Related Manuals for PRODEM PDS Series
Summary of Contents for PRODEM PDS Series
- Page 1 A Force You Can Depend On VERSION 2.0 / 2018 PDS RANGE OPERATING INSTRUCTIONS MANUAL www.prodem-attachments.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS INTRODUCTION INSTALLATION Purpose of the operation instruction and Transport and handling maintenance manual Storage Preserving the instruction manual Coupling check Updating the instruction manual Mounting Recipients Use on construction cranes Glossary and symbols Connections Copyright Stopping and dismounting... -
Page 3: Purpose Of The Operation Instruction And
Manuals without any obligation to update previous production and Manuals. The PRODEM Group will not be liable in the following cases: Improper use of the attachment; Use contrary to specific national law;... -
Page 4: Preserving The Instruction Manual
INTRO SECTION PRESERVING THE INSTRUCTION MANUAL The Manual must be carefully preserved and must accompany the attachment every time its ownership changes throughout its life. You must help preserve the Manual by using it carefully with clean hands and not laying it down on dirty surfaces. -
Page 5: Glossary And Symbols
INTRO SECTION GLOSSARY AND SYMBOLS This paragraph explains the abbreviations used and the meaning of the symbols used to indicate the operator qualifications and the state the attachment. Their use allows the information necessary for the correct and safe use of the attachment to be communicated quickly and unequivocally. -
Page 6: Copyright
COPYRIGHT This Manual is copyrighted by PRODEM. This Manual is intended for operating and maintenance personnel. It contains instructions and technical diagrams that may not be copied, in whole or in part, distributed or examined by unauthorized persons for competitive purposes or divulged to any other third party. -
Page 7: Manufacturer's Identification Plate And Data
INTRO SECTION MANUFACTURER’S IDENTIFICATION DATA MANUFACTURER PRODEM Global Ltd 10 Gillmans Industrial Estate, Natts Lane, Billingshurst, West Sussex, RH14 9EZ, UK CONTACTS Tel.: +44 (0) 1403 787 949 Fax.: +44 (0) 845 017 6973 sales@prodem-attachments.com www. prodem-attachments.com OPENING HOURS 8am - 5.30pm Mon-Fri... -
Page 8: General Information
Each attachment is identified by a CE plate (Fig. 1.2. 1 ) on which the reference data is indelibly printed. Always provide this information in any communications with the manufacturer. Fig. 1.2.1 PRODEM Global Ltd, 10 Gillmans Industrial Estate, Natts Lane, Billingshurst, West Sussex,... -
Page 9: Safety Standards
GENERAL INFORMATION SAFETY RULES The attachment has been constructed in conformity with the safety standards listed below: UNI EN ISO 12100 Machine safety - Fundamental Concepts, General design principles, Risk assessment and risk reduction. UNI EN ISO 13857 Safe Distances from Machinery - Safe distances for preventing the upper limbs from reaching dangerous areas. -
Page 10: General Guarantee Conditions
The guarantee does not include parts subject to normal consumption and/or wear and to breakage due to improper use of the attachment supplied by PRODEM Global Ltd. In this case, the customer will have to provide for delivery to, and pick up from, our workshop at its own expense; if the customer wishes the repair to be performed at its office, so long as this is possible, it will be required to pay the seller’s transport and travel... -
Page 11: Safety
SAFETY GENERAL INSTRUCTIONS The operator’s safety is one of the manufacturer’s principal concerns. In constructing a new attachment, we attempt to foresee all possible situations of danger and, obviously, adopt suitable safety measures, paying a great deal of attention to operations that are especially dangerous. - Page 12 SAFETY GENERAL INSTRUCTIONS The user may supplement the manufacturer’s information with additional instructions that, obviously, do not conflict with what is shown in the manual to contribute to the safe use of the attachment. Anyone working on the attachment must pay attention to the clothing he is wearing.
- Page 13 SAFETY GENERAL INSTRUCTIONS Functional check of the attachment; A check of the state of the attachment; A check of the seal and efficiency of the hydraulic system. ATTENTION! If anomalies are found, they must be eliminated before putting the attachment back into operation.
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Page 14: Safety Instructions
SAFETY SAFETY INSTRUCTIONS During overhead work, fragments or blocks of material can fall. Make sure that the machine on which the attachment is installed has the necessary protections for performing this time of work and has a FOPS cabin (Fig. 2.2. 1 ). -
Page 15: Danger Zones
SAFETY SAFETY INSTRUCTIONS When performing cleaning, mounting, dismounting, maintenance and transport, take care to place the attachment in a condition of perfect stability and lock its rotation with the pins provided. The movements of its various parts must be inhibited by external constraints (such as slings or supports). -
Page 16: Attachment Stickers
SAFETY ATTACHMENT STICKERS Stickers are applied on the attachment with the main warnings and instructions to keep in mind during use. Symbol Description Symbol Description “Read the manual” “Greasing points” Carefully read this Use and Indicates points to be lubricated. -
Page 17: Safety Pictograms
SAFETY SAFETY PICTOGRAMS Pictograms in a triangle indicate DANGER. Pictograms in a circle are PROHIBITIONS. Symbol Description Attention to your hands Crushing limbs Getting tangled Dragging Generic hazard Removing safety devices prohibited Prohibited to clean, grease, repair or adjust moving parts by hand Table 2.5.1... -
Page 18: Individual Protection Devices (Ipd)
SAFETY INDIVIDUAL PROTECTIVE DEVICES (IPD) Pictograms in a blue circle are OBLIGATIONS. Symbol Description It is obligatory to use protective goggles It is obligatory to wear work clothing It is obligatory to protect your hearing It is obligatory to wear protective gloves... -
Page 19: Residual Risks
SAFETY RESIDUAL RISKS DEFINITION OF RESIDUAL RISK: “A hazard that cannot be totally reduced through design and protective techniques or a potential hazard that is not obvious.” Attention must be paid to the following residual risks that are present when the attachment is used and that cannot be eliminated. -
Page 20: Attachment Description
ATTACHMENT DESCRIPTION The ProDem PDS Shear range is an attachment entirely designed and constructed by PRODEM. It is intended for modern industrial demolition job sites that need significant cutting force at considerable heights and professionals that recycle ferrous scrap and materials. -
Page 21: Permitted Uses
ATTACHMENT DESCRIPTION PERMITTED USE 1st level machine operator: an operator with no specific skills, only capable of performing simple duties, i.e., operating the machine through the use of the buttons on the pushbutton pad and loading and unloading the materials used during production with the protections installed and active;... -
Page 22: Technical Data
ATTACHMENT DESCRIPTION TECHNICAL DATA Fig. 3.5.1 Mod el 030R 050R 070R 120R 200R 250R 300R 400R 500R 550R 700R 900R 1600R Excavator 2 : 4 3 : 4 4 : 7 7 : 12 10 : 16 16 : 20... -
Page 23: Sticker Position
ATTACHMENT DESCRIPTION ILLUMINATION The illumination of the work area must conform to current law in the country where the attachment is being used and, in any case, must provide good visibility at every point, not create dangerous reflections and allow clear visibility of the controls and the entire work area up to the safety limits required for the projection of objects. -
Page 24: Installation
INSTALLATION TRANSPORT AND HANDLING Driver of lifting and handling equipment: an operator qualified to use vehicles to lift and handle materials and machinery (scrupulously following the manufacturer’s instructions) in observance of current law in the country of use of the machinery. -
Page 25: Storage
INSTALLATION TRANSPORT AND HANDLING ATTENTION! When the attachment arrives, the user must check for damage (breakage or significant dents) during transport or unloading. If damage has occurred, immediately make it know to the transporter and add the words “ACCEPTED WITH RESERVATIONS” to the delivery document. In the presence of damage, submit a written claim to the transporter within 8 days of receiving the attachment. -
Page 26: Mounting
INSTALLATION MOUNTING Mounting begins with the attachment supported stably on the ground with the operating machine’s engine stopped and parking brakes engaged. If the attachment is supplied without the operating machine fitting, it is the customer/operator’s responsibility to provide for the application of a suitable connection fitting corresponding to the characteristics of the operating machine. -
Page 27: Use On Construction Cranes
INSTALLATION USE ON CONSTRUCTION CRANES The range of possible uses for the hydraulic demolition PDS Range attachments includes the option of installing it on a construction crane. Below, we list the operating systems, rules and requirements to respect for operating in this manner. - Page 28 INSTALLATION CONNECTIONS SPECIFIC CONNECTION TECHNIQUES HYDRAULIC CONNECTIONS Attachment Operating Machines Power Rotation Drainage PDS Range B optional B optional B optional 3/8" 3/8" 1/4" 1/4" S 16 (M24x1,5) L 12 (M18x1.5) PDS 030R 3/4" 3/4" 3/8" 3/8" PDS 050R - PDS 070R S 25 (M36x2) S 16 (M24x1.5)
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Page 29: Stopping And Dismounting
INSTALLATION STOPPING AND DISMOUNTING At the end of work and before putting down the attachment, proceed as follows: Activate the operating machine’s OPEN/CLOSE control to return the entire rod of the attachment inside the cylinder. Place the attachment on two wooden supports on the ground, orienting it horizontally. -
Page 30: Use Of The Attachment
USE OF THE ATTACHMENT PUTTING INTO OPERATION 1st level machine operator: an operator with no specific skills, only capable of performing simple duties, i.e., operating the machine through the use of the buttons on the pushbutton pad and loading and unloading the materials used during production with the protections installed and active;... -
Page 31: Taking Out Of Service
INSTALLATION TAKING OUT OF SERVICE On the occasion of long periods of inactivity, it is necessary to disconnect the hydraulic power from the attachment. WASTE DISPOSAL The user is responsible for the correct disposal of the waste produced by the attachment in conformity with the current law in the country of use. -
Page 32: Maintenance
MAINTENANCE ISOLATING THE ATTACHMENT Generic unskilled worker: an operator with no specific skills only capable of performing simple duties on the instructions of a qualified technician. Before performing any type of maintenance and/or repairs, the attachment must be isolated from the hydraulic power. - Page 33 MAINTENANCE REGULAR MAINTENANCE Generic unskilled worker: an operator with no specific skills only capable of performing simple duties on the instructions of a qualified technician. Regular maintenance includes inspections and controls to monitor the state of the attachment. Regular Maintenance Table:...
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Page 34: Scheduled Maintenance
MAINTENANCE SCHEDULED MAINTENANCE Maintenance mechanic: a qualified technician capable of operating the machine under normal conditions, operating it with the jog command with the protections deactivated, working on mechanical components to perform the necessary adjustments, maintenance and repairs. Typically not qualified to work on electrical systems under voltage. - Page 35 MAINTENANCE SCHEDULED MAINTENANCE LUBRICATION The frequency of lubrication must be determined as a function of the operating conditions. The attachment must be relubricated before or after a long period of inactivity. This is especially true for the winter break. Take care that no detergent penetrates the rolling system or damages the gasket seals.
- Page 36 MAINTENANCE SCHEDULED MAINTENANCE GREASING POINTS Fig. 6.4.2 TIGHTENING SCREWS OF THE ROTATION THRUST BLOCK Tightening must be performed exclusively by specialized technicians with a torque wrench using the torque values shown in the following table (Table 6.4.3). The screws can only be retightened once and then must be replaced.
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Page 37: Extraordinary Maintenance
MAINTENANCE EXTRAORDINARY MAINTENANCE Maintenance mechanic: a qualified technician capable of operating the machine under normal conditions, operating it with the jog command with the protections deactivated, working on mechanical components to perform the necessary adjustments, maintenance and repairs. Typically not qualified to work on electrical systems under voltage. - Page 38 MAINTENANCE EXTRAORDINARY MAINTENANCE ADJUSTMENT AND REPLACEMENT OF PARTS SUBJECT TO WEAR The paragraphs that follow describe the operations to be performed on the attachment when it is necessary to adjust or replace components subject to wear (due to normal use when cutting materials).
- Page 39 MAINTENANCE EXTRAORDINARY MAINTENANCE CLUTCH BLOCK Definition: The clutch block (T) is located on the frame of the attachment (A) above the center pin and it has the function of keeping the movable jaw in line during cutting and avoiding scissoring. It has to do with an adjustment slide block (J) that comes into slight contact with the sliding surface (R) of the movable jaw (Q).
- Page 40 MAINTENANCE EXTRAORDINARY MAINTENANCE Replacement: If there is still excessive play despite the use of all the shims provided (L) and after having rotated it, it is necessary to replace the guide blade (E). REMOVE the worn guide blade and all the shims by loosening the locking screws.
- Page 41 MAINTENANCE EXTRAORDINARY MAINTENANCE Anti-wear plate and/or piercing tip replacement: To replace the anti-wear plate (U) and/or the piercing tip (V), it is necessary to unweld them from the movable jaw (Q). Before beginning the replacement of the anti-wear plate and/or the piercing tip, it is necessary to remove the primary upper blade (Y) because heating the product in the intervention area could damage the blade.
- Page 42 MAINTENANCE EXTRAORDINARY MAINTENANCE Adjustment: Slowly move the movable jaw (Q) and check the play between the blades on the frame (B and C) and the blades on the movable jaw (X and Y). Make sure that it never exceeds 0.4 mm (it is initially adjusted to 0. 1 mm).
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Page 43: Diagnostics And Troubleshooting
MAINTENANCE EXTRAORDINARY MAINTENANCE To add material use 57 HRC (600 Brinell) fill wire, Ø 1.2 mm K 300. The recommended wires are: UTP: A67S Ø 1.2 mm FORTARGEN: A7111 MIG Ø 1.2 mm DANGER! Before adding material, it is necessary to turn off the operating machine and wear suitable IPDs (gloves, goggles, safety shoes and suitable clothing). -
Page 44: Replacement Parts
Order the part using the order form on the next page; Indicate the shipping method. If this item is not specified, while dedicating particular care to this service PRODEM will not be liable for any delivery delays due to force majeure. The recipient is always responsible for shipping expenses. -
Page 45: Replacement Parts
Year of manufacture: Customer: Replacement parts order date: LIST OF PARTS TO BE ORDERED Quantity Description Code SHIPPING SERVICE To be completed and sent by e-mail or fax to: sales@prodem-attachments.com - +44 (0) 845 017 6973 Translated by the original... - Page 46 NOTES...
- Page 47 NOTES...
- Page 48 A Force You Can Depend On PRODEM Global Ltd, 10 Gillmans Industrial Estate, Natts Lane, Billingshurst, West Sussex, RH14 9EZ, UK Telephone +44 (0)1403 787 949 Email sales@prodem-attachments.com Opening Hours 6am - 4pm Mon-Fri www.prodem-attachments.com...