SASFORKS EXTREME User manual

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page © 2014-2019 S.A.S. of Luxemburg, LLC.
EXTREME™
Auto Processor
Excavator Attachment
==================
Manual v13
USA Patents: D672,369 ; D704,752 ; D740,861, 9,211,832 ; D747,170 ; 8,414,704 ; D779,564; D779,565,
9,414,704 & Other Patents Pending

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 2 © 2014-2019 S.A.S. of Luxemburg, LLC.
SERIAL NUMBER LOCATIONS (PAGE 2)
SAS™ EXTREME™ AUTO PROCESSOR
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA
Phone: [phone] 1-877-SAS-FORK Fax: [phone] Web: www.sasforks.com
Local Distributor or Supplier Name ____________________ Phone ___________________
Locate serial numbers and model numbers on SAS EXTREME Auto Processor Attachment..
Note below for easy reference. Providing this information when contacting your local Distrib-
utor, Supplier, Service Representative, or SAS will improve accuracy and level of service.
SAS EXTREME ………………….ddddddddddddddddd……..SAS EXTREME:
Head Assembly.......................................................................Rotator Only:
Model………...______________ sdddddds s s .Model:………..____________
Serial Number ______________ s s s s s s s ddddd.s s ..Serial Number __________
SAS EXTREME Hold Down Arm Assembly...……...Model…………______________
SAS EXTREME Hold Down Arm Assembly...……...Serial Number ______________
PATENTED JAWS
& patents pending
PATENTED
hold down arm
PATENTED
WIRE STRIPPER

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 3 © 2014-2019 S.A.S. of Luxemburg, LLC.
TABLE OF CONTENTS (PAGE 3)
SAS™ EXTREME™ AUTO PROCESSOR
Serial Number Location Reference……………………………………………. Page 2
Limited intended use of this equipment……………………………………….. Page 3
Introduction Letter……………………………………………………………….. Page 4
General Safety Guidelines……………………………………………………... Page 5 - 7
Specific Notices CE …………………………………….. Page 7
Emergency STOP Function……………………………. Page 7
Safety Labels ……………………………………...……. Page 8
Installation Guidelines…………………………………………………………… Page 9 - 14
Optional Hold Down Hinge & Hydraulics Parts List Page 12 –13
Pressure & Flow Settings Required……………………. Page 14
Maintenance: …….. Torque intervals …………………………………………. Page 15
Grease grapple ………………………………………….. Page 16
Grease rotator ………………...…………………………. Page 17
Accumulator………………………………………………. Page 18
Pre-operation: …….Checklist guide ……………………………………………. Page 19
Daily checklist………..………….………………………… Page 20
Determining Lift Capacity………………………………… Page 21-22
Operation Guidelines …………………………………………………………….. Page 23
EX-25 & EX-35 SAS EXTREME Replaceable Claw Tips…………………….. Page 24
EX-25 v3 SAS EXTREME Parts Diagram (Serial Number SAS F5343 & Higher) Page 25
EX-25 v2 SAS EXTREME Parts Diagram (Serial Number SAS F4775-F5330) Page 26
EX-25 v1 SAS EXTREME Parts Diagram (Serial Number SAS F4627 only) Page 27
EX-25 v2 & V3 Rotator RLP-902 Parts (Serial Number SAS F4989-F5687) Page 28 - 37
EX-25 v1 Rotator RD20A500BA2 (Serial Number SAS F4968 & Lower) Page 38 - 39
EX-35 v2 SAS EXTREME Parts Diagram (Serial Number SAS F5453-F5720) Page 40
EX-35 v1 SAS EXTREME Parts Diagram (Serial Number SAS F5188 only) Page 41
EX-35 Lg Rotator RGP-1302 Parts (S/N: F5188, F5453, F5545, F5685, F5720) Page 42 - 54
Wire Stripper……………………………………………………………………….. Page 55
Optional Electronics Parts Guide ……………………………………………….. Page 56 - 58
Limited warranty…………………………………………………………………… Page 59
CE Declaration of Conformity…………………………………………………… Page 60
LIMITED INTENDED USE OF THIS EQUIPMENT:
SAS EXTREME™ Auto Processor excavator attachment is designed break recyclable scrap materials from
end of life cars and trucks. Materials removed from cars and trucks will be damaged. Some excavators may
require modification to pressures, valves, cylinders, reinforcement of x-frame, or other modifications for installa-
tion and to operate in a desirable manner. This attachment is considered a non-OEM attachment and has not
been approved by any specific excavator manufacturer. Customer is responsible to read the excavator’s manu-
al and warranty documents, if any, and identify any impact installation and use of this attachment may have on
the excavator’s warranty. Read this manual completely before installation or use.
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA
Phone: [phone] 1-877-SAS-FORK Fax: [phone] Web: www.sasforks.com

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 4 © 2014-2019 S.A.S. of Luxemburg, LLC.
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA
Phone: [phone] 1-877-SAS-FORK Fax: [phone] Web: www.sasforks.com
INTRODUCTION LETTER (PAGE 4)
SAS™ EXTREME™ AUTO PROCESSOR
TO THE OWNERS, MANAGERS, AND OPERATORS OF EXCAVATORS
EQUIPPED WITH SAS™ EXTREME™ AUTO PROCESSOR
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:
The 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
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
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 you encounter additional information that would be helpful to us, or others, please contact us.
Thank you for your business,
SAS Ltd. Phone: Email:
S.A.S. OF LUXEMBURG, LLC. U.S.A. Dial: 920-845-2198 [email protected]
133 Center Dr Hwy 54 · PO Box 260 International: 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, LLC. to
Buyer are to remain the property of S.A.S. of Luxemburg, LLC., and Buyer shall honor all proprietary legends.
Notice: The SAS FORKS™, this operator manual, www.sasforks.com web site, the pictures, content, designs,
forks, and likeness of such, are property of S.A.S. of Luxemburg, LLC. and are protected under all applicable
Copyright, Trade Mark, Trade Dress, Patents and/or Pending Patent.
USA Patents: D672,369 ;D704,752 ; D740,861; D779,564; 9,815,128; D779,565; 9,211,832; 9,414,704; D747,170
No information, pictures, designs, products, features, or forks may be duplicated in part, entirety, or in likeness.

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 5 © 2014-2019 S.A.S. of Luxemburg, LLC.
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA
Phone: [phone] 1-877-SAS-FORK Fax: [phone] Web: www.sasforks.com
Serious bodily injury, death and property damage can caused by an operator that is
under the influence of drugs or alcohol (of any type, illegal, prescribed or over the
counter) due to impaired operator judgment. Do not operate when impaired.
Consult your physician before operation of this equipment while on medication.
Inspect the device and perform all preventative maintenance before operation at the
start of every work shift. Failure to perform inspections or proper maintenance can
result in equipment failure resulting in serious injury or property damage.
This equipment has numerous moving components. Operate only from the cab
equipped with safety glass windshield and adequate protective steel guard while
seated and wearing a safety belt. Be aware of potential pinch points and keep clear
during operation, inspection and maintenance. Pinch points exist between grapple
attachment jaws, cab swing, hold down arms and others, failure to keep clear while
in operation can result in serious injury or death.
Do not exceed posted weight limits on equipment. Exceeding rated load limits will re-
sult in equipment damage, loss of steering control, machine tip over, serious injury or
death.
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 substances to avoid risk of ignition. Operating in an explosive environ-
ment may cause an explosion and fire, resulting in injury, death, property damage.
Operation of equipment by un-qualified or un-trained individuals can result in seri-
ous injury or death. All operators must be properly trained prior to operation.
Installation & operation of equipment should only be performed by qualified and trained individuals. All per-
sons operating or working in the area of operation should read this manual. A copy of this manual should
be kept with the equipment. A qualified operator will operate the machine safely in accordance with, and:
 Understand the written instructions supplied by the manufacturer of the device, the manufacturer of
the excavator, all company rules and any applicable OSHA or regulatory governing body regulations.
 Completed training including actual operation of the device and excavator to which it is attached.
 Know and follow the safety rules and regulations of the jobsite.
GENERAL SAFETY GUIDELINES (PAGE 5)
SAS™ EXTREME™ AUTO PROCESSOR
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 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 and cause injection into skin. Wear safety glasses and appropriate gloves
while inspecting, operating and maintaining this equipment.

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 6 © 2014-2019 S.A.S. of Luxemburg, LLC.
PROTECTIVE EQUIPMENT
 Safety glasses with side shields ● Leather gloves
 Work boots with heavy sole and safety toes ● Hard hat
 Fire extinguishing equipment ● Adequate spill kit, oil dry etc.
 Other such safety equipment to protect personnel from injury.
Puncture or cut injuries may occur if contact made with sharp objects. Sharp
objects are present from breaking materials out of scrap cars. Avoid contact.
Do not work under grapple claws, hold down, or any object lifted by this equip-
ment. An unexpected movement, shift in the object, or hydraulic failure may
cause claw, hold down, or object drop. Serious injury or death may occur.
PERSONNEL TRAINING
Prior to installation or use of this equipment all personnel must review this operator
manual, excavator manufacturer’s manual and other pertinent safety manuals and be
trained by qualified personnel. All hazards must be identified to ensure personnel
avoid these hazards. Signed documentation certifying individual training has been
completed is a must. Periodic retraining is recommended. Failure to follow Manufac-
turers recommendations can result in serious injury and property damage.
SITE PREPARATION & CLEAR OPERATING SPACE RECOMMENDED
 The Extreme™ Auto Processor should only be used in areas that are equipped
with proper fluid containment measures, to ensure capture and containment of
residual fluids in accordance with any and all environmental regulating body.
 Operation area must be sufficiently clear of buildings and overhead power lines.
 No Smoking, Safety Glasses & Hard Hat Required signage is recommended.
 Provide adequate space around this equipment to ensure all persons are kept at
least 15 Meters (50 feet) away from the equipment and cars being moving by it.
VEHICLE PREPARATION PRIOR TO USING THE EXTREME™ AUTO PROCESSOR
 Prior to use of this attachment, remove all batteries, gasoline, diesel fuel, all
types of fuels, mercury switches, air conditioning Freon, engine oil, transmission
fluid, antifreeze and other fluids.
 Engines, transmissions, and other components will be damaged, and only be
suitable for metals recycling, not as cores or resalable operable parts.
Vehicles contain several hazardous elements that pose explosion and fire haz-
ards, such as gasoline and electric batteries containing battery acid. Be sure
these are safely removed prior to using the EXTREME™ Auto Processor.
Failure to remove may result in explosion, fire hazard & injuries.
Keep adequate fire suppression equipment accessible and persons trained on
operation.
GENERAL SAFETY GUIDELINES (PAGE 6)
SAS™ EXTREME™ AUTO PROCESSOR
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA
Phone: [phone] 1-877-SAS-FORK Fax: [phone] Web: www.sasforks.com

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 7 © 2014-2019 S.A.S. of Luxemburg, LLC.
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA
Phone: [phone] 1-877-SAS-FORK Fax: [phone] Web: www.sasforks.com
CE SPECIFIC NOTICES (PAGE 7)
SAS™ EXTREME™ AUTO PROCESSOR
EMERGENCY STOP FUNCTION
To immediately stop the motion of this equipment:
1. Operator is to release all joystick button(s).
Additional secondary measures to immediately stop the motion include:
2. Moving excavator’s auxiliary hydraulic 3rd spool lever to neutral position
3. Turn off ignition key of excavator to shut off engine
All three emergency stop options stop flow of hydraulic fluid. See excavator manufac-
turer’s operator manual to identify proper controls & functions prior to use.
Even after emergency stop function is followed, there is residual stored hy-
draulic 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 dis-
charge at great velocity and cause injection into skin. Wear safety glasses and appro-
priate gloves while inspecting, operating and maintaining equipment.
STAY CLEAR
 Do not lift persons with this equipment. Not intended to lift people
 Always maintain a safe distance away from this equipment.
 Do not go near or under this equipment or any object lifted by this
equipment. Failure to stay clear will result in injury or death.
 Refer to and follow all additional safety information in excavator
manufacturer’s operator, safety and service manuals.
POWER FAILURE
In the event of electrical or hydraulic supply failure from the excavator 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. See excavator manufacturer’s operator
manual to identify actual operation during power failure mode prior to use.
SOUND
This equipment does not emit more than 70dba.
VIBRATIONS
This equipment does not transfer vibrations in excess of 2.5m/s2.
OPERATING TEMPERATURE
Equipment is best suited to operate in temperatures 0°C to 32°C (32°F to 90°F )
with minimum temperature –30°C (–23°F) and maximum temperature 65°C (150°F)

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 8 © 2014-2019 S.A.S. of Luxemburg, LLC.
SAFETY LABELING (PAGE 8)
SAS™ EXTREME™ AUTO PROCESSOR
LABEL 2 (BOTH COVERS)
SAS PATENTED JAWS
& patented tips
SERIAL NUMBER LOCATIONS
-Stamped in steel
Serial Number Format SAS F####
LABELS 3,4,5
Label Description Quantity Label reorder #
LABEL 1: PRODUCT ID PLATE 1ID PLATE CE-EX
LABEL 2: KEEP BACK 15 METERS (50 FT) 2W-LAB-STAYBACK50FT
LABEL 3: KEEP AWAY MOVING PARTS 1W-LAB-WARNING-PINCH
LABEL 4: READ EQUIPMENT MANUALS 1W-LAB-READ-504060
LABEL 5: HIGH PRESSURE HYDRAULICS1 1W-LAB-PRES-503600
LABEL 6: STABILITY LABEL FOR CAB 1W-LAB-EX-STABLE-1
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA
Phone: [phone] 1-877-SAS-FORK Fax: [phone] Web: www.sasforks.com
LABEL 1

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 9 © 2014-2019 S.A.S. of Luxemburg, LLC.
INSTALLATION: PREPARATION (PAGE 9)
SAS™ EXTREME™ AUTO PROCESSOR
COMPONENT IDENTIFICATION
ADVANCE PREPARATION BEFORE ARRIVAL & INSTALLATION OF EXTREME AUTO PROCESSOR
 Review this operator manual. Review operator, safety & service manuals of excavator manufacturer.
Items you need to obtain before arrival of Extreme™ Auto Processor:
 Excavator must have two bi-directional auxiliary hydraulics at the end of the stick with cab controls.
 Excavator must have one filtered free flow drain line back to tank
 Hydraulic fluid (specific for your machine). Identify fluid check and fill points.
 Identify and obtain needed hydraulic hose quick connections on your machine and fitting required.
 Locate supplier to make hydraulic hoses (Minimum recommend 19 mm (3/4”) diameter, 34 Mpa
(5,000 PSI) hoses and fittings once proper length is determined during installation.
Tools your mechanic may need for installation:
 Sockets, wrenches, large adjustable wrench, large rubber hammer, hydraulic bottle jack, grease gun
Service to do on your excavator in advance:
 Have maintenance personnel replace hydraulic system filters & fluids (as needed)
 Pressure and flow test. Have pressure results available. Set pressures between
24-31 Mpa, 240-310 Bar (3,500-4,500 PSI). Not to exceed 31 Mpa, 310 Bar (4,500 PSI)
 Inspect pins & bushings in arm and dozer blade for wear (replace as needed)
 SAS has no responsibility as to performance of excavator’s hydraulic system with this attachment.
Available for training:
 Designate an area (i.e. where it is safe to run equipment) and an employee to operate unit
 Designate operator who can read and speak English, if SAS staff onsite to assist your mechanic.
Installation Hazards (Additional details covered elsewhere in this manual):
Pinch & crush points, High pressure hydraulics, Stored pressure, Skin injection risk
Installing this Extreme Head & Hold Down Assembly will change lifting dy-
namics & likely reduce lift capacity and reduce stability of the excavator.
Installer and operator must use caution in establishing reasonable lift capacities. Consider Head &
HDA attachment weights and excavator manufacturer’s manual guidance. These hazards may cause
equipment damage, injury or death. Only qualified persons should complete installation.
HYDRAULIC
ROTATOR
ASSEMBLY
CLAWS HOLD DOWN
ASSEMBLY
“HDA”
WIRE
STRIPPER
INSTALLATION
LIFT EYELETS
HEAD
ASSEMBLY
“HEAD”
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA
Phone: [phone] 1-877-SAS-FORK Fax: [phone] Web: www.sasforks.com
PATENTED JAWS & tips

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 10 © 2014-2019 S.A.S. of Luxemburg, LLC.
High pressure hydraulics. Stay clear of pinch points to avoid serious injury. Relieve pressure prior to work.
Follow safety precautions in SAS EXTREME Auto Processor Manual prior to work. www.sasforks.com/safety
Welding can damage excavator electronics.
Read excavator manufacturer’s manual before welding.
Intent is to extend the force back further on x-frame where there is internal support to dissipate the loading forces.
Reference: 1 - OEM hinge base plate existing 5 - NEW lower base plate expansion (two)
2 - NEW hinge base plate expansion (two) 6 - NEW lower load rib extension (four)
3 - NEW inner vertical load rib extension (two) 7 - NEW mid hinge frame tie in plate (one)
4 - NEW outer vertical load rib extension (two)
Upper view Lower view
3 4
1 2
5 6 7
47
3
2
1
5
6
INSTALLATION: PREPARATION (PAGE 10)
EXCAVATOR FRAME REINFORCEMENT
POTENTIAL X-FRAME REINFORCEMENTS TO CONSIDER:
Excavator OEM x-frame brackets which mount OEM dozer blade may not provide sufficient distribution of
loads from SAS Extreme Hold Down Arm attachment & may result in x-frame & bracket structural failure.
●Careful consideration of this information will reduce the likelihood of x-frame & x-frame bracket failure.
●Operational advice: Minimize the amount of down force applied when restraining the car, specifically,
avoid pushing down to the extent that the front of the excavator is lifted and suspended.
●This document is not authorization to modify excavator x-frame, it is intended to provide a guide for con-
sideration of reinforcements for Customer, OEM, OEM authorized equipment tech., & professional welder.
NOTICE: Any reinforcement work may cause Excavator OEM warranty, if any, to be void.
●Any reinforcement/modification of x-frame may cause other unintended cracking or damage. SAS is not responsible
for reinforcement installation or performance, or resulting issues, if any.
SAS Limited Warranty applies only to SAS manufactured components, not excavator, x-frame or x-frame brackets.

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 11 © 2014-2019 S.A.S. of Luxemburg, LLC.
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA
Phone: [phone] 1-877-SAS-FORK Fax: [phone] Web: www.sasforks.com
INSTALLATION: HOLD-DOWN ASSEMBLY (PAGE 11)
SAS™ EXTREME™ AUTO PROCESSOR
GROUND
INSTALLATION OF SAS™ EXTREME™ AUTO PROCESSOR HOLD DOWN ASSEMBLY (HDA):
INSTALLATION SHOULD BE COMPLETED BY AN EXPERIENCED HEAVY EQUIPMENT MECHANIC
AFTER INSTALLATION, PRIOR TO OPERATION
1. Grease all pivot points with Stick and HDA resting on the ground and machine engine off.
2. Stay clear of pinch points. Slowly engage controls. Watch for interference. Stop if interference occurs.
a) Test up and down motions of HDA. Due to differences in machines and cylinder control valves, if
down cycle is not smooth, a jerking condition may occur.
Typically this can be rectified by installing simple flow control
valves on the hydraulic lines which feed the extend side of the
dozer cylinders. (Indicated by arrows). (see Hold Down Parts list
on separate page). Two flow control valves are included in parts
kit with Qty 2, SAS Part No. HV-FLW-D-EF30S : Thread #8 NPT
Install flow control valves with fittings between car body frame
hose connection and hydraulic hose. Turn settings to near zero.
Test motion. Slightly open valves uniform amount. Retest. Repeat
until jerking occurs, then turn back to achieve smooth motion.
b) Test rotational clearance with HDA raised incrementally higher. Stay clear of pinch points, overhead
electrical wires, and other structures, slowly and cautiously rotate cab and counter weight visually
checking for interference of lower cab and counter weight with HDA lifted at highest level.
Stop if interference occurs.
1. Remove existing dozer blade. Inspect pins and bushings. Replace as needed.
2. Hold Down Assembly (HDA) weight approximately 1,600 kg ( 3,500 LB ).
Eyelets in center of HDA is balance point. If excavator is sufficiently rated to
lift such, align stick with lifting eyelets. Using safe and adequately rated rig-
ging chains, keeping all persons clear, lift HDA off pallet. Move away from
shipping pallet and place on ground with block in place which will allow upper
surface of HDA to be level.
3. HDA should be set level as shown below for staging. Drive excavator up to
HDA and align lower pivot holes in dozer blade mount on excavator with holes
“A” in HDA. Insert and secure pivot pins into assembly.
4. With pivot pins inserted and secure, slowly extend dozer blade hydraulic cylin-
ders to align holes in rod end of cylinder to lift holes “B” in HDA. Keep clear of
pinch points. Insert and secure pivot pins into assembly.
5. Replace any guarding that may have been removed during the removal of the
dozer blade assembly.
SAS has no responsibility as to performance of excavator’s Hydraulic system or
structural adequacy or durability with this attachment.
block

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INSTALLATION: HINGE & HYDRAULICS (PAGE 12)
SAS™ EXTREME™ AUTO PROCESSOR
DESCRIPTION QTY PART NUMBER
[ I ]Cylinder for SAS Hinge & Hold Down 2HY-CYL-5.0X11.25-5K
This cylinder is not for use with excavator which had existing dozer blade. Call excavator manufacturer.
I.1 Cylinder seal rebuild kit 2HK-5.00-783-244
I.2 Cylinder pin bushing 4W-B2.500X3.000X2.000
I.3 Cylinder pin grease seal 4W-WIPER-2.5X3.0
I.4 Hinge (weldment) 10-EX-HGN- (Custom # per machine)
Read warnings on “Excavator Frame Reinforcement’ page & separate instructions provided with hinge.
I.5 Id plate 1ID-PLATE-CE-EX (Specify serial no.)
I.6 Hold down arm (weldment)……………… 10-EX-HD- (Custom # per machine)
[J] Pin (cylinder to hold down:rod end) 21903-202VOL220-5112
J.1 Bolt (for cyl rod end pin) 2WBOLT 0.375X425 GR8
J.2 Nut (for cyl rod end bolt)………………… 2WNUT 0.375-16-GR8-NY
[K] Pin (cylinder to hinge: base end) 21904-006VOL220-5112A
K.1 Bolt (cylinder base pin) 2 WBOLT 0.625X1.50 GR8
K.2 Pin lock spacer (cylinder base pin)……..2SPACER-0625-0000
K.3 Flat Washer (cylinder base pin)…………2 WASHER-F 0.625 GR8
[L] Pin (hold down to hinge: lower pivot) 21315TILT-3454 ASY
L.1 Bolt (lower pivot pin) 2WBOLT 0.625X1.50 GR8
L.2 Pin lock spacer (lower pivot pin)………...2SPACER-0625-0000
L.3 Flat Washer (lower pivot pin) 2WASHER-F 0.625 GR8
[M] HYDRAULICS
These parts are not for use with excavator which had existing dozer blade. Call excavator manufacturer.
M.1 Flow valves (thread #8 NPT)…… 2HV-FLW-D-EF30S
If jerking occurs during lowering Hold Down Arm (HDA), install flow valves on hydraulic lines
which feed extend side of both cylinders, adjust equally reduce flow to eliminate or reduce this issue.
M.2 Counter balance block (empty block) 2HV-BLK-S-YEJ-S
M.3 Counter balance valve (valves for block)4HV-CB-S-CBPA20MNS050
After cycling the Hold Down Arm a number of times to eliminate air in lines, if Hold Down Arm does
not hold it’s positioning, install counter balance valve block with valves in line before each cylinder.
M.4 Pilot valve……………………..… 1HV-BLK-F-DS70HP-1
See following page for additional information.
OPTIONAL: SAS SUPPLIED HINGE, HYDRAULIC DIVERTER BLOCK & CYLINDERS:
INSTALLATION SHOULD BE COMPLETED BY AN EXPERIENCED HEAVY EQUIPMENT MECHANIC
(Hoses are not included)
I, I.1, I.2, I.3
I.4
I.6
I.5
J, J.1, J.2
J, J.1, J.2
K, K.1,K.2, K.3
L, L.1, L.2, L.3

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 13 © 2014-2019 S.A.S. of Luxemburg, LLC.
DESCRIPTION QTY PART NUMBER
M.4 Pilot Operated Selector Valve Block [‘Valve’]……………….. 1HV-BLK-F-DS70HP-1
Locate ‘Valve’ for installation within protected area inside the x-frame belly.
Purpose: Divert fluid from right track to hydraulics to SAS Extreme hold down cylinders.
●Ports A & B are input Into ‘Valve’ which are pulled downstream of swivel/collector underneath the excavator that
would originally route to one drive motors for one of the tracks, SAS has always used the ‘right’ track hydraulics.
●Ports E & F are then routed to drive motor for right track in standard position.
●The high speed pilot line that originally runs to each the left and the right track drive motors is disconnected from
the motors and now only is routed to the pilot port on this ‘Valve’. This pilot line is typically the smaller of the two
small lines that run through the swivel/collector. This enables the 2nd position of the ‘Valve’ to function when the
‘high speed’ function is actuated in the cab of the excavator.
●With this pilot line pressurized, the ports C & D are now live and will be routed to the cylinders to position the hold
down up and down.
●’Drain line’ is final port on ‘Valve’, this will be need to be teed into existing drain line that runs from each track
drive motor and back up through the swivel. This line is typically larger of two ‘small’ lines running through swivel/
collector.
S.A.S. of Luxemburg, LLC. Phone: 920-845-2307 1-877-SAS-FORK Web: www.sasforks.com
INSTALLATION: HINGE & HYDRAULICS (PAGE 13)
SAS™ EXTREME™ AUTO PROCESSOR
OPTIONAL: SAS SUPPLIED HINGE, HYDRAULIC DIVERTER BLOCK & CYLINDERS:
INSTALLATION SHOULD BE COMPLETED BY AN EXPERIENCED HEAVY EQUIPMENT MECHANIC
(Installation may impact or void machine OEM warranty, if any)
(Hoses are not included)
Hydraulic Schematic

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 14 © 2014-2019 S.A.S. of Luxemburg, LLC.
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA
Phone: [phone] 1-877-SAS-FORK Fax: [phone] Web: www.sasforks.com
INSTALLATION OF SAS™ EXTREME™ AUTO PROCESSOR HEAD ASSEMBLY:
INSTALLATION SHOULD BE COMPLETED BY AN EXPERIENCED HEAVY EQUIPMENT MECHANIC
1. Remove existing bucket and inspect pins and bushings.
Replace as needed.
2. Line up palletized head assembly with machine as
shown in image (i).
Note: Head weight approximately:
Model EX-25, standard: 1,400 kg ( 3,000 lb )
Model EX-35, large: 2,064 kg ( 4,550 lb )
3. Lower stick of excavator down to line up with hole at top of
assembly and insert and secure pin “A” into head assembly.
4. With pin “A” secure in head assembly, lift assembly so that
only the tips of the head assembly are resting on pallet as
shown in image (ii). Align curl linkage to other hole in head
Assembly mount. Insert and secure pin “B” into head assembly.
5. Connect hydraulic hoses 34 Mpa, 344 Bar (5,000 psi)
Jaw (Grapple) & Rotator minimum hose dia. 19 mm (3/4”).
Motor drain (case drain) free flow hydraulic return 12.5mm (1/2”)
SAS has no responsibility as to performance of
excavator’s hydraulic system with this attachment.
Connection jaws ( Fittings: 12 ORFS )
Maximum Pressure
31 MPa, 310 Bar (4,500 psi)
Maximum Flow
130 L/min (35 gpm)
Connection rotator ( Fittings: 12 ORFS )
Maximum Pressure
31 MPa, 310 Bar (4,500 psi)
Model EX-25 (Rotator RLP-902)
Maximum Flow 45 L/min (12 gpm)
Model EX-35 (Rotator RGP-1302)
Maximum Flow 125 L/min (33 gpm)
Connection drain ( Fittings: 10 ORFS )
“D” Drain line must be connected to
the drain line filter on the carrier.
INSTALLATION: HEAD (PAGE 14)
SAS™ EXTREME™ AUTO PROCESSOR
A
B
AFTER INSTALLATION PRIOR TO OPERATION
1. Grease all pivot points with Head and Hold Down resting on ground and machine engine off.
2. Read excavator manufacturer’s manual to identify control levers operation, method to stop mo-
tions, safety parameters related to operation of the excavator with any specialized attachment.
3. Stay clear of pinch points. Slowly engaging controls, test all motions of Head Assembly.
Watch for interference points and stop further motion if interference occurs.
(i)
(ii)

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 15 © 2014-2019 S.A.S. of Luxemburg, LLC.
PREVENTIVE MAINTENANCE (PAGE 15)
SAS™ EXTREME™ TORQUE INTERVALS
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA
Phone: [phone] 1-877-SAS-FORK Fax: [phone] Web: www.sasforks.com
Set attachments on ground, turn off excavator, depressurize hydraulic supply to attachments, stay clear of pinch points during
greasing. Safe & proper daily maintenance will help ensure long term performance and prevent failures. Failure to follow pre-
ventive maintenance guidelines can result in equipment failure resulting in injury or property damage.
√ Bolt
√ C Clip
√ Pin
JAWS, WIRE STRIPPER & HOLD DOWN ARM PATENTED
Re-Torque interval chart: Frequency after first 100 hours of operation & every 500 hours thereafter.
Visual Inspections: Frequency daily, pre-operation inspection (or every 10 operating hours)
√ Bolt
√ Pin
√ Bolt
√ C Clip
√ Pin
√ Bolt
√ C Clip
√ Pin
√ Bolt(s)
√ Pin √ Bolt(s)
√ Pin
√ Bolt(s)
√ Pin
√ Bolt(s)
√ Pin
√ Bolt
√ Pin
√ All Fasteners
Ref. Location Torque Spec Inspection# Bolts Wrench Size 50010 100 Bolt
Item
No.
AStick mount bolts 500 ft-lbs.18 1 - 1/2”
7&10
BStick large hoses 70-78 ft-lb Leaks & condition41 - 3/8”
CStick small hose 50-56 ft-lb Leaks & condition11 - 1/16”
DHydraulic motor 480 ft-lb 3/4”8
EHydraulic motor cover 160 ft-lb2 15/16”6
F.1 Slewing ring 35 160 ft-lb 15/16”5
F.2 Slewing ring 36 160 ft-lb 15/16”50
GSide service covers Hand tighten2 & 2 15/16”9
HCylinder hoses 4 fitgs 46-56 ft-lb 30mm:1-3/16” Leaks & condition
ICylinder service cover 4 & 4 Hand tighten 9/16”
JBolts, clip & pin (head) 5Hand tighten 15/16” Bolts & C clip in place
KClaw tips bolts 10 160 ft-lb 3/8” HEX &
15/16 Socket
LHold down bolts & pins 4Hand tighten 9/16”
Hour Interval
Inside side covers under round yellow cap

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 16 © 2014-2019 S.A.S. of Luxemburg, LLC.
Lubricating the rotating grapple head (For models: SAS EXTREME EX-25 v2 & v3 )
Lubricate the SAS EXTREME Auto Processor rotating grapple head daily. Use this opportunity to closely
inspect the pins and pin retaining hardware and conduct necessary repairs.
Recommended grease
Grease should have excellent water-repulsion durability, antirust capabilities, adhesive abilities and me-
chanical stability.
Grease nipples (zerks) are 1/8” NPT
**operating hours
Lubrication interval chart
Grease nipple
locations
PREVENTIVE MAINTENANCE (PAGE 16)
SAS™ EXTREME™ GREASING
S.A.S. of Luxemburg, LLC. 133 Center Drive Hwy 54, PO Box 260, Luxemburg, WI 54217 USA
Phone: [phone] 1-877-SAS-FORK Fax: [phone] Web: www.sasforks.com
Place grapple on firm level surface, turn off machine & avoid pinch points.
√ Bolt
√ C Clip
√ Pin
JAWS, WIRE STRIPPER & HOLD DOWN ARM PATENTED
Rotator grease points; see next page.
√ Bolt
√ Pin
√ Bolt
√ C Clip
√ Pin
√ Bolt
√ C Clip
√ Pin
√ Bolt(s)
√ Pin √ Bolt(s)
√ Pin
√ Bolt(s)
√ Pin
√ Bolt(s)
√ Pin
√ Bolt
√ Pin
√ All Fasteners
Brand Grapple Pins
Mobil *
(11/4/2016 Per Eric @ Harlon Oil) Centaur Moly EP2 *
Mobil Mobilegrease CM-P
Comparable Comparable
EXTREME head Grapple Pins
Quantity of nipples 5 nipples
Every 10 hours** 4 shots grease
Every 40 hours** 4 shots grease
EXTREME hold down Pivot Pins
Quantity of nipples 4 nipples
Every 10 hours** 2 shots grease
Every 40 hours** 4 shots grease
Grease
Grease

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 17 © 2014-2019 S.A.S. of Luxemburg, LLC.
PREVENTATIVE MAINTENANCE (PAGE 17)
ROTATOR RLP-902 SPECIFIC GREASING
Place grapple on firm level surface, turn off machine & avoid pinch points.
Lubricating the RLP rotator (For models: SAS EXTREME EX-25 v2 & v3 )
Lubricate the RLP rotator after it has been working for several hours because the new grease penetrates
more easily when the old grease is hot. If the working environment contains a high percentage of dirt
and/or humidity, the lubrication period must be shortened.
Recommended grease
This grease can also be used in winter conditions. Avoid mixing different types of grease. Grease should
have excellent water-repulsion durability, antirust capabilities, adhesive abilities and mechanical stability.
Lubrication interval chart
Grease nipple locations
Raceway (2 nipples)
Gear (1 nipple)
Brand Raceway Gear Grapple Pins
Mobil *
(11/4/2016 Per Eric @ Harlon Oil) Centaur Moly EP2 * Centaur Moly EP2 * Centaur Moly EP2 *
Mobil Mobilux EP2 Centaur Moly EP1 Mobilegrease CM-P
Shell Albida EP2 SRS 2000 Extreme EP2 Comparable
Petro-Canada Precision EP2 XCG-Flex EP1 Comparable
Mobil Mobilux EP2 Centaur Moly EP1 Comparable
Exxon Beacon EP2 Ronex Extra Duty Moly EP2 Comparable
Chevron Texaco Multifak EP2 Open Gear 100 NC Comparable
RLP-902 Raceway Gear Grapple Pins
Quantity of nipples 2 nipples 1 nipples 5 nipples
Every 10 hours
operating 0 none 2 shots of grease 2 shots grease
Every 40 hours
operating 4 shots of grease 6 shots of grease 2 shots grease

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 18 © 2014-2019 S.A.S. of Luxemburg, LLC.
PREVENTATIVE MAINTENANCE (PAGE 18)
ROTATOR RLP-902 SPECIFIC ACCUMULATOR
Place grapple on firm level surface, turn off machine & avoid pinch points.
Inspection of Accumulator inside the RLP rotator (For models: SAS EXTREME EX-25 v2 & v3 )
Rotators without case drain line installed require regular accumulator pressure inspection by a profession-
al equipment service technician with a Hydac charging & gauging unit (PN#02068195) or similar device.
Pressure test interval
Perform a pressure check bi-monthly, or at 100 hour intervals. Hour meter and date should be recorded.
Overview accumulator pressure requirement
Accumulator should have 15 PSI. Test at accumulator pressure port, only with proper test kit.
OPTIONAL CASE DRAIN LINE INSTALLATION WILL PROMOTE LONGER LIFE:
From factory the rotator came with an accumulator to relieve pressure. These parts have a life cycle and
can fail. Installing a case drain (free flow return line) can help prevent damage to motor if accumulator
fails. Extreme units with five hoses have already have the case drain installed.
Installation of case drain line will help prevent damage risk due to pressure spikes to hydraulic motor.
High pressure hydraulics. Stay clear of pinch points to avoid serious injury. Relieve pressure prior to work.
Follow safety precautions in SAS EXTREME Auto Processor Manual prior to work. www.sasforks.com/safety
Motor
Accumulator
Tank
Accumulator
Pressure Port
Hose
Case drain free flow return line filtered to tank:
Contact your local equipment dealer for proper installation
Bulkhead:
#10 MORFS x #10 MORFS
Angle fitting:
#10 FORFS x #10 MORFS 45⁰
Reducer:
#10 FORFS x #6 MORFS reducer
Hose: #6 >20 MPa
#6 FORFS straight x #6 FORFS 90⁰ x
450 mm long
T fitting:
#6 FORFS on run x #6 MORFS x #6 MORFS
Interior Reference View:
Bulkhead
bracket
Added hole
Existing holes
or
or

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 19 © 2014-2019 S.A.S. of Luxemburg, LLC.
PRE-OPERATION CHECKLIST (PAGE 19)
SAS™ EXTREME™ AUTO PROCESSOR
READ & FOLLOW SAFETY INFORMATION IN ORIGINAL EXCAVATOR MANUFACTURER’S
OPERATOR, SAFETY AND SERVICE MANUALS. This checklist is limited to pre-operations
inspection focused on Extreme Head and Hold Down Arm assemblies (HDA).
Additional inspection points will be recommended in the excavator manufacturer manuals.
Failure to follow instructions and precautions noted in excavator manufacturer’s
manuals and this manual can result in serious damage to equipment and/or result
in injury or death.
Use caution while inspecting. Be aware of:
Pinch points (and additional risks covered throughout this manual)
High pressure hydraulic fluids or stored energy
Location of other individuals in the work area
Prior to conducting inspection;
Stick and Head assembly must be resting on firm level ground.
Hold Down Assembly (HDA) must be resting on firm level ground.
Excavator must be parked on firm level ground
Excavator engine must be turned ‘off’
EXTREME AUTO PROCESSOR ATTACHMENT INSPECTION POINTS:
Head to stick fastening pins
Check both pins for proper securement.
Check stick mount for cracks
Rotator
Check bolts that fasten the rotator to the stick mounts
Check for leaks or damage on hoses.
Clamp body
Check for damaged pins, pin retention hardware or misaligned pins
 Check clamp body for cracks
Claws & tips
Check claws for cracks
Check claw tip bolts (loose or missing pins and bolts)
Hold Down Assembly (HDA)
Check all pins for properly secured
Check HDA for cracks
Check wire stripper for loose or missing bolts
Excavator x-frame inspection
Look from bottom up & or cracks around hinges
Operator cab
Cab should have Roll Over Protection System
Verify safety glass windshield in place
Verify exterior steel guard is in place over
front windshield to protect operator.
Repair all problems before operation.
Lock out / tag out excavator if defects present.
Repairs must only completed by authorized mechanic.

SAS/op/proc/forks/op manuals/Ex/EXTREME MANUAL v13.pub 2/24/2019 Page 20 © 2014-2019 S.A.S. of Luxemburg, LLC.
DAILY PRE-OPERATION CHECKLIST (PAGE 20)
SAS™ EXTREME™ AUTO PROCESSOR
Set attachments on ground, turn off excavator, depressurize hydraulic supply to attach-
ments, stay clear of pinch points during greasing. Safe & proper daily maintenance will help
ensure long term performance and prevent failures. Failure to follow preventive mainte-
nance guidelines can result in equipment failure resulting in injury or property damage.
JAWS, JAW TIPS, WIRE STRIPPER
& HOLD DOWN ARM PATENTED
Grease
√ Bolt(s)
√ Pin
√ Bolt(s)
√ Pin
√ Bolt(s)
√ Pin
√ Bolt(s)
√ Pin
√ Bolt
√ C Clip
√ Pin
√ Bolt
√ Pin
√ Bolt
√ C Clip
√ Pin
Grease
Grease
√ Bolt
√ Pin
√ All Fasteners
Item √√√√√√√√√√
Stick pin & bolt
Stick pin & bolt
Stick mount bolts
R-Cyl bolt, clip, pin
L-Cyl bolt, clip, pin
Main pivot grease
Main pivot grease
Main pivot pin, bolt
Main pivot pin, bolt
Parallel bar pin,
bolt, clip
R-Claw tip bolts
L-Claw tip bolts
Hold arm bolt, pin
Hold arm bolt, pin
Wire stripper bolts
Date
Machine hours
Inspection by:
√ Bolt
√ C Clip
√ Pin