Sasforks Scorpion User manual

SAS™FORKS

SCORPION™

========20 SERIES=========

ENGINE PULLER

OPERATOR MANUAL

========MANUALv10=========

TABLE OF CONTENTS (PAGE 2)

SAS™ SCORPION™ 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

Letter to Owners, Managers, and Operators.................................................................. Page 3

General Safety Guidelines .…………………………………………........................... Page 4—5

CE Specific Notices & 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

Preventative Maintenance ………………...……………………………………… ..... Page 17

Electronics parts guide ……………………………………………………………….. Page 18

Valve block parts guide………………………………………………………………. Page 20

Moveable parts guide…………………………………………………………………. Page 21

Cylinder & pins parts guide…………………………………………………………… Page 22-23

Framework parts guide ………………………………………………………………. Page 24

Wiring schematic parts ……………………………………………………………….. Page 25

Trouble shooting guide ................................................................................................. Page 26-27

1. Nothing works……………………………………………………………….. Page 28

2. Operates backwards ………………………………………………………… Page 29

3. Lack of power ………………………………………………………………. Page 30

4. Drops engines ……………………………………………………………….. Page 31

5. Transmissions breaking ……………………………………………………... Page 31

6. Moves by itself ……………………………………………………………… Page 32

7. Misaligned claws …………………………………………………………… Page 32

8. Hydraulic connectors won’t come off ……………………………………… Page 33

9. Hydraulic lines pop off ……………………………………………………… Page 33

Important Weld notice................................................................................................... Page 34

Limited warranty ........................................................................................................... Page 35

CE Declaration of Conformity ...................................................................................... Page 36

INTRODUCTION LETTER (PAGE 3)

SAS™ SCORPION™ 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

·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 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, Ltd. and are protected under all applicable Copy-

right, Trade Mark, Trade Dress, and Pending Patent. No information, pictures, designs, or forks may be duplicated

in part, entirety, or in likeness.

TO THE OWNERS, MANAGERS, AND OPERATORS OF LOADERS EQUIPPED

WITH SAS™ SCORPION™ ENGINE PULLER & 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, man-

agement 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 sym-

bols is important. The following is a definition of each symbol you will encounter in this manual

The Caution symbol is intended to draw your attention to important safety infor-

mation, a 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 laid out 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 any 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, LTD. 920-845-2198 [email protected]

133 Center Dr Hwy 54 · PO Box 260

LUXEMBURG, WI 54217 USA

General Safety Guidelines (PAGE 4)

SAS™ SCORPION™ ENGINE PULLER

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.

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 safety procedures for the equipment this

device is attached to. Failure to follow Manufacturers recommendations can result

in serious injury and property damage.

Do not exceed posted weight limits on equipment or loader. Exceeding rated load

limits will result in equipment damage, serious injury or death.

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 pres-

sure has been relieved prior to handling, inspecting or performing maintenance on

this unit. Follow lockout tag out procedures and release all stored energy before ser-

vicing equipment. Failure to release 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.

Operation of equipment should only be performed by qualified and trained individuals. All persons oper-

ating or working in the area of operation should read 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 manufac-

turer 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

 Know and follow all guidelines outlined in this manual.

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 gases,

liquids or other hazards to avoid risk of ignition. Operating this equipment in an ex-

plosive environment may cause an explosion and fire resulting in injury, death, and

substantial property damage.

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

This equipment has numerous moving components. Do not wear loose fitting cloth-

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 mainte-

nance. 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.

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.

PROTECTIVE EQUIPMENT & CLEAR OPERATING SPACE RECOMMENDED

•Safety glasses with side shields, •Leather gloves, •Hard hat

•Fire extinguishing equipment

•Spill kit (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 operating loader and Scorpion Engine Puller.

Do not work under the fork or any object lifted by this equipment.

An unexpected movement, shift in the object, or hydraulic failure may

cause the forks and object drop. Serious injury or death may occur.

PERSONNEL TRAINING & PREPARATION

Prior to installation or use of this equipment all personnel should re-

view the appropriate equipment & safety manuals and be trained by

qualified personnel. Hazards, pinch points, and potential injury risks

should be thoroughly covered to ensure personnel 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 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 local, state,

federal, building or environmental regulating body.

•No smoking, Safety glasses & Hard hat required signage is

recommended.

VEHICLE PREPARATION PRIOR TO USING THE SCORPION™ ENGINE PULLER

•All batteries, mercury switches, air conditioning Freon, engine oil,

transmission fluid, antifreeze and other fluids should be removed.

•Engines, transmissions, and other components will be damaged, and

only be suitable for metals recycling, not as cores or resalable opera-

ble parts.

Vehicles contain several hazardous elements that pose explosion and

fire hazards, 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 explosion, fire hazard & injuries.

General Safety Guidelines (PAGE 5)

SAS™ SCORPION™ 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

General Safety Guidelines (PAGE 6)

SAS™ SCORPION™ 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

CE SPECIFIC NOTICES

EMERGENCY STOP FUNCTION

To immediately stop the motion 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 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. Be certain to wear safety glasses while inspecting, operat-

ing 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” item A through H.

The symbol at the left indicates hydraulic hose coupling quick release self sealing,

which 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

This equipment is best suited to operate in temperatures between 30°F to 90°F

with minimum allowable temperature –25°F and maximum temperature 150°F

General Safety Labeling (PAGE 7)

SAS™ SCORPION™ 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

CE SPECIFIC LABEL LOCATIONS

LABEL 1: KEEP AWAY FROM MOVING PARTS

Label reorder # W-LAB-WARNING-PINCH

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

Label 5

Labels 1,2,3,4

Label 5

Serial Number Locations

-Stamped in aluminum id plate

-Stamped in steel on left side

Serial Number Format SAS F____

INSTALLATION (PAGE 8)

ADVANCE PREPARATION

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

TO HELP YOU GET UP AND RUNNING QUICKER WHEN YOUR SCORPION ARRIVES:

 Review this operator manual.

 Review your wheel loader manufacturer’s manual & warranty document, if any.

Installation of this attachment may void machine manufacturer warranty, if any.

 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)

 Locate area to mount control box or module (recommend dry area, clear of seat and door)

 Misc. nuts, bolts (1/4”) or self tapping bolts

 Identify the hydraulic hose quick connections on your machine & obtain the

 corresponding female ends.

 Locate a local hydraulic hose supplier who can make two 3/4” diameter 4,000 PSI hoses

with heavy duty quick connection fittings same day once proper length is determined

during installation.

Tools your mechanic will need for installation:

Electric Drill & 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:

 Have the maintenance personnel replace the hydraulic system filters & fluid

 (recommend pressure and flow test but not required)

 Inspect lift arm pins & bushings for wear (replace as needed)

Available for training:

 At least 20 vehicles with fluids & AC Freon drained & batteries removed available.

 Designate an area (where it is safe to run the Scorpion) & employee to operate unit

 Your loader operator (person who can have conversation in English) Thank you.

COMPONENT IDENTIFICATION QUESTIONS?

1-920-845-2198 or Email:

[email protected]

BOOM

CARRIAGE

TILT

CLAWS

BLADES

INSTALLATION GUIDELINES (PAGE 9)

SAS™ SCORPION™ 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

Step 1. RELAYS: Find a location to mount relay module [B].

The location should be accessible enough to get into the

box and wires, but out of the way so it will not get dam-

aged. Mount box where it will not be exposed to the

weather.

Needs to be within 5’ of power supply

Step 2. JOYSTICK: Install joystick[C] to third function lever in cab

Remove current knob. Screw on new joystick with

supplied adapter in the bottom of the joystick.

Standard bushing 10mm x 1.25. Drill and tap bushing as

needed if your thread requirements differ.

Route wires to control box, avoid rubbing points.

Connect to proper connection on side of control box.

Step 3. POWER CABLE: Locate 15 amp fused lead and connect a 24V power supply

which energizes with ignition key and a good ground connection for cable [A].

Route cable [A] and connect to control box [B].

Step 4. ATTACH SCORPION™ TO WHEEL LOADER

Quick coupler attachments: Be sure lower locking pins fully extend to lock in

coupler & 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. Apply ample grease to all pins.

Quick coupler locking pins are integral to the attachment of this unit to

wheel loader vehicle. Verify the pins are locked in fully prior to lifting

unit or using the Scorpion. Failing to verify proper securement may

cause the Scorpion Engine Puller falling off the loader resulting in

property damage, injury or death.

►Installation of the Scorpion Engine Puller on a wheel loader requires interfacing

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 manufacturer’s service manual can result

in serious damage to equipment and/or result in injury or death.

►Failure of hydraulic system can result in serious injury and property damage

►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

Installation of purchased attachment may void machine manufacturer warranty, if any.

INSTALLATION GUIDELINES (PAGE 10)

SAS™ SCORPION™ 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

Step 5. CONTROL CABLE: 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 lift-

ed 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,

following lines into frame

& across frame

articulation point, to cab

of loader. Leave enough

slack in the cable keeping

in mind articulation of

loader & 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 grommet or drill a hole large enough to fit the end of

the wire through.

Protect the cable from rubbing on the edge of the hole, either install a rubber

grommet or 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.

Step 6. IDENTIFY PRESSURE SIDE LINE ON LOADER by pulling joystick lever back brief-

ly, you will see one of the lines move, or have someone hold the line to feel the

pressure build. Label this line “Boom Lift Pressure”.

Step 7. HYDRAULIC LINES: Determine adequate length of lines needed 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 re-

quired from bulkhead on Scorpion to loader connection. Make a loop in line

to have sufficient length in hose to avoid creating tension in all positions.

Use a 4,000 PSI min hose to fit hydraulic quick coupler fittings on machine and

¾” (#12) male JIC fittings on the Scorpion™.

Attach the line (labeled “Boom Lift Pressure”) which is pressurized when the

joystick is pulled back to the bulk- head fitting on the Scorpion

that is farthest from the loader. Clearly mark lines as desired

or use opposite quick coupler set up to ensure proper re-

connection after disconnected.

INSTALLATION GUIDELINES (PAGE 11)

NEWS BULLETIN 2/20/2012

SAS™ SCORPION™ENGINE PULLER Hydraulic Fitting

IMPROPER INSTALLATION & ALIGNMENT WILL CAUSE DAMAGE TO FITTINGS

 Misalignment may cause undue side pressure on the fittings.

 Failing to secure the black ring lock may cause the fitting to not be secure.

 Internal ball bearing parts may break out, fitting may fail and become disconnected.

 This condition will not be warranted.

COMPONENT IDENTIFICATION QUESTIONS?

Phone: 1-920-845-2198

BOOM

CARRIAGE

TILT

CLAWS

BLADES

HYDRAULIC QUICK

COUPLER FITTINGS

TO LOADER

HYDRAULIC SYSTEM

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 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.

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 on page 9 of the manual to safely park Scorpion & 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 fittings to align squarely, eliminating

side pressure.

 1. Note the position of any brackets which hold fittings.

 2. Loosely attach hoses to the carriage and the loader mount.

 3. Fit the hydraulic quick coupler fittings together.

 4. Adjust either or both of these to allow good fit:

a) Reposition mounting bracket (1) which is

fastened to the back of coupler up or down.

And / Or

b) Loosen nut(s) (4) fastening the stainless steel

line (only 1 turn) to 90 degree fitting on carriage,

c) Loosen lock nut on 90° fitting (5) to carriage

d) 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

FITTINGS.

 5. Tighten lock nut (5) on 90 degree fitting on carriage

 6. Tighten the nut(s) (4) fastening stainless steel line

 7. Tighten all hose connections.

 8. If equipped, secure black locking ring on hydraulic

quick coupler fittings.

 9. Check for leaks. Repair as needed.

Step 8. HYDRAULIC FLUID LEVEL. You will need to add 7 gallons at initial installation.

Check level regularly. Refer to the wheel loader manufacturer’s manual for

proper filling specifications. Failure to keep fluid at proper operating levels

can result in equipment failure.

Step 9. INITIAL TEST FOR INTERFERENCE during lifting, tilting, or dumping movements

►Watch for pinch points. Stay clear of moving parts while equipment is

in operation. Moving parts can cause serious injury or death

►Watch for leaking hydraulic fittings, fix any leaks and clean up spills if

they occur. Hydraulic fluid can cause eye irritation and slippery condi-

tions which can result in injury.

►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.

►Verify all individuals are clear before performing test.

Check for undesirable contact between loader lift arms and Scorpion

framework. Watch for 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.

Step 10. Check proper sequence. Engage button or trigger before moving joystick.

>Left button depressed: Pull back joystick to lift the “Boom”.

Push forward on joystick to lower the “Boom”

>Right button depressed: Pull back joystick to swing “Tilt” away from loader

Push forward joystick to swing “Tilt” towards

loader

>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.

INSTALLATION GUIDELINES (PAGE 12)

SAS™ SCORPION™ 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

7 gal.

Hydr.

DAILY PRE-OPERATION INSPECTION (PAGE 13)

(Suggested minimum inspection guidelines)

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

PULLING ENGINES (PAGE 14)

SAS™ SCORPION™ 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

Operation Procedure

A. When tipping the forks up (roll back), tips down (dump), it is best to avoid unneces-

sarily bottoming out the stops to avoid possible damage to the stops, lift arms, or

hydraulic cylinders. Always slow the movements when nearing a stop, including

when raising the Scorpion™ “Boom” to fully raised position.

B. Approach the vehicle;

1. Front wheel drive vehicles: Approach from the side of the timing belt, opposite

the transmission, typically passenger side.

2. Rear wheel drive vehicles: Approach directly from the front.

C. 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 right button, move the joystick forward and move the “Tilt” about 1/2 way

out. Reposition joystick to neutral and release the button.

F. Press the left button, move the joystick forward and lower the “Boom” down, posi-

tioning 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 “Boom” 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 trans-

mission 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.

I. Continuing to hold trigger & joystick back, now also press the right button to lift the

“Tilt”. This will provide additional lift height to clear the transmission out vehicle.

J. Transport the engine in the “Claws” to the desired location to deposit the engine

and transmission, 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 engine and transmission. Be cautious not to open the

“Claws” to far that they hit the forks.

FRONT WHEEL DRIVE VIEW

Engine Mount

Frame

Members Transmission Mounts

Engine Transmission

PROPER USE OF THE SCORPION ENGINE PULLER WILL ENSURE LONG LIFE:

 Read your manual

 Grease daily

 Method of proper use is covered on page 10 of the manual. This is a 4 step summary:

 1. Always lower & set blades on top of car, securing car firmly to ground, position the

claws (to clear blades) & 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.

SAS™ SCORPION™ENGINE PULLER USE

1 2 3 4

Failure to follow proper instructions or using Scorpion for any other purpose will void warranty.

IMPROPER USE WILL CAUSE DAMAGE AND POTENTIAL CRACKING OF THE SCORPION

 To prevent damage or potential personal injury avoid the following actions:

 An example of improper use:

 1. Lowering the boom, extending tilt fully forward & opening claws before approaching car.

 2. Dropping the Scorpion down onto the car with the claws below the fork blades.

 3. Clamping on engine & extracting without the blades securely holding down the car down.

 4. Having the blades come in contact with car before engine in disengaged.

These operations will cause stress & cracking of the tilt assembly resulting in equipment damage.

1 2 3 4

COMPONENT IDENTIFICATION

BOOM

CARRIAGE

TILT

CLAWS

BLADES

PULLING ENGINES (PAGE 15)

SAS™ SCORPION™ ENGINE PULLER

CONNECTING / DISCONNECTING

SAS™ SCORPION™ ENGINE PULLER (PAGE 16)

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

DISCONNECTING:

When disconnecting from Scorpion™ Engine Puller

A. Set Scorpion down to position the blades flat on level ground.

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 pres-

sure. This position with the boom lowered and the tilt ex-

tended will allow weight to be balanced forward enough on

the blades so the Scorpion™ will be stable.

C. Set the loader’s parking brake.

D. Turn off the loader.

E. Turn the key of the loader back on without starting the en-

gine.

F. Cycle through all joystick buttons moving the joystick forward and back several times

to relieve all the hydraulic pressure in the lines.

G. Turn the key back off and remove hydraulic lines & control cable.

H. Carefully place control cable and hoses where they will not be damaged or get soiled.

I. Disengage the quick coupler and drive away.

Do not allow the hydraulic connections to get dirty. Allowing dirt into the hydraulics

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

A. Drive straight up to the Scorpion™ avoid contact with hydraulic lines or control cable.

B. Engage the quick coupler. Visually verify quick coupler locking pins are fully engaged.

C. Turn off the loader.

D. Cycle joystick and other lift levers in cab to relieve pressure in hydraulic lines.

E. Connect hydraulic lines and control cable.

F. Start loader and ensure proper operation.

Always select and engage a button or trigger before moving the joystick.

>Left button depressed: Pull back joystick to lift the “Boom”.

Push forward on joystick to lower the “Boom”

>Right button depressed: Pull back joystick to swing “Tilt” away from loader

Push forward joystick to swing “Tilt” towards loader

Hydraulic system may have unexpected pressure.

Always train operators on proper procedures. Set forks on the ground, depressurize

hydraulic system, wear safety glasses, gloves and other personal protective equip-

ment required by your workplace before attempting to disconnect hydraulic hoses.

Practice lockout/tagout procedures to prevent operation of equipment while servicing.

Failure to follow these instructions can result in serious injury or property damage.

A. Daily: Grease all 18 points; with particular attention to Boom pivot points & cylinders.

Cylinder Grease Points Pivot Point Grease Points

BC-L(R) Boom Cylinder-Left (Right) BP-L(R) Boom Pivot-Left (Right)

TC-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)

B. Daily: Inspect all pivot point pins and retaining bolts to be sure properly secured.

C. Daily: Inspect forks, carriage, and Scorpion™ framework for damage.

D. Daily: Check loader hydraulic fluid level. Add fluid as required to maintain proper level.

E. Weekly: Inspect hose fittings to be sure they are tight.

F. Weekly: Inspect hoses for pinching or rubbing and correct or replace as needed.

G. Monthly: Inspect skid plates under the carriage.

PREVENTIVE MAINTENANCE

SAS™ SCORPION™ ENGINE PULLER (PAGE 17)

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

BC-L

1 & 2

BC-R

17&18

BP-L

TC-L

4 & 5 TP-L

CC-L

7 & 8

CC-R

11&12

TP-R

TC-R

14&15

BP-R

*Claw Pivot 9 and 10 can be reached through

round holes when claws are all the way apart.

CP-L

CP-R

10*

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

1/8” NPT Grease Zerks

Grease Recommended:

Mobilgrease® CM-P

ELECTRONICS PARTS GUIDE (PAGE 18)

SAS™ SCORPION-20™ ENGINE PULLER

[F]

[C]

[B]

[A] [D]

. [E]

DESCRIPTION PART NUMBER

[..] COMPLETE ELECTRICAL KIT (A,B,C,D,E) 24 VOLT HC-KIT-S-24-1-20

[..] OPTION: ELECTRICAL KIT (A,B,C,D,E) 24V VOLVO L70/L90 HC-KIT-S-PCKNPL-20

[A&B] CONTROL MODULE W/LOCAL TEST & 2’ PWR WIRE HC-MOD-S-21478

B.1 RELAY 24 VOLT (BLACK) SN:F4655 & NEWER (3 REQ.) HC-BRL-H-4RD933332

B.2 15 AMP FUSE (TYPICAL AUTOMOTIVE STYLE FUSE) (1 REQ.) HC-FUS-…-ATC15

A POWER SUPPLY CABLE (F4647 & EARLIER) (1 REQ.) HC-CAB-S-50265

B CONTROL BOX ASSEMBLY (F4647 & EARLIER) (1 REQ.) HC-BOX-S-50267-1

B.1 RELAY 24 VOLT (ORANGE) (F4097-F4647) (3 REQ.) HC-BRL-S-RT314024

B.1 RELAY 24 VOLT (BLUE) (UP TO F4026) (3 REQ.) HC-BRL-I-50264

[C] JOYSTICK & 10’ CABLE ASSEMBLY W/PLUG HC-JYA-S-50270

[D] 30’ FORWARD CONTROL CABLE W/FLAT 4 WIRE PLUG HC-CAB-S-50266-1

USE HC-CAB-S-50266-1 FOR ALL SC30 & SC20 EXCEPT ALUM CONTROL PANEL TYPE

D OPTION: FORWARD CABLE L90 FOR ALUMINUM HC-PANEL-S-01 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] SPLIT CABLE FOR DUAL VALVE BLOCKS W/COIL PLUGS HC-CAB-S-50276

[F.7] OPTION: SPECIAL SPLIT CABLE DUAL BLOCK (Use w/o Jumper Cable) HC-CAB-S-PCKNPL-SC20

OPTIONAL TEST LIGHTS

SINGLE LED CIRCUIT TESTER FOR WIRE AT HYDRAULIC BLOCK HC-PLG-I-TESTLIGHT-1

THREE LED CIRCUIT TESTER FOR FLAT 4 WIRE CABLE ON LOADER HC-PLG-I-TESTLIGHT-3

Forward [D]

Joystick Relay Test

Test Point Test Point Point

[C]

3-LEDtestplugfits

allthreetestpoints.

Fuse holder Relays

[A&B] [E]notshown

~BLANK PAGE~ (PAGE 19)

SAS™ SCORPION-20™ ENGINE PULLER

Phone: 920-845-2198 1-877-SAS-FORK Fax: 920-845-2309 Web: www.sasforks.com

We appreciate your business!

Thank you!

DESCRIPTION PART NUMBER

[F] HYDRAULIC VALVE BLOCK ASSY W/SOLENOIDS & COILS HV-BLK-S-FV9292

F.1 SOLENOID CARTRIDGE VALVE (SCREWS IN BLOCK)(6 REQ.) HV-CRT-V-SBV1112VC00

O-RING SIZE: SAE # 12—O-RING KIT (1 big & 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 STD (6 REQ.) HV-COL-V-300AA00142A

COIL INSTALLATION NOTE: REQUIRES 7/8” WRENCH, TORQUE TO 6 FT LBS

F.3 SOLENOID ELECTRIC COIL 12 VOLT OPTION (6 REQ.) HV-COL-V-300AA00141A

F.7 DUAL VALVE BLOCK SPLIT CABLE W/FLAT PLUG SEE PRIOR PAGE

[G] UNASSIGNED

System may have stored hydraulic pressure. Disassembly of any hydraulic part, cartridge

valve, 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 per-

sonnel ship service this unit. Boom & tilt should be lowered to the ground & secured.

VALVE BLOCK PARTS GUIDE (PAGE 20)

SAS™ SCORPION-20™ ENGINE PULLER

Wires:

Brown/Black

Blue/Black

Grey/Black

Yellow/Black

Red/Black

Orange/Black

BOOM

CONTROLS

LEFT EXTEND

RIGHT RETURN

TILT

CONTROLS

LEFT EXTEND

RIGHT RETURN

CLAW

CONTROLS

LEFT EXTEND

RIGHT RETURN

[F.1]

[F.2/F.3]

TORQUE 6fts.

TORQUE 60fts.

[F]

Scorpion-20 has two Valve Blocks (one shown here)

Phone: 920-845-2198 1-877-SAS-FORK Fax: 920-845-2309 Web: www.sasforks.com

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