GYRU-STAR 2-50E User manual

INSTALLATION, OPERATION AND MAINTENANCE MANUAL
USER MANUAL
SPECIFICATION MANUAL
Manufactured By
Wheatway Solutions Ltd
B3 Brearley, Bair Road
Waterwells Business Park
Gloucester, GL2 2AF
England
ORIGINAL INSTRUCTIONS
Please Read This Document Before Operating The Machinery
Copyright
GYRU-STAR Screening Bucket
MODELS COVERED:
2-50E, 3-80E, 3-80A, 3-120E, 3-120HE, 4-100E, 4-100A, 4-100HE, 4-120HE

Index
1. SCOPE
2. WARNINGS
3. SAFETY INSTRUCTIONS
4. COPY OF WARNING NOTICES
5. LIFTING AND HANDLING INSTRUCTIONS
6. INSTILLATION INSTRUCTIONS
7. OPERATING INSTRUCTIONS
8. MAINTENANCE
9. MAINTENANCE INSTRUCTIONS
10. FAULT FINDING PROCEDURE
11. PARTS LIST
12. HYDRAULIC DRAWINGS
13. DRILL PATTERN

1. Scope
The GYRU-STAR Screening bucket is a bucket type attachment fitted either to
a hydraulic excavator or a wheeled loader replacing the standard digging
bucket.
The GYRU-STAR Screening bucket shell is a steel structure with welded joints,
integrated driveline cavities, double skin floor, and with a wear resistant cutting
edge. The shell has been tested to 1.5x maximum permissible load.
The horizontal shafts fitted with Polypropylene flexi-stars rotating in the same
upwards direction. The rotors are supported at each end by a seal bearing unit
and is driven by a hydraulic motor via a carbon chain belt and dive pulleys
system.
The hydraulic motor, driveline and bearings are housed within the main
structure of the bucket with access via a bolted access panel. The hydraulic
power is produced by the hydraulic excavator or wheeled loader hydraulic pump
and control system via its auxiliary/option circuit and transferred through by
flexible hoses to the GYRU-STAR Screening bucket hydraulic motor(s).
The Non Hazardous material to be screened is loaded in to the, GYRU-STAR
Screening bucket in the same manner as the standard excavator or wheeled
loader bucket; once the bucket has been loaded with marital to be screened and
positioned the excavator or wheeled loaders auxiliary hydraulic circuit is
activated causing the star rotors to turn in upwards direction.
The GYRU-STAR Screening bucket efficient screening process is created by
rotating star rotors agitating the material causing the fines to flow through the
rotating stars leaving the oversize material in the bucket.
Once the screening process is completed the oversize material is tipped out and
the process is repeated.

2. WARNINGS
Throughout this manual these symbols & notes are used to
indicate the following;
DANGER
Imminent danger that is likely to cause serious injury or loss of
life.
WARNING
Safety situations that may cause serious injury or loss of life.
CAUTION
Safety situations that may cause problems or damage to the
equipment.
NOTE
To draw attention to procedures or information which it is
essential to observe for correct operation.

3. Safety Instructions
WARNING
Special attention must always be paid to the safe use and maintenance of the
GYRU-STAR Screening bucket.
The GYRU-STAR Screening bucket should only be used by a trained and
competent operator and must have read and understood the operator’s manual
before operating the GYRU-STAR Screening bucket.
Before operating the operator must ensure the GYRU-STAR Screening bucket
is suitable for the carrier and ensuring when fully loaded it does not exceed the
carriers’ safe working capacity
Before operating the GYRU-STAR screening bucket the operator must ensure it
is fitted correctly to the excavator or wheel loader, ensuring all locking devices,
mounting pins and hydraulic connections are made correctly.
Before operating GYRU-STAR Screening bucket the operator must carry out a
visual inspection of the general condition of the bucket and the hydraulic hoses,
Ensuring all guards are fitted and are in good order. Any defects are to be
reported and rectified.
Always detach and store the GYRU-STAR Screening bucket on a firm level
surface.
Do not carry out any inspections, maintenance, adjustments, or cleaning until
the excavator or wheeled loader is stopped and the auxiliary hydraulics are
isolated.
Do not leave the excavator or wheeled loader while the rotor are turning.
Do not go under GYRU-STAR Screening bucket in any circumstances.
Allow hydraulic oil to cool down and any pressures to decay. Always wear
correct PPE before disconnection hydraulic hoses.
Always ensure a safe working area of 10 meters in case of flying material.
Before operating the GYRU-STAR Screening bucket ensure all guards are
fitted securely and all safety decals are in good order.

Do not use to lift GYRU-STAR Screening bucket or carry persons in the
bucket.
Only use the for its GYRU-STAR Screening bucket intended purpose of
screening, separating and mixing of soils, aggregates and aeration compost.
The operator must wear appropriate PPE (hard hat and safety glasses) when
used with a carrier without a full operators cabin.

4. Copy of Warning Notices
NOTE

5. Lifting and Handling Instructions
WARNING
Shipping
The GYRU-STAR Screening bucket should be securely fastened to a standard
shipping pallet with steel banding and a shrink wrap cover sheet over the
bucket.
Lifting and moving should only be done with a suitable forklift with a lift
capacity capable of handling the combined weight of the bucket and packaging.
General operation
The GYRU-STAR Screening bucket should only be lifted or moved by its
carrier interface bracket securely attached to the carrier.
The GYRU-STAR Screening bucket must be sited on firm and level ground
when it is detached from the carrier.

6. Instillation Instruction
CAUTION
The GYRU-STAR Screening bucket is connected to the carrier by its dedicated
carrier interface bracket.
Quick Couplers
Carry out a visual inspection to ensure all semi-automatic and automatic locking
systems have locked the carrier/bucket interface bracket correctly (see carrier
operator’s manual for correct operation and locking instructions).
Once the GYRU-STAR Screening bucket is connected to the carrier by its
dedicated carrier interface bracket, lower the GYRU-STAR Screening bucket
on to a suitable flat level site.
Stop the carrier and ensuring all hydraulic pressure in auxiliary circuit is
released (see carrier operator’s manual for instructions) before making the
hydraulic connections.
Hydraulic Connections
Connect the bucket hydraulic supply and return hose quick coupler to the
carrier’s auxiliary supply and return quick couplers (see carrier operators
manual for instructions).
Oil Flow
Connect oil supply and return hoses to the GYRU-STAR Screening bucket as
the decal indicates
Optional hydraulic Control Valves
The GYRU-STAR Screening bucket is designed to operate within fixed oil flow
and pressure parameters for each model with an open tank line for the return oil.
Ensure the appropriate optional hydraulic valve is fitted if the installation is
outside of the required parameters.

7. Operating Instructions
NOTE
The GYRU-STAR Screening bucket is designed as a re-handling bucket only
for the screening, aeration and mixing of Non Hazardous pre dug material (not
to be used as primary digging bucket or used in contaminated areas).
The material to be screened is loaded in to the GYRU-STAR Screening bucket
in the same manner as the standard excavator or wheeled loader bucket. Once
the bucket has been loaded with material to be screened and positioned the
excavator or wheeled loaders auxiliary hydraulic circuit is activated causing the
star rotors to turn in upwards direction.
Do not over fill the bucket as this will reduce the performance of the screening
process.

The GYRU-STAR Screening bucket efficient screening process is created by
the star rotors rotating the pre screened material in the bucket, agitating the pre
screened material allowing fines to flow through the rotating stars leaving the
oversize material in the bucket.
Once the screening process is completed the oversize material is tipped out and
the process is repeated.

8. Maintenance
NOTE
SERVICING DESCRIBED IN THIS MANUAL IS ONLY TO BE PERFORMED BY A
QUALIFIED PERSON.
Daily Maintenance
Carry out visual inspection ensuring excavator or wheeled loader fixing pins
and fixing pin securing devices are fitted correctly (check carries operators hand
book for more information).
Inspect hydraulic hoses for damage and leaks. Replace the hoses if they are
damaged or leaking.
Remove any material wrapped around the flexi-star rotor shafts.
Periodic or Monthly Maintenance
Check the flexi-star rotor bearings for wear and replace if necessary.
Check rotors for damaged flexi stars and replace flexi stars if necessary.
NOTE
Long Term Storage
Power-wash the GYRU-STAR Screening bucket carefully, avoiding prolonged
high pressure water around the flexi-star rotor bearings.
Ensure hydraulic lines are suitably plugged.
Apply a suitable anticorrosion product to all bright metal surfaces.

9. Maintenance Instructions
WARNING
General Information
Before commencing any repairs or servicing ensure the GYRU-STAR
Screening bucket is sited on firm and level ground if it’s detached from the
excavator or wheeled loader.
If attached to the excavator or wheeled loader ensure the GYRU-STAR
Screening bucket is both lowered to the ground and sitting flat on its base,
ensuring that the excavator or wheeled loader has been suitably isolated to
prevent unexpected operation.
Hydraulic system
Ensure all hydraulic pressure has decayed before carrying out any repair or
maintenance. Follow procedures in the carries operators hand book, if unsure
contact the carrier’s technical centre.
Ensure hydraulic oil temperature has decayed sufficiently before carrying out
any repair or maintenance.
Hydraulic oil
Avoid skin contact where ever possible, wash exposed skin with a suitable
detergent and water and always use correct protective equipment when handling
mineral oils.
Clean up any spills immediately with a suitable absorbent material and dispose
of correctly to prevent damage to the environment.
Consult oil suppliers Date Sheet for more detailed information
CAUTION
Welding
Connect the earth clip as close to the weld as possible, making sure that the
welding current doesn’t travel through the flexi-star bearings or hydraulic
motor.
If attached to the excavator or wheeled loader check the manufactures hand
book for welding procedure to prevent damage to PLC units.

NOTE
Flexi-star Replacement
Before commencing flexi-star replacement, ensure the above safety measures
are in place;
Remove both drive line covers and remove carbon chain belt and drive wheel by
releasing the carbon chain belt adjuster of the rotor that requires the flexi-star
replacing.
Support flexi-star rotor and remove both rotor support bearing fixings, with the
rotor supported pull both stub shaft assemblies complete with bearings out from
the rotor shaft.
Slide the flexi-star discs from square section shaft observing the stagger pattern.
To re- assemble repeat the above instructions in reverse.
General Arrangement

10. Fault Flow Chart
Rotors Do Not Rotate
QRC couplings fitted
correctly
Rotor do not rotate when carrier
hydraulic circuit is activated
YES
Connect, repair or replace QRC
coupling
YES
NO
Screen bucket over
loaded with
compacted material
Is the Carrier
hydraulic circuit
being loaded?
See fault finding flow diagram 10.2
NO
NO
Contact you Gyru-star
dealer/distributor for more assistance

YES
Rotors Do Not Rotate 10.2
Motor to shaft
coupling defective
Rotors do not rotate when carrier
hydraulic circuit is activated
Replace coupling, Contact
Gyru-star dealer/distributor for
more assistance
YES
NO
Hydraulic motor
defective
Top rotor rotates
See fault finding flow diagram
10.3
NO
YES
Replace HYD motor, Contact
Gyru-star dealer/distributor for
more assistance
Contact Gyru-star
dealer/distributor for more
assistance

YES
Rotors Do Not Rotate 10.3
Carbon belt
Slipping
Top rotor rotates Top rotor rotates
one or more does not rotate
check Rosta belt adjuster unit.
Contact Gyru-star
dealer/distributor for more
assistance
YES
NO
Rotor stub shaft
failed
Carbon belt broken
Replace damage or broken
carbon belt, Contact Gyru-star
dealer/distributor for more
assistance
NO
YES
Replace damage or brocket
stub shaft, Contact Gyru-star
dealer/distributor for more
assistance
Contact Gyru-star
dealer/distributor for more
assistance

11. Parts List
Article No
Part No
Description
1-01
GY101-060
2 Rotor Left Side Cover Plate
GY101-062
3 Rotor Left Side Cover Plate
GY101-064
4 Rotor Left Side Cover Plate
1-02
GY101-061
2 Rotor Right Side Cover Plate
GY101-063
3 Rotor Right Side Cover Plate
GY101-065
4 Rotor Right Side Cover Plate
1-03
GY100-062
M6 Socket Countersunk Screw
1-04
GY100-063
M6 Nut Insert

Article No
Part No
Description
2-01
GY200-012
Belt Pulley 2-50
GY200-011
Belt Pulley 3-80
GY200-010
Belt Pulley 3-120, 4-100, 4-120
2-02
GY200-015
Taper Lock
2-03
GY200-022
Carbon Belt 2-50
GY200-021
Carbon Belt 3-80
GY200-020
Carbon Belt 3-120, 4-100, 4-120
2-04
GY200-030
Bearing
2-05
GY200-031
Stub Shaft 3-120, 4-100, 4-120
GY200-032
Stub Shaft 2-50, 3-80
GY200-033
Short Stub Shaft
2-06
GY200-050
Rosta Belt Adjuster
2-07
GY200-040
Bearing Support Plate
2-08
GY200-051
Belt Adjuster Plate
2-09
GY100-069
M8 x 20 Socket Countersunk Screw
2-10
GY100-067
M8 Flange Nut
2-11
GY100-068
M8 x 16 Socket Cap Screw
2-12
GY100-070
M8 x 25 Socket Countersunk Screw
2-13
GY200-049
Key 8mm x 8mm