Scorpion 30 Engine Puller Operator Manual
Contents
1. BLUE 2a GREY ED PNW WATE 08 5 5024 7 AMPER CABLE GREEN HC CHE 5 50272 PNY FLOW 32 SOLENOID CABLE BRONN PAW WHE veLLow 2c RH BUTTON S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd SASFORKS SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd TROUBLE SHOOTING PAGE 27 eXSFORKS SAS SCORPION ENGINE PULLER Hydraulic system may have stored energy Electrical system is hazardous AWARNING Be certain to follow all safety procedures and guidelines while trouble shooting Only qualified heavy equipment technicians should service this equipment Malfunctions of equipment can result in un expected movements resulting from stored energy releases Failure to follow safe procedures or practices can result in property damage injury or death PROBLEM Key is on amp loader running when move the joystick nothing works Fluid Checks STEP 1 Is hydraulic fluid level in tank of loader at proper level Yes Go to next step No Add needed2. S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd PULLING ENGINES PAGE 14 eXSFORKS SAS SCORPION ENGINE PULLER OPERATING PROCEDURE A When tipping the forks up roll back tips down dump it is best to avoid unnecessarily bottoming out the stops to avoid possible damage to the stops lift arms or hydraulic cylin ders Always slow the movements when nearing a stop including when raising the Scorpi on Boom to fully raised position Approach the vehicle 1 Front wheel drive vehicles Approach from the side of the timing belt opposite the trans mission typically passenger side 2 Rear wheel drive vehicles Approach directly from the front Position and set the forks down 1 Front wheel drive Place fork on top of fire wall cowl and other fork over the radiator support positioning the forks to allow you best visibility of the Claws 2 Rear wheel drive Place forks on top of both fenders positioning forks to allow you best visibility of the Claws D Squeeze the trigger and reposition the Claws so they will clear the middle of the forks as they are lowered into the engine compartment E Press the righ
3. SASFORKS e ng 4i m e e r e SAS FORKS SCORPION ENGINE PULLER OPERATOR MANUAL MANUAL v11 TABLE OF CONTENTS PAGE 2 eXSFORKS SAS SCORPION ENGINE PULLER Introduction Letter Page 3 General Safety Guidelines Page 4 7 CE Specific Notices amp EMERGENCY STOP FUNCTION Page 6 Safety Labels on Scorpion Page 7 Installation Guidelines Page 8 12 Pre Operation Inspection Form Page 13 Pulling Engine Best Practice Page 14 15 Connecting Disconnecting Scorpion Page 16 Regular Maintenance Page 17 Electronics Parts Guide 18 Valve Block Parts Guide Page 19 Moveable Parts Guide Page 20 Cylinder amp Pins Parts Guide Page 21 Framework Parts Guide Page 23 Hose Parts List Page 24 Page 26 Page 27 Nothing Works Page 27 Operates Backwards Page 28 Lack of Power Page 29 Drops Engines Page 30 Transmissions Breaking Page 30 Hydraulic Lines Pop Off Page 30 Moves By Itself Page 31 Misaligned Claws Page 31 Hydraulic Connectors Won t Come Off Page 32 Skid Plate Inspection amp Replacement Page 33 Important Weld Notice Page 33 Limited warranty 34 CE Declaration of Conformity Page 35 SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 43 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd INTRODUCTION LETTER PAGE 3 eXSFORKS SAS SCORPION ENGINE PULLER TO THE
4. 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 2 2 UNASSIGNED amp 5 UNASSIGNED S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd FRAMEWORK PARTS GUIDE PAGE 23 SASFORKS SAS SCORPION 30 ENGINE PULLER T TOWER 7 U IW DESCRIPTION QTY PART NUMBER T TOWER N A U BOOM SOLID REST PAD V CARRIAGE FRAME ASSEMBLY N A V 1 VALVE BLOCK ACCESS PANEL 1330CARRIAGE V 2 3 8 BUTTON HEAD BOLT GR8 WBOLT 0 375X1 00 BTH V 3 LOCK WASHER WASHER L 375 GR8 W SKID PLATE SKID PLATE LARGE X SCRAPER BLADE 1 1308CARRIAGE 2 BFF 300 06 90 00 12T STANDARD BLADE BFF 300 06 90 00 12T Z UNASSIGNED S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd HOSE PARTS LIST PAGE 24 SASFORKS SAS SCORPION 30 ENGINE PULLER When contacting SAS FORKS for parts always provide your serial number Serial number format is SAS F1234 Stampe
5. S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd SKID PLATES amp WELD NOTICE PAGE 33 EXSFORKS SAS SCORPION ENGINE PULLER NOTE USE 7018 OR 8018 WELDING ROD TO INSTALL SKID PADS NO WELDING ALONG FRONT OR BACK EDGES OF SKID PAD FRONT OF CARRIAGE CARRIAGE 5 7 N Location oF PAD 28 WELD 4 BOTH SIDES BOTH ENDS amp 47 WELD CENTERED BOTH SIDES MAXIMIZE SAS FORKS LIFE WITH SKID PLATE MAINTENANCE To get the maximum life from your SAS FORK carriage the skid plates on the bottom should not wear thinner than 1 8 Periodic inspection of the skid plates is needed Order factory replacement skid plates from S A S of Luxemburg Ltd when they are worn thin about 1 8 Carriage Skid Plates Failure to keep skid plates on the carriage will result in AWARNING structural damage to the carriage and could result in tearing out one or both blades and necessitating the purchase of a new carriage Do not use forks without skid plates in place Skid plate and fork failure can result in equipment damage injury or death DO NOT MAKE UNAUTHORIZED WELDS TO SAS FORKS To prolong the life of the SAS FORK assembly do not
6. RETURN PORT PLUG NOT SERVICEABLE TORQUE 55ft Ibs TORQUE 601 Ibs TORQUE 5ft Ibs DESCRIPTION PART NUMBER F HYDRAULIC VALVE BLOCK ASSY W VALVES COILS amp PSI REL HV BLK S FV9537 V3 F 1 SOLENOID CARTRIDGE VALVE SCREWS IN BLOCK 6 REQ HV CRT V SBV1112C000 O RING SIZE SAE 12 O RING KIT 1 big amp 1 small 2 split HV ORG SA 5940 VALVE INSTALLATION NOTE REQUIRES 1 1 4 WRENCH TORQUE TO 60 FT LBS F 2 SOLENOID ELECTRIC COIL 24 VOLT STANDARD 6 REQ HV COL V 300AA00142A COIL INSTALLATION NOTE REQUIRES 7 8 WRENCH TORQUE 6 FT LBS F 4 PRESSURE RELIEF CARTRIDGE 6 REQ HV REL P RDH103S50 O RING SIZE SAE 10 O RING 1 big 1 small 2 split HV ORG SA 5941 RELIEF CARTRIDGE INSTALLATION NOTE REQUIRES TORQUE TO 55 FT LBS F 7 32 VALVE BLOCK CABLE W FLAT END amp COIL PLUGS HC CAB S 50272 System may have stored hydraulic pressure Disassembly of any hydraulic part cartridge AWARNING 41 coil pressure relief valve or hose may result in sudden release of hydraulic fluid and may result in boom or tilt unexpected movement Avoid this fluid or pinch hazard Only qualified personnel ship service this unit Boom amp tilt should be lowered to the ground amp secured SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd MOVEABLE PARTS GUIDE PAGE 20 SASFORKS SAS SCORPION 30 ENGINE
7. B Raise the boom then raise the tilt then open the claws gently lower the boom to allow the claws to touch the ground or blades Avoid applying any down pressure This position with the boom lowered and the tilt extended will allow weight to be balanced forward enough on the blades so the Scorpion will be stable Setthe loader s parking brake Turn off the loader Turn the key of the loader back on without starting the engine Cycle through all joystick buttons moving the joystick forward and back several times while pressing amp holding each button to relieve all the hydraulic pressure in the lines Turn the key back off and remove hydraulic lines amp control cable Disconnect hydraulic hoses at quick release self sealing fittings only Carefully place control cable and hoses where they will not be damaged or get soiled Disengage the quick coupler and drive away Do not allow the hydraulic connections to get dirty Allowing dirt into the hydraulics NO CE will damage the Scorpion hydraulics and may cause catastrophic failure of the wheel loader s hydraulic pump CONNECTING To re connect to the Scorpion Engine Puller Drive straight up to the Scorpion avoid contact with hydraulic lines or control cable Engage the quick coupler Visually verify quick coupler locking pins are fully engaged Turn off the loader Cycle joystick and other lift levers in cab to relieve pressure in hydraulic lines
8. SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd
9. By Who Fan Alternator Belts Fuel System Leaks Tire Condition Tire Pressure Tire Lug Bolts Tight Hydraulic Hoses Dash Warning Lights Grease Lifting Pins Fuel Level Engine amp Keys Out Parking Brake Set Engine Oil Level Hydraulic Fluid Level Antifreeze Level Lift Arms Chains Forks Secure Seat Belt Operation Fire Ext Charged Parking Brake Engine Noises Steering System Brake System Reverse Warning Lift operation e SAS SCORPI Think Safety First Unit X item OK S needs Service Inspection Date By Who Hydraulic Hoses Not Damaged or Worn Power cable condition Quick Coupler if any free from cracks z Hydraulic Fitting Leaks Scorpion PLOW Free From Cracks 5 Fork BLADES Free of cracks amp Scorpion Fork BLADES Free of cracks E Engine Off amp Keys Out Parking Brake Set Forks on the ground Scorpion Boom Lowered Pivot Pin Lock Bolts Pivot Pin Condition Grease All Pins lt gt Scorpion Forks Securely Mounted to Loader amp Boom solid roll back rest pad in place Scorpion smooth operation _ EET 5 BOOM Free From Cracks E Scorpion TILT Free From Cracks E Scorpion CLAW mounting pins secure amp Scorpion TOWERS Free From Cracks Scorpion FRAME Free From Cracks Manual Page Number Refer a
10. Connect hydraulic lines and control cable Start loader and ensure proper operation Always select and engage a button or trigger before moving the joystick gt Left button depressed Pull back joystick to lift the BOOM Push forward on joystick to lower the BOOM gt Right button depressed Pull back joystick to swing TILT away from loader Push forward joystick to swing TILT towards loader gt Trigger button depressed Pull back joystick to squeeze CLAWS together Push forward on joystick to open CLAWS G Check hydraulic fluid level on loader Add fluid as required to maintain adequate level S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd PREVENTIVE MAINTENANCE PAGE 17 SASFORKS SAS SCORPION ENGINE PULLER Daily maintenance will help ensure long term performance and prevent failures Failure to follow preventive maintenance guidelines can result in equipment failure resulting in injury or property damage Daily Grease all 18 points with particular attention to Boom pivot points amp cylinders Cylinder Grease Points Pivot Point Grease Points BC L R Boom Cylinder Left Right BP L R Boom Pivot Left Right T
11. OWNERS MANAGERS AND OPERATORS OF LOADERS EQUIPPED WITH SAS SCORPION amp SAS FORKS Safety is the most important issue in the workplace Observing safety guidelines equipment capacities and using common sense will provide a work environment that is safe and efficient for employees management and customers It is important that you and your operators read and understand the information included in this manual prior to use of this equipment Safety warnings are highlighted through out this manual Understanding the significance of these symbols is important The following is a definition of each symbol you will encounter in this manual A The Caution Symbol is intended to draw your attention to important safety information hazard or precaution The Danger Symbol indicates a hazardous situation that if not avoided will result in serious injury or death ANGER AWARNING The Warning Symbol indicates a hazardous situation that if not avoided could result in serious injury or death The Caution Symbol indicates a hazardous situation that if not avoided could result in minor injury or potential property damage 111904193 The Notice Symbol indicates worst credible severity of harm is property damage The following information presented in this Operator Manual for SAS FORKS is intended to be a guide only and is not meant to encompass all issues that may need to be addressed for your particular type of business operation If
12. gt Trigger button depressed Pull back joystick to squeeze CLAWS together Push forward on joystick to open CLAWS If functions operate backwards switch main hydraulic lines from loader S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd DAILY PRE OPERATION INSPECTION PAGE 13 SASFORKS SUGGESTED MINIMUM INSPECTION GUIDELINES gt Inspection Required at start of each shift gt Responsible Person First employee to use this piece of equipment on each shift each day H gt If you find any safety problems fix them immediately or tag and lock out this unit so no one uses i gt Notify your supervisor about any problems and arrange for immdiate service gt A record of repairs made should be attached to this sheet for proof of safe operating condition gt Park safely Do not obstruct exit set parking brake lower forks with tips on ground shut off light gt When this page is full tum page into office for filing request a blank form gt Office Supervisor Keep this completed sheet and associated records of repairs on file A WHEEL LOADER GENERAL PRE OPERATION INSPECTION Think Safety First Unit s X item OK S needs Service Inspection
13. off the engine STEP 1 Check the fluid level in the hydraulic tank of the loader Does the tank indica tor show the fluid at the proper level No Add needed fluid and retest Yes Go to next step STEP 2 Typically immediately after installing the Scorpion there may be air in the lines which will reduce the effectiveness of the moving parts Cycle the boom tilt and claws through the motions completely from one position to the other several times Then re test at pulling an engine out Did this resolve the issue Yes End No Go to next step STEP 3 Squeeze and hold the trigger while the auxiliary function lever is pulled back Continuously hold the trigger while also selecting the boom lift button then alternat ing to the tilt lift button after the boom has reached it s full lift Did this technique resolve the issue Yes End No Go to next step STEP 4 Contact a local wheel loader or hydraulics service technician or contact SAS with your Scorpion serial for advice on the telephone PROBLEM The transmissions seem to break off often when pulling engines STEP 1 See page 10 Review PULLING ENGINES Operation Procedure See page 25 STEP 3 for resolution PROBLEM The hydraulic line connections for the auxiliary function on the loader arms pop off STEP 1 Typically this is a result of not engaging the line quick couplers fully Check for dirt in the fittings that may not allow the fitting to fully eng
14. only be used in areas that are equipped with proper fluid containment measures to ensure capture and containment of residu al fluids in accordance with any local state federal building or environmental regulating body A Smoking Safety Glasses amp Hard Hat required signage is recommended vence PREPARATION PRIOR TO USING THE SCORPION ENGINE PULLER All batteries mercury switches air conditioning Freon engine transmission fluid antifreeze and other fluids should be removed Engines transmissions and other components will be damaged and only be A suitable for metals recycling not as cores or resalable operable parts A Vehicles contain several hazardous elements that pose explosion and fire hazards AWARNING such as electric batteries containing battery acid and gasoline Be sure these are safely removed prior to using the engine puller Failure to remove may result in ex plosion fire hazard amp injuries S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v11 pub 1 43 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd GENERAL SAFETY GUIDELINES PAGE 6 eXSFORKS SAS SCORPION ENGINE PULLER CE SPECIFIC NOTICES EMERGENCY STOP FUNCTION To immediately stop the motion
15. park Scorpion amp depressurize system Goal is to align the hoses coming from the Scorpion carriage toward the wheel loader at an angle that allows the hydraulic quick coupler ings to align squarely eli ing side pressure side tension on the hose connection is undesirable Note the position of any brackets which hold fit tings Loosely attach hoses to the carriage and the load er mount Fit the hydraulic quick coupler fittings together Adjust either or both of these to allow good fit Reposition mounting bracket 1 which is fas tened to the back of coupler up or down And Or Loosen nut s 4 fastening the stainless steel line only 1 turn to 90 degree fitting on carriage Loosen lock nut on 90 fitting 5 to carriage Reposition the angle of the fitting to allow the hose to smoothly transition from the Scorpion to the fitting on the black bracket RESULTING IN A STRAIGHT ON ALIGNED CONNECTION OF THE HYDRAULIC QUICK COUPLER FIT TINGS Tighten lock nut s 5 on 90 degree fitting on carriage Tighten the nut s 4 fastening stainless steel line Tighten all hose connections If equipped secure black locking ring on hydraulic quick coupler fittings This equipment is operated by high pressure hydraulics Hydraulics are a stored power 1161221 source and as such must be treated as energized at all times Be certain pressure has been relieved prior to handling inspecting or performing maintenance on this unit
16. the best method to successfully have the transmission come out with the engine at the same time due to it will lift the engine side up and allow the transmission to pivot clear of the frame rail Did this method work better Yes End No Go to next step STEP 4 Either inspect the tips of the claws or observe the front of the car to determine if you have the claws pushed too deeply into the engine compartment that you have hold of the frame or engine cross member This will result in the enter front of the car begin to bend and try to be pulled up between the forks Open the claws and reposition a bit less deep into the engine compartment to avoid grabbing the frame or cross member Did this work better Yes End No Go to next step STEP 5 Contact a professional wheel loader service technician to see if your PSI on the auxiliary spool can be increased but no greater than 4 000 PSI If that doesn t work contact SAS with your Scorpion serial for technical support S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd TROUBLE SHOOTING PAGE 30 SASFORKS SAS SCORPION ENGINE PULLER PROBLEM The Scorpion claws won t hold onto the engine The claws keep slipping
17. turn on when joystick buttons are pressed one at a time Yes Inspect amp repair cable D or replace No Goto step 9 STEP 9 Attached 3 LED tester to joystick test point see page 18 Do individual LED lights turn on when joystick buttons are pressed one at a time No Check fuse verify proper ground amp power supply Yes Identify amp replace bad relay retest Are all connectors for cables A C and D tightly secured to control box B Yes Go to next step No Properly attach amp twist the outer lock to secure Before accessing Scorpion carriage service panel in step 12 be sure to secure boom to prevent becoming entangled in a pinch point between the boom amp carriage tower Serious injury or death may result if proper safety precautions are not taken STEP 10 Check the wire leads in the Scorpion carriage under the service access panel that connect to each solenoid coil Connect 1 LED tester to each coil feed wire When the buttons are pressed on the joystick does the 1 LED light up Or using test light Is there positive amp negative in each pair of wires at the hydraulic block No Replace carriage cable F Yes Contact local wheel loader service technician S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v11
18. weld on the forks except as shown in this diagram Improper welding repairs can result in equipment failure resulting in injury or death If you need to make any other repairs on the SAS FORKS please contact S A S of Luxemburg Ltd Engineering and discuss the situation with them RECOMMENDED PRECAUTIONS TO TAKE PRIOR TO WELDING NO CE Weld repairs should only be performed by qualified individuals Completely disconnect the Scorpion from the wheel loader before welding Do not weld if connected to wheel loader due to the risk of damage to the loader s electrical system or on board electronics Disconnect hydraulic valve block electrical cord from the loader and carriage Connect the welder ground directly to the part being welded Avoid attaching ground S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com across pivot points this may cause an arc torm damaging the pivot pomt SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v11 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd LIMITED WARRANTY PAGE 34 SASFORKS SAS SCORPION ENGINE PULLER SAFETY Buyer accepts the responsibility to 1 Ensure that all personnel that will use and or work in the area of the purchased product will read the safety ID plate and the Operator Manual For Machines Equipped Wit
19. 2 B 2 15 AMP FUSE TYPICAL AUTOMOTIVE STYLE FUSE 1 REQ HC FUS TC15 C JOYSTICK amp 10 CABLE ASSEMBLY WIPLUG HC JYA S 50270 C JOYSTICK amp 10 CABLE ASSY CAT924K 930K 938K SPECIAL ONLY HC JYA C 356 5206 D 30 FORWARD CONTROL CABLE W FLAT 4 WIRE PLUG 5 50266 1 ALL SC30 amp SC20 EXCEPT A CONTROL PANEL TYPE 28 LE 190 FOR ALUMINUM 1 ONLY HC CAB S PCKNPL 28FT E 7 JUMPER CABLE w PLUGS LOADER TO CARRIAGE HC CAB S 50274 E OPTION NO JUMPER CABLE ON PCKNPL KITS N A F 7 32 VALVE BLOCK CABLE W BULKHEAD amp COIL PLUGS HC CAB S 50272 F 7 4 VALVE BLOCK CABLE L70 L90 SPECIAL ONLY HC CAB S PCKNPL 48IN OPTIONAL TEST LIGHTS 1 LED CIRCUIT TESTER FOR WIRE F 7 AT HYDRAULIC BLOCK HC PLG I TESTLIGHT 1 3 LED CIRCUIT TESTER FOR Test Points SHOWN BELOW HC PLG I TESTLIGHT 3 D Joystick Relay Test Test Point TestPoint Point 3 LED test plug fits all three test points Relays E not shown SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd VALVE BLOCK PARTS GUIDE PAGE 19 SASFORKS SAS SCORPION 30 ENGINE PULLER as 1 F 2 F 3 BOOM Brown Black 2 2A RETURN Blue Black Grey Black r TILT CONTROLS 2G 2D EXTEND Yellow Black 2 RETURN Red Black CLAW CONTROLS 2F EXTEND ES Orange Black pd E 1 2 2
20. 8 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 43 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd GENERAL SAFETY GUIDELINES PAGE 5 eXSFORKS SAS SCORPION ENGINE PULLER PROTECTIVE EQUIPMENT amp CLEAR OPERATING SPACE RECOMMENDED Safety glasses with side shields Leather gloves Hard hat Fire extinguishing equipment Spill kit i e oil dry absorbent towels etc as required by your company Other such safety equipment to protect personnel from injury Clear operating space All personnel should be at least 50 feet away from operat ing loader and Scorpion Engine Puller Do not work under the fork or any object lifted by this equipment An unex pected movement shift in the object or hydraulic failure may cause the forks and object drop Serious injury or death may occur PERSONNEL TRAINING amp PREPARATION Prior to installation or use of this equipment all personnel should review the appropri ate equipment amp safety manuals and be trained by qualified personnel Hazards pinch points and potential injury risks should be thoroughly covered to ensure per sonnel avoid these hazards at all times Signed documentation certifying individual training is a must Periodic refresher training meetings are highly recommended SITE PREPARATION RECOMMENDED Scorpion engine puller should
21. BOLT 0 625X1 50 GR8 WASHER F 625 GR8 WASHER L 625 GR8 2 1311CARRIAGE 3453ASY 4 WBOLT 0 625X1 50 GR8 WASHER F 625 GR8 WASHER L 625 GR8 W B3 002X3 750X5 500 HY CYL 04X10 4000PSI HY CYL 04 PACK KIT B HY CYL 04 PACK KIT4 1314BOOM 3453 ASY 1316TILT 3453 ASY WBOLT 0 625X1 50 GR8 WASHER F 625 GR8 WASHER L 625 GR8 1315TILT 3453 ASY 0 1 RETAINER BOLT FOR TILT PIVOT PIN 0 2 WIDE WASHER FOR TILT CYL PIN 0 3 RETAINER BOLT LOCK WASHER 0 4 TILT PIVOT BUSHING 0 5 THREADED PIN LOCK WELD ON PART P CLAW CYLINDER WBOLT 0 625X1 50 GR8 WASHER F 625 GR8 WASHER L 625 GR8 W B3 002X3 500X3 000 103 PINLOCK HY CYL 04X10 4000PSI P 1 INTERNAL SEAL REBUILD KIT FOR CLAW CYL P 2 UPPER PIN CYLINDER END ON CLAW CYL P 3 LOWER PIN ROD END ON CLAW CYL P 4 RETAINER BOLT FOR CLAW UPPER PIN P 5a WIDE WASHER FOR CLAW UPPER PIN P 5b LOCK WASHER FOR CLAW UPPER PIN P 7 RETAINER BOLT FOR CLAW LOWER PIN ROD END P 8 LOCK WASHER FOR CLAW LOWER PIN ROD END Q MAIN CLAW PIVOT PIN HY CYL 04 PACK KIT B 1317TILT 3453 ASY 1303CLAW F3453 WBOLT 0 625X1 50 GR8 WASHER F 625 GR8 WASHER L 625 GR8 WBOLT 0 500X3 50 TAP WASHER L 500 GR8 1005CARRIAGE 3152ASY Q 1 REAR LOCKING SLEEVE BRACKET Q 2 GR8 LONG RETAINING BOLT Q x GR8 FLAT WASHER Q 3 GR8 NYLOCKING NUT Q 4 CLAW PIVOT BUSHING 1006CARRIAGEPP 3152 WBOLT 1 00X12 00 GR8 WASHER F 1 000 GR8 WNUT 1 000 8 NY GR8 W B2 002X2 500X5 875 2 2 2 2 2 2 4 4 4 2 2
22. C L R Tilt Cylinder Left Right TP L R Tilt Pivot Left Right CC L R Claw Cylinder Left Right CP L R Claw Pivot Left Right Daily Inspect all pivot point pins and retaining bolts to be sure properly secured Daily Inspect forks carriage and Scorpion framework for damage Daily Check loader hydraulic fluid level Add fluid as required to maintain proper level Weekly Inspect hose fittings to be sure they are tight Weekly Inspect hoses for pinching or rubbing and correct or replace as needed Monthly Inspect skid plates under the carriage 1 8 NPT Grease Zerks Recommended Grease Mobilgrease Claw Pivot 9 and 10 can be reached through round holes when claws are all the way apart of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd ELECTRONICS PARTS GUIDE PAGE 18 SXSFORKS SAS SCORPION 30 ENGINE PULLER B eC ge 5 DESCRIPTION PART NUMBER COMPLETE ELECTRICAL KIT 124 VOLT HC KIT S 24 1 30 OPTION ELECTRICAL k A B C D E CKNPL 30 A amp B CONTROL MODULE W LOCAL TEST amp 2 PWR WIRE HC MOD S 21478 B 1 RELAY 24 VOLT BLACK 5 4655 amp NEWER 3 REQ HC BRL H 4RD93333
23. Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd TROUBLE SHOOTING PAGE 29 SASFORKS SAS SCORPION ENGINE PULLER PROBLEM The Scorpion doesn t seem to have the power to pull engines out The claws hold tight on the engine but won t lift it out STEP 1 Check the fluid level in the hydraulic tank of the loader Does the tank indica tor show the fluid at the proper level No Add needed fluid and retest Yes Go to next step STEP 2 Typically immediately after installing the Scorpion there may be air in the lines which will reduce the effectiveness of the moving parts Cycle the boom tilt and claws through the motions completely from one position to the other several times Then re test at pulling an engine out Did this resolve the issue Yes End No Go to next step STEP 3 When grabbing the engine with the claws try repositioning the claws on the far end of the engine away from the transmission typically on the block near the timing chain This will allow the Scorpion to lift one side of the engine Engine Mount Transmission mount breaking the side motor mounts then gradually breaking the center and then oppo site side motor mounts Additionally this method is
24. Follow lockout tag out procedures and release all stored energy before servicing equipment Failure to re lease energy or disable hydraulic energy can result in serious injury or death High pressure fluids can also discharge at great velocity Be certain to wear safety glasses while inspecting operating and maintaining equipment IMPROPER INSTALLATION amp ALIGNMENT WILL CAUSE DAMAGE TO FITTINGS e Misalignment may cause undue side pressure on the fittings e Failing to secure the black ring lock may cause the fitting to not be secure e Internal ball bearing parts may break out fitting may fail and become disconnected This condition will not be warranted COMPONENT IDENTIFICATION cim QUESTIONS Phone 1 920 845 2198 HYDRAULIC QUICK BOOM COUPLER FITTINGS TO LOADER HYDRAULIC SYSTEM CARRIAGE SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd INSTALLATION GUIDELINES PAGE 12 D ASFORKS SAS SCORPION ENGINE PULLER STEP 8 HYDRAULIC FLUID LEVEL You will need to add 7 gallons at initial installation A Check level regularly Refer to the wheel loader manufacturer s manual for proper filling specifi cations Failure to keep fluid at proper operating levels can result in iipment failure STEP 9 INITIAL INTERFERENCE FOR LIFTING TILTING OR DUMPING MOVEMENTS gt Watch for pinch points Stay clear
25. IDELINES PAGE 10 eXSFORKS SAS SCORPION ENGINE PULLER STEP 5 CONTROL CABLE e Determine a suitable location for the bulkhead connection end on cable D on the forward area of the left loader arm Pick a location that cable E can reach and provides enough flex as the loader arms are lifted or tilted This is typically 2 from the lower pivot point Mount the bulkhead securely on the loader arms Run control cable D up loader arm along hydraulic lines fol lowing lines into frame amp across frame articulation point to cab of loader Leave enough slack in the cable keeping in mind articu lation of loader amp lift of main arms so there is no tension on the control cable in all positions Find a suitable location to bring the control cable into the cab Enter through a existing grom met or drill a hole large enough to fit the end of the wire through center the cable in the hole and fill around with silicone Damage to wires can result in equipment failure leading to injury or property damage Protect the cable from rubbing on the edge of the hole either install a rubber grommet or STEP 6 IDENTIFY PRESSURE SIDE LINE ON LOADER Pull joystick lever back briefly You will see one of the lines move or have someone wearing safety glasses amp leather gloves hold the line to feel the pressure build Label this line Boom Lift Pressure STEP 7 HYDRAULIC LINES e Determine adequate length of lines n
26. L STRAIGHT FITTINGS CONNECT HOSE TO CYLINDER HY 848 FS0 08X08 S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd WIRING SCHEMATIC GUIDE PAGE 26 EXSFORKS SAS SCORPION 30 ENGINE PULLER MAIN PLUG ON LOADER ARM LEADING TO CONTROL BOX Fa GREEN POSITIVE WITH BUTTON PRESSED YELLOW TILT POSITIVE WITH BUTTON PRESSED BROWN CLAW POSITIVE WITH BUTTON PRESSED WHITE GROUND 98821478 Control Module O0 0 er ser Rela Bea 2 at Tigger Lot Bitton Butin PN 8 BROW Ly PIA WHITE 24000 BATTERY 8 dost Test 1 NW oy Stick Pinout Hydravlie Bock Pinout 1 Red LH Bullen 2 Block LH Button 5 Button ONLY HC JYA C 356 5206 A550270 Joystick 3 Green RH Button 5 Orange Trigger Pin Wire Color Function Button 12 Ground 1 White CLAW Forward Button Redipower 2 Black BOOM Middle Button 3 Green TILT Rear Button 9 Red Power sovne 20918 IC C p 5 50065 7 IONER CABLE
27. PULLER CAT924K 930K 938K WITH JOYSTICK HC JYA C 356 5206 rear button To operate Press amp hold desired button amp rock 3rd spool rocker switch Stop release rocker amp button DESCRIPTION PART NUMBER H BOOM EP SC 30 BOOM 01 MOVEMENT OF BOOM 657 PRESS LEFT BUTTON JOYSTICK gt PULL BACK ON JOYSTICK RAISES BOOM lt PUSH FORWARD ON JOYSTICK LOWERS BOOM 1 TILT EP SC 30 TILT 01 MOVEMENT OF TILT of PRESS RIGHT BUTTON ON JOYSTICK lt PULL BACK ON JOYSTICK amp TILT WILL SWING OUT AWAY FROM LOADER lt gt PUSH FORWARD JOYSTICK amp TILT SWINGS TOWARD LOADER CLAW TWO REQUIRED EP SC 30 CLAW 01 OF CLAWS SQUEEZE JOYSTICK TRIGGER lt PULL BACK ON JOYSTICK CLAWS WILL PINCH TOGETHER Kj 2 PUSH FORWARD ON JOYSTICK CLAWS WILL MOVE APART The moving parts shown on this page pose several pinch points Keep all persons clear of pinch points at all times including but not limited to operation and maintenance activities Failure to stay clear and avoid all pinch points could result in serious injury or death of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd CYLINDER amp PIN DIAG
28. RAM PAGE 21 SASFORKS SAS SCORPION 30 ENGINE PULLER S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd M SASFORKS DESCRIPTION L BOOM LIFT CYLINDER SHIP WT 115 L 1 SEAL REBUILD KIT AFTER 2010 INTERNAL END CAP 2 CYLINDER amp PIN PARTS LIST PAGE 22 SAS SCORPION 30 ENGINE PULLER 2 HY CYL 05X16 4000PSI HY CYL 05 PACK KIT B 1 0 SEAL REBUILD KIT BEFORE 2009 EXTERNAL END 2HY CYL 05 4 L 2 UPPER PIN CYLINDER END ON BOOM CYL L 3 LOWER PIN ROD END ON BOOM CYL L 4 RETAINER BOLT BOOM CYL PIN L 5a WIDE WASHER FOR RETAINER BOLT L 5b LOCK WASHER FOR RETAINER BOLT M MAIN BOOM PIVOT PIN M 1 RETAINER BOLT FOR BOOM PIVOT PIN M 2a WIDE WASHER FOR RETAINER BOLT M 2b LOCK WASHER FOR RETAINER BOLT M 4 BOOM PIVOT BUSHING N TILT CYLINDER 60 1 SEAL REBUILD KIT AFTER 2010 INTERNAL END 0 SEAL REBUILD KIT BEFORE 2009 EXTERNAL END CAP N 2 LOWER PIN CYLINDER END ON TILT CYL N 3 UPPER PIN ROD END ON TILT CYL N 4 RETAINER BOLT FOR TILT CYL PIN N 5a WIDE WASHER FOR TILT CYL PIN N 5b LOCK WASHER FOR TILT CYL PIN MAIN TILT PIVOT PIN 20 2 4 4 2 1310CARRIAGE 3453ASY 1308BOOM 3453 ASY 4 W
29. S FLAT ON GROUND TURN ENGINE OFF amp KEY ON FOR THESE TESTS Disconnect cable D amp E Attach 3 LED test light end of cable D When no buttons are pressed is one of the LED lights on Yes the orange relay is bad Replace amp retest No go to next step STEP 3 Move joystick lever forward and back without pressing any buttons Is one of the LED lights come on occasionally Yes the joystick cable is shorting out likely just under the handle Repair cable or replace joystick and cable assembly No Go to next step STEP 4 Identify specifically which item is moving when you are not selecting that but ton Does this uncontrolled or undesired movement happen all the time Yes Replace the appropriate pair of solenoids cartridge valves in the valve block which control this specific function No If this only happens very rarely you may have dirt in your hydraulic system which is interfering with the solenoid valve closing and sealing properly Be sure prior to connecting hydraulic fittings that both ends are clean PROBLEM The claws on the Scorpion get misaligned or off set to one side STEP 1 This is common due to the shared hydraulic lines between the two cylinders This design is necessary to allow both claws to fully move into the engine compartment to secure against engine To correct be sure the claws are clear from the forks then engage the claw function by squeezing the trigger and pushing the joystick forward This is cause the cl
30. SAS may approve field repair of defective product SAS will approve an appropriate amount of hours and cost for the repair before authorizing repairs to begin No provisions will be made for incidental damages mileage travel time overtime downtime or special freight charges CONDITIONS THAT WILL VOID YOUR WARRANTY Failures which in our determination were the result of Improper installation Misapplication See SAS FORKS Operator Manual Misuse or Improper operation See SAS FORKS Operator Manual Exceeding the weight and or lift limitation posted on the Identification Plate attached the SAS FORKS Negligence or Failure to perform routine inspection and or maintenance as outlined in the SAS FORKS Operator Manual Unauthorized modification welding burning grinding installation of non factory skid plates etc unless otherwise specified in the SAS FORKS Operator Manual or as provided in a written authorization directly from SAS factory Engineers Continued use after a malfunction of the hydraulic system in the forklift or loader Accidental damage LIMITED WARRANTY REMEDIES Buyer must notify SAS of any warranty claim within 10 days after such claim arises other wise buyer waves all rights to such claim Unless agreed otherwise in writing Buyer s sole remedy for breach of warranty is at seller s option the repair of the defect or the providing of a replacement part F O B seller s office Seller will not be responsib
31. afety procedures for the equipment this de vice is attached to Failure to follow Manufacturers recommendations can result in serious injury and property damage This equipment is operated by high pressure hydraulics Hydraulics are a stored A DANGER power source and as such must be treated as energized at all times Be certain pressure has been relieved prior to handling inspecting or performing maintenance on this unit Follow lockout tag out procedures and release all stored energy before servicing equipment Failure to release energy or disable hydraulic energy can re sult in serious injury or death High pressure fluids can also discharge at great ve locity Be certain to wear safety glasses while inspecting operating and maintaining equipment This equipment has numerous moving components Do not wear loose fitting cloth A DANGER ing rings jewelry or other items that may become entangled in the device Be aware of resulting pinch points and keep clear during operation inspection and maintenance Pinch points exist between the puller and vehicle puller and wheel loader failure to keep clear while in operation can result in serious injury or death Do not exceed posted weight limits on equipment or loader Exceeding rated load A 97161515 limits will result in equipment damage loss of steering control serious injury or death S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 219
32. age Yes End No Go to next step STEP 2 The fitting coupler may have an outside collar that may need to be rotated to lock in place Check the fitting and rotate as needed to lock in Yes End No Go to next step STEP 3 Contact a local wheel loader or hydraulics service technician or contact SAS with your Scorpion serial for technical support S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd TROUBLE SHOOTING PAGE 31 SASFORKS SAS SCORPION ENGINE PULLER PROBLEM tilt boom or claws seem to move by themselves or when choose dif ferent function STEP 1 Are you selecting 1 button or trigger on the joystick before moving joystick No Only move the joystick forward or back after you have selected one of the buttons or engaged the trigger If you move the joystick without selecting one of these you are sending the full pressure of hydraulic fluid into a closed valve control body which will dead head the fluid and may cause some bleed by the solenoids Yes Go to next step STEP 2 Do you have one function that is moving by itself consistently Yes See electronic parts guide page 18 for test location Then follow directions PLACE FORK
33. aws to spread apart Keep engaged until claws move fully to open extended dead end Did this get both claws even Yes End No Go to next step STEP 2 Run claws from fully open to fully closed Fully pressurize when in each direc tion to force claws to even out Did this correctly even out claws Yes End No Go to next step STEP 3 Check for interference by claws such as broken auto parts rocks or other de bris Remove debris carefully with a pry bar Do not place hands near any moving parts Residual pressure may cause claws to move unexpectedly Yes End No Go to next step STEP 4 Contact a local wheel loader or hydraulics service technician or contact SAS S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd TROUBLE SHOOTING PAGE 32 eXSFORKS SAS SCORPION ENGINE PULLER PROBLEM either can t disconnect the hydraulic quick disconnect fittings on the load can t connect them push real hard and they still won t come off on Hydraulic system may have stored energy Be certain to follow all safety procedures and guidelines while trouble shooting Malfunctions of equipment can result in un expected movements resulting from stored energ
34. ble link separation bent fork mounting shafts hoses cables or wires SAS does not warrant the products that it does not manufacture Rather all warranties if any for these products are supplied by the manufacture SELLER EX PRESSLY DISCLAIMS ALL OTHER WARRANTIES WHETHER EXPRESSED OR IMPLIED INCLUDING THE IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE CALL FOR WARRANTY CONSIDERATION To be considered for warranty repairs or replacement buyer must notify SAS of any warranty claim within 10 days after such claim arises and prior to expiration of the warranty period and prior to the performance of any repairs being done otherwise buyer waives all rights to such claim Obtain the SAS Fork serial number amp call SAS at 920 845 2198 Clearly describe the problem and the operation that was taking place when it occurred Buyer is to return defective assembly freight prepaid or photographic evidence clearly showing the problem area and details of failure to SAS for review When necessary a factory representative may evaluate the problem in the field WHAT SAS WILL DO SAS will examine the defective product and the details of the failure If SAS determines that the failure of materials or workmanship was proven to be within the terms of this limited warranty SAS will at it s option repair or replace FOB the factory in Luxemburg WI USA the defective product If the product cannot be returned to the factory
35. d on the left side of the carriage Stamp location indicated by arrow x fo AN 0 2 TORQUE TO 110 FT LBS 4 S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd HOSE PARTS LIST PAGE 25 SASFORKS SAS SCORPION 30 ENGINE PULLER SAS PART NUMBER DESCRIPTION HY SC30 SS OUTLET MAIN LINE OUT HY SC30 SS INLET MAIN LINE IN 30 03 BOOM EXTEND 30 04 BOOM RETURN 30 05 TILT RETURN 30 06 TILT EXTEND 30 07 CLAW EXTEND GR 30 08 CLAW RETURN 5 30 09 BOOM LIFT LEFT 5 30 10 BOOM LOWER LEFT 5 30 11 BOOM LIF RIGHT HH SC30 12 BOOM LOWER RIGHT 5 30 13 TILT BACK LEFT 30 14 TILT OUT LEFT 5 30 15 TILT BACK RIGHT 5 30 16 TILT OUT RIGHT HH SC30 17 CLAW OPEN LEFT 30 18 CLAW CLAMP LEFT 30 19 CLAW OPEN RIGHT 30 20 CLAW CLAMP RIGHT HY SCORPION 30 KIT COMPLETE HYDRAULIC HOSE KIT TILT amp CLAW CY
36. e Lowering the boom extending tilt fully forward amp opening claws before approaching car Dropping the Scorpion down onto the car with the claws below the fork blades Clamping on engine amp extracting without the blades securely holding down the car down Having the blades come in contact with car before engine in disengaged These operations will cause stress amp cracking of the tilt assembly resulting in equipment dam Check for leaks as needed NY BLADES CARRIAGE xc V4 S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd CONNECTING DISCONNECTING PAGE 16 eXSFORKS SAS SCORPION ENGINE PULLER gt Hydraulic system may have unexpected pressure gt Always train operators on proper procedures Set forks on the ground depressur ize hydraulic system wear safety glasses gloves and other personal protective equipment required by your workplace before attempting to disconnect hydraulic hoses gt Practice lockout tagout procedures to prevent operation of equipment while servic ing DISCONNECTING When disconnecting from Scorpion Engine Puller A Set Scorpion down to position the blades flat on level ground
37. e and transmission Be cautious not to open the Claws to far that they hit the forks FRONT WHEEL DRIVE VIEW Engine Mount Frame Members ansmission Mounts S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL 11 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd PULLING ENGINES PAGE 15 EASFORKS SAS SCORPION ENGINE PULLER SAS SCORPION ENGINE PULLER USE PROPER USE OF THE SCORPION ENGINE PULLER WILL ENSURE LONG LIFE e Read your manual Grease daily Method of proper use is covered on page 10 of the manual This is 4 step summary 1 Always lower amp set blades on top of car securing car firmly to ground position the claws to clear blades amp position the tilt about 1 2 way out Tilt straight down off boom 2 Lower the boom allowing the claws to penetrate the engine compartment 3 Securely clamp claws on engine 4 While keeping the claws engaged raise boom to lift out engine E yp Failure to follow proper instructions or using Scorpion for any other purpose will void war ranty IMPROPER USE WILL CAUSE DAMAGE AND POTENTIAL CRACKING OF THE SCORPION prevent damage or potential personal injury avoid the following actions An example of improper us
38. eeded from existing third function connections on loader arms to bulkhead lines on Scorpion To decide length of line raise unit tilt unit full down then measure distance required from bulk head on Scorpion to loader connection Make a loop in line to have sufficient length in hose to avoid creating tension in all positions e Use 4 000 PSI minimum hoses amp high volume heavy duty self sealing hydraulic quick coupler fittings on machine amp 12 male JIC fittings to Scorpion e Attach the line labeled Boom Lift Pressure from STEP 6 above which is pressurized when the joystick is pulled back to the LEFT 12 bulkhead fitting on the Scorpion Clearly mark lines or use opposite quick coupler set up to ensure proper re connection after disconnected Re of Scorpion Right side S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd INSTALLATION GUIDELINES PAGE 11 SASFORKS SAS SCORPION ENGINE PULLER HYDRAULIC FITTING PROPER ALIGNMENT OF HOSE TO ENSURE STRAIGHT FITTING WILL PROMOTE LONG LIFE Read the Scorpion operator manual Wear safety glasses and gloves Follow DISCONNECTING instructions PAGE 9 of the manual to safely
39. els 1 2 3 4 LABEL 1 KEEP AWAY FROM MOVING PARTS Label reorder W LAB WARNING PINCH Mantanor Lejos Pes Cabello de ios objectos eh movimiento LABEL 2 HIGH PRESSURE HYDRAULICS Label reorder W LAB PRES 503600 LABEL 3 READ EQUIPMENT MANUALS Label reorder W LAB READ 504060 LABEL 4 PRODUCT IDENTIFICATION LABEL SERIAL NUMBER MODEL LIFT CAPACITIES Label reorder ID PLATE CE LABEL 5 KEEP BACK 15 METERS 50 FEET Label reorder W LAB STAYBACK50FT S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd INSTALLATION PAGE 8 eXSFORKS ADVANCE PREPARATION TO HELP YOU GET UP AND RUNNING QUICKER WHEN YOUR SCORPION ARRIVES Review this operator manual If you ve optionally opted for SAS to be onsite to assist your mechanic with installation and provide training please be sure the following items are completed Items you need to obtain before arrival of Scorpion 7 Gallons of hydraulic fluid specific for your machine e Locate area to mount control box or module i e recommend dry area clear of seat and door e Misc nuts bolts 1 4 or self tapping bolts e Identify the hydraulic ho
40. fluid and retest STEP 2 Are hydraulic hoses properly attached from the wheel loader to Scorpion Yes Go to next step No Properly secure hoses from loader to Scorpion STEP 3 Some wheel loaders have hydraulic cut outs which turn off the 3rd spool when the other levers are moved Is the operator only moving one lever in the cab at a time Yes Go to next step No Test only moving 3rd spool auxiliary hydraulic lever STEP 4 Check if your machine has a manual diverter valve at the front of the machine arms where the auxiliary hydraulic function maybe shared with the quick coupler Is the lever for this valve turned properly to divert fluid to Scorpion Yes Go to next step No Move lever amp lock in to ensure fluid flow to Scorpion Electrical Control Checks STEP 5 Are you pressing amp holding one button with moving the joystick Yes Go to next step No Proper operation requires to keep a button on the joystick pressed while moving joystick STEP 6 Are both front connectors properly plugged in cord D to E and cord E to F Yes Go to next step No Properly attach wire connection and retest STEP 7 Attach 3 LED tester at end of cable D on wheel loader arm Press one button at a time on the joystick Did a LED light come on with each button Yes Go to step 10 or Yes sometimes go to step 8 No Check fuse If fuse good go to step 8 STEP 8 Attach 3 LED tester to relay test point see page 18 Do individual LED lights
41. h SAS FORKS and the Machine Manufacturer s Operators Manual prior to use and 2 Ensure that all personnel follow the safety guidelines outlined on these materials S A S OF LUXEMBURG LTD IS NOT RESPONSIBLE FOR SAFETY IN THE FIELD GOALS OF THE S A S OF LUXEMBURG LTD LIMITED WARRANTY PROCEDURE ASSURE MINIMUM CUSTOMER DOWNTIME by resolving the problem correctly on a timely basis ASSURE END USER CONFIDENCE while maintaining an equitable Warranty expense for both your company and SAS PRODUCT IMPROVEMENT We have an engineering staff ready to assist you Call us at 1 877 SAS FORK 1 877 727 3675 Please call SAS before attempting any repair modification or questionable job applications LIMITED WARRANTY FOR SAS FORKS For products that S A S of Luxemburg Ltd SAS manufactures SAS warrants that such products conform to all specifications for materials and workmanship for the period of time indicated below after delivery when used in compliance with the SAS FORKS Operator Manual PRODUCT LIMITED WARRANTY PERIOD ITEM COVERED SCORPION 1 year from original ship date CARRIAGE amp FRAME DEFECTS IN MATERIALS amp WORKMANSHIP SCORPION 90 days from original ship date Hydraulic cylinders controls joystick DEFECTS IN MATERIALS No warranty on other products not listed above unless specified on the face of the original invoice No warranty against abrasion wear claw chip wear fork tip damage blade bending fusi
42. is held to be invalid or unenforceable for any reason in consideration of the other provisions of this agreement the parties understand and agree that all limitations of liability under this provision will nevertheless remain in effect SEVERABILITY 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 SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd CE DOCUMENT PAGE 35 SASFORKS SAS SCORPION ENGINE PULLER Declaration of Conformity for CE Marking EU Directive 2006 42 EC Machinery Directive SAS FORKS 133 Center Drive Hwy 54 Luxemburg WI 54217 USA We declare that the products listed below conform to the listed provisions of the following Council Directives Model Description Scorpion Engine Puller Hydraulically actuated attachment for wheel loader used to extract vehicle engines for salvage operations Conforms to the following directives 2006 42 EC Machinery Directive Date of CE Marking 10 1 2012 Technical Construction File is maintained at SAS Forks 133 Center Drive Hwy 54 Luxemburg WI 54217 USA S A S of Luxemburg Ltd DBA SAS FORKS 133 Center Drive Hwy 54 Luxemburg WI 54217 0260 U S A
43. le for costs of shipping travel time travel expense dismantling or reassembling the product Further seller will not be liable for any direct indirect consequential incidental or special damages arising out of a breach of warranty These remedies are ex clusive and all other warranty remedies are excluded PROPRIETARY RIGHTS All designs and other proprietary rights provided by SAS to Buyer are to remain the property of S A S and Buyer shall honor all proprietary legends Buyer agrees not to copy the design of S A S Forks amp SAS Scorpion or hire a third party to copy S A S may u product modification ideas suggested by user without any obligation to originator of modification suggestion If S A S chooses to implement such product modifi cation such becomes property of S A S of Luxemburg Ltd LIMITATION OF LIABILITY The seller s price is based on the enforceability of this limitation of liability and the buyer under stands that the price would be substantially higher without this limitation Seller shall have no liability to buyer for lost profits or for special consequential exem plary or incidental damages of any kind whether arising in contract tort product liability or otherwise even if advised of the potential damages in advance In no event shall seller be liable to buyer for any damages whatsoever in excess of the contract price In the event that any warranty or warranty remedy fails of its essential purpose or
44. manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd INSTALLATION GUIDELINES PAGE 9 eXSFORKS SAS SCORPION ENGINE PULLER gt Installation of the Scorpion Engine Puller on a wheel loader requires interfacing AWARNING with electrical power system and high pressure hydraulic systems Installation should be performed by qualified individuals Failure to follow these instructions and precautions noted in the wheel loader manu facturer s service manual can result in serious damage to equipment and or result in injury or death gt Failure of hydraulic system can result in serious injury and property damage gt Use caution while testing operation of this unit Be aware of Pinch Points High Pressure hydraulic fluids or stored energy Location of other individuals in the work area STEP 1 CONTROL Find a location to mount control module A amp B The location should be accessible enough to get into the box and wires but out of the way so it will not get damaged Mount where it will not be exposed to the weather Needs to be within 2 of power supply STEP 2 JOYSTICK wa Install joystick C to third function lever in cab Tle Wrap Remove current knob Screw on new joystick with supplied adapt gt er in the bottom of the joystick Drill and tap bushing as needed if your thread requirements differ Do not clamp wire tightly Route wires to cont
45. of moving parts while equipment is in opera AWARNING Moving parts can cause serious injury or death gt Watch for leaking hydraulic fittings fix any leaks and clean up spills if they occur Hydraulic fluid can cause eye irritation and slippery conditions which can result in injury gt Watch for unexpected movements or erratic operation stop test if unexpected movement occurs Stored energy can cause unexpected movements that can result in serious injury or death gt Verify all individuals are clear before performing test any loader arm hoses or cable pinch points Begin testing by moving control levers slowly A With carriage on the ground fully roll back fork tips up B With carriage lifted high fully rotate to the dump position for tips down Pin attach units may require addition of mechanical stops If you experience interference you may need to install special roll back or dump stops Contact SAS FORKS if you experience interference issues to discuss stop options Check for undesirable contact between loader lift arms Scorpion framework Watch for STEP 10 CHECK PROPER SEQUENCE e Engage button or trigger before moving joystick gt Left button depressed Pull back joystick to lift the BOOM Push forward on joystick to lower the BOOM gt Right button depressed Pull back joystick to swing TILT away from loader Push forward joystick to swing TILT towards loader
46. of this equipment 1 Operator is to release joystick button s Additional secondary alternative measures to immediately stop the motion include 2 Moving wheel loader s auxiliary hydraulic 3rd spool lever to neutral position 3 And or turning off the ignition key of the wheel loader to shut off the engine All three emergency stop options above ultimately stop the flow of hydraulic fluid Notice Even after emergency stop function is followed there is residual stored hydraulic pressure in the system See following THIS EQUIPMENT IS OPERATED BY HIGH PRESSURE HYDRAULICS Hydraulics are a stored power source and as such must be treated as energized at all times Be certain pressure has been relieved prior to handling inspecting or per forming maintenance on this unit Follow lockout tag out procedures and release all stored energy before servicing equipment Failure to release energy or disable hy draulic energy can result in serious injury or death High pressure fluids can also discharge at great velocity Be certain to wear safety glasses while inspecting oper ating and maintaining equipment STAY CLEAR Do not lift persons with this equipment People should always stand a safe distance away from this equipment Do not go near or under this equipment or any object lifted by this equipment ENERGY ISOLATION Follow Refer to PAGE 16 DISCONNECTION items A through H The symbol at the left indicates hydraulic hose cou
47. pling quick release self sealing It is recommended to be installed by the customer at the time this equipment is initially attached to the wheel loader POWER FAILURE In the event of electrical or hydraulic supply failure from the wheel loader occurs the equipment will stop further motion Under normal circumstances the equipment is not expected to drop a load The symbol at the left indicates the hydraulic controls on this equipment are normally closed Thus without electrical power the gate valves are closed in essence halting further movement SOUND This equipment does not emit more than 70dba VIBRATIONS This equipment does not transfer vibrations in excess of 2 5m s2 OPERATING TEMPERATURE 1 This equipment best suited to operate in temperatures between 30 F to 90 F with minimum allowable temperature 25 and maximum temperature 150 F S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v11 pub 1 44 10 14 2014 2008 2014 S A S of Luxemburg Ltd GENERAL SAFETY LABELING PAGE 7 EXSFORKS SAS SCORPION ENGINE PULLER CE SPECIFIC LABEL LOCATIONS Serial Number Locations 4 Stamped in aluminum id pute Stamped steel on left side 3 Serial Number Format SAS Lab
48. pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd TROUBLE SHOOTING PAGE 28 D ASFORKS SAS SCORPION ENGINE PULLER PROBLEM The Scorpion parts move backwards or opposite of the direction indicated in the manual Hydraulic system may have stored energy Electrical system is hazardous Be certain to follow all safety procedures and guidelines while trouble shooting Only qualified heavy equipment technicians should service this equipment Malfunctions of equipment can result in un expected movements resulting from stored energy releases Failure to follow safe procedures or practices can result in property damage injury or death STEP 1 The main hydraulic lines routed from the wheel loader to the Scorpion are hooked up backwards to the Scorpion Switch the two hoses where they connect to the Scorpion Retest Did that correct the problem Yes End No Go to next step STEP 2 Check to be sure harness A which provides the ground and power to the con trol box is hooked up properly The wire with the fuse link should be positive power The wire without the fuse should be ground If the wires are not hooked up properly then remove and hook up properly Retest movement Does the Scorpion work properly now Yes End No Go to next step STEP 3 Contact a local wheel loader or hydraulics service technician or contact SAS with your Scorpion serial for technical sup port S A S of Luxemburg Ltd 133
49. rol module avoid rubbing points with tio wraps Connect to proper connection on side of control box STEP 3 POWER CABLE e Locate 15 amp fused lead and connect a 24V power supply which energizes with ignition key and a good ground connection for control module A amp B Power amp ground cable A is integrat ed with module B STEP 4 ATTACH SCORPION TO WHEEL LOADER Quick Coupler Attachments Be sure lower locking pins fully extend to lock in coupler amp Scorpion This may require you to slightly lift or tilt the coupler to lock in We recommend operator actually inspect each pin to be sure they are fully locked in Direct Pin Mounting Remove existing pin attachment align arms to Scorpion insert and fasten pins in place Ap ply ample grease to all pins Quick coupler locking pins are integral to the attachment of this unit to wheel AWARNING loader vehicle Verify the pins are locked in fully prior to lifting unit or using the Scorpion Failing to verify proper engagement may cause the Scorpion Engine Puller falling off the loader resulting in property damage injury or death S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v1 1 pub 1 44 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd INSTALLATION GU
50. se quick connections on your machine Check with your machine manufacturer and obtain the heaviest duty highest volume male amp female quick connec tions e Locate a local hydraulic hose supplier who can make 2 3 4 diameter 4 000 PSI hoses with heavy duty quick connection fittings same day once proper length is determined dur ing installation Tools your mechanic will need for installation Electric Drill amp 1 25 hole drill saw Basic socket and wrench set 2 large adjustable wrenches or large wrench set Teflon tape or thread sealer Wire cutter crimper Service to do on your loader in advance e Have the maintenance personnel replace the hydraulic system filters amp fluid e Pressure and flow test recommend but not required e Inspect lift arm pins amp bushings for wear replace as needed Available for training e Atleast 20 vehicles with fluids Freon drained and batteries removed available e Designate an area where it is safe to run the Scorpion and employee to operate unit e Your loader operator person who have conversation in English Thank you COMPONENT IDENTIFICATION QUESTIONS 2 1 920 845 2198 Email paul sasforks com BOOM CLAWS adam sasforks com BLADES CARRIAGE S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator
51. t button move the joystick forward and move the Tilt about 1 2 way out Re position joystick to neutral and release the button F Press the left button move the joystick forward and lower the Boom down positioning the Claws low on the engine block on the end of the engine block farthest away from the transmission Don t go too low that the Claws grab the frame G Squeeze trigger move joystick backwards causing Claws to grab engine block H While continuing to hold the trigger and the joystick back press the left button to cause the to lift the engine out This should break the passenger side mounts then the center mounts pulling the engine up and begin to lift the transmission clear of the frame member When lifted to maximum height continue to hold the joystick back and holding the trigger Only release the button Watch the front of the car if the entire car is pulling up you have caught the frame with the Claws reposition the Claws and try again Continuing to hold trigger amp joystick back now also press the right button to lift the Tilt This will provide additional lift height to clear the transmission out vehicle Transport the engine in the Claws to the desired location to deposit the engine and trans mission then press the left button and move the joystick forward to lower the Boom Then squeeze the trigger and move the joystick forward to open the Claws and release the engin
52. this manual and a copy of this manual should be kept with the equipment To be considered qualified you must Understand the written instructions supplied by the manufacturer of the device the manufacturer of the wheel loader all company rules and any applicable OSHA regulations Completed training including actual operation of the device Know and follow the safety rules and regulations of the jobsite Operation of equipment by un qualified or un trained individuals can result in serious injury or death Verify all operators have received proper training on operation of this equipment Not designed to be operated in an explosive environment Only use this equipment in well ventilated areas a sufficient distance away from flammable or explosive gas es liquids or other hazards to avoid risk of ignition Operating this equipment in an explosive environment may cause an explosion and fire resulting in injury death and substantial property damage Operation of equipment under the influence of illegal prescribed or over the counter drugs can result in potential injury or property damage Consult your physician be fore operation of this equipment while on medication Inspect the device and perform all preventative maintenance before operation at the start of every shift Failure to perform inspections or proper maintenance can result in equipment failure resulting in serious injury or property damage Read operators manual and follow all s
53. y releases Only qualified heavy equipment technicians should service this equipment Failure to follow safe proce dures or practices can result in property damage injury or death STEP 1 Is the loader engine turned off No Turn off engine and follow next step Yes Go to next step STEP 2 Did you release the pressure from the lines by Placing the Scorpion flat on the ground Set the parking brake on the loader B Position the Boom and Claws so they are forward gently resting on the ground or on the forks C Shut off the engine of the loader and turn the key off D Turn the key without starting engine then move each hydraulic control lever forward and back a few times E Press each button on the joystick and move the joystick forward and back a few times F Turn off the key then briefly move joystick forward and back Now try to either remove or install the hydraulic lines with gloves and safety glasses Did this work Yes End No Go to next step STEP 3 Closely inspect the fittings as they may have a twist lock feature Common on Volvo machines for example Yes End No Go to next step STEP 4 Closely inspect the fittings for damage or other reasons why they will not con nect disconnect Try to resolve Yes End No Go to next step STEP 5 Contact a local wheel loader or hydraulics service technician at your expense or contact SAS with your Scorpion serial for technical support
54. you encounter any additional information that would be helpful to us or others please contact us Thank you for your business Email S A S OF LUXEMBURG LTD U S A 920 845 2198 buyit sasforks com 133 Center Dr Hwy 54 PO Box 260 Outside U S A 00 1 920 845 2198 LUXEMBURG WI 54217 U S A Proprietary Rights All designs and other proprietary rights provided by S A S of Luxemburg Ltd to Buyer are to remain the property of S A S of Luxemburg Ltd and Buyer shall honor all proprietary leg ends Notice The SAS FORKS this Operator Manual www sasforks com web site pictures content designs forks and likeness of such are property of S A S of Luxemburg Ltd and are protected under all applicable Copyright Trade Mark Trade Dress and Pending Patent No information pictures designs or forks may be duplicated in part entirety or in likeness S A S of Luxemburg Ltd 133 Center Drive Hwy 54 PO Box 260 Luxemburg WI 54217 USA Phone 920 845 2198 1 877 SAS FORK Fax 920 845 2309 Web www sasforks com SAS operations procedures forks operator manuals sc30 SCORPION 30 MANUAL v11 pub 1 43 PM 10 14 2014 2008 2014 S A S of Luxemburg Ltd GENERAL SAFETY GUIDELINES PAGE 4 D ASFORKS SAS SCORPION ENGINE PULLER Operation of equipment should only be performed by qualified and trained individuals All persons operating or working in the area of operation should read
Download Pdf Manuals
Related Search