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Page 12

Section 5

Maintenance

MOBILE DEMOLITION PROCESSORS

GENERAL GUIDELINES FOR

BUILD UP AND WEAR PLATE

REPLACEMENT

Proper build up and wear plate replacement is done

according 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.

Allow the wear plates to wear down, but not com-

pletely away, before installing new wear plates. The

quality and attention to detail in welding can signifi-

cantly affect the life of the jaws. LaBounty strongly

recommends that only certified welders perform

this procedure.

BUILD UP RECOMMENDATIONS

The build up material acts to replace any parent

material that has worn away. See the list of AWS

classifications below to select a suitable build-up

material for your proceesors. Weld products within

these classifications meet the combined require-

ments for strength, toughness, and ductility that are

essential for LaBounty applications.

Shielded Metal Arc Welding - Stick Electrodes

• E7018

• E8018-C 3

Gas Metal Arc Welding - Solid Wire Electrodes

• ER 70S-6

Gas Metal Arc Welding - Flux Cored Electrodes

• E71 T- 1

• E71T-1M

• E80T1-Ni1

• E80T1-Ni1M

Gas Metal Arc Welding - Metal Powder Cored Elec-

trodes

• E70C-6M
• E80C-Ni1

BUILD UP PROCEDURE

PREHEAT

Preheat the general surrounding area to at least

200°F (100°C) to remove moisture from the base

material.

Before ANY thermal process is applied

to the processor steel, including welding, tack

welding, torch cutting, and air-arcing, preheat

the area within 6

(150 mm) of the local area to

a minimum of 400°F (200°C) and a maximum of

450°F (230°C). This includes adding and remov-

ing lifting lugs.

Preheat must be uniform through-

out the material thickness and maintained until all

welding has been completed. Avoid cyclic heating

and large temperature swings. Preheating may

be done by localized gas torches, or thermal strip

blankets.

POST HEAT

If preheat has dropped below 400°F (200°C) within

6" (150 mm) of the weld area, post heat to 400°

(200°C) and wrap with heat blanket to allow it to

cool slowly to the ambient temperature. Plan to

perform build up and hardsurfacing at the end of

the day or when there will be adequate time for the

welded areas to cool before placing the proceesor

back into service.

HANDLING AND STORAGE OF WELD

MATERIALS

Follow the weld manufacturer’s handling and stor-

age instructions closely. Make sure the electrodes

and/or wire are free of moisture. Moisture can

cause cracks and porosity in the weld and in the

base metal beneath the weld.

WELD QUALITY

Quality and attention to detail in welding signifi-

cantly affects the life of the MDP. Stanley LaBounty

strongly recommends that only qualified and certi-

fied welders perform this work. Be sure the weld

consumables and base material are clean and dry.

Содержание 513914

Страница 1: ...Mobile Demolition Processors Part Number 513914 Safety Operation Maintenance Manual...

Страница 2: ...N 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 7 487 930 5 992 023 7 578 461 7 322 273 7 832 130 8 146 256 8 104 384 EPO Patent Numb...

Страница 3: ...operty damage and personal injury The instructions in this manual have been prepared to ensure that when followed properly the attachment will provide efficient and reliable service Continuing product...

Страница 4: ......

Страница 5: ...ation 3 9 Hydraulic Start up Procedure 3 9 SECTION 4 OPERATION Before You Start 4 2 First Things First 4 2 General Rules for Safe Operation 4 3 Getting the Feel of the Attachment 4 3 Attachment Contro...

Страница 6: ...ll Capacities 5 23 Turntable Bearing Lubrication 5 24 Turntable Bearing Lubricants 5 24 Hydraulic Requirements 5 25 Crossover Relief Flow Control Manifold 5 25 Motion Control Valve Manifold 5 26 Case...

Страница 7: ...Introduction to Safety Section 1 Page 1 MOBILE DEMOLITION PROCESSORS SECTION 1 INTRODUCTION TO SAFETY Introduction 1 2 Understand Signal Words 1 2 Safety Summary 1 3 Attachment Decals 1 4...

Страница 8: ...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...

Страница 9: ...stead of shearing The material being processed could become a projectile and cause injury or death DO NOT process any material in any position that may propel it toward operator other workers building...

Страница 10: ...or component while it is pressurized Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines See Figure 1 3 Tighten all...

Страница 11: ...ety Section 1 Page 5 MOBILE DEMOLITION PROCESSORS STANLEY LABOUNTY BRAND DECALS REPLACEMENT DECALSAVAILABLE UPON REQUEST FIGURE 1 1 SAFETY FIRST DECAL PART NUMBER 503590 INCLUDEDWITH MANUALS FIGURE 1...

Страница 12: ...Two Harbors MN 55616 tel 1 800 522 5059 fax 218 834 3879 www stanleyhydraulic com Made in the U S A with Global Materials Attachment Model Serial Number Year of Manufacture Weight ATTACHMENT DECALS c...

Страница 13: ...About the Attachment Section 2 Page 1 MOBILE DEMOLITION PROCESSORS SECTION 2 ABOUTTHEATTACHMENT Attachment Model Description 2 2 Attachment Features 2 2 Jaw Options 2 3 Attachment Glossary 2 4...

Страница 14: ...to draw the materials in to the point where the proceesor force is greatest making them the most efficient cutting tool possible MDPs can crush concrete and cut a wide variety of materials including I...

Страница 15: ...About the Attachment Section 2 Page 3 MOBILE DEMOLITION PROCESSORS JAW OPTIONS CONCRETE CRACKER JAW CONCRETE PULVERIZER JAW FIGURE 2 2 FIGURE 2 3...

Страница 16: ...PPER JAW FRONT CYLINDER PIN MDP CYLINDER MOUNTING BRACKET LINKAGE CONNECTION HYDRAULIC MANIFOLD BLOCK STICK CONNECTION MDP STICK APEX MDP LOWER JAW UPPER HEAD TURNTABLE BEARING HYDRAULIC MANIFOLD BLOC...

Страница 17: ...the attachment The crossover is preset at the factory Valve and must not be tampered with Cylinder Hydraulic component that actuates the jaw set LaBounty cylinders are designed to withstand an extrem...

Страница 18: ...excavator boom tip and stick cylinder Planetary Hydraulic rotation component on larger rotating attachments The planetary gear box rotates the body of the Gear Box attachment with the aid of the hydr...

Страница 19: ...to the attachment Bearing stick and is driven by hydraulic components in the upper head of the attachment Upper Head Mounting bracket portion of the MDP Attaches to the turntable bearing that attache...

Страница 20: ...Page 8 Section 2 About the Attachment MOBILE DEMOLITION PROCESSORS...

Страница 21: ...ass 3 3 Third Member Attachment Mounting Procedure 3 3 Second Member Attachment Mounting Procedure 3 4 Third Member Attachment Removal 3 5 Second Member Attachment Removal 3 6 Attachment Storage 3 6 H...

Страница 22: ...e properly rated hooks and rigging to lift the at tachment 2 Lift the attachment using all four hooking points with rigging lengths that keep the attachment level See Figure 3 1 Hooking points are for...

Страница 23: ...unting bracket linkage connection see Figure 3 2 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 t...

Страница 24: ...mount it may be necessary to block the rear of the attach ment in a position to allow boom pivot pin installation NOTICE 5 Pin the excavator s boom and attachment boom pivot together using the same pi...

Страница 25: ...ld See Figure 3 6 6 Plug the open manifold ports and hose ends with pressure plugs to prevent contamination of the MDP hydraulic system 7 At this point be extremely sure that the attachment is stable...

Страница 26: ...e boom pivot pin from the attachment Figure 3 7 ATTACHMENT STORAGE 1 Securely block the attachment up off the ground using wood blocking 2 Plug all open hydraulic ports 3 Grease the pins and machined...

Страница 27: ...ut ow is not advised for continuous duty due to inef ciency of the circuit If an OEM auxiliary circuit is not available with these requirements the LaBounty Rotation kit should be used Recommended Pre...

Страница 28: ...o tank HYDRAULIC PORT DEFINITION The CD Motor Case Drain port is only required on specific models The function of this port is to drain oil from the hydraulic motor case during back driving conditions...

Страница 29: ...een stored or idled for an extended period of time Start with the attachment cylinder either fully retract ed or extended Shut off the excavator and operate the attachment jaw controls in order to rel...

Страница 30: ......

Страница 31: ...You Start 4 2 First Things First 4 2 General Rules for Safe Operation 4 3 Getting the Feel of the Attachment 4 3 Attachment Controls 4 4 Operating the Rotator 4 5 Backdriving the Rotator 4 5 Speed Va...

Страница 32: ...IRST 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 Infor...

Страница 33: ...control levers and their functions Note ALL safety devices on the machine and ensure that they are working properly 2 KNOW the capacity of the excavator and its attachments DO NOT overload the machin...

Страница 34: ...tor and operates with the same controls no additional hydraulics are required The bucket dump control opens the processor and the bucket curl control closes the processor thus there are four movements...

Страница 35: ...tor to square the jaws to the cut If the jaws are not square the rotator will backdrive to adjust to the cut DO NOT use the processor rotator for any other purpose except to position the processor for...

Страница 36: ...motion to desired speed Do the same when stopping a motion OPERATING TIPS As an operator gains experience processing material with the Mobile Demolition Processor he or she will learn what the machin...

Страница 37: ...d Hardsurfacing 5 15 Hydraulic System Maintenance 5 17 Flange Type Hose Fittings 5 18 The Rotator 5 19 Backdriving the Rotator 5 19 Major Components of Typical Rotation Systems 5 20 Bolt Torquing 5 21...

Страница 38: ...our 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 maj...

Страница 39: ...8 DO NOT disconnect any hydraulic hoses or fittings without first relieving machine hydraulic pressure 9 DO NOT exert excavator weight on the attachment in order to free the jaws if they become jammed...

Страница 40: ...ry _______ 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 pin _______ d...

Страница 41: ...this manual for shimming procedure and tolerance range _______ 2 Inspect upper jaw _______ a Replace Swift Locks if necessary _______ b Check for cracks _______ c Replace upper wear plates if necessar...

Страница 42: ...ON ATTACHMENT NUMBER OF SHOTS 1 Rear cylinder connection 6 2 Front cylinder connection 6 3 Thrust bearing 6 4 Turntable bearing 6 5 Main jaw pivot 2 fittings per side 6 LOCATION ON BRACKET 6 Stick co...

Страница 43: ...rt 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 fa...

Страница 44: ...21 Rotation Assembly Bolts Page 5 21 Blades Page 5 10 Speed Valve Bolts Page 5 33 39 For all other bolts used in the LaBounty proceesor use the Generic Torque Table below Always replace bolts and nut...

Страница 45: ...talled in the same blade seat Torque the blade bolts according to the Dry Bolt Torque charts in this chapter 5 For the second blade flip turn the blades to a new face and reinstall in the same seats 6...

Страница 46: ...ese fasteners Stanley LaBounty requires that blade fasteners bolts and washers be replaced with each set of new blades When using existing blade fasteners during blade rotations always inspect the har...

Страница 47: ...imately 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 th...

Страница 48: ...area to at least 200 F 100 C to remove moisture from the base material Before ANY thermal process is applied to the processor steel including welding tack welding torch cutting and air arcing preheat...

Страница 49: ...t be put back into service until it has cooled completely 7 If you have any questions contact LaBounty Service Department 800 522 5059 for specific welding in structions HARDSURFACING RECOMMENDATIONS...

Страница 50: ...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 lo cated in its seat in the receptacle befo...

Страница 51: ...se 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 i...

Страница 52: ...derlayment beads It is important to use an air operated slag peener on each pass of weld to relieve stress 7 Taper the ends of each hardsurface bead by grinding in line with the cutting edges Do not u...

Страница 53: ...anifold is equipped with a diag nostic fitting to check the pressure coming from the base machine Maintaining proper operating pres sure will result in optimum cutting performance and also as a quick...

Страница 54: ...ed are for general use only Check tightness of cap screws periodically Proceesor bolts are designed to fail under predeter mined loads Always replace bolts with the identical grade Make sure fastener...

Страница 55: ...t is possible to force the attachment to rotate even when the rotation circuit is not operated This is known as backdriving the rotation system Backdriving puts undue stress on the rotation system and...

Страница 56: ...E DEMOLITION PROCESSORS MAJOR COMPONENTS OF TYPICAL ROTATION SYSTEMS FIGURE 5 9 CONTROL VALVE ASSEMBLY HYDRAULIC MOTOR GREASE FITTING TURNTABLE BEARING MANIFOLD BLOCK FIGURE 5 10 MOTOR TURNTABLE BEARI...

Страница 57: ...0 1 1 10 9 10 9 10 9 L9 ZN L9 435 752 1511 900 2600 590 1020 2049 1220 3525 TORQUE VALUES FOR ROTATION ASSEMBLY BOLTS SIZE CLASS FT LBS NM M10 M12 M16 M20 38 12 9 10 9 10 9 10 9 Gr 8 Gr 8 Gr 8 64 92 2...

Страница 58: ...s 4 Remove the drain plug bottom and the visible top plug These plugs are magnetic and will attract metal filings from inside the gearbox These filings should be removed from the plugs before reinstal...

Страница 59: ...75W 90 80W 140 Product Number SAE Number Gravity API Flash PT C F Min Pour PT C F Max 51100 6 75W 90 29 8 204 400 48 55 51101 4 80W 140 30 2 218 425 43 45 Viscosity cP 40 C cP 26 C cSt 40 C cSt 100 C...

Страница 60: ...s 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...

Страница 61: ...th 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 fl...

Страница 62: ...rake valves have been preset at the factory and require no adjustment do not tamper with these valves If a malfunction is suspected due to a lack of performance in the rotator a pressure check should...

Страница 63: ...DESCRIPTION See Figure 5 13 Crossover Relief Flow Control Valve used on MDP 50 Mobile Demolition Processors Work Ports A B SAE 8 O Ring Boss Ports Gauge Ports G1 G2 SAE 4 O Ring Boss Ports Drain Port...

Страница 64: ...ing the speed valve on any Stanley LaBounty Saber Series Hydraulic Cylinder Reminder Always wear the proper personal protec tion equipment including the following 1 Steel toe safety shoes or boots 2 S...

Страница 65: ...se The pilot valve portion of the regenerative valve which in turn causes the valve spool to shift out of regenerative mode senses the increased pressure During this phase the rod side fluid is direct...

Страница 66: ...ION PROCESSORS SPEED VALVE ADJUSTMENT continued A MAIN SPOOL VALVE ADJUSTMENT B PILOT VALVE C PILOT VALVE HOUSING D MAIN SPOOL HOUSING Your speed valve may vary slightly from this isometric illustrati...

Страница 67: ...capture all escaping fluid 5 Install the test fittings supplied with the Stanley LaBounty Digital Gauge Kit P N 169832 into the MBS and MAZ ports on the Speed Valve If the MAZ port is too difficult t...

Страница 68: ...sor to the closed position six times normally and six times with the proceesor stalled in the closed position Monitor the gauge attached to the MAZ carefully During normal cycling the gauge should rea...

Страница 69: ...an be ordered from the Stanley LaBounty Parts Department to ensure the correct part is used Unless otherwise specified use class 10 9 metric hex head capscrews class 10 9 metric flat head capscrews an...

Страница 70: ...LUG 8 513086 2 SCREW PLUG 9 513087 7 SCREW PLUG 10 513877 1 CHECK VALVE 13 513878 8 SOCKET HEAD CAPSCREW 14 511504 1 GROMMET NUT 15 511550 2 SPRING 16 511503 2 O RING SEAL 18 511505 1 THREAD SEAL 19 5...

Страница 71: ...TION QTY TORQUE 2 512317 Valve Seat 1 73 ft lbs 100 Nm 4 512318 Spring Cap 1 162 ft lbs 220 Nm 11 512323 Capscrew 8 1 5 ft lbs 2 Nm 12 511514 Screw Plug 10 7 5 ft lbs 10 Nm 24 511504 Seallock Nut 1 22...

Страница 72: ...R MOBILE DEMOLITION PROCESSORS ITEM PART NUMBER DESCRIPTION QTY TORQUE 5 511579 Screw Plug 1 103 ft lbs 140 Nm FIGURE 5 50 Bezeichnung R ckschlagventil EGV 800 Ltr min lks Designation Check Valve Rege...

Страница 73: ...pect pinheads and pinkeepers Inspect all bolts for looseness or damage Inspect hoses for wear and potential failure Inspect cylinder for leaks If rotator equipped Grease turntable bearing Inspect rota...

Страница 74: ......

Страница 75: ...ECTION 6 PIVOT ADJUSTMENT AND JAW CHANGEOUT GUIDE Safety Points 6 2 Pivot Adjustment 6 2 Isometric Drawing of MDP Pivot Assembly 6 3 Lower Jaw Preparation 6 4 Upper Jaw Preparation 6 5 Main Shaft Inst...

Страница 76: ...s clear NEVER remove any pins unless the attachment is on the ground and blocked or serious injury or death could result Metal chips or debris may fly when a connecting pin is struck Use a brass drift...

Страница 77: ...Pivot Adjustment and Jaw Changeout Guide Section 6 Page 3 MOBILE DEMOLITION PROCESSORS...

Страница 78: ...lign the dowel clearance holes on the bearing with the pins on the lower jaw assembly perform a dry fit check of the main pivot bearings in the main pivot bore This should be a slip fit and the bearin...

Страница 79: ...main shaft Position the upper on the table as shown and lower the main shaft into the upper bore This should be a slip fit If this fit is tight notify engineering if measurements are out of tolerance...

Страница 80: ...ll debris and build up from the bores using a shop rag if not sufficiently clean 9 Using the large micrometer measure the diameter of the main shaft and record the data on the inspec tion sheet 10 Ins...

Страница 81: ...Install 2 bolts into shaft on the guide side to act as handles for maneuvering the shaft 13 Partially install the left hand side main bearing in order to start centering the shaft and upper 14 Fully i...

Страница 82: ...l the left hand side main bearing 16 Wedge the main shaft and upper over tight against the thrust washer 17 Mic the shaft stick out on the RH side Record Dimension A diagram Pivot Section 2 18 Mic the...

Страница 83: ...Place preliminary shims in the right hand end cap blue 005 brown 010 yellow 020 steel 060 20 Install the right hand end cap w shims onto the main shaft 21 Check to see how the upper moves from its ow...

Страница 84: ...20 21 23 When the proper amount of movement is reached Torque all right hand end cap bolts Use Per matex removable thread locker 24225 First torque bolts in a star pattern then go around one more time...

Страница 85: ...t Guide Section 6 Page 11 MOBILE DEMOLITION PROCESSORS 24 ASSEMBLY CONTINUED 24 Repeat steps 17 23 for the left hand side NOTE ALL BOLTS WITH CORRECT TORQUE APPLIED SHOULD BE IDENTIFIED BY A WHITE GRE...

Страница 86: ...rust washer side 27 Install a magnetic dial indicator on the RH side and set the indicator to zero 28 Next with the pry bar on the RH side of the up per pry the upper jaw towards the LH side While pry...

Страница 87: ...ades but do not torque 32 Measure the gap Z between the upper and lower blades at both the throat and tip as well as the adjustment plate thickness T 33 Initial Blade Gap Z T 34 Install the adjustment...

Страница 88: ...Section 6 Pivot Adjustment and Jaw Changeout Guide MOBILE DEMOLITION PROCESSORS MDP UPPER JAW INSTALLATION DONE AND READY TO GO PLEASE CONTACT THE LABOUNTY SERVICE DEPARTMENT WITH ANY QUESTIONS 800 5...

Страница 89: ...age 1 MOBILE DEMOLITION PROCESSORS SECTION 7 TROUBLESHOOTING General Troubleshooting Checklist 7 2 Hydraulic Performance Troubleshooting Guide 7 3 Rotation Circuit Troubleshooting Guide 7 5 Speed Valv...

Страница 90: ...s and excessive wear e Swift Lock Seats Inspect for material cracks weld cracks and excessive wear f Wear Plates Inspect for wear replace if necessary LOWER WELDMENT a Cross Plate Inspect for weld fai...

Страница 91: ...too rapidly a Hydraulic flow to attachment is excessively high i Reduce flow to the attachment NOTE The attachment may be damaged if flow exceeds the recommended GPM 4 Jaw drifts open or close contin...

Страница 92: ...cylinder iii Check the attachment rotation manifold if rota tor equipped iv Check the base machine s hydraulic system i Check for kinked lines ii Check the size of the lines iii Check for restrictor...

Страница 93: ...e drain line and mea sure the amount of flow out of the case i Rebuild or replace the gearbox i Check base machine hydraulic system i Check base machine hydraulic system 2 Rotation is excessively slow...

Страница 94: ...plying oil d Faulty electrical signal at control valve if electrically controlled e Planetary gearbox binding f Motor binding in planetary gearbox g Fault circuit relief valve h Varying pilot pressure...

Страница 95: ...d tools for installing the fittings a set of open or box end wrenches 12mm 19mm a set of Allen wrenches 4mm 12 mm SYMPTOM PROBABLE CAUSE REMEDY 1 Proceesor does not shift con sistently into speed mode...

Страница 96: ...Department 2 A factory 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 F...

Страница 97: ......

Страница 98: ...513914 ver 8 2013 2012 The STANLEY and LABOUNTY names and logos are registered trademarks of Stanley Solutions...

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