5 Torque Values Tor T ouPBolt Flange Fittings uin eoo gue eei eU EU Ve ieee Applying Split Flange Clamps Cylinder Gap IOC T canes Hydraulic Schematic Standard Rotating 5 Hydraulic Schematic Standard Non rotating Speed Valve AUS UI LULU eut Decal Maintenan CE sieren ore SECTION 6 ROTATOR MAINTENANCE Major Components of Typical Rotation
13. CONTROLVALVE ASSEMBLY i i I I I I I I I A FOOT SWITCH INSIDE OPERA TOR S CAB INSIDE ATTACHMENT INSTALLED AT FACTORY FIGURE 3 5 Gr Installation Section 3 7 MSD SABER SERIES SHEARS HYDRAULIC RETURN LINE INSTALLATION INSTRUCTIONS INTERNAL ROTATION CONTROL SYSTEM 1 Always relieve all hydraulic pressure of the base machine by working the controls in all directions with the engine off before beginning work on any hydraulic component See Figure 3 6 2 Shut off the base machine and check the hydraulic sys tem pressure It should be zero PSI 3 Hydraulic oil becomes hot during operation DO NOT let hydraulic oil get in contect with the skin as it will cause severe burns Servicing while pressurized can cause Severe injury LOCK OUT source and HELIEVE PRESSURE before servicing FIGURE 3 6 4 Whenever hydraulic lines are disconnected hoses must be capped and ports much be plugged to prevent contami nation of the hydraulic system 5 Install a 1 2 diameter hydraulic line customer supplied from the attachment s return fitting located in the right hand hydraulic manifold to the base machine s hydraulic reservoir or return line Secure the line properly to the exca vator boom and stick Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before discon necting hydraulic lines Tighten all connections before applying pressu
14. Check guide blade Saber Tip gap refer to manual is gap exceeds 030 75mm Check cutting blade gap refer to manual is gap exceeds 030 75mm Oe E GE e EE i NE NN m EE Inspect Saber Tip ensure it fits squarely in upper jaw Inspect cross blade for any looseness or damage o Inspect hoses for wear and potential failure Inspect cylinder for leaks If rotator equipped Grease turntable bearing ae Sa Inspect rotation hoses and hose connections for wear leaks potential failure Check rotation assembly bolts Inspect all bolts connecting turntable bearing to upper head and shear replace as needed Rotate or replace cutting blades Saber Tip cross and guide blades Check slide screw wear replace if necessary Inspect upper shear check build up and hardsurface around blade edges build up if needed Replace wear plates on lower shear if necessary Check split flanges and fitting for looseness tighten if necessary Inspect and maintain the lower secondary blade buffer or build up strip Replace shear cylinder seals including Nylock lock ring HOURS L NEM p ERE S S S S S S S p E MEN S E MENSEM as a 2 000 HOURS Replace swivel manifold seals if equipped 2 Section 5 Maintenance MSD SABER SERIES SHEARS RECOMMENDED SPARE PARTS LI
15. I TO EXCAVATOR T ws ur BLOCKS ON EO SPEEDVALVE SHEAR 1 t FEE ASSEMBLY E sj TO EXCAVATOR FIGURE 5 45 Maintenance Section 5 41 MSD SABER SERIES SHEARS SPEED VALVE ADJUSTMENT The speed valve LaBounty shears is factory adjusted by Stanley LaBounty technicians prior to shipment Field adjustments of the valve should only be necessary if the operator senses that the valve is not functioning properly Some indicators of a poorly functioning valve are eThe shear does not consistently shift into speed mode when closing the jaw The shear jaw continues to close after the operator has let go of the controls shear shifts into speed mode but seems to lack power Follow the procedure below if speed valve adjust ment is necessary TOOLS NEEDED The following tools are recommended for speed valve adjustment on any Stanley LaBounty Saber Series Hydraulic Cylinder 1 Open end or box end wrenches 12 19 mm sizes 2 Digital gauge kit Stanley LaBounty P N 169832 3 Allen wrenches 4 12 mm sizes SAFETY POINTS Stanley LaBounty recommends that the following safety precautions be followed when adjusting the speed valve on any Stanley LaBounty Saber Series Hydraulic Cylinder Reminder Always wear the proper personal protec tion equipment including the following 1 Steel toe safety shoes or boots 2 Shatter proof safety glas
16. OEO E 5 12 Blade Removal uu na entes viret 5 14 Blade Bolt Torque Specification a E tuu BUD Ie 5 15 Torque Values tor Blade od bon 5 15 Guide Blade end R tatl n rsrsrsrsrs aM dd tee S 5 16 Cutting Blade Rotation Procedure peo rm tesa EXP ad Gates pd 5 17 Weld in Tip Cutting Blade Rotation 5 21 Cutting Blade SANTA VMN PERRO 5 22 General Guidelines for Build up and HardSurfacing 5 23 Build up Recommendations 5 24 Hardsurta ing Recommendations 5 24 Critical Wear Pe 5 26 Upper Shear and e auqa as 5 27 Weld in Maintenance cece cece cece m rm nm nnn nn nnn nnn n EE EEE LEAL EELS EEE EERE e 5 28 Welin TIP Replacement PEE 5 30 Front Wear Plate 5 32 Lower Wear Plate 5 33 Lower Shear Build up and Hardsurfacing 5 3
17. Pressure Release Td d bM ne qe E Ned PII m UM Uu IM D Md un DRE IE 6 12 Accumulator Pre charging sssssssssssssssssssssesseee eee ee 6 12 Flow vor Internal Rotation uuu a qaq AEE 6 13 Operating Pressure for Internal enn nennen 6 13 Rotator Maintenance Section 6 Page 1 MSD SABER SERIES SHEARS MAJOR COMPONENTS OF TYPICAL ROTATION SYSTEMS Typical second member upper head assembly see Figure 6 1 below with an internal drive rotator a gearbox and standard rotation CONTROL VALVE MANIFOLD _ MOTOR FIGURE 6 1 GEARBOX GREASE FITTING TURNTABLE BEARING BEHIND RING GREASE FITTING 55 Typical third member upper head assembly see Figure 6 2 below with an external drive rotator no gearbox and optional internal rotation control system FOOT SWITCH RETURN LINE FITTING AND ELECTRICAL CONTHOLVALVE MANIFOLD Z FAR SIDE GREASE FITTING CONTROL VALVE C MANIFOLD TURNTABLE BEARING ACCUMULATOR Page 2 Section 6 Rotator Maintenance MSD SABER SERIES SHEARS THE ROTATOR The rotator gives the shear 360 degrees of continuous rotation in both directions for easy accurate process ing at all angles The hydraulic rotation circuit consists of the hydraulic motor driving a turntable bearing either directly or through a planetary gearbox It is necessary to
18. SABER SERIES SHEARS GLOSSARY Accumulator Used in a hydraulic rotation kit to store hydraulic fluid to drive the rotation motor Adjustment Custom made plates that precisely adjust the lower cutting blades to the upper blades These plates Plates make it possible to achieve a uniform blade gap on the shear Apex The point where the primary and secondary cutting blades come together Blade Gap The gap between the upper and lower cutting blades as the blades bypass A very important item that must be maintained regularly to prevent material from jamming in the blades Blade Shims Thin metal shims used to adjust the position of the lower cutting blades to maintain a proper blade gap Blades should never be shimmed out farther than 0 13 3 3 mm Boom Pivot Part of the shear mounting bracket that attaches to the excavator s boom tip second member mounts Build Up Welding process where worn off parent material is replaced with new metal A very important maintenance procedure that must be performed regularly throughout the life of the shear Control Valve Used in the hydraulic rotation kit to direct flow to the accumulator and back to the hydraulic motor Manifold Cross Blade A replaceable component located on the inside of the lower shear cross plate The cross blade is an easy to replace wear part that reduces maintenance time in the piercing area Cross Plate Plate located at the front of the lower shear which ties
19. accompanying blade set Due to the critical nature of these fasteners Stanley LaBounty requires that blade fasteners bolts and washers be replaced with each set of new blades When using existing blade fasteners during blade rotations always inspect the hardware for any im perfections or damage and replace as necessary If a bolt has become elongated or a washer has spun it will be difficult or impossible to achieve proper torque to secure the blade in the seat Proper torque values for blade bolts are listed below These values should only be used for blade bolts TORQUE VALUES FOR BLADE BOLTS CLASS 10 9 ASSEMBLY PROCEDURE Your new Saber shear has a raised area on the Saber Tip that fits into the Secondary Blade of the upper jaw This helps provide uniform support and load ing of blade seats when piercing items that do not extend totally across the piercing tip m NOTICE Earlier model blades have a counter bore and remov able dowels to do the same function as the updated four bolt tip design 0000 7526 0 at e 0 9 e 0 a v e 9 e 9 FIGURE 5 7 Maintenance Section 5 15 MSD SABER SERIES SHEARS GUIDE BLADE SHIMMING AND ROTATION The guide blade gap is another adjustment that keeps the shear blades in line and ensures the proper opera tion of the shear This adjustment should be checked daily 1 Close the shear until the Saber Tip on the upper shear begins t
20. fails to shift into speed mode You may need to open and close the shear multiple times to reach the pilot valve minimum setting The pressure gauge attached to the MBS port should read approximately full system pressure when not in speed mode Pay careful attention to the number of turns required to reach this setting 12 Have the excavator operator return the shear to the fully open position a second time Re adjust the pilot valve adjustment screw to the final setting by turning the adjustment screw clockwise 1 2 of the number of turns required to reach the minimum set ting and tighten the lock nut This brings the valve to its median setting which is optimum for most operating conditions 13 Test the adjustments by cycling the shear to the closed position six times normally and six times with the shear stalled in the closed position Moni tor the gauge attached to the MAZ carefully During normal cycling the gauge should read 400psi 26 bar or higher When stalling the shear gauge pres sure should drop to zero Page 46 Section 5 Maintenance 14 Verify the shift pressure Have the excavator operator cycle the shear to the fully closed position and carefully monitor the pressure gauge attached to the MAZ test port Note the pressure reading immediately before the shear stalls This pressure is the shift pressure required to shift the speed valve out of speed mode Shift pressure should be 3600 3700 PSI 248 255 BAR 15
21. hardware etc every 80 hours 4 Have the shear cylinder seals replaced by an au thorized Stanley LaBounty dealer every 2 000 hours 5 Whenever hydraulic lines are disconnected hoses must be capped and ports must be plugged to prevent contamination of the hydraulic system Relieve pressure before disconnecting hydraulic lines Tighten all connections before applying pressure Keep hands and body away from pin holes and nozzles which can eject fluids under high pressure Use a piece of cardboard to search for leaks Escaping fluid under pressure can penetrate the skin and cause serious injury If ANY fluid is injected into the skin seek immediate medical attention NOTICE NEVER adjust pressure relief valves to get higher operating pressures The manufacturer s recommended pressures give the safest performance with the longest life Maintenance Section 5 Page 37 MSD SABER SERIES SHEARS FLANGE TYPE HOSE FITTINGS Check flange fittings for smooth tight fit of matching surfaces If any cap screws are loose or matching sur faces are not tight tighten the loose cap screw then tighten the diagonally opposite cap screw Tighten the two remaining cap screws then torque all four screws as specified in the Torque Chart in this manual Tolerance is 1096 The torques given are enough for the given size connection with the recommended work ing pressure Torques can be increased to the maximum shown for each screw size if desired DO
22. in place 6 Check the tip profile with the build up template supplied by Stanley LaBounty see Figure 5 32 7 Close the shear until the tip begins to enter the lower shear and check the clearance of the new tip If clearance is correct proceed with the following steps If not adjust the position of the tip as needed TIP FLUSHWITH BLADE BUILD UP TEMPLATE FIGURE 5 32 Page 30 Section 5 Maintenance e MSD SABER SERIES SHEARS WELD IN TIP REPLACEMENT continued The upper shear must be grounded when welding on the upper shear to prevent the possibility of electric shock and arcing through the cylinder or main pivot components NOTICE Check temperature frequently during this procedure tain 400 450 F 200 230 C Do not exceed 450 230 C 8 Once it is tacked in the proper position preheat the tip area to a minimum of 400 F 200 C and a maximum of A50 F 230 C 9 Use the recommended build up weld rod to fill the chamfered areas with multiple passes Do the sides first and stress relieve each pass by peening A weld is required on both sides of the tip see Figure 5 33 10 Weld the back and front to the upper shear following the same procedure 11 Grind the welds flush on the sides The weld on the wear plate side should be ground flush with the front wear plate 12 If the temperature within 6 150 mm of the area has dropped below 400 F 200 C during the weld process post heat this area to
23. is where the shear replaces the bucket 1 Place the shear upside down on the ground with FIGURE 3 1 blocking to keep the shear level Locate flat hard ground for installation 2 For a second member mount remove the excava tor stick following the manufacturer s recommended procedure 3 For a third member mount remove the bucket or other attachment following manufacturer s recom mended procedure To prevent contamination of the hydraulic system plug the hydraulic hose when they are disconnected NOTICE j It be necessary to lift the rear of the shear into position to allow boom pivot pin installation on second member mounts 4 With the jaws of the shear facing the excavator walk the excavator into position aligning the excava tor s boom or stick into the boom pivot or stick con nection of the shear bracket see Figure 3 1 5 For second member mounts pin the shear boom pivot to the excavator boom using the excavator boom pin second member For third member mounts pin the stick tip to the stick connection us ing the pin provided by LaBounty 6 Instruct the operator to slowly pick th
24. lower blades and guide blades fasteners and open the shear This will allow the blades to come out of their seats thus freeing the jam Upon jam removal perform the proper maintenance on the shear as detailed in this manual SYMPTOM PROBABLE CAUSE REMEDY 6 Does not shear material continued 7 Blade gap is uneven 8 Individual hydraulic function is slow e Excessive guide blade front Saber Tip Wear f Worn cross blade a Non LaBounty blades being used b Debris in blade seat behind blades or adjustment plates from blade seats c Inconsistent amount of blade shims between primary and sec ondary blades d Upper shear is bent a Pilot control hoses pinched b Jumpline or connections c Excavator hydraulic malfunction d Circuit relief valve for the func tion is set low or malfunctioning Page 4 Section 7 Troubleshooting i Add guide blade shims refer to guide gap blade shimming procedure ii Rotate guide blade or replace when both sides are worn Replace Saber Tip i Rotate or replace the cross blade i Replace with LaBounty approved blades i Remove blades and adjustment plates and clear all debris NOTE Adjustment plates must be replaced exactly as they were removed i Reshim blades for consistency refer to blade shimming procedure i Consult the LaBounty Customer Service depart ment for repair i Inspect and correct i Inspect and correct leaking i Check excavator hydraulic
25. of its travel is reached then turn the adjustment clockwise until you feel the spring tension of the main spool af ter tension is felt turn the adjustment one full turn clockwise Re tighten the 19mm lock nut 8 Loosen the 19mm lock nut on the pilot valve but DO NOT turn the 6mm socket head pilot valve adjustment screw 9 Have a co worker restart the excavator Check for leaks in the test fittings by using a piece of card board or other rigid material Repair all leaks before proceeding NOTICE Note that turning the pilot valve adjustment screw past the locking nut could cause severe damage to the pilot valve Maintenance Section 5 Page 45 MSD SABER SERIES SHEARS SPEED VALVE ADJUSTMENT continued 10 Have the excavator operator cycle the shear to the fully closed position and set the pilot valve to its maximum setting Turn the pilot valve adjust ment screw clockwise until the cylinder just fails to shift out of speed mode You may need to open and close the shear multiple times to reach the pilot valve maximum setting The pressure gauge attached to the MAZ port should read approximately 400 psi or higher when in speed mode NOTICE DO NOT make adjustments to the speed valve while the cylinder is extending 11 Have the excavator operator cycle the shear to the fully closed position then set the pilot valve to its minimum setting Turn the pilot valve adjustment screw counterclockwise until the cylinder just
26. or replace Rotator if equipped Check all turntable bearing bolts for looseness or damage Bolts may be retorqued only once and then must be replaced Refer to the Turntable Bearing Bolt Torque Chart on page 6 3 for proper torque values Lubricate according to instructions in this manual m 80 HOUR SERVICE RECOMMENDED Cutting Blades Measure blade gap rotate blades and shim blades according to procedures in this manual Upper Shear Inspect cutting blades Saber Tip and parent material around blade edges Refer to manual for build up hardsurface or blade replacement instructions Lower Shear Inspect guide blade nose blade and lower shear Refer to manual for build up hardsurface or replacement instructions Rotator If equipped Inspect all bolts connecting the turntable bearing to the head and shear for looseness or damage Bolts must be replaced if re torque is necessary Refer to the Turntable Bearing Bolt Torque Chart on page 6 3 for proper torque values 2 000 HOUR SERVICE RECOMMENDED Shear Cylinder Seals is recommended that the shear cylinder seals be replaced every 2 000 hours Operating the shear with worn out seals will decrease shear performance and may cause internal damage to the cylinder Please note that cylinder seal life is highly dependent on the care taken to properly maintain the hydraulic fluid Fluid with higher levels of contaminants and particulates will wear down cylinder seals fas
27. qual pump flow is recommended for shear munting second member most excavators Due to the increase in flow there may be a requirement to add larger hydraulic lines or dual lines up the boom to minimize back pressure reduce heat and maximize shear performance e About the Attachment Section 2 Page 7 MSD SABER SERIES SHEARS SECTION 3 INSTALLATION Shear Mounting FRO CSCI Gist capacities ua m qawasaq aaa 3 2 Mobile Shear Startup Proce re J uuu ao ara 3 4 Shear Removal Procedure 3 5 REP 3 5 External Rotation Control System Installation if 3 6 Electrical Installation Internal Rotaiton Control 3 6 Electrical Schematic Internal Rotation Control System 3 7 Hydraulic Return Line Installation Instructions Interal Rotation Control System 3 8 Hydraulic Schematic Internal Rotation Control 3 9 Installation Section 3 Page 1 MSD SABER SERIES SHEARS SHEAR MOUNTING PROCEDURE Take note whether yours is a second member or a third member installation A second member mount is where the shear replaces the excavator stick a third member mount
28. rod or equivalent It is important to al ways use a hardsurfacing weld material with a chro mium content of less than 10 percent and a severe impact resistance rating to prevent cracking If you have questions about what hardsurface material to use please contact the Stanley LaBounty Customer Service Department Failure to adhere to LaBounty hardsurfacing rec ommendations may compromise the attachment warranty Hardsurfacing should be applied directly on top of the build up welds The build up acts as a bonding or underlayment for the hardsurfacing which reduces the chances that the hardsurfacing will crack Contact Information for Amalloy Welding and Industrial Supply Phone 800 735 3040 toll free Fax 763 753 8263 Web site amalloy com NOTICE DO NOT use stainless hardsurface rod It will crack the base metal which can cause a major structural failure of your shear jaws MSD SABER SERIES SHEARS CRITICAL WEAR AREAS NOTICE The area shown in Figure 5 20 must be inspected daily and maintained whenever the crosshatch pattern is almost worn down to the base metal surface If you have any questions regarding this information please call the Stanley LaBounty Service Department at 218 834 6901 Close attention must be paid to the crosshatch hardsurfacing This area should be inspected daily When the crosshatch is worn down almost to the base metal surface clean the surface by wire brushing preheat to 400 and appl
29. see previous page for instructions 4 Use the straight edge across the top of the blades to find the build up requirements on the top side of the lower shear All edges should be square 5 Preheat the area surrounding the tip to about 200 F 100 C to remove moisture Preheat the area within 6 150 mm of the weld location to a minimum of 400 F 200 C and a maximum of 450 230 C Maintain this temperature range throughout the process The lower shear must be grounded when weld ing on the lower shear to prevent the possibility of electric shock and arcing through the cylinder or main pivot components Page 34 Section 5 Maintenance MSD SABER SERIES 5 5 LOWER SHEAR BUILD UP AND HARDSURFACING continued 6 Apply build up to the worn areas in single passes USE STRAIGHT EDGE side by side running with the grain of the base ACROSS SURFACES material see General Rules for Build Up and Hard surfacing Use the airoperated slag peener to peen each pass to relieve weld stress and remove slag Grind all edges to 90 NOTICE Check temperature regularly during this procedure Maintain 400 450 F 200 230 C not exceed 450 F 230 7 If necessary build up the area beneath the edge of the secondary blade so it is flush with the blade see Figure 5 37 The blade should not stick out beyond the edge of the seat in this area 8 To hardsurface the top sides of the lower shear establish the patt
30. system i See your excavator dealer MSD SABER SERIES SHEARS ROTATION CIRCUIT TROUBLESHOOTING GUIDE The information contained in this guide provides for troubleshooting the LaBounty shear only Any reference to the excavator will be made only to give some guidance as to where a problem may exist Any specific maintenance and troubleshooting information will need to be provided by the original equipment manufacturer of the excavator or the authorized dealer SYMPTOM PROBABLE CAUSE REMEDY 1 Shear will not rotate a Operating flow is too low i Flow control valve needs adjustment ii Check supply flow b Crossover relief valve is bypassing oil i Replace crossover relief valve c Operating pressure is too low i Check crossover relief valve ii Check supply pressure d System hydraulic fluid i Check base machine hydraulic system tempera ture excessively high e Broken output shaft drive i Replace or rebuild the hydraulic motor f Internal leakage in manifold block i Replace manifold block on motor motor ii Check cartridge valve seals for damage 9 Excessive wear on motor rotating i Replace or reseal the hydraulic motor components il To check this remove the case drain line and mea sure the amount of flow out of the case h Speed reducer gearbox shaft broken i Rebuild or replace the gearbox i Internal leakage in valve supplying oil i Check base machine hydraulic system j Valve supplying hydraulic f
31. the machine or serious injury could result The attachment may have altered the base machine s lift capabilities 3 It is required that a Falling Objects Protection Structure be installed surrounding the excavator cab for all material handling applications 4 The shear is for processing materials DO NOT use the attachment for unapproved purposes or warranty may be voided 5 DO NOT continuously process oversized materials by forcing them into the shear throat with the downward force of the excavator This practice is detrimental to the life of the shear and is strongly discouraged 6 If the shear stalls during processing scale back the amount of material being processed at one time Continuously overloading the shear and cycling the excavator to full system pressure can cause overheating and have adverse effects on the shear and the excavator hydraulic system 7 Whenever possible cycle the shear cylinder completely during processing Fully opening and closing the shear allows more hydraulic fluid to circulate through the system to help prevent overheating 8 Inspect and lubricate the shear daily Tighten any loose bolts or fittings to the proper torque as specified in this manual 9 Maintain a safe distance and avoid contact between the excavator and the shear or any material held by the shear jaws 10 NEVER leave the shear suspended or pass it over people occupied vehicles or buildings 11 When working in confined s
32. the top of the shear to be used when mounting or transporting the shear There are two holes near the front of the shear and one lug at the rear These points must never be used for cable hanging the shear for cutting operations The frontal area of the lower shear through which the upper piercing tip passes This area contains the guide blade and the cross blade The lower stationary jaw of the shear The lower shear contains the lower cutting blades the guide blade and the cross blade Replaceable abrasion resistant wear plates that protect the cross plate of the lower shear Hardened bushings that the main shaft of the shear rotates on during operation There are two main bearings bolted in on both sides of the main pivot group High tolerance area of the shear that contains the two main bearings two thrust washers main shaft hub shims and two end caps The shaft on which the upper shear pivots causing the shearing action of the attachment Hydraulic block that directs the excavator s hydraulic flow to the shear cylinder and rotation assembly Hydraulic rotation component that drives the turntable bearing or planetary gear box on rotating shears The bracket at the rear of the shear that allows it to be attached to the excavator For a typical second member mount the mounting bracket pins to the excavator boom tip and stick cylinder Hydraulic rotation component on larger rotating shears The planetary gear box rotates the body
33. weld in place 6 Use the recommended build up weld rod to fill the area between the wear plates Then weld an approxi mate 3 8 10 mm fillet on all remaining sides around the wear plates Also weld a fillet around the inside of the holes on the front Stress relieve each pass by peening Grind welds smooth 7 If the temperature within 6 150 mm of the weld area has dropped below 400 F 200 C during the weld process post heat this area to 400 200 C 8 Wrap with a heat blanket and allow the welded area to cool slowly to the ambient temperature The shear should not be put back into service until it has cooled completely LOWER SHEAR BUILD UP AND HARDSURFACING For maximum performance and long life all edges on the lower shear should be kept square and flush with the blades Check the lower shear every 80 hours and maintain it when necessary All blade maintenance must be done before building up and hardsurfacing the lower shear It is recommended that this mainte nance be done at the end of the working day to allow adequate cooling time before putting the shear back Into service 1 Remove all existing hardsurfacing by grinding down to the base metal Do not weld on top of the existing hardsurfacing 2 Clean all dirt and grease from area to be maintained 3 Use a straight edge to determine how much build up is required on the cross plate If the lower wear plates on the nose plate are worn these should be replaced at this time
34. 0 SHEARS REGEN VALVE P N 512327 USED IN MSD 7500AND 9500 SHEARS FIGURE 5 53 ITEM PART NUMBER DESCRIPTION TORQUE 512338 Screw Plug M8X1 75 ft lbs 10 Nm 511515 Screw Plug 7 16 20 5 ft 165 20 Nm 14 512339 Seallock Nut M20X1 5 512342 Socket Head Capscrew M14X70 2 512343 Socket Head Capscrew 14 50 8 51 165 70 Nm 73 ft 105 100 Nm 51 ft lbs 70 Nm em Maintenance Section 5 Page 53 MSD SABER SERIES SHEARS DECAL AND LABEL MAINTENANCE Be sure that all safety decals are installed and visible see Figure 5 54 Replacement decals are available from your Stanley LaBounty dealer Complete label installation kits are available upon request FIGURE 5 54 ITEM PART NUMBER DESCRIPTION 116388 Grease Decal one at each grease fitting 116389 DANGER Decal on both sides Keep 75 feet away during opera tion 503647 DANGER Decal on both sides top and front cab guarding required 511045 Model and Serial Number right side only 116404 Stanley LaBounty Decals on both sides toward rear of shear BY MODEL Stanley LaBounty Decals on both sides toward rear of shear 7 BY MODEL Model Decals on both sides Page 54 Section 5 Maintenance MSD SABER SERIES SHEARS SECTION 6 ROTATOR MAINTENANCE Major Components of Typical Rotation Systems 6 2 THe ROLO ce EC 6 3 Oli MOMS xia eck esse 6 3 Torque values Tor Turntable BOlES
35. 1000 1500 and 1000 1500R not have slide screws on the right cutting blade side FIGURE 5 5 ve Section 5 13 MSD SABER SERIES SHEARS BLADE REMOVAL 5 If you are unable to dislodge the blades using Removing and handling shear blades can be hazard these methods please contact your Stanley LaBoun ous if done incorrectly To ensure your safety and to ty dealer for further assistance Also note that blade prevent damaging the shear please read the fol replacement kits are available For best service lowing warnings and instructions when removing a please have the serial number of your shear on hand blade from its seat when calling for blade replacement kits NOTICE To prevent injury wear safety equipment at Do not strike directly on the blade bolts with a ham all times when maintaining the attachment mer or other hard object This may cause damage to Safety equipment includes eye protection hard the blade threads hat steel toe shoes work gloves and hearing tection protection NOTICE Full blade kits are available by calling Stanley Make sure the blade is well supported before LaBounty Customer Service at 800 522 5059 For removing the blade bolts When the bolts are best service please have the shear serial number removed the blade may drop and cause severe on hand when calling injury 1 Loosen all blade bolts but leave them partially PRY HERE IF installed and thre
36. 11 ACCUMULATOR Ivlainterarice eos eoi etes teme rb pd e e blend da on ER De Er 6 11 Testing the Accumulator Pre charge n n ener nnne nnne 6 12 Pressure Release sha raasaka qasapas Ea Ee R ENEE 6 12 Accumulator 6 12 Operating Flow for Internal 6 13 Operating Pressure for Internal Rotation nnns 6 13 SECTION 7 TROUBLESHOOTING Cutting Performance Troubleshooting Guide eoe vh Ero rU pape P Ra Ue suci avid 7 2 Rotation Circuit Troubleshooting nennen 7 5 Internal Rotation Control System Troubleshooting Guide if 7 7 Speed Valve Troubleshooting Guide 7 10 Appendices Bolt Torque 1 8 25 WGI IVEY A 3 MSD SABER SERIES SHEARS SECTION 1 INTRODUCTION TO SAFETY Wiad oy Ufo ot D 1 2 Understand Signal Words iesus 1 2 iener r nE ET E E E E S uersa aphasquysaahus amas a 1 3 Attachment Deca
37. 150 mm of the FIGURE 5 38 weld area has dropped below 400 F 200 C dur ing the weld process post heat this area to 400 F 200 12 Wrap with a heat blanket and allow the welded area to cool slowly to the ambient temperature The shear should not be put back into service until it has cooled completely CROSSHATCH PATTERN MB FIGURE 5 39 36 Section 5 Maintenance MSD SABER SERIES SHEARS HYDRAULIC SYSTEM MAINTENANCE Use the following instructions to safely perform hydraulic checks and maintenance on the shear 1 Always relieve all excavator hydraulic pressure before working on any hydraulic component Relieve hydraulic pressure before working on the machine by working the controls in all directions with the engine off 2 In order to test the hydraulic system a diagnostic fitting will need to be installed into the shear hydrau lic manifold block To do this shut off the excavator and relieve the system pressure Make sure the sys tem pressure is at zero 0 psi and remove the dash 4 1 4 O ring boss plug from the diagnostic port on the hydraulic manifold block Replace this plug with a diagnostic fitting for your test gauge Maintaining proper operating pressure will result in the best cut ting performance This is also a quick check to make sure that the excavator is performing up to specifica tions 3 Check all hydraulic components split flanges hoses fittings mounting
38. 4 0 61 mm thick shims would be used to achieve the desired guide blade gap Page 16 Section 5 Maintenance MSD SABER SERIES SHEARS GUIDE BLADE SHIMMING AND ROTATION continued 5 To shim the blade loosen the guide blade bolts and move the guide blade out far enough to slide the shims between the blade seat and the guide blade If all five shims are installed and the gap still exceeds 0 030 0 76 mm it will be necessary to rotate or replace the guide blade 6 The guide blade can be rotated once so the whole face of the blade can be used to increase its life When itis time to rotate the blade remove it and turn it end for end and place it back in its seat The same face should be used for the entire life of the blade Use the steps above to shim the guide blade to the correct gap When the whole face of the blade is worn and it cannot be shimmed anymore it is time to replace it with a new one 7 If a gap greater than 0 030 0 76 mm still exists with a new guide blade and a full set of shims the Saber Tip will need to be replaced Refer to Cutting Blade Rotation in this section Always wear proper safety equipment when doing blade maintenance This includes eye protection hard hat steel toe shoes work gloves and hearing protection Wear an approved respirator when grinding CUTTING BLADE ROTATION PROCEDURES Proper rotation and adjustment of the cutting blades is very important for the best shear performance and longe
39. 4 Hydraulic System MaintenanG 5 37 Flange Type ITH GS e c u u a sa 5 37 Torque Values Tor FourBolt Flange FItting8___ u uuu ulussasaasasassaqashusaqaqaypasankayawasaqa assawqanaqapnik 5 38 Applying Split Flange Clamps 5 39 Cylinder TEC H 5 40 Hydraulic Schematic Standard Rotating 5 41 Hydraulic Schematic Standard Non rotating Shears sss 5 41 Speed Valve 5 42 5 54 Maintenance Section 5 1 MSD SABER SERIES SHEARS SERVICE AND MAINTENANCE PROCEDURES 8 HOURS 7 Visually inspect shear for damage Inspect all safety decals Inspect cab protection on excavator Confirm all excavator warning systems are operational Lubricate each side of main pivot group 2 each side Lubricate end slide puck assemblies each side Lubricate end of front cylinder pin Lubricate end of rear cylinder pin Lubricate boom pivot connection of mounting bracket Lubricate cylinder connection of mounting bracket Inspect pinheads and pinkeepers Inspect all bolts for looseness or damage Check slide puck back wear plate gap refer to manual if gap exceeds 010 25mm
40. 400 F 200 C 13 Wrap with a heat blanket and allow the welded area to cool slowly to the ambient temperature The shear should not be put back into service until it has cooled FIGURE 5 33 Maintenance Section 5 31 MSD SABER SERIES SHEARS FRONT WEAR PLATE REPLACEMENT if equipped The front wear plate bears against the guide blade to support the upper shear during operation see Figure 5 34 To prevent damage to the shear it is crucial to replace this wear part when it is worn Replace the front wear plate when the guide blade gap is greater than 0 030 0 75 mm with a new guide blade and a full set of shims installed Whenever the front wear plate is replaced also replace the piercing tip Use the following instructions to replace the front wear plate 1 Preheat the area surrounding the wear plate to about 200 F 100 C to remove moisture Preheat the area within 6 150 mm of the wear plate to a minimum of 400 F 200 C and a maximum of 450 230 C Maintain this temperature range throughout the process Temperature melt sticks are available from Stanley LaBounty 2 Airarc the old wear plate to remove it completely Please note that the upper shear has a machined sur face for the wear plate 3 Use a grinder to make sure the area 15 flat and smooth with all carbon residue removed 4 Place the new wear plate into the machined area existing on the upper Position the new we
41. E EDGES FIGURE 5 28 FIGURE 5 29 Maintenance Section 5 Page 29 MSD SABER SERIES SHEARS WELD IN TIP REPLACEMENT if equipped If the piercing tip is badly worn it is advisable to install a new piercing tip using the following instructions NOTICE If the front wear plate is also worn replace it at the same time as the piercing tip E 1 Preheat the surrounding area to about 200 F 100 to remove moisture Preheat the area within FIGURE 5 30 45 CHAMFERS 6 150 mm of the tip to a minimum of 400 F 200 C and a maximum of 450 F 230 C Maintain this tem perature range throughout the process 2 Airarc the old tip to remove it Be sure to remove the old tip completely Please note that a notch or seat for the tip is present in the upper shear 3 To completely prepare the surface for the new tip the upper must be chamfered as shown see Figure 5 30 The chamfer size should be approximately one half the thickness of the new tip NOTICE Before installing the new piercing tip grind the area flat and smooth Remove carbon residue with the airarc FIGURE 5 31 4 Place the new tip into the seat Use a straightedge to position the tip before tacking it into place The side edge of the new tip should be flush with the face of the blade see Figure 5 31 5 Make sure the tip is squarely against the edge Once the tip is positioned properly bring the preheat back up to 400 F 200 C and tack the tip
42. EMBER INSTALLATION Shear replaces bucket FIGURE 4 1 Bucket CURL Shear IN Bucket DUMP Shear OUT Page 4 Section 4 Operation e MSD SABER SERIES SHEARS MOBILE SHEAR CONTROLS CONTINUED SECOND MEMBER INSTALLATION Shear replaces stick FIGURE 4 2 BUCKET CURL SHEAR CLOSE ARM IN SHEAR IN ARM OUT SHEAR OUT les Grm em Operation Section 4 Page 5 MSD SABER SERIES SHEARS OPERATING THE ROTATOR if equipped The rotator gives the shear 360 of continuous rotation in both directions for easy accurate processing at all angles The rotator requires special attention when operating the shear The rotator is to be used only to position the shear not as a means of bending twisting or breaking material DO NOT use the shear rotator for any other purpose except to position the shear for a cut Using the rotator for any other purpose such as bending or twisting material will damage the rotation components and may void the shear warranty BACKDRIVING THE ROTATOR Backdriving occurs when an excessive off center force is applied to the shear Examples of this are closing the jaws on a rigid member without the jaws being square to the member or handling a heavy load off center in the jaws Backdriving puts undue stress on the rotation system and if done continually can lead to rotation component problems Follow the tips below to minimize backdriving as much as possible 1 When handling a load in the jaws try to grip it as
43. GURE 5 26 PIERCING TIP FLUSHWITH WEAR PLATE STRAIGHT EDGE FIGURE 5 27 Gr MSD SABER SERIES SHEARS WELD IN TIP MAINTENANCE continued 6 Apply build up to the worn areas see General Rules for Build Up and Hardsurfacing Peen each pass vigor ously to relieve weld stress and remove slag NOTICE Check temperature frequently during this procedure Maintain 400 450 F 200 230 not exceed 450 230 C 7 To hardsurface the built up area apply single pass es side by side Peen each pass 8 When welding is complete grind the tip smooth and square with wear plate and cutting blades Check it again with the straight edge and build up template 9 To check the fit of the tip close the shear until the piercing tip begins to enter the lower shear see Fig ure 5 29 The piercing tip should fit squarely into the lower 10 When finished reworking the tip work harden it by peening the welded area until it is shiny or until the peener cannot dent the weld anymore approximately five minutes 11 If the temperature within 6 150 mm of the weld area has dropped below 400 F 200 C during the weld process post heat this area to 400 F 200 C 12 Wrap with a heat blanket and allow the welded area to cool slowly to the ambient temperature The shear should not be put back into service until cooled CHECK FOR CLOSE AND SQUARE FIT UPPER BUILD UP TEMPLATE al LINE UP TEMPLATE WITH BLAD
44. HEARS NOTICE e The amount of rotation your shear will achieve per fluid charge depends on the shear model e Continuous rotation can be achieved by cracking an excavator function that charges the accumulator The accumulator needs to be charged with fluid when the base machine is first started up The unloading valve is designed to drain to the accumulator whenever the base machine is shut off SPEED VALVE OPERATING CHARACTERISTICS The function of the speed valve is to increase the shear closing speed cylinder extend function when the shear is not under a load thereby reducing cycle times and increasing efficiency The speed valve directs return flow from the rod side of the cylinder to the bore side as the cylinder extends This function occurs only when the cylinder is extending in a low to medium load condition which occurs as the upper shear jaw is moving toward the material to be cut As the shear jaws close down on the material to be cut the cylinder meets resistance and requires more operating pressure The pilot valve on the speed valve senses this increased pressure and shifts the valve spool out of the speed mode The rod side fluid is now directed back to the base machine reservoir and full system operating pressure can now be directed to the bore side of the cylinder allowing the shear to cut the material with maximum force GETTING THE FEEL OF THE SHEAR Before starting the first job with a new machine it is suggested
45. N 4 OPERATION EI e CEN ESQ 4 2 4 2 Safety Devices You ll Need 4 2 General Rules for Safe Operati PPM 4 3 Mobile Shear Controls a a a aea anina EEEREN 4 4 Operating the Rotat 4 6 Backdrivirig the Rotator iea a 4 6 Operating the Internal Rotation Control aaaaasssssisasqaysyiqhaqaqasawanqusaqaaqkiha 4 6 Recharging the Accumulator with Fluid 4 6 Speed valve Operating m oreet EU RUDI ERU Hum Ld ees 4 7 Getting the Feel of the Attachment rene eene 4 7 SECTION 5 MAINTENANCE Scheduled Maintena ge 5 2 Recommended Spare Parts uuu u u u w unssuasmakanaspakastuikanssqaqaysudhwskusysiaquskayashasqakapasskaya 5 3 Maintenance Safety Procedures 5 4 General Rules Tor uuu 5 4 8 Hour Service Recommended 5 5 80 Hou r Service Recommended 22 senes aane 5 5 2000 Hour Service Recommended rne nire brake innen anta ena rk I La PROP PRIX APA 5 5 PIOUS SC IO utis 5 6 80 H
46. NOT use these values if a different torque value or tightening procedure is listed for a specific application Torque values listed are for general use only Check tightness of cap screws periodically Shear bolts are designed to fail under predetermined loads Always replace shear bolts with identical grade To prevent them from failing when tightening make sure fastener threads are clean and properly engaged TORQUE VALUES FOR FOUR BOLT FLANGE FITTINGS CODE 62 FLANGES NOMINAL TORQUE TORQUE 2724505 FFLBS N M D MI2x175 7 1 1 4 M12x1 75 CAUTION 1 1 4 1 T 00 Use only metric tools on metric 1 1 2 M16 2 00 hardware Other tools may not fit pes properly They may slip and cause M20x2 50 injury CODE 61 FLANGES NOTICE NOMINAL CAPSCREW TORQUE TORQUE Do not use air wrenches Tighten each sa 09005 o 3 4 M10x1 50 hum Mis 7o 2 wi2x78 7o Page 38 Section 5 Maintenance e MSD SABER SERIES SHEARS APPLYING SPLIT FLANGE 4 Torque the fasteners in diagonal sequence in CLAMPS small increments until final torque level is achieved 1 Clean sealing surfaces and make certain they are Torque values for flange connections are listed on free from nicks scratches and burrs Foreign mate page 34 Notice that the torque values vary accord rial prevents a proper seal see Figure 5 40 ing to the size and fastener type lt q oo Y I j ED Gi 5 0 000
47. NOTICE Never operate a shear when the blade edges have round to a 1 4 6 mm radius or more Operating the shear with badly worn blades greatly decreases shear performance and can eventually cause structural and hydraulic damage to the shear 1 Keep track of all parts and their positions as you remove them This will be important when reinstalling 2 Once the blades are removed use a small grinder to clean up the edges and blade seats remove sharp burrs and smooth out deformations 3 See Figure 5 16 Turn each original blade end forend and return each one to its original seat When done you have completed the procedure for the first blade edge rotation 4 See Figure 5 17 For the second blade edge rotation when edges have rounded to a 1 4 radius swap the blade positions primary to secondary and secondary to primary 5 Whenever you rotate or replace cutting blade edges make sure all blades are seated properly and use a new set of blade bolts and torque according to the Dry Bolt Torque Chart in the SOM Always use the same size and class of bolts Refer to your Parts Catalog to order replacement bolts from your authorized Stanley LaBounty dealer 6 Cross blade and guide blade maintenance should be performed when lower blades are being rotated Keep track of all parts and their positions as you remove them to make reinstallation easier Maintenance Section 5 21 MSD SABER SERIES SHEARS CUTTING BLADE SHIMMING
48. S continued 1538 HIGHWAY 2 TWO HARBORS MN 55616 tel 1 800 522 5059 fax 1 218 834 3879 www stanleyhydraulic com Attachment Model GREASE DECAL PART NUMBER 116338 FIGURE 1 4 DANGER Serial Number Year of Manufacture Weight kg Made in the U S A with Global Materials MODEL SERIAL NUMBER PLATE PART 511045 FIGURE 1 7 Top and front cab guarding required during any material processing application U S PATENT NUMBERS EPO PATENT NUMBERS 5 474 242 7 240 869 435 702 AE s HOI08 5 531 007 7487930 737 107 FIGURE 1 5 5 992 023 7578 461 1 682 299 7322 273 7832 130 1 789 225 8 146 256 8 104 384 STANLEY LABOUNTY 1538 Highway 2 1 800 522 5059 Two Harbors MIN 55616 www stanleyhydraulic com FOREIGN PATENTS AND OTHER PATENTS PENDING T 75 feet 23m NCC FIGURE 1 8 KEEP AWAY 116404 SAFE VIEWING DISTANCE DECAL PART NUMBER 116389 FIGURE 1 6 Page 6 Section 1 Introduction to Safety lt gt MSD SABER SERIES SHEARS SECTION 2 ABOUT THE ATTACHMENT Niodel 8 tION e pa u mm 2 2 2 2 Attachment ISIS 2 3 Attachment a ar a ar a ee 2 4 Flow and Pressure Requirements 2 7 About the Attachment Section 2 Page 1 MSD SABER SERIES SHEARS MODEL DESCRIPTION Since LaBounty mobile shear technology was introduced many FEATURES changes have tak
49. ST The following is a description of the parts Stanley LaBounty recommends to have on hand for these benefits 1 Less downtime for lack of a part 2 Original equipment manufacturer parts are inspected to Stanley LaBounty standards for proper fit and function 3 Eliminate the possibility of a part being unavailable for immediate delivery 4 Eliminate overnight air freight costs 5 The accessibility of replacement parts assures the proper shear maintenance will be followed and there fore increase the efficiency of the shear UPPER AND LOWER JAWS OFTHE SHEAR NOTICE BASIC ASSEMBLY Do not substitute parts unless you know they are Cutting blades the same in ALL characteristics Your warranty could Guide blade be compromised by using parts other than original All bolts and washers used to fasten blades LaBounty parts Blade shims for lower shear blades not supplied with new blades Complete blade kits NOTICE UPPER SHEAR Refer to the shear parts catalog for specific part Saber Tip numbers Be sure to reference the attachment serial One extra upper secondary blade number All bolts amp washers used to fasten tip HYDRAULIC ASSEMBLY All hydraulic hoses O ring face seal adapters ORS CYLINDER ASSEMBLY Cylinder seal kit ordered by cylinder part number and serial number ROTATION ASSEMBLY if equipped Crossover relief or motion control valve one is applicable to each rotation assembly MANIFOLD ASSEMBLY if equi
50. The following procedure is recommended by Stanley LaBounty for speed valve adjustment on any fully assembled and installed Saber Series Hydraulic Cylinder Prior to making any adjustments to the valve verify whether the valve is operating properly by checking the following operational conditions For condition a as described on page 5 43 install a pressure gauge into the MAZ test port to see if the pressure drops to zero when fully closing the shear jaw For condition b as described on page 43 compare the closing speed of the shear to the open ing speed If the closing speed is equal to or less than the opening speed then the valve is shifting properly into the regenerative speed mode This procedure requires more than one individual in close proximity to the shear and shear operation Keep within sight when operating the shear Ensure all persons are clear before cycling the shear This procedure requires adjustments to be performed with the hydraulic system pressurized 1 Position the attachment on firm level ground so the speed valve is easily accessible 2 Turn the excavator off and release all hydraulic pressure to the shear by working the excavator controls in all directions Be certain to relieve the air pressure in the excavator reservoir Refer to the excavator operator s manual for proper excavator hydraulic pressure relief procedures 3 Slowly remove the plugs from the MBS port and the MAZ port on the sp
51. Turn the excavator off and release all hydraulic pressure to the shear by working the excavator controls in all directions Be certain to relieve the air pressure in the excavator reservoir Refer to the excavator operator s manual for proper excavator hydraulic pressure relief procedures Detach the digital pressure gauge s and pressure line s from the MBS and or MAZ test fitting s Slowly remove the test fitting s from the test port s as in step 3 of this procedure and replace the MBS and or MAZ port plug s 16 Restart the excavator Check for leaks by using a piece of cardboard or other rigid material Repair all leaks before using the shear Re apply the correct torque to all speed valve fasteners including split flanges if found leaking Use the table on page 8 26 for correct torque values 17 Speed valve troubleshooting procedures can be found on page 7 10 in the Troubleshooting section in the back of this manual MSD SABER SERIES SHEARS SPEED VALVE ADJUSTMENT continued SPEED VALVE ASSEMBLY TORQUE VALUES MSD 1500 4500 SHEARS Proper bolt installation is critical to ensure the safe and efficient operation of the speed valve Carefully follow the steps below to properly install bolts NOTICE Please note that the parts illustrated below Figure 5 47 and on pages 5 50 through 5 51 are for 513029 which is used in MSD 1500 2000 2500 3000 4000 and 4500 shears For MSD 7500 and above refer to your parts catalog for the
52. ace any damaged lines d Hydraulic swivel seal bypass i Check for seal bypass consult your dealer service department for instructions Install new seal kit if neces sary 3 Jaws move too rapidly a Hydraulic flow to attachment is i Reduce flow to the attachment excessively high NOTE The attachment may be damaged if flow exceeds the recommended GPM 4 Upper shear jaw drifts a Excavator hydraulic valve open i Check hydraulic circuit to verify Replace with closed or closed is open center type center spool type b Excavator control valve is faulty 1 Refer to excavator maintenance manual for correct procedures check for sticky spool check for circuit relief valve bypass check for spool seal bypass c Hydraulic cylinder seal bypass i Check for seal bypass replace seals if necessary d Hydraulic swivel bypass if rota i Check swivel for bypass replace seals if necessary tor Page 2 Section 7 Troubleshooting em continued MSD SABER SERIES SHEARS CUTTING PERFORMANCE TROUBLESHOOTING GUIDE SYMPTOM PROBABLE CAUSE REMEDY 5 Does not shear material 6 Material jams a Wrong type of material for shear size b Worn blades Excessive blade gap d Hydraulic lines are kinked e Hydraulic pressure at shear is too low f Excessive back pressure g Cylinder seal bypass a Excessive blade gap b Worn Saber tip c Dull blades d Blades not within LaBounty specifications i C
53. aded into the blade NECESSARY 2 The blades may come loose from their seats without much effort If the blades are loose make sure they are well supported before removing the blade bolts 3 If the blades are not loose tap on the blade face with a soft faced mallet to loosen the bond between the blade and seat Use a pry bar between the top of the blade and the blade seat to loosen the blade Never strike against any blade with a hardened steel tool of any kind The blade may chip and cause severe inj ALL BOLTS jury PARTIALLY UNTHREADED 4 If the blade is still jammed in its seat place a wood block or similar object against the head of one of the blade bolts and strike with a mallet see FIGURE 5 6 Figure 5 6 The bolt being struck should be within 1 2 13 mm of being fully threaded into the blade to prevent thread damage am Page 14 Section 5 Maintenance MSD SABER SERIES SHEARS BLADE BOLT TORQUE SPECIFICATIONS Proper torque of the LaBounty shear blade bolts is a crucial factor in extending the life of the shear and blade components Maintaining the proper torque according to the specifications in this manual will help prevent loosening of blades and possible dam age to the blade seats LaBounty shear blades can be rotated to utilize all four blade edges see Figure 5 7 for the compo nents of a typical blade replacement kit Blade bolts and washers can typically be used for the life of the
54. amage i Rebuild or replace motor i Check base machine s hydraulic system i Adjust flow control to decrease flow from the accumulator i Push in manual overrides alternately then if sticking try operating valve i Check electrical wiring valve coil elec trical ground i Chec age for contamination or seal dam i Check shear manual i Check shear manual i Push in manual overrides alternately then try operating valve Troubleshooting Section 7 Page 9 MSD SABER SERIES SHEARS SPEED VALVE TROUBLESHOOTING GUIDE There are two basic operating conditions of the speed valve that have a negative effect on shear performance and require troubleshooting and adjustment or repair The first condition occurs when the speed valve does not seem to shift into the regenerative or speed mode resulting in the shear closing slowly The second con dition occurs when the speed valve does not shift out of the speed mode at the appropriate time resulting in a loss of shear cutting force These conditions are referred to below with corrective actions listed to remedy the problem For complete step by step instructions on adjusting the speed valve please refer to page 4 37 If the problem still exists after attempting these adjustments please contact your Stanley LaBounty dealer or the Stanley LaBounty Customer Service Department for further instructions The following tools and equipment are needed to properly troubleshoot an
55. and outer edges e Stagger the ends of the welds and do not end a weld adjacent to a blade bolt hole Use a grinder to taper the ends of each weld down to the base material Grind marks should go with the grain Do not undercut the ends of the weld with the grinder 5 Apply hardsurfacing on top of each of the underlayment beads Do not apply hardsurface directly to the parent material It is important to use an air operated slag peener on each pass of weld to relieve stress 6 If the temperature within 6 150 mm of the weld area has dropped below 400 F 200 C during the weld process post heat this area to 400 200 C 7 Wrap with a heat blanket and allow the welded area to cool slowly to the ambient temperature The shear should not be put back into service until it has cooled completely STAGGERWELDS BUILD UP AREA FLUSH 5 BUILD UPAREA FLUSH WITH BLADE GRAIN DIRECTION FIGURE 5 23 FIGURE 5 24 FIGURE 5 25 Maintenance Section 5 27 MSD SABER SERIES SHEARS WELD IN MAINTENANCE if equipped Check the condition of the piercing tip daily It should be square and fit closely between the blades of the lower shear All blade maintenance should be complet ed before building up the piercing tip The condition of the piercing tip has a large effect on the piercing ability of the shear If the tip is worn it is suggested that the tip be built up and hardsurfaced If the tip is badly worn it is reco
56. ar plate so there is approximately 1 2 12 7 mm gap between the wear plate and the piercing tip and equal dis tances on the other sides of the seat Clamp the wear plate into position 5 Bring the preheat back up to 400 F 200 C and tack the tip in place The upper shear must be grounded when welding on the upper shear to prevent the possibility of electric shock and arcing through the cylinder or main pivot components Page 32 Section 5 Maintenance NOTICE Check temperature frequently during this procedure Maintain 400 450 F 200 230 C Do not exceed 450 230 FRONT WEAR PLATE FIGURE 5 34 MSD SABER SERIES SHEARS LOWER WEAR PLATE REPLACEMENT The lower wear plates protect the lower cross plate from excessive wear Inspect these plates every 80 hours and replace them before the cross plate is in danger of being exposed to wear Use the following instructions to replace the lower wear plates 1 Preheat the surrounding area to about 200 F 100 C to remove moisture Preheat the area within six inches 150 mm of the lower wear plates to a minimum of 400 F 200 C and a maximum of 450 230 C Maintain this temperature range throughout the process Temperature melt sticks are available from Stanley LaBounty 2 Airarc the old wear plates to remove them com pletely from the nose plate 3 Use a grinder to make sure the surfaces are flat and smooth with all weld and carbon residue re moved If
57. auge wire from the base machine s DC voltage power supply and connect it to a 15 amp circuit breaker fuse The power source should be accessory side or a similar source that provides volt age only when the starter key switch is in the ON position and should have a 5 amp minimum rating 4 Connect a 14 gauge wire from the circuit breaker or fuse to the red wire of the electrical cord running up the boom to the electrical plug Connect another 14 gauge wire from the circuit breaker or fuse to this red wire of the electrical cord coming from the foot switch The red wire from the electrical plug and the red wire from the foot switch can be con nected 5 Connect the black wire from the boom cord to the black wire from the foot switch cord Connect the white wires in the same way The green wire from the foot switch cord will not be used To prevent electrical shock short or accidental start up do not connect to the power source until the entire system is installed NOTICE Make sure to complete all installation procedures de scribed in this section before starting the machine Operating the shear before proper installation is complete may cause damage to the base machine MSD SABER SERIES SHEARS ELECTRICAL SCHEMATIC INTERNAL ROTATION CONTROL SYSTEM if equipped 12V OR 24V DC ELECTRICAL CORD POWER SUPPLY RECEPTACLE 5 AMP FUSE OR PLUG BREAKER RED RED WHITE i WHITE BLACK GREEN H BLACK GREEN LL
58. ble Bearing Bolts Page 6 3 8 26 Rotation Assembly Bolts Page 6 3 8 26 e End Cap Bolts Page 8 26 e SAE Straight Thread Port Hex Head Bolts Page 8 25 e Nation Pipe Thread NPT Page 8 26 For all other bolts used in the LaBounty shear use the Generic Torque Table below SIZE FTLBS FTLBS 7n de 85 ne Always replace bolts and nuts with the same size and class of fastener Inferior fasteners can fail and cause injury or death and damage to the equipment NOTICE It is preferred to apply torque to the nut rather than the bolt head wherever pos sible Section 5 11 MSD SABER SERIES SHEARS SLIDE SCREW MAINTENANCE Maintenance of the slide screw area is very important for keeping the cutting blades in line and for proper operation of the shear This critical area should be inspected and adjusted every 80 hours Use the following instructions to maintain and adjust the slide screw 1 See Figure 5 3 To check and or replace the slide screw remove the bolts and lock plate see Figure 5 5 page 5 13 Use a crescent wrench on the square end of the slide screw and turn it clockwise to adjust counterclockwise to remove 2 Look at the face of the slide screw to determine if there are still grease grooves see Figure 5 4 If the grease grooves are worn away it will be necessary to replace the slide screw If the slide screw needs to be repla
59. ced continue on with step 3 3 remove the slide screw turn counterclockwise and back it completely out To adjust the slide screws cycle the upper jaw until the slide screw is centered on the wear plate Clean the inside threads if neces sary and thread in the new slide screw until it just makes contact with the wear plate both sides Re install the lock plate and lock bolts and lock the adjusted slide screw into position 4 Apply grease to the entire assembly through the grease fitting in the slide screw Also apply a layer of grease to the rear wear plates on the upper shear with a brush or grease gun Do not apply grease by hand 5 t is recommended that the slide screws be completely removed every 80 hours of operation the threads both internal an external be cleaned and then coated with 2 EP Lithium grease Failure to do so will result in the slide puck jamming and becoming ineffective SQUARE END LIDE SCREW Pid GREASE GROOVES 95 FIGURE 5 3 k WY FIGURE 5 4 DANGER DO NOT cycle or move the shear while unthread ing the slide screw by hand This will result in severe injury Keep clear when the shear is in motion Avoid pinch points such as the upper shear or the shear cylinder or severe injury could result Page 12 Section 5 Maintenance La County MSD SABER SERIES SHEARS SLIDE SCREW MAINTENANCE continued NOTICE e Some models 2500 have a spacer beneath the lock plate e MSD
60. charge with i Unloading valve is faulty Replace un hydraulic fluid loading valve 2 Rotation very slow a Operating pressure is too low i Check pressure at the gauge G port this should be 2000 2500 PSI adjust pressure reducing valve if necessary b Flow control valve cartridge i Remove check for contamination ii Replace flow control valve c Faulty unloading valve i Check electrical ground wire at the unloading valve ii Remove cartridge and check for con tamination or seal damage d Crossover relief bypassing oil i Replace crossover relief valve e Operating flow is too low i Adjust shear flow control to increase flow to the rotation assembly Page 8 Section 7 Troubleshooting GUIDE if equipped continued MSD SABER SERIES SHEARS INTERNAL ROTATION CONTROL SYSTEM TROUBLESHOOTING SYMPTOM PROBABIECAUSE REMEDY 2 Rotation very slow continued 3 Rotation speed too fast 4 Rotation is erratic f Internal leakage of valve g Hydraulic motor is faulty h Supply flow too low a Operating flow too high a Directional valve spool b Faulty electrical signal at directional valve or unloading valve c Flow control valve cartridge is faulty d Faulty crossover relief on motor e Faulty hydraulic motor a Directional valve spool 15 sticking i Remove unloading valve and relief valve cartridges in control valve cartridges check for contamination or seal manifold d
61. close to its center of gravity as possible 2 When processing a long member that is suspended make several shorter cuts rather than one long cut where the member can come loose and backdrive the rotator 3 When processing any rigid member use the rotator to square the jaws to the cut If the jaws are not square the rotator will backdrive to adjust to the cut OPERATING THE INTERNAL ROTATION CONTROL SYSTEM if equipped The foot switch installed in the operator s cab is used to operate the Internal Rotation Control System assuming an alternative customer provided switch is not used The foot switch provided by LaBounty has three positions center front toe and back heel The switch will automatically move to the neutral center position when it is not being used No rotation occurs in this position The other two positions will cause the shear to rotate One position will cause clockwise rotation and the other will cause counterclockwise rotation RECHARGING THE ACCUMULATOR WITH FLUID When using the Internal Rotation Control System the shear will typically rotate between 100 and 270 each time the accumulator is charged with fluid When the accumulator runs out of fluid charge it is necessary to recharge the system before rotating the shear again To recharge the system simply open or close the shear The system draws hydraulic fluid from the jaw circuit when the jaws are operated Page 6 Section 4 Operation e MSD SABER SERIES S
62. crease shear performance and may cause internal damage to the cylinder It is recommended that this work by performed by an authorized Stanley LaBounty Dealer The Nylock lock ring must be replaced each time a new seal kit is installed It is recommended that the cylinder shear seals be replaced by an authorized Stanley LaBounty dealer The Nylock lock ring must be replaced each time the cylinder seals are installed 07 Maintenance Section 5 7 MSD SABER SERIES SHEARS 8 HOUR INSPECTION ROTATOR CHECKLIST Shear Model Excavator Hour Meter Shear Serial Number Date 1 Visually check all turntable bearing bolts and replace any that are loose or damaged 2 Grease the turntable bearing refer to the Rotator Maintenance section for instructions 3 Inspect the rotation hydraulics system a Inspect rotation hoses for wear and potential failure b Inspect rotation hose connections for leaks 4 Visually check all rotation assembly bolts Inspected by Page 8 Section 5 Maintenance MSD SABER SERIES SHEARS LUBRICATION Regular lubrication of the attachment is absolutely vital to proper operation and long life of the attachment The speed valve feature accelerates the shear cycle time and allows the shear to open and close more often throughout the day This makes it necessary to lubricate the shear more frequently than was required with older models Use premium grease No 2EP or equivalent and lubricate all points every 4 hours of o
63. d adjust the speed valve e pressure gauges two are recommended so that two test ports can be checked simultaneously e diagnostic test fittings and tools for installing the fittings set of open or box end wrenches 12mm 19mm e a set of Allen wrenches 4mm 12 mm SYMPTOM PROBABLE CAUSE REMEDY 1 Shear does not shift consistently a Pilot pressure setting is too high i Adjust the pilot valve adjustment screw into speed mode when closing counterclockwise in increments of 1 8 of the jaw a turn 45 until corrected 2 Shear shifts into speed mode a Too much back pressure in the base i Minimize back pressure if possible by when jaw has been fully opened machine return line using lines with larger diameters but will not shift if jaws have only ii If i is not possible or does not com been opened partially pletely solve the problem adjust the main spool and then close adjustment screw clockwise in increments of 1 8 of a turn 45 until corrected 3 Shear jaw continues to close The main valve spool in the speed valve i Adjust the main spool adjustment after the shear has shifted into is not fully shifting out of speed mode screw clockwise in increments of 1 8 of a speed mode and the operator has turn 45 until corrected let go of the control 4 Shear properly shifts into speed a The main valve spool is not fully shifting i Adjust the pilot valve adjustment screw mode but seems to lack power out of spee
64. d mode counterclockwise in increments of 1 8 of a turn 45 until corrected Page 10 Section 7 Troubleshooting LIMITEDWARRANTY NEWATTACHMENT Stanley LaBounty warrants its manufactured products against deficiency in material or workmanship for a period of 12 months from the date of first use rental sale or 1500 hours of operation whichever occurs first Limitations Remanufactured or used product or service repair are not warranted under this Limited Warranty e Product that is damaged by alteration improper maintenance unauthorized service abuse misuse or contamination by the base machine is not warranted e This Limited Warranty is the exclusive warranty Stanley LaBounty makes no representations expressed or implied of merchantability or fitness for a particular purpose e Agents of Stanley LaBounty have no authority to make representations beyond those contained herein Exclusive Remedy The exclusive remedy for a product Stanley LaBounty determines deficient in material or workmanship is repair or replacement at Stanley LaBounty s option The following procedure governs a repair or replacement warranty claim 1 All warranty claims require a claim number provided by Stanley LaBounty Service Department 2 Afactory issued Return Goods Authorization tag RGA must accompany returned product 3 Returned product found deficient by Stanley LaBounty will be replaced or repaired without charge FOB Distr
65. dislodge the blade 6 Use a small grinder to clean up the blade edges Remove sharp burrs and smooth out deformations Clean out the blade seats in the same way remov ing any debris or burrs 7 Ihe cross blade can be rotated one time to in crease its life If the current cross blade has not already been rotated once turn it end for end and NO GAP lace it back in its seat If the cross blade has al been rotated once it will need replaced APPLYINGTORQUETO BLADE AND SABER 8 If there were shims behind the cross blade when BOLTS it was removed make sure to reinstall them see Figure 5 12 Replace any damaged shims Tap the face of the blade with a soft faced mallet to make sure that it seats firmly 9 Like the cross blade the guide blade can be rotated one time to increase its life If the current CROSS BLADE CROSS BLADE SHIMS guide blade has not already been rotated once turn it end for end and place it back in its seat Only use one face of the guide blade before replacing FIGURE 5 11 FIGURE 5 12 m Maintenance Section 5 Page 19 MSD SABER SERIES SHEARS CUTTING BLADE ROTATION continued 10 After rotation or replacement place the guide blade back in its seat without shims Use a new set of guide blade bolts and tighten them until snug Do not apply torque to the bolts yet Make sure the blade is seated snugly 11 Rotate the lower cutting blades accordin
66. duction to Safety DO NOT weld on any structural member unless specifically authorized by LaBounty Any unauthorized welding or welding procedures will void the warranty and may cause structural failure or result in personal injury ALWAYS wear close fitting clothing and safety equipment appropriate to the job Safety equipment should be worn at all times when viewing operating or maintaining the attachment to prevent injury Safety equipment includes eye protection hard hat steel toe shoes gloves and hearing protection i Keep clear of all potential pinch points including the moving upper jaw cylinder connections bucket linkages or other moving parts Before operating the attachment read and observe all safety instructions in the Operation and Maintenance sections of this manual If you are unfamiliar with any operation or maintenance procedure seek instruction before proceeding MSD SABER SERIES SHEARS DECALS STANLEY m STANLEY LABOUNTY BRAND DECALS REPLACEMENT DECAT E UPON REQUEST MODEL DECAL FIGURE 1 2 SAFETY FIRST Read the Safety Operation and Maintenance Manual before operating or servicing the equipment Keep the manual with the attachment 50 it is available for reference SAFETY FIRST DECAL PART NUMBER 503590 INCLUDED WITH MANUALS FIGURE 1 3 Introduction to Safety Section 1 5 MSD SABER SERIES SHEARS ATTACHMENT DECAL
67. e adapter to tap into base machine reservoir or return line c One 8 1 2 SAE hydraulic line plumbed from the base machine s hydraulic return to the end of the boom if the shear is mounted in place of the Stick or the stick if the shear is mounted in place of the bucket d One 15 amp circuit breaker or fuse ELECTRICAL INSTALLATION INTERNAL ROTATION CONTROL SYSTEM if equipped LaBounty provides a three position foot switch with the Internal Rotation Control System Alternative types of switches may be used in place of the pro vided foot switch if preferred Contact your LaBoun ty dealer for information on operating the control valve Any of the following can be used a Joystick handle equipped with a single pole double throw momentary three position rocker Switch b Two joystick handles each equipped with a single pole single throw momentary rocker switch or push button switch c a single pole double throw three position momen tary toggle switch mounted to the control lever with a fabricated bracket Page 6 Section 3 Installation INSTALLATION 1 Place the foot switch or other preferred control switch inside the cab in a convenient location for operating 2 Route the electrical cord with the plug up the boom and stick if the shear replaces the bucket Secure the cord to an existing hydraulic line using tie straps Attach the green wire of this cord to the base machine chassis to ground the system 3 Run a 14 g
68. e shear Stanley LaBounty strongly recommends that only qualified and certi fied welders perform this work Make sure the weld consumables and base material are clean dry and free of grease paint dirt or any other foreign sub stance that may harm the weld NOTICE Preheat and post heat Instructions must be followed exactly Failure to do so can compromise warranty coverage NOTICE Using improper build up and hardsurfacing products may result in premature wear or Increased potential for cracking and may compromise warranty coverage Maintenance Section 5 Page 23 MSD SABER SERIES SHEARS BUILD UP RECOMMENDATIONS Refer to the list of AWS classifications below to se lect a suitable build up material for LaBounty shears Weld products within these classifications meet the combined requirements for strength toughness and ductility that are essential for LaBounty applica tions Shielded Metal Arc Welding Stick Electrodes E7018 E8018 C 3 Gas Metal Arc Welding Solid Wire Electrodes e ER 705 6 Gas Metal Arc Welding Flux Cored Electrodes E711 1 e E71T 1M E80T1 Ni1 E80T1 Ni1M Innershield NR 233 Gas Metal Arc Welding Metal Powder Cored Electrodes E70C 6M E80C Ni1 Welding suppliers can assist in identifying products that meet these AWS classifications Page 24 Section 5 Maintenance HARDSURFACING RECOMMENDATIONS For hardsurfacing Stanley LaBounty recommends Amalloy 814H
69. e shear up into a position where there will be enough clearance to pin the other connection of the shear mounting bracket see Figure 3 2 FIGURE 3 2 Page 2 Section 3 Installation La gt MSD SABER SERIES SHEARS SHEAR MOUNTING PROCEDURE continued 7 Extend the cylinder rod or bucket linkage and move into position as necessary to pin this connection Install shear supplied pin It may be necessary to use a lifting device overhead hoist forklift etc to position the cylinder or linkage correctly 8 Connect the hydraulic hoses to the manifold located on each side of the head Remember to cap all hydrau lic hoses and fittings immediately to prevent contamination of the hydraulic system Tighten the bolts to the proper torque refer to Split Flang Fitting Torque Tables on page 8 26 9 On rotating models the following procedures are to be followed a After installing a hydraulic circuit on the excavator install additional hydraulic lines up the boom these will include two 1 2 13 mm diameter feed lines and one 1 2 13 mm diameter case drain line These will terminate at the end of the boom b Install jump lines from the above hydraulic lines to the shear bulkhead or manifold fittings Please refer to the parts catalog for specific flow and pressure requirements if in doubt call Service 800 522 5059 10 Check to make sure all collars fasteners and other connecting hardware are secure before proceeding 11 Lift the boom a
70. e upper secondary position Swap positions of the upper primary and lower secondary Continue this sequence discarding the lower primary and installing a new upper secondary at each blade position swap This results in an optimal Saber Tip performance at the one time cost of an additional upper secondary blade after two edges are used See Figures 5 9 and 5 10 on page 5 18 07 Maintenance Section 5 17 MSD SABER SERIES SHEARS CUTTING BLADE ROTATION continued The startup kit for every new shear contains two extra blades Keep these blades for the second time you rotate edges and replace blades For the first rotation you ll only need the original four blades the second time you ll be using new blades If you follow these directions correctly each time you order a new set of four blades you ll be setting aside two blades for a second rotation at every second blade flip two new blades will be inserted in the top blade seats NEVER ROTATE USED LOWER BLADES INTO UPPER BLADE SEATS NOTICE Never operate a shear when the blade have rounded to a 1 4 6 mm radius or more Operating the shear with badly worn blades greatly decreases shear performance and can eventually cause structural and hydraulic damage to the shear 1 See Figure 5 9 Turn each original blade end for end and return each one to its original seat When done you have completed the procedure for the first blade edge rotation
71. ears only or the rotation component will be damaged Smaller shears MSD 1000 do not require a case drain 8 HOUR SERVICE RECOMMENDED Inspect the Shear Look over the shear for damage or any clues that might indicate a potential problem Inspect Safety Devices Make sure all decals are installed and legible Inspect the condition of the cab protection and make sure visual and audible warning devices are working properly Make all repairs before using the equipment Grease Fittings Lubricate according to the shear Lubrication section Replace broken fittings Connecting Pins Inspect the mounting bracket pins and shear cylinder pins for looseness or damage Check pinheads and pin keepers Bolts Check for looseness or damage Torque if necessary according to the proper torque chart in this manual Slide Screws Inspect for damage Refer to the adjustment procedure on page 5 12 Lubricate the puck assembly and contact area Saber Tip Guide Blade Gap Inspect for damage If gap exceeds 0 030 0 76mm refer to the shimming instructions in this manual Cutting Blade Gap Inspect Shimming is necessary if the gap exceeds recommendations see page 5 17 For most applications this gap should be maintained at 0 010 to 0 020 0 25 to 0 50 mm This gap may shimmed down to 0 005 0 13 mm if jamming becomes a problem when processing thin materials Hoses Connections Cylinders Inspect for leaks wear and damage Tighten repair
72. eck cutting blade gap a Refer to manual if gap exceeds 0 030 0 75 mm 9 Inspect Saber Tip a Saber Tip fits squarely in upper jaw 10 Inspect cross blade for looseness or damage 11 Inspect Hydraulic System a Inspect hoses for wear and potential failure b Inspect hose connections for leaks c Inspect cylinder for leaks Inspected by Page 6 Section 5 Maintenance MSD SABER SERIES SHEARS 80 HOUR INSPECTION CHECKLIST Attachment Model Excavator Hour Meter Attachment Serial Number Date 1 Inspect blades a Rotate or replace upper cutting blades b Rotate or replace Saber Tip nose blade and guide blade c Measure blade gap refer to manual for shimming procedure and tolerance range 2 Inspect slide screw and slide screw gaps each side a Check for slide screw wear replace if necessary b Measure slide screw gap adjust if necessary 3 Inspect upper shear a Build up and hardsurface upper shear 4 Inspect lower shear a Replace wear plates if necessary 5 Inspect hydraulic components a Check split flanges and fittings for looseness tighten if necessary b Check hoses for wear or cracking If Rotator equipped 1 Inspect all bolts connecting the turntable bearing to the upper head and shear a Replace bolts if retorque is necessary Inspected by NOTICE IMPORTANT It is recommended that the shear cylinder and swivel seals be replaced every 2 000 hours Operating the shear with worn out seals will de
73. eed valve Turn the plugs counterclockwise until fluid begins to seep from the port Allow the fluid seepage to slow before con tinuing 4 Continue to slowly turn the plugs counterclock wise pausing momentarily in 1 4 to 1 2 turn in tervals until the plug is removed This ensures all residual pressure is relieved from the speed valve Refer to the illustration on page 5 44 of this section m for port locations Place a drainage basin below the ports to capture all escaping fluid 5 Install the test fittings supplied with the Stanley LaBounty Digital Gauge Kit P N 169832 into the MBS and MAZ ports on the Speed Valve If the port is too difficult to access for test fitting instal lation the MX port on the speed valve may also be used to monitor valve pressure 6 Attach the digital gauge and pressure line to the MAZ test port on the speed valve If two gauges are available install the second digital gauge and pres sure line to the MBS test port on the speed valve If only one digital gauge is available the MBS test port on the speed valve must be plugged at this time with the MBS port plug Mechanical liquid filled dial gauges may be used to monitor pressure in place of the digital gauges 7 Reset the main spool valve adjustment by loosen ing the 19mm lock nut on the main spool valve and turning the 6mm socket head adjustment screw counter clockwise Continue to turn the socket head adjustment screw until the end
74. eel of the Attachment nennen eene nennen 4 7 Operation Section 4 Page 1 MSD SABER SERIES SHEARS BEFORE YOU START KNOW YOUR SAFETY PROGRAM 1 Read and understand the safety section of this manual and the base machine manual 2 Know the employer s safety rules for your job Consult your foreman for specific instructions and safety equipment required 3 Learn the traffic rules at the work site 4 Know the hand signals used on the job and who is responsible for signaling Take signals from only KNOW YOUR EQUIPMENT Learn the location and function of all controls Test all controls to ensure proper operation If any malfunctions are found shut the machine down and report the malfunction for repair Be familiar with the safety devices on the machine indicators warning devices and caution instructions They will alert you to conditions that may make it hazardous to continue operating e Wear proper protective clothing including hard hat safety shoes ear protectors reflective clothing safety goggles and work gloves Loose clothing can get caught in machinery and cause injury Wrist watches rings and other accessories can be dangerous as well Know the clearances in the work area Page 2 Section 4 Operation FIRST THINGS FIRST 1 Ensure all safe viewing distance decals are installed and legible contact LaBounty for replacements as required 2 Have a DAILY Safety Dial
75. en place A wide selection of models and sizes are e Patented wear parts sys now available Product refinements like 360 continuous rotation high tem for increased efficiency performance reversed cylinders tougher steels and bolt on replace and less downtime for able wear parts have altered the look and improved the performance of maintenance LaBounty Mobile Shears Dependable spool type speed valve technology to MSD Saber Series shear models are currently available for base decrease cycle times machines with operating weights from 20 000 280 000 Ibs 9091 e Maximum cutting 130 000 kg with a range of cutting depths Both rotating and non strength and reach with rotating models are available Rotating models feature hydraulically minimal weight powered 360 continuous rotation This option allows the shear jaws to Optimum reach reduces be positioned to cut at virtually any angle machine movement and wear greatly reduces the MSD Saber Series models feature a cylinder mounted speed valve to need for stick mounting and decrease cycle times and increase efficiency This patented spool type increases safety valve design has proven significantly more dependable than cartridge Made with high strength type regenerative systems favored by other mobile shear manufactur abrasion resistant steel for ers These shears feature high strength abrasion resistant steel durability Fourway indexable blades Installs in as little as
76. er or gauge are installed in the manifold to provide a means of checking pressure Contact the Stanley LaBounty Service Department for the proper procedure for performing this check CASE DRAIN A case drain is required because back pressure can develop in the hydraulic motor case as a result of metering flow out of the motor Depending upon the shear model this port will either be a bulkhead in the upper head side plate or will be located in the hydraulic port block A 1 2 hydraulic line should be connected to this port and routed back directly to the tank via a return line filter or a filter of its own The maximum allowable back pres sure in this line should not exceed 300 PSI NOTICE The case drain line must be connected to prevent failure to the case or motor seals Rotator Maintenance Section 6 7 MSD SABER SERIES SHEARS ROTATION CONTROL VALVE ASSEMBLY SCHEMATICS AND DESCRIPTIONS Please refer to the Parts Catalog to identify the control valve assembly in your specific attachment ROTATION CONTROL VALVE USED ON MODELS MSD 1500R AND MSD 2000R MOTOR WORK PORTS A amp B SAE 8 O Ring Boss Ports GAUGE PORTS G1 amp G2 SAE 4 O Ring Boss Ports RELIEF VALVES BRAKE VALVES FIGURE 6 3 ROTATION CONTROL VALVE USED ON MODELS MSD 2500R 3000R 4000R 4500R WORK PORTS A amp B i SAE 10 O Ring Boss Ports RELIEF VALVES GAUGE PORTS G1 amp G2 SAE 4 O Ring Boss Ports
77. erating frequently in extreme environments should be lubricated at least every eight hours If the 019 grease is noted to be in good condition and free of contamination the interval may be extended Converse ly if the old grease is contaminated or deteriorated the interval should be shortened Rotating shears in storage should be lubricated at least every six months LUBRICATION PROCEDURES Bearings are equipped with one to four grease fittings depending upon the model The grease fittings will be located either on the outside of the bearing if it is an internal drive rotator or on the upper head side plate ex ternal drive To lubricate the bearing grease a fitting and then stand clear to rotate the shear This will uniformly distribute the grease and effectively flush out the old grease and contaminants Grease the same fitting again after rotating before moving on to the next fitting Grease each fitting a total of eight pumps of the grease gun or until grease escapes through the bearing seals Stand clear of the shear while rotating Grease a fitting and then stand clear to rotate the bear ing to distribute the grease DO NOT attempt to grease the bearing while the shear is rotating or severe injury could occur TURNTABLE BEARING LUBRICANTS For normal operating conditions periodic lubrication with lithium Grade 2 extreme pressure grease is recom mended For operation below 32 F 0 C Grade 0 is recommended the following table lis
78. erial make sure that the shear blades are sharp and properly adjusted Otherwise such material may become jammed in the shear blades 22 The lifting lugs are to be used for shipping and installation They are not for use in cable hung applications 23 The shear rotation function is for positioning only DO NOT use it for bending breaking or prying 24 DO NOT use the force of the excavator to force the shear into a pile 25 DO NOT apply excavator force or weight at either end of the upper shear in an attempt to un jam the shear or to cut materials that are too large for the shear Operation Section 4 Page 3 MSD SABER SERIES SHEARS MOBILE SHEAR CONTROLS There are four basic movements of a mobile shear plus one for rotating the shear if it is equipped with the rotation option Mobile shear controls will vary slightly depending on the type of base machine and whether the shear is mounted as a second or third member The shear open close and rotation systems are customized to each machine Review the shear operations with an authorized dealer or the installation technician before operating The functions for a typical shear third member installation are illustrated below see Figure 4 1 and on page 4 5 second member installation Determine the control for each movement of the shear before attempting to operate Practice the machine movements as described in Getting the Feel of the Shear instructions in this section THIRD M
79. ern with three or four passes of build up hese beads should run parallel to the blades from the nose plate back to about the mid point of the primary blade Do this on the guide blade side also This will establish the hardsurfacing pattern and serve as an underlayment 9 Apply a bead of hardsurface rod on top of each of the underlayment beads DO NOT apply hardsur face directly to the parent material It is important to use an air operated slag peener on each pass of weld to relieve stress FIGURE 5 36 BUILD UP AREA FLUSH WITH BLADE FIGURE 5 37 07 Maintenance Section 5 35 MSD SABER SERIES SHEARS LOWER SHEAR BUILD UP AND HARDSURFACING continued NOTICE Keep the outside passes at least 1 4 6 mm back from the blade seat and outer edges e Stagger the ends of the welds and do not end a weld adjacent to a blade bolt hole See Figure 5 38 Use a grinder to taper the ends of each weld down to the base material Grind marks should go with the grain Do not undercut the ends of the weld with the grinder 10 Use a similar technique to hardsurface the sides of the nose plate Establish a 45 diamond pattern of approximately 1 1 2 38 mm see Figure 5 39 Again use the build up rod to lay down the pattern and use the hardsurface rod on top Use the air operated slag peener to peen each pass to relieve weld stress and remove slag DO NOTWELD EDGES 11 If the temperature within 6
80. es shears that increases the shear closing speed cylinder extend function when the shear is not under a load thereby reducing cycle times and increasing efficiency Stanley LaBounty uses a spool type speed valve design for better durability over cartridge type regenerative valves Allows continuous hydraulic flow to the shear cylinder during rotation of shear without twisting hoses Main pivot group component that is located inside the end caps as a wear part for the main shaft Rod that extends through the center of the main pivot group The tie rod adds lateral support to the main pivot group Area of both the upper and lower jaw near the main pivot where the primary blades are located The throat area is the optimum area for shearing material The shear is most powerful on the primary blades nearest the pivot point Rotary gear bearing used in rotating shears It is mounted to the shear stick and is driven by hydraulic components in the upper head or mounting bracket This bearing is sometimes called a slewing ring Mounting bracket portion of a rotating shear Attaches to the turntable bearing that attaches to the rear of the shear stick The upper head contains the hydraulic manifolds and the swivel manifold Movable jaw of the shear that contains cutting blades the Saber Tip V and the wear area for the slide pucks The shear cylinder articulates the upper shear into the lower shear to perform the cutting action of the shear Consis
81. flow path of the fluid to the shear cylinder is the valve spool The valve spool is of similar construction to that of the excavator s main control valve spool Therefore it is considerably larger than the components found in a typical cartridge type regenerative valve OPERATING CHARACTERISTICS The function of the regenerative valve is to provide for rapid advance of the shear hydraulic cylinder during the closing phase of the shear cycle The valve accomplishes this function by shifting a valve spool to open the rod side of the cylinder to the bore side of the cylinder thus allowing the fluid in the rod side to fill the bore side when the cylinder is extending This function only occurs when the cylinder is advancing in a low load condition which occurs as the shear jaw is closing down onto the material that it is about to be cut As the shear enters the cutting phase the operating pressure requirements increase The pilot valve portion of the regenerative valve which in turn causes the valve spool to shift out of regenerative mode senses the increased pressure During this phase the rod side fluid is directed to the work line and back to the base machine s reservoir low pressure Meanwhile only the flow from the excavator s control valve is directed to the bore side of the cylinder allowing it to reach full system operating pressure This allows the shear to cut by utilizing the full power of the excavator with resistance coming only from the
82. g to the Blade Rotation Sequence diagrams on page 5 18 12 Make sure the adjustment plate is reinstalled properly and then place the blades into their proper positions without shims Use a new set of blade bolts and tighten until snug Do not apply torque to the bolts yet Ensure the blades are seated snugly NOTICE The adjustment plate behind the lower cutting blades must be reinstalled properly for the blades to be aligned The notched end of the adjustment plate should be toward the throat Figure 5 13 13 The guide blade and lower cutting blades are now ready for shimming DO NOT operate the shear without shimming the guide blade and cutting blades to the proper blade gaps Page 20 Section 5 Maintenance ADJUSTMENT PLATE NOTCH TOWARD SHEAR THROAT FIGURE 5 13 MSD SABER SERIES SHEARS WELD IN TIP CUTTING BLADE ROTATION PROCEDURE Proper rotation and adjustment of the cutting blades is very important for the best shear performance and longer shear life It is recommended that the blades be rotated after every 80 hours of use FIRST AND THIRD BLADE EDGE ROTATION SECOND AND FOURTH BLADE EDGE ROTATION FIGURE 5 16 FIGURE 5 17 i x UPPER SECONDARY K es OJ LOWER PRIMARY 1 Remove each blade 1 Remove all blades 2 Turn end for end 2 Swap the blade positions 3 Reinstall in same seat 3 Replace Weld In Tip as required 4 Replace Weld In Tip as required
83. gs to relieve air pressure to the shear cylinder Position the shear so the cylinder is as horizontal as possible Sett the excavator at idle speed or slightly above idle speed WITH CYLINDER FULLY RETRACTED 1 Slowly fill the rod end of the cylinder open the shear until a noticeable change in tone of the excavator is heard indicating full cylinder Do not operate to the machine s full operating pressure 2 Change direction of oil flow slowly fill the bore end of the cylinder close the shear until the rod is extended approximately 1 4 of stroke 3 Retract the cylinder rod all the way 4 Repeat steps 2 and 3 extending rod to approximately 1 2 stroke then 3 4 stroke then full stroke 5 When cylinder is full of oil slowly cycle cylinder rod back and forth at least five times through full stroke Do not operate to the machine s full operating pressure WITH CYLINDER FULLY RETRACTED 1 Slowly fill the bore end of the cylinder close the shearO until a noticeable change in tone of the excavator is heard indicating full cylinder Do not operate to the machine s full operating pressure 2 Change direction of oil flow slowly fill the rod end of the cylinder open the shear until the cylinder rod is retracted approximately 1 4 stroke 3 Extend the cylinder rod all the way 4 Repeat steps 2 and 3 retracting cylinder rod to appoximately 1 2 stroke then 3 4 stroke then full stroke 5 When cylinder is full of oil slowly cycle cylinde
84. he following tools and equipment are needed Hydraulic pressure gauge 0 5000 PSI range Accumulator charge and test unit O 1000 PSI range e Volt Ohm meter e Standard blade screwdriver e Crescent wrench or similar tools for cover removal 3 16 Allen wrench Test Ilght optional SYMPTOM PROBABLE CAUSE REMEDY 1 Will not rotate a Faulty rotation motor i Check motor per manual b No flow to rotation motor no fluid in i Check for flow out of ports A amp B accumulator ii Check accumulator precharge pres sure should be 650 PSI c Faulty unloading valve i Check electrical power to the unloading valve ii Remove cartridge and check for con tamination d Operating pressure is too low i Check pressure at the gauge G port which should be 2000 2500 PSI adjust pressure reducing valve if necessary Troubleshooting Section 7 7 MSD SABER SERIES SHEARS ie ROTATION CONTROL SYSTEM TROUBLESHOOTING if equipped continued SYMPTOM PROBABLE CAUSE REMEDY 1 Will not rotate continued e Directional valve not operating i Check electrical signal to valve coils If Spool sticking the electrical signal is good the coil is faulty electrical signal faulty and must be replaced faulty valve solenoid coil ii Check continuity of valve coil f Flow control valve cartridge is faulty i Remove check for cartridge contamina tion ii Replace flow control valve 9 Accumulator does not
85. heck material size and type then consult your LaBounty dealer or factory i Rotate blades per maintenance manual instructions i Check blade gap and shim refer to shimming proce dure ii Replace with LaBounty approved blades iii Replace thrust washers NOTE Always consult your LaBounty dealer before entering the main pivot group i Check the lines feeding oil to the shear replace any kinked lines i Compare with excavator s specific operating pressure ii Check the shear cylinder Check the shear rotation manifold if equipped iv Check the excavator hydraulic system i Check for kinked lines on the return side rod ii Check the size of the lines iii Check for restrictor valve in the circuit iv Check the return filter replace if necessary v Check the control valve i Replace seal kit and inspect for any necessary repairs to the cylinder i Add blade shims refer to blade shimming in jaws procedure ii Replace worn blades i Either rotate or replace i Rotate blades ii Replace if all four edges are dull with LaBounty ap proved blades i Replace blades with LaBounty approved blades Troubleshooting Section 7 Page 3 MSD SABER SERIES SHEARS CUTTING PERFORMANCE TROUBLESHOOTING GUIDE continued IMPORTANT NOTE If the shear is jammed with material caught in the jaws and will not open lubricate the blades with penetrating oil and attempt to cycle the shear open If the jam persists remove the
86. ibutor Customer or will be credited to account balance 4 Authorized repair can occur at the Stanley LaBounty factory or authorized Stanley LaBounty Dealer Labor for warranty repair will be paid under a formula determined by Stanley LaBounty Stanley LaBounty is not liable for incidental or consequential costs or losses incurred by the product purchaser or user Limited Warranty To validate the Limited Warranty a completed warranty certificate and delivery inspection report must be returned to Stanley LaBounty Prohibited operation and or unauthorized adjustment or assembly will void this Limited Warranty See the Operation Maintenance and Safety Manual Contact Information Contact your Stanley LaBounty Dealer or Stanley LaBounty regarding warranty questions All requests for information service or spare parts should include model and serial numbers For the nearest Stanley LaBounty dealer contact Stanley LaBounty 1538 Highway 2 Two Harbors MN 55616 8015 USA Phone 218 834 2123 or 800 522 5059 FAX 218 834 3879 E mail labountyQstanleyworks com Website www stanleyhydraulic com A 3 512141 ver 6 2012 The STANLEY and LABOUNTY names and logos are registered trademarks of Stanley Infrastructure Solutions
87. is Eben tata ree n Ese Fas aeria itai tA 7 10 Troubleshooting Section 7 Page 1 MSD SABER SERIES SHEARS CUTTING PERFORMANCE TROUBLESHOOTING GUIDE The information contained in this guide provides for troubleshooting the LaBounty shear only Any references to the excavator will be made only to give some guidance as to where a problem may exist Any specific main tenance and troubleshooting information will need to be provided by the Original Equipment Manufacturer of the excavator or the authorized dealer If a question arises regarding the operation or maintenance of the shear contact your LaBounty dealer for the proper instruction SYMPTOM PROBABLE CAUSE REMEDY 1 Upper shear jaw will not No hydraulic fluid to shear i Check hydraulic flow at hydraulic manifold block on move cylinder shear ii Check excavator hydraulic circuit b Broken hydraulic swivel i Replace swivel and flush hydraulic circuit if rotator c Shear is jammed i Consult the LaBounty Customer Serice department for instructions 2 Cutting speed is ex a Excavator oil supply flow is too i Check flow to shear and compare with recommended tremely slow low flow see hydraulic letter ii Check for excessive back pressure Check excavator hydraulic system b Hydraulic cylinder seal bypass i Check for cylinder seal bypass replace seals if neces c Hydraulic lines are kinked i Check hyaraulic lines repl
88. it directly affects the performance of the rotator For this reason it is necessary to check and maintain the proper accumulator precharge Prior to testing or precharging lower the shear to the ground and support it properly in a position that will give you the best possible access to the accumulator It is necessary to drain the accumulator of hydraulic fluid to accurately measure its precharge This is done by shutting off the base machine which will cause the unloading valve to drain the accumulator To work on the accumulator the protective cap and cap nut must be removed The O ring must not be removed Install a Schrader valve into the accumulator if one does not already exist there Contact the LaBounty Service Department if the Schrader valve hasn t been installed on your accumulator Attach an accumulator charge and test unit so the gauge can be easily read The location of some accumulators may require a special adapter for access to the gas valve Rotator Maintenance Section 6 11 MSD SABER SERIES SHEARS TESTING THE ACCUMULATOR CAP PRECHARGE Once the test united is attached make sure the relief valve is closed and then turn the spindle When CAP NUT the pointer of the gauge begins to move turn the spindle one more full turn The gauge should now show the amount of accumulator precharge pres sure The proper amount of accumulator precharge is 1100 1200 PSI 76 83 BAR If the gauge is showing something o
89. lease note that the parts illustrated below Figure 5 51 and on pages 5 54 through 5 55 are for speed valve 511461 which is used in MSD 7500 and 9500 shears 1 Always replace bolts and nuts with the same size and class of fastener Replacement fasteners can be ordered from the Stanley LaBounty Parts Department to ensure the correct part is used Unless otherwise specified use class 10 9 metric hex head capscrews class 10 9 metric flat head capscrews and class 12 9 metric socket head capscrews 2 Make sure bolts nuts and bolt holes are free of dirt oil grease and other contaminants 3 The torque values in this manual are for use with non plated fasteners with clean dry threads These val ues are suitable for use with or without thread adhesives such as Loctite products SPEED VALVE ASSEMBLY P N 511461 USED IN MSD 7500 AND 9500 SHEARS FIGURE 5 51 ITEM PART NUMBER DESCRIPTION TORQUE 512210 Socket Head Screw 4 31 ft 165 43 Nm M8X1 25X35 Maintenance Section 5 51 MSD SABER SERIES SHEARS SPEED VALVE ADJUSTMENT continued SPEED VALVE ASSEMBLY TORQUE VALUES MSD 7500 9500 SHEARS MAIN BLOCK ASSEMBLY P N 512330 USED IN MSD 7500AND 9500 SHEARS FIGURE 5 52 ITEM PART NUMBER DESCRIPTION TORQUE 5 1512338 Screw Plug M8X1 75 ft lbs 10Nm Page 52 Section 5 Maintenance MSD SABER SERIES SHEARS SPEED VALVE ADJUSTMENT continued SPEED VALVE ASSEMBLY TORQUE VALUES MSD 7500 950
90. llow recommended precautions and safe operating practices Indicates immediate hazards that WILL result in severe personal injury or death Indicates hazards or unsafe practices that CAN result in severe personal injury or death Indicates hazards or unsafe practices that could result in damage to the machine or personal injury NOTICE Indicates notes of importance to a procedure or part MSD SABER SERIES SHEARS SAFETY SUMMARY DANGER If the attachment is functioning properly you MUST shut the machine down and follow proper lock out tag out and repair procedures NEVER operate equipment without the original equipment safety guards in place the cab glass is missing or damaged check with your dealer or manufacturer for proper replacement DANGER Ensure that the cab is equipped with the proper safety guards for LaBounty applications In addition it is required that the cab be equipped with an approved Falling Object Protection Structure FOPS when processing materials The FOPS must meet the requirements of SAE standard J1356 A transparent shatter resistant shield covering the front of the cab is also required Contact your base machine equipment dealer or manufacturer for more information on the availability of FOPS Lack of proper FOPS may result in injury or death A DANGER DO NOT process or handle material with the attachment over the operator s cab DO NOT attempt to shear brittle ma
91. low is faulty i Check base machine hydraulic system 2 Rotation is excessively a Operating pressure is too low i Replace crossover relief valve to increase the pres slow sure b Crossover relief valve bypassing oil i Replace crossover relief valve c Operating flow is too low i Adjust flow control to increase flow to rotation group 2227 Troubleshooting Section 7 5 MSD SABER SERIES SHEARS ROTATION CIRCUIT TROUBLESHOOTING GUIDE continued SYMPTOM PROBABLE CAUSE REMEDY i Replace manifold block on motor 2 Rotation is excessively d Internal leakage in manifold block on slow continued 3 Rotation speed exces sively high 4 Rotation erratic 5 Rotation drifts Page 6 Section 7 Troubleshooting motor e Motor is worn out f Supply pressure too low g Supply flow too low h Internal leakage in valve i Valve supplying hydraulic fluid is not working a Operating flow too high b Supply flow too high a Crossover relieve valve cartridge is faulty b Flow control valve cartridge is faulty c Valve spool sticking in valve supplying oil d Faulty electrical signal at control valve if electrically controlled e Planetary gearbox binding f Motor binding in planetary gearbox g Fault circuit relief valve h Varying pilot pressure to control valve a Control valve ports are open to tank with spool in neutral position b Excessive leakage in control valve spool
92. ls RE 1 4 Introduction to Safety Section 1 Page 1 MSD SABER SERIES 5 5 INTRODUCTION Your safety and the safety of others is a direct result of how you operate and maintain your equipment Read and understand this manual and other safety information provided with the base machine and be sure that you understand all controls and operating instructions before attempting to operate this equipment Failure to follow the safety precautions can result in personal injury death or property damage Carefully read all safety messages in this manual and on your equipment safety signs Keep safety signs in good condition replace missing or damaged safety signs Because LaBounty cannot foresee all hazardous circumstances the precautions listed in this manual and on the equipment are not all inclusive If a procedure method tool or part is not specifically recommended by LaBounty determine whether it is safe for you and others and that the equipment will not be damaged or made unsafe as a result of your decision to implement it The basic rules are summarized in this section of the manual They also appear throughout the manual along with additional specific rules for safety and operation Page 2 Section 1 Introduction to Safety UNDERSTAND SIGNAL WORDS When you see the following symbols and signal words on your equipment or in this manual be alert to the potential for personal injury or equipment or property damage Fo
93. m inside the gearbox These filings should be removed from the plugs before reinstalling 5 Reinstall the drain plug once the gearbox is fully drained 6 Add the applicable gearbox lubricant through top plug hole Refer to the chart on the following page for proper fill capacity for your gearbox 7 Remove lubricant catch basin 8 Reinstall top plug and gearbox access cover Support the shear with blocking or cribbing during this procedure Be sure the excavator is shut off Page 4 Section 6 Rotator Maintenance KZ MSD SABER SERIES SHEARS PLANETARY GEARBOX LUBRICANTS to 120 F 14 o to 49 C APPROVEDSOURCE GRADE SYNTHETIC SPECIFICATION Product Number 51100 6 51101 4 SAE Number 75W 90 80W 140 Gravity API 29 8 30 2 Flash PT C F Min 204 400 218 425 Flash PT C F Max 48 55 42 45 Viscosity cP Q 40 109 000 cP 26 C cST 40 C 117 cST 100 C 15 5 Viscosity Index 139 GEARBOX FILL CAPACITIES PART NUMBER FILL CAPACITY MODEL NUMBER 510783 17 fluid ounces 0 5 liter MSD 1500R MSD2000R 511491 68 fluid ounces 2 0 liters MSD 2500R 511493 68 ounces 2 0 liters MSD3000R MSD4500R 511373 68 ounces 2 0 liters MSD7500R MSD9500R 512565 22 fluid ounces 0 66 liter MSD1500R MSD2000R Rotator Maintenance Section 6 5 MSD SABER SERIES SHEARS TURNTABLE BEARING LUBRICATION FREQUENCY Equipment op
94. material being cut by the shear NOTICE TROUBLESHOOTING There are two operating conditions that affect the performance of the speed valve and will require If making the appropriate adjustments does not remedy the above conditions refer to page 6 11 of this manual for further troubleshooting guidelines If some troubleshooting by an equipment mechanic or Service representative These conditions are further difficulties are encountered the speed valve a speed valve does not seem to shift out of regenerative mode at the appropriate time resulting in the shear appearing to lose cutting power or b The speed valve does not appear to shift into regenerative mode resulting in a slow closing move ment of the shear jaw Both of these conditions can be remedied by following the speed valve adjust ment procedure discussed on the following pages may require replacement of the hydraulic seals Seal kits are available from the Stanley LaBounty Customer Service Department Shear serial number will be required when ordering Maintenance Section 5 Page 43 MSD SABER SERIES SHEARS SPEED VALVE ADJUSTMENT continued FIGURE 5 46 A MAIN SPOOL VALVE ADJUSTMENT B PILOT VALVE C PILOT VALVE HOUSING D MAIN SPOOL HOUSING Your speed valve may vary slightly from this isometric illustration which is not to scale Page 44 Section 5 Maintenance MSD SABER SERIES SHEARS SPEED VALVE ADJUSTIVIENT continued
95. mmended that a new piercing tip be installed Instructions for replacing the tip are on the following pages This maintenance should be done at the end of the work day to allow adequate cooling time before putting the shear back into production 1 Use a straight edge to determine how much build up is needed along the sides of the piercing tip Place the straightedge along the cutting blades and extend it beyond the tip see Figure 5 26 The tip should be flush with the blades 2 Now do the same on the other side of the upper shear The tip should be flush with the front wear plate see Figure 5 27 If there is a gap this area needs to be built up 3 Use the build up template provided by Stanley LaBounty to determine the amount of build up needed on the front and bottom surfaces of the tip Line up the template with the edges of the cutting blade and check the wear see Figure 5 28 on page 31 4 Clean all dirt and grease from area to be built up 5 Preheat the area surrounding the tip to about 200 F 100 C to remove moisture Preheat the area within 6 inches 150 mm of the weld location to a minimum of 400 F 200 C and a maximum of 450 230 C Main tain this temperature range throughout the process The upper shear must be grounded when welding on the upper shear to prevent the possibility of electric shock and arcing through the cylinder or main pivot components Page 28 Section 5 Maintenance PIERCING TIP FI
96. mportant when Material hardsurfacing any part of the shear to weld with the grain of the steel Cross grained hardsurfacing has the tendency to start cracks in the base material Page 4 Section 2 About the Attachment MSD SABER SERIES SHEARS ATTACHMENT GLOSSARY continued Guide Blade Guide Blade Shims Guide Blade Gap Hardsurface Hub Shims Lifting Points Lower Piercing Area Lower Shear Lower Wear Plates Main Bearing Main Pivot Group Main Shaft Manifold Block Motor Mounting Bracket Planetary Gear Box Rear Cylinder Pin e m A replaceable component located opposite the cutting blades in the lower shear The main purpose of the guide blade is to support the upper shear during the cutting cycle This is a very important maintenance item Thin metal shims used to adjust the guide blade out to maintain the proper guide blade gap Shims come in a designated set that determines when the guide blade will be indexed or replaced The gap between the front wear plate and the guide blade as the upper shear is cycled into the lower This is an important maintenance item to ensure longevity of the shear s structure Welding process for protecting the parent material of the shear jaws The hardsurface acts as a wear surface Thin metal circular shims used in the main pivot group of LaBounty shears Hub shims provide factory adjustment of the upper shear for close blade tolerance Small holes in
97. nd slowly try the shear rotate function and shear open and close function see Figure 3 3 Watch for hydraulic oil leaks LU When installation is complete slowly curl the shear to tuck it under the boom Check for sS ETIS E I ir EA N interference Contact factory immediately if interference occurs FIGURE 3 3 an Installation Section 3 3 MSD SABER SERIES SHEARS MOBILE SHEAR START UP PROCEDURE Air must be bled out of the cylinder prior to operation of the shear Trapped air in the system leads to cavita tion oxidation of the oil and excessive heat These conditions promote hydraulic oil break down contamina tion noise sluggish operation reduced component life and potential cylinder damage This procedure will need to be followed upon installation after hydraulic repairs have been made or when a shear has been stored or idle for an extended period of time Make sure the shear cylinder is either fully retracted or extend ed if not mechani cally place into either of these positions loosen end plugs or caps on the manifold fit tin
98. necessary build up the edges of the cross plate before installing the new wear plates See the lower shear build up instructions in this chapter 4 Position the new front wear plate so it is centered across the width of the cross plate The holes in the wear plate should be aligned with the holes in the nose plate This should leave a gap between the top of the wear plate and the top of the nose plate that will be filled with weld later see Figure 5 35 Clamp the wear plate into position bring the pre heat back up to 400 F 200 C Tack weld in place NOTICE Lower wear plates have been added to the sides of the cross plate in 1000 1500 and 2000 Saber Shears NOTICE Check temperature regularly during this procedure 400 450 F 200 230 C not 450 F 230 C The lower shear must be grounded when weld ing on the lower shear to prevent the possibility of electric shock TOPWEAR PLATE CROSSPLATE QC 7 FRONTWEAR PLATE SIDEVIEW FRONTVIEW FIGURE 5 35 Maintenance Section 5 Page 33 MSD SABER SERIES SHEARS LOWER WEAR PLATE continued 5 Position the new top wear plate so it is also centered across the width of the cross plate This wear plate should overhang the front edge of the cross plate to be flush with the face of the front wear plate Clamp the wear plate into position bring the preheat back up to 400 F 200 C and tack
99. nge out procedures are critical to maintain depend able gearbox operation The Planetary Gearbox Lubricants chart on the following page specifies correct lubri cants for various operating temperature The gearbox lubricant must be changed after the first 50 hours of operation to remove metal filings from the gearbox break in period Thereafter refer to the following change out schedule GRADE TIME SAE 80W 90 500 hours or one year Synthetic ISO 150 104 F 1000 hours or two years Synthetic ISO 460 Q 104 F 1000 hours or two years Recommended inspection of the gearbox fluid level is every 250 hours or six months Cold weather lubrication is critical If the temperature is below 5 F 14 C change out lubricant to synthetic specification e Slow rotation of the shear is recommended with all grades of lubricant at temperatures below 20 F 7 C to warm up the rotation system prior to working the shear All rotating shears leaving the factory have synthetic ISO 150 104 F grade lubricant in the gearbox LUBRICATION CHANGE OUT PROCEDURE 1 Position the shear at a comfortable working height and in a position where gearbox is near level gearbox rotation axis should be horizontal 2 Remove the upper head to access cover 3 Place a lubricant catch basin below the drain plug capable of hold more than 2 quarts 4 Remove the drain plug bottom and the visible top plug These plugs are magnetic and will attract metal filings fro
100. o r Inspection Checklist aa aa a TA 5 7 8 Ho r Inspection Rotator 5 8 TABLE OF CONTENTS SECTION 5 MAINTENANCE continued MIG AU OM ss c HS Bolt Torque Guidelines Metric C apscrew Size GUId6 us una arpaahasshisqhqsayasatatshidaquassqhiqaqkiyaahasaqqaqisspaqkas Torque Values for Metric Fasteners canine Slide Sciew usaha kaa Swa Blade Removal mE E Blad Bolt Icrtque SpecifitatiOnS aara Ar NE REA TER Torque Values for E ag Guide Blade Shimming and TAC era ates eater taa uuu Cutting Blade Rotation Procedure Weld in Tip Cutting Blade Rotation Procedure iier ett eerta hne maerens C tting Blade RP OL EO TRENT General Guidelines for Build up and Build up Recommendations PEDE et RR DOE V nte de Dad Hardsurfacing Recornieraatlol lassi uas uu au istud onusta Pese mtis Sec ba Re ET TTE Upper Shear
101. o bypass the guide blade see Figure 5 8 Use a feeler gauge to check the gap and record it Close the shear in steps and check the gap at different spots along the Saber Tip surface 2 Find the smallest gap along the Saber Tip and mark it The gap at this spot should not exceed 0 030 0 76 mm If the gap is more than this it will be necessary to shim the guide blade 3 Guide blade shims are provided with a new shear The shim kit includes four shims that are 0 024 0 61 mm thick and one that is 0 12 3 mm thick 4 To determine the amount of shims to use subtract the desired gap of 0 010 0 25 mm from the smallest gap that was recorded earlier See the example at the right side of this page Do not check gaps while the shear is in motion Stay clear when closing the shear or severe in jury could result SABERTIP Wear gloves at all times during blade maintenance MEASURE GAP HERE NOTICE e If the guide blade is stuck in its seat refer to the Blade Removal procedure in this section f the shear has been operated for more than 80 hours since the last blade rotation it is ed that all blades be rotated at this time Follow the GUIDE BLADE instructions on this page and the following pages NV FIGURE 5 8 Example Recorded Gaps 0 035 0 89mm 0 040 1 02 mm 0 045 1 14 mm Smallest Gap 0 035 Minus Desired Gap 0 010 Shim Amount 0 025 For this example one of the 0 02
102. of the shear with hydraulic motor The output shaft of the component directly drives the turntable bearing of the rotating shear Pin that connects the rod end of the shear cylinder to the rear of the shear The rear cylinder pin must be greased according to the required maintenance About the Attachment Section 2 Page 5 MSD SABER SERIES 5 5 ATTACHIVIENT GLOSSARY continued Rotation Assembly Saber Tip Shear Cylinder Shear Stick Slide Screw Speed Valve Swivel Manifold Thrust Washer Tie Rod Throat Turntable Bearing Upper Head Upper Shear Wear Parts Page 6 Section 2 About the Attachment Hydraulic drive assembly allows full 360 continuous rotation of the shear This option gives greater positioning capabilities when processing with the mobile shear Bolt on two way indexable piercing tip wear plate found at the top of the upper jaw Hydraulic cylinder that powers the cutting action of the shear The barrel end of the cylinder attaches to the shear s upper jaw and the rod end attaches to the rear cylinder lugs The cylinder rod stays protected from damage inside the shear The main body of the shear that includes the lower shear This weldment must be regularly inspected for damage Adjustable components installed through both sides of the stick Aligns and supports the upper shear for a uniform blade gap Regenerative hydraulic valve mounted on the cylinder of LaBounty MSD Saber Seri
103. og with all those with whom you work Inform them of any out of the ordinary work that may be planned for the day Remind them of the safe working distance 3 Clear the area inspect ALWAYS look out for others In any work area people constitute a serious safety hazard Before operating walk completely around the machine to be sure there are no workers next to under or on it Warn nearby workers that you are starting up DO NOT start up until they are out of danger 4 Each day before starting visually inspect the machine by walking around it entirely check the location of cables gas lines and water mains before any operations Make sure work site footing has sufficient strength to firmly support the machine When working close to an excavation position machine with the propel motors at the rear 5 Once started keep bystanders clear especially before moving the boom swinging the upper structure or traveling ALWAYS be alert for bystanders in or near the operating area SAFETY DEVICES YOU LL NEED Seat belts Canopies Falling Objects Protective Structures FOPS Shields and guards Safety decals Visual or audible warning devices Flags and flares Barricades Signs and other markings Warning lights MSD SABER SERIES SHEARS GENERAL RULES FOR SAFE OPERATION 1 Read the Operator s Manual for the base machine on which the shear is mounted 2 KNOW the capacity of the excavator and its attachments DO NOT overload
104. ore unpinning the boom pivot pin and releasing the weight of the shear 10 Remove the boom pivot pin from the shear SHEAR STORAGE 1 Block the shear up off the ground using wood blocking 2 Grease the pins and machined bores of the mounting bracket of the attachment Apply a gener ous amount of grease to the shear blades cylinder rod and all other exposed unpainted surfaces NOTICE Watch the boom to attachment pivot for any interfer ence If interference is present DO NOT force the attachment under any further Block the attachment up before it interferes with the boom or stop Servicing while pressurized can cause severe injury LOCK OUT source and HELIEVE PRESSURE before servicing Figure 3 4 See Figure 3 4 Trapped hydraulic pressure may be present after the base machine is shut off Extreme caution must be taken when removing attachment hydraulic hoses or possible injury or death could result Installation Section 3 Page 5 MSD SABER SERIES 5 5 INTERNAL ROTATION CONTROL SYSTEM INSTALLATION if equipped BEFORE GETTING STARTED 1 Have the Parts Catalog for the shear and the installation manual on hand for reference The parts information for the Internal Rotation Control System is included in it 2 Check if the following items exist on the base machine a A preferred control switch other than the foot switch provided see Foot Pedal Switch Installa tion b One 8 1 2 SAE JIC typ
105. other blades into their blade seats The guide blade is needed for proper adjustment of the shear DO NOT allow excessive gap between guide blade and Saber Tip 11 DO NOT weld or hardsurface across the grain of the steel at any time When hardsurfacing do not exceed two passes of hardsurface rod 12 DO NOT weld on the excavator boom or stick without first consulting the excavator manufacturer for proper welding procedures 13 Rotate or replace the blades when edges have rounded to approximately 14 6 mm radius or after 80 hours whichever comes first 14 DO NOT adjust the slide screws when the upper shear is in either the full open or full closed position Be sure the slide screw will contact the rear wear plate when adjusting Lubricate the slide screw assembly every eight hours of operation 15 DO NOT weld on blades 16 Torque bolted connections as prescribed in this manual 17 DO NOT disconnect any hydraulic hoses or fittings without first relieving the excavator system hydraulic pressure 18 DO NOT exert the weight of the excavator on the shear in order to free the upper shear if it becomes jammed Please consult the factory e m MSD SABER SERIES SHEARS GENERAL RULES FOR MAINTENANCE continued 19 DO NOT let hot hydraulic oil get in contact with the skin as it could cause severe burns 20 DO NOT operate a rotating shear without a case drain line connected back to the tank or return line filter rotating sh
106. otion of the machine move the control slightly from neutral until it starts to move then smoothly move the control to increase motion to desired speed Do the same when stopping a motion La Bounty Operation Section 4 Page 7 MSD SABER SERIES SHEARS SECTION 5 MAINTENANCE Scheduled MAaI tenmafi6e satuan es cesta alan ene ead uaa qapas ence 5 2 Recommended Spare Parts List 5 3 Maintenance Safety u uu uuu senini aa EE a a ENE EE RE NE 5 4 General Rules for Maintenance 5 4 8 Hour Service Recommended eee 5 5 80 Hour Service Recommended nennen enne nnne nnne nnne 5 5 2D00 Hour Service Recommended ssenarini sto lire erba b parks te hanaq 5 5 8 Hour Inspection Checklist 5 6 80 Hou rlnspection Checklists IU DUI DU E 5 7 8 Hour Inspection Rotator amp 5 8 MVlenu 5 9 ere Meis masuala 5 10 Metric Size Guide su n ad cs eee 5 10 Torque Values for Metric Fasteners 5 11 Slide Screw IV IN WOMEN NOG ace oco tot eret ERE nU debe eR Lp ES EET
107. paces keep a watchful eye on exposed parts such as cylinder rods and hoses to avoid damage 12 Maintain at least 15 feet b meters between the shear and any nearby power lines 13 ALWAYS lower the shear to the ground and turn the base machine off when leaving the machine unattended m 14 DO NOT close the shear on a structure and reverse the excavator in an attempt to pull down material This is not only dangerous but will likely damage the excavator and shear 15 Avoid collision of the boom or shear especially when working with limited visibility or inside buildings Know the height and reach of the shear during operation transport and when swinging the excavator 16 Use machine swing for positioning only DO NOT use the shear as a jack hammer or wrecking ball 17 Avoid contact between boom arm or shear stick and overhead obstacles when you operate move or haul the machine 18 DO NOT alter factory preset hydraulics of the shear or vary from the excavator manufacturer specifications This may void the warranty 19 DO NOT shear high tensile steel such as railroad rail spring steel axles and some types of wire as blade Saber Tip and or upper damage will result This type of material breaks when processed and can become a projectile which could cause injury or death 20 To prevent bending the upper shear DO NOT attempt to shear material stuck through the lower jaw 21 Before attempting to shear thin mat
108. peration Grease fitting locations are indicated in Figure 5 1 and by the GREASE decals on the attachment Grease all fittings at the main pivot group with the shear jaws open AND with the shear jaws closed to evenly dis tribute the grease throughout the pivot group FIGURE 5 1 ROTATOR DESIGNS VARY BY MODEL LOOK FOR GREASE DECALS WHEN LUBRICATING THE ATTACHMENT LOCATION ON ATTACHMENT NUMBER OF SHOTS 1 Rear cylinder connection 6 2 Front cylinder connection 6 3 Main jaw pivot 2 zerks each side 6 a Jaw Open 6 b Jaw closed 6 4 Slide screw a Left side 6 at each grease fitting b Right side 6 at each grease fitting 5 Turntable bearing rotators only 6 at each grease fitting LOCATION ON BRACKET 6 Boom pivot connection consult excavator maintenance manual 7 Linkage connection 3rd member mount or cylinder pivot connection 2nd member mount Maintenance Section 5 9 MSD SABER SERIES SHEARS BOLT TORQUE GUIDELINES Proper bolt installation is critical to ensure the safe and efficient operation of the shear Carefully follow the steps below to properly install bolts 1 Always replace bolts and nuts with the same size and class of fastener Replacement fasteners can be ordered from the Stanley LaBounty Parts Department to ensure the correct part is used refer to Figure 5 2 Unless otherwise specified use class 10 9 metric hex head capscrews class
109. pped O ring seals Crown seals STANLEY LABOUNTY BLADE MAINTENANCETOOL KIT P N 184238 Maintenance Section 5 3 MSD SABER SERIES SHEARS MAINTENANCE SAFETY PROCEDURES During maintenance of the shear it is imperative that the excavator is turned OFF to prevent injury Inspect the shear daily DO NOT operate a poorly maintained or damaged shear or major structural damage could result ALWAYS lower the shear to the ground before leaving the cab If it is necessary to work on a shear off the ground securely support the base machine and shear DO NOT support the shear on cinder blocks hollow tiles or props that may crumble under continuous load DO NOT rely on the cylinder to hold the shear in the air If a control is moved or hydraulic pressure is otherwise released the shear will drop DO NOT work under a machine that is supported solely by a jack NEVER operate the machine if an unsafe condition exists Attach a DO NOT OPERATE tag to the machine f more than one person is working on a machine each must be familiar with the controls and aware of what the others are doing Before working on a machine BE SURE TO TAG THE CONTROLS SO NO ONE ELSE WILL START IT ALWAYS use two people when making checks with the engine running Keep hands away from moving parts NEVER lubricate or work on a machine while it is moving ALWAYS wear proper safety equipment when maintaining the shear including
110. r rod back and forth at least five times through full storke Do not operate to machine s full operating pressure 6 Slowly cycle the cylinder five or more times reaching machine s normal operating pressure at end of each stroke open or close Listen for unusual noise and check for any hydraulic leaks NOTICE After the cylinder has been bled and drained of air check the excavator hydraulic fluid and fill to the proper level Page 4 Section 3 Installation La County MSD SABER SERIES SHEARS MOBILE SHEAR REMOVAL PROCEDURE 1 Position shear under the boom of the excavator as far as the stick cylinder will extend and lower shear to the ground 2 Use blocking to support the stick cylinder from the excavator boom 3 Remove the stick cylinder pin from the shear mounting bracket 4 Fully retract the stick cylinder as it is unattached from the shear mounting bracket 5 Cycle the upper jaw closed far enough to allow the upper to lay flat on the ground with the rest of the shear The object of this is to create as many possible shear contact points with the ground 6 Cycle all controls with the excavator off to relieve any trapped pressure 7 Carefully remove the jump lines at the shear mani fold 8 Plug the open manifold ports and hose ends with pressure plugs to prevent contamination of the hy draulic system 9 At this point be extremely sure that the shear is stable and tension to the boom pivot pin is released bef
111. r shear life It is recommended that the blades be rotated after every 80 hours of use Regular blade rotation keeps the blades and blade gaps uniform which allows the blades to be shimmed properly Regular blade maintenance is especially important when processing thinner materials It may be necessary to rotate and adjust the cutting blades more often when processing thin or non ferrous materials Frequent rotation and adjustment of the cutting blades is not as critical when processing larger materials but it will extend the life of the blades Use the following instructions to properly rotate the cutting blades 1 Use the Blade Removal instructions from this section to remove the upper shear blades Take care to keep track of all parts and their positions as you remove them This will be important when reinstalling 2 Once the blades are removed use a small grinder to clean up the edges Remove sharp burrs and smooth out deformations Clean out the blade seats in the same way removing any debris or burrs NOTICE For optimal Saber Tip performance and to assure that two flat surfaces are torqued together the upper secondary blade should always be new at each blade position change To accomplish this do the following Use first edge of new shear all blades new rotate all blades end for end in original location Use second edge and then discard lower primary blade Move upper secondary blade to lower primary position and install new blade in th
112. rded open the shear Shim the lower blades by using the same amount of shims that you were able to slip between the blades earlier 5 To install the shims loosen the lower blade bolts and move the blades out slightly Slide the shims be tween the lower blades and the existing adjustment plate Tighten the blade bolts until snug 6 Cycle the shear slowly to the full closed position Check the gap at different points to make sure it is be tween 0 010 and 0 020 0 25 and 0 50 mm If it is too tight you may need to remove a shim 7 When the gap is correct apply the correct torque to the blade bolts Refer to the Dry Bolt Torque Charts in this section for the proper torque value CHECK GAP HERE CHECK GAP HERE ee 010 020 040 M PRIMARY BLADES _ SECONDARY BLADES FIGURE 5 18 FIGURE 5 19 Keep hands away from moving shear Be sure the shear will not move while checking the blade gaps or severe injury could result Page 22 Section 5 Maintenance La County MSD SABER SERIES 5 5 GENERAL GUIDELINES FOR BUILD UP AND HARDSURFACING The steel used in LaBounty Saber Series shears is stronger and more durable than ever However this steel requires special attention during maintenance Pay special attention to the preheat and post heat instructions and follow them exactly Review the fol lowing guidelines for build up and hardsurfacing the shear Detailed instructions on maintaining
113. re Use a piece of cardboard to search for leaks If ANY fluid is injected into the skin seek im mediate medical assistance Page 8 Section 3 Installation MSD SABER SERIES SHEARS HYDRAULIC SCHEMATIC INTERNAL ROTATION CONTROL SYSTEM Check your internal rotation control system regularly TO ATTACHMENT ROTATION CIRCUIT FLOW FROM i DRAULIC MANIFOLDS ACCUMULATOR FIGURE 3 7 1 DIRECTIONAL CONTROL VALVE 2 RELIEF VALVE SET AT 3000 PSI 200 BAR 3 FLOW CONTROL 4 UNLOADING VALVE 5 PRESSURE REDUCING VALVE SET AT 2500 PSI 170 BAR 6 CHECK VALVE 7 ACCUMULATOR SET GAS CHARGE 1100 PSI 76 BAR Installation Section 3 Page 9 MSD SABER SERIES SHEARS SECTION 4 OPERATION Before YOU uy oae aaa 4 2 is ETE 4 2 Safety Devices You ll 4 2 General Rules for Sate an E E E d pue eS edes 4 3 Mobile Shear aos ected PEE ET UTERE 4 4 Operating the Cms 4 6 Backdriving the oa ee erede tette a repere bete dete usa a uka 4 6 Operating the Internal Rotation Control 4 6 Recharging the Accumulator with 4 6 speed Valve Operating GCharacteriSH68 aree Ser trie tn eor ros a oo Fix ee A UE ED Ev RU DRE DRE 4 7 Getting the F
114. regularly maintain this system to ensure long life and good performance The maintenance requirements of the rotator are outlined in the following pages BOLT TORQUE The bolts connecting the turntable bearing are a critical structural area The bolts must be inspected after the initial eight hours of operation and weekly thereafter Damaged fasteners must always be replaced with the same size and grade of fastener If bolts are found to be loose after operation they should never be retorqued more than one time before they are replaced Please contact the Stanley LaBounty Service Department for specific information about replacement TORQUE VALUES FOR TURNTABLE BOLTS Always replace bolts and nuts with the same size and class fastener Inferior fasteners can fail and cause injury or death and damage to the equipment NOTICE Use of the rotation feature for any other purpose may damage the rotation components and may void the shear warranty t may be necessary to rotate the shear to access all the bolts connecting the shear turntable bearing and rotating head Be sure to use the proper torque value for the size class and type of bolt Rotator Maintenance Section 6 3 MSD SABER SERIES SHEARS PLANETARY GEARBOX LUBRICATION it equipped The planetary gearbox is used if changes in gear ratios are required between the hydraulic motor and turn table bearing to rotate the shear Correct lubricant and cha
115. rod or E 70 series wire following the welding procedures outlined on pages 5 19 through 5 20 of this manual Use build up template provided in the maintenance kit to profile upper f restoring the profile of the tip pocket is unattainable through welding and grinding please contact LaBounty Service Department 800 522 5059 There is a tip grinding tool that follows a template that will restore the seat to factory specifications FIGURE 5 22 Page 26 Section 5 Maintenance MSD SABER SERIES SHEARS UPPER SHEAR BUILD UP AND HARDSURFACING 1 Apply a bead of hardsurface rod on top of each of the underlayment beads It is important to use an air operated slag peener on each pass to relieve weld stress 2 determine how much build up is required along the blade seats place a straightedge across the blades Repeat steps 4 and 5 to build this area flush with the blade see Figure 5 23 3 If necessary build up along the top and front edges of the secondary blade seat flush with the blade see Figure 5 24 The blade should not stick out beyond the edge of the seat in this area 4 To hardsurface the area alongside the upper blades establish the pattern with three or four passes of build up These beads should run parallel to the blades from behind the Saber to approximately the mid point of the primary blade see Figure 5 25 NOTICE e Keep the outside passes at least 1 4 6 mm back from the blade seat
116. safety glasses with side shields hard hat steel toe shoes gloves and hearing protection GENERAL RULES FOR MAINTENANCE 1 Read the maintenance manual Be sure all maintenance personnel read and understand all maintenance procedures before they attempt them 2 Use factory approved parts Use of parts that are not factory approved may cause damage or unnecessary downtime and may void the warranty 3 Lubricate every four hours follow the lubrication schedule as outlined on page 5 9 Page 4 Section 5 Maintenance 4 Use the included Inspection Checklists during shear inspections to make sure all maintenance is complete 5 n extremely cold temperatures work the shear on lighter materials first before working up to heavier materials DO NOT operate at temperatures below 10 23 C 6 To get maximum life from the shear blades rotate to utilize all four edges 7 DO NOT enter the pivot group of the shear without first consulting your dealer or the Stanley LaBounty Customer Service Department 8 The machined adjustment plates behind the cutting blades in the lower shear have been custom machined for each shear If they should come loose be sure to replace them properly 9 ALWAYS connect the welding ground cable directly to the attachment component that you are welding on DO NOT allow ground current to run through the pivot group the rotation group or the hydraulic cylinder 10 DO NOT weld guide blades and or the
117. ses and head wear such as a hard hat Page 42 Section 5 Maintenance 3 Insulating gloves for low and high temperatures 4 Overalls or other uniform no loose fitting cloth ing that may become entangled in machinery 5 Hearing protection ear muffs or plugs Relieve pressure before disconnecting hydraulic lines Tighten all connections before applying pressure Keep hands and body away from pin holes and nozzles which can eject fluids under high pressure Use a piece of cardboard to search for leaks Escaping fluid under pressure can penetrate the skin and cause serious injury If ANY fluid is injected into the skin seek immediate medical attention DO NOT let hydraulic oil get in contact with the skin as it could cause severe burns Hydraulic oil becomes hot during operation Wear adequate protective clothing and safety equipment Chemicals used on Stanley LaBounty Saber Series hydraulic cylinders include hydraulic oil refer to the excavator operator s manual and have MSDS sheets and proper treatment equipment available MSD SABER SERIES SHEARS SPEED VALVE ADJUSTMENT continued REGENERATIVE VALVE DESIGN The design of the regenerative flow valve used in Stanley LaBounty Mobile Shears consists of a pilot valve mounted onto a spool valve The pilot valve is used for regulating the movement of the spool valve in shift ing the valve into and out of regenerative mode See Figure 5 46 The only component that is in the working
118. sing he gauge port is a 7 16 20 SAE O Ring Boss threaded port Once the pressure is hooked up to the gauge port have the operator start up the base machine Cycle the shear until it is either fully open or fully closed and continue to operate this hydraulic func tion even after the jaws have bottomed out This will cause the base machine operating pressure to rise and will enable you to check the operating pressure of the rotation system m To adjust the operating pressure first loosen the lock nut on the Pressure Reducing Valve see Figure 6 8 Then slowly turn the adjustment screw in the end of this valve to adjust the pressure until it falls within the specified range Retighten the lock nut when you have completed these adjustments NOTICE The operating pressure of the Internal Rotation Control System should be 2000 2500 PSI 138 172 BAR If your pressure does not fall within this range it will be necessary to adjust it or the Rotation sys tem may be damaged PRESSURE OW REDUCING VALVE FIGURE 6 8 Rotator Maintenance Section 6 Page 13 MSD SABER SERIES SHEARS SECTION 7 TROUBLESHOOTING Cutting Performance Troubleshooting Guide 7 2 Rotation Circuit Troubleshooting Guide uuu u ua Edo E dg 7 5 Internal Rotation Control System Troubleshooting Guide if 7 7 Speed Valve Troubleshooting uoo ior
119. specific areas of the shear are on the following pages PREHEAT Preheat the general surrounding area to at least 200 100 C to remove moisture from the base material NOTICE Before ANY thermal process is applied to the shear steel including welding tack welding torch cutting and airarcing preheat the area within 6 150 mm of the local area to a minimum of 400 200 C and a maximum of 450 F 230 C This includes adding and removing lifting lugs Preheat must be uniform throughout the material thickness and maintained until all welding has been completed Avoid cyclic heating and large tempera ture swings Preheating may be done by localized gas torches or thermal strip blankets POST HEAT If preheat has dropped below 400 F 200 C within 6 inches 150 mm of the weld area post heat to 400 200 and wrap with heat blanket to allow it to cool slowly to the ambient temperature Plan to perform build up and hardsurfacing at the end of the day or when there will be adequate time for the welded areas to cool before placing the shear back into service HANDLING AND STORAGE OFWELD MATERIALS Follow the weld manufacturer s handling and stor age instructions closely Make sure the electrodes or wire are free of moisture Moisture can cause cracks and porosity in the weld and the base metal beneath the weld WELD QUALITY Quality and attention to detail in welding can signifi cantly affect the life of th
120. speed valve part number and call Stanley LaBounty for torque values MSD 1000 models do not have speed valves 1 Always replace bolts and nuts with the same size and class of fastener Replacement fasteners can be ordered from the Stanley LaBounty Parts Department to ensure the correct part is used Unless otherwise specified use class 10 9 metric hex head capscrews class 10 9 metric flat head capscrews and class 12 9 metric socket head capscrews 2 Make sure bolts nuts and bolt holes are free of dirt oil grease and other contaminants 3 The torque values in this manual are for use with non plated fasteners with clean dry threads These values are suitable for use with or without thread adhesives such as Loctite products SPEED VALVE ASSEMBLY 5 P N 513029 USED IN MSD 1500 2000 2500 3000 4000 AND 4500 SHEARS FIGURE 5 47 CHECK VALVE ASSEMBLY SEE PAGE 5 52 PILOT VALVE ASSEM BLY SEE PAGE 5 51 MAIN VALVE ASSEMBLY SEE PAGE 5 50 ITEM PART NUMBER DESCRIPTION TORQUE 5 512210 Socket Head Screw M8X35 32 ft Ib A3 Nm 82ftlb 84 Nm 6 513133 Socket Head Screw M10X45 Maintenance Section 5 47 MSD SABER SERIES SHEARS SPEED VALVE ADJUSTMENT continued SPEED VALVE ASSEMBLY TORQUE VALUES MAIN VALVE ASSEMBLY MAIN VALVE ASSEMBLY P N 513080 USED IN MSD 1500 2000 2500 3000 4000 AND 4500 1 FIGURE 5 48 ITEM PART NUMBER DESCRIPTION TORQUE 511515 15 f
121. t lbs 20 Nm 1 513087 Screw Plug Allen 511504 7 ft 1 5 10 Nm 22 ft Ibs 30 Nm 8_ 1513086 Het T5ftlbs DONm 9 Page 48 Section 5 Maintenance MSD SABER SERIES SHEARS SPEED VALVE ADJUSTMENT continued SPEED VALVE ASSEMBLY TORQUE VALUES PILOT VALVE ASSEMBLY 323244 22 33 16 5 Q x COs PILOT VALVE P N 512288 USED IN MSD 1500 2000 2500 3000 4000 AND 4500 9 SHEARS FIGURE 5 49 1 kpl 7 I 12 P ud Pp Haa goto pl 24 P d es QO 2 kpl 107 Za 167 i kpl A NGO 32 8 71 26 2521 12 12 kpl 12 kpl 11 1512323 Capsrew 8 15ftibs2Nm 511514 Screw Plug 10 75 ft 165 10 Nm 511504 Seallock Nut 22 ft Ibs 30 Nm 511563 18 ft Ibs 25 Nm Maintenance Section 5 49 MSD SABER SERIES SHEARS SPEED VALVE ADJUSTMENT continued SPEED VALVE ASSEMBLY TORQUE VALUES CHECK VALVE ASSEMBLY CHECK VALVE ASSEMBLY P N 511540 USED IN MSD 1500 2000 2500 3000 4000 AND 4500 SHEARS FIGURE 5 50 ITEM PART NUMBER DESCRIPTION TORQUE 5 1511579 Screw Plug 103 ft Ibs 140 Nm Page 50 Section 5 Maintenance MSD SABER SERIES SHEARS SPEED VALVE ADJUSTMENT continued SPEED VALVE ASSEMBLY TORQUE VALUES MSD 7500 9500 SHEARS Proper bolt installation is critical to ensure the safe and efficient operation of the speed valve Carefully follow the steps below to properly install bolts NOTICE P
122. t when striking pins and always wear protective clothing and proper eye protection Pins may fly when struck with force to drive them in or out Keep people clear when removing or installing pins Introduction to Safety Section 1 Page 3 MSD SABER SERIES 5 5 SAFETY SUMMARY continued Under no circumstances should any modifications be made to LaBounty equipment without factory authorization ALWAYS lower the boom to the ground before leaving the cab If it is necessary to work on an attachment off the ground securely support the machine and attachment DO NOT support the machine on cinder blocks hollow tiles or props that may crumble under continuous load DO NOT rely on a cylinder to hold the attachment in the air DO NOT work under a machine that is supported only by a jack DO NOT let hot hydraulic oil get in contact with the skin as it could cause severe burns Wear adequate protective clothing and safety equipment DO NOT tamper with any hydraulic line or component while it is pressurized Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If ANY fluid is injected into the skin seek immediate medical assistance Page 4 Section 1 Intro
123. ted NIPPLE 12 Section 6 Rotator Maintenance MSD SABER SERIES SHEARS OPERATING FLOW FOR INTERNAL ROTATION The operating flow of the Internal Rotation Control System directly affects the speed at which the shear will rotate Two people are necessary to check the operating flow of the Internal Rotation Control Sys tem Install a flow meter between the A and B ports on the Accumulator Control Valve Assembly these are the works ports for the valve The direction in which the flow meter is installed does not matter Operate the direction valve by using the foot switch in the operator s cab and check the flow meter read ing LaBounty recommends that a flow of 6 10 GPM 23 38 LPM be maintained It may be desirable for you to adjust the flow within the recommended range to increase or decrease the speed of rotation To do this the lock nut on the flow control valve firs t must be loosened then turn the flow control adjustment knob until you reach the de sired flow Make sure to retighten the lock nut when the adjustments are completed NOTICE Do not exceed 10 GPM 38 LPM or damage to the rotation system may result OPERATING PRESSURE FOR INTERNAL ROTATION To check the operating pressure of the Internal Rotation Control System the plug in the gauge port of the Control Valve Assembly marked with G must be replaced with an adapter fitting that is com patible with the pressure gauge you are u
124. ter than fluid that is properly filtered and changed out regularly It is necessary to replace the cylinder seals more frequently if the shear works regularly in severe duty applications or if the hydraulic fluid is not properly maintained Maintenance Section 5 Page 5 MSD SABER SERIES SHEARS 8 HOUR INSPECTION Shear Model Excavator Hour Meter Shear Serial Number Date Visually inspect shear for any damage 2 Inspect safety devices a All safety decals in place and legible seal decal and label maintenance section b All cab protection in good condition c All excavator warning systems working 3 Lubricate all points Refer to shear lubrication in this section a Each side of main pivot group two each side b End of slide puck assemblies each side c End of front cylinder pin d End of rear cylinder pin e Boom pivot connection of mounting bracket f Cylinder connection of mounting bracket 4 Inspect connecting pins and pin retaining hardware a Boom pivot pin of mounting bracket b Cylinder connection pin of mounting bracket c Front shear cylinder pin d Rear shear cylinder pin e Pinheads and pinkeepers 5 Inspect all bolts a Visually inspect all bolts and replace any that are loose or damaged 6 Check slide puck wear plate gap a Refer to manual if gap exceeds recommendations see page 5 21 7 Check guide blade Saber Tip gap a Refer to manual if gap exceeds recommendations see page 5 21 8 Ch
125. terials such as axles and railroad rail Brittle material breaks or shatters instead of shearing The material being processed could become a projectile and cause injury or death DO NOT process any material in any position that may propel it toward operator other workers buildings or equipment e m A DANGER DO NOT close the attachment on a structure and reverse the excavator in an attempt to pull down material DANGER Clear all persons and equipment from the area of operation and machine movement NEVER move loads over people or equipment When viewing the operation of the attachment maintain a safe distance of at least 75 feet 22 9 meters A DANGER NEVER approach power lines with any part of the machine Keep clear at a minimum of 15 feet 5 meters A DANGER Avoid tipping The attachment will alter the lift capacities of the base machine DO NOT overload the excavator or serious injury could result Lift capacities will vary if the base machine is not on level ground Carry loads in recommended positions for maximum stability Use the recommended excavator counterweight Use short slings and lift the load only as high as necessary DANGER DO NOT allow riders on the machine DANGER NEVER remove any pins unless the attachment is on the ground and blocked up or serious injury or death could result Metal chips or debris may fly when a connecting pin is struck Use a brass drif
126. that the operator find an open spot on firm level ground that s free of obstructions such as trees buildings people and other equipment Move the machine to this area and spend some time just getting to know the operating feel of the machine and the shear The machine is extremely powerful Be concerned about safety when preparing to operate the new machine Ensure safe operation by inspecting the machine as stated in Getting Started Safely Read the Getting Started Safely section of this manual and understand it The control levers should be moved in a gradual deliberate way rather than with jerky abrupt movements Jerky operation can cause damage and early wear to various parts on the machine and can also overheat the hydraulic system For example as each control lever is moved forward or backward from the center or neutral position the oil flows to the cylinder or motor controlling a function The component boom attachment etc starts to move The component moves faster as the control lever is moved further forward or backward Holding the lever in the forward or backward position will hold that movement at a given rate of speed To slow the movement down gradually move the lever toward the neutral position Movement is stopped at the neutral position The position is maintained until the control lever is moved again Feathering the controls is a technique that will increase output and make operating the shear easier When starting any m
127. the two halves of the lower shear together The cross blade is contained in the cross plate Requires regular build up and hardsurface Crossover A hydraulic component used in a rotating shear that limits the amount of hydraulic pressure sent to the Relief Valve rotation assembly The crossover is preset at the factory and must not be tampered with Cutting The blades in the upper and lower shear jaws that shear materials as they bypass The primary blades are Blades those in the upper and lower jaws that are nearest to the shear throat The secondary blades are those that are farthest from the shear throat Cylinder Part of the shear mounting bracket that articulates the tip up function of the shear The cylinder Connection connection attaches to the excavator s stick cylinder second member mounts End Cap Protects and adjusts the main pivot group of the shear The end cap is a vital component to the adjustment of the main pivot group and must not be removed without first consulting the LaBounty Customer Service Department Flow Control hydraulic component used in a rotating shear that meters out the hydraulic fluid from the rotation Valve motor The flow control should be set to limit the rotator from spinning faster than 1 2 revolutions per minute Front Cylinder The pin that attaches the shear cylinder barrel end to the upper shear Pin Grain of The direction that the parent material was initially rolled at the steel mill It is very i
128. ther than the proper precharge it will be necessary to either release pressure or further precharge the accumulator PRESSURE RELEASE To release pressure slowly open the relief valve see Figure 6 7 This will release nitrogen into the atmo sphere Close the valve when the desired pressure is reached ACCUMULATOR PRECHARGE Never use oxygen or shop air to precharge the accumulator This could cause an explosion Use only dry nitrogen for precharging accumulators O RING SCHRADER VALVE SPINDLE 1 Connect a charging hose to the shut off valve of a commercially avallable nitrogen supply bottle Con nect the other end of the charging hose to the nipple of the charging unit With the spindle open slowly open the valve on the nitrogen supply bottle to re lease nitrogen into the accumulator until the desired RELIEF level is reached VALVE 2 Allow five minutes for the nitrogen temperature to adjust Recheck and repeat process until proper pressure 1100 PSI 76 is reached 3 When the required precharge pressure is reached unscrew the spindle valve so the gas valve on the accumulator closes Check the valve on the accumu lator for leaks by using sealing spray or soapy water Replace cap nut and protective cap If the gas pressure in the nitrogen supply bottle FIGURE 6 7 is higher than the maximum operating pres sure of the accumulator a gas pressure reducing valve or regulator must be fit
129. ts of the cutting blades guide blade cross blade and Saber Tip These parts can be easily replaced to refresh the System wear areas of the shear jaws Dramatically increased surface areas on these wear parts provide better wear and less downtime for maintenance MSD SABER SERIES SHEARS FLOW AND PRESSURE REQUIREMENTS The following table prvodes the MSD Saver Series Mobile Shear flow and pressure requirements for the open and close function Please note that all models include speed valves also note that these calculations are theoretical and that actual cycle times will vary depending upon the specific excavator s hydraulic efficiency possible back pressure in the system operator competency etc These cycle times are calculated with not material in the jaws The cycle times will be longer when maximum shear force is required shear will go out of speed valve mode REQUIRED FLOW GPM TO MEET SHEAR RECOMMENDED SHEAR 8 10 12 AND 14 SECOND CYCLE TIMES MODEL PRESSURE RANGE FORCE 8 SEC 10 SEC 12 SEC 14 SEC MSD 1000 s 40 MSD 1500 920 60 4 MSD2000 1169 MSD 2500 276 379 BAR MSD 3000 MSD 4000 2400 15 MSD 4500 MSD 7500 2 4 MSD 9500 410 350 NOTICE e Rotation Circuit 8 12 2000 2500 PSI A 1 2 case drain line going from the hydraulic rotation motor to the excavators hydraulic tank is required to relieve back pressure Pump summation or
130. ts typical lubricants for turntable bearings comparable lubricants by other manufacturers may also be used Page 6 Section 6 Rotator Maintenance em MSD SABER SERIES SHEARS HYDRAULIC REQUIREMENTS The rotating shear requires an auxiliary hydraulic circuit in order to operate the rotator This circuit will need to be a medium pressure 2000 2500 PS1 138 172 BAR low flow 8 10 GPM 30 39 LPM hydraulic circuit There are minimum and maximum pressure and flow requirements that may vary depending upon the shear model These requirements are listed in the Hydraulic Installation Requirements sheet in the Parts Catalog for the shear The rotation control manifold my vary depending upon the type of the rotation system and the par ticular requirements for the rotation circuit Adjustment procedures for the rotation control valve are given on the following pages ROTATION CONTROL VALVE MANIFOLD One of two rotation control valves is installed on the shear depending upon the model The rotation control valve manifold provides overload protection and a load control system for the rotator with two crossover relief valves and two brake valves The crossover relief valve and brake valves have been preset at the factory and require no adjustment Do not tamper with these valves If a malfunction is suspected due to a lack of perfor mance in the rotator a pressure check should be performed Diagnostic fittings which require a Parker PD Series coupl
131. two san hours At factory upgrading and rebuilding services available for extended life OPTIONS e 360 continuous rotation Magnet lifting eye Auxiliary hydraulic kit for rotation circuit 3 construction to assure long uninterrupted service even in the harshest conditions The main pivot shaft of every model is manufactured for long life and pivots on Stanley LaBounty s specially designed bearings These shears are designed to draw the material into the jaws to the point where the shear force is greatest making them the most efficient cutting tool possible Mobile shears can cut a wide variety of materials including l beams H beams channel iron steel plate pipe round stock wire rebar concrete etc They are ideal for scrap processing demolition work road and bridge reconstruction and jobs where torching is not feasible or possible Page 2 Section 2 About the Attachment MSD SABER SERIES SHEARS ATTACHMENT TERMS ROTATOR ROTATING HEAD CYLINDER TURNTABLE BEARING FRONT CYLINDER PIN CONNECTION HYDRAULIC MANIFOLD BLOCK UPPER SHEAR SPEED VALVE INSIDE SHEAR SHEAR STICK GUIDE SHEAR BODY BLADE SLIDE SCREW RIGHT LIFTING POINT SHEAR WEAR PLATE NON ROTATOR SHEAR CYLINDER SPEED VALVE INSIDE SHEAR MOUNTING BRACKET REAR CYLINDER PIN HYDRAULIC MANIFOLD BLOCK MAIN PIVOT GROUP em About the Attachment Section 2 Page 3 MSD
132. u RF Fit tegis its a ia E kuskakunapa 6 3 Torque Values for Rotation Assembly 6 3 Planetary Gearbox Lubrication if equipped eter nce Ried nee es 6 4 Lubricant Change out 6 4 Planetary Gearbox as NL LLN na o E E islam MIRA Edi ad adt 6 5 Synthetic SDBCHNOBEIDI 6 5 Gearbox Fill Capacities 6 5 TUWEN1a 6 BEARING 6 6 Turritable Beanng EuBrIeante_ u u u totes nerd essa Redux 6 6 Hydraulic REQUIFEKN ENTS u n n n u Ua saa Sua Veste e etre apustul e 6 7 Ionio o u E saywa 6 7 Case Dr 6 7 Rotation Control Valve Assembly Schematics and 6 8 Internal Rotation Control System if enne 6 9 Accumulator Control Valve Assembly if equipped 6 10 Maintenance Intervals for Internal Rotation if 6 11 IMairitenariee s i u ette aE a EE E a riari 6 11 Testing the Accumulator Pre charge sssessssssssesee n e nn nnne n nnn nennen nnn nn nnne 6 12
133. y new underlayment beads to the pattern using E 7018 welding rod or E 70 series wire After the pattern has been established with underlayment beads apply hardsurface to the pattern It is rec ommended that only one pass bead of hardsurfacing be applied After welding wrap the upper in a heat blanket and allow to cool slowly Apply hardsurfacing on top of each of the underlayment beads DO NOT APPLY HARDSURFACE DIRECTLY TO THE PARENT MATERIAL It is important to use an air operated slag peener on each pass of weld to relieve stress If as a result of production considerations the crosshatch pattern has been worn down into the base metal of the shear upper jaw the Saber Tip can be used as a guide for build up to proper profile prior to applying new hardsurfacing If the edge of the Saber has been worn it will be necessary to remove the tip rotate to the new front edge and bolt into place The surface of the upper shear face should be built up using E 7018 welding rod or E 70 series wire following pre heat procedures to conform in profile to the new Saber Tip edge Depending upon the model this surface should be flush with the Saber Tip edge to 1 16 above the edge Once the surface has been built up and ground to profile the crosshatch hardsurface pat tern can be applied Use 172 spacing in the crosshatch hardsurface pattern as shown in Figure 5 20 NOTICE Recommended Hardsurfacing Vvelding Rod for this application Amalloy 814 H

MSD Saber Series User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents