Home

UPSV User Manual - Stanley Hydraulic Tools

1. FIGURE 3 3 KEE Installation Section 3 Page 3 UNIVERSAL PROCESSORS SECOND MEMBER ATTACHMENT MOUNTING PROCEDURE 1 Locate flat hard ground for installation Place the attachment on the ground with blocking 2 Remove the excavator stick following manufacturer s recommended procedure 3 Take care to properly plug any hydraulic hoses when disconnected to prevent contamination from entering the hydraulic system 4 With the jaws of the attachment facing the excavator bring the excavator into position carefully lining up the excavator boom tip with the boom pivot connection on the attachment mounting bracket figure 3 4 second member mount it may be necessary to block the rear of the attachment in a position to allow boom pivot pin installation FIGURE 3 4 5 Pin the excavator s boom and attachment boom pivot together using the same pin that was used for pin ning on the stick 6 Have all personnel stand clear and instruct the operator to slowly lift the attachment into a position where there will be enough clearance to pin the excavator cylinder to the cylinder connection on the mounting bracket figure 3 5 Never move or operate the attachment without all collars and hardware installed on t
2. 5 9 Hydraulic System 5 10 Flange Type Hose nns 5 11 Madri IE 5 12 Backdriving the t e tet ee hp eae ee er arre ra een 5 12 Major Components of Typical Rotation SyStelris 5 13 Bolt Net cR EMEN 5 14 Planetary Gearbox ERE 5 15 Lubricant Changoe Out Procedure lalate ended 5 15 Planetary Gearbox MES OT 5 16 5 16 5 16 TUMMtabl Bearing 5 17 Turntable Bearing 9788 99 5 17 Hydraulic 9 9 5 18 Crossover Relief Flow Control 1 2 2 0000606600000 000000000008 5 18 Motion Control Manifold E 5 19 5 19 Control Valve Assembly Schematics and Description 22 2 5 20 Universal Processor Hydraulic EE 5 21 Hydraulic Schematic Internal Rotation Control System 5
3. 1 2 Understand Signal 1 2 Safety Eye buic septa vt EMO MI ER ra eR PM IER EVER PHP 1 3 Decal Maintenance 1 5 SECTION 2 ABOUT THE ATTACHMENT Model Description PEN 2 2 gp D ce 2 2 Attachment RTE 2 3 Attachment 55 2 4 SECTION 3 INSTALLATION Lifting MNS cor 3 2 Attachment Mounting Procedure 3rd member mounts 2 2 9 3 3 Attachment Mounting Procedure 2nd member mounts ees 3 4 Attachment Removal Procedure 3rd member 5 3 5 Attachment Removal Procedure 2nd member 2 2 3 6 Attachment SUT mere R ai pM cuia duae ER M 3 6 Exchanging Jaws Removal 1508060 3 7 Mydraulie INSTA 3 9 Star 9 cR 3 9 Speed 3 10 Internal Rotation Control Kit Installation if 22 96 3 11 3rd member to 2nd member Adapter Bracket Installation if
4. 3 14 SECTION 4 OPERATION e Peu MONEO 4 2 TE T 4 2 Safety Devices Ro 4 2 General Hules Tor sate 4 3 shear Pe 4 4 Rr 4 6 Backdriving the 4 6 Operating the Internal Rotation Control System 4 6 Recharging the Accumulator with 2 4 6 Speed Valve Operating Characteristics 2 1 2 4 00000 000000000000 4 7 Getting the Feel of the Attachment nnns 4 7 SECTION 5 ATTACHMENT MAINTENANCE Maintenance Safety Procedures 5 2 General Rules for Maintenance NEN EX oM IUIS 5 3 Periodic Service Schedule MM 5 3 Recommended 5 3 Inspection iii 5 4 Recommended Spare Parte toda att 5 5 Attachment CUDMCATION 5 6 Bolt ML 5 7 Bolt Torque o 5 8 Metric Capscrew Size Guide 5 8 SECTION 5 ATTACHMENT MAINTENANCE continued Torque Values for Metric
5. 7 33 Jaw Options Section 7 1 UNIVERSAL PROCESSORS SECTION 7 JAW OPTIONS CONTINUED Shear Jaw 222 2 0 0 0 Shear Jaw Features DT tasers sta aaa TEES Sac 2 TEMS KR ShearJaw OS SAY oa Periodic Service Schedule 8 Hour Inspection Checklist MM 80 Hour zie eut Checklist M Shear Jaw LUDTICA HON NEM Main Pivot Group LAGS Guide Blade end IOIIHOD a AGES ROTATION EMI Blade e MINICOM E General Build Up Upper Piercing Tip Build Up and ccce nennen Upper Shear Build Up and 0 21 2 2 1 72 02000 000000000 Replacing Piercing 1 Front Wear Lower Piercing Area Build Up Hardsurfacing Lower Shear Build Up and
6. Swift Lock Build up Template Part Page 2 Section 7 Jaw Options UNIVERSAL PROCESSORS UNIVERSAL PROCESSOR CONCRETE CRACK JAWS LaBounty Universal Processor Concrete Cracker Jaws are the safe and economical alternative for efficient quiet controlled on site processing These jaws excel a wide range of demolition work They are ideal for downsizing large concrete for handling and transportation High tensile abrasion resistant steel construction assures long uninterrupted service even in the harshest conditions The main pivot of every model is designed for long life and pivots LaBounty s specially designed bearings FEATURES e Patented Swift Lock pin on replaceable teeth offer long wear and im pact resistance One pin secures each tooth segment A complete set of teeth can be replaced in minutes e Replaceable two way indexable rebar cutting blades e At factory upgrading and rebuilding services available for extended life CONCRETE CRACK JAW TERMS FRONT CYLINDER PIN CRACKER JAW CONNECTION GREASE FITTINGS SWIFTLOCK RECEPTACLE MAIN PIVOT GROUE yy N 5 AN 7 gt P gt TAPPED HOLES FOR REBAR sWiFFLOCK BEARING REMOVAL TOOTH TOOTH PINS AND RETAINER RIN FIGURE 7 1 CRACKER JA Jaw Options Section 7 3 UNIVERSAL PROCESSORS CONCRETE CRACK JAWS GLOSSARY Build Up Welding process
7. 7 7 Concrete Crack Jaw 7 7 Concrete Crack Jaw Switt Lock Tooth Replacement isses imt motn 7 8 Concrete Crack Jaw Tooth Build Up and Hardsurfacing 2 2 2 000 000000000008 7 9 Concrete Crack Jaw Build Up and Hardsurfacing 222 09 7 10 Concrete Pulverizer Jaw 7 11 Concrete Pulverizer Jaw Feliu es sesto sete tu Pata D 7 11 Concrete Pulverizer Jaw ineo rr intr as 7 11 Concrete Pulverizer Jaw 22 7 12 Concrete Pulverizers Jaw Periodic Service Schedule 7 12 Concrete Pulverizer Jaw Daily Service 7 12 Concrete Pulverizer Jaw Daily Inspection Checklist c terere 7 13 Concrete Pulverizer Jaw LUDPCAEOF cator rre patera pite eH dd orat tbe EX Ride iet vta 7 14 Concrete Pulverizer Jaw Blade Mlaintenance sienten tria rn 7 15 Concrete Pulverizer Jaw Blade 7 15 Concrete Pulverizer Jaw Swift Lock Tooth 7 15 Concrete Pulverizer Jaw Tooth Bui
8. 3 11 3rd member to 2nd member Adapter Bracket Installation if 3 14 Installation Section 3 Page 1 UNIVERSAL PROCESSORS LIFTING THE ATTACHMENT Hooking points are integrated into the stick for safe lifting of the attachment see figure 3 1 The smaller diameter eye in the lug prevents the use of hooks without shackles threading the lugs with slings and the use of the lug as a lifting eye for lifting other objects during operation Hooking points are for installing transporting and moving the attachment only Do not use them for lifting other objects or processing with the attachment in a cable hung application Con tact the LaBounty Customer Service department for approval and evaluation before operating the attachment in a cable hung application 1 Before lifting the attachment check its weight 2 Lift the attachment using all four hooking points with rigging lengths that keep the attachment level Use only approved rigging and hardware rated for loads greater than the weight of the attachment Page 2 Section 3 Installation La Bounty UNIVERSAL PROCESSORS THIRD MEMBER ATTACHMENT MOUNTING PROCEDURE 1 Locate flat hard ground e g concrete floor for installation Place the attachment on the ground and use blocking if necessary 2 Remove the bucket or other attachment from the end of the excavator stick following the manufacturer
9. 5 16 Turntable Bearing sus ciiin iit entero Eero ete id 5 17 TurntablesB Caring EUDEICaFIES sioe tese 5 17 Hydraulic REQUIFCIMENIS a 5 18 Crossover Relief Flow Control 5 18 Motion Control ERE 5 19 5 19 Control Valve Assembly Schematics and Description 5 20 Universal Processor Hydraulic Schernatio eterni 5 21 Hydraulic Schematic Internal Rotation Control System 5 22 Speed Valve Test and 2 eene ener nennen nnne 5 23 Torque Values tor Speed Valve Fasteners 5 25 Internal Rotation 5 26 Accumulator Control Valve ecc apes 5 27 Maintenance Intervals Tor Int rmal ROtatiON 5 28 Accumulator MAINTE NAN CO 5 28 Testing the Accumulator 5 29 Accumulator Precharge 22 9 5 29 Operating How for Internal BOtatiOni nna ratae 5 30 Maintenance Section 5 1 UNIVERSAL PROCESSORS
10. 7 55 Swift Lock Build up Template Part 7 57 UNIVERSAL PROCESSORS SECTION 1 INTRODUCTION E 1 2 Understand Signal WordS 1 2 Safety SUMMAN re uA exa M 1 3 cre catt deal auc 1 5 Introduction to Safety Section 1 1 UNIVERSAL PROCESSORS 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 re
11. 15 amp circuit breaker or fuse The power source should be accessory side or a similar source that provides voltage 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 the 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 connected 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 La Bounty Installation Section 3 Page 11 UNIVERSAL PROCESSORS INTERNAL ROTATION CONTROL SYSTEM ELECTRICAL INSTALLATION continued If an alternative type of switch is preferred to the provided foot switch contact your LaBounty dealer for in formation on operating the control valve If an alternative switch is used it must be provided by the customer Any of the following can be used a Joystick handle equipped with a single pole double throw momentary three 3 position rocker switch b Two joystick handles each equipped with a single pole sing
12. 5 f the bores need to be aligned rotate each sleeve in its bore This can be done by pounding against the notches in the head of the sleeve see figure 3 15 6 Once the bores are aligned the linkage tion pin may be installed figure 3 16 7 Secure the pins by installing the collars Use the second member installation instructions in this chap ter to mount the attachment to the larger excavator 5 FIGURE 3 15 LINKAGE CONNECTION PIN FIGURE 3 16 La Bounty Installation Section 3 Page 15 UNIVERSAL PROCESSORS SECTION 4 OPERATION Berore 4 2 What You MT E aa EE 4 2 PAE SU UNOS WS Lm 4 3 General Rules for Safe 4 3 Attachment COMMONS TRI T 4 5 Speed Valve Operating Characteristics 4 6 Operating the Internal Rotation Control System 2 9 4 6 Recharging the Accumulator with Fluid esros sesoses eere eeno nennen 4 5 Getting the Feel ofthe Attachment rte rte 4 7 Feathering the AMTET 4 7 Operating TIOS sseni nien A A ENE 4 8 Operation Section 4 1 UNIVERSAL PROCESSORS BEFORE YOU START KNOW YOUR SAFETY PROGRAM 1 Read and understand
13. FIGURE 7 13 Page 18 Section 7 Jaw Options Do not remove the pin until you are sure the cylinder is safely supported If the weight is not properly supported it may drop and cause seri ous injury Make sure that the lifting strap and crane are rated to safely lift the cylinder FIGURE 7 14 9 Fasten the loose hoses to the hose termination block on the connector link Torque to specifications found in this manual 10 Start the base machine Lift the attachment off the ground and rotate it 180 so the remaining cylin der is now facing up The connector link should now be beneath the attachment 11 Secure the jaw set as necessary to keep it up right and stable during installation With the attach ment still facing out walk it into position to line up the main pivots of the attachment and jaw set see Figure 7 15 Install the main pin FIGURE 7 15 UNIVERSAL PROCESSORS PLATE SHEAR JAW INSTALLATION continued 12 Extend the cylinder as necessary to line up the cylinder bore with the bore on the upper shear In stall the front cylinder pin 13 With everyone standing clear raise the attach ment in the air slightly and place some blocking beneath the lower shear Lower the attachment onto the blocking to raise the lower into position so the bores in the connector link and lower shear line up 14 Pin the lower shear to the connector link When all pins are fully installed cycle the upper shear into the lower
14. MAINTENANCE SAFETY PROCEDURES Before attempting any maintenance procedure read this entire Safety Manual carefully If any question arises regarding a safety or maintenance procedure contact your LaBounty dealer For the nearest LaBounty dealer see the Contact Information at the front of this manual Inspect the attachment daily DO NOT operate a poorly maintained or damaged attachment or major structural damage could result 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 base 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 the cylinder to hold the attachment in the air If a control is moved or hydraulic pressure is otherwise released the attachment will drop DO NOT work under a machine that is supported solely by a Jack DO NOT attempt to alter or change the physical mechanical or hydraulic operation of the attachment during the warranty period without first consulting Stanley LaBounty as this could invalidate the Manufacturer s Warranty NEVER operate the machine if an unsafe condition exists Attach a DO NOT OPERATE tag to the machine e f more than one person is working on 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 CONTROL
15. Safety Operation amp Maintenance Manual Universal Processors SV Series Jaw options Part Numbers T020205 T050205 T069605 1099605 T059605 um QOO 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 7578 461 7322 273 7 832 130 8 146 256 8 104 384 EPO Patent Numbers 435 702 737 107 1 682 299 1 789 225 PREFACE This manual contains information for the safe and proper operation and maintenance of the universal processor and its jawset options 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 TABLE OF CONTENTS SECTION 1 INTRODUCTION e T
16. or shimming the blades use the instructions from earlier in this chapter to make sure the main pivot group is within wear specifica tions Jaw Options Section 7 Page 45 UNIVERSAL PROCESSORS GENERAL BUILD UP AND HARDSURFACING See page 7 30 for additional important information Proper build up and hardsurfacing requires inspection ac cording to the inspection scheduled for each jaw type If the jaws are in a severe application the interval for maintenance may need to be shortened Excessive hardsurfacing can damage the jaws and affect the per formance Allow the hardsurfacing to wear down but not completely away before hardsurfacing again Never apply more than two layers of hardsurfacing The quality and attention to detail in welding can significantly affect the life of the jaws LaBounty strongly recommends that only certified welders perform this procedure Strict adherence to the welding rod manufacturer s handling and storage instructions is essential Electrodes exposed to the atmosphere for more than four hours must not be used the moisture absorbed by the elec trode covering will change the mechanical properties of the weld This can cause cracks and porosity in the weld or adjacent base metal LaBounty recommends that AWS E7018 rod or equivalent is used for build up After vigorously peening each pass the hardsurfacing is placed directly on top of the E7018 beads The E7018 becomes the bonding or un derlayment for the
17. B VALVES SAE 10 O Ring Boss Ports Gauge Ports 1 amp G2 G1 x G2 SAE 4 O Ring Boss Ports BRAKE Drain Ports D amp FIGURE 5 8 VALVES 20 Section 5 Maintenance UNIVERSAL PROCESSORS UNIVERSAL PROCESSOR HYDRAULIC SCHEMATIC HYDRAULIC MANIFOLD BLOCK TO ONATTACHMENT ATTACHMENT EXCAVATOR CYLINDERS __ _________ SPEED VALVE i ASSEMBLY 3 1 i i i 8 1 i 1 p CASE DRAIN LINE EN LO TO EXCAVATOR HYDRAULIC ROTATION TEST PORT cos MANIFOLD BLOCK CONTROL VALVE FIGURE 5 9 Maintenance Section 5 Page 21 UNIVERSAL PROCESSORS HYDRAULIC SCHEMATIC INTERNAL ROTATION CONTROL SYSTEM if equippe TOATTACHMENT ROTATION CIRCUIT INPUT FLOW FROM HYDRAULIC MANIFOLDS FIGURE 5 10 DIRECTIONAL CONTROL VALVE RELIEF VALVE FLOW CONTROL UNLOADING VALVE PRESSURE REDUCING VALVE CHECK VALVE ACCUMULATOR NO OA CN Page 22 Section 5 Maintenance UNIVERSAL PROCESSORS SPEED VALVE TEST AND ADJUSTMENT TOOLS NEEDED The following tools are recommended for speed valve adjustment on Stanley LaBounty Universal Processors 1 Pressure gauges two are recommended so that two test ports can be checked at the same time 2 Appropriate diagnostic test fittings and
18. Check temperature during this procedure maintain 300 400 F 150 200 C Do not exceed 450 230 7 UNIVERSAL PROCESSORS FIGURE 7 44 8 To determine how much build up is required along the blade seats place a square or straight edge across the blades Repeat steps 3 and 4 to build up this area flush with the blade see Figure 7 44 9 To hardsurface the area from behind the piercing tip to approximately the midpoint to the primary blade apply three or four beads of AWS E7018 in single passes running the length of the jaw to establish the hardsur face pattern see Figure 7 45 This will serve as an underlayment for the hardsurface rod DO NOT apply hard surface directly to the parent material Apply a bead of Amalloy 814H rod or equivalent on top of each of the underlayment beads It is important to use an air operated slag peener on each pass of weld to relieve stress 10 Hardsurface should end approximately at the midpoint of the primary blade Stagger the ends of the welds DO NOT end welds within 1 25 mm of bolt holes DO NOT undercut the ends of the weld beads with the grinder Taper ends of welds into the base metal with grind marks going with the grain of the base material in line with the upper shear FIGURE 7 45 STAGGER WELDS GRAIN When welding on the upper jaw the upper jaw MUST be grounded La Bounty Jaw Options Section 7 Page 49 UNIVERSAL PROCESSORS REPLACING PIERCING TIP If th
19. UNIVERSAL PROCESSORS ATTACHMENT GLOSSARY Accumulator Used in a hydraulic rotation kit to store hydraulic fluid to drive the rotation motor Accumulator Hydraulic hose that directs flow from the control valve assembly to the accumulator and back Line Backdriving condition that occurs when a force such as a heavy unbalanced load in the jaws overpowers the rotation system and drives the attachment to rotate even though the rotation function is not being operated Excessive backdriving is hard on the rotation system and can lead to premature wear of the rotation components or even component failure and downtime Boom Pivot Part of the Universal Processor mounting bracket that attaches to the excavator s boom tip second member mounts Case Drain Hydraulic hose that drains fluid from the rotation motor case Conduit Where the wiring for the directional valve and unloading valve is connected to the electrical cable from Junction Box the foot switch if equipped with a rotation control kit Control Valve Used in the rotation control kit to direct flow to the accumulator and the hydraulic motor Assembly Cross Pattern method of torquing a circular pattern of bolts to achieve proper seating Based on a clock face the Technique technique pattern would follow the order of 12 6 11 5 10 4 9 3 8 2 7 1 Crossover A hydraulic component used in a rotating attachment that limits the amount of hydraulic pressure Relief Valve sent to
20. and blocked up if necessary or serious injury or death could result NOTICE If replacement of any bolt or nut is necessary it MUST be replaced with the same grade fastener em Maintenance Section 5 Page 7 UNIVERSAL PROCESSORS BOLT TORQUE GUIDELINES Proper bolt installation is critical to ensure the safe and efficient operation of the attachment 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 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 Use the Capscrew Size Guide on this page to help determine the size of the bolt being installed 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 attachment Refer to page 5 19 for de tails METRIC CAPSCREW SIZE GUIDE HEX HEAD 0 63 Hemm emm 0 71 18mm 0 71 18mm M16 0 94 24mm SOCKET HEAD 1 18 30mm FIGURE 5 2 1 42
21. gearbox rotational axis level with respect to horizontal Support the attachment with blocking in this position be sure the base machine is shut off 2 Remove the upper head top access cover 3 Place a lubricant catch basin capable of holding more than 2 quarts below the drain plug 4 Remove the drain plug bottom and the visible top plug These plugs are magnetic and will attract metal fil ings from 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 Maintenance Section 5 15 UNIVERSAL PROCESSORS PLANETARY GEARBOX LUBRICANTS OPERATING AMBIENT TEMPERATURE RANGE RECOMMENDED GRADES 5 F TO 120 F 14 C TO 49 C SAE 80W 90 50 TO 120 F 46 C TO 49 C Synthetic ISO 150 104 F 25 F TO 180 F 32 C TO 82 C Synthetic ISO 460 104 F APPROVED SOURCE GRADE Manufacturers of approved SAE lubricants SAE 80W 90 Mobile Oil Mobilube SHC 75W 90 Synthetic ISO 150 104 F Mobile Oil Corp Mobilube SHC 80W 140 Synthetic ISO 460 104 F SYNTHETIC SPECIFICATION MOBILUBE SHC 75W 90 80W 140 Product Number 51100 6 51101 4 SAE Number 75W 90 80W 140 Gravity API 29 8 30 2 Flas
22. p 5 10 6 Individual hydraulic function a Pilot control hoses pinched i Inspect and correct is slow b Jumpline connections leaking i Inspect and correct Base machine hydraulic malfunc i Check base machine hydraulic system tion d Circuit relief valve for function set i See your base machine dealer low malfunctioning e Faulty speed valve operation i See speed valve troubleshooting guide p 5 10 Troubleshooting Section 6 Page 3 UNIVERSAL PROCESSORS ROTATION CIRCUIT TROUBLESHOOTING GUIDE The information contained in this guide provides for troubleshooting the LaBounty attachment 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 Attachment will not a Operating flow is too low i Flow control valve needs adjustment rotate ii Check supply flow b Crossover relief valve is bypassing oil i Replace crossover relief valve 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 b
23. 22 Speen Valve Test anc AdjUStMEN tocar tables s o GR Y Rud 5 23 Torque Values ior Speed Valve aii 5 25 Internal Rotation Control oaa Sua imn 5 26 Accumulator Control Valve 222 0 5 27 Maintenance Intervals for Internal Rotation 22 2 99 5 28 Accumulator Maintenance 99999 5 28 Testing the Accumulator Precharge 5 29 Accumulator Precharge aik 5 29 Operating Flow for Internal 4444 0 4 eene nennen nennen enne 5 30 SECTION 6 TROUBLESHOOTING Hydraulic Performance Troubleshooting 6 2 Rotation Circuit Troubleshooting see o Ep ntn Ruhr KORR Ie nx t asi dee una 6 4 Internal Rotation Control System Troubleshooting Guide if equipped 6 7 Speed Valve Troubleshooting es 6 10 SECTION 7 AW OPTIONS Concrete Crack Jaw Description niet tA PRSE RA 7 3 Concrete Crack Features NNI Um RH CMM 7 3 Concrete Crack JaW III D 7 3 Concrete MET 7 4 Concrete Crack Jaws Periodic Service Schedule risu 7 4 Concrete Crack Jaws Daily Servic
24. 36mm 1 77 45mm 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 8 Section 5 Maintenance UNIVERSAL PROCESSORS TORQUE VALUES FOR METRIC FASTENERS IMPORTANT Please note that some parts of the attachment require special torque values these parts are listed below with the page number where the proper torque values for that area can be found e Hydraulic Connection Bolts split flange connections Page 5 11 e Speed Valve Bolts Page 5 25 Turntable Bearing Bolts Page 5 14 e Rotation Assembly Bolts Page 5 14 For all other Universal Processor bolts use the Generic Torque Table below CLASS 10 9 CLASS 12 9 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 e Apply torque to the nut rather than the bolt head wherever possible e Be sure to use the proper torque values for the class of bolt being torqued If unsure of what torque value to use contact your dealer or the Stanley LaBounty Customer Service Department La Bounty Maintenance Section 5 Page 9 UNIVERSAL PROCESSORS HYDRAULIC SYSTEM MAINTENANCE Use the following instructions to safely perform hy draulic checks and maintenance on the attachment 1 Always relieve all hydraulic pressure of the excava tor before attemp
25. 6 Troubleshooting UNIVERSAL PROCESSORS HYDRAULIC PERFORMANCE TROUBLESHOOTING GUIDE continued SYMPTOM PROBABLE CAUSE REMEDY 4 Jaws drift open or closed a Excavator hydraulic valve is 1 Check hydraulic circuit to verify Replace with center type closed center spool type b Excavator control valve is faulty ii Refer to excavator manual check for sticky spool check for circuit relief valve bypass check for spool seal bypass if applicable c Hydraulic cylinder seal bypass i Check for seal bypass replace seals if needed d Hydraulic swivel bypass i Check swivel for bypass replace seals if needed e Faulty speed valve operation i See speed valve troubleshooting guide p 5 10 5 Will not process or hold ma a Wrong type or size of material i Check material size and type consult factory terial in jaws i Check the lines feeding oil to the attachment b Hyraulic lines are kinked replace any kinked lines i Compare with base machine s operating pres Attachment pressure 1 too low sure d Excessive back pressure on the i Check for kinked lines return side rod ii Check the size of the lines ili Check for restrictor valve in the circuit iv Check the return filter replace if needed v Check the control valve e Cylinder seal bypass i Replace seal kit and inspect for any necessary repairs to the cylinder f Faulty speed valve operation i See speed valve troubleshooting guide
26. ATTACHMENT NUMBER OF SHOTS 1 Main pivot each jaw half 6 2 Main pivot at least one of these two locations on each side should be greased 6 3 Cylinder connections two places 6 qm Page 6 Section 7 Jaw Options UNIVERSAL PROCESSORS BLADE MAINTENANCE New blades in proper adjustment will increase the cutting performance Proper rotation of blades will provide optimum use and the best performance Recommended blade rotation is after approximately 80 hours of use depending on the material being processed During blade maintenance leather work gloves must be worn to prevent injury 1 To rotate the blades remove the blade from the jaw set Do one blade at a time 2 Grind all rough edges from the blade 3 Clean out the blade seat 4 Reinstall the blade The blade should be flipped end for end see Figure 7 3 and reinstalled in the same blade seat Torque the blade bolts according to the Dry Bolt Torque charts in this chapter 5 When all possible edges of the blades have been worn to 6 4 mm radius or more it will be nec essary to replace the blades Remember with damaged or badly worn blades cutting ability decreases tremendously and it may eventually cause structural damage to the jaws This condition also causes the attachment and base ma chine hydraulic systems to work harder resulting in premature wear REBAR BLADE BLADE SHIM FIGURE 7 3 m BLADE SHIMMING Blade rotating is recom
27. 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 g Accumulator does not charge with hydraulic fluid i Unloading valve is faulty Replace un 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 faulty 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 6 Troubleshooting UNIVERSAL PROCESSORS CUDE ROTATION CONTROL SYSTEM TROUBLESHOOTING if equipped continued SYMPTOM PROBABLE CAUSE REMEDY 2 Rotation very slow continued f Internal leakage of valve cartridges in
28. The upper half of the shear jaw set It contains a primary blade secondary blade piercing tip and front wear plate The upper jaw passes into the lower jaw qm m UNIVERSAL PROCESSORS PERIODIC SERVICE SCHEDULE SERVICE THE JAWS AT SPECIFIED INTERVALS Inspect lubricate make service checks and adjustments according to the 8 hour and 80 hour Inspection Checklists reproduced from this manual A program of regular service should be established using the machine hour meter to determine when the jaws should be serviced Use the intervals on the Service Schedule when operating in normal conditions Service the attachment at shorter intervals when operating in extreme environmental or abrasive conditions USE CORRECT LUBRICANTS AND BOLT TORQUES Refer to the Lubrication Instructions and Bolt Torque Table in this section of the Safety Operation and Maintenance manual when performing maintenance on the attachment 8 HOUR SERVICE RECOMMENDED GREASE FITTINGS according to the Lubrication Section on page 7 40 Replace broken fittings BOLT Check for looseness and damage Retorque if necessary Refer to Dry Bolt Torque tables in this manual Bolts may be retorqued once and then must be replaced GUIDE BLADE GAP If the gap exceeds 0 030 0 76mm refer to manual for adjustments PRIMARY AND SECONDARY BLADE GAP The gap is acceptable if it is less than 0 060 1 50 mm and the jaws are not jamming If jamming occurs between the
29. a malfunction is suspected due a lack of rotator performance a pressure check should be performed Diagnostic fittings 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 MOTION CONTROL VALVE MANIFOLD See figure 5 5 One of two motion control valves are installed on the attachment depending on the size of the rotation motor The motion 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 valves and brake valves have been preset at the factory and require no adjustment do not tamper with these valves If a malfunction is sus pected due to a lack of performance in the rotator a pressure check should be performed Diagnostic fittings are installed in the manifold to provide a means of checking pressure Contact the LaBounty Service Department for the proper procedure for performing this check Diagnostic fittings require a Parker PD series coupler on gauge GAUGE RELIEF VALVES CASE DRAIN NON ADJUSTABLE PORT RELIEF VALVE A case drain is required to relieve the LOAD NON ADJUST back pressure that develops in the hy a ABLE draulic motor case as a result of meter C3 949 p ing flow out of the motor Depending on the model this port is located on the M motor is routed to bul
30. attachment 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 On an internal drive rotator there are also two grease fittings in the base plate of the rotating head These provide grease to the gear teeth and pinion gear Stand clear of the attachment while rotating Grease a fitting and then stand clear to rotate the bearing to distribute the grease DO NOT attempt to grease the bearing while the attachment 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 32F 0 C Grade 0 is recommended The following table lists typical lubricants for turntable bearings FOR OPERATION BELOW FOR OPERATION ABOVE APPROVED SOURCE TRADE NAME 32 0 32 F 0 C OR STORAGE Rycon Dura Lith Lidok Mobilux Alvania Bearing Guard Prestige Multifak Unoba La Bounty Maintenance Section 5 Page 17 UNIVERSAL PROCESSORS HYDRAULIC REQUIREMENTS The rotating attachment requires an auxiliary hydraulic circuit in order to operate the rotator This circuit will need to be a medium pressure 1350 2500 51 93 172 BAR low flow 4 12 GPM 15 45 LPM hydraulic
31. circuit There are minimum and maximum pressure and flow requirements that may vary depending on the model of the attachment These requirements are listed in the Hydraulic Installation Requirements sheet in the Parts Catalog for the attachment The rotation motor on the attachment is equipped with manifold mounted load controls The design of the load control manifold varies depending upon the type of the rotation system and the particular requirements for the rotation circuit The two designs currently used are referred to as the Crossover Relief Flow Control Valve and the Motion Control Valve Adjustment procedures for the load control manifolds are given below After identifying which manifold is on the attachment determine which of the procedures follow CROSSOVER RELIEF FLOW CONTROL MANIFOLD The Crossover Relief Flow Control Manifold is mounted directly to the hydraulic port of the rotation motor The manifold controls rotation speed with flow control valves and overload protection with crossover relief valves to govern pressure at both motor ports The valves have been adjusted at the factory to provide optimal performance of the rotation motor The flow control valves meter out flow from the rotation motor they are factory adjusted to a recommended rotation speed of 4 to 6 RPM They may be adjusted to suit a speed preference however keep in mind that the rotation feature is to be used only as a positioning device Operat ing i
32. during which 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 Jaws Cracker Jaw Half One half of the jaw set The two jaw halves are identical mirror images of each other They each contain a Swift Lock tooth and a rebar blade Front Cylinder Pins pins that connect the attachment cylinders to the jaws Grain of Materials The direction that the parent material was initially rolled at the steel mill It is very important when hardsurfacing any part of the shear jaws to weld with the grain of the steel Cross grained hardsurfacing has the tendency to start cracks in the base material beneath it Hardsurfacing Welding process of protecting the parent material of the shear jaws This acts as a wear surface Main Bearings Bushings located in the main pivot group which provide a wear surface between the jaws and the main pin There are two main bearings in the lower jaw and one in the upper jaw Main Pin Pin on which the jaws rotate It is a component of the main pivot group Main Pivot Group High tolerance area of the attachment where the jaws pivot The main pivot group includes the main pin main bearings and thrust washers Rebar Blades Short cutting blades in the jaw throat for cutting rebar Swift Lock Seats for the teeth that are welded in place on the upper and lower jaws Receptacles Swift Lock Teeth Easily replaceable wear
33. full operating pressure to the cylinders 2 Change direction of oil flow slowly fill the rod end of the cylinders open jaws until the rod is retracted ap proximately stroke 3 Extend the cylinders all the way 4 Repeat steps 2 and 3 retracting rods to approximately 72 stroke then 34 stroke then full stroke 5 When cylinders are full of oil slowly cycle back and forth at least five times through full stroke Be careful not to apply full operating pressure to the cylinders at this time 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 After the cylinders have been bled check the base machine for proper hydraulic fluid level SPEED VALVE ADJUSTMENT The speed valve on LaBounty Universal Processors 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 e The attachment does not consistently shift into speed mode when closing the jaws The jaws continue to close after the operator has let go of the controls The attachment shifts into speed mode but seems to lack power For instructions on testing and adjusting the speed valve refer to page 5 23 of this manual Page 10 Section 3 Inst
34. i Remove unloading valve and relief valve control valve manifold cartridges in control valve cartridges check for contamination or seal manifold damage g Hydraulic motor is faulty i Rebuild or replace motor h Supply flow too low i Check base machine s hydraulic system 3 Rotation speed too fast a Operating flow too high i Adjust flow control to decrease flow from the accumulator 4 Rotation is erratic a Directional valve spool i Push in manual overrides alternately then if sticking try operating valve b Faulty electrical signal at directional i Check electrical wiring valve coil elec valve or unloading valve trical ground c Flow control valve cartridge is faulty i Check for contamination or seal dam age d Faulty crossover relief on motor i Check attachment manual e Faulty hydraulic motor i Check attachment manual 5 Attachment rotation drifts a Directional valve spool is sticking i Push in manual overrides alternately then try operating valve Troubleshooting Section 6 Page 9 UNIVERSAL PROCESSORS SPEED VALVE TROUBLESHOOTING GUIDE There are two basic operating conditions of the speed valve that have a negative effect on attachment per formance 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 condition occurs when the spee
35. jaw options provide true multitasking capabil ity This means an immediate payback in recyclable concrete rebar and scrap steel It also means a reduction in tipping fees transportation costs and work force The Universal Processor is the ideal solution for contractors in demoli tion reconstruction and concrete processing applications Page 2 Section 2 About the Attachment FEATURES Speed valve generates fast cycle times resulting in increased productivity Made with high strength abrasion resistant steel for durability e Added reach reduces ma chine movement and wear and greatly reduces the need for arm mounting safety is increased Pin on replaceable wear parts for easy maintenance On site material process ing means immediate pay back in recyclable products Installs in as little as two hours e At factory upgrading and rebuilding services available for extended life UNIVERSAL PROCESSORS ATTACHMENT TERMS LINKAGE CONNECTION ROTATING HEAD CYLINDER SHROUDS CYLINDERS FRONT CYLINDER PINS JAWSET ALIGNMENT CHANNEL NOT VISIBLE MAIN PIVOT GROUP JAWSET SHEAR JAWS SHOWN La Bounty About the Attachment Section 2 Page 3 UNIVERSAL PROCESSORS JAW OPTIONS Stanley LaBounty offers four standard jaw options for the Universal Processor SV Find more information about each of them in Section 7 of this manual Page 4 Section 2 About the Attachment
36. 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 UNIVERSAL PROCESSORS 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 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 surr
37. lower profile build up template supplied by LaBounty see Figure 7 53 3 Clean all dirt and grease from area to be built up 4 Remove any existing hardsurface material down to base metal by grinding 5 Preheat the surrounding area to at least 200 F 100 C to remove moisture Preheat the area to be built up to 300 400 F 150 200 C Use a tempera ture stick to test the area frequently as overheating can harm the jaws Maximum heat is 450 F 230 C Temperature melt sticks are available from LaBounty 6 For build up start inside the lower in front of the cutting blade see upper illustration in Figure 7 52 Use AWS E7018 to make single passes side by side until the area is covered Repeat the process on the guide blade side see lower illustration in Figure 7 52 and inside the nose plate Peen each pass to relieve stress and remove slag NOTICE Check temperature during this procedure maintain 300 400 150 200 Do not exceed 450 F 230 START BUILD UP HERE FIGURE 7 52 2 7 lt lt gt IT 7 FIGURE 7 53 Jaw Options Section 7 Page 53 UNIVERSAL PROCESSORS LOWER PIERCING AREA BUILD UP AND HARDSURFACING continued 7 To hardsurface the build up just completed we recommend using Amalloy 814H or equiva lent Start approximately 2 3 50 75 mm down from the top edge of the lower Apply single passes side by side running the length of the shear on each si
38. mounted 3rd member according to the instruc tions in this chapter Position the attachment upside FIGURE 3 12 down on a firm and level surface as shown in figure 3 13 2 Use an overhead crane with a lifting strap through the stick cylinder connection to lower the adapter bracket into place so the stick connection pin can be installed Use the existing 3rd member bracket pin figure 3 13 Be sure that the crane and the lifting strap are rated to safely lift the adapter bracket 3 Apply a thin coating of grease to the inside and outside diameters of the linkage connection sleeves and slide the sleeves into the bores in each side of the adapter bracket W FIGURE 3 13 Page 14 Section 3 Installation UNIVERSAL PROCESSORS THIRD MEMBER TO SECOND MEMBER ADAPTER BRACKET ier CEE INSTALLATION continued 4 Use the crane to lower the bracket so the linkage connection bores line up closely If the bores line up closely it may be possible to install the pin at this time NOTICE The linkage connection are designed so the inside diameter is off center from the outside diam eter This allows for the bores on the adapter bracket FIGURE 3 14 to be aligned with the bores on the third member bracket by rotating the sleeves OFF CENTER BORE
39. of hardsurface material The quality and attention to detail in welding can significantly affect the life of the jaws LaBounty strongly rec ommends that only experienced certified welders do this work Stanley LaBounty recommends that build up and hardsurfacing is performed at the end of the work day to al low them adequate time to cool Strict adherence to the welding rod manufacturer s handling and storage instructions is essential Electrodes exposed to the atmosphere for more than four hours must not be used the moisture absorbed by the elec trode covering will change the mechanical properties of the weld which can cause cracks and porosity in the weld or adjacent base metal LaBounty recommends using AWS E7018 rod or equivalent for build up After vigorously peening each pass the hardsurfacing is placed directly on top of the E7018 beads The E7018 becomes the bonding or underlayment for the hardsurfacing This will help reduce the chances of having the hardsurface material crack LaBounty recommends using Amalloy 814H rod or equivalent for hardsurfacing DO NOT use stainless hardsurface rod it is too brittle and cracks weakening the base metal GENERAL PROCEDURE 1 Clean all dirt and grease from the area to be built up 2 Remove the worn hardsurfacing by grinding to the base metal DO NOT build up on top of any hardsurface material 3 Preheat the surrounding area to at least 200 F 100 C to remove moisture Prehe
40. on each side The blade gaps are critical to how the plate shear jaws will perform Depending on the specific material being processed it may be desirable to change the blade gaps for better performance For instance when cutting thin material it is best to set the gaps very narrow to prevent mate rial from jamming in the blades A wider blade gap may be preferred for processing thicker materials Adjusting the blade gap is done by adding or removing blade shims The shims are located between the lower blades and adjustment plates in the lower shear LaBounty sets the blade gaps on new plate shear jaws at 0 005 0 13 mm on each side It is possible to widen the blade gaps from 0 005 0 13 mm up to 0 130 3 2 mm Use the directions on the following page to properly adjust the blade gaps The blade gaps should be checked and adjusted every 80 hours after rotating or replacing the blades UPPER HEAR UPPER LOWER SHEAR LOWER BLADES FRONT GAP BLADE GAP NOSE BLADE SIDE VIEW FRONT VIEW FIGURE 7 20 Jaw Options Section 7 27 UNIVERSAL PROCESSORS ADJUSTING THE BLADE GAPS After rotating or replacing the blades it may be nec essary to adjust the blade gaps This is accomplished by shimming the lower blades Follow the steps below to check and adjust the blade gap NOTICE Before checking the gap or shimming the blades use the instructions from page 7 23 to check the main pivot group for w
41. products against deficiency in material or workmanship for a period of 12 months from the date of first use rental or sale or 1500 hours of operation whichever occurs first Limitations e Remanufactured or used product or service repair are not warranted under this Limited Warranty 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 Material Authorization tag RMA must accompany returned product 3 Returned product found deficient by Stanley LaBounty will be replaced or repaired without charge FOB Distributor 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 for
42. s recommended procedure 3 Take care to properly plug any hydraulic hoses when disconnected to prevent contamination from entering the hydraulic system 4 With the jaws of the attachment facing the excavator bring the excavator into position carefully lining up the stick tip with the proper connection on the attachment mounting bracket 5 Pin the excavator stick tip to the mounting bracket stick connection using the pin provided 6 Carefully extend the bucket cylinder to move the bucket linkage forward far enough to position the link into the mounting bracket linkage connection see figure 3 3 It may be necessary to use a lifting device overhead hoist forklift etc to correctly position the link 7 Pin the link to the linkage connection using the pin provided third member mounting brackets the stick and linkage connections can be difficult to tell apart because they often have the same dimensions In nearly all cases the linkage connection is the one closest to the rotation components see figure 3 2 LINKAGE CONNECTION Never move or operate the attachment without all collars and hardware installed on the connect ing pins ROTATION COMPONENTS FIGURE 3 2
43. strike against a hardened blade with a hardened steel tool of any kind The blade may chip and cause severe injury NOTICE One method of preventing a blade from dropping is to leave at least two blade bolts installed with the nuts loosely threaded When the blade becomes dis lodged the bolts will keep the blade from falling and causing injury or damage If the blade does not come out easily continue with step 2 NOTICE Never drive wedges between the blade and the BOTTOM of the blade seat This can cause dam age to the shear blade seat which will cause future problems with jamming or stuck blades Wedges may only be used between the blade and the BACK of the blade seat BLADE SEAT BOTTOM SOFT METAL PUNCH OR DRIFT 4 PY SOFT METAL BLADE BACK SEAT Z FIGURE 7 35 Page 42 Section 7 Jaw Options WEDGE UNIVERSAL PROCESSORS GUIDE BLADE SHIMMING AND ROTATION Guide blade shimming keeps the upper jaw properly supported during use and must be checked daily 1 With the jaws partially closed so the front wear plate is beginning to bypass into the lower shear check the gap between the front wear plate on the upper shear and the top edge of the guide blade Cycle the upper jaw into the lower and check in sev eral spots Shim to the smallest gap This gap should not exceed 0 030 0 76 mm See Figure 7 36 2 Shims have been provided for shimming out the guide blade
44. the blade seat DO NOT apply hardsurface directly to the parent material DO NOT apply build up and hardsur face to the front of the cutting blades 7 Apply a bead of Amalloy 814H rod on top of each of the underlayment beads It is important to use an air operated slag peener on each pass of weld to relieve stress Page 32 Section 7 Jaw Options FIGURE 7 25 When welding on the upper jaw the upper jaw MUST be grounded NOTICE Check temperature during this procedure maintain 300 400 F 150 200 C Do not exceed 450 F 230 HARDSUR FACE PAT DO NOT WELD TERN ON BLADES FIGURE 7 26 UNIVERSAL PROCESSORS LOWER SHEAR BUILD UP AND HARDSURFACING It is necessary that the lower portion of the shear be maintained routinely by the following process GENERAL PROCEDURE 1 Clean all dirt and grease from area to be built up 2 Remove all existing hardsurfacing by grinding down to the basemetal before beginning build up and hardsurfacing procedures 3 Use a square to determine how much build up is required on the edges of the nose plate and sides of the lower shear see Figure 7 27 4 Preheat the surrounding area to at least 200 F 100 C to remove moisture Preheat the area to be built up to 300 400 F 150 200 C Use a tempera ture stick to test the area frequently as overheating can harm the jaws The maximum temperature is 450 F 230 C NOTICE FIGURE 7 27 Check temperature during t
45. the cab of the base machine used to operate the rotation function of the attachment if equpped with a rotation control kit Front Cylinder The pins that connect the attachment cylinders to the jaws Pins Hydraulic Machined block located in the attachment mounting bracket that directs hydraulic flow from the base Manifold machine to the attachment cylinders The port that feeds the Internal Rotation Control Kit is located in Block this manifold if equipped Internal An optional kit that provides a medium pressure low flow hydraulic source to rotate the attachment The Rotation kit taps the hydraulic system of the attachment jaws and draws only enough fluid to charge an Control Kit accumulator When the rotation function is used this pressurized fluid is released to the rotation motor to rotate the attachment The internal kit is mounted inside the attachment upper head Option not available on UP 15SV Linkage Part of the Universal Processor mounting bracket that attaches to the base machine s bucket linkage Connection when mounting third member in place of the bucket Main Pivot Area where the jawset is pinned into the main body of the attachment The main pivot group contains a Group main pin end cap thrust washers and main bearings About the Attachment Section 2 5 UNIVERSAL PROCESSORS ATTACHMENT GLOSSARY continued Main Bearings Bushings pressed into the main pivot bores of the upper and lower jaw halves The ma
46. the upper shear The left hand and right hand upper blades are not interchangeable The upper half of the jaw set It contains left and right cutting blades and a ripper tooth The upper shear passes into the lower shear Jaw Options Section 7 Page 17 UNIVERSAL PROCESSORS PLATE SHEAR JAW INSTALLATION Installation of Plate Shear jaws is quite different than the other jaw sets The Plate Shear jaws use only one of the Universal Processor cylinders This makes it necessary to remove one cylinder to install these jaws Use the steps below to install this jaw set 1 Remove both cylinder shrouds 2 Remove the existing jaw set 3 Use the excavator to position the attachment straight out and rest it on a firm level surface with one cylinder facing up see Figure 7 13 4 Shut off the machine and ensure the system hy draulic pressure is relieved 5 Disconnect the hoses from the top cylinder Be careful not to spill hydraulic fluid Cap the hose ends temporarily Plug the ports of the cylinder for remov al and storage 6 Place a lifting strap in a choke hold around the main tube of the cylinder near the head see Figure 7 14 Use an overhead crane to hold the weight of the cylinder and remove the rear cylinder pin 7 Use the crane to lift the cylinder up and away from the attachment 8 Unpin the connector link from the Plate Shear jaw set Use the existing cylinder pin to connect the link to the rear cylinder connection
47. 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 e Accumulator Precharge Pressure Operating Flow 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 attachment leaves the factory When the accumulator is filled with hydraulic fluid this nitrogen bladder compresses and pressur izes the accumulator When the rotator function is operated the pressurized accumulator sends the fluid to the hydraulic motor to rotate the attachment If the accumulator is not properly precharged 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 attachment 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 shut
48. tools for installing fittings 3 Open or boxend wrenches 12mm 19mm 4 Allen wrenches 4mm 12mm TEST AND ADJUSTMENT 1 From the fully open position cycle the jaws into the closed position and observe the jaw speed f functioning properly the jaw speed will increase after closing approximately 1 to 2 25 to 50mm f no change in speed is noticed turn the pilot valve adjustment screw clockwise see figures 5 11 5 12 45 each time until the valve begins to function properly NOTICE When making adjustments keep track of how much adjustment has been made at each position in case the screws need to be restored to their original posi tions 2 If the speed valve operates properly from the fully open position check its operation when closing the shear jaw from a partially open position f functioning properly the jaw speed will increase after closing approximately 1 to 2 25 to 50mm f no change In speed is noticed turn the main spool adjustment screw clockwise see figures 5 11 5 12 45 each time until it begins to function prop erly from the partially open position PILOT VALVE ADJUSTMENT SCREW MAIN SPOOL ADJUSTMENT SCREW FIGURE 5 11 LARGER UNIVERSAL PROCESSOR MODELS PILOT VALVE ADJUSTMENT SCREW MAIN SPOOL ADJUSTMENT SCREW FIGURE 5 12 SMALLER UNIVERSAL PROCESSOR MODELS Maintenance Section 5 Page 23 UNIVERSAL PROCESSORS SPEED VALVE TEST AND ADJUSTMENT cont
49. up in a diamond pattern of approximately 1 50 38 mm to establish the pattern see Figure 7 8 This will serve as an underlayment for the hardsurfacing 7 Apply a bead of Amalloy 814H rod or equivalent di rectly on top of each of the underlayment beads It is important to use an slag peener on each pass to relieve weld stress 8 Taper the ends of each hardsurface bead by grind ing in line with the jaws Do not undercut the weld 9 When welding and grinding is complete peen the welded area until it is shiny or until your peener can not dent the weld anymore typically 5 to 10 min utes This will help to harden the welded area 10 When finished be sure to cover the reworked area with a heat blanket and allow the jaws to cool slowly HARDSURFACE BEADS FIGURE 7 8 UNIVERSAL PROCESSORS CONCRE FRONT CYLINDER PIN CONNECTION MAIN PIVOT GROUP THRUST WASHERS TOOTH PINS AND RETAINER RINGS UNIVERSAL PROCESSOR CONCRETE PULVERIZER JAWS LaBounty Universal Processor Concrete Pulverizer Jaws are the safe and economical alternative for efficient quiet controlled on site processing The jaw design excels at crushing concrete and separating the rebar creating two recyclable products High tensile abrasion resistant steel construction assures long uninterrupted service even in the harshest conditions The main pivot of every model is designed for long life and pivots on LaBounty s speci
50. upper and lower jaws that bypass to cut various materials The upper and lower jaws each have a primary and a secondary blade The pins that connect the attachment cylinders to the jaws A replaceable wear plate that is welded to the upper jaw on the opposite side from the upper cutting blades The upper wear plate makes contact with the guide blade during shearing This is very important maintenance item and must be replaced when worn The direction that the parent material was initially rolled at the steel mill It is very important when hardsurfacing any part of the shear jaws to weld with the grain of the steel Cross grained hardsurfacing has the tendency to start cracks in the base material beneath it A replaceable component located opposite the cutting blades in the lower jaw The main purpose of the guide blade is to support the upper jaw during the cutting cycle This is a very important maintenance item The gap between the guide blade and the front wear plate as the upper jaw is cycled into the lower Jaw A very important maintenance item that must be maintained to ensure the structural integrity of the jaws Thin metal shims used to adjust the guide blade to maintain the proper guide blade gap Shims come in a designated set that determines when the guide blade will be indexed or replaced Welding process of protecting the parent material of the shear jaws This acts as a wear surface The lower half of the shear jaw set It contains
51. vary slightly depending on the attachment model 4 INTERNAL DRIVE 4 EXTERNAL DRIVE 7 LOCATION ON ATTACHMENT NUMBER OF SHOTS 1 Rear cylinder connections 2 Front cylinder connections 3 Main jaw pivot 4 Turntable bearing 5 Jawset see jawset manual for specific grease locations LOCATION ON BRACKET 6 Stick connection 3rd member mount or boom pivot connection 2nd member mount 7 Linkage connection 3rd member mount or cylinder pivot connection 2nd member mount 6 Section 5 Maintenance UNIVERSAL PROCESSORS BOLT TORQUE SPECIFICATIONS 1 All bolts should be visually checked for looseness or damage every 8 hours of operation 2 After installation a new bolt should not retorqued more than once before it is replaced Always replace with the same grade of bolt 3 Check all attachment connecting pins and pin retaining bolts daily to ensure that they are in place and properly secured Pins that must be checked are a Stick connection or boom pivot connection b Linkage connection or arm cylinder connection c Front cylinder pins d Rear cylinder pins e Main pivot pin refer to jaw option 4 All bolts and their respective tapped holes must be free of grease and contaminants before installing to ensure a proper seat for a bolt torque Disassembly of any pin connected attachment can be hazardous Never remove any pins unless the attach ment is on the ground
52. 1538 Highway 2 1 800 522 5059 Two Harbors MN 55616 www stanleyhydraulic com FOREIGN PATENTS AND OTHER PATENTS PENDING STANLEY 116404 Top and front cab PATENT PLATE gareng required PART NUMBER 116404 uring any material processing application FIGURE 1 7 SAFETY DECAL PART NUMBER 503647 FIGURE 1 5 Page 6 Section 1 Introduction to Safety em UNIVERSAL PROCESSORS SECTION 2 ABOUT THE ATTACHMENT Model DESEHOTOM EE 2 7 icc ad fasten cute 2 7 Universal Processor 2 2 8 M R 2 9 2 9 Attachment Glossary La Bounty About the Attachment Section 2 Page 1 UNIVERSAL PROCESSORS MODEL DESCRIPTION Product refinements like 360 continuous rotation and high perfor mance cylinders have altered the look and performance of LaBounty Universal Processors Models are available for excavators ranging in size from 15 metric tons 30 000 pound class to 75 metric tons 170 000 pound class Standard 360 continuous rotation provides easy accurate processing at all angles High tensile high alloy abrasion resistant steel construction assures long uninterrupted service even in the harshest conditions An im proved main pivot designed specifically to each jaw application pro vides long life and higher productivity Multiple interchangeable
53. AL PROCESSORS 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 the following tools and equipment are needed Hydraulic pressure gauge 0 5000 PSI range Accumulator charge and test unit O 1000 PSI range Volt Ohm meter Standard blade screwdriver Crescent wrench or similar tools for cover removal 3 16 Allen wrench Test Llght 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 6 7 UNIVERSAL PROCESSORS cope ROTATION CONTROL
54. AT Page 24 Section 7 Jaw Options Safety equipment including eye protection hard hat steel toe shoes gloves and hearing protec tion should be worn at all times when viewing operating or maintaining the attachment to prevent injury Never strike against a hardened blade with a hardened steel tool of any kind The blade may chip and cause severe injury NOTICE One method of preventing a blade from dropping is to leave at least two blade bolts installed with the nuts loosely threaded When the blade becomes dislodged the bolts will keep the blade from falling and causing injury or damage If the blade does not come out easily continue with step 2 NOTICE Never drive wedges between the blade and the BOTTOM of the blade seat This can cause dam age to the shear blade seat which will cause future problems with jamming or stuck blades Wedges may only be used between the blade and the BACK of the blade seat FIGURE 7 16 UNIVERSAL PROCESSORS LOWER BLADE ROTATION Proper rotation of the lower blades will ensure the best jaw performance and also makes it possible to maintain an even blade gap Recommended blade rotation is after approximately 80 hours of use Depending on the material being processed this interval may vary When processing thin plate lower blade rotation and shimming is of greater importance than when processing thicker material It may be necessary to shorten blade rotation intervals when proce
55. Check the gap at this point using a feeler gauge and record this measurement also If the blades have been rotated properly the gap in the secondary blades should be fairly even for the entire span of the blades 3 Subtract the desired blade gap from the actual blade gap that was just recorded This will determine the amount of shims to use 4 Shim only the lower blades It is recommended that the blades with the least amount of wear be in stalled in the upper jaw when possible Never shim the lower blades out more than 0 125 8 mm total This can cause structural damage to the jaws and jeopardize the warranty 5 To install the shims loosen the blade bolts and slide the shim s between the existing blade adjust ment plate and the blade to be shimmed Retorque the blade bolts to specifications If the existing blade bolts have been retorqued more than once they must be replaced with new bolts of the same type 6 Cycle the jaws slowly and check that the gap is not too tight the throat area and then recheck tolerances Regular blade rotation and shimming will provide maximum shearing efficiency and blade life Remem ber if the blades are not rotated every 80 hours shimming may not be possible because of uneven wear on the blades m THROAT AREA FIGURE 7 38 Stand clear before moving the jaws Do not check blade gaps with the feeler gauge while the jaws are moving Before checking the
56. Control Valve Assembly Foot Switch The circuit taps into the attachment s hydraulic supply manifolds to draw only enough fluid to charge the accumulator This fluid is held in reserve until the control valve is actuated which sends the fluid to the rota tion motor to drive the rotator The diagram below figure 5 14 represents a typical Internal Rotation Control System The layout of the system that has been installed in your attachment may vary slightly but the main components between attachment models are generally the same FOOT SWITCH ACCUMULATOR CONTROL VALVE ASSEMBLY INSTALLED IN CAB RETURN LINE TO ELECTRICAL SUPPLY TO ROTATION ELECTRICAL CORD MOTOR SUPPLY LINES HYDRAULIC RETURN TINE MANIFOLD CAN BE ONE OR TWO MANIFOLD BLOCKS FIGURE 5 14 Page 26 Section 5 Maintenance UNIVERSAL PROCESSORS ACCUMULATOR CONTROL VALVE ASSEMBLY if equipped ADJUSTMENT SCREW PRESSURE REDUCING MANIFOLD MANI VALVE MANUAL OVERRIDE CHECK VALVES FLOW CONTROL VALVE ADJUSTMENT KNOB CONDUIT GAUGE JUNCTION PORT BOX RELIEF VALVE UNLOADING DIRECTIONAL VALVE soLENoip FIGURE 5 15 La Bounty Maintenance Section 5 Page 27 UNIVERSAL PROCESSORS MAINTENANCE INTERVALS FOR INTERNAL ROTATION if equipped A program of regular service should be established for the attachment including maintenance of the Internal Rotation Control System Use the base machine hour meter
57. G e tal Build Up and TRE 7 30 Upper She r Build Up and Hardsurfacihg E EEES 7 31 Lower Shear Build 7 33 shear Tau aiid MM din M A RR LA M 5 7 35 Shear Im Np MR 7 35 Shear Jaw Te eM PPP 7 35 SIN EN IE PN EDEN T A R PES 7 36 Periodic Service Schedule CRT 7 37 8 Hour Inspection Checklist 7 38 80 Hour Inspection 7 39 Sh ar Jaw MII 7 40 Main Pivot Group Wear 7 41 Blade Removal P LL 7 42 Blade Shimming and bariin 7 43 Blade EE 7 43 Blade EE DTE 7 45 General Build Up Fardsurkacilt 7 46 Upper Piercing Tip Build Up anres orte taie 7 47 Upper Shear Build Up and 7 48 Replacing Piercing EE 7 50 Front Wear Plate 2 7 52 Lower Piercing Area Build Up and Hardsurfacing 2 10000 0000000 000000000 7 53 Lower Shear Build Up Hardsurfacing
58. GURE 7 31 UPPER JAW FRONTWEAR PLATE FAR SIDE MAIN PIVOT GROUP PIERCING TIP THROAT PRIMARY BLADE X 3 GUIDE BLADE ADJUSTMENT 5 AND BLADE SHIMS SECONDARY BLADE LOWER JAW Jaw Options Section 7 35 UNIVERSAL PROCESSORS UP SHEAR JAW GLOSSARY Adjustment Plates Apex Blade Gap Blade Shims Build Up Cutting Blades Front Cylinder Pins Front Wear Plate Grain of Material Guide Blade Guide Blade Gap Guide Blade Shims Hardsurfacing Lower Jaw Lower Piercing Area Main Bearings Main Pin Main Pivot Group Nose Plate Piercing Tip Primary Blades Secondary Blades Throat Thrust Washer Upper Jaw Page 36 Section 7 Jaw Options Custom made plates that precisely adjust the lower primary and secondary blades to be parallel to the upper blades These make it possible to achieve a uniform blade gap The point where the primary and secondary blades come together The gap between the upper and lower blades as they bypass each other A very important maintenance item that must be maintained to ensure longevity of the shear jaws and to prevent material from jamming in the cutting blades Thin metal shims used to adjust lower cutting blades to maintain the proper blade gap Welding process during which worn off parent material is replaced with new metal A very important maintenance procedure that must be performed regularly Replaceable components bolted into the
59. ION FIGURE 7 18 Jaw Options Section 7 Page 25 UNIVERSAL PROCESSORS UPPER BLADE REPLACEMENT A CAUTION The upper jaw of a Plate Shear jaw set has two blades a left hand blade and a right hand blade Because the upper blades are each made for a specific side they cannot be rotated like the lower blades When the upper blades are worn they must be replaced or reworked Replacing the upper blades is done most safely with at least two persons Do not attempt to do it alone The upper blades are NOT bolted directly to the upper shear see Figure 7 19 Make sure the blades are supported before loosening the blade bolts If the blades are not supported when the bolts are loosened the blades may drop and cause serious injury Be careful when handling blades and always wear protective gloves eye protection and steel toe boots Blade edges are sharp and each blade can weigh as much as 120 Ibs 55 g de pending on the model NOTICE When removing the upper shear blades it is recom mended to position the attachment so the upper shear is upside down This will help prevent injuries or damage to the equipment if the blades fall UPPER SHEAR LADE POCKETS BOLT HOLE SECTION A A FIGURE 7 19 Page 26 Section 7 Jaw Options UNIVERSAL PROCESSORS BLADE GAP RECOMMENDATIONS The blade gaps are the spaces between the upper and lower blades as they bypass see Figure 7 20 Plate shear jaws have two blade gaps one
60. Piercing tip fit squarely in lower piercing area 7 Inspect Lower Piercing Area a Piercing tip fit squarely in lower piercing area INSPECTED BY Page 38 Section 7 Jaw Options UNIVERSAL PROCESSORS UP SHEAR JAW 80 HOUR INSPECTION CHECKLIST ATTACHMENT MODEL EXCAVATOR HOUR METER ATTACHMENT SERIAL NUMBER DATE 1 Inspect Blades a Rotate or replace all blades b Measure blade gap refer to manual for shimming procedure and tolerance range 2 Inspect Upper Shear a Replace or build up and hardsurface piercing tip b Replace wear plate c Build up and hardsurface upper 3 Inspect Lower Shear a Build up and hardsurface lower piercing area b Build up and hardsurface lower c Replace guide blade 4 Inspect Main Pivot a Check for sideplay and wear INSPECTED BY La Bounty Jaw Options Section 7 Page 39 UNIVERSAL PROCESSORS SHEAR JAW LUBRICATION FIGURE 7 32 Grease all points every 8 hours of attachment operation Use premium grease no 2Ep or equivalent Grease fitting locations are indicated on the illustrations and by grease decals on the attachment LOCATION ON ATTACHMENT NUMBER OF SHOTS 1 Rear cylinder connections 6 2 Front cylinder connections 6 3 Main jaw pivot 6 Page 40 Section 7 Jaw Options UNIVERSAL PROCESSORS MAIN PIVOT GROUP WEAR WASHES For blade maintenance of the shear jaws to be effec tive the main pivot group must be within specifica tions Always check the piv
61. R eventually cause structural damage to the shear This SECONDARY condition also causes the shear and base machine BLADE hydraulic systems to work harder resulting in prema ture wear An approved respirator and gloves must be worn when grinding blades PLATES FIGURE 7 37 Page 44 Section 7 Jaw Options UNIVERSAL PROCESSORS BLADE SHIMMING Blade rotation is recommended every eighty hours of operation for even blade wear This makes blade shimming possible After rotating the blades it may be necessary to shim the lower blades to tighten the blade gap The proper blade gap depends on the type of material being processed with the shear jaws A large blade gap from 0 030 to 0 060 0 76 to 1 50 mm may be acceptable when processing large structural members or concrete A smaller blade gap of 0 030 0 76 mm or less is necessary when processing thin materials such as sheet metal If material is not jamming in the jaws and the blade is less than 0 060 1 50 mm shimming is not necessary The maximum allowable blade gap is always 0 060 1 50 mm Follow the steps below to check the blade gap and shim if necessary 1 To check for blade gap cycle the jaws closed so the secondary blades in the upper and lower start to bypass Using a feeler gauge between the upper and lower blades check the blade gap and record it 2 Cycle the jaws closed so the secondary blades start to bypass at the apex see Figure 7 38
62. S SO NO ONE ELSE WILL START IT ALWAYS use two people when making checks with the engine running the operator at the controls must be able to see the person doing the checking 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 attachment including safety glasses with side shields hard hat steel toe shoes gloves and hearing protection Be sure you understand a service procedure before working on the machine DO NOT ATTEMPT REPAIRS YOU DO NOT UNDERSTAND Page 2 Section 5 Maintenance CAUTION Refer to the proper maintenance procedure in this manual before servicing the machine to prevent injury or damage to the equipment During maintenance of the shear it is imperative that the excavator is turned OFF to prevent injury GENERAL RULES FOR MAINTENANCE 1 Read the maintenance manual Be sure all maintenance personnel read and understand all maintenance procedures before they are attempted 2 Use factory approved parts Use of parts that are not factory approved may cause damage or unnecessary downtime and may void the attachment warranty 3 Lubricate daily follow the lubrications schedule as outlined on page 5 6 4 Use the included Inspection Checklists during inspections to make sure all maintenance is complete 5 In extremely cold temperatures work the attachment on lighter materials first before worki
63. When all of these provided shims have been placed between the guide blade and seat and the gap again exceeds 0 030 0 76 mm the guide blade can then be turned end for end and reshimmed for proper gap When all shims have been used again the guide blade is worn out and must be replaced 3 If a new guide blade is installed and fully shimmed and the gap still exceeds 0 030 0 76 mm the front wear plate must be replaced Refer to the procedure for replacing the front wear plate later in this chapter BLADE ROTATION New blades in proper adjustment will increase the cutting performance of the shear Proper rotation of blades will provide optimum use and the most performance from the shear Recommended blade rotation is after approximately 80 hours of use depending on the material being processed this interval may vary When processing thin materials blade rotation and shimming is of greater importance than when processing larger materials It may be necessary to shorten blade rotation intervals when processing thin or non ferrous materials When processing large materials frequent blade rotation will extend the life of the blades however maintaining the close tolerance blade gap is not as important Never operate a shear when the blades have rounded to a 4 6 4 mm radius or more Maintaining the guide blade gap is very important at all times regardless of the material being cut Protective gloves must be worn at all times d
64. a primary blade secondary blade and guide blade The upper jaw passes into the lower jaw The front area of the lower jaw through which the piercing tip passes Requires regular build up and hardsurfacing Bushings located in the main pivot group which provide a wear surface between the jaws and the main pin There are two main bearings in the lower jaw and one in the upper jaw Pin on which the jaws rotate It is a component of the main pivot group High tolerance area of the attachment where the jaws pivot The main pivot group includes the main pin main bearings and thrust washers Tie plate located at the front of the lower jaw The profile of the nose plate is a very important maintenance item that must be maintained with build up and hardsurface to prevent wear of the parent material Replaceable wear part that is welded to the tip of the upper jaw The cutting blades in the shear jaws that are closest to the throat Primary blades are found in both the upper and the lower jaws The cutting blades in the shear jaws farthest from the throat Secondary blades are found in both the upper and lower jaws Area of the jawset nearest the main pivot group where the primary blades are located The throat is the optimum area for shearing material The shear is most powerful on the primary blades nearest the pivot point Component located between the upper and lower jaws in the main pivot group to serve as a wear surface between the jaw halves
65. achment immediately following welding repairs without allowing it to cool properly Page 46 Section 7 Jaw Options UNIVERSAL PROCESSORS UPPER PIERCING TIP BUILD UP AND HARDSURFACING For maximum efficiency the piercing tip should be checked daily If the tip is badly worn it is best to NOTE WEAR replace it However if the wear is not severe build up and hardsurface may be a good alternative Blade maintenance must be performed before any pierc ing tip build up or hardsurfacing is done It is recom mended that piercing tip maintenance be done at the end of the working day to allow adequate cooling FIGURE 7 39 time before putting the shear back into service STRAIGHT EDGE 1 check for wear close the shear jaws so the piercing tip is just entering into the lower jaw see Figure 7 39 The piercing tip should fit squarely into the lower jaw To determine how much build up 1 quired place a straightedge along the cutting blades and extend beyond the tip or use the upper tem plate supplied by LaBounty Figure 7 40 There will be a gap indicating how much build up is required see Figure 7 41 2 Clean all dirt and from area gt be built P 3 Preheat the surrounding area to at least 200 100 C to remove moisture Preheat the area to be FIGURE 7 40 built up to 300 400 F 150 200 C Use a tem perature stick to test the area frequently as over heating can harm the s
66. allation UNIVERSAL PROCESSORS INTERNAL ROTATION CONTROL SYSTEM INSTALLATION if equippe BEFORE GETTING STARTED 1 Have the Parts Catalog for the attachment on hand for reference The parts information for the Internal Rota tion Control System is included in it 2 Check if the following items exist on the base machine a A preferred switch other than the foot switch provided see Foot Pedal Switch Installation b One 8 SAE JIC type adapter to tap into the base machine reservoir or return line c One 8 SAE hydraulic line plumbed from the base machine s hydraulic return to the end of the boom if the attachment is mounted in place of the stick or the stick if the attachment is mounted in place of the bucket d One 15 amp circuit breaker or fuse Make sure to complete all installation procedures described in this section before starting the machine Operating the attachment before installation is com plete may cause damage to the base machine or attachment ELECTRICAL INSTALLATION 1 Place the foot 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 attachment 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 gauge wire from the base machine s DC voltage power supply and connect it
67. allation 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 UNIVERSAL PROCESSORS ATTACHMENT CONTROLS There are four movements of the Universal Processor plus rotation The attachment controls will vary depending on the base machine on which it is mounted and whether it is mounted as a second or third member The typical functions of the attachment are illustrated below see figure 4 1 The Universal Processor jaw and rotation systems are customized to each machine Review these functions with your authorized dealer or installation technician before operating the attachment Determine the control for each movement of the attachment before attempting to operate Practice the machine movements as described in Getting the Feel of the Attachment section of this manual THIRD MEMBER INSTALLATION BUCKET DUMP ATTACHMENT OUT BUCKET CURL ATTACHMENT IN SECOND MEMBER INSTALLATION BUCKET DUMP JAWS OPEN STICK INZATTACHMENT IN FIGURE 4 1 Page 4 Section 4 Operation UNIVERSAL PROCESSORS SPEED VALVE OPERATING CHARACTERISTICS The function of the speed val
68. ally designed bearings FEATURES Patented Swift Lock pin on replaceable teeth offer long wear and impact resistance One pin secures each tooth segment A complete set of teeth can be replaced in minutes At factory upgrading and rebuilding services available UPPER JAW FIGURE 7 9 Jaw Options Section 7 Page 11 UNIVERSAL PROCESSORS CONCRETE PULVERIZER JAWS GLOSSARY Build Up Front Cylinder Pins Grain of Material Hardsurfacing Lower Jaw Main Bearings Main Pin Main Pivot Group Receptacles Swift Lock Teeth Thrust Washers Tooth Pins Retaining Rings Upper Jaw Welding process during which worn off parent material is replaced with new metal A very important maintenance procedure that must be performed regularly The pins that connect the attachment cylinders to the jaws The direction that the parent material was initially rolled at the steel mill It is very important when hardsurfacing any part of the shear jaws to weld with the grain of the steel Cross grained hardsurfacing has the tendency to start cracks in the base material beneath it Welding process for protecting the parent material of the jaws The hardsurface acts as a wear surface The lower half of the jaw set It is the wider of the two jaw halves Bushings located in the main pivot group which provide a wear surface between the jaws and the main pin There are two main bearings in the lower jaw and one in the upper jaw Pin on whi
69. ammable material from the area before cutting welding or grinding Have a fire extinguisher nearby during all cutting and welding operations Clean areas to be cut or welded of oil and flammable materials Protect all flammable areas from sparks Do all work in a well ventilated area Dispose of paint and solvent properly 1 Clean all dirt and grease from the areas to be built up If any old hardsurfacing still exists remove it down to the base metal by grinding 2 Place the build up template along the tooth to determine the amount of build up required 3 Preheat the tooth to about 200 F 100 C to remove moisture Preheat the area to be built up to 300 400 F 150 200 C Do not exceed 450 F 230 C Use a temperature stick to test the area frequently because overheating can harm the tooth Temperature sticks are available from LaBounty 4 Using AWS E7018 welding rod or equivalent make side by side passes down the face of the cutting edge until the area is covered Stress relieve and remove slag after each pass by peening vigorously Continue to do this until the profile of the tooth matches the template as closely as possible Grind the edges square to match the template profile m BUILD UP TEMPLATE HARDSURFACE BEADS NS FIGURE 7 6 FIGURE 7 7 5 To hardsurface the tooth start by applying parallel passes of AWS E7018 build up running the length of the tooth Figure 7 7 These single pas
70. ance on the attachment DAILY SERVICE REQUIRED Inspect connecting pins and retainers for looseness damage or wear on the main pivot pin and cylinder pins Check pinheads and pinstops Lubricate grease fittings according to lubrication section of this manual Replace broken fittings Inspect teeth for wear indicating that tooth replacement or build up and hardsurfacing is required Refer to this manual for tooth maintenance procedures Check for loose or damaged tooth pins and replace if necessary Page 12 Section 7 Jaw Options UNIVERSAL PROCESSORS CONCRETE PULVERIZER JAWS DAILY INSPECTION CHECKLIST ATTACHMENT MODEL EXCAVATOR HOUR METER ATTACHMENT SERIAL NUMBER DATE 1 Inspect the jawset for any damage or missing parts 2 Inspect Swift Lock teeth for wear If necessary replace or maintain the teeth according to the instructions in this manual 3 Inspect connecting pins and retaining hardware for looseness damage or wear a Main Pin b Front cylinder pins c Pinheads and pinstops d Retainer pins and retainer ring e Tooth pins and retainer rings A Grease all fittings until excess appears a Lower jaw at main pivot b Upper jaw at main pivot c Lower jaw at cylinder connection d Upper jaw at cylinder connection INSPECTED BY La Bounty Jaw Options Section 7 Page 13 UNIVERSAL PROCESSORS CONCRETE PULVERIZER JAW LUBRICATION FIGURE 7 10 Grease all points every 8 hours of attachment o
71. any decals that are damaged or worn Replacement decals and decal kits are available through your Stanley LaBounty Service Department Always place replacement decals in the same position as the original decals Replace all safety decals promptly if they become damaged or worn Operating the attachment with safety decals in poor condition can result in severe injury or death STANLEY STANLEY LABOUNTY BRAND DECALS REPLACEMENT DECALS AVAILABLE UPON REQUEST FIGURE 1 1 SAFETY FIRST Read the Safety Operation and Maintenance Manual before operating or servicing the equipment Keep the manual with the attachment so it is available for reference SAFETY FIRST DECAL PART NUMBER 503590 MANUALS FIGURE 1 2 Introduction to Safety Section 1 5 UNIVERSAL PROCESSORS 1538 Highway 2 Two Harbors MN 55616 tel 1 800 522 5059 fax 218 834 3879 www stanleyhydraulic com GREASE DECAL PART NUMBER 116338 Made in the U S A with Global Materials FIGURE 1 3 Attachment Model Serial Number Year of Manufacture MODEL SERIAL NUMBER PLATE PART NUMBER 511045 KEEP AWAY FGURE 16 75 feet 3 U S PATENT NUMBERS EPO PATENT NUMBERS 5 474 242 7 240 869 435 702 SAFE VIEWING DISTANCE DECAL 5 531 007 7487930 737 107 ADANGER PART NUMBER 116389 5 992 023 7 578 461 1 682 299 FIGURE 1 4 7 322 273 7 832 130 1 789 225 8 146 256 8 104 384 A DANGER STANLEY LABOUNTY
72. ar parts for easy maintenance Fourway indexable cutting blades in lower shear Ripper tooth on upper jaw for piercing a hole for jaw to enter e At factory upgrading and rebuilding services available FRONT CYLINDER PIN CONNECTION PLATE SHEAR TERMS UPPER SHEAR FIGURE 7 12 RIPPER TOOTH MAIN PIVOT GROUP M f HOSE Y TERMINATION CONNECTOR LINK gt ADJUSTMENT PLATES AND BLADE SHIMS LOWER SHEAR LOWER BLADES Page 16 Section 7 Jaw Options UNIVERSAL PROCESSORS PLATE SHEAR JAW GLOSSARY Adjustment Plates Blade Gap Blade Shims Build Up Connector Link Front Cylinder Pins Grain of Material Hardsurface Hose Termination Block Lower Blades Lower Shear Main Bearings Main Pin Main Pivot Group Nose Blade Ripper Tooth Throat Thrust Washer Upper Blades Upper Shear m Machined plates that precisely adjust the lower primary and secondary blades to be parallel to the upper blades These make it possible to achieve a uniform blade gap The gap between the upper and lower blades as they bypass each other A very important maintenance item that must be maintained to ensure longevity of the shear jaws and to prevent material from jamming in the cutting blades Thin metal shims used to adjust lower cutting blades to maintain the proper blade gap Welding process during which worn off parent material is replaced with new metal A very important maintenance procedur
73. ar plate into the machined area existing on the upper Position the new wear plate so there is approximately 12 7 mm gap between the wear plate and the piercing tip and equal distanc es on the other sides of the seat Clamp the wear plate into the proper position and tack it in place 4 Keep the area heated to 300 400 F 150 200 C DO NOT exceed 450 F 230 C 5 Use AWS E7018 rod to fill the area between the wear plate and the piercing tip Then weld an approxi mate 13 mm fillet on all remaining sides around the wear plate Stress relieve each pass by peening 6 When welding is complete grind off welds flush with wear plate and piercing tip 7 Check the gap again and shim the guide blade ac cordingly FILLAREA Page 52 Section 7 Jaw Options FRONT WEAR PLATE PIERCING TIP FIGURE 7 51 UNIVERSAL PROCESSORS LOWER PIERCING AREA BUILD UP AND HARDSURFACING In order to perform maintenance on the lower pierc ing area all blade maintenance and piercing tip maintenance must be completed It is necessary to maintain the lower portion of the shear regularly by the following process 1 Place the shear in a horizontal position and block it up about 18 0 5 m high or preferred working height 2 Determine the amount of build up and hardsur facing required There are two ways to do this Use a straight edge on the inside of the shear blades and guide blade see Figure 7 52 or use the
74. at the area to be built up to 300 400 F 150 200 C Use a temperature stick to verify that this temperature is maintained throughout the welding process Temperatures in excess of 450 F 230 C may harm parent metal 4 Build up and restore any worn or damaged surfaces with E7018 or equivalent Each pass must be peened vigorously to relieve stress and remove slag 5 Hardsurface as instructed in this manual It is not necessary to cover the entire surface with hardsurfacing to be effective Vigorously peen the hardsurfacing to stress relieve and work harden the material 6 Post heat to 300 400 F 150 200 C Again DO NOT exceed 450 F 230 C Cover with a heat blanket and allow to cool slowly to the ambient temperature Never operate an attachment immediately following welding repairs without allowing it to cool properly Page 30 Section 7 Jaw Options UNIVERSAL PROCESSORS GENERAL BUILD UP AND HARDSURFACING IMPORTANT NOTES 1 Always hardsurface in the direction of the grain of the steel 2 Use an air operated slag peener on each pass of all welds to relieve weld stress 3 DO NOT start or stop a weld bead within 1 25 mm of a blade bolt hole 4 Stagger the ends of the adjacent beads DO NOT stop or start beads in a straight line with each other 5 Grind the end of a hardsurfacing bead smooth tapering for 174 172 31 38 mm to the parent ma terial DO NOT undercut the bead with the gr
75. ation speed exces a Operating flow too high i Adjust flow control to decrease flow to rotation sively high group b Supply flow too high i Check base machine hydraulic system 4 Rotation erratic a Crossover relieve valve cartridge is i Replace crossover relief valve faulty b Flow control valve cartridge is faulty i Replace flow control valve c Valve spool sticking in valve supplying i Check base machine hydraulic system oil d Faulty electrical signal at control valve i Replace electric solenoid if electrically controlled e Planetary gearbox binding i Rebuild or replace gearbox f Motor binding in planetary gearbox i Disassemble motor from gearbox and inspect to determine cause of binding g Faulty circuit relief valve i Check base machine hydraulic system h Varying pilot pressure to control valve i Check base machine hydraulic system Troubleshooting Section 6 5 UNIVERSAL PROCESSORS ROTATION CIRCUIT TROUBLESHOOTING GUIDE continued SYMPTOM PROBABLE CAUSE REMEDY 5 Rotation drifts a Control valve ports are open to tank i Check excavator hydraulic system with spool in neutral position b Excessive leakage in control valve i Check excavator hydraulic system spool c Crossover relief valve is leaking Replace crossover relief valve excessively d Crossover relief valve set too low i Replace crossover relief valve Page 6 Section 6 Troubleshooting UNIVERS
76. blades the gap will need to be tightened to 0 030 0 76 mm or less The maximum allowable gap is 0 060 1 50 mm Refer to the blade shimming procedure in this manual PIERCING TIP Inspect piercing tip for square fit in lower jaw Refer to manual for maintenance procedure LOWER PIERCING AREA Inspect for wear indicating build up or hardsurfacing is required Refer to manual for maintenance procedure 80 HOUR SERVICE RECOMMENDED BLADES Measure blade gap rotate replace or shim blades according to procedures in this manual UPPER JAW Inspect piercing tip wear plate and upper Refer to manual for build up hardsurface or replacement LOWER JAW Inspect guide blade lower piercing area and lower Refer to manual for build up hardsurface or replacement Jaw Options Section 7 37 UNIVERSAL PROCESSORS UP SHEAR JAW 8 HOUR INSPECTION CHECKLIST ATTACHMENT MODEL EXCAVATOR HOUR METER ATTACHMENT SERIAL NUMBER DATE 1 Visually inspect jaws for any damage 2 Grease All Points Refer to lubrication section in this manual a Each side of lower shear in main pivot b Each side of pivot group end cap 3 Inspect all Bolts a Visually check all bolts b Check blade bolt torque 4 Check Wear Plate Guide Blade Gap a Refer to manual if gap exceeds 0 030 0 76 mm 5 Check Primary and Secondary Blade Gap a Refer to manual if gap exceeds 0 060 1 50 mm or if jamming occurs 6 Inspect Piercing Tip a
77. ce 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 UNIVERSAL PROCESSORS FLANGE TYPE HOSE FITTINGS Check flange fittings for smooth tight fit of matching surfaces If any capscrews are loose or matching sur faces are not tight tighten the loose capscrew then tighten the diagonally opposite capscrew Tighten the two remaining capscrews then torque all four screws as specified in the Torque Chart in this manual Tolerance is 10 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 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 capscrews periodically Attachment bolts are designed to fail under predetermined loads Always replace shear bolts with identical grade To prevent them from failing when tightening ensure fastener threads are clean and properly engaged TORQUE VALUES FOR FOUR BOLT FLANGE FITTINGS CODE 62 FLANGES NOMINAL FLANGE NOTICE SIZE Use only metric tools o
78. ch the jaws rotate It is a component of the main pivot group High tolerance area of the attachment where the jaws pivot The main pivot group includes the main pin main bearings and thrust washers Seats for the teeth that are welded in place on the upper and lower jaws Easily replaceable pin on wear parts on the upper and lower jaws for pulverizing concrete Each tooth is fastened to its receptacle with a pin and retainer ring Wear components located between the upper and lower jaws in the main pivot group to serve as a wear surface between the jaw halves There are also thrust washers located between the jawset and the Universal Processor stick in the main pivot The hardware that fastens each tooth to its receptacle The tooth pin is held in place by the retainer ring The upper half of the jaw set It is the narrower of the two jaw halves PERIODIC SERVICE SCHEDULE Inspect lubricate make service checks and adjustments according to the Daily Inspection Checklist A program of regular service should be established using the machine hour meter to determine when the concrete pulverizer jaws should be serviced Use the intervals on the Service Schedule when operating in normal conditions Service the attachment at shorter intervals when operating in extreme environmental or abrasive conditions Refer to the Lubrication Instructions and Bolt Torque Table in this section of the Safety Operation and Maintenance Manual when performing mainten
79. chment is on the ground and blocked up if necessary or serious injury could result Trapped hydraulic pressure may be present after the base machine is shut off Extreme caution must be taken when removing attachment hy draulic hoses or possible injury or death could result 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 ATTACHMENT STORAGE 1 Block the attachment up off the ground using wood blocking 2 Plug all open hydraulic ports 3 Grease the pins and machined bores of the mounting bracket of the attachment refer to the at tachment lubrication section of the maintenance 5 tion of the manual Then apply a generous amount of grease to shear blades cylinder rods and all other exposed unpainted surfaces UNIVERSAL PROCESSORS EXCHANGING JAWS Changing out the jaws on a LaBounty Series SV Uni versal Processor is easier than ever The SV Series is designed to make this process faster and safer as well The yoke of the attachment stick features a jaw align ment channel that helps to line up the stick with the jawset for easier main pin installation JAW REMOVAL 1 Park the excavator on solid level ground 2 Extend the cylinders to close the jaws and lower the attachment until the jaws are placed solidly on the ground or on appropriate blockin
80. cked for wear regularly All edges should be kept square It is recommended that this maintenance be done at the end of the working day to allow adequate cooling time before putting the plate shear jaws back into service GENERAL PROCEDURE 1 Clean all dirt and grease from area to be built up 2 Remove all existing hardsurfacing by grinding down to the base metal before beginning build up and hardsurfacing procedures 3 To determine how much build up is required on the front edges of the upper shear place a square along the sides and front of the upper shear If the edges are worn there will be a gap indicating how much build up is required see Figure 7 25 4 Preheat the surrounding area to at least 200 F 100 C to remove moisture Preheat the area to be built up to 300 400 F 150 200 C Use tempera ture stick to check the temperature frequently as overheating can harm the jaws The maximum tem perature 15 450 F 230 C 5 For build up apply AWS E7018 welding rod Each pass must be peened vigorously to relieve weld stress and remove slag Grind all edges to 90 6 To protect the area just built up hardsurface the front face of the upper shear from the cutting blades about halfway up to the ripper tooth by applying single passes of AWS E7018 build up in a diamond pattern of approximately 172 38 see Figure 7 26 This will serve as an underlayment for the hard surface rod DO NOT weld on the blades or in
81. d routinely by the following process 1 Place the lower jaw in a horizontal position and block it up about 18 0 5 m high or preferred work ing height 2 Clean all dirt and grease from area to be built up 3 Remove any existing hardsurface material down to base metal by grinding 4 Use a straight edge or the lower profile template supplied by LaBounty to determine how much build up is required on the nose plate see Figure 7 56 Use a square or straight edge as on the upper shear to determine build up requirements on the top side of the lower shear 5 Preheat the surrounding area to at least 200 F 100 C to remove moisture Preheat the area to be 4 built up to 300 400 F 150 200 C Use tempera ture stick to test the area frequently as overheating can harm the jaws The maximum temperature is 450 230 NOTICE Check temperature during this procedure maintain 300 400 150 200 C Do not exceed 450 230 ARROWS SHOW GRAIN DIRECTION FIGURE 7 57 La Bounty Jaw Options Section 7 Page 55 UNIVERSAL PROCESSORS LOWER SHEAR BUILD UP AND HARDSURFACING continued 7 To hardsurface the build up just completed apply three or four passes of AWS E7018 build up running the length of the shear and across the nose plate to establish the hardsurface pattern see figure 7 58 This will serve as an underlayment for the hardsurface rod DO NOT apply hardsu
82. d Refer to this manual for tooth maintenance procedures Check for loose or damaged tooth pins and replace if necessary Page 4 Section 7 Jaw Options ZZ UNIVERSAL PROCESSORS CONCRETE CRACK JAWS DAILY INSPECTION CHECKLIST ATTACHMENT MODEL EXCAVATOR HOUR METER ATTACHMENT SERIAL NUMBER DATE 1 Visually inspect jaws for any damage especially check for cracks and wear on the Swift Lock receptacles Maintain the receptacles if necessary 2 Inspect Swift Lock teeth for wear Replace or maintain the teeth if necessary 3 Inspect all Bolts a Visually check all bolts for looseness or damage 4 Inspect connecting pins and retaining hardware for looseness damage or wear a Main Pin b Front cylinder pins c Pinheads and pinstops d Retainer pins and retainer ring e Tooth pins and retainer rings 5 Grease all fittings until excess appears a Lower jaw at main pivot b Upper jaw at main pivot c Lower jaw at cylinder connection d Upper jaw at cylinder connection 6 Inspect rebar blades a Rotate or replace blades b Measure blade gap refer to blade shimming procedures INSPECTED BY La Bounty Jaw Options Section 7 Page 5 UNIVERSAL PROCESSORS CONCRETE CRACKER JAW LUBRICATION FIGURE 7 2 Grease all points every 8 hours of attachment operation Use premium grease no 2Ep or equivalent Grease fitting locations are indicated on the illustrations and by grease decals on the attachment LOCATION ON
83. d valve does not shift out of the speed mode at the appropriate time resulting in a loss of processing 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 5 23 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 and adjust the speed valve e Pressure gauges two are recommended so that two test ports can be checked simultaneously Diagnostic test fittings and tools for installing the fittings Open or box end wrenches 12mm 19mm Allen wrenches 4mm 12 mm SYMPTOM PROBABLE CAUSE REMEDY 1 Attachment does not shift con a Pilot pressure setting is too high i Adjust the pilot valve adjustment screw sistently into speed mode when counterclockwise in increments of 1 8 of closing the jaw a turn 45 until corrected 2 Attachment shifts into speed a Too much back pressure in the base i Minimize back pressure if possible by mode when jaw has been fully machine return line using lines with larger diameters opened but will not shift if jaws ii If this is not possible or does not have only been opened partially completely solve the problem adjust the main spool then close adjustment scr
84. de and across the inside of the nose plate see Figure 7 54 Peen each pass No more than two layers of this rod should be used 8 Hardsurface the top side of the lower 1 1 2 38 mm 50 mm wide see Figure 7 55 us ing the same preheating welding and peening procedure Be sure to weld with the grain of the steel 9 Grind the lower jaw to a sharp edge flush with the cutting blades and guide blade by using a straightedge across the blades After welding and grinding has been completed peen the welded area until it is shiny or until the peener cannot dent the weld anymore typi cally 5 to 10 minutes This will work harden the welded area 10 Be sure to cover the lower with a heat blan ket when procedure is complete to allow it to cool slowly to the ambient temperature The hardsurfaced area acts like an extension of the blades Following these procedures will make cutting easier and prolong the life of the cutting edges and guide blade NOTICE It is important to use an airoperated slag peener on each pass of weld to relieve stress Grind off in line with cutting edges Page 54 Section 7 Jaw Options 2 03 FIGURE 7 54 FIGURE 7 55 UNIVERSAL PROCESSORS LOWER SHEAR BUILD UP AND HARDSURFACING All piercing tip and lower piercing tip seat mainte nance must be performed before any lower shear build up and hardsurfacing is done It is necessary that the lower portion of the shear be maintaine
85. de the attachment stick onto the jaws using the jaw alignment channel to properly locate the jaws in the yoke of the stick FIGURE 3 9 Avoid all potential pinching points when exchang ing jaw sets or serious injury could result For maximum efficiency and safety some operators of Universal Processors have successfully used a concrete parapet or specially designed cradle to hold the jaws during storage and installation see figure 3 10 for an example Whatever method is used be sure that the jaws are secure during removal installa tion and storage FIGURE 3 10 Page 8 Section 3 Installation La County UNIVERSAL PROCESSORS HYDRAULIC INSTALLATION Prior to hydraulic installation read the hydraulic letter provided by LaBounty before the arrival of the attach ment This letter states the hydraulic requirements for the specific attachment being installed Also read the manual for the base machine for specific information on attachment hydraulics 1 Connect the hydraulic hoses to the hydraulic con nections located on each side of the upper head Remember to cap all hydraulic hoses and fittings im mediately to prevent contamination of the hydraulic systems 2 After installing the hydraulic circuit on the base machine install additional hydraulic lines up the boom these
86. e 7 4 Daily Inspection Checklist MTM 7 5 Concrete 7 6 Concrete Crack Jaw Blade Maintenance 2 2 2 0 0000000 000000000 7 7 Concrete Crack Jaw Blade SHINING 7 7 Concrete Crack Jaw Swift Lock Tooth 21 4 4 4 4 7 8 Concrete Crack Jaw Tooth Build Up and Hardsurfacing 2 10000000 0 7 9 Concrete Crack Jaw Build Up and Hardsurfacing 2222 2 7 10 SECTION 7 AW OPTIONS continued Concrete Pulverizer Jaw 7 11 Concrete Pulverizer Jaw 2 2 2 22 02002 2 000000 7 11 Concrete Pulverizer Jaw Terms 2 2 oe 7 11 Concrete Pulverizer Jaw 7 12 Concrete Pulverizers Jaw Periodic Service Schedule 7 12 Concrete Pulverizer Jaw Daily Service 222 2 7 12 Concrete Pulverizer Jaw Daily Inspection Checklist 7 13 Concrete Pulvenzer Jaw E Pit sua De 7 14 Concrete Pulverizer Jaw Mlairtenangce uiis cei terror 7 15 Concrete Pulverizer Jaw Blade ion 7 15 Concrete Pulverizer Jaw Swift Lock To
87. e Use a piece of cardboard to search for leaks If ANY fluid is injected into the skin seek immediate medical attention 4 Whenever hydraulic lines are disconnected hoses must be capped and ports must be plugged to prevent contamination of the hydraulic system 5 Install 72 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 excavator boom and stick La Bounty Installation Section 3 Page 13 UNIVERSAL PROCESSORS THIRD MEMBER TO SECOND MEMBER ADAPTER BRACKET INSTALLATION if equipped The third member to second member adapter brack 3RD MEMBER et option makes it possible for a Universal Processor BRACKET to be mounted as a third member on one carrier and LINKAGE as second member on another smaller carrier see CONNECTION figure 3 12 Keep in mind that not all combinations will work and that the use of an adapter bracket must be approved by the Stanley LaBounty Applica tions Department for your specific combination of machines Safety equipment should be worn at all times DUE j intaini STICK when viewing operating or maintaining the at STICK CYLINDER CONNECTION tachment to prevent injury CONNECTION BRACKET INSTALLATION INSTRUCTIONS CONNECTION 1 Remove the attachment from the excavator where BRACKET it is
88. e As sembly these are the work ports for the valve The direction in which the flow meter 15 installed does not matter Operate the directional valve by using the foot switch in the operator s cab and check the flow meter reading LaBounty recommends that a flow of 4 12 GPM 15 45 LPM be maintained It may be desirable 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 must first be loosened Turn the knob clockwise to decrease flow turn the knob counter clockwise to increase 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 a G must be replaced with an adapter fitting that is com patible with the pressure gauge you are using The gauge port is a 7 16 20 SAE O ring Boss threaded port Once the pressure gauge is hooked up to the gauge port have the operator start up the base ma chine Cycle the attachment jaws until they are either fully open or fully closed and continue to operate this hydraulic function even after the jaws have bot tomed out This will cause the base machine operat ing pressure to rise and will enable you to check the
89. e Swift Lock Tooth replacement procedure on page 7 8 TOOTH BUILD UP AND HARDSURFACING If desired Swift Lock teeth can be built up and hardsurfaced to increase their life Depending on the situation it may be more cost effective to replace the teeth when they become worn rather than build them up Build up and hardsurface the teeth when there is adequate time for them to cool slowly before they are put back into service Follow the tooth build up and hardsurfacing procedure on page 7 9 FIGURE 7 11 BLADE SHIM REBAR f BLADE Jaw Options Section 7 Page 15 UNIVERSAL PROCESSORS PLATE SHEAR JAWS Plate Shear jaws are easily installed and removed and are interchangeable with other UP sets Plate Shear jaws are designed to cut plate steel up to 1 32 mm thick UP 70 model The Plate Shear jaws cut plate cleanly reducing the amount of material distortion to provide denser loads and make the plate more salvageable They are ideal for tank farm demolition work processing underground storage tanks and other applications involving cutting plate steel Jobsite and environmental safety iS greatly increased compared to out dated torching methods The main pin of every model is heavy duty for long life and pivots on LaBounty s specially designed bearings FEATURES Combines maximum cutting force with minimal weight Made with high tensile abrasion resistant steel for durability Bolt on replaceable we
90. e 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 attachment easier When starting any motion 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 UNIVERSAL PROCESSORS OPERATING TIPS As an operator gains experience processing material with the Universal Processor he or she will learn what the machine s capabilities and limitations are along with the different techniques for processing various types and sizes of materials We strongly suggest that these techniques be shared among operators to help achieve the greatest efficiency possible The following operating tips are offered to help you to get the most production and best service from your Universal Processor Start processing smaller materials and work up to larger materials This will help you to learn the limitations of the machine and will allow the machine to warm up properly e Understand that the attachment does have limits Sometimes it may be necessary to downsize very large material by another method before the attachment can process it effectively e When processing oversized concrete make partial bites to start the breakage and then back off before mak
91. e piercing tip has been neglected and the profile is badly worn it is advisable to install a new one 1 Preheat the tip and surrounding area to 300 400 F 150 200 C Use a temperature stick to test the area frequently as overheating can harm the jaws The maximum temperature is 450 F 230 C Temperature melt sticks are available from LaBounty 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 jaw 3 To completely prepare the surface for the new tip the upper must be chamfered as shown see Figure 7 46 The chamfer size should be approximately one half the thickness of the tip 4 Place the new tip into the seat Use a straight edge to position the tip before tacking it into place Place the straightedge against the face of the sec ondary blade and maintain the alignment to the side edge of the replaceable tip see Figure 7 47 5 Move tip squarely against edge make sure it is level then tack firmly in place 6 Check tip profile with the LaBounty supplied tem plate see Figure 7 48 Before installing the new piercing tip grind the area flat and smooth and remove carbon residue from the Page 50 Section 7 Jaw Options 45 FIGURE 7 46 FIGURE 7 47 OLY TEMPLATE D FIGURE 7 48 UNIVERSAL PROCESSORS REPLACING PIERCING TIP CONTINUED 6 Cycle the upper jaw into the
92. e that must be performed regularly throughout the life of the shear jaws The link arm that connects the lower shear to the rear cylinder connection of the Universal Processor The lower shear and connector link replace the hydraulic cylinder that is removed when the Plate Shear jaw set is used The pins that connect the attachment cylinders to the upper shear The lower cylinder is removed when the Plate Shear jaws are installed so only one of the two front cylinder pins is used The direction that the parent material was initially rolled at the steel mill It is very important when hardsurfacing any part of the shear jaws to weld with the grain of the steel Cross grained hardsurfacing has the tendency to start cracks in the base material beneath it Welding process of protecting the parent material of the shear jaws It acts as a wear surface Machined surface located on the connector link The hoses that are disconnected from the removed cylinder can be terminated by bolting them to this surface while the Plate Shear jaws are in use The cutting blades in the lower shear There are lower blades on both sides of the lower shear and the upper shear passes between them The lower half of the jaw set It contains cutting blades a nose blades and adjustment plates The upper shear passes into the lower shear When the Plate Shear jaw set is installed the lower cylinder is removed The lower shear connects to the connector link which connects to t
93. ear GENERAL PROCEDURE 1 To check the blade gap cycle the jaws closed so the upper blades bypass the lower blades see side view of Figure 7 20 Use a feeler gauge between the upper and lower blades to check the blade gap on each side and record it Check the gap near both ends of the blades The gap should be even for the entire span of the blades Stand clear before moving the jaws DO NOT check blade gaps with the feeler gauge while the jaws are moving 2 Subtract the desired blade gap from the actual blade gap that was just recorded This will determine the amount of shims to use To widen the gaps sub tract the actual gap from the desired gap to deter mine the amount of shims to remove 3 Shim only the lower blades Never shim the lower blades out more than 0 125 3 mm total This can potentially cause structural damage to the jaws 4 To install the shims loosen the blade bolts and slide the shim s between the existing blade adjust ment plate and the blade to be shimmed see Figure 7 21 Retorque the blade bolts to specifications If the existing blade bolts have been retorqued more than once they must be replaced with new bolts of the same size and class Page 28 Section 7 Jaw Options 5 Cycle the jaws slowly and check that the gap is correct and the jaws are not binding Regular blade rotation and shimming will provide maximum shearing efficiency and blade life If the blades are not rotat
94. ed every 80 hours shimming may not be possible because of uneven wear on the blades BLADE BOLTS ADJUSTMENT PLATES LOWER BLADES BLADE SHIMS UPPER SHEAR IS NOT SHOWN FIGURE 7 21 UNIVERSAL PROCESSORS NOSE BLADE REPLACEMENT When the nose blade becomes badly worn it will be necessary to replace it with a new one Since it is necessary to remove the lower blades to remove the nose blade it is suggested that the nose blade be inspected each time the lower blades are rotated or replaced If the nose blade must be replaced use the following procedure GENERAL PROCEDURE 1 See Figure 7 22 Remove the lower blades to get access to the nose blade bolts 2 Remove the worn nose blade and clean its seat thoroughly 3 Place the new nose blade into the seat and install the nose blade bolts and nuts loosely 4 Place all lower blades into their seats Make sure they are tight against the adjustment plates in the back of the blade seat 5 Shim the nose blade out until it is snug against the front edges of the lower blades Slide the shims between the blade and the back of the seat 6 Remove the lower blades and tighten the nose blade bolts to the proper torque The lower blades may then be installed NOSE BLADE BOLTS NOSE BLADE SHIM FIGURE 7 22 FRONT GAP RECOMMENDATIONS The front gap is the space between the front edge of the upper shear blades and the nose blade in the lower shear as they bypass The s
95. eld 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 DANGER DO NOT process material with the attachment over the operator s cab Doing so will result in severe personal injury or death from falling debris DANGER DO NOT attempt to process brittle materials such as axles and railroad rail DO NOT process any material in any position that may propel it toward the operator other workers buildings or equipment 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 23 meters DANGER NEVER approach power lines with any part of the machine Keep clear at a minimum of 15 feet 6 meters A DANGER DO NOT close the attachment on a structure and reverse the excavator in an attempt to pull down material 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 Lifting incorrectly can cause severe injury or machine damage Carry loads in recommended positions for maximum stability Use the recommended excavator counter
96. en operating in extreme environmental or abrasive conditions Use correct lubricants and bolt torques Refer to the lubrication and bolt torque instructions in this manual when performing maintenance on the attachment 8 HOUR SERVICE RECOMMENDED 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 Grease Fittings Lubricate according to the Lubrication section page 5 6 Replace broken fittings Connecting Pins Inspect the mounting bracket pins and shear cylinder pins for looseness or damage Check pinheads and pin keepers Bolts Visually check all bolts If any are loose or damaged replace them with the same grade bolt Tighten to the proper torque using the bolt torque charts in this manual Bolts should not be retorqued more than once before they are replaced Hoses Connections Cylinders Inspect for leaks wear and damage Tighten repair or replace Cylinder Shrouds Check the shrouds for dents that could come into contact with the cylinder when the jaws are cycled Check the cylinder shroud bolts to ensure the shrouds are secure Maintenance Section 5 Page 3 UNIVERSAL PROCESSORS 8 HOUR INSPECTION CHECKLIST Attachment Model Excavator Hour Meter Attachment Serial Number Date 1 Inspect safety devices a All safety decals in place and legible see decal and label maintenance sectio
97. eplace the main pivot group components Contact your LaBounty dealer or the LaBounty Customer Service Department for assis tance with this maintenance FIGURE 7 15 Jaw Options Section 7 23 UNIVERSAL PROCESSORS BLADE REMOVAL Safe and proper removal of blades from their blade seats is necessary when performing various types of maintenance on the plate shear To ensure your safety and to avoid damaging the attachment always use the following procedure when removing a cut ting blade or guide blade from its seat GENERAL PROCEDURE 1 Loosen the blade bolts one blade at a time Make sure the blade is adequately supported so it will not drop and cause injury when the blade comes loose from its seat 2 Lightly tap on the blade face in several places with a soft faced hammer This will sometimes loosen a slightly jammed blade 3 If the blade is jammed in the seat and is difficult to dislodge take a soft metal punch or drift pin and insert it in a blade bolt hole from the back side nut side see Figure 7 16 Place the punch at an angle against the inside countersink of the blade and strike the punch with a hammer or mallet 4 f this method fails to dislodge the blade drive wedges between the blade and the back of the blade seat as shown Start with small wedges and increase the size as the opening grows SS SOFT METAL BOTTOM PUNCH OR DRIFT SOFT METAL WEDGE m BLADE BLADE BACK SE
98. ew clockwise in increments of 1 8 of a turn 45 until corrected 3 Jaws continue to close after the a The main valve spool in the speed valve attachment has shifted into speed is not fully shifting out of speed mode i Adjust the main spool adjustment mode and the operator has let go screw clockwise in increments of 1 8 of a of the control turn 45 until corrected 4 Attachment properly shifts into a The main valve spool is not fully shifting speed mode but seems to lack out of speed mode i Adjust the pilot valve adjustment screw power counterclockwise in increments of 1 8 of a turn 45 until corrected Page 10 Section 6 Troubleshooting UNIVERSAL PROCESSORS SECTION 7 JAW OPTIONS Concrete Crack Jaw DESCHIPUOM 7 3 Concrete Crack Jaw Features 8 7 3 Mucius E METEO 7 3 Concret Crack 7 4 Concrete Crack Jaws Periodic Service Schedule 22 0000001 7 4 Concrete Crack Jaws Daily Service ROQUINOG 7 4 Baily Inspection E M 7 5 Concrete Crack Jaw LUD 7 6 Concrete Crack Jaw Blade Maintenance
99. g see figure 3 8 3 Secure the jaws to prevent them from tipping or fall ing when the pins are removed Be sure that the jaws are secure before removing any pins 4 Remove both of the front cylinder pins and retract the cylinders 5 Remove the main pin Again be sure the jaws are secure 6 Slowly and carefully raise the attachment allowing the jaws to remain on the ground amp Removal of the attachment pin can be hazard rds ous Never release the weight of the attachment jawset unless it is fully secured or serious injury could result FIGURE 3 8 Avoid all potential pinching points when exchang ing jaw sets or serious injury could result For maximum efficiency when exchanging jaws de sign a cradle or rack to securely hold the jaws in the proper position for storage and installation em Installation Section 3 Page 7 UNIVERSAL PROCESSORS JAW INSTALLATION 1 Remove the existing jawset using the previous directions 2 Place the jawset to be installed in a secure posi tion with the pin connections at the top see figures 3 9 and 3 10 3 Slowly and carefully walk the excavator into posi tion so that the attachment stick can be placed onto the jawset The attachment cylinders should be fully retracted for now 4 Use the excavator to sli
100. ging accumulators 1 Connect a charging hose to the shut off valve of a commercially available 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 level is reached If the gas pressure in the nitrogen supply bottle is higher than the maximum operating pressure of the accumulator a gas pressure reducing valve or regulator must be fitted 2 Allow five minutes for the nitrogen temperature to adjust Check and repeat process until proper pres sure 1100 PSI 76 BAR 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 4 Replace cap nut and protective cap CAP SCHRADER VALVE aN CAP NUT O RING SPINDLE NIPPLE RELIEF VALVE FIGURE 5 16 TYPICAL CHARGE AND TEST UNIT Maintenance Section 5 Page 29 UNIVERSAL PROCESSORS OPERATING FLOW FOR IN TERNAL ROTATION The operating flow of the Internal Rotation Control System directly affects the speed at which the at tachment will rotate Two people are necessary to check the operating flow of the Internal Rotation Control System Install a flow meter between the A and B ports on the Accumulator Control Valv
101. h PT C F Min 204 400 218 425 Pour PT C F Max 48 55 43 45 Viscosity cP 40 C 109 000 cP 26 C cSt 40 C 117 cSt 100 C 15 5 Viscosity Index 139 GEARBOX FILL CAPACITIES Typically the fill capacity for the rotation gearbox is approximately 3 4 full Use the chart below for actual fill capacities for your specific gearbox Refer to the Parts Catalog for the attachment to determine the LaBoun ty part number of your gearbox LaBounty Part Number Fill Capacity Models Where Used 510783 17 fluid ounces 0 5 liter UP 30SV amp UP 45SV 511488 2 pints 1 liter UP 70SV Page 16 Section 5 Maintenance em UNIVERSAL PROCESSORS TURNTABLE BEARING LUBRICATION LUBRICATION FREQUENCY Equipment operating frequently in extreme environments should be lubricated at least every eight hours If the old grease is noted to be in good condition and free of contamination the interval may be extended Conversely whenever the grease is contaminated or deteriorated the interval should be shortened Rotating attachments 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 external drive To lubricate the bearing grease a fitting and then stand clear to rotate the
102. h and receptacle Make sure to install the pin so the groove in the pin will line up with the retainer ring inside The retainer ring should seat in the pin groove Page 8 Section 7 Jaw Options FIGURE 7 4 7 When this jaw is done start up the base machine With all personnel standing at a safe distance lift the attachment and rotate it 180 Lay the attachment back down on the ground and make sure it will not drop or close 8 Use steps 3 through 6 to replace the tooth on the other jaw RECEPTACLE OR SEAT TOOTH PIN FIGURE 7 5 UNIVERSAL PROCESSORS TOOTH BUILD UP AND HARDSURFACING See the table on page 7 57 for the part numbers for UP Swift Lock build up templates If desired Swift Lock Teeth can be built up and hardsurfaced to increase their life Depending on the situation it may be more cost effective to replace the teeth when they become worn rather than build them up Build up and hardsurface the teeth when there is adequate time for them to cool slowly before they are put back into service Paint removal and grinding can be hazardous and cause personal injury e Remove paint before welding or heating Haz ardous fumes can be generated when paint is heated When sanding or grinding paint avoid breathing the dust wear an approved respirator If you use solvent or paint stripper remove strip per with soap and water before welding Remove solvent or paint stripper containers and other fl
103. hardsurfacing This will help reduce the chances of having the hardsurfacing material crack LaBounty recommends using Amalloy 814H rod or equivalent for hardsurfacing Do not use stainless hardsur face rod For LaBounty applications it is too brittle and cracks weakening the base metal NOTICE It is recommended that build up and hardsurfacing be performed at the end of the work day to allow adequate time to cool GENERAL PROCEDURE 1 Clean all dirt and grease from the area to be built up 2 Remove the worn hardsurfacing by grinding to the base metal DO NOT build up on top of any hardsurface material 3 Preheat the surrounding area to at least 200 F 100 C to remove moisture Preheat the area to be built up to 300 400 F 150 200 C Use a temperature stick to verify that this temperature is maintained throughout the welding process Temperatures in excess of 450 F 230 C may harm parent metal 4 Build up and restore any worn or damaged surfaces with E7018 or equivalent Each pass must be peened vigorously to relieve stress and remove slag 5 Hardsurface as instructed in this manual It is not necessary to cover the entire surface with hardsurfacing to be effective Vigorously peen the hardsurfacing to stress relieve and work harden the material 6 Post heat to 300 400 F 150 200 C Again DO NOT exceed 450 F 230 C Cover with a heat blanket and allow to cool slowly to the ambient temperature Never operate an att
104. he connecting pins 7 Extend the cylinder rod and position as necessary to connect to the cylinder connection of the attachment Install the pin provided with the mounting bracket It may be necessary to use a lifting device overhead hoist forklift etc to position the cylinder correctly FIGURE 3 5 Page 4 Section 3 Installation e UNIVERSAL PROCESSORS THIRD MEMBER ATTACHMENT REMOVAL PROCEDURE 1 Curl the attachment under until it is horizontal and lower the attachment to the ground figure 2 6 2 Use blocking to support the bucket cylinder and linkage from the excavator stick 3 Remove the linkage connection pin from the attachment mounting bracket 4 Fully retract the bucket cylinder and linkage after it is detached from the attachment mounting bracket 5 CAREFULLY remove the jumplines at the attachment manifold Disassembly of any pin connected attachment can be hazardous Never remove any pins unless the attachment is on the ground and blocked up if necessary or serious injury could result 6 Plug the open manifold ports and hose ends with pressure plugs to prevent contamination of the hydraulic system 7 Ensure that the attachment is stable before unpinning the stick pivot pin and releasing the weight of the attachment 8 Remove the stick pivot pin from the attachment Tra
105. he proper torque value for the size Class and type of bolt UNIVERSAL PROCESSORS PLANETARY GEARBOX LUBRICATION if equipped The planetary gearbox is used if changes in gear ratios are required between the hydraulic motor and turntable bearing to rotate the attachment Correct lubricant and change out procedures are critical to maintain depend able gearbox operation The Planetary Gearbox Lubricants chart on the following page 4 16 specifies correct lubricants for various operating temperatures NOTICE 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 SAE 80W 90 500 hours or one year Synthetic ISO 150 104 F 1000 hours or two years Synthetic ISO 460 104 F 1000 hours or two years Recommended inspection of the gearbox fluid level is every 250 hours or 6 months Cold weather lubri cation is critical If the temperature is below 5 F 14 C change out lubricant to synthetic specification Slow rotation of the attachment is recommended with all grades of lubricant at temperatures below 20 F 7 C prior to working the attachment All rotating attachments leaving the factory have synthetic ISO 150 104 F grade lubricant installed LUBRICANT CHANGE OUT PROCEDURE 1 Position attachment at a comfortable working height and in a position where gearbox is near level
106. he rear cylinder connection Bushings located in the main pivot group which provide a wear surface between the jaws and the main pin There are two main bearings in the lower jaw and one in the upper jaw Pin on which the jaws rotate It is a component of the main pivot group High tolerance area of the attachment where the jaws pivot The main pivot group includes the main pin main bearings and thrust washers A blade located in the inside front of the lower shear This blades acts as a cutting edge to cut off the strip of plate steel as it passes through the lower shear The nose blade also acts as a wear surface There are two different nose blade options one for ribbon cutting and one for coupon cutting A pointed horn that is welded on the top of the upper shear It can be used for a number of purposes The main purpose of the ripper tooth is to puncture a tank wall to create a hole where the jaws can start cutting Area of the jawset nearest the main pivot group where the primary blades are located The throat is the optimum area for shearing material The shear is most powerful on the primary blades nearest the pivot point Component that acts as a wear part between adjoining surfaces There are thrust washers located between the upper shear and the lower shear There are also thrust washers located between the jaw set and the Universal Processor stick Cutting blades located in the upper shear There is an upper blade on each side of
107. hear The maximum heat is 450 F 230 4 Apply AWS E7018 welding rod to build up the worn area Each pass must be peened vigorously to relieve stress and remove slag 5 To hardsurface the build up just completed use Amalloy 814H or equivalent and apply single passes side by side No more than two layers of this rod should be applied 6 When build up and hardsurfacing are complete grind weld smooth and square with wear plate and cutting blades After welding and grinding have been BUILD UP TEMPLATE FIGURE 7 41 completed peen the welded area until it is shiny or until the peener can no longer dent the weld typical ly 5 to 10 minutes each side This will work harden the welded area NOTICE Check temperature during this procedure maintain 300 400 F 150 200 Do not exceed 450 230 Jaw Options Section 7 47 UNIVERSAL PROCESSORS UPPER SHEAR BUILD UP AND HARDSURFACING All upper piercing tip and lower piercing area main tenance must be performed before any upper shear build up and hardsurfacing is done It is recommend ed that this maintenance be done at the end of the working day to allow adequate cooling time before putting the shear back into service 1 For maximum efficiency the upper should be checked for wear regularly All edges should be kept square with the blades and piercing tip 2 Clean all dirt and grease from area to be built up 3 Remove all exis
108. heck blade bolt torque 4 Inspect Connecting Pins and Pin Retainers a Main pin b Cylinder pins 5 Check Blade Gap a Refer to manual for proper adjustment 6 Check Front Gap a Refer to manual for proper adjustment INSPECTED BY Page 20 Section 7 Jaw Options UNIVERSAL PROCESSORS 80 HOUR INSPECTION CHECKLIST ATTACHMENT MODEL EXCAVATOR HOUR METER ATTACHMENT SERIAL NUMBER DATE 1 Inspect Blades a Rotate or replace lower blades b Replace upper blades if necessary c Measure blade gap 2 Inspect Upper Shear a Build up and hardsurface upper 3 Inspect Lower Shear a Build up and hardsurface lower 4 Inspect Main Pivot a Check for sideplay and wear INSPECTED BY La Bounty Jaw Options Section 7 Page 21 UNIVERSAL PROCESSORS PLATE SHEAR JAW LUBRICATION FIGURE 7 13 Grease all points every 8 hours of attachment operation Use premium grease 2Ep or equivalent Grease fitting locations are indicated on the illustrations and by grease decals on the attachment LOCATION ON ATTACHMENT NUMBER OF SHOTS 1 Two in upper shear main pivot 2 One in each side of lower shear main pivot 3 One in cylinder connection of upper shear 4 Two in connector link one at each end Page 22 Section 7 Jaw Options UNIVERSAL PROCESSORS MAIN PIVOT GROUP WEAR WASHEHS For blade maintenance of the plate shear jaws to be ef MAIN BEARING fective the main pivot group must be w
109. hen performing maintenance on the jaw set 8 HOUR SERVICE RECOMMENDED GREASE FITTINGS Lubricate according to the Section on page 7 22 Replace broken Ittings CONNECTING PINS AND PIN RETAINERS Inspect for looseness and damage or wear on the main pin and cylinder pins BOLTS Check for looseness and damage Retorque if necessary Refer to Dry Bolt Torque tables in this manual Bolts may be retorqued once and then must be replaced BLADE GAP Inspect for proper gap See Blade Gap Recommendations on page 7 27 for information on properly setting FRONT GAP Inspect for proper gap See Front Gap Recommendations section on page 7 29 for information on properly setting this gap 80 HOUR SERVICE RECOMMENDED BLADES Measure blade gap rotate replace or shim blades according to procedures in this manual UPPER SHEAR Inspect the upper upper tooth and wear areas for damage Refer to manual for build up hardsurface or replacement LOWER SHEAR Inspect nose blade and wear areas Refer to manual for build up hardsurface or replacement Jaw Options Section 7 Page 19 UNIVERSAL PROCESSORS 8 HOUR INSPECTION CHECKLIST ATTACHMENT MODEL EXCAVATOR HOUR METER ATTACHMENT SERIAL NUMBER DATE 1 Visually inspect jaws for any damage 2 Grease all Points Refer to lubrication section in this manual a Each side of lower shear in main pivot b Each side of pivot group end cap 3 Inspect all Bolts a Visually check all bolts b C
110. his procedure maintain 300 400 F 150 200 C Do not exceed 450 F 230 5 For required build up apply AWS 7018 welding rod in single passes running with the grain of the base material see Figure 7 28 Peen each pass to relieve weld stress and remove slag Grind all edges to 90 6 Hardsurfacing must follow the grain of the material To hardsurface the area just built up start by applying three or four passes of AWS E7018 build up running the length of the shear and across the nose plate to establish the hardsurface pattern This will serve as an underlayment for the hardsurface rod DO NOT apply hardsurface directly to the parent material ARROWS INDICATE GRAIN OF DIRECTION FIGURE 7 28 La Bounty Jaw Options Section 7 Page 33 UNIVERSAL PROCESSORS LOWER SHEAR BUILD UP AND HARDSURFACING CONTINUED 09 NT 7 The beads along the sides of the lower shear should end between the first and second blade IN THROAT STAGGER bolts closest to the throat DO NOT weld into the WELDS throat area Stagger the ends of the welds see Figure 7 29 Taper the ends of each weld down to the base material with grind marks going with the grain but do not undercut the ends of the weld with the grinder 8 Apply Amalloy 814H rod or equivalent on top of each of the underlayment beads It is important to use an air operated slag peener on each pass of weld to relieve stress No more than two layers of this rod should be
111. in pin passes Main Pin Manual Override Motion Control Valve Motor Planetary Gear Box Pressure Reducing Valve Rear Cylinder Pins Relief Valve Return Line Rotation Assembly Second Member Mount Solenoid Speed Valve Stick Stick Connection Swivel Manifold Third Member Thrust Washers Turntable Bearing Unloading Valve Page 6 Section 2 About the Attachment through these bearings Pin that connects the jawset to the main body of the attachment The jaws rotate on this pin when opening and closing Override button on the directional valve to allow for manually operating the valve in the event of electrical failure if equipped with a rotation control kit A manifold including two crossover relief valves and two brake valves that provides overload protection and a load control system for the rotator Hydraulic rotation component that drives the turntable bearing either directly or through a planetary gear box on rotating attachments Hydraulic rotation component on larger rotating attachments The planetary gear box rotates the body of the attachment with the aid of the hydraulic motor The output shaft of the component directly drives the turntable bearing of the rotating attachment Valve that regulates the system pressure in the accumulator circuit Reduces base machine pressure to meet rotation requirements if equipped with a rotation control kit The pins that connect the attachment cylinder ends to
112. inder Grind marks must be in the same direction as the grain of the base material 6 DO NOT hardsurface into the throat area of the lower or upper which can cause surface cracks that may develop into major structural failures 7 Check temperature frequently to maintain 300 400 F 150 200 C throughout the process DO NOT exceed 450 F 230 C 8 Never operate an attachment following repairs without first allowing it to cool slowly to ambient temperature PAINT REMOVAL AND GRINDING CAN BE HAZARD OUS AND CAUSE PERSONAL INJURY PLEASE TAKE THE FOLLOWING PRECAUTIONS REMOVE PAINT BEFORE WELDING OR HEATING HAZARDOUS FUMES CAN BE GENERATED WHEN PAINT IS HEATED WHEN SANDING OR GRINDING PAINT AVOID BREATHING THE DUST WEAR AN APPROVED RESPI RATOR USE SOLVENT OR PAINT STRIPPER RE MOVE STRIPPER WITH SOAP AND WATER BEFORE WELDING REMOVE SOLVENT OR PAINT STRIPPER CONTAINERS AND OTHER FLAMMABLE MATERIAL FROM THE AREA BEFORE CUTTING WELDING OR GRINDING HAVE A FIRE EXTINGUISHER NEARBY DURING ALL CUTTING AND WELDING OPERATIONS CLEAN AREAS TO BE CUT OR WELDED OF OIL AND FLAM MABLE MATERIALS PROTECT ALL FLAMMABLE AREAS FROM SPARKS DO ALL WORK INA WELL VENTILATED AREA DIS POSE OF PAINT AND SOLVENT PROPERLY FIGURE 7 24 La Bounta Jaw Options Section 7 Page 31 UNIVERSAL PROCESSORS UPPER SHEAR BUILD UP AND HARDSURFACING For maximum life and efficiency the upper shear should be che
113. ing the next partial bite This will allow the broken material to fall away between bites When shearing larger steel members such as or tubing try doing it in two cuts rather than one Pierce the material about halfway through with the first cut and then finish it off with the second cut Keep the attachment properly maintained Jaws with excessive blade gaps or dull teeth are much less effective lack of maintenance can lead to greater problems and potential downtime f possible sort your scrap to get the highest capacity from the attachment The shear jaws are best capable of processing light thinner gauge materials immediately after performing blade maintenance When processing larger materials the condition of the blades and the blade gap are not as critical Avoid handling or processing long heavy materials off center Excessive weight held out to one side can force the attachment to rotate This is known as backdriving the rotation system Backdriving puts increased strain on the rotation system and if done continually can lead to rotation component problems Remember the rotator is intended for positioning the attachment only When handling materials keep the load as close to the base machine as safely possible This will provide the greatest machine stability Operation Section 4 Page 7 UNIVERSAL PROCESSORS SECTION 5 ATTACHMENT MAINTENANCE Wiailitenance Safety PrOCBEUBG
114. inued The pilot valve adjustment is used for setting the point at which the speed valve shifts into and out of the regenerative mode The main spool adjustment is used to overcome the back pressure in the base machine and to eliminate cylinder drift 3 If the speed valve operates properly regardless of jaw position it will then be necessary to check to make sure the valve is shifting out of the regenera tive high speed mode Test fittings will need to be installed into the MBS and MAZ test ports on the valve see figure 5 13 f functioning properly the hydraulic pressure will be approximately the same while the jaws are clos ing When the jaw is fully closed the pressure at the MBS port will reach full system pressure while the pressure at the MAZ port will drop to nearly zero f no change in pressure is evident turn the pilot valve adjustment screw counterclockwise see figure 5 11 45 each time until the pressures are correct The MBS port gives the hydraulic pressure at the cylinder bore side The MAZ port gives the hydraulic pressure at the cylinder rod side 4 Another adjustment will need to be made if the jaws continue to drift toward the closed position after the operator has released the control Turn the main spool adjustment screw clockwise see figure 4 31 45 each time until this condition ceases Then repeat steps 1 and 2 to make sure the valve is still shifting into
115. ithin specifica UPPER tions Always check the pivot group for excessive wear before doing any blade maintenance The main pivot group consists of main bearings and thrust washers see Figure 7 14 The main bearings act as a wear surface between the jaw bore and the main pin The thrust washers act as a wear surface between the upper and lower jaw halves Plate shear jaws do not have outer thrust washers like the other jaw set options When the main pivot components are excessively worn there will be sideplay in the main pivot group Sideplay is when the upper jaw can move from side to side in re lation to the lower jaw When sideplay is present adjust ing the blade gaps will be ineffective Use the following steps to check for sideplay in your jawset Wear proper safety equipment including eye pro FIGURE 7 14 tection and gloves when performing this procedure GENERAL PROCEDURE 1 With the jaw set fully installed in the Universal Pro cessor retract the attachment cylinder to fully open the jaws Lower the attachment so the lower jaw is on the ground and shut off the base machine Make sure the attachment is secure and will not drop 2 Use a pry bar between the upper and lower jaws in the main pivot area on each side to see if the upper can be moved back and forth in relation to the lower jaw See Figure 7 15 MAIN BEAR INGS LOWER If there is sideplay or looseness greater than 3 32 2 5 mm it may be necessary to r
116. ize of the front gap is an important factor how the jaws will process plate If the front gap is set wide the material being cut is more likely to form a continuous ribbon of steel that will be pushed through the lower shear as the cut is made If the front gap is set narrow the rib bon of steel is more likely to be clipped off with each cut This will create many short rectangular pieces of steel called coupons The decision to set the front gap for ribbon or coupon cutting depends on what is preferred for your application The front gap can only be changed if and or when a different nose blade is installed NOTICE Two different nose blades are offered for each model one for ribbon cutting and one for coupon cutting see Figure 7 23 LaBounty Plate Shear jaws are set up for ribbon cutting unless otherwise specified when the jaw set is ordered RIBBON NOSE BLADE STANDARD COUPON NOSE BLADE OPTIONAL FIGURE 7 23 Jaw Options Section 7 Page 29 UNIVERSAL PROCESSORS GENERAL BUILD UP AND HARDSURFACING Proper build up and hardsurfacing requires inspection according to the inspection scheduled for each jaw type If the jaws are in severe application the interval for maintenance may need to be shortened Excessive hard surfacing can damage the jaws and affect the performance Allow the hardsurface material to wear down but not completely away before hardsurfacing again Never apply more than two layers
117. khead in the upper head side plate or port block A hydraulic line should be connected Y to this port and routed back directly to PORTS the tank via a return line filter or a filter jai of its own The maximum allowable back j LOAD CONTROL pressure in this line should not exceed VALVE 300 PSI LOAD RELIEF VALVE 1 TEST GAUGE VALVES NON ADJUSTABLE PORT FIGURE 5 5 The case drain line must be connected to prevent failure to the case or motor seals La Bounty Maintenance Section 5 Page 19 UNIVERSAL PROCESSORS CONTROL VALVE ASSEMBLY SCHEMATICS AND DESCRIPTIONS Please refer to the Parts Catalog to identify the control valve assembly in your specific attachment See figure 5 6 Crossover Relief Flow Control Valve used on UP 20SV and UP 25SV Work Ports A amp B SAE 8 O Ring Boss Ports for 5 8 OD Tube 7 8 14UNF 2B Gauge Ports GA amp GB SAE 4 O Ring Boss Ports for 1 4 OD Tube 3 8 24UNF2B FIGURE 5 6 See figure 5 7 Crossover Relief Flow Control Valve used on UP 70SV Work Ports A amp B 48 O Ring Boss Ports Gauge Ports G1 amp G2 SAE 4 O Ring Boss Ports SAE 6 O Ring Boss Ports MOTOR FIGURE 5 7 L RELIEF Drain Ports 0 amp i VALVES SAE 4 O Ring Boss Ports ED T BRAKE VALVES A D T B MOTOR See figure 5 8 Motion Control Valve used on UP 30SV and UP 45SV M1 2 RELIEF Work Ports A amp
118. ld Up and Hardsurfacing 7 15 Plate Shear Jaw Os 7 16 Plate Shear Jaw Features DROP 7 16 Plate Shear Jaw Terms 7 16 Plate Shear Jaw GIOSSaTY 7 17 Plate Shear Javy stell dtiOrics made acero 25 7 18 Plate Shear Jaw Removal Storage ise etai eines 7 19 Plate Shear Jaw Service deor ei 7 19 sine dinct euijbd e MM REN 7 20 80 Hour inspection CIC KIS boa MERE 7 21 Plate Shear og EET TP 7 23 Main Pivot Group Wear rax cH 7 24 Blade 7 25 LOWEMB ROTATION 7 25 Upper Blade 2 7 26 Gap RecommnerndatiOns 2 7 27 Adj sting Blade Gaps EE 7 28 Nose Blade Replacement EE 7 29 Front Gap AC ONION OA OEE 7 29 General Build Ep and Malet mewn 7 30 Upper Shear Build Up anid Hardsurfeellf 7 31 bower Shear Build Ub Elardsurfacilt uoo terra
119. ld up and hard surface the upper and lower jaws 1 Carefully remove the Swift Lock teeth from their receptacles If the teeth need to be built up and hardsurfaced follow instructions on previous pages 2 Place the build up template along the jaw profile to determine the amount of build up required The templates should be identified for the upper and lower jaws 3 Clean all dirt and grease from the areas to be built up If any old hardsurfacing still exists remove it down to the base metal by grinding 4 Preheat the area to about 200 F 100 C to remove moisture Preheat the area to be built up to 300 400 F 150 200 C Do not exceed 450 F 230 C Use a temperature stick to test the area frequently because overheating can harm the jaws Tempera ture sticks are available from LaBounty 5 Using AWS E7018 welding rod or equivalent make side by side passes to build up the worn areas Peen vigorously after each pass to relieve weld stress relieve and remove slag Continue to do this until the profile matches the template as closely as possible Grind the edges square to match the template profile NOTICE Check temperature during this procedure maintain 300 400 F 150 200 C Do not exceed 450 230 DO NOT apply the hardsurface directly to the parent material Page 10 Section 7 Jaw Options 6 To hardsurface the area just built up start by applying single passes of AWS E7018 build
120. le throw mo mentary rocker switch or push button switch c A single pole double throw three 3 position momentary toggle switch mounted to the control lever with a fabricated bracket ELECTRICAL SCHEMATIC 12V OR 24V DC POWER RECEPTACLE IN SIDE PLATE BREAKER OF UPPER HEAD OFATTACHMENT UG AT END OF CORD GROUND ON CHASSIS CONTROL VALVE ASSEMBLY INSIDE loa Sea a This is a normally closed system FIGURE 3 11 INSIDE ATTACHMENT INSTALLED AT FACTORY Page 12 Section 3 Installation UNIVERSAL PROCESSORS INTERNAL ROTATION CONTROL SYSTEM HYDRAULIC RETURN LINE INSTALLATION INSTRUCTIONS 1 Always relieve all hydraulic pressure of the base machine before attempting to work on any hydraulic component Relieve all hydraulic pressure before working on the machine by working the controls in all directions with the engine off 2 Shut off the base machine and check the hydraulic system pressure It should be PSI 3 Hydraulic oil becomes hot during operation DO NOT let hot hydraulic oil get in contact with the skin as it will cause severe burns Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before dis connecting hydraulic lines Tighten all connections before applying pressure Keep hands and body away from pin holes and nozzles that may eject fluids under high pressur
121. lock on motor motor ii Check cartridge valve seals for damage 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 hyaraulic flow 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 Page 4 Section 6 Troubleshooting UNIVERSAL PROCESSORS ROTATION CIRCUIT TROUBLESHOOTING GUIDE continued SYMPTOM PROBABLE CAUSE REMEDY 2 Rotation is excessively d Internal leakage in manifold block i Replace manifold block on motor slow continued motor ii Check cartridge valve seals for damage e Motor is worn out i Rebuild or replace the motor f Supply pressure too low i Check base machine hydraulic system g Supply flow too low i Check base machine hydraulic system h Internal leakage in valve i Check base machine hydraulic system i Valve supplying hydraulic fluid is not i Check base machine hydraulic system working 3 Rot
122. lower jaw to check the clearance of the new tip If clearance is correct proceed with the following steps If not determine where the interference is and adjust the position of the tip accordingly 7 Preheat the upper and the surrounding area to 300 400 F 150 200 C Again never exceed 450 F 230 8 Use AWS E7018 weld rod and fill the chamfered areas with multiple passes Do the sides first and stress relieve each pass by peening FRONT VIEW 9 A weld is required on both sides of tip see Figure 7 49 10 Weld the back and front to the upper following neu the same procedure see Figure 7 50 11 When all welding is complete grind the welds flush The weld on the side opposite the blades should be ground flush with the front wear plate NOTICE If the front wear plate needs to be replaced it is suggested that the piercing tip be replaced also SIDE VIEW FIGURE 7 50 Jaw Options Section 7 Page 51 UNIVERSAL PROCESSORS FRONT WEAR PLATE REPLACEMENT 1 To remove the old wear plate first preheat it and the surrounding area to 300 400 F 150 200 C DO NOT exceed 450 F 230 C use temperature stick Airarc the old wear plate to remove it completely Please note that a machined area for the wear plate iS present in the upper 2 Before installing the new wear plate make sure the area is flat and smooth with all carbon residue removed 3 Place the new we
123. mended every 80 hours of jaw set use in order to assure uniform wear so shimming is possible After rotating or replacing the blades there is a possibility there will be a gap between the blades and shimming may be necessary It is necessary to maintain a blade gap of 0 060 1 50 mm or less to prevent jamming and damage to the jaw set 1 To check for blade gap cycle the jaws closed so the blades bypass Use a feeler gauge between the blades to check the blade gap and record it Do not move the attachment or jaw set while checking with a feeler gauge 2 The amount of shims to install behind the blade should be approximately 0 010 0 25 mm less than the measurements you recorded earlier Do not shim out the blade more than 0 125 3 2 mm or you may cause structural damage and the warranty may be voided 3 To install the shims loosen the blade bolts and slide the shim between the blade and the blade seat see Figure 7 3 Tighten the blade bolts to the proper torque according to this manual 4 Cycle the jaws slowly to ensure there is no blade interference and then recheck tolerances Maintain this shimming procedure for maximum shearing efficiency and blade life If the blades are not rotated every 80 hours shimming may not be possible because of uneven wear on the blades Jaw Options Section 7 Page 7 UNIVERSAL PROCESSORS SWIFT LOCK TOOTH REPLACEMENT When the jawset teeth are badly worn or crack ing perfo
124. mula 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 labounty stanleyworks com Website www stanleyhydraulic com Part Numbers 020205 T050205 T069605 099605 T059605 The STANLEY and LABOUNTY names and logos are registered trademarks of Stanley Solutions
125. n b All cab protection in good condition c All excavator warning systems working 2 Visually inspect attachment for any damage 3 Lubricate all points Refer to attachment lubrication in this section a Rear cylinder connections 2 each side b Front cylinder connections 2 c Main pivot area 2 each side d Mounting bracket stick connections if necessary e Mounting bracket link connection if necessary 4 Inspect connecting pins and pin retaining hardware a Stick connection or boom pivot pin b Link connection or cylinder connection pin c Front cylinder pins upper and lower cylinders d Rear cylinder pins upper and lower cylinders e Main pin 5 Inspect all bolts a Visually inspect all bolts and replace any that are loose or damaged 6 Check hydraulic system a Inspect hoses for wear and potential failure b Inspect hose connections for leaks c Inspect cylinders for leaks d Inspect speed valve connections for leaks 7 Inspect cylinder shrouds a Inspect shrouds for dents that may come in contact with cylinders c Inspect shroud bolts for looseness or damage Rotator 1 Visually check all turntable bearing bolts and replace any that are loose or damaged 2 Grease the turntable bearing Refer to Rotator Maintenance section for procedure 3 Inspect hydraulic system a Inspect hoses for wear and potential failure b Inspect hose connections for leaks 4 Remove covers and inspect rotation compone
126. n excess of 10 RPM may damage the hydraulic and mechanical components of the attachment FIGURE 5 4 ua aie The motion control manifold does not provide directional control of hydraulic fluid an auxiliary hydraulic circuit is required to operate the rotator JAMNUT ADJUSTMENT CROSSOVER RELIEF VALVE SCREW NON ADJUSTABLE ADJUSTINGTHE FLOW CONTROLS UP 15SV 20SV 25SV 1 See figure 5 4 Loosen the jamnut locking the adjustment screw 2 increase speed turn the adjustment screw Allen head counterclockwise check rotation speed at each 1 8 turn interval Recommended rotation speed is 4 to 6 RPM If the attachment fails to increase in speed it may be that all of the circuit flow is being used Check the supply circuit flow with a flow meter to verify whether or not more flow is available 3 decrease speed turn the adjustment screw Allen head clockwise check rotation speed at each turn interval If the rotation speed does not decrease replace the flow control valve 4 Retighten the jamnut after the desired adjustment has been made Page 18 Section 5 Maintenance UNIVERSAL PROCESSORS THE CROSSOVER RELIEF VALVE continued The crossover relief valve provides overload protection for the rotator This is not intended to replace the circuit relief valve on the base machine This valve has been preset at the factory and requires no adjustment Do not tamper with the crossover relief valve If
127. n metric hardware Other tools may not fit properly They may slip and cause injury 14 2 00 11 16 2 00 224 2 M20x2 50 435 TORQUE VALUES FOR FOUR BOLT FLANGE FITTINGS CODE 61 FLANGES NOTICE NOMINAL CAPSCREW TORQUE TORQUE SIZE CLASS FFLBS N M ie Do not use air wrenches Tighten a 10 1 50 each bolt equally an alternating M10x1 50 42 pattern Do not over tighten 42 42 70 70 70 mas mas 12175 70 KZ Maintenance Section 5 Page 11 UNIVERSAL PROCESSORS THE ROTATOR The rotator gives the attachment 360 of continuous rotation in both directions for easy accurate processing at all angles The hydraulic rotation circuit consists of a hydraulic motor driving a turntable bearing either directly or through a planetary gearbox It is necessary to regularly maintain this system to ensure long life and good performance The maintenance requirements of the rotator are outlined in the following pages The rotator requires special attention when operating the attachment The rotator is to be used only to position the at tachment not as a means of bending twisting or breaking material Use of the rotation feature for any other purpose may damage the rotation components and may compromise the attachment s warranty BACKDRIVING THE ROTATOR It is possible to force the attachment to rotate even when the rotation circuit is not operated This is known as backdriving the rotatio
128. n system Backdriving puts undue stress on the rotation system and if done exces sively can lead to rotation component problems Backdriving occurs when an excessive force is applied to the attachment jaws and the force is off center 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 see figure 5 3 Follow the tips below to minimize backdriving as much as possible 1 When handling a load in the jaws try to grip it as close to its center of gravity as possible 2 When processing a long member that is suspended i e a horizontal beam in a structure make several shorter cuts rather than one long cut where the member can come loose and backdrive the attachment 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 FIGURE 5 3 Page 12 Section 5 Maintenance UNIVERSAL PROCESSORS MAJOR COMPONENTS OF TYPICAL ROTATION SYSTEMS Second member upper head with an internal drive rotator gearbox and standard rotation CONTROL VALVE ASSEMBLY MOTOR HYDRAULIC PORT ROTATION PORT GREASE FITTING BEHIND RING TURNTABLE BEARING Third member upper head with an external direct drive rotator no gearbox and optional internal rotation control system LOCATED IN CAB ACCUMULATOR CONTROL VALVE ASSEMBLY lt g
129. ng up to heavier materials This allows the attachment and jaws to warm up and makes them less susceptible to damage 6 Do not weld on the excavator boom or stick without first consulting your dealer 7 Properly torque bolted connections as prescribed in this manual Refer to the charts on pages 5 8 and 5 9 of this manual for complete information on proper torque values 8 DO NOT disconnect any hydraulic hoses or fittings without first relieving machine hydraulic pressure 9 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 Jamming is the result of poor maintenance or improper operational techniques 10 DO NOT let hot hydraulic fluid get in contact with the skin as it could cause severe burns 11 DO NOT operate a rotating attachment without a case drain line connected back to the tank or return line filter or the rotation component will be damaged e m UNIVERSAL PROCESSORS PERIODIC SERVICE SCHEDULE SERVICE THE ATTACHMENT SPECIFIED INTERVALS Inspect lubricate make service checks and adjustments according to the 8 hour Inspection Checklist reproduced from this manual A program of regular service should be established using the machine hour meter to determine when the attachment should be serviced Use the intervals on the Service Schedule when operating in normal conditions Service the attachment at shorter intervals wh
130. nly 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 Jaws will not move a No hydraulic fluid to the attach i Check for hydraulic flow at the hydraulic lines to ment cylinder the manifold ii Check base machine hydraulic circuit b Broken hydraulic swivel i Replace swivel and flush hydraulic circuit 2 Jaw speed is extremely slow Base machine oil supply flow 15 i Check the flow to the attachment and compare too low with the recommended flow see hydraulic letter for attachment ii Check for excessive back pressure Check base machine s hydraulic system b Hydraulic cylinder seal bypass i Check for cylinder seal bypass replace seals if necessary c Hydraulic lines are kinked i Check hydraulic lines replace any damaged lines i Check for seal bypass consult your dealer ser d Hydraulic swivel seal bypass vice department for instructions Install new seal kit if necessary i See speed valve troubleshooting guide on page e Faulty speed valve operation 5 10 3 Jaws move too rapidly a Hydraulic flow to attachment is i Reduce flow to attachment excessively high NOTE The attachment may be damaged if flow exceeds the recommended GPM Page 2 Section
131. nt mounting bolts Inspected by Page 4 Section 5 Maintenance UNIVERSAL PROCESSORS RECOMMENDED SPARE PARTS LIST The following is a description of the parts Stanley LaBounty recommends to have on hand for these benefits e Less downtime for lack of a part e Original equipment manufacturer parts are inspected to Stanley LaBounty standards for proper fit and func tion e Eliminate the possibility of a part being unavailable for immediate delivery Eliminate overnight air freight costs The accessibility of replacement parts assures the proper shear maintenance will be followed and therefore increase the efficiency of the attachment HYDRAULIC ASSEMBLY All hydraulic hoses Speed valve Speed valve seal kit 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 EQUIPPED O ring seals Crown seals JAWSET ASSEMBLY Please refer to the manual for the specific jawset for its recommended spare parts list KZ Maintenance Section 5 Page 5 UNIVERSAL PROCESSORS ATTACHMENT LUBRICATION Grease all points every 8 hours of attachment operation Use premium grease No 2EP or equivalent Grease fitting locations are indicated on the illustration see figure 5 1 below and by yellow GREASE decals on the attachment Grease locations may
132. o hold the attachment in the air If a control is moved or hydraulic pressure is otherwise released the attachment may drop DO NOT work under a machine that is supported only by a jack Page 4 Section 1 Introduction to Safety Hydraulic oil becomes hot during operation 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 itis pressurized Escaping fluid under pressure can penetrate the skin causing serious injury 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 DO weld any structural member unless specifically authorized by LaBounty 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 Keep clear of all potential pinch points including the moving upper jaw cylinder connections bucket linkages or other moving parts UNIVERSAL PROCESSORS DECAL MAINTENANCE Be sure that all safety decals are installed and visible Keep decals clean and promptly replace
133. ol levers and attachment before beginning work The Universal Processor is exceedingly powerful Do not operate carelessly there is potential for personal injury and equipment damage Be concerned about safety when preparing to operate the new machine Ensure safe operation by inspecting the machine as explained in the Getting Started Safely section earlier in this chapter This inspection amounts to a common sense visual check of the machine at the beginning of every operation Follow a preventive maintenance program to reduce the possibility of costly downtime Page 6 Section 4 Operation FEATHERING THE CONTROLS The fluid nature of hydraulic power requires a special operating approach to the attachment that can be described as a smooth even technique 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 th
134. operating pressure of the rotation system Page 30 Section 5 Maintenance 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 system may be damaged To adjust the operating pressure first loosen the lock nut on the Pressure Reducing Valve Then slowly turn the adjustment screw in the end of the valve to adjust the pressure until it falls within the speci fied range Turn the screw clockwise to increase the pressure and turn the screw counterclockwise to decrease the pressure Make sure to retighten the lock nut when the adjustments are completed WORK PORTS SIDE GAUGE PORT PRESSURE REDUCING VALVE FLOW CONTROL CONTROL VALVE ASSEMBLY FIGURE 5 17 UNIVERSAL PROCESSORS SECTION 6 TROUBLESHOOTING Hydraulic Performance Troubleshooting Guide 5 2 Rotation Circuit Troubleshooting e un dade chair Pietas pg ucc t 5 4 Internal Rotation Control System Troubleshooting Guide if equipped 5 7 Speed Valve Troubleshooting E E R E ROTE EEn ik 5 10 Troubleshooting Section 6 Page 1 UNIVERSAL PROCESSORS HYDRAULIC PERFORMANCE TROUBLESHOOTING GUIDE The information contained in this guide provides for troubleshooting the LaBounty attachment o
135. ot group for excessive wear before doing any blade maintenance MAIN BEARING The main pivot group consists of main bearings and UPPER thrust washers The main bearings act as a wear surface between the jaw bore and the main pin The inner thrust washers act as a wear surface between the upper and lower jaw halves The outer thrust washers are located between the jaw set and the attachment stick When the main pivot components are excessively worn there will be sideplay in the main pivot group Sideplay is when the upper jaw can move from side to side in relation to the lower jaw When sideplay is present adjusting the blade gaps will be ineffective Use these steps to check for sideplay in your jawset Wear proper safety equipment including eye protection and gloves when performing this MAIN BEAR 1 With the jawset fully installed in the Universal Pro FIGURE 7 33 cessor retract the attachment cylinders to fully open the jaws Lower the attachment so the lower jaw is on the ground and shut off the base machine Make sure the attachment is secure and will not drop 2 Use a pry bar between the upper and lower jaws in the main pivot area on each side to see if the upper can be moved back and forth in relation to the lower jaw If sideplay or looseness is visible it may be neces sary to replace the main pivot group components Contact your LaBounty dealer or the LaBounty Cus tomer Service Department for assistance with thi
136. oth Replacement 222 2 2 7 15 Concrete Pulverizer Jaw Tooth Build Up and Hardsurfacing 7 15 Plate Shear Jaw Descriptio Messrs inanan sn 7 16 Plate Shear Jaw 7 16 Plate Shear Jaw NER T TR X 7 16 Plate Shear Jaw GIOSSary 4 7 17 Plate Shear Jaw NERO OE 7 18 Plate Shear Jaw Removal Storage 2 99 2 7 19 Plate Shear Jaw Periodic Service 5 7 19 8 Hour Inspection GING IGE METMMT 7 20 80 H ur Inspection MP 7 21 Plate Shear Jaw nb n soda 7 23 Main Pivot Group ud 7 24 Blade 7 25 Lower Blade 7 25 Upper Blade 7 26 Blade 7 27 Adjusting Blade 7 28 Nose Blade 22 7 29 Front Gap Recommendations err 7 29
137. ounding 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 spaces 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 lo
138. parts on the upper and lower jaws for pulverizing concrete Each tooth is fastened to its receptacle with a pin and retainer ring Thrust Washer Component located between the upper and lower jaws in the main pivot group to serve as a wear surface between the jaw halves Tooth Pins Retainer hardware that fastens each tooth to its receptacle The tooth pin is held in place by the Rings retainer ring PERIODIC SERVICE SCHEDULE SERVICE THE JAWS AT SPECIFIED INTERVALS Inspect lubricate make service checks and adjustments according to the Daily Inspection Checklist A program of regular service should be established using the machine hour meter to determine when the jaws should be serviced Use the intervals on the Service Schedule when operating in normal conditions Service the attachment at shorter intervals when operating in extreme environmental or abrasive conditions USE CORRECT LUBRICANTS AND BOLT TORQUES Refer to the Lubrication Instructions and Bolt Torque Table in this section of the Safety Operation and Maintenance manual when performing maintenance on the attachment DAILY SERVICE REQUIRED Connecting Pins and Pin Retainers Inspect for looseness damage or wear on the main pivot pin and cylinder pins Check pinheads and pinstops Grease Fittings Lubricate according to Lubrication Section of this manual Replace broken fittings Teeth Inspect for wear indicating that tooth replacement or build up and hardsurfacing is require
139. peration Use premium grease no 2Ep or equivalent Grease fitting locations are indicated on the illustrations and by grease decals on the attachment LOCATION ON ATTACHMENT NUMBER OF SHOTS 1 Main pivot both sides 6 2 Cylinder connections two places 6 qm Page 14 Section 7 Jaw Options UNIVERSAL PROCESSORS CP BLADE MAINTENANCE New blades in proper adjustment will increase cutting performance Proper rotation of blades will provide optimum use and the best performance Recommended blade rotation is after approximately 80 hours of use depending on the material being processed Follow blade maintenance procedure on page 7 7 CP BLADE SHIMMING Blade rotating is recommended every 80 hours of jaw set use in order to assure uniform wear so shimming is possible See figure 7 11 After rotating or replacing the blades there is a possibility there will be a gap between the blades and shimming may be necessary It is necessary to maintain a blade gap of 0 060 1 50 mm or less to prevent jamming and damage to the jaw set Follow blade shimming instructions on page 7 7 SWIFT LOCK TOOTH REPLACEMENT When the concrete pulverizer jawset teeth are badly worn or cracking performance is decreased the teeth should be replaced Depending on the type of concrete being processed the interval between teeth changes will vary It is recommended that the teeth be replaced as a set for even wear and the best performance Follow th
140. pped 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 FIGURE 3 6 La Bounty Installation Section 3 Page 5 UNIVERSAL PROCESSORS SECOND MEMBER ATTACHMENT REMOVAL PROCEDURE 1 Curl the attachment under the boom of the ex cavator as far as the stick cylinder will extend and lower shear to the ground see figure 3 7 2 Use blocking to support the stick cylinder from the excavator boom 3 Remove the stick cylinder pin from the attach ment mounting bracket 4 Fully retract the stick cylinder as it is unattached from the attachment mounting bracket 5 CAREFULLY remove the jump lines at the attach ment manifold 6 Plug the open manifold ports and hose ends with pressure plugs to prevent contamination of the hy draulic system 7 Make sure that the attachment is stable before un pinning the boom pivot pin and releasing the weight of the attachment 8 Remove the boom pivot pin from the attachment FIGURE 3 7 Page 6 Section 3 Installation Disassembly of any pin connected attachment can be hazardous Never remove any pins unless the atta
141. r an extended period of time Start with the attachment cylinders either fully retracted or extended Shut off the excavator and op erate the attachment jaw controls in order to relieve any existing hydraulic pressure to the attachment cylinders Position the attachment so the cylinders are as hori zontal as possible Set the excavator at idle speed or slightly above idle speed Installation Section 3 Page 9 UNIVERSAL PROCESSORS HYDRAULIC START UP PROCEDURE continued WITH CYLINDERS FULLY RETRACTED 1 Slowly fill the rod end of the cylinders open the jaws until a noticeable change in tone of the excavator is heard indicating full cylinders Release the controls and do not continue to apply full operating pressure to the cylinders 2 Change direction of oil flow slowly fill the bore end of the cylinders close the jaws until the rods are ex tended approximately of stroke 3 Retract the cylinder rods all the way 4 Repeat steps 2 and 3 extending rod to approximately 72 stroke then 94 stroke then full stroke 5 When cylinders are full of oil slowly cycle back and forth at least five times through full stroke Be careful not to apply full operating pressure to the cylinders at this time WITH CYLINDERS FULLY EXTENDED 1 Slowly fill the bore end of the cylinders close the jaws until there is a noticeable change in the tone of the excavator indicating full cylinders Release the controls and do not continue to apply
142. reinoirei O E E E M REEE D 5 2 General for a algae ial des 5 3 Periodic Service 5 5 3 8 Hour Service 5 3 Inspection Checklist NER NEU TE d NE 5 4 Recommended Spare Parts 1151 eene eene 5 5 Attachment aeta E pE eane e ee EA Te EEA PE EEEE EEEE Eaa E PEREA 5 6 Bolt Torque Specifications 5 7 Bolt Guideline DP E 5 8 Metric Capserew Size M 5 8 Torque Values Tor Metric Fasteners ees 5 9 Hydraulic System 5 5 10 Flange lype Hose Fittings 5 11 Rotator 5 12 Backdriving the BOtatOE stet EE aE 5 12 Major Components of Typical Rotation 5 5 13 PET 5 14 Planetary Gearbox LUDTICAtIONS 5 15 Lubricant Change Out 41292791115 RR T 5 15 uci Ae mete DIRETTO TT 5 16 Synthetic ION Senda dak E rr 5 16 Gearbox Fill Capacities acc asst ne
143. rface directly to the parent material Apply Amalloy 814H rod or equivalent on top of each of the underlayment beads It is important to use an air operated slag peener on each pass of weld to relieve stress No more than two layers of this rod should be used 8 The hardsurface should end approximately at the midpoint of the primary blade see figure 7 58 Stagger the ends of the welds Do not end welds within 1 25 mm of bolt holes Do not undercut the ends of the weld with the grinder Taper ends of welds down to the base material with grind marks going with the grain 9 To hardsurface the front and sides of the nose plate establish a diamond pattern of approximately 174 38 En see figure 7 59 Again use the build up rod to lay down the pattern and use the hardsurface rod on top of it as in step 7 DO NOTWELD IN THROAT AREA STAGGERWELDS FIGURE 758 FIGURE 7 59 Page 56 Section 7 Jaw Options UNIVERSAL PROCESSORS SWIFT LOCK BUILD UP TEMPLATE PART NUMBERS 15 14938 Template 149117 Build up Temp 20 157499 ate 149117 Build up Temp 25 1174835 Template 3 164947 ate 149117 Build up Temp s 00007 160884 uild up Temp 1 NE NN EN 2222 149117 Build up Temp O1 UEM MEN Ep 1 em Jaw Options Section 7 Page 57 LIMITED WARRANTY New Attachment Stanley LaBounty warrants its manufactured
144. rmance is decreased the teeth should be replaced Depending on the type of concrete being processed the interval between teeth changes will vary It is recommended that the teeth be replaced as a set for even wear and the best performance Safety equipment should be worn at all times when maintaining the attachment to prevent injury Safety equipment includes eye protec tion hard hat steel toe shoes leather gloves and hearing protection 1 Curl the attachment under and lay it down flat on a firm and level surface with the jaws open figure 7 4 Turn the base machine off Make sure that the attachment and jaws are stable and will not drop or close 2 Work only on the jaw closest to the ground with the tooth facing up The tooth on this jaw will be properly supported when the tooth pin is removed Each tooth is very heavy Removing a tooth pin when the tooth is not supported will cause the tooth to fall which could cause serious injury 3 Use a soft metal drift such as brass and a mallet to drive out the tooth pin 4 If the tooth is loose in the receptacle lift and slide it out If necessary use a pry bar to loosen the tooth from the receptacle Do not lose the retainer ring 5 Insert the new tooth by sliding it into the slot in the receptacle Make sure the retainer ring is located in its seat in the receptacle before installing the tooth Figure 7 5 6 Use a mallet to insert the pin through the holes in the toot
145. s maintenance FIGURE 7 34 La Bounty Jaw Options Section 7 Page 41 UNIVERSAL PROCESSORS BLADE REMOVAL Safe and proper removal of blades from their blade seats is necessary when performing various types of maintenance on the shear To ensure your safety and to avoid damaging the attachment always use the following procedure when removing a cutting blade or guide blade from its seat 1 Loosen the blade bolts one blade at a time Make sure the blade is adequately supported so it will not drop and cause injury when the blade comes loose from its seat 2 Lightly tap on the blade face in several places with a soft faced hammer This will sometimes loosen a slightly jammed blade 3 If the blade is jammed the seat and is difficult to dislodge take a soft metal punch or drift pin and insert it in a blade bolt hole from the back side nut side see Figure 7 35 Place the punch at an angle against the inside countersink of the blade and strike the punch with a hammer or mallet 4 If this method fails to dislodge the blade drive wedges between the blade and the back of the blade seat as shown Start with small wedges and increase the size as the opening grows Safety equipment including eye protection hard hat steel toe shoes gloves and hearing protec tion should be wom at all times when viewing operating or maintaining the attachment to prevent injury Never
146. ses should be approximately 13 mm apart and will serve as an underlayment for the hardsurface rod DO NOT apply hardsurface directly to the parent material 6 Apply a bead of Amalloy 814H rod or equivalent directly on top of each of the underlayment beads It is important to use an airoperated slag peener on each pass of weld to relieve stress 7 laper the ends of each hardsurface bead by grind ing in line with the cutting edges Do not undercut the weld with the grinder 8 When welding and grinding is complete peen the welded area until it is shiny or until the peener cannot dent the weld anymore typically 5 to 10 minutes This will harden the welded area 9 When finished be sure to cover the reworked teeth with a heat blanket to allow them to cool slowly NOTICE Check temperature during this procedure maintain 300 400 F 150 200 Do not exceed 450 230 Jaw Options Section 7 9 UNIVERSAL PROCESSORS JAW BUILD UP AND HARDSURFACING As the jaws become worn from use it will be neces sary to build up the worn areas to prolong the life and increase productivity It is especially important not to allow the wear to damage the Swift Lock receptacles If the receptacles become damaged it may become necessary to replace them Build up and hardsurface the jaws when there is adequate time for them to cool slowly before they are put back into service Use the following instructions to bui
147. shear several times and check clearances and blade gaps Install a cylinder shroud over the remaining cylinder PLATE SHEAR JAWS REMOVAL PROCEDURE Reverse the installation procedure on pages 7 17 to properly remove the jaw set PLATE SHEAR JAWS STORAGE 1 Block the attachment up off the ground using wood blocking 2 Plug all open hydraulic ports 3 Grease the pins and machined bores of the mounting bracket of the attachment refer to the at tachment lubrication section of the maintenance sec tion of the manual Then apply a generous amount of grease to shear blades cylinder rods and all other exposed unpainted surfaces Trapped hydraulic pressure may be present after the base machine is shut off Extreme caution must be taken when removing attachment hy draulic hoses or possible injury or death could result PERIODIC SERVICE SCHEDULE Inspect lubricate make service checks and adjustments according to the 8 hour and 80 hour Inspection Checklists reproduced from this manual A program of regular service should be established using the machine hour meter to determine when the jaws should be serviced Use the intervals on the Service Schedule when operating in normal conditions Service the attachment at shorter intervals when operating in environments that are extreme or in abrasive conditions Refer to the Lubrication Instructions on page 7 22 and Bolt Torque Table in this Safety Operation amp Maintenance manual w
148. ssing thin materials When processing thicker materials frequent blade rotation will extend the life of the blades however maintaining a close tolerance blade gap is not as important Never operate a shear when the blades have rounded to a 6 4 mm radius more GENERAL PROCEDURE 1 Remove each blade and grind all rough edges 2 Remove each blade adjustment plate from the blade seat and clean out the blade seat thoroughly Reinstall each adjustment plate in the same po sition see Figure 7 17 Blade adjustment plates are custom machined for a specific blade seat 3 The first and third times the lower blades are ro tated each blade should be turned end for end and reinstalled in the same blade seat The second time the blades are rotated each blade should be flipped over see Figure 7 18 4 When the blades have been used on all four edges and edges are 6 4 mm radius or more it will be necessary to replace the blades Remember with damaged or badly worn blades cutting ability decreases tremendously and it may eventually cause structural damage to the shear This condition also causes the shear and base ma chine hydraulic systems to work harder resulting in premature wear ADJUSTMENT PLATES BLADE SHIMS FIGURE 7 17 An approved respirator and leather gloves must be worn when handling and grinding blades foo FIRST amp THIRD gt ROTATIONS 9 S 1 ROTA T
149. sult of your decision to implement 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 the manual be alert to the potential for personal injury or equipment or property damage Follow recommended precaustions and safe operating practices A DANGER 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 personal injury NOTICE Indicates notes of importance to a procedure or part UNIVERSAL PROCESSORS SAFETY SUMMARY DANGER If the attachment is not functioning properly you must shut the machine down and follow proper lockout tag and repair procedures DANGER NEVER operate equipment without the original equipment safety guards in place 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 shatterresistant shi
150. t S RETURN LINE FITTING AND p ELECTRICAL PLUG FAR SIDE GREASE FITTING W HYDRADU 1 gt CONTROL VALVE qu ASSEMBLY FIGURE 5 4 TURNTABLE ACCUMULATOR BEARING Maintenance Section 5 Page 13 UNIVERSAL PROCESSORS BOLT TORQUING The bolts connecting the turntable bearing are an im portant part of attachment maintenance These bolts must be inspected each 8 hours of operation Dam aged 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 once before they are replaced Fasteners retorqued more than once will fatigue due to stretching These bolts should be inspected daily and re placed after 1500 hours or 12 months TORQUE VALUES FORTURNTABLE BOLTS 1486 rrBS NM 100 19 90 1220 TORQUE VALUES FOR ROTATION ASSEMBLY BOLTS SIZE 1486 FFLBS Page 14 Section 5 Maintenance 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 Use of the rotation feature for any other purpose may damage the rotation components and may void the attachment warranty NOTICE t may be necessary to rotate the attachment to ac cess all the bolts connecting the attachment turn table bearing and rotating head e Make sure to use t
151. tation and the other position will cause counterclockwise rotation RECHARGING THE ACCUMULATOR WITH FLUID When using the Internal Rotation Control System the shear will typically rotate between 180 and 360 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 attachment again To recharge the system simply open or close the jaws The system draws hydraulic fluid from the jaw circuit when the jaws are operated The amount of rotation your shear will achieve per fluid charge depends the attachment model The accumulator needs to be charged with fluid when the base machine is first start ed up The unloading valve drains the accumulator whenever the base machine 15 shut off La Bounty Operation Section 4 Page 5 UNIVERSAL PROCESSORS GETTING THE FEEL OF THE ATTACHMENT Every operating part of any machine has a slightly different operating feel an individual machine response to the movement of the controls Before starting the first job with a new machine it is suggested that the operator find an open spot on firm level ground that s free of people trees buildings 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 attachment This get acquainted time will allow the operator to become familiar with the contr
152. the cylinder lugs at the rear of the attachment stick The rear cylinder pins have a grease fitting and must be greased according to the required maintenance Valve used to protect the rotation motor from excessive pressure A customer provided hydraulic hose that needs to be installed to return flow from the Internal Rotation Control System to the base machine s reservoir see the Installation section of this manual Hydraulic assembly that allows full 360 continuous rotation of the attachment for greater positioning capabilities when processing with the attachment When the attachment is mounted in place of the excavator stick at the end of the boom Electrical coil on the directional valve that activates the valve if equipped with a rotation control kit Regenerative hydraulic valve in Series SV Universal Processors that increases the jaw closing speed cylinder extend function when the jaws are not under a load thereby reducing cycle times and increasing efficiency Stanley LaBountyuses a spool type speed valve design for better durability over cartridge type regenerative valves The main body of the attachment The stick must be regularly inspected for any damage Part of the Universal Processor mounting bracket that attaches to the base machine stick tip when mounting third member in place of the bucket Allows continuous rotation of attachment and fluid supply to attachment cylinders without twisting hoses When the attachment is mo
153. the regenerative speed mode properly 5 After making the proper adjustments cycle the jaws open and closed a number of times to ensure the speed valve is functioning properly Page 24 Section 5 Maintenance MBS TEST PORT 2 TEST PORT LABOUNTY PART NUMBER 511025 MBS TEST PORT LABOUNTY PART MAZTEST PORT NUMBER 511389 FIGURE 5 13 UNIVERSAL PROCESSORS TORQUE VALUES FOR SPEED VALVE FASTENERS For the fasteners used to secure the LaBounty speed valve to the attachment cylinder use the torque values listed here 100 gpm 378 lpm speed valves LaBounty part number 511025 185 ft lbs 250 Nm For 200 gpm 756 lpm speed valves LaBounty part numbers 511022 and 511389 370 ft lbs 500 Nm For 250 945 lpm speed valves LaBounty part number 511461 ee 348 ft lbs 472 Nm It is imperative that the fasteners used for mounting the speed valve to the cylinder are properly torqued to the manufacturer s specifications Maintenance Section 5 Page 25 UNIVERSAL PROCESSORS INTERNAL ROTATION CONTROL SYSTEM equipped The optional Internal Rotation Control System not available for the UP 15SV is designed to provide a me dium pressure low flow hydraulic power source for rotating the attachment The system is factory installed inside the rotating head of the attachment and consists of the following major components Accumulator Accumulator
154. the rotation assembly The crossover is preset at the factory and must not be tampered with Cylinder Hydraulic component that actuates the jaw set LaBounty cylinders are designed to withstand an extreme duty life Cylinder The excavator stick cylinder attaches to this part of the Universal Processor mounting bracket to Pivot articulate the tip up function of the attachment when mounted second member Directional Valve that directs fluid from the accumulator to the rotation motor if equipped with a rotation control kit Valve Electrical Plug located in the side of the attachment mounting bracket that connects the foot pedal to the solenoid Plug on the control valve assembly if equipped with a rotation control kit End Cap Main pivot group component that fastens to the end of the main pin External An optional kit that provides a medium pressure low flow hydraulic source to rotate the attachment The Rotation kit taps the hydraulic system of the base machine and draws only enough fluid to charge an accumulator Control Kit When the rotation function is used this pressurized fluid is released to the rotation motor to rotate the attachment The external kit is mounted on the excavator with hydraulic lines running up the boom Flow Control hydraulic component used in the rotation group of a rotating attachment that meters out the hydraulic Valve fluid to the rotation motor of the attachment Foot Switch Electrical switch to be installed in
155. 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 ONE Oce KNOW YOUR EQUIPMENT e 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 Dialog 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
156. ting hardsurfacing by grinding down to the base metal before beginning build up and hardsurfacing procedures 4 determine how much build up is required on the front of the upper shear place a straightedge along cutting blades and the newly maintained or replaced piercing tip There will be a gap indicating how much build up is required see Figure 7 42 5 Preheat the surrounding area to at least 200 F 100 C to remove moisture Preheat the area to be built up to 300 400 F 150 200 C Use a tem perature stick to test the area frequently as over heating can harm the jaws The maximum tempera ture is 450 F 230 6 For build up apply AWS E7018 welding rod Each pass must be peened vigorously to relieve weld stress and remove slag Grind all edges to 90 7 To hardsurface this area beginning above the piercing tip to approximately half way up the front of the upper shear apply single passes of AWS E7018 build up in diamond pattern of approximately 172 38 mm to establish the hardsurface pattern see Figure 7 43 This will serve as an underlayment for the hardsurface rod DO NOT apply hardsurface di rectly to the parent material Apply a bead of Amalloy 814H rod or equivalent on top of each of the under layment beads It is important to use an air operated slag peener on each pass of weld to relieve stress Page 48 Section 7 Jaw Options STRAIGHT EDG FIGURE 7 42 FIGURE 7 43 NOTICE
157. ting off the base machine This 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 re moved Install a Schrader valve into the accumulator if one does not already exist there Contact the Stanley LaBounty Service Department if the Schrader valve has not 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 Page 28 Section 5 Maintenance em UNIVERSAL PROCESSORS TESTING THE ACCUMULATOR PRECHARGE Once the test unit is attached make sure the relief valve is closed and then turn the spindle When the pointer of the gauge begins to move turn the spin dle one more full turn The gauge should now show the amount of accumulator precharge pressure The proper amount of accumulator precharge is 1100 1200 PSI 76 83 BAR If the gauge is showing something other 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 This will release nitrogen into the atmosphere Close the valve when the desired pressure is reached ACCUMULATOR PRECHARGING Never used oxygen or shop air to precharge the accumulator this could cause an explosion Use only dry nitrogen for prechar
158. ting to work on any hydraulic com ponent Relieve hydraulic pressure before working on machine by working controls in both directions with the engine off and the ignition switch in the off position Also relieve the hydraulic reservoir air pres sure 2 Shut off the base machine and check the hydrau lic system pressure It should be zero 0 PSI There is a diagnostic port on the attachment manifold to check the pressure the 1 4 NPT 1 4 18 plug will need to be replaced with an adapter fitting for your test gauge 3 Hydraulic oil becomes hot during operation DO NOT let hot hydraulic oil get in contact with the skin as it could cause severe burns 4 Check all hydraulic components split flanges hoses fittings mounting hardware etc every 80 hours 5 The hydraulic manifold is equipped with a diag nostic nipple to check the pressure coming from the base machine Maintaining proper operating pressure will result in optimum cutting performance also as a quick check to see if the base machine is performing up to manufacturer s recommendations 6 Whenever hydraulic lines are disconnected hoses must be capped and ports must be plugged to pre vent contamination of the hydraulic system Page 10 Section 5 Maintenance 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 pie
159. unted in place of the excavator bucket at the end of the stick Main pivot group component located between the jawset and the stick and also located between the two halves of the jawset The thrust washer acts as a wear part between adjoining surfaces Large rotation bearing used rotating attachments The turntable bearing is mounted to the attachment stick and is driven by hydraulic components in the upper head of the attachment Sometimes called the slewing ring Valve in the control valve assembly that drains the fluid from the accumulator when the base machine is shut off UNIVERSAL PROCESSORS SECTION 3 INSTALLATION Attachment 3 2 Attachment Mounting Procedure 3rd member mounts 222 2 99999 3 3 Attachment Mounting Procedure 2nd member mounts ens 3 4 Attachment Removal Procedure 3rd member 165 222 2 9999 3 5 Attachment Removal Procedure 2nd member 2 99 3 6 IOTSE Next da Reise tr epe E 3 6 Exchanging Jaws Removal 3 7 Hydraulic Installation 9 99999 gt 3 9 Hydraulic Star UP D NET 3 9 Speed Valve 3 10 Internal Rotation Control Kit Installation
160. ur ing blade maintenance LOWER JAW UPPER JAW WEAR PLATE GUIDE BLADE 0 030 O 76 MM OR LESS FIGURE 7 36 Jaw Options Section 7 Page 43 UNIVERSAL PROCESSORS BLADE ROTATION cowriNUED 1 Remove each blade and grind all rough edges from it Clean out the blade seat 2 blade adjustment plate in lower jaw only is loose remove it clean out the blade seat and rein stall the adjustment plate in the same position Blade adjustment plates are machined to fit in one blade seat only 3 For parallelogram blades The first and third times the blades are rotated each blade should be turned end for end and reinstalled in the same blade seat The second time the blades are rotated the blades will change positions The upper primary blade and lower secondary blade should swap posi tions and the lower primary blade and the upper secondary blade should swap positions Figure 7 37 For rectangular blades UP 90 only The first and UPPER third times the blades are rotated each blade should PRIMARY BLADE be turned end for end and reinstalled in the same blade seat The second time the blades are rotated each blade should be flipped over 4 When the blades have been used on all four edges lf and edges are 34 6 4 mm radius or more it will be necessary to replace the blades UI SECONDARY BLADE Remember with damaged or badly worn blades cutting ability decreases tremendously and it may LOWE
161. used 9 To hardsurface the front and sides of the nose plate establish a diamond pattern of parallel lines approximately 172 38 mm apart see Figure 7 30 Again use the build up rod to lay down the pattern and use the hardsurface rod on top of it as in step 7 Taper the ends of each weld down to the base mate FIGURE 7 29 rial with the grind marks going in the same direction as the weld bead DO NOT undercut the ends of the weld with the grinder NO STARTS OR STOPS LOWER NOSE PLATE HARDSURFACE PATTERN FIGURE 7 30 Page 34 Section 7 Jaw Options UNIVERSAL PROCESSORS UP SHEAR JAWS High tensile abrasion resistant steel construction assures long uninterrupted service even in the harshest conditions The main pin of every model is heavy duty for long life and pivots LaBounty s specially designed bearings Shear jaws can cut a wide variety of materials including and H beams other building materials steel plate round stock wire rebar and concrete They are ideal for demolition work road and bridge reconstruction scrap processing and in jobs where torching is not possible FEATURES e Patented design combines maximum cutting strength and reach with minimal weight e Made with high tensile abrasion resistant steel for durability e Replaceable wear parts for easy maintenance e Fourway indexable blades e At factory upgrading and rebuilding services available UP SHEAR JAW TERMS FI
162. ve is to increase the jaw closing speed cylinder extend function when the jaws are not under a load thereby reducing cycle times and increasing efficiency The speed valve directs return flow from the rod side of the cylinders to the bore side as the cylinders extend This function occurs only when the cylinders are extending in a low to medium load condition which occurs as the jaws are moving toward the material to be processed As the jaws close down on the material the cylinders meet resistance and require 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 attachment cylinders allowing the jaws to process the material with maximum force OPERATING THE INTERNAL ROTATION CONTROL SYSTEM IF EQUIPPED NOT AVAILABLE ON UP 15SV 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 attachment to rotate One position will cause clockwise ro
163. weight Use short slings and lift the load only as high as necessary Introduction to Safety Section 1 Page 3 UNIVERSAL PROCESSORS Disassembly of any pin connected attachment can be hazardous 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 drift 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 always keep people clear when removing or installing pins DO NOT allow riders on the machine Riders are subject to serious injuries such as being struck by foreign objects or being thrown off the machine Riders also distract and obstruct the operator resulting in the machine being operated in an unsafe manner NEVER use the attachment as a work platform or personnel carrier Under no circumstances should any modifications be made to LaBounty equipment without factory authorization This equipment was designed to do a specific job and alterations to it could result in injury to operator or machine 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 t
164. wer the shear to the ground and turn the base machine off when leaving the machine unattended 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 qm m 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 material 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 inst
165. will include two 10 mm diameter feed lines and 1 2 13 mm diameter case drain line these will terminate at the end of the boom 3 Install jump lines from the above hydraulic lines to the attachment bulkhead or manifold fittings 4 Check to make sure all bolts and nuts are properly installed and torqued 5 Lift the attachment and slowly try the rotate func tion and open and close functions see page 4 5 Watch for any hydraulic oil leaks and interference 6 Follow the hydraulic start up procedure as de scribed in this manual When installation is complete slowly extend retract the excavator cylinder to its limits to curl the attachment Check for interference between the attachment and the excavator boom or stick Check the hydraulic lines that connect to the attachment hydraulic connections to make sure they are not rubbing or getting damaged in any way Contact your dealer immediately if any interference occurs HYDRAULIC START UP PROCEDURE Air must be bled out of the cylinders prior to opera tion of the attachment Entrained air in the system leads to cavitation oxidation of the oil and exces sive heat These conditions promote hydraulic oil break down contamination noise sluggish opera tion reduced component life and potential cylinder damage This procedure needs to be followed upon installation after hydraulic maintenance or when the attachment has been stored or idled fo

UPSV User Manual - Stanley Hydraulic Tools

Contents

Download Pdf Manuals

Related Search

Related Contents