OPERATION AND PARTS MANUAL

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1 manual-r-pul, 30p, 21 April, 2000 MYUNGSAN HYDRAULIC ROTATABLE PULVERIZER OPERATION AND PARTS MANUAL MYUNGSAN

2 Congratulations on your joining as a MYUNG SAN customer Myungsan pulverizer have been developed based on the long year s accumulated excellent design technologies. Several years field test ensures its durability and high performance. However, the customer is kindly requested to read this manual and to understand necessary instructions for the safe and long life usage. Any troubles caused by improper maintenance, abnormal usage and repairs using non-genuine spare parts can not be covered by warranty claims. WARRANTY INFORMATION WARRANTY is provided as part of the Myungsan support program for customers who operate and maintain their equipment as described in this manual. Should the equipment be abused or modified to alter its performance beyond original specifications, the warranty will become void. Setting the carrier hydraulic pressure above specification or changing the size of the attachment cylinder to increase performance will also void warranty. SAFETY FIRST It is the responsibility of the operator and service technician to read rules and instructions for safe and proper operation and maintenance. A cautious worker using common sense is the greatest safety device. 1

3 CONTENTS CHAPTER 1. PRECAUTIONS AND SAFETY SYMBOLS PRECAUTIONS 1.2 SAFETY SYMBOLS 1.3 LABEL LOCATIONS CHAPTER 2. SPECIFICATIONS..9 CHAPTER 3. EXTERNAL DIMENSIONS MS850FHR 3.2 MS1000FHR 3.3 MS1300FHR CHAPTER 4. INSTALLATION GENERAL VIEW OF CRUSHER 4.2 HYDRAULIC CIRCUIT 4.3 PULVERIZER MOUNTING PROCEDURE 4.4 PULVERIZER REMOVAL PROCEDURE CHAPTER 5. OPERATION AND MAINTENANCE PRECAUTIONS FOR SAFE OPERATION 5.2 MAINTENANCE CHAPTER 6. TROUBLE CAUSE AND REMEDY CHAPTER 7. EXPLODED VIEW AND PARTS LIST EXPLODED VIEW 7.2 PARTS LIST 2

4 CHAPTER 1. PRECAUTIONS AND SAFETY SYMBOLS 1.1 PRECAUTIONS The Myungsan Hydraulic Rotatable Pulverizer can operate safely and normally if it is operated in accordance with instruction given in this manual. Read this manual thoroughly before operation. If operator do not understand necessary instructions completely serious personal injury or equipment damage can occur. (1) Observe all laws and regulations that affect you and your equipment when you operate the pulverizer. (2) Read the excavators operation manual and understand the safety and operation instructions completely. (3) Check all the necessary maintenance procedures are completed. (4) The operator should quit the operation immediately if anyone moves in the working area which is much larger than that of excavator due to the risk of flying debris. (5) Before leaving the excavator, set the boom lower position and insure the excavator is stable. Never leave the excavator while the engine is running. Fasten the parking brake. (6) Stop the engine when you want to repair or adjust the pulverizer. (7) Keep temperature of the working fluid of excavator between 20 o C ~ 80 o C for proper performance. (8) To avoid personal injury and pulverizer damage genuine parts of Myungsan should be used. Also, only the authorized person or well trained person should repair the pulverizer. (9) Keep this manual near operator. 3

5 (10) Do not operate this pulverizer when you are under the influence of drug or alcohol. (11) Detach pulverizer from excavator during transport. (12) Observe the excavator manufacturer s safety regulations. 4

6 1.2 SAFETY SYMBOLS Your safety and the safety of others is a result of how you operate and maintain your equipment. Read and understand this manual and other safety information provided with the carrier machine. Carefully read all safety messages in this manual and on your equipment safety signs. Keep safety signs in good condition, replace missing or damaged safety signs. Understand signal words Indicates immediate hazards which will results in severe personal injury and death. Indicates hazards or unsafe practices which could result in severe personal injury or death. Indicates hazards or unsafe practices which could result in damage to the machine or personal injury. GREASING Indicates to fill cavity with recommended grease through the grease nipple before use. 5

7 1.3 LABEL LOCATIONS ITEM DESCRIPTION 1 GREASE DECAL- one at each grease fitting 2 DANGER DECAL-1-one on front side of body 3 DANGER DECAL-2-one on back side of body 4 LOGO DECAL-one on front side of body 5 MODEL DECAL-one on back side of body 6 MODEL and SERIAL NUMBER plate-one on front side of top bracket 7 WARNING DECAL one on back side of top bracket 6

8 ITEM 1 GREASE DECAL ITEM 2 DANGER 1 DECAL 7

9 ITEM 3 DANGER-2 DECAL-2 ITEM 6 MODEL and SERIAL NUMBER PLATE ITEM 7 WARNING DECAL 8

10 CHAPTER 2. SPECIFICATIONS ITEM Cylinder Force U.S Metric (lb) (ton) MODEL MS850FHR MS1000FHR MS1300FHR 263, , , Attachment Weight-Approx U.S (lb) Metric (kg) 4,829 2,200 6,804 3,100 9,219 4,200 Carrier Weight-Approx U.S (lb) Metric (ton) Dimension Length (in) (mm) 39,509-61, ,296 61,459-87, ,543 87, , ,200 Width (in) (mm) 47 1, , ,480 Jaw Opening (in) (mm) ,100 Max. Working Pressure Cylinder (psi) (bar) 4, , , Motor Flow Range(Q) Cylinder (psi) (bar) (lpm) 3, , , Motor (lpm) Cycle Time(under Q max ) Open (sec) Close (sec)

11 CHAPTER 3. EXTERNAL DIMENSIONS Model Length(L) Width(W) Opening Width(O) MS850FHR (in) (mm) 90 2, , MS1000FHR (in) (mm) 100 2, , MS1300FHR (in) (mm) 126 3, , ,100 10

12 CHAPTER 4. INSTALLATION 4.1 GENERAL VIEW No Name 1 Hydraulic Pump 2 Oil Tank 3 Main Control Valve 4 Directional Control Valve for Cylinder 5 Directional Control Valve for Rotating Motor 6 Pedal Switch 7 Electric Fuse 11

13 4.2 HYDRAULIC CIRCUIT 12

14 4.3 PULVERIZER MOUNTING PROCEDURE 1. Place the pulverizer on the ground(or wood block) with blocking to keep the pulverizer level for installation. 2. Remove the bucket or other attachment following the manufacturer s recommended procedure. Be careful not to contaminate the hydraulic system by plugging the hydraulic hoses. 3. With the jaws of the pulverizer facing the excavator, operate the excavator into proper position, lining the excavator s arm(second boom) into the top bracket pivot of the pulverizer. 4. Pin the excavator s arm and pulverizer top bracket pivot together. 5. Pick the pulverizer up into a proper position where the second linkage pin can be inserted. Insert pin. 5. Connect the hydraulic hoses to the manifolds(or fitting) located on each side of the Top bracket. Tighten the bolts or cap to the proper torque. When installation is complete, fully extend excavator bucket cylinder to curl pulverizer. Check for interference. Contact factory or authorized dealer if any interference occurs. 7. Lift the boom and slowly try the pulverizer rotate function and pulverizer open and close function. Watch for hydraulic oil leakage. Observe flow rate and pressure range(both cylinder and motor) or the warranty will become void. 13

15 4.4 PULVERIZER REMOVAL PROCEDURE 1. Position the pulverizer under the boom of the excavator. Trapped hydraulic pressure may be present after base machine is turned off. Extreme caution must be taken when removing pulverizer hydraulic hoses or possible injury or death could result. 2. Disconnect the hydraulic hoses. Be careful not to contaminate the hydraulic system by plugging the hydraulic hoses. 3. Remove the bucket cylinder pin from the pulverizer mounting bracket. 4. Remove the arm pin of the excavator from the pulverizer mounting bracket. 14

16 CHAPTER 5. OPERATION AND MAINTENANCE 5.1 PRECAUTIONS FOR SAFE OPERATION (1) Check the excavator position is stable. (2) Do not use pulverizer like a lever. 15

17 (3) Do not pull or push object with pulverizer when cylinder is acting. (4) Do not hit the pulverizer against the object. 16

18 (5) Inadequate operation can cause damage to the cylinder rod. (6) Operate carefully not to hit the excavator with the pulverizer 17

19 5.2 MAINTENANCE Inspection Items Check Points and Remedy 1. Bolts, Nuts, Snap-Ring, etc -Looseness, damage, missing Tighten, replace 2. Cylinder-Rod -Damage on the surface of cylinder rod. Surface finishing or replace 3. Center-Joint -Oil leakage, or bolt looseness Replace seals, tighten the bolts 4. Cutter -Damage, gap more than 1mm due to wear, breakage, and or bolt looseness Replace or tighten the bolts 5. Pins, Bush 6. Rotation motor-malfunction -Gap more than 1mm due to heavy wear or breakage Replace -Problem of motor, pinion or bearing, Adjust brake valve pressure, Replace 7. Grease -Grease every 4~8 working hours (Slew-ring, Pins, Gear) 8. Damage on the structure -Check crack, breakage, damage Repair 9. Oil leakage -Check piping and seals Tighten, Replace seals 10. Pressure setting -Check main relief pressure Adjust relief valve(280~300 bar) -Check setting pressure of motor brake valve and flow rate Adjust pressure(140-~210 bar) and flow rate(10~40 lpm) 11. Fluid contamination -Check fluid(oil) contamination regularly Replace oil and filter 18

20 ROTATOR MAINTENANCE The rotator is capable of 360 degree continuous rotations for easy, accurate crushing at all angles. The rotator is to be used only as a positioning features, not as a means of bending or breaking material. Use of he rotation feature for any other purpose may damage the rotation components and may compromise the attachment s warranty. The rotation mechanism consists of a hydraulic motor driving a turntable bearing. Periodic maintenance requirements include maintaining proper bolt torque and lubrication, these items are detailed below. BOLT TORQUING The bolts connecting the turntable bearing are important maintenance area. After the first eight hours of use the bolt must be retorqued. Bolts be retorqued only once and then must be replaced if they loosen due to fatigue caused by stretching the bolt during torquing. If the bolts continue to loosen, contact the dealer or factory. These bolts should be inspected daily and replaced after 1,500 hours or 12 months. TURNTABLE BEARING LUBRICATION Rotating attachments in storage should be lubricated at least every six months. Equipment operating frequently in extreme environments should be lubricated at least every eight hours. If old grease is noted to be in good condition and free of contamination, the interval may be extended. Conversely, if the old grease is contaminated or deteriorated, the interval should be shortened. LUBRICATION PROCEDURES Bearings Are equipped with 1 to 4 grease fittings, depending upon model used. The grease fittings will be located either on the outside of the bearing or on the upper head side plate. It is recommended to rotate bearing while greasing in order to uniformly distribute the grease and to most effectively flush out the old grease and contaminants. The bearing should be turned through two full revolutions while greasing through any one fitting. Continue greasing until clean grease can be felt exiting at the seals. TURNTABLE BEARING LUBRICANTS For normal operating conditions, periodic lubrication with lithium Grade 2 extreme pressure grease is recommended. For operation below 0 o C (32 o F), Grade 0 is recommended. Comparable lubricants produced by other reputable manufacturers not referred below may also be used. 19

21 Maker AMOCO CHEVRON EXXON MOBIL SHELL SOHIO SUN TEXACO UNION Trade Name Rycon Dura Lith Lidok Mobilux Alvania Bearing Guard Prestige Multifak Unoba For Operation Below 0 o C (32 o F), & For storage EP0 EP0 EP0 EP0 EPR0 LT0 740EP EP0 EP0 For Operation Above 0 o C (32 o F) EP2 EP2 EP2 EP2 EP EP EP2 EP2 HYDRAULIC REQUIREMENTS The rotating attachment requires an auxiliary hydraulic circuit in order to operate the rotator. This circuit will need to be a medium pressure(140 ~ 210 BAR / 2000PSI ~ 3000PSI), low flow(15 ~ 45 LPM / 4 ~ 12 GPM) hydraulic circuit. There are minimum and maximum pressure and flow requirements which may vary depending on the model of the attachment. These requirements are listed in the specification chart. BRAKE VALVE PRESSURE ADJUSTMENT The rotation motor on the attachment is equipped with Brake Valve(Dual Relief Valve). The pressure adjusting procedures of the brake valve are as follows : 1. Loosen the jamnut locking the adjustment screw. 2. To increase pressure turn the adjustment screw clockwisw; check pressure every 1/8 turn interval. 3. To decrease the pressure turn the adjustment screw counterclockwise: check pressure every 1/8 turn interval. 4. Retighten the jamnut after the desired adjustment has been made. 20

22 PULVERIZER STORAGE 1. Block the pulverizer up off the ground using wood blocking. 2. Grease the pins and machined bores of the mounting bracket of the attachment. Then apply a generous amount of grease to shear blades, cylinder rod and all other exposed and unpainted surfaces. 21

23 CHAPTER 6. TROUBLE CAUSE AND REMEDY Trouble Phenomena Cause Remedy 1. Cylinder do not operate 1.1 Electric shortage. 1.2 Sticking in solenoid valve. 1.3 Working fluid(oil) do not flow. 1.4 Damage of seal of center joint. 1.5 Damage of seal of Cylinder. Check battery or electric wire. Connect wire. Repair solenoid spool or replace with new one. Check the piping(turn on stop valve). Replace damaged seal. Replace damaged seal. 2. Motor do not rotate 2.1 Electric shortage. 2.2 Sticking in solenoid valve. 2.3 Motor damage. 2.4 Breakage of pinion or motor 2.5 Too low brake pressure Check battery or electric wire. Connect wire. Repair solenoid spool or replace with new one. Repair or replace with new one. Replace with new one. Adjust brake valve pressure 3. Oil leakage from Cylinder 3.1 Seal damage. Replace with new one. 4. Oil leakage from center joint 4.1 Seal damage. Replace with new one. 22

24 CHAPTER 7. EXPLODED VIEW AND PARTS LIST 7.1 EXPLODED VIEW 23

25 7.2 PARTS LIST MS850FHR Name Part No Quantity Remark 1 BODY MF TOOTH MF CYLINDER MF SLEW-RING MF TOP MF CENTER JOINT MF CAP MF MOTOR MF PINION MF BUSH-B3 MF x 2 11 PIN-BODY MF PIN-CYLINDER MF PLUG-B MF x 2 14 PLUG-C MF BUSH-L2 MF x 2 16 END-CAP MF BUSH-L3 MF x 2 18 BUSH-B4 MF x 2 19 CUTTER MF x 2 20 PLATE-M MF HOSE-I MF x 4 22 ELBOW-CAP MF x 4 23 NIPPLE-SHAFT MF x 2 24 FLANGE-HALF MF x 4 25 PIN-STOPPER MF x 4 26 O-RING MF x 4 27 BOLT MF M12 x L35(D) 28 BOLT MF M12 x L45 29 BOLT MF M16 x L70 30 BOLT MF OPTION 31 WASHER MF M16 32 BOLT MF M12 x L25 33 BOLT MF M16 x L45 34 WASHER MF M10 35 END-PINION MF BEARING MF SB100A 37 GREASE NIPPLE MF x 7 1/8 38 BOLT MF M10 x L35 39 NUT MF OPTION 40 DIVIDER MF x 4 24

26 No Name Part No Quantity Remark 41 O-RING MF x 3 P90 42 BACKUP RING MF x 4 For P90 43 DUST SEAL MF LBI WEAR RING MF x 3 45 ROD PACKING MF ISI BACKUP RING MF For ISI O-RING MF G BACKUP RING MF For G O-RING MF P BACKUP RING MF For P PISTON PACKING MF x 2 OSI BACKUP RING MF x 2 For OSI O-RING MF G COVER-C MF COVER-B MF WASHER MF M12 57 BOLT MF M16 x L55 25

27 7.2.2 MS1000FHR No Name Part No Quantity Remark 1 BODY MF TOOTH MF CYLINDER MF SLEW-RING MF TOP MF CENTER JOINT MF CAP MF MOTOR MF PINION MF BUSH-B3 MF x 2 11 PIN-BODY MF PIN-CYLINDER MF PLUG-B MF x 2 14 PLUG-C MF BUSH-L2 MF x 2 16 END-CAP MF BUSH-L3 MF x 2 18 BUSH-B4 MF x 2 19 CUTTER MF x 2 20 PLATE-M MF HOSE-I MF x 4 22 ELBOW-CAP MF x 4 23 NIPPLE-SHAFT MF x 2 24 FLANGE-HALF MF x 4 25 PIN-STOPPER MF x 4 26 O-RING MF x 4 27 BOLT MF M12 X L 35(D) 28 BOLT MF M12 X L45 29 BOLT MF M16 X L70 30 BOLT MF OPTION 31 WASHER MF M16 32 BOLT MF M12 X L25 33 BOLT MF M16 X L45 34 WASHER MF M10 35 END-PINION MF BEARING MF SB100A 37 GREASE NIPPLE MF x 7 1/8 38 BOLT MF M10 X L35 39 NUT MF OPTION 40 DIVIDER MF x 4 26

28 No Name Part No Quantity Remark 41 O-RING MF x 3 P90 42 BACKUP RING MF x 4 For P90 43 DUST SEAL MF LBI WEAR RING MF x 3 45 ROD PACKING MF ISI BACKUP RING MF For ISI O-RING MF G BACKUP RING MF For G O-RING MF P BACKUP RING MF For P PISTON PACKING MF x 2 OSI BACKUP RING MF x 2 For OSI O-RING MF G COVER-C MF COVER-B MF WASHER MF M12 57 BOLT MF M16 x L55 27

29 7.2.2 MS1300FHR No Name Part No Quantity Remark 1 BODY MF TOOTH MF CYLINDER MF SLEW-RING MF TOP MF CENTER JOINT MF CAP MF MOTOR MF PINION MF BUSH-B3 MF x 2 11 PIN-BODY MF PIN-CYLINDER MF PLUG-B MF x 2 14 PLUG-C MF BUSH-L2 MF x 2 16 END-CAP MF BUSH-L3 MF x 2 18 BUSH-B4 MF x 2 19 CUTTER MF x 2 20 PLATE-M MF HOSE-I MF x 4 22 ELBOW-CAP MF x 4 23 NIPPLE-SHAFT MF x 2 24 FLANGE-HALF MF x 4 25 PIN-STOPPER MF x 4 26 O-RING MF x 4 27 BOLT MF BOLT MF BOLT MF BOLT MF OPTION 31 WASHER MF BOLT MF BOLT MF WASHER MF END-PINION MF BEARING MF GREASE NIPPLE MF x 7 38 BOLT MF NUT MF OPTION 40 DIVIDER MF x 4 28

30 No Name Part No Quantity Remark 41 O-RING MF x 3 42 BACKUP RING MF x 4 43 DUST SEAL MF WEAR RING MF x 3 45 ROD PACKING MF BACKUP RING MF O-RING MF BACKUP RING MF O-RING MF BACKUP RING MF PISTON PACKING MF x 2 52 BACKUP RING MF x 2 53 O-RING MF COVER-C MF COVER-B MF WASHER MF BOLT MF

POWERGRIP PRODUCT MANUAL

PRODUCT MANUAL & INSTALLATION KIT POWERGRIP PRODUCT MANUAL & INSTALLATION KIT THANK YOU FOR YOUR PURCHASE You have received a high quality, extremely versatile attachment that will increase your machine