PRODEM PRB008 User manual

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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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.

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TABLE OF CONTENTS
FOREWORD............................................................................................................................................................ 2
1. Safety Information................................................................................................................................................ 6
1.1 Basic Safety Information .............................................................................................................................. 7
1.2. Preparation for safe operation..................................................................................................................... 8
1.3. Safety information on safe operating........................................................................................................... 9
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. Installation.......................................................................................................................................................... 18
5.1. Carrier requirements ................................................................................................................................. 18
5.2. Attaching the mounting adapter................................................................................................................. 19
5.3. Mounting the hydraulic hammer on the carrier .......................................................................................... 19
5.4. Connecting the hydraulic lines of the hammer........................................................................................... 21
5.5. Connection ports 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 selection ................................................................................................. 26
5.10. Anti-Blank-Blow (Auto-Stop) function....................................................................................................... 27
5.11. Inspection after installation ...................................................................................................................... 28
6. Operating the hydraulic hammer........................................................................................................................ 29
6.1. Selecting the right chisel ........................................................................................................................... 29
6.2. Correct working methods .......................................................................................................................... 30
7. Maintenance ...................................................................................................................................................... 33
7.1. General Information................................................................................................................................... 33
7.2. Care and maintenance schedule............................................................................................................... 34
7.3. Hydraulic oil............................................................................................................................................... 34
7.4. Grease ...................................................................................................................................................... 36
7.5. Gas............................................................................................................................................................ 37
7.5.1. Checking and charging the gas in the back-head................................................................................... 37
7.5.2. Checking and charging the gas in the accumulator................................................................................ 39
7.6. Chisel, wear bushings and chisel pins....................................................................................................... 40
7.7. Bracket and Adapter..............................................................................................................................- 43 -
7.8. Screw tightening....................................................................................................................................- 43 -
7.9. Replacing the through bolts...................................................................................................................- 45 -
7.10. Checking the bottom of the piston.......................................................................................................- 45 -

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7.11. Storage of the hammer ........................................................................................................................- 46 -
8. Troubleshooting .............................................................................................................................................- 47 -
* Specifications and features presented in this document are subject to change without notice.

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Blank page

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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.
The safety messages in this manual do not describe all the possibilities that could cause personal injury,
death or damage to the product. These safety messages are intended to provide basic instructions for safe
operation and service.
Although this manual does not cover all the possible situations, it is the operator’s responsibility to observe
the safety instructions and regulations.
Remember! Safety is up to you.
Safety Alert Symbol
The Safety Alert 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 caused to the product or
shorten the product life.

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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.
Always use the proper tools for inspection or maintenance work, which
must only be carried out after ensuring that the equipment has been
stopped completely, and it is placed suitably in a safe place.
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 instructions.
Only the operator who has been trained and qualified to operate the
carrier and hammer should do so. Be skilled and knowledgeable in all
operational and technical aspects of the carrier and hammer.
Figure 2
Know the work site
Before operating the hammer, check the area of work site for any
unusual conditions that could be dangerous,
and prepare the appropriate
warnings for safe work
ing. Be careful, particularly when working in the
vicinity of electric power lines, gas pipes or other buried services.
Pay particular attention to other workers, bystanders and other
machinery that may pass by near to the work site. Immediately stop
operation of the hammer if personnel enter the danger area.
Figure 3

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Know the rules
Everybody who operates or maintains the equipment should know the
meaning of the rules and laws in terms of handling the equipment. Use
the hammer in accordance with all regulations regarding construction
practice and public safety.
For emergency use, keep the fire extinguisher and the first-aid case in
the operator’s cab.
Figure 4
1.2. Pre aration for safe o eration
Some prior checks and scheduled maintenance must be performed on installing a new hydraulic hammer.
The hydraulic hammer should only be mounted on a carrier with sufficient load capacity.
In case of using a quick coupler (hitch), determine the total weight including the quick coupler.
Carriers below this weight class will not provide the required degree of stability and could even fall over
during hammer use, causing personnel injury or machine damage. Carriers above this weight class may
apply excessively high mechanical 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 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. The carrier driver and assistant should agree beforehand on clear hand signals.
To avoid equipment damage, follow the carrier maintenance schedule before operating the hammer.
Check the hammer for wear, getting loose, breakage or crack. Do not operate in case any damages or
failure is found.
Recommended carrier weight (in tonne) for hammer models:
Hammer Model Carrier class
(Standard) Hammer Model Carrier class (Standard)
PRB008
0.
7
~ 1.
0
PRB
15
0
12 ~ 16
PRB010
0.7 ~
1.2
PRB170
1
8
~ 2
2
PRB
02
0
1.0 ~ 2.0
PRB
20
0
20
~ 2
4
PRB
03
0
1.5 ~ 3.0
PRB
25
0
20 ~ 26
PRB
04
0(H)
2.5 ~ 4.5
PRB
30
0
26 ~ 32
PRB
05
0
4.0 ~ 6.0
PRB
40
0
32 ~ 40
PRB
06
0
6.0 ~ 8.0
PRB
50
0
40 ~ 60
PRB100
8.0 ~ 12
PRB7
0
0
6
0 ~
110

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1.3. Safety information on safe o erating
Always operate the hammer from the operator’s seat in the carrier cab, and also close the splinter guard
on the driver’s cab during hammer operations.
The hydraulic hammer must not be used for disallowed applications. Refer to Section “6.2. Correct
working methods” of this manual for instructions on how to handle the hydraulic hammer, and
applications for which the hydraulic hammer is unsuitable and must not be used.
Stop the operation if an abnormal noise or vibration is detected during the operation. Check the carrier
and hammer.
Never use the hammer in or underwater unless compressed air is supplied to the hammer. Refer to
Section “6.2. Correct working methods for details”.
1.4. Safety information on maintenance
Always follow the instructions described in this manual when performing maintenance work on the hammer.
Pay careful attention to all relevant safety regulations. Most accidents occur when the instructions are
not observed.
Maintenance work should be performed with the carrier completely stopped, the stop valves shut off.
The carrier must be on firm and flat ground with all the control levers switched off.
Use only the lifting points 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 components, for example, chisel (tool), valve, piston or hydraulic connection parts
become very hot.
The hydraulic oil may be very hot and may cause severe scald. Before disconnecting hydraulic lines,
bleed all hydraulic pressure in the lines. And, always relieve tank pressure of the carrier.
Oil spouted out from the crack or small hole on hydraulic system can penetrate the skin and cause
serious injury. Therefore, be sure that all the connections are tight and pipes and hoses are in good
condition. Use a sheet of cardboard or wood to search for suspected oil leaks.
To avoid an explosion and equipment damage, use only pure nitrogen gas (99.8% or over) in the gas
chamber of the back-head and accumulator.
Only the proper tools should be used for maintenance. Use of improper tools may cause personal injury,
or damage to the hammer.
Oily, greasy ground may be very slippery. Collect any oil and grease, and dispose it correctly for safety
and environment.
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.

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2. Warranty
The warranty period for PRODEM hydraulic hammers is provided as below.
Base warranty
PRODEM’s products to be well-made, durable and of good material are warranted for twelve (12)
months from the date of delivery of such new products to the actual and original buyer, but no more than
eighteen (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’.
Limited warranty
1. Sealing parts
Sealing parts such as seals, O-rings and diaphragms installed in new products are warranted for six (6)
months from the date of delivery to actual and original buyer, but no more than twelve (12) months
from shipping date from PRODEM’s factory.
2. Wear parts
Wear items listed herein below are warranted for three (3) months from the date of delivery to actual
and original buyer, but no more than eighteen (18) months from shipping date from PRODEM’s factory.
chisel, tooth, bush, pin, ring, plug, fitting, fastener, rubber, hose, wearing plate, damper, polyurethane
form, shim
3. Through bolts
Through bolts are warranted for six (6) months from the date of delivery to actual and original buyer,
but no more than 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 date of delivery to the actual or original buyer, but within eighteen (18)
months from the shipping date from PRODEM’s factory. PRODEM adopt whichever period comes first
out of two conditions.
5. Multi-shift work
PRODEM guarantee the defect and failure caused by PRODEM’s fault under the normal condition of
work which means that customer should comply with maintenance schedule, precautions and 8 hours
(day shift) working a day. In case that the breaker is operated with multi-shift (day and night shift)
working, the warranty period will be cut by half.


Exclusion of warranty
PRODEM does not take responsibility for the results of use not recommended in this manual and
specifically for:
1. Problems caused by incorrect operation or using to non-recommended application
2. Problems caused by improper handling or storage
3. Problems caused by improper maintenance
4. Problems caused by using non-genuine parts
These exclusions apply to damage to the hammer, the carrier, and associated equipment and personnel
injury.
For further information, refer to the “Warranty & service guide line” provided by PRODEM.
PRODEM reserve the right to modify the design or change the specifications without prior notice for the
improvement of performance or quality.