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5. Service and maintenance

IMPORTANT!

To use the product in its best condition without any troubles for a long time, observe the
following inspection and maintenance instructions.

In addition, be sure to follow the safety instructions in performing inspection and maintenance.

5.1. General guidelines

Be sure to do the following sequence prior to inspection or maintenance work:

1. Stop the carrier completely.

2. Shut off the stop valves.

3. When disconnecting the hoses, seal them with plugs or caps to prevent entry of impurities.

Whenever maintenance work is carried out, always follow the basic instructions of maintenance for your
safety and product life.

Use proper tools only. Using improper tools may cause personal injury or part damage.

Even after the carrier completely stopped, quite high hydraulic pressure may remain within the compactor.

Disassemble slowly with care.

All of the rotating parts assembled in the drive casing of the compactor are precise parts. Be sure to

handle them carefully, and keep them free of foreign substances or humidity.

Use only genuine parts. Use of unapproved parts may cause damage to the compactor or personal injury.

The troubles in this case voids the warranty.

Do not make any modification to the compactor. We do not take responsibility for accidents and product

damages resulting from unauthorized product modification.

Please contact PRODEM or our dealer for details regarding service and maintenance.

5.2. Daily inspection

To use the compactor for a long time in its best condition, do the following daily inspection and maintenance
job regularly.

CHECK POINTS

RELATED PARTS

ACTION

Tightening of Bolts and Nuts

All the bolts and nuts of
Cushion Plates, Motor, Covers, Valve,
etc.

Mounting adapter bolts

Retighten the loose one,

Replace the broken or worn parts.

Oil Leak

Hoses, Fitting or Plugs

Hydraulic Motor

Motor Control Valve

Retighten the loose one.

Replace damaged O-ring or seal.

Abnormal Noise or Vibration
during Operation

Hydraulic Motor

Bearings (in Drive Casing)

Cushion Plates (Cushion Rubbers)

Check oil level and inspecting after
refilling oil.

Contact PRODEM service if the
problem persists.

Breakage, Deformation, Crack,
or Wear and Tear

Base Frame and Mounting Frame

Cushion Plates (Cushion Rubbers)

Mounting Pins

Contact PRODEM service, if any
problem is detected.

Содержание PHC 050

Страница 1: ...Operation and Maintenance Manual Plate Compactor PHC 050 PHC 100 PHC 150 PHC 200 PHC 300 Parts No AA099 0053 Revision Date 2011 12 15 ProDem ...

Страница 2: ...of this manual may be changed If you found the parts unclear or not corresponding to the compactor 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 unauthoriz...

Страница 3: ...oduct configuration 9 2 2 Product features 10 2 3 Specifications 11 3 Installation 13 3 1 Installation of the piping 13 3 2 Installation of the compactor 15 4 Operation 17 4 1 How to use compactor 17 4 2 Correct working mothod 18 5 Service and maintenance 20 5 1 General guidelines 20 5 2 Daily inspection 20 5 3 Gear oil inspection and oiling 21 5 4 Maintenance instructions 21 5 5 Tightening torque...

Страница 4: ...never fail 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 unsafe practices All four degrees of risk indicate that safety is involved Observe precautions indicated whenever you see the Safety Alert Symbol no matter which signal word appears next to t...

Страница 5: ...allation and operation of the compactor The operator who has been trained and licensed should only operate the carrier and the compactor Familiarize yourself with the operating especially safety related devices such as safety lock emergency stop and the others Figure 2 Know the work site Before beginning operation check in and around the work site for any unusual conditions that could be dangerous...

Страница 6: ...g the mounting pin tighten the bolts firmly so that the pin may not get loose during work When installing a pipe for mounting the compactor follow our pipe installation specification When connecting a hydraulic hose connect it with the specified connection torque and check if the hose is completely connected before starting the excavator If a sudden pressure is applied when the connection is incom...

Страница 7: ...y damage the product and shorten its life so it is absolutely prohibited Do NOT use under water Never use the compactor in or under water Operating the compactor under water will cause serious damage to the cushion rubber Do NOT support carrier with compactor Do not support the carrier using the compactor body or do not apply excessive force to it For piling work always use pile clamp When operati...

Страница 8: ...it For the compactor cylinder in particular there may be pressure left in the system even after the compactor stops and it may be exploded when it is disassembled Therefore be sure to follow the disassembly order If there is a tiny hole or crack in the hydraulic device pressurized fluid may spout from it to injure people near it Fluid that spouts lightly may not be seen by the naked eye In this ca...

Страница 9: ...t the hydraulic motor There are two type of the motor control valve N type valve has the reverse flow bypass and anti cavitation functions and P type valve includes flow and pressure control function in addition to the standard features of the N type valve Compacting plate contacting the ground compacts soil and make surface flat Cushion rubbers cushion plates is parts that help get effective comp...

Страница 10: ... for the maintenance Motor with built in cross check valve Built in cross check valve within the hydraulic motor eliminates the need of a additional drain line thus provides great versatility for using general 2 line plumbing And it also protects the motor shaft seal from damage caused by internal oil leak of the motor Standard motor control valve Reverse flow bypass and anti cavitation check Buil...

Страница 11: ...action Area N m 2 ft 2 0 24 2 6 Compaction Area G m 3 ft 3 0 40 4 3 0 55 5 9 0 78 8 4 Oil Flow with N type valve lpm gpm 50 72 13 2 19 0 80 116 21 1 30 6 with P type valve 2 lpm gpm 45 65 11 9 17 2 50 120 13 2 31 7 80 170 21 1 44 9 Max Cycles Per Minute rpm 2 100 2 000 2 000 Operating Pressure Free load bar psi 30 50 440 730 30 50 440 730 30 50 440 730 With load bar psi 100 220 1 450 3 190 100 138...

Страница 12: ...Pressure Free load bar psi 30 50 440 730 30 50 440 730 With load bar psi 100 138 1 450 2 000 100 138 1 450 2 000 Recommended Carrier tonne ton 17 25 19 28 26 40 29 44 Weight Recommended Hydraulic mm in 25 1 32 1 1 4 Line Size In Out Max Acceptable Back bar psi 15 220 15 220 Pressure Max Pressure Relief bar psi 138 2 000 138 2 000 Type of Hose Connection Ports BSP 1 O Ring Boss Female BSP 1 1 4 O R...

Страница 13: ...g flow of the compactor System Pressure 180 bar or higher Allowable Back Pressure 15 bar or less Compactor piping is basically the same as breaker piping and thus it is possible to use the breaker piping as it is without any modification But the drain low pressure line must be connected directly to oil cooler or oil tank If the drain line is connected to the control valve of the carrier the compac...

Страница 14: ...or does not work or rotate very slowly by means of the reverse flow bypass check valve of the motor control valve to protect the hydraulic motor So make it sure that piping is installed in right direction When you newly install piping make it sure that there is no foreign substance inside piping sub parts such as hoses pipes valves and fittings After finishing installation of piping connect P and ...

Страница 15: ...h with the pin bore of the mounting adapter and insert the mounting pins 5 Assemble the stop rings and tighten bolts and nuts to fix the mounting pins 6 Then assemble the mounting pin for carrier s link in the same way as for carrier s arm Arm Link Spacer Shim Mounting Pin Mounting Adaptor Bolt Stop Ring Nuts Compactor Hose Connector P T Figure 13 DANGER When moving the carrier do not touch any pa...

Страница 16: ...seat Figure 14 When all installation works are completed check the followings before operating the compactor While moving the carrier s bucket cylinder slowly in and out in the direction of crowd and dump check Any interference or obstruction between the compactor and carrier Whether the length of the connecting hoses are too short or too long Twisting excessive bending or squeezing of the connect...

Страница 17: ...or bedrock it would apply very high impact to the compactor which might result in a serious damage to the compactor When the ground starts to be lowered by compacting work lower the carrier s boom gradually and keep a constant applying pressure At this time also make it sure that the cushion plate is not pressed too much When compacting a wide area advance working positions sequentially in a unifo...

Страница 18: ...he compacting plate in parallel to the ground and press it vertically to the ground IMPORTANT Figure 17 Do not transport using the compactor Do not move or break a heavy object using the compactor which may result in the compactor damage or shorten its life IMPORTANT Figure 18 Do not support carrier with the compactor Do not support the carrier using the compactor body and do not apply excessive f...

Страница 19: ...ER Figure 20 Do not use for crane work The compactor is not equipped with safety devices for crane work so it is very dangerous to use the compactor for crane work And also lifting a heavy object up with the compactor will result in severe damage and shortening of its life IMPORTANT Figure 21 Do not work under water The compactor should not be used for underwater work Operating the compactor under...

Страница 20: ... Use only genuine parts Use of unapproved parts may cause damage to the compactor or personal injury The troubles in this case voids the warranty Do not make any modification to the compactor We do not take responsibility for accidents and product damages resulting from unauthorized product modification Please contact PRODEM or our dealer for details regarding service and maintenance 5 2 Daily ins...

Страница 21: ... be tightened Tighten to half of the specified torque in a cross pattern Finally tighten to the specified torque in the same pattern Use only PRODEM s genuine bolts or nuts The bolts and nuts for general purpose can be replaced with approved equivalents Hydraulic motor The hydraulic motor is a precision made hydraulic parts Foreign particles in contaminated hydraulic oil may result in failures to ...

Страница 22: ...mble other parts in reverse order of the removal procedure 5 Be sure to follow the specified tightening torque 6 Refill gear oil Cushion plates rubbers Because the cushion plates are subject to high load and large deflection scratch aging by oxidization etc it is required to check and replace them periodically Although the life of cushion plates depends primarily on operating time it can be affect...

Страница 23: ... Housing cover bolts PHC050 PHC100 PHC150 PHC 200 PHC 300 M10 8 wrench M10 17 M16 24 M22 32 70 10 70 10 280 30 750 80 Apply the thread locking adhesive Loctite 271 272 or equivalent Cushion plate bolts cushion rubber PHC 050 PHC 100 PHC 150 PHC 200 PHC 300 M12 19 M18 30 120 20 460 60 Motor fixing bolts PHC 050 PHC 100 PHC 150 PHC 200 PHC 300 M12 19 M16 24 120 20 270 30 Motor control valve fixing b...

Страница 24: ...e or dealer if the problem persists low relief pressure setting Check the relief valve setting of the carrier s hydraulic system re adjust it if needed Refer to section 3 1 Contact PRODEM service or dealer if the problem persists Low oil level of oil tank Fill up carrier s hydraulic oil tank Oil temperature is too high Check the carrier s oil cooling system Contact carrier supplier or service Faul...

Страница 25: ...lugs to the hoses to prevent contamination by foreign substance Dismount the compact in reverse order to that of mounting described in section 3 2 Storing When you store compactor observe the following guidelines Inadvertent storing may result in faults or shortening of life Store the compactor by erecting it straight using firm supports such solid wood blocks Put the hose plug firmly to the hose ...

Страница 26: ... 26 Notes ...

Страница 27: ......

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