SASFORKS EXTREME Auto Processor Manual

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EXTREME

™

Auto Processor

Excavator Attachment

==================

Manual v16

USA Patents: D672,369 ; D704,752 ; D740,861, 9,211,832 ; D747,170 ; 8,414,704 ; D779,564; D779,565,

9,414,704 & Other Patents Pending

Page

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v16.pub 3/24/2020

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Page 1 EXTREME ™ Auto Processor Excavator Attachment ================== Manual v16 USA Patents: D672,369 ; D704,752 ; D740,861, 9,211,832 ; D747,170 ; 8,414,704 ; D779,564; D779,565, 9,414,704 & Other Patents Pending Page © 2014-2020 S.A.S. of Luxemburg, LLC. SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v16.pub 3/24/2020...
Page 2: Serial Number Location Reference
SAS™ EXTREME™ AUTO PROCESSOR Local Distributor or Supplier Name ____________________ Phone ___________________ Locate serial numbers and model numbers on SAS EXTREME Auto Processor Attachment.. Note reference below. Providing this information when contacting your local Distributor, Supplier, Service Representative, or SAS will improve accuracy and level of service.
Page 3: Table Of Contents
Read this manual completely before installation or use. S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 3 © 2014-2020 S.A.S. of Luxemburg, LLC.
Page 4: Introduction Letter
No information, pictures, designs, products, features, or forks may be duplicated in part, entirety, or in likeness. S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 4 ©...
Page 5: General Safety Guidelines
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 5 © 2014-2020 S.A.S. of Luxemburg, LLC.
Page 6 Keep adequate fire suppression equipment accessible and persons trained on operation. S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 6 © 2014-2020 S.A.S. of Luxemburg, LLC.
Page 7: Specific Notices Ce
–30°C (–23°F) and maximum temperature 65°C (150°F) S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 7 © 2014-2020 S.A.S. of Luxemburg, LLC.
Page 8: Safety Labels
STABILITY LABEL FOR CAB W-LAB-EX-STABLE-1 S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 8 © 2014-2020 S.A.S. of Luxemburg, LLC. SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v16.pub 3/24/2020...
Page 9: Installation Guidelines
INSTALLATION: PREPARATION (PAGE 9) SAS™ EXTREME™ AUTO PROCESSOR ADVANCE PREPARATION BEFORE ARRIVAL & INSTALLATION OF EXTREME AUTO PROCESSOR • Review this operator manual. Review operator, safety & service manuals of excavator manufacturer. Items you need to obtain before arrival of Extreme™ Auto Processor: •...
Page 10 Welding can damage excavator electronics. Read excavator manufacturer’s manual before welding. High pressure hydraulics. Stay clear of pinch points to avoid serious injury. Relieve pressure prior to work. Follow safety precautions in SAS EXTREME Auto Processor Manual prior to work. www.sasforks.com/safety Page 10 ©...
Page 11 Stop if interference occurs & contact SAS FORKS with serial number for engineering assistance. S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 11 ©...
Page 12: Optional Hold Down Hinge & Hydraulics Parts List
INSTALLATION: HINGE & HYDRAULICS (PAGE 12) SAS™ EXTREME™ AUTO PROCESSOR OPTIONAL: SAS SUPPLIED HINGE, HYDRAULIC DIVERTER BLOCK & CYLINDERS: INSTALLATION SHOULD BE COMPLETED BY AN EXPERIENCED HEAVY EQUIPMENT MECHANIC (Hoses are not included) J, J.1, J.2 K, K.1,K.2, K.3 I, I.1, I.2, I.3 L, L.1, L.2, L.3 J, J.1, J.2 DESCRIPTION...
Page 13 Alternate Pilot Feed (APF?), valve, drain & switch to connect to “Pilot In” rather than OEM pilot. M.5 Valve Block [for Alternative Configuration]………………………………….1 HV-BLK-E-AT180585 Hydraulic Schematic S.A.S. of Luxemburg, LLC. Phone: • 920-845-2307 • 1-877-SAS-FORK • Web: www.sasforks.com Page 13 © 2014-2020 S.A.S. of Luxemburg, LLC. SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v16.pub 3/24/2020...
Page 14: Pressure & Flow Settings Required
Watch for interference points and stop further motion if interference occurs. S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 14 © 2014-2020 S.A.S. of Luxemburg, LLC.
Page 15: Maintenance
Apply Blue Loctite 243 to bolts Ref. C, D, E, F when replacing. S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 15 ©...
Page 16: Grease Rotator & Grapple
Lubricating the rotating grapple head (For models: SAS EXTREME EX-25 v4 & v5 ) Lubricate the SAS EXTREME Auto Processor rotating grapple head daily. Use this opportunity to closely inspect the pins and pin retaining hardware and conduct necessary repairs.
Page 17: Pre-Operation
Hold Down Assembly (HDA) must be resting on firm level ground. • Excavator must be parked on firm level ground • Excavator engine must be turned ‘off’ EXTREME AUTO PROCESSOR ATTACHMENT INSPECTION POINTS: Head to stick fastening pins Single direct stick mount Stick mount & stick adaptor •...
Page 18: Daily Checklist
DAILY PRE-OPERATION CHECKLIST (PAGE 18) SAS™ EXTREME™ AUTO PROCESSOR Set attachments on ground, turn off excavator, depressurize hydraulic supply to attach- ments, stay clear of pinch points during greasing. Safe & proper daily maintenance will help ensure long term performance and prevent failures. Failure to follow preventive mainte- nance guidelines can result in equipment failure resulting in injury or property damage.
Page 19: Determining Lift Capacity
The purpose of this document is to describe the method of load rating and operating limitation parame- ters of the Extreme auto processor as indicated on the operating data plate of the device. On this product, SAS Forks installs a data plate on the product which specifies ;...
Page 20 DETERMINING LIFT CAPACITY (PAGE 20) SAS™ EXTREME™ AUTO PROCESSOR Establishing Load Ratings Page 20 © 2014-2020 S.A.S. of Luxemburg, LLC. SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v16.pub 3/24/2020...
Page 21: Operation Guidelines
OPERATION GUIDE (PAGE 21) SAS™ EXTREME™ AUTO PROCESSOR FOLLOW SAFETY INFORMATION IN EXCAVATOR Minimize amount of MANUFACTURER OPERATOR MANUAL. down force applied when restraining Be cautious, as working load capacities are determined. car. Avoid pushing down to extent that Secure car down with Hold Down Arm. front of excavator is lifted and suspend- Use jaws to pull and break out desired scrap metal.
Page 22: Parts Lists
Only an authorized and experienced person should perform this work. S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 22 © 2014-2020 S.A.S. of Luxemburg, LLC.
Page 23: Grapple Head ( Ex25 V3, V4, V5 F5343 & Higher)
EX-25 PARTS DIAGRAM (PAGE 23) SAS™ EXTREME™ AUTO PROCESSOR 15-26 TON EX-25 SERIAL NUMBER F5343 & UP Pin Type R-3.3 R-3.4 N-4 & N-5 R-3.5 N, N-1, N-2, N-3 P-3.2 PATENTED JAWS & tips DESCRIPTION PART NUMBER [N] CLAW CYLINDER HY-CYL-5.0X11.25-5K N-1 CYLINDER SEAL REBUILD KIT HK-5.00-783-244...
Page 24: Stick Mount ( Ex25, Ex30, Ex35; F5692 & Higher)
EX-25, EX-30 & EX-35 PARTS (PAGE 24) SAS™ EXTREME™ AUTO PROCESSOR HEAD & ROTATING PARTS EX-25 S/N F5909 & HIGHER EX-25 S/N F5692 TO F5903 EX-30 S/N F5902 EX-30 HIGHER THAN F5909 EX-35 HIGHER THAN F5909 EX-35 S/N F5764 TO F5801 Only EX25v4 N-4.1...
Page 25: F5692&Up ,Ex30
EX-35 v3 #F5764 & UP Rotator Model: XR600 S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 25 © 2014-2020 S.A.S. of Luxemburg, LLC.
Page 26 XR 600 HR-N-6005-178 S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 26 © 2014-2020 S.A.S. of Luxemburg, LLC. SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v16.pub 3/24/2020...
Page 27: Wire Stripper
U.S.A. PATENT NUMBER: 9414704 S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA Phone: 920-845-2307 • 1-877-SAS-FORK • Fax: 920-845-2309 • Web: www.sasforks.com Page 27 © 2014-2020 S.A.S. of Luxemburg, LLC. SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v16.pub 3/24/2020...
Page 28: Ex30 V1
EX-30 PARTS DIAGRAM (PAGE 28) SAS™ MID-SIZE EXTREME™ AUTO PROCESSOR 26-35 TON EX-30 SERIAL NUMBER F5902 & UP R-3.3 R-3.4 N-4 & N-5 R-3.5 N, N-1, N-2, N-3 P-3.2 PATENTED P-10 JAWS & tips DESCRIPTION PART NUMBER [N] CLAW CYLINDER HY-CYL-5.0X11.25-5K N-1 CYLINDER SEAL REBUILD KIT HK-5.00-783-244...
Page 29: Ex35 V3
EX-35 PARTS DIAGRAM (PAGE 29) SAS™ LARGE EXTREME™ AUTO PROCESSOR 26-35 TON EX-35 SERIAL NUMBER F5764 & UP PATENTED JAWS & PATENTED TIPS. P.10 DESCRIPTION PART NUMBER CLAW CYLINDER HY-CYL-5.0X15.25-5K N.1 CYLINDER SEAL REBUILD KIT ………………………………… HK-5.00-783-244 N.2 CYLINDER PIN BUSHING……………………………………….. W-B2.500X3.000X2.125 N.3 CYLINDER PIN GREASE SEAL W-WIPER-2.5X3.0...
Page 30: Limited Warranty
Any legally unenforceable provision may be severed from this agreement, and the remaining terms and conditions will be enforced as a whole. SALES TERMS: SAS FORKS™ SALES TERMS document is included as part of this document. See www.sasforks.com/SalesTerms.pdf Page 30 ©...
Page 31: Ce Declaration Of Conformity
We declare that the products listed below conform to the listed provisions of the following Council Directives Model Description Extreme Auto Processor Hydraulically actuated attachment for excavator used to extract vehicle engines for salvage operations Conforms to the following directives:...
Page 32 A A s s s s e e m m b b l l y y i i n n s s t t r r u u c c t t i i o o n n s s 8300003 XR 300 LS 8300006 XR 300 T LS 8300010 XR 300 LS P AV...
Page 34 Introduction Introduction These assembly instructions must accompany the rotator until it has been fully installed. The instructions must be added to the technical documentation for the complete machine. Designated use • The rotator may only be used by trained personnel. •...
Page 35 Introduction • The base machine valve that controls rotator rotation must have a closed neutral position in order to avoid uncontrolled movement. • Install a pressure limiter in the base machine's hydraulic system if the pres- sure cannot be controlled sufficiently. •...
Page 36 Introduction Painting If the rotator is repainted, the seal on the bearing must be renewed. Spare parts are available from your supplier. Other information The information in this manual was correct at the time of going to print. No li- ability is accepted for any errors or omissions in this manual.
Page 37 Safety Safety Risk area The size of the risk area depends on the application and is determined by the application manufacturer. The risk area must be at least as big as the largest load, or as the width of the tool on a horizontal plane. The manufacturer must provide clear warnings about this.
Page 42 Assembly Option XR 300 C LS, XR 400 C, XR 500 C, XR 500 C HPL, XR 600 C, XR 600 C HPL X R 400 HT X2 C M24, XR 400 HT X2 C M20 2300028 2020-02-24 © Indexator Rotator Systems AB...
Page 44 Maintenance Maintenance 250h XR 600 Max 2mm XR 500 / XR 400 / XR 300 Max 1,6mm 2300028 2020-02-24 © Indexator Rotator Systems AB...
Page 45 Maintenance 1: 50h 2: 250h XR400 T M12 x 90 12,9 136Nm XR300 / XR500 / XR600 M16 333Nm XR400 M12 136Nm 250h © Indexator Rotator Systems AB 2300028 2020-02-24...
Page 46 Maintenance 100h • Aralub HLP 2 243 K to 393 K (-30°C to +120°C) • Spheerol EPL 2 253 K to 413 K (-20°C to +140°C) • Centoplex EP 2 253 K to 403 K (-20°C to +130°C) • Lagermeister EP 2 253 K to 403 K (-20°C to +130°C) •...
Page 47 Maintenance XR 600 M16 x90 12.9 333 Nm XR 500 M16 x100 12.9 333 Nm XR 400 M12 x100 12.9 136 Nm XR 300 M12 x65 12.9 136 Nm 12000h XR 400T M12 x90 12.9 136 Nm x 10 May not take place in conjunction with start-up ©...
Page 48 Technical data Technical data Max. axial Max. axial Max. tor- Weight static load dynamic Max. tor- que load (kg) (kN)* load (kN) que (Nm) (kNm)** XR 300 LS ±300 ±90 3000 XR 300 T LS ±300 ±90 3000 ±300 ±90 3000 XR 300 LS P XR 300 C LS...
Page 49 Technical data Hydraulics XR 300 LS XR 300 T LS XR 300 LS P XR 300 C LS Maximum pressure (MPa) Max oil flow (l/min) G 1/2 G 1/2 G 1/2 G 1/2 Rotator G 3/4 G 3/4 G 3/4 connections M10x1,0 ©...
Page 50 Technical data XR 400 XR 400 C XR 400 I XR 400 T Max. Pres- sure (MPa) Max oil flow (l/min) G 1/2 G 1/2 G 1/2 G 1/2 Rotator connections M10x1,0 2300028 2020-02-24 © Indexator Rotator Systems AB...
Page 51 Technical data XR 400 P XR 400 HT P XR 400 HT XR 400 HT X2 C M24 X2 C M20 Max. Pres- sure (MPa) Max oil flow (l/min) G 1/2 G 1/2 G 1/2 G 1/2 Rotator connections © Indexator Rotator Systems AB 2300028 2020-02-24...
Page 52 Technical data XR 400 P XR 400 HT P XR 400 HT XR 400 HT X2 C M24 X2 C M20 M10x1,0 M10x1,0 2300028 2020-02-24 © Indexator Rotator Systems AB...
Page 53 Technical data XR 500 XR 500 C XR 600 XR 600 C Max. Pres- sure (MPa) Max oil flow (l/min) G 1/2 G 1/2 G 1/2 G 1/2 SAE 6000 DN SAE 6000 DN Rotator connections M10x1,0 M10x1,0 © Indexator Rotator Systems AB 2300028 2020-02-24...
Page 54 Technical data Measurements XR 300 XR 300 XR 300 XR 300 XR 300 XR 300 XR 300 300 LS T LS LS P AV C LS T LS LS P AV C LS ØA 244.7 244.7 244.7 244.7 ØK – 206.3 206.3 206.3...
Page 55 Technical data XR 400 XR 400 C XR 400 I XR 400 XR 400 C XR 400 I ØA ØK M° N° ØD ØE ØO ØF R° ØH ØI ØS J° U° ØY (mm) © Indexator Rotator Systems AB 2300028 2020-02-24...
Page 56 Technical data XR 400 T XR 400 T ØA ØK M° N° ØD ØE ØO ØF R° ØH ØI ØS J° U° ØY ØZ AA° (mm) 2300028 2020-02-24 © Indexator Rotator Systems AB...
Page 57 Technical data XR 400 P XP 400 HT XR 400 P XP 400 HT P AV P AV ØA ØK M° N° ØD ØE ØO ØF R° ØH ØI ØS J° U° – ØV ØY (mm) © Indexator Rotator Systems AB 2300028 2020-02-24...
Page 58 Technical data XR 400 HT XR 400 HT XR 400 HT XR 400 HT X2 C M24 X2 C M20 X2 C M24 X2 C M20 ØA ØK M° N° ØD ØE ØO ØF R° ØH ØI ØS J° 59,15 59,15 24,5 24,5...
Page 59 Technical data XR 500 XR 500 ØA ØK 228.5 M° N° ØD ØE ØO ØF 98.5 17.5 R° ØH ØI ØS J° U° ØY (mm) © Indexator Rotator Systems AB 2300028 2020-02-24...
Page 60 Technical data XR 500 C XR 500 C ØA ØK 228.5 M° N° ØD ØE ØO ØF 98.5 17.5 R° ØH ØI ØS J° U° ØY (mm) 2300028 2020-02-24 © Indexator Rotator Systems AB...
Page 61 Technical data XR 600 XR 600C XR 600 XR 600C ØA ØK M° N° ØD ØE ØO ØF 17.5 17.5 R° ØH ØI ØS J° U° ØY (mm) © Indexator Rotator Systems AB 2300028 2020-02-24...

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