Table of Contents
Related Manuals for PRODEM PRB008
Summary of Contents for PRODEM PRB008
- Page 1 Operation and Maintenance Manual Hydraulic Hammers PRB008 PRB 010 PRB 020 PRB 030 PRB 040(H) PRB 050 PRB 060 PRB 100 PRB 150 PRB 170 PRB 200 PRB 250 PRB 300 PRB 400 PRB 500 PRB 700 Documents No.: AA099-0018 Revision Date: 2016-12-05 ©PRODEM...
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Page 2: Foreword
For warranty, we refer you to the warranty conditions provided separately. We always exert all our efforts for your satisfaction, and promise you quick and constant service. We thank you for using PRODEM hydraulic hammer and wish you a good luck in every your job, Jul. 2010 PRODEM Copyright ©... -
Page 3: Table Of Contents
1.4. Safety information on maintenance ......................9 2. Warranty ................................10 3. Product information ............................11 3.1. Configuration of the PRODEM hydraulic hammer ..................11 3.2. Information for ordering and service ......................12 3.3. Markings and labels ..........................13 4. Technical specifications ............................15 5. - Page 4 7.11. Storage of the hammer ........................- 46 - 8. Troubleshooting ............................. - 47 - * Specifications and features presented in this document are subject to change without notice. - 4 -...
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Page 6: Safety Information
1. Safety Information This manual describes the correct use of the product and basic safety instructions. Important instructions in this manual are marked with this symbol . When you see this symbol in this manual or stickers on the product, you must be alert to the possibility of personal injury or death. Be sure to observe the instruction in the safety message. -
Page 7: Basic Safety Information
1.1 Basic Safety Information WARNING! The following instructions are those that should ALWAYS be observed in operation of construction equipment. Know yourself Operators and service personnel must wear appropriate safety equipment, including hearing protection, respirator, hardhat, safety shoes, eye protection, heavy gloves etc, as required. Note: The wearing of loose clothing or any accessories such as neckties, scarves, untied shoe laces, rings, wrist watches or long hair could cause personal injury or death. -
Page 8: Preparation For Safe Operation
To protect the operator from injury due to flying rock splinters, the operator’s cab should be equipped with a protective shield or splinter guard. For information on the cab protector, consult carrier manufacturer or PRODEM dealer. Mounting the hydraulic hammer requires the presence of an assistant, who must be instructed by the carrier driver. -
Page 9: Safety Information On Safe Operating
Keep personnel away from the hammer while servicing the chisel, gas chambers or hydraulic system. Unauthorized alteration on the hammer may cause the hammer serious troubles or reduce hammer life and performance. These cases cannot be guaranteed by PRODEM. - 9 -... -
Page 10: Warranty
(18) months from the date of shipment from PRODEM’s factory for the failure by the reason of defective material or poor workmanship, except wear and sealing items such as stipulated in the ‘Limited Warranty’. -
Page 11: Product Information
3. Product information 3.1. Configuration of the PRODEM hydraulic hammer The PRODEM hydraulic hammer has the following main components or assemblies Cylinder Piston Valve Cylinder bush Accumulator Front-head Chisel bush Thrust ring Chisel pins 10. Front bush 11. Chisel 12. Back-head 13. -
Page 12: Information For Ordering And Service
3.2. Information for ordering and service The equipment serial number is marked with the type and serial number on the nameplate (refer to Section “3.3. Markings and labels”. It is important to make correct reference to the serial number of the hammer when making repairs or ordering spare parts. -
Page 13: Markings And Labels
3.3. Markings and labels This figure shows only a general view. Details may vary on different hammer models. 1. PRODEM Logo 3. Greasing Port Indicates grease point. Apply grease at the interval prescribed. EVERY 2 HOURS 2. Name plate (with CE label) 4. - Page 14 Pay special attention to the marks and labels related to safety such as follows. 5. General safety 7. Safety on gas charging in Back-head 8. Safety on gas charging in Accumulator 6. Stay clear Indicates the distance that must be kept from the breaker, to be safe from the flying rock splinter - 14 -...
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Page 15: Technical Specifications
1,000 ~ 12 1,000 ~ 12 1,000 ~ 12 Note: 1) For the specifications of other versions of bracket, contact your PRODEM dealer or service. 2) Including standard tool, standard mounting adapter and spacers but excluding hydraulic hoses, fittings and mounting pins. - Page 16 1,000 ~ 10 1,000 ~ 10 35 ~ 65 Note: 1) For the specifications of other versions of bracket, contact your PRODEM dealer or service. 2) Including standard tool, standard mounting adapter and spacers but excluding hydraulic hoses, fittings and mounting pins.
- Page 17 1,000 ~ 10 1,000 ~ 10 1,000 ~ 10 1,000 ~ 10 1,000 ~ 10 1,000 ~ 10 Note: 1) For the specifications of other versions of bracket, contact your PRODEM dealer or service. 2) Including standard tool, standard mounting adapter and spacers but excluding hydraulic hoses, fittings and mounting pins.
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Page 18: Installation
Excavator model and year built Arm(stick) type PRODEM’s standard mounting adapters are designed to fit most carrier, and parts for fitting, such as spacers and pins can also be provided. Hydraulic line: Check the nominal bore size of the hammer piping lines on the carrier. -
Page 19: Attaching The Mounting Adapter
For silenced hammer, insert the upper damper (2) in the hammer box before fixing the adapter. 3. Then fit all screws (3) and tighten to the specified torque. The sizes of screws for different hammer types are as follows; PRB008 ~ 030 : 12 mm PRB040 ~ 150... - Page 20 During hammer mounting, the carrier should only be operated from the operator’s cab. 1. Following the direction of an assistant, carefully move the excavator arm (2) into the adapter (4), until the bore in the arm is flush with those in the adapter. 2.
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Page 21: Connecting The Hydraulic Lines Of The Hammer
After mounting the hammer, extend and retract the carrier’s cylinder to its full extent in each direction to ensure that carrier’s cylinder can move without any difficulty or damage. If problems are encountered, consult your local PRODEM dealer. 5.4. Connecting the hydraulic lines of the hammer Before connecting the hydraulic lines to the carrier, check following points To avoid hammer damage, the hydraulic oil of the carrier must be kept clean. -
Page 22: Connection Ports Of The Hammer
TT : Test port to measure the return pressure PRB008 ~ 100 PRB150 ~ 700 The graphic shows only a general view of the connection ports on the hammer power-cell, and the brackets are not shown for explanation. The details of port location and port size may vary on different hammer models. -
Page 23: Dismounting The Hydraulic Hammer From The Carrier
IMPORTANT! Use only genuine PRODEM chisels. Use of other brands of chisel may occur serious trouble to the hammer and cause warranty rejected. It is important that the chisel be used correctly for longer chisel life. Pay particular attention to Section “... - Page 24 Silenced version bracket (BA version) 1. Stop pins 2. PU-sleeves 3. Plugs 4. Chisel pins 5. Plugs 6. Chisel This figure shows only a case of the BA version. Detail configurations may vary on different bracket version and hammer models. For the entire bracket version, fit the chisel as follows: 1.
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Page 25: Adjusting The Pressure-Adjusting Valve
5.8. Adjusting the pressure-adjusting valve For PRB150 and bigger model 1. Pressure-adjusting valve 2. O-ring 3. O-ring 4. Backup ring 5. Adjuster nut The graphic shows only a general view of the pressure-adjusting valve. The position of the pressure- adjusting valve may vary on different hammer models. -
Page 26: Adjusting Impact Rate - 2-Speed Selection
5.9. Adjusting impact rate – 2-speed selection For PRB150 and bigger model 1. Speed selection switch 2. Locking button 3. Cylinder Low speed High speed (mark I) (mark II) The PRB150 ~ PRB700 hydraulic hammers have a 2-speed selection valve on the cylinder body to change the impact rate and the impact energy according to working condition. -
Page 27: Anti-Blank-Blow (Auto-Stop) Function
5.10. Anti-Blank-Blow (Auto-Stop) function For PRB200 and bigger model 1. Plug 2. O-ring 3. Shut-off valve The PRB200 ~ PRB700 hydraulic hammers are equipped with Anti-Blank-Blow (Auto-Stop) function as standard for easier operation and longer product life. The Anti-Blank-Blow function prevent the hammer operating in no-load condition, i.e., when the chisel is not properly pre-loaded by contact with the object to be broken. -
Page 28: Inspection After Installation
5.11. Inspection after installation After the hammer has been installed on the carrier and set ready to operate, installation inspection must be carried out. Check inspection items and specifications as follows: The oil flow supplied to the hammer; should be measured from the ‘IN’ line with a flowmeter while operating the hammer. As alternative, oil flow can be measured, without hammer operating, using a flowmeter that has a throttle valve, which set to the operating pressure of the hammer. -
Page 29: Operating The Hydraulic Hammer
Chisels are subject to wear and tear in the course of normal operations. (Replacement of these parts due to wear is not covered by the warranty.) Only genuine PRODEM chisels should be used, if other makes of chisels are used the warranty may become void. -
Page 30: Correct Working Methods
6.2. Correct working methods Advance: Move the impact point from the edge to the interior. Never try to break off a too large block, if the object has not broken within 30 seconds. The object should be broken up piece by piece in small blocks. - Page 31 Never drive the chisel into the ground: If the advance is too large and the chisel is not rocked to release the dust, the chisel will be driven into the material without breaking the material. This causes the chisel tip to glow red-hot and lose its hardness. As a result, the chisel wears out more quickly.
- Page 32 Recent PRB200 and bigger hammers have a Anti-Blank-Blow function to prevent blank blowing. Consult PRODEM dealer for the operating the hammer in special applications such as: operation under water, operation in very high or low temperature, operation in chemical factory, etc.
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Page 33: Maintenance
PRODEM cannot guarantee these cases. Since the hydraulic hammer is a precision machine, never disassemble the power-cell and main moving parts. If it needs disassembly, contact your local PRODEM dealer. If the customer disassembles the hammer, we don’t take responsibility for it. -
Page 34: Care And Maintenance Schedule
Check the conditions of the power cell and bracket. 7.3. Hydraulic oil Most of the hydraulic oil brands prescribed by the carrier manufacturer are suitable for the PRODEM hydraulic hammer. However, operating the hydraulic hammer will heat up the oil much more than the usual earth moving work. - Page 35 Low impact rate; low breaking efficiency Insufficient lubrication; accelerated wear of hammer parts and damage to the sealing parts When using special oils (e.g. biological oils or fire-resistive oils), contact oil manufacturer or PRODEM. Hydraulic oil filter Contamination of the hydraulic oil may result in parts damage, not only to the hammer, but also to the hydraulic components of carrier.
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Page 36: Grease
Inject grease between the chisel and the chisel bush, through the grease nipple provided. Every 2 hours 5 ~ 10 strokes for PRB008 ~ 150, 12 ~ 15 strokes for PRB170 ~ 500 using a large size grease gun Adjust greasing interval and amount of grease to the hammer models and working conditions. -
Page 37: Gas
Using other gases could result in an explosion. Use pure nitrogen; 99.8% purity, only. The PRODEM hammer is a gas assisted type hydraulic hammer. The gas prefilled in the back-head gives strong impact power and the gas prefilled in the accumulator decrease the pressure fluctuation in the hammer. - Page 38 Gas charging kit: 1. Regulator 2. Adapter 3. Mini-mess coupling I 4. Exhaust valve I 5. Cap nut 6. Coupling 7. Hose 8. Adapter 9. Handle 10. Gas valve 11. Accumulator gauge 12. Back-head gauge 13. Back-head mini-mess coupling 14. Accumulator charging plug 15.
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Page 39: Checking And Charging The Gas In The Accumulator
Back-head gas charging pressure: CHARGING CHECKING at ambient temperature; at operating temperature; Hammer model 20° C (68° F) 60~70°C (140~158° F) (psi) (psi) PRB008 PRB010 8 ~ 10 (116 ~ 145) 9.1 ~ 11.4 (132 ~ 165) PRB020 PRB030 PRB040(H) 10 ~ 12 (145 ~ 174) 11.4 ~ 13.7... -
Page 40: Chisel, Wear Bushings And Chisel Pins
Accumulator gas charging pressure: CHARHING CHECKING at ambient temperature; at operating temperature; Hammer model 20° C (68° F) 60~70°C (140~158° F) (psi) (psi) PRB170 PRB200 PRB250 PRB300 60 ± 2 (870 68 ± 2 (990 ± ± PRB400 PRB500 PRB700 7.6. - Page 41 PRB008 ~ 040(H) is equipped with the front bush by 1-piece type, so checking of the front-head is required. When replacing the chisel bush and the front bush, ensure the bushes and bore of the front head are cleaned without any dirts.
- Page 42 Dimension limits of Chisel Pins: Unit: mm Original Dimensions Lower Limits Hammer Model Pin shape (D1) (D2) PRB008 / 010 / 020 / 030 / 040(H) PRB050 Circular PRB060 33 / 38 31 / 36 PRB100 PRB150 PRB170 / 200 / 250...
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Page 43: Bracket And Adapter
If any crack is found out, the breaker must not be used until it is repaired. If the bottom of the bracket is worn away, replace the bottom plate as needed. If it is necessary to repair by welding, contact your local PRODEM dealer for advice. 7.8. Screw tightening On percussive tools such as hydraulic hammers, the screw fasteners are subjected to particularly high loads and extreme vibration. - Page 44 80 ~ 100 (59 ~ 74) Plug for accumulator gas charging port 40 ~ 60 (30 ~ 44) 150 ~ 200 (111 ~ 148) PRB008, 010 PRB020, 030, 200 ~ 250 (148 ~ 184) 040(H), 050 Connecting adapters for hose,...
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Page 45: Replacing The Through Bolts
7.9. Replacing the through bolts The through bolts connect and retaining the body sections of the hydraulic hammer. The through bolts for PRB008 ~ PRB150 models are directly assembled directly into the female threads in the front-head. The through bolts for PRB170 ~ PRB700 models use the separate nuts (the front-head nuts) at the front- head. - Page 46 7.11. Storage of the hammer Short periods of non-use Dismount the hammer from the carrier according to the instruction in Section “ 5.6. Dismounting the hydraulic hammer from the carrier ”. Storing the hydraulic hammer in horizontal position can be permitted for short period (maximum 2 weeks).
- Page 47 Check and refill hydraulic oil tank Relief valve opens at to low a Re-adjustment relief pressure pressure Failure in valve and piston Contact your PRODEM dealer Leakage from pressure to return in Check the installation, pump and other excavator hydraulic circuit hydraulic components...
- Page 48 Oil leaks at accumulator O-ring and or back-up ring Check and replace o-ring and back-up defective ring Oil leaks from chisel Cylinder seals defective Disassemble hydraulic hammer and replace the seals Hydraulic oil temperature Hydraulic oil level in tank too low Refill hydraulic oil tank too high Carrier pump delivery too high...
- Page 49 Notes - 49 -...