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PRODEM PRB 010 Operation And Maintenance Manual Download Page 2

 

- 2 - 

 

FOREWORD 

 

 

 

WARNING! 

It is very important for you to read and understand this manual before operating and to keep 
the instructions provided herewith. Never fail to follow the instruction related to safety. 

 

This manual contains instructions and information on safe and correct use of PRODEM hydraulic hammers. 

  Please read and understand this manual before operation, inspections and maintenance of the hydraulic 

hammer. 

Keep this manual with your equipment all the time for your quick and easy reference, and read it 
regularly. 

  Do not operate the hydraulic hammer until you have been trained in the use of all operating controls and 

understand the hydraulic hammer operation. 

  Get a replacement manual from PRODEM dealer if you lost it. 

  If you transfer the hydraulic hammer to the other, do transfer this manual as well. 

  The figures in this manual are for better understanding and may not correspond exactly to the hydraulic 

hammer. For exact shape, refer to the parts list or ask PRODEM. 

  For  the  purpose  of  constant  product  improvement,  some  parts  of  this  manual  may  be  changed.  If  you 

found the parts unclear or not corresponding to the hydraulic hammer, call and consult PRODEM dealer 
or service center 

  Important  information  on  safety  is  described  in  the  safety  information  chapter  of  this  book.  Be 

familiarized  with  the  instructions  on  the  safe  operation  and  observe  the  instructions  before  and  during 
operation 

  Injury, death or  damage caused by  unauthorized  product modifications and  operation under  unallowed 

application  will  not  be  responsible  by  PRODEM.  Consult  PRODEM  for  such  modifications  and 
applications. 

  Use  PRODEM  genuine  parts.  PRODEM  takes  no  responsibility  for  damages  caused  by  use  of  non-

PRODEM spare parts. 

  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 © 2010 PRODEM. All rights reserved. 

This manual is copyrighted by PRODEM with all rights reserved in accordance with prevailing law. It is positively 

prohibited to use or reproduce its contents in whole or in part without prior written permission. 

Summary of Contents for PRB 010

Page 1: ...tenance 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...

Page 2: ...ment some parts of this manual may be changed If you found the parts unclear or not corresponding to the hydraulic hammer call and consult PRODEM dealer or service center Important information on safe...

Page 3: ...orts of the hammer 22 5 6 Dismounting the hydraulic hammer from the carrier 23 5 7 Fitting removing the chisel 23 5 8 Adjusting the pressure adjusting valve 25 5 9 Adjusting impact rate 2 speed select...

Page 4: ...4 7 11 Storage of the hammer 46 8 Troubleshooting 47 Specifications and features presented in this document are subject to change without notice...

Page 5: ...5 Blank page...

Page 6: ...to read and observe the instructions for safe operation Signal Words The words DANGER WARNING CAUTION and IMPORTANT appeared with the above Safety Alert Symbol indicate degree of risk of hazards or u...

Page 7: ...ce Figure 1 Know your equipment Before installation or operation of the hammer the operator and maintenance personnel must read and understand the safety messages operation manual and service instruct...

Page 8: ...hanical loads to the hammer Make sure the hammer is compatible and match in capacity with carrier hydraulic systems To protect the operator from injury due to flying rock splinters the operator s cab...

Page 9: ...nts provided and sufficiently strong lifting equipment when lifting the hammer Do not start maintenance on the hammer until it has cooled because the hammer is heated up during operation Some componen...

Page 10: ...eighteen 18 months from shipping date from PRODEM s factory 4 Spare parts Spare parts other than those indicated as wearing parts or consumable parts will be warranted for three 3 months after the da...

Page 11: ...s 10 Front bush 11 Chisel 12 Back head 13 Minimess coupling 14 Through bolts 15 Front head nuts 16 Back head nuts 17 Lower damper 18 Wear plates 19 Support damper 20 Upper damper 21 Bracket The graphi...

Page 12: ...plate B silenced A Mounting type A adapter mounted type D direct mounted type L backhoe loader mount type 15 Model number H Factory code 001 Serial number Available bracket version Hammer model code...

Page 13: ...etails may vary on different hammer models 1 PRODEM Logo 2 Name plate with CE label 3 Greasing Port Indicates grease point Apply grease at the interval prescribed EVERY 2 HOURS 4 Lifting Point Indicat...

Page 14: ...bels related to safety such as follows 5 General safety 6 Stay clear Indicates the distance that must be kept from the breaker to be safe from the flying rock splinter 7 Safety on gas charging in Back...

Page 15: ...0 H Gas charging pressure Back head bar 8 10 8 10 8 10 8 10 10 12 Accumulator bar n a n a n a n a n a Hydraulic piping Line size min internal diameter mm in 9 5 3 8 9 5 3 8 12 1 2 12 1 2 12 1 2 Accep...

Page 16: ...a 60 Pressure adjust valve setting No of turns open from full close n a n a n a n a 1 5 2 0 Hydraulic piping Line size min internal diameter mm in 12 1 2 19 3 4 19 3 4 19 3 4 25 1 Acceptable back pres...

Page 17: ...bar 60 60 60 60 60 60 Pressure adjust valve setting No of turns open from full close 2 0 2 5 2 5 3 0 2 5 3 0 3 0 3 5 3 0 3 5 2 0 2 5 Hydraulic piping Line size min internal diameter mm in 25 1 25 1 32...

Page 18: ...arge inner diameters Small line size causes backpressure increase overheating of oil or irregular blows Hydraulic pressure The hydraulic pressure and oil flow of the carrier s hammer piping should be...

Page 19: ...llows PRB008 030 PRB040 150 PRB170 300 PRB400 700 12 mm 20 mm 30 mm 36 mm 3 4 1 2 1 Adapter 2 Upper damper 3 Screw and washer 4 Nuts and washer Number of nuts single or double may vary on different ha...

Page 20: ...by using the bolt and nuts 6 1 Hydraulic hammer 2 Excavator arm 3 Arm pin 4 Mounting adapter 5 Stop ring 6 Bolt and nuts 4 Lift up the hammer 1 to a proper height 5 Extend the bucket cylinder 7 until...

Page 21: ...hout connecting the hammer Check the pressure setting of the relief valve on the hammer hydraulic line this pressure relief setting should be at least 30 40 bar higher than the measured maximum operat...

Page 22: ...ew 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 Refer to followings Co...

Page 23: ...chisel Always wear safety glasses and gloves because metal chips or debris may fly off when driving the chisel or the chisel pins Never put fingers in the chisel pin bores of the hammer Do not stand...

Page 24: ...es In case of replacing the chisel after use do check and maintenance work according to Section 7 6 Chisel wear bushings and chisel pins 5 While lifting up the chisel clean away any dirt adhering to t...

Page 25: ...sing operation By controlling the working pressure the blow power can be increased or decreased To increase the blow power turn the pressure adjusting valve clockwise To decrease the blow power turn t...

Page 26: ...breaking productivity because the chisel cannot penetrate into the material For this kind of work maximum percussive power even though low impact rate is needed The speed selection switch is set to th...

Page 27: ...Blank Blow function the hammer does not start operating unless the chisel is pre loaded by contact with the object and the hammer stop operating automatically when the chisel does not contact with th...

Page 28: ...te The oil flow and the operating pressure should be measured in minimum and maximum values because those fluctuate slightly while operating the hammer The relief pressure of the hammer piping should...

Page 29: ...breaking hard material will cause the sharp edges to wear very quickly Impact breaking Transferring strong mechanical stress wave into material breaks material Best possible energy transfer between c...

Page 30: ...e damage to the hammer Angle of attack The hammer should always be positioned at right angles to the surface of the material If the hammer is operated at slant angle The chisel slide off the material...

Page 31: ...ard not more than 5 while operating so that the dust can escape Do not rock the hammer at angles greater than 5 or the chisel will be broken Never use as a lever Do not use the chisel as a lever e g c...

Page 32: ...underwater kit Never use the chisel or hydraulic hammer to move rocks or other objects The hydraulic hammer is not designed for this usage Do not use the hammer or chisel to roll push the object or re...

Page 33: ...e hydraulic hammer should be oiled with clean hydraulic oil before assembling Especially for sealing parts used for tight fitting apply lubricant paste onto the sliding portions of the seals Always re...

Page 34: ...pipe connections Check interference between hoses with carrier Every 600 hours or 6 monthly It is recommended that the annual maintenance be carried out by your local PRODEM dealer or after 600 opera...

Page 35: ...r 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...

Page 36: ...below 0 C 32 F the carrier must be warmed up prior to use in the way described by the carrier manufacturer Ensure that the hydraulic oil of the carrier is at least at 0 C 32 F before starting up the...

Page 37: ...must always be maintained within the specified limits refer to Section 4 Technical specifications This section describes how to fill the gas and check the gas pressure in the back head and accumulato...

Page 38: ...ed and then connect the cap nut 5 to the nitrogen bottle 2 Be sure handle 9 is fully opened loosened 3 Connect each end of the hose 7 to the Mini mess coupling I 3 and the Mini mess coupling 13 on the...

Page 39: ...opened loosened 3 Remove the accumulator charging plug 14 and the O ring 15 from the accumulator 19 Put them in the toolbox for safekeeping 4 Connect the Mini mess coupling III 22 to the gas charging...

Page 40: ...cle engaged abrasive wear Collapse or peeling of surface by extremely high contact pressure Heat generated by friction accelerates wear Check the chisel chisel bush and front bush for wear every 50 ho...

Page 41: ...ded upper limit specified in the table 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 t...

Page 42: ...PRB150 PRB700 Check the width of the chisel pins including the worn out portion If the wear on the first side exceeds 1 5 mm both chisel pins must be inverted together to use the other side Replace th...

Page 43: ...tightening torque below Screws to check and or re tighten regularly Applied part Hex size mm Tightening Torque Applied hammer models N m ft lbs Accumulator body 17 socket 500 550 370 410 PRB170 500 A...

Page 44: ...PRB170 200 250 300 400 500 700 Accumulator gas charging valve 8 S 40 60 30 44 Fixing cap for accumulator gas charging valve old version 24 H 140 160 103 118 Plug for accumulator gas charging port 10 S...

Page 45: ...ys apply thread paste made of molybdenum disulphide MoS2 to the threads of the through bolts before installing 5 At first tighten the entire bolts to the half of the specified torque in diagonal patte...

Page 46: ...The percussion piston must be positioned at the upper end of its stroke The lower end of the piston chisel and bushes must be well protected with grease or anti lust fluid All the hydraulic connectio...

Page 47: ...place Hydraulic oil overheated Check and replace filter cooler Gas pressure in back head too low Check and refill back head gas pressure Chisel out of range for piston Push down chisel by carrier Insi...

Page 48: ...Refill hydraulic oil tank Carrier pump delivery too high Correct carrier engine speed Reset pump High outside temperature and no cooler fitted Fit oil cooler Pressure relief valve defective Fit new p...

Page 49: ...49 Notes...

Page 50: ......

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