Pladdet PSS230 User manual
2
Preface
WARNING!
It is very important for you to read and undertand this manual before operating and to keep
the instructions provided herewith. Do not operate the shear until you have read and fully
understand these instructions.
This manual contains instructions and information on safe and correct use of YONIL shears.
Please read and understand this manual before operation, inspections and maintenance of the shears.
Keep this manual with your equipment all the time for your quick and easy reference, and read it regularly.
Do not operate the shears until you have been trained in the use of all operating controls and understand
the hydraulic shears operation.
Get a replacement manual from YONIL dealer if you lost it.
If you transfer the shears 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 shears. For
exact shape, refer to the parts list or ask YONIL.
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 shears, call and consult YONIL 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 un-allowed
application will not be responsible by YONIL. Consult YONIL for such modifications and applications.
Use YONIL genuine parts. YONIL takes no responsibility for damages caused by use of non- YONIL
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 YONIL shears and wish you a good luck in every your job,
.
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Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of Contents . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1. Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1. Basic safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2. Preparation for safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3. Safety information for operating the shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4. Safety information for maintenance of the shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2. Configuration and ordering information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1. Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1. Lifting the shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2. Requirements on the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. Operating the shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1. Preparation for safe and correct operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2. Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5. Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.2. Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3. Changing the cutter blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.4. Check the slide puck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.5. Adjustment blade gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.6. Welding guide for the jaws and teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7. Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6. Dismounting and Storing the shears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7. Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
* Specifications and features presented in this document are subject to change without notice.
4
1. Safety Information
This manual describes correct use of the product and safety messages. Important or certain instructions in
this manual are marked with symbol. When you see this symbol provided in the manual or on the product,
be alert to the possibility of personal injury or death. Be sure to observe the instruction in the safety message.
The safety messages in this manual do not describe all the possibilities of personal injury or death or of
damages to the product. This safety manual and the marks with symbols are intended to provide some of
basic instructions for safe operation, inspection and maintenance. It is operator’s responsibility to observe the
safety instructions and regulations though this manual does not include all the possible situations.
Remember! Safety is up to you
Safety Alert Symbol
The SafetyAlert Symbol represents that ATTENTION is involved.
If you see the mark in this manual or on the products, 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 the “Exclamation Point” symbol.
DANGER!
Indicates imminent hazard of a situation that, if not avoided, is very likely to cause
death or extremely serious injury. It may also be used to alert against product that
may exploded or detonate if handled or treated carelessly.
WARNING!
Indicates potential of a hazardous situation that, if not avoided, could result in serious
injury or death. It may also be used to alert against a highly unsafe practice.
CAUTION!
Indicates potential of a hazardous situation that, if not avoided, could result in minor
or moderate injury. It may also be used to alert against a general unsafe practice.
IMPORTANT!
Indicates potential of damages that, if not avoided, could cause to the product or
shorten the product life.
5
1.1. Basic safety information
WARNING!
The following instructions are those that should never be fail to observe in operation of
construction equipment.
Know yourself
All the operators and service men must wear safety equipment
required, hearing protection, respirator, hard hat, safety shoes, eye
protection glass, heavy gloves and other necessary equipment.
Wearing loose clothing or any accessories such as flopping cuffs,
dangling neckties and scarves, untied shoe-laces, rings, wrist
watches and long hair could be the cause of personal injury or
death.
Use the proper tools for inspection or maintenance work, which
must be carried out after ensuring the equipment stops completely
and is placed stably in the safe place
Figure 1
Know your equipment
Never fail to read and understand the safety messages, operation
manual and maintenance manual before installation and operation
of the shears. The operator who has been trained and licensed
should only operate the carrier and the shears. 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 and prepare the
appropriate warnings for safe work.
Be careful, especially when work in the vicinity of electric power
line, buried gas lines or oil tank. And pay your careful attention to
the people and the cars reside and passing near to the work site.
Prepare for every possible injury and damages.
Figure 3
6
Know the rules
Every people who operate or maintain the equipment should know
the meaning, rules and laws in terms of equipment handling. They
should know also the traffic rules, fire service act, emergency
measures and where the relief equipment is.
Keep the fire extinguisher and the first aid case in the operator’s
cabin for emergency use.
Figure 4
1.2. Preparation for safe operation
Install the shears on the suitable carrier
The suitable carrier must be selected taking the weight and hydraulic system of the shears into consideration.
The carrier may fall over if the shears is installed on the carrier, which does not fit the shears. All hydraulic
lines for the shears use must satisfy the specification and quality provided in page 11, “Requirements on the
carrier”.
Protect the operator from the flying splinters
To protect the operator from the heavy concrete elements falling down when the shears is working on the tall
columns, supports and brick, the carrier should be equipped with the cab protector strong enough for the
falling elements. For more information on the cab protector, please consult carrier manufacturer or YONIL
dealer.
Safety instructions on the shears installation
When insert the mounting pin to install the shears on the carrier, the pin holes in the carrier’s arm must be
flush with those in the mounting adapter of the shears. For this job, a carrier operator and an assistant should
be careful and agree on the hand signals beforehand. Your finger or hand must not use to check whether the
holes are flush. Once the mounting pins are inserted, lock the pins so that they are not taken off.
If quick coupler is used, be sure clamping is completed. When you connect the hose, tighten the connectors
with prescribed torques.
WARNING!
Read and observe the following instructions on safety.
7
And make sure of complete connection when you open the stop valve. It may cause personal injury if the
incorrectly connected hose is pressurized. When connecting the hose, be careful not to have the O-ring
damaged or missed, and keep all the connectors clean.
Check the shears and carrier
Please check every necessary parts of the shears
and the carrier before starting operation. Referring to
check points in the manuals of the shears and carrier,
check any damages, breakage, crack, wear,
deformation, connections, oil leak and the safety
related points.
For the shears, check carefully crack in the welded
parts of shears body, bolt and nut, pin, oil leak on the
cylinder and hose. Do not operate in case any
damages or failure is found until it is fixed. In case
such trouble is found, put the warning tag like the
picture. It is good to let the same person remove the
tag after trouble shooting. (Figure 5)
Figure 5
Check safety in work site
Check if the building has a sufficient load capacity to bear the weight of the carrier in case it is necessary to
work on the roof or ceiling of the building.
1.3. Safety information for operating the shears
WARNING!
The following instructions are on safety in operation with shears. Read, understand and
observe the instructions. More information is provided in page14, “Operation”.
Never operate in un-allowed applications
Operation in applications not allowed by the manufacturer must not be carried out. Refer to page14,
“Operation” for such applications.
Operate from the top downwards
Heavy broken concrete elements may fall down and damage the hydraulic shears and the carrier, therefore,
columns and supports must be broken from the top downwards.
8
Never use for transportation purpose
Lifting and transporting loads such as concrete columns, steel beams or pipes on the shears may result in
accident. There is a risk of shearing or cutting during the transportation.
Never use for hammering or ramming
Hammering or ramming with the shears may cause serious damage to the shears.
Prepare an escape for the carrier
Never fail to prepare a escape for the carrier for emergency. The direction needs to be opposite to the object
of shearing and it should be straight way.
Stop operation on finding uncertainties
Never fail to stop the operation if an uncertain noise or vibration is detected during the operation and check
the condition of the carrier and the shears.
Pay attention during operation
Do not read, do not listen to music, do not talk over the cell phone during the operation. Do not operate the
shears as well as the carrier carelessly.
1.4. Safety information for maintenance of the shears
Follow the manual
Follow the instructions described in the manual when performing
maintenance work on the Shears. Pay your careful attention to all
relevant safety regulations. Do not hurry. Most of accidents occur
when the instructions are not observed.
Use proper tools
The proper tools should be used for the maintenance work. Use of
improper tools may cause personal injury or damage to the parts
of the Shears. Wear the eye protective glasses especially when
removing and replacing the cutter blades because the metal chips
may fly off and cause injury if they are struck with a hand hammer
made of steel.
Figure 6
Use only the lug provided and sufficiently powerful lifting equipment when lifting the Shears. Lug and ropes
must be in good condition.
9
Ensure that the shears and carrier stop completely
Maintenance work should be performed with the shears jaw completely closed. Make sure to shut-off the stop
valve of the hydraulic line for the shears or to use a support to sustain the opened jaw if maintenance work
should be carried out with the jaw opened.
Place the carrier on the firm and flat ground with all the control levers or switches in a safe position.
Pay attention to hot oil and high pressure in hydraulic system
Special attention is required when performing maintenance of
hydraulic system. Never disassemble the Shears as soon as the
Shears has been stopped because the hydraulic system is still in
high pressure. Follow the instructions and release the residual
pressure in the system. Pressure may remain in the speed up
valve, and it may be burst if it is disassembled with the pressure
inside.
Oil running out from the crack or small hole on hydraulic system
may cause personal injury. The hydraulic oil becomes very hot.
And compressed air in the oil tank may cause oil spouting when
disconnecting the line. Bleed off the compressed air by opening
slowly the filer cap of the oil tank.
Figure 7
Wet ground may be slippery
The oil wet on the ground may be very slippery. Collect any oil and dispose it correctly.
Do not alter or modify
Unauthorized alteration or modification of the shears shall not be guaranteed by YONIL.
10
2. Configuration and ordering information
2.1. Main components
- Designed to prevent outward slipping & jamming of the object while jaw is closing, and
increased the durability by adopting a gun drill type cylinder. The shear consists of five
main parts as like below decal. And want to know more detailed, kindly refer to the parts
list.
Externals structure
①Body ②Mounting Bracket ③Cylinder ④Jaw
Figure 8
11
3. Installation
3.1. Lifting the shears
DANGER!
Be sure of observing the instructions below because they are related to safety
Move the shears with the jaw completely closed and hydraulic lines plugged.
When lifting the shears, use sufficiently powerful lifting equipment.
Ropes and lugs must be in good condition.
3.2. Requirements on the carrier
WARNING!
Be sure of observing the instructions because they are related safety and the life of the
shears.
YONIL hydraulic shears, YSR-series is designed to be used with a hydraulic excavator. Refer to the following
points when deciding an excavator for the shears.
Carrier weight
The excavator may fall over if the capacity is not good enough to use the shears or if it is equipped
with a long boom and/or a long reach arm. Proper excavator should be decided for use with the
shears or such long boom and arm.
Hydraulic system
The hydraulic system of the carrier must be suitable for the shears. Low flow rate and pressure
results in slow working speed and low shearing force respectively. Check the specification of the
carrier.
12
Generally speaking the hydraulic oil originally recommended for the carrier can be used for the
YONIL hydraulic shears. However, since working with the hydraulic shears will heat the oil much
more than the usual excavation work, the viscosity of the oil must be checked. When the shears is
used continuously, the viscosity of the hydraulic oil should be 15~100 cSt at the whole operating
temperature range. For more details about hydraulic oil, refer to page 20, Chapter “5.5. Hydraulic oil”
When installing the shears with no pre-filled oil in it, the shears cylinders need a lot of oil. So you
must fill the oil by the proper level in oil tank after operating the shears two or three times.
Hydraulic system must have a proper cooling system in order the temperature of the hydraulic oil not
to exceed 90 °C (194 °F) which may cause damage to the shears as well as the carrier. If the
carrier’s oil cooler is too small either the original cooler must be replaced with a larger one or an
auxiliary cooler must be installed.
Retrofitting from breaker piping to shears piping :
When retrofitting the breaker piping lines to shears piping lines, take the return line of the existing
breaker piping lines for the jaw closing lines of the shears. If the return line of the existing breaker
lines is also installed for low pressure only, we recommend you to replace all the piping lines with the
adequate piping lines as required above and make the lines both supply and return lines to high
pressure lines. If the breaker supply line is taken for the jaw opening line, relief valve on the breaker
supply line does not need to be reset.
For more detailed information, refer to YONIL service center.
13
4. Operating the shears
4.1. Preparation for safe and correct operation
After whole installing procedure as described in the previous chapter, the shears is ready to operate. However,
before starting up the shears, please make sure the following :
mechanical connection between the shears and the carrier.
locking status of the mounting pins.
hydraulic connections between the shears and the carrier.
exact setting of the relief pressure.
no oil leaks from the hydraulic connections and any parts of the shears.
no defective or loosened parts of the shears.
cracks, wear, loss, etc.
Check the followings moving the shears :
corresponding the jaw movements and the rotating direction with the appropriate actuating switches
in the carrier’s cab.
smooth opening and closing of the jaws.
smooth rotating of the shears.
no abnormal sound and no vibration during the operation.
WARNING!
Read carefully and follow all safety regulations concerned with the preparation for safe
operation. Refer to page 6, ”Preparation for safe operation”.
4.2. Greasing
Apply grease to every grease nipple at the joint pins and slewing bearing of the shears using recommended
greases.
Recommended greasing Interval : Every two hours
4 ~ 5 strokes from a grease gun to each greasing nipples are sufficient in each case
Adapt greasing interval and amount of grease to working conditions
Insufficient greasing may cause abnormal wear of the joint pin or slewing bearing
14
Grease with the following properties are recommended :
No dropping point (or very high, over 250 °C / 480 °F)
Max. working temperature over 150 °C / 300 °F
Min. working temperature under lowest ambient temperature
Additives : molybdenium disulphide (MoS2), graphite or equivalent
Grade (thickness) NLGI 0~2
Water resistant
4.3. Operation
WARNING!
Read carefully and follow all safety regulations concerned with safe operation. Refer to page
7, “Safety information for operating the shears”.
Operating temperature :
The operating temperature of the shears is -20 ~ +90°C (-4 ~
+194°F).
If the ambient temperature is lower than -20°C(-4°F), the
shears have to be warmed up before starting operation in the
way described at the carrier’s manual. During operation, they
will remain warm.
If the oil temperature exceeds +90°C(+194°F), please stop the
carrier and wait until the oil has cooled to operating
temperature range. For continuous operation with high duty,
maximum oil temperature is recommended not to exceed
+80°C(+175°F). An auxiliary oil cooler must be fitted if needed.
Figure 9
15
The oil temperature during operating the shears depends on ambient temperature condition, on cooling
capacity of carrier’s hydraulic system and on working duty for the shears. Use the hydraulic oils of high
viscosity in high oil temperature.
IMPORTANT!
If the oil temperature exceeds +90°C(+194°F), please stop the carrier and wait until the oil
has cooled to operating temperature range. Extreme oil temperature may cause serious
damage on the seals in the carrier and shears.
Correct working method :
WARNING!
Stop operating immediately if anyone moves into the danger area, i.e. within a radius of at
least 20 meters around the shears. Must be observant of other workers, bystanders and other
equipments in the danger area.
WARNING!
Please do install the proper protection shield on the carrier’s cab to prevent possible injury
from flying pieces of broken rock or the cut steel pieces.
DANGER!
Improper operation of the shears could result in serious injury or death. Never operate the
shears unless you are properly trained.
16
Read these notice before operation the shears.
WARING!
Do not operate to either side of the carrier with the boom and arm extended.
This can make a danger of the carrier fall over.
DANGER!
Make sure the strength of structure which supports the carrier.
WARING! IMPORTANT!
Do not use for transport purpose.
IMPORTANT!
Do not operate with the carrier’s hydraulic cylinders fully extended or retracted.
Failure to do so will cause damage to the carrier’s hydraulic cylinders.
IMPORTANT!
Never use as a hammer.
Never attempt to use the shears as a hammer or ramming tool.
IMPORTANT!
Never use as a lever..
Never attempt to use the shears as a lever or support.
IMPORTANT!
Do not move the carrier while shearing is in progress.
This will cause serious damage to the shears.
IMPORTANT!
Do not move the carrier while shearing is in progress.
This will cause serious damage to the shears.
IMPORTANT!
Never pull at heavy elements.
This will cause serious damage both the shears and the mounting adapter.
IMPORTANT!
Do not rotate the shears whole shearing is in progress.
This will cause damage to the shears and carrier’s arm.
17
5. Inspection and Maintenance
5.1. General information
Routine inspections and maintenance work must be carried out to keep the hydraulic shears in the best
operating condition. The following sections list the inspection and maintenance intervals, check points over the
shears and carrier.
WARNING!
Read carefully and follow all safety regulations concerned with maintenance of the shears.
Refer to page 8, “Safety information for maintenance of the shears”.
Whenever maintenance work is carried out, keep always following instructions.
1. Park the carrier on a firm and flat ground
2. Close the jaws of the shears completely.
3. Lower the shears to ground and put the shears on a rigid and clean support.
4. Lower the engine speed to the lowest idle position.
5. Wait for at least 10 minutes to allow the residual pressure in the shears be released.
6. Turn the stop valves to “OFF” position.
DANGER!
Never put your body into the open jaws. Risk of death or serious injury!
Followings are the basic inspections to be checked always :
Check, whenever inspecting, if there is a crack at the welded part of the shears (visual inspection).
Check, whenever inspecting, the wear and rounding of the jaws, cutter blades and teeth. Change
worn blades and teeth in good time.
Check, whenever inspecting, if there are oil leaks at the hydraulic components or the hydraulic
connections of the shears.
Check, whenever inspecting, if all fasteners such as bolts, nuts and snap-rings come loose, and
retighten them to the prescribed tightening torque, if necessary. Broken parts must be replaced
immediately.
Check that the blade clearances. The blade clearance should not exceed 1 mm.
Adjust the clearance of cutter blade according to the instructions, if necessary.
18
In order to prevent possible damages to the shears from un-allowed maintenance work, please keep following
instruction :
Absolute cleanliness and great care are basic and essential matters in handling of any hydraulic
components. Dirt is the worst enemy in hydraulic system.
Sealing components such as packings, O-rings and plugs in the hydraulic system should be oiled with very
clean oil before assembly.
DANGER!
Never attempt to disassemble the hydraulic cylinder and the speed-up valve of the shears.
High pressure can be maintained in these components long after the system has been shut
down. This residual pressure can cause hydraulic oil or parts such as plugs to shoot out at
high speed if the pressure is not released completely.
Please consult YONIL service for the maintenance of these components.
19
5.2. Maintenance intervals
Every two hours
Grease the joint pins.
Daily
Retighten loose components. Especially :
- Bolts at the rotation bearing
- Bolts in the cutter blades
Check the wear or breakage of the cutter blades.
Check if the hydraulic connection becomes loose.
Weekly
Check the wear of the jaws and shears body.
Check carefully if there is a crack in the welded part of the shears.
Check the hydraulic components of the carrier.
Check abnormal sound or vibration during the jaw movements and rotation of the shears.
5.3. Changing the cutter blades
Change the cutter blades if there are the wear, breakage or any damage at the edge of cutter blade during the
operation. When replacing the cutter blades, please observe the following instructions :
Always wear the eye protective glasses and use a plastic or copper hammer when removing and inserting
the cutter blades. Because the cutter blades are made of very hard material, the metal chips may fly off to
eye and cause serious injury if they are struck with a steel hammer.
Ensure that they are tightened correctly to the prescribed tightening torque.
If the condition of the bolts and lock-washers is not good, always use new bolts and lock-washers when
fitting new cutter blades.
Make sure there is no particle at the contact surface between the jaw and blades. Cutter blades must
contact the jaw completely.
20
Replace the tip blade before it is worn as the “Figure 10”.
Figure 10
5.4. Check the slide puck
Check tolerances every eight hours of operation. Never over-tighten the slide puck against the wear surface.
Perform slide puck maintenance before performing blade maintenance.
Figure 11
JAW
Gap 0.1 ~ 0.5mm
Table of contents
