Concrete Pulverizer User Manual
Contents
1. ee eh ann ne 1 4 Section 2 About the Attachment DSS ChIPIOM iste set c E 2 2 gs ccc EI 2 2 Concrete Pulvetizer Terms eet c engere 2 3 Concrete Pulvanzer NOS SONY EAA ase rM LIUM EMI EARNE 2 4 Section 3 Installation Concrete Pulverizer Mounting INSITUCTIONS Lue ees ae E qns Renta res re usi aane 3 2 Concrete Removal INStrUCtIONS 3 5 Concrete Pulverizer Storage en a an ann nennen nennen 3 5 Section 4 Operation Before YOU Start een 4 2 What YOU WING SO u a ee 4 2 ISU MAGS eR 4 3 General Rules for Safe 4 3 Attachment ee tm bona gent paca teni en 4 4 Getting the Feel of the 4 5 EE 4 5 Concrete Pulvarizer Operating Tips STU pM gr tace bbc eS 4 6 Section 5 Maintenance Maintenance Safety 5 2 General Rules for Maintenance 5 3 Periodic Service Scheaulen ee 5 3 Daily InspechH nC Rack nenne een 5 4 Concrete Pulverizer Lubrication u a een 5 6 General Guidelines for Build up an2. Safety Operation amp Maintenance Manual Concrete Pulverizers um OQO 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 7 487 930 5 992 023 7 578 461 4922 213 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 concrete pulverizer 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 za sen TL 1 2 Understand MEET 1 2 Safety SUMMAN 1 3 tabel EOCatlORis
3. 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 cut ting 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 NOTICE Check the temperature often during this procedure to maintain 300 400 F 150 200 C Do not exceed 450 F 230 C Page 10 Section 5 Maintenance BUILD UP TEMPLATE FIGURE 5 5 Remove paint before welding or heating Hazardous fumes can be generated when paint is heated e When sanding or grinding paint do not breathe the dust Wear an approved respirator f you use solvent or paint stripper remove the stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from the area 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 TOOTH BUILD UP AND HARDSURFACING cont
4. when maintaining the attachment to prevent injury Safety equipment includes eye protection hard hat steel toe shoes leather gloves hearing protection etc 1 To change the teeth on the upper jaw curl the attachment under and set it down on a firm and level surface with the jaws open figure 5 2 Turn the base machine off Make sure that the attachment and jaws are stable and will not drop or close Block up if necessary 2 Work only on the upper jaw with the pulverizer in this position figure 5 2 With the teeth facing up their weight will be properly supported when the pins are removed Each tooth is very heavy Removing a tooth pin when the tooth is not supported will cause the tooth to fall and could cause serious injury 3 Use a soft metal drift such as brass and a mallet to drive out the tooth pins figure 5 3 4 the tooth is loose on its seat lift and slide it out If necessary use a pry bar to loosen the tooth from the seat Do not lose the retainer ring Page 6 Section 5 Maintenance FIGURE 5 2 RECEPTACLE RETAINER RING amp SEAT TOOTH PIN FIGURE 5 3 m CONG mies SIS SWIFT LOCK TOOTH REPLACEMENT continued 5 Insert the new tooth by sliding it into the slot in the seat Make sure the retainer ring is located in its pocket in the tooth seat before installing the tooth figure 5 3 on page 6 6 Use a mallet to insert the pin through the holes in the tooth and
5. 7 DO NOT exceed bolt torque specifications see the Dry Bolt Torque Chart in this manual 8 DO NOT disconnect 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 use substitute parts unless you know that they are the identical to original factory parts in all characteristics 12 Refer to the Parts Catalog for your attachment for LaBounty replacement part numbers Be sure to reference the attachment model and serial number when ordering e m EONEREIER UFGERIZERS PERIODIC SERVICE SCHEDULE SERVICE THE ATTACHMENT AT SPECIFIED INTERVALS Inspect lubricate make service checks and adjustments according to the Daily 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 when operating in extreme environmental or abrasive conditions Use correct lubricants and bolt torques Refer to the lubrication and bolt torque instructions in t
6. Customer Service Department Failure to adhere to LaBounty hardsurfacing recommendations may compromise the attachment warranty Hardsurfacing should be applied directly on top of the build up welds The build up acts as a bonding or underlayment for the hardsurfacing This reduces the chances that the hardsurfacing will crack Contact Information for Amalloy Welding and Indus trial Supply Phone 800 735 3040 toll free Fax 623 792 8706 Website www amalloy com Maintenance Section 5 Page 9 CONCRETE PULVERIZERS TOOTH BUILD UP AND HARDSURFACING See the table on page 5 15 for the part numbers for 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 be come worn rather than build them up Build up and hardsurface the teeth when there will be adequate time for them to cool slowly before they are put back into service Use the following process to build up and hardsurface the teeth 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 de termine the amount of build up required figure 4 5 Build up templates can be ordered from LaBounty 3 Preheat the tooth to about 200 F 100 C to remove moisture Preheat the area to be built up
7. and follow proper lockout tag and repair procedures A 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 shield covering the front of the cab is also required Contact your base machine equipment dealer or manufacturer for more information on the availability of FOPS Lack of proper FOPS may result in injury or death A DANGER DO NOT process or handle material with the attachment over the operator s cab A DANGER DO NOT attempt to shear brittle materials such as axles and railroad rail Brittle material breaks or shatters instead of shearing The material being processed could become a projectile and cause injury or death DO NOT process any material in any position that may propel it toward operator other workers buildings or equipment A DANGER DO NOT close the attachment on a structure and reverse the excavator in an attempt to pull down material Clear all persons and equipment from the area of operation and machine movement NEVER move loads over people or equipment When viewing the operation of the attachment maintain a safe distance of at least 75 feet 22 9 meters NEVER approach power lines with any part of the machine Kee
8. and the stick tip of the excavator Make sure to install the spacers on each side of the stick tip as you slide the main pin through the main pivot 4 Install the washer and slotted nut on the threaded end of the main pin Turn the slotted nut until it is snug against the washer and the spool head Tighten the nut further until the next available slot line sup with the hole in the main pin Install the cotter pin see figure 3 2 FIGURE 3 1 Page 2 Section 3 Installation La Bounty CONCRETE AU Bri ein enfe CONCRETE PULVERIZER MOUNTING INSTRUCTIONS continued SPOOL HEAD MAIN PIN THREADED END WASHER SLOTTED NUT COTTER PIN FIGURE 3 2 5 Extend the bucket cylinder and line up the power link with the linkage connection of the pulverizer Install the link pin Place the collar on the end of the link pin and secure it with the bolt and nut provided 6 With all personnel standing clear curl the excavator stick and extend the bucket cylinder to position the lower jaw as shown in figure 3 3 7 Place the mounting pad on the bottom of the excavator stick Connect the position arm to the lower jaw of the puliverizer Make sure the position arm grease fittings will be accessible 8 Connect the position arm to the mounting bracket at the center hole 9 Position the mounting pad along the bottom of the stick to obtain the proper distance from the main pin to the center hole of the mounting pad This distance is
9. 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 Preheat must be uniform throughout 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 putting the attachment back into service HANDLING AND STORAGE OFWELD MATERIALS Follow the weld manufacturer s handling and storage instructions closely Make sure the electrodes or wire are free of moisture Moisture can cause cracks and porosity in the weld and possibly the base metal beneath the weld WELD QUALITY Quality and attention to detail in welding can significantly affect the life of the attachment Stanley LaBounty strongly recommends that only qualified and certified welders perform this work Make sure the weld con sumables and base material are clean dry and free of grease paint dirt or any other foreign substance that may harm the weld NOTICE Preheat and post heat instructions must be followed exactly Failure to do so can compromise warranty cove
10. pins both ends 5 Grease all points until excess appears Use premium grease no 2EP or equivalent a Link pin connection in upper jaw lugs b Main pin connection in upper jaw lugs c Main pivot in stationary jaw d Position arm ends e End of link pin and main if required f Check excavator for grease fittings at other connections Inspected by Page 4 Section 5 Maintenance CONCRETE IUS CONCRETE PULIVERIZER LUBRICATION Grease all points every 4 hours of concrete pulverizer operation Use Amoco Rykon 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 Fill with grease until excess appears 2 BOTH SIDES FIGURE 5 1 LOCATION ON ATTACHMENT eee OF SHOTS 1 Link pin connection movable jaw 2 Main pin connection movable jaw 2 3 Main pivot stationary jaw 2 4 Position arm ends 2 5 Main pin in end of pin if needed 6 Link pin in end of pin if needed Maintenance Section 5 Page 5 CONCRETE PULVERIZERS SWIFT LOCK TOOTH REPLACEMENT When the teeth are badly worn or crushing 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 Safety equipment should be worn at all times
11. shown in the Parts Catalog e Installation Section 3 Page 3 CONCRETE PULVERIZERS CONCRETE PULVERIZER MOUNTING INSTRUCTIONS continued 10 VVeld the pad in position using E7018 low hydrogen welding rod Make 1 2 12 7 mm fillet welds 3 78 mm long 6 150 mm on center see figure 3 4 Run out welds 1 1 2 40 mm on ends grind to taper in both the side view as shown in figure 3 5 and in the top view figure 306 NOTICE Under no circumstances should the mounting pad be welded around the ends see figure 3 4 NOTICE If the pulverizer is equipped with a custom mounting pad refer to the Parts Catalog for special mounting instructions 6 00 3 00 150 150 MM 75 MM 40 x 2 XX HEHE EAKA KAKA HEHE XXXX XXXX HEHE K DONGTWEID RUN OUTWELDS GRIND WELD TO TAPER SEE AROUND ENDS WELD DETAILS wa SIDE VIEW WELD DETAILS TOP VIEW WELD DETAILS FIGURE 3 5 FIGURE 3 6 Page 4 Section 3 Installation La Bounty CONCRETE AU Bs ein ente CONCHETE PULVERIZER REMOVAL 1 Fully close the pulverizer and place it on a solid level surface in the position shown in figure 3 7 2 Support the position arm while removing the pin from the mounting pad then lower the position arm to the ground 3 Remove the pin from linkage connection 4 Remove the pin from the main pivot With all personnel standing clear carefully raise the excavator stick away from the puliverizer FIGURE
12. 3 7 CONCRETE PULVERIZER STORAGE 1 Place the attachment on a solid level surface 2 Apply a coating of grease to the bores pins and any other exposed unpainted surface 3 Replace all pins in their bores to prevent misplacing them 4 Grease at all locations refer to the lubrication instructions in the maintenance section of this manual La Bounty Installation Section 3 Page 5 COIN meds AU Bs ein ente SECTION 4 OPERATION Before YOU Dante ie 4 2 4 2 First TANINOS e 4 3 General Rules for Safe Operation ss kann naar 4 3 Attachment Controls 4 4 Getting the Feel of the 4 5 the S mr 4 5 Concrete Pulverizer Operating ae 4 6 Introduction to Safety Section 4 Page 1 CONCRETE PULVERIZERS BEFORE YOU START KNOWYOUR SAFETY PROGRAM 1 Read and understand the safety section of this manual and the base machine manual 2 Know the employer s safety rules for your job Consult your foreman for specific instructions and safety equipment required 3 Learn the traffic rules at the work site 4 Know the hand signals used on the job and who is responsible for signaling Take signals from only ONE KNOW YOUR EQUIPMENT earn the location and function of all controls Test all controls to ensure prope
13. 3 7 832 130 8 146 256 8 104 384 EPO PATENT NUMBERS 435 702 737 107 1 682 299 1 789 225 STANLEY LABOUNTY 1538 Highway 2 Two Harbors MN 55616 FOREIGN PATENTS AND OTHER PATENTS PENDING VALED 1 800 522 5059 www stanleyhydraulic com 116404 PATENT PLATE PART NUMBER 116404 FIGURE 1 7 CONCRETE PULVERIZERS SECTION 2 ABOUT THE ATTACHMENT Model Description A O E ON AEE 2 2 REU EE E A AEE TA E E AE EAE AEE ES 2 2 Concrete 2 3 9 2 4 About the Attachment Section 2 Page 1 CONCRETE PULVERIZERS MODEL DESCRIPTION The LaBounty Concrete Pulverizer CP is a simple yet powerful tool that excels at separating rebar and con crete turning these two waste materials into recyclable profitable products It is a quiet alternative to tradi tional demolition and concrete processing methods such as hydraulic hammers and wrecking balls Concrete Pulverizers are available in sizes for base machines ranging from 25 000 to 160 000 pounds 11 500 to 73 000 kg and openings from approximately 28 to 54 0 7 to 1 4 meters The LaBounty Concrete Pulverizer mounts in place of the excavator bucket The bucket cylinder and linkage provide the crushing force no additional circuits are required Each CP is designed to get maximum power and productivity from the excavator Depending on the mounting option
14. al Authorization tag RMA must accompany returned product Returned product found deficient by Stanley LaBounty will be replaced or repaired without charge FOB Distributor Customer or will be credited to account balance Authorized repair can occur at the Stanley LaBounty factory or authorized Stanley LaBounty Dealer Labor for warranty repair will be paid under a formula determined by Stanley LaBounty gt WNS 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 1039705 2012 The STANLEY LABOUNTY names and logos are registered trademarks of Stanley Solutions
15. ce procedure contact your LaBounty dealer For the nearest LaBounty dealer see the Contact Information at the front of this manual e Inspect the attachment daily DO NOT operate a poorly maintained or damaged attachment or major structural damage could result e 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 a machine each must be familiar with the controls and aware of what the others are doing Before working on a machine BE SURE TO TAG THE CONTROLS SO NO ONE ELSEWILL 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 checki
16. d 5 8 Build up Recornmendatlons css rte Fete a E E PER RR VER eds 5 9 Hardsurfacing sanos sd sepu ate trad pim Sa Pan 5 9 E 5 10 Attachment Build up and urn een 5 12 Boli ae 5 14 Metric ee aE ee 5 14 Dry Bolt orale Charts I 5 14 Swift Lock Build up Template Kit Parts Numbers 5 15 CONCRETE AU Bs SECTION 1 INTRODUCTION TO SAFETY RNC 1 2 Understand OLET 1 2 Safety SUMMA 1 3 Attachment Decals tette ee enden inne 1 4 Introduction to Safety Section 1 Page 1 CONCRETE PULVERIZERS 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 r
17. der blocks hollow tiles or props that may crumble under continuous load DO NOT rely on a cylinder to hold the attachment in the air DO NOT work under a machine that is supported only by a jack DO NOT let hot hydraulic oil get in contact with the skin as it could cause severe burns Wear adequate protective clothing and safety equipment DO NOT tamper with any hydraulic line or component while itis pressurized Escaping fluid under pressure can penetrate the skin causing serious injury Relieve pressure before unhooking hydraulic or other lines Tighten all connections before applying pressure Keep hands and body away from pinholes and nozzles which eject fluids under high pressure Use a piece of cardboard to search for leaks If ANY fluid is injected into the skin seek immediate medical assistance Page 4 Section 1 Introduction to Safety DO NOT weld any structural member unless specifically authorized by LaBounty Any unauthorized welding or welding procedures may result in personal injury i 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 mo
18. e air pass it over people occupied vehicles or buildings or serious injury could result 8 ALWAYS keep a watchful eye on exposed parts such as the position arm so as to not damage them when working in confined spaces 9 ALWAYS maintain at least 15 feet 5 meters between the attachment and any nearby power lines or serious injury could occur 10 When leaving the machine for any reason ALWAYS lower the attachment to the ground 11 DO NOT close the attachment on a structure and reverse the excavator in an attempt to pull down material 12 AVOID collision of the boom or attachment especially when working with limited visibility or inside buildings Know the height and reach of the processor during operation travel and swinging upper structure 13 AVOID contacting machine with the attachment or any material held by it 14 Use machine swing for positioning only DO NOT use the attachment as a jack hammer or wrecking ball 15 AVOID contact between boom arm or attachment and overhead obstacles when you operate move or haul the machine 16 The attachment is not a dozer DO NOT position it on the ground and travel forward Determine the control for each movement of the excavator before attempting to operate Practice the machine movements as described in Getting the Feel of the Attachment on page 4 6 Introduction to Safety Section 4 Page 3 CONCRETE PULVERIZERS ATTACHMENT CONTROLS The LaBounty concrete pulveriz
19. e 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 Introduction to Safety Section 4 Page 5 CONCRETE PULVERIZERS CONCRETE PULVERIZER OPERATING TIPS 1 To get the most crushing force from the pulverizer pin the position arm in a mounting pad hole that allows the guide link to travel beyond 90 to the bucket cylinder before crushing begins see figure 4 3 GUIDE LINK 7 Uu FIGURE 4 3 2 When processing large heavy materials open and close with short cycles r ther than attempt to crush the material in one cycle see figure 4 4 This allows the pulverizer to downsize the material until it is able to pulverize it completely This technique creates less stress on the attachment and excavator hydraulics OPENAND CLOSE ON HEAVY MATERIAL FIGURE 4 4 17 Page 6 Section 4 Introduction to Safety CONCRETE Bs ein ente CONCRETE PULVERIZER OPERATING TIPS continued 3 The mounting pad of the LaBounty Concrete Pulverizer has three pin positions By using the different positions the angle of the lower stationary jaw can be adjusted see figure 4 5 For each job the lower jaw can be positioned to make the CP more productive or easier to use Some experimentation may be necessary to learn the advantages of each position Using the front position provides the least amount of total opening while the rear posit
20. ead all safety messages in this manual and on your equipment safety signs Keep safety signs in good condition replace missing or damaged safety signs Because LaBounty cannot foresee all hazardous circumstances the precautions listed in this manual and on the equipment are not all inclusive If a procedure method tool or part is not specifically recommended by LaBounty determine whether it is safe for you and others and that the equipment will not be damaged or made unsafe as a result of your decision to implement it The basic rules are summarized in this section of the manual They also appear throughout the manual along with additional specific rules for safety and operation Page 2 Section 1 Introduction to Safety UNDERSTAND SIGNAL WORDS When you see the following symbols and signal words on your equipment or in this manual be alert to the potential for personal injury or equipment or property damage Follow recommended precautions and safe operating practices ADANGER 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 CONCRETE Diem SIS SAFETY SUMMARY A DANGER If the attachment is not functioning properly you must shut the machine down
21. ecting 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 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 the lever toward the neutral position Movement is stopped at the neutral position The position is maintained until the control lever is moved again m Feathering the controls is a technique that will increase output and make operating the attachment easier When starting any motion of the machine move th
22. er replaces the bucket of an excavator and operates with the same controls no additional hydraulics are required The bucket dump control opens the attachment and the bucket curl closes 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 BUCKET DUMP ATTACHMENT BUCKET CURL ATTACHMENT OPEN CLOSE FIGURE 4 1 Page 4 Section 4 Introduction to Safety em CONCRETE AU B ein eine 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 safely away from other people that s free of obstructions such as 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 see figure 4 2 This get acquainted time will allow the operator to become familiar with the control levers and attachment before beginning work The machine 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 insp
23. he life of the pulverizer Guide Link Part of the excavator bucket linkage that pins at one end to the excavator stick and pins at the other end to the bucket cylinder and the power link Hardsurface Welding process to protect the parent material of the pulverizer The hardsurface acts as a wear surface Link Pin The pin that connects the upper jaw of the pulverizer that is held stationary by the position arm Lower Jaw The lower half of the pulverizer that is held stationary by the position arm Main Pin The pin that connects the upper and lower jaws to the excavator stick tip The main pin is a component of the main pivot group Mounting Pad A bracket welded to the bottom of the excavator stick at a specific location The position arm pins between the mounting pad and the pulverizer to hold the lower jaw stationary The mounting pad properly positions the lower jaw and distributes stresses evenly through the stick during operation Position Arm A structural member pinned between the lower jaw and mounting pad to support the lower jaw and hold it stationary Power Link Part of the excavator bucket linkage that pins at one end to the upper jaw of the pulverizer and pins at the other end to the guide link and bucket cylinder Spool A flanged tube that holds the two jaws together and creates a pivot for the upper jaw There are two spools in the main pivot of a pulverizer Swift Lock Easily replaceable pin on wear parts on the upper and lower jaws fo
24. his manual when performing maintenance on the attachment DAILY SERVICE REQUIRED Bolts Check for looseness or damage Retorque if necessary Refer to Bolt Torque tables in this manual Bolts may be retorqued once then must be replaced Connecting Pins and Pin Retaining Bolts Inspect for looseness damage and or wear on main pivot pin and linkage pin Check pinheads and pinstops Grease Fittings Lubricate according to the instructions in this section Replace broken fittings Swift Lock Teeth and Tooth Seats Make sure all tooth pins are in place Inspect for wear indicating build up or hardsurfacing is required Rotate or replace if necessary Refer to page 5 6 for instructions Maintenance Section 5 Page 3 CONCRETE PULVERIZERS DAILY INSPECTION CHECKLIST Attachment Model Excavator Hour Meter Attachment Serial Number Date 1 Visually inspect attachment for any damage a Check for cracks or excessive wear that may cause structural failure 2 Inspect the Swift Lock teeth and tooth seats a Check for excessive looseness or damage It is acceptable for the teeth to move slightly from side to side on on their seats b Check the tooth pins for damage or looseness c If necessary rework or replace the teeth as outlined in this manual 3 Inspect all bolts a Visually inspect all bolts and replace any that are loose or damaged 4 Inspect pins and pin retaining hardware a Main pivot pin b Link pin c Position arm
25. ing 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 FIGURE 5 7 CONG EEUU SIS ATTACHMENT BUILD UP AND HARDSURFACING CONTINUED 4 Apply a bead of Amalloy 814H rod or equivalent directly on top of each of the underlayment beads to create a 45 cross hatch or diamond pattern on the approved sur faces of the attachment Space the beads approximately 1 to 2 apart It is important to use an airoperated slag peener on each pass of weld to relieve stress 5 Taper the ends of each hardsurface bead by grinding in line with the cutting edges Do not undercut the weld with the grinder 6 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 7 When finished be sure to cover the reworked teeth area with a heat blanket to allow it to cool slowly a Y wv BASE PLATE BOTH SIDES iy A Ay a MA Em BLADE SEATS BOTH SIDES OUTER TINES A CAA ss j n FIGURE 4 8 DETAIL B UPPER JAW SIMILAR Maintenance Section 5 Page 13 CONCRETE PULVERIZERS BOLT TORQUING GUIDELINES P
26. inued 5 Start hardsurfacing the tooth by applying parallel passes of AWS E7018 build up running the length of the tooth figure 5 6 These single passes should be 1 2 13 mm apart and will serve as an underlayment for the hardsurface rod NOTICE DO NOT apply the 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 impor tant to use an airoperated 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 undercut the weld with the grinder 8 When welding and grinding is complete peen the welded area until it is shiny or until your peener cannot dent the weld anymore typically five to ten 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 HARDSURFACE BEADS 0 50 13 MM FIGURE 5 6 Maintenance Section 5 Page 11 CONCRETE PULVERIZERS ain BUILD UP HARDSURFACING If desired additional areas of the lower and upper jaws may be built up and hardsurfaced to increase their life Stanley LaBounty recommends that only certain areas of the attachment be hardsurfaced Hardsurfacing applied to non approved areas can cause serious damage to the attachment and limit its performance See figure 5 7 for approved surfac es Hardsurface these a
27. ion provides the most The center position is the best for general use MOUNTING PAD Eon CENTER POSITION REAR POSITION FRONT CENTER FIGURE 4 5 e Introduction to Safety Section 4 Page 7 CONCRETE SECTION 5 MAINTENANCE Maintenance Safety Procedures eene nennen enne nenne een nnne nnn 5 2 General Rules for enne 5 3 Peri dic DEVISE he ani MK c o 5 3 Daily Inspection Checklist RR ee ee ea NT 5 4 Concrete Pulverizer scere e rtu 5 6 General Guidelines for Build up and 5 8 Build up Recommendations rennen 5 9 Hardeunselng Recommendations a Eb qub uM bea RR Ode am aM 5 9 Tooth B ild up and an Food vila deo th ME etra 5 10 Attachment Build up andHl rdsuracsiig anne tns vaa molten clas Fue la E 5 12 Bolt Te MI IO DOO 5 14 Metric Capscrew Size Guide sale 5 14 Dry Bolt Torque Charts PL 5 14 Swift Lock Build up Template Kit Parts 5 15 Maintenance Section 5 Page 1 CONCRETE PULVERIZERS MAINTENANCE SAFETY PROCEDURES Before attempting any maintenance procedure read the entire Safety Manual carefully If any question arises regarding a safety or maintenan
28. late 807990 Inner Template f304885 Build up Template 804886 Build up Template o0 307569 Template _ _ 80 MEE 304644 Build up Template 304645 Build up Template 304646 Build up Template Maintenance Section 5 Page 15 LIMITED WARRANTY New Attachment Stanley LaBounty warrants its manufactured products against deficiency in material or workmanship for a period of 12 months from the date of first use rental or sale or 1500 hours of operation whichever occurs first LIMITATIONS Remanufactured or used product or service repair are not warranted under this Limited Warranty e Product that is damaged by alteration improper maintenance unauthorized service abuse misuse or contamination by the base machine is not warranted e This Limited Warranty is the exclusive warranty Stanley LaBounty makes no representations expressed or implied of merchantability or fitness for a particular purpose e Agents of Stanley LaBounty have no authority to make representations beyond those contained herein EXCLUSIVE REMEDY The exclusive remedy for a product Stanley LaBounty determines deficient in material or workmanship is repair or replacement at Stanley LaBounty s option The following procedure governs a repair or replacement warranty claim All warranty claims require a claim number provided by Stanley LaBounty Service Department A factory issued Return Materi
29. ng 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 ASK FOR HELP BEFORE STARTING IF YOU ARE UNSURE Page 2 Section 5 Maintenance During maintenance of the shear it is imperative that the excavator is turned OFF to prevent injury Inferior parts can fail and cause equipment damage or personal 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 5 4 Use the included Inspection Checklist during inspections to make sure all maintenance is complete 5 In extremely cold temperatures work the attachment on lighter materials first before working 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
30. of your CP it may be possible to mount it on other excavator makes and models within the same weight class by installing a new mounting kit Conctact your LaBounty representative with the serial number to evaluate other mounting options for your CP Concrete Pulverizers include LaBounty s patented Swift Lock pin on replaceable teeth These teeth offer long wear impact resistance and simple maintenance Each tooth segment is secured to the jaw with one pin making it possible to replace a complete set of teeth in as little as a half an hour FEATURES e Patented Swift Lock pin on replaceable teeth offer fast and easy maintenance as well as long wear and impact resistance Made with high strength abrasion resistant steel for durability e Multimachine mounting is possible among some excavator models within the same weight class Mounting pad may also be used with LaBounty Grapples BLS Shears and MWS Wood Shears e Installs in as little as 30 minutes e At factory upgrading and rebuilding services avail able for extended life FIGURE 2 1 Page 2 Section 2 About the Attachment CONCRETE PULVERIZERS ATTACHMENT TERMS EXCAVATOR STICK BUCKET CYLINDER SWIFT LOCK TEETH AND TOOTH SEATS About the Attachment Section 2 Page 3 CONCRETE PULVERIZERS ATTACHMENT GLOSSARY Build up Welding process where worn off parent material is replaced with new metal A very important maintenance procedure to extend t
31. p clear at a minimum of 15 feet 5 meters Avoid tipping The attachment will alter the lift capacities of the base machine DO NOT overload the excavator or serious injury could result Lift capacities will vary if the base machine is not on level ground Carry loads in recommended positions for maximum stability Use the recommended excavator counterweight Use short slings and lift the load only as high as necessary DO NOT allow riders on the machine Introduction to Safety Section 1 Page 3 CONCRETE PULVERIZERS SAFETY SUMMARY continued 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 Keep people clear when removing or installing pins NEVER operate equipment without the original equipment safety guards in place If the cab glass is missing or damaged check with your dealer or manufacturer for proper replacement Under no circumstances should any modifications be made to LaBounty equipment without factory authorization ALWAYS lower the boom to the ground before leaving the cab If it is necessary to work on an attachment off the ground securely support the machine and attachment DO NOT support the machine on cin
32. r 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 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 Introduction to Safety 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 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 opera
33. r pulverizing concrete Each tooth fastens to Teeth its tooth seat with a pin and retainer ring Thrust Wear components in the main pivot between the upper and lower jaws that act as a wear surface between the jaws Washers as they pivot Tooth Pins amp The hardware that fastens each tooth to its seat The tooth pin is held in place by the retainer ring Retainer Rings Tooth Seats Receptacles that are welded in place on the upper and lower jaws Each Swift Lock tooth attaches to its seat with a single pin and retainer Upper Jaw The upper half of the pulverizer that is connected to the bucket linkage of the excavator It pivots against the lower Page 4 Section 2 About the Attachment stationary jaw to crush concrete CONCRETE AU Diem SECTION 3 INSTALLATION Concrete Pulverizer Mounting Instructions Concrete Pulverizer Removal Concrete Pulverizer Storage Installation Section 3 Page 1 CONCRETE PULVERIZERS CONCRETE PULVERIZER MOUNTING INSTRUCTIONS It is recommended that the mounting bracket not be welded to the excavator stick until the pulverizer is installed Mount the attachment as follows 1 Postion the pulverizer on a flat level surface as shown in figure 3 1 Remove the main pin and link pin 2 With all personnel standing clear walk the excavator into position and line up the excavator stick tip with the main pivot of the pulverizer as shown in figure 3 1 3 Install the main pin through the main pivot of the CP
34. rage Page 8 Section 5 Maintenance EONEHREIEIRZUFGERIZERS BUILD UP RECOMMENDATIONS Refer to the list of AWS classifications below to select a suitable build up material for LaBounty concrete pulverizers Weld products within these classifications meet the combined requirements for strength toughness and ductility that are essential for LaBounty applications Shielded Metal Arc Welding Stick Electrodes 1 E7018 1 E8018 C3 Gas Metal Arc Welding Solid Wire Electrodes 1 ER70S 6 Gas Metal Arc Welding Flux Cored Electrodes gl E71T1 1 E71 1M Pl EBOT 1 Ni1 1 E80T1 Ni1M Gas Metal Arc Welding Metal Powder Cored Electrodes 1 E70C 6M 7 E80C Ni1 Welding suppliers can assist in identifying products that meet these AWS classifications NOTICE Using improper build up and hardsurfacing products may result in premature wear or increased potential for cracking and may compromise warranty coverage NOTICE Do not use stainless hardsurface rod It is too brittle for LaBounty applications and has a tendency to crack weakening the base metal HARDSURFACING RECOMMENDATIONS For hardsurfacing Stanley LaBounty recommends Amalloy 814H rod or equivalent It is important to always use a hardsurfacing weld material with a chromium content of less than 10 and a severe impact resistance rating to prevent cracking If in doubt about what hardsurface material to use please contact the Stanley LaBounty
35. reas only when there will be adequate time for them to cool slowly before they are put back into service Use the following process to build up and hardsurface the desired area 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 Preheat the area to approximately 200 F 100 C to remove moisture then heat 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 to avoid overheating and damaging the attachment Temperature sticks are available from Stanley LaBounty 3 Using AWS E7018 welding rod or equivalent make side by side passes 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 area matches the template NOTICE Check the temperature often during this procedure to maintain 300 400 F 150 200 C Do not exceed 450 F 230 C Page 12 Section 5 Maintenance Remove paint before welding or heating Hazardous fumes can be generated when paint is heated e When sanding or grinding paint do not breathe the dust Wear an approved respirator f you use solvent or paint stripper remove the stripper with soap and water before welding Remove solvent or paint stripper containers and other flammable material from the area Have a fire extinguisher nearby dur
36. roper bolt installation is critical to ensure the safe and efficient operation of the attachment and jaw set 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 LaBounty Parts Department to ensure the correct part is used Unless otherwise speci fied 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 If necessary use the Capscrew Size Guide below to determine the size of the bolt being installed 4 Use the Dry Bolt Torque Chart below to find the proper torque When possible torque the nut rather than the bolt head METRIC CAPSCREW SIZE GUIDE SCREW HEX HEAD FLAT HEAD SOCKET SIZE HEAD aa M10 x 1 50 0 63 16mm CL NBN ot emm HEX HEAD 24mm 18mm M14 x 2 00 m uu 0 63 21 mm mm B XQ mm 0 907 Due FLAT HEAD 000 30mm 24mm en 30mm 36mm 30mm Emm e 45mm DRY BOLT TORQUE CHARTS METRIC CLASS 12 9 METRIC CLASS 10 9 SIZE see rss Im MI2x178 MI2x175 1 175 16 2 M20 x 2 5 M24 x 3 1220 M30 x 3 5 1806 2450 Page 14 Section 5 Maintenance CONCRETE SWIFT LOCK BUILD UP TEMPLATE PARTS NUMBERS 807989 Outer Temp
37. seat Be sure to install the pin so the groove in the pin will line up with the retainer ring inside the tooth seat The retainer ring should seat in the pin groove 7 Repeat this process for the other worn teeth on that jaw 8 When this jaw is done start up the base machine With all personnel standing at a safe distance lift the attachment and put it out in front of the excavator figure 5 4 Set the attachment back down on the ground and make sure it will not drop or close 9 Follow steps 3 through 7 to replace the teeth on this jaw FIGURE 5 4 Maintenance Section 5 Page 7 CONCRETE PULVERIZERS GENERAL GUIDELINES FOR BUILD UP AND HARDSURFACING The steel used in LaBounty attachments is stronger and more durable than ever However this steel requires special attention during maintenance Pay particular attention to the preheat and post heat instructions and follow them exactly Review the following guidelines for build up and hardsurfacing the attachment detailed instructions on maintaining specific areas of the attachment are on the following pages Contact your Stanley LaBounty dealer or the Stanley LaBounty Service department for further information 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 concrete pulverizer steel including welding tack welding torch cutting and airarcing preheat the
38. tions 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 EONEHEIEIR FGERIZERS GENERAL RULES FOR SAFE OPERATION 1 Read the Operator s Manual for the excavator that the grapple is on Know the control levers and their functions Also 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 machine or serious injury could result 3 It is required that a Falling Objects Protection Structure be installed surrounding the excavator cab for all material handling applications 4 DO NOT use attachment for anything except what it is intended for or warranty will be voided 5 DO NOT operate a poorly maintained or damaged attachment 6 ALWAYS maintain a safe operating distance between any material suspended and held by the attachment and the cab of the machine 7 NEVER leave a load suspended in th
39. ving parts Before operating the attachment read and observe all safety instructions in the Operation and Maintenance sections of this manual If you are unfamiliar with any operation or maintenance procedure seek instruction before proceeding CONG EEUU SIS ATTACHMENT DECALS STANLEY m STANLEY LABOUNTY BRAND DECALS REPLACEMENT a ea UPON REQUEST SAFETY FIRST Read the Safety Operation and Maintenance Manual before operating or servicing the equipment Keep the manual with the attachment so itis available for reference SAFETY FIRST DECAL PART NUMBER 503590 INCLUDED WITH MANUALS FIGURE 1 2 La Bounty Introduction to Safety Section 1 Page 5 CONCRETE PULVERIZERS ATTACHMENT DECALS cowriNUED GREASE DECAL PART NUMBER 116338 FIGURE 1 3 ADANGER KEEP AWAY 75 feet 23m SAFE VIEWING DISTANCE DECAL PART NUMBER 116389 FIGURE 1 4 4 DANGER Top and front cab guarding required during any material processing application SAFETY DECAL PART NUMBER 503647 FIGURE 1 5 Page 6 Section 1 Introduction to Safety 1538 Highway 2 Two Harbors MN 55616 tel 1 800 522 5059 fax 218 834 3879 www stanleyhydraulic com STANLEY Made in the U S A with Global Materials Attachment Model Serial Number Year of Manufacture MODEL SERIAL NUMBER PLATE PART NUMBER 511045 FIGURE 1 6 U S PATENT NUMBERS 5 474 242 7 240 869 5 531 007 7487930 5 992 023 7578 461 7 322 27
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