socomec PDO 100 User manual

CATALOGUE
USE - MAINTENANCE
AND SPARE PARTS
Demolition Crusher
PDO 100
Before carrying out any operation with or on the
machine, you must read
carefully and understand each individual instruction written
in this manual
43014 Medesano (Parma) Italia
-
Strada Ferrari, 38
Tel. [phone] r.a.
Fax [phone]
http://www.socomecspa.com
E-mail: [email protected]

This manual is reserved by law and it is formally forbidden to reproduce or to give to any third party
without explicit authorization by
SOCOMEC S.p.A.
The machines can be modified so that some details can be different from those shown herein;
nevertheless this cannot be prejudicial for the texts of the following instructions.
The instruction manual is an integral part of the machine so it must always accompany the
machine until its demolition.
For each demolition always refer to the instructions.
Follow all the information in this manual very carefully.
The operators with look of knowledge of the instructions must be prevented from using the
machine.
Keep the manual intact and readable in a place accessible to the operators.
Give this service manual to any other user or following owner of the machine.
This machine can’t be put in service if the carrier machine is not declared conform to the CE no.
2006/42 directive.
MANUFACTURER
Socomec S.p.A.
Strada Ferrari, 38
43014 Medesano (PR) - Italy
Phone [phone] Fax [phone]
Socomec S.p.A. is not responsible for any inconvenience, breaking, accident and so on, due to
lack of knowledge or to the non-application of the information given by this manual.
The same is valid for all those modifications, changes and/or installations of attachments not
previously authorized.
!
!

Page
3
GENERAL WARNINGS
5
1
Avvertenze generali
2
EQUIPMENT USE AND MAINTENANCE
6
Uso e manutenzione
3
TECHNICAL DESCRIPTION
8
Descrizione tecnica
4
GENERAL WARNINGS
9
Istruzioni generali
5
INSTALLATION
10
Installazione
6
EQUIPMENT START-UP
11
Avviamento
7
EQUIPMENT USE
12
Uso dell'attrezzatura
8
MAINTENANCE AND INSPECTIONS
Manutenzione e controlli
9
PROBLEMS AND SOLUTIONS
16
Problemi e soluzioni
10
PROTECTIONS AGAINST MECHANICAL RISKS
17
Misure di protezione
11
TECHNICAL FEATURES
19
Caratteristiche tecniche
14
12
COMPLETE PDO PARTS DRAWINGS
21
Esploso pinza completa
13
COMPLETE JAW WITHOUT ADAPTING PLATE
23
Pinza completa senza testa
14
COMPLETE CYLINDER
25
Cilindro completo
15
COMPLETE DISTRIBUTOR
27
Distributore completo
of
29

Page
4
REQUEST OF SPARE PARTS
29
16
Richiesta parti di ricambio
of
29

1 General warnings
The following pictograms are used:
DANGER
• This symbol informs that if the operations are not carried out correctly, huge injuries, if not
deadly, can occur. Moreover the equipment can suffer damages.
.
GENERAL WARNINGS
5
Page
of
29
1

2 Maintenance and Manufacturer’s Responsibility
Instructions Manual
• This manual is studied in order to use the equipment the safe and proper way, in order to avoid
an improper use of the equipment with the possibility of causing injuries.
• Information regarding the transportation, installation, maintenance and problem solving of the
equipment is also supplied. All this information respects fully the limits imposed by the
manufacturer.
• The manual is for the attention of the person responsible for the installation, maintenance and
repair of the equipment (mainly the parts regarding the safety on the worksite).
• The equipment does not have its own control devises but is used with the excavator devises
(hydraulic excavator).
• The equipment must be used by qualified personnel. The operator must be a person who is
professionally, physically and psychologically suited to withstand the demands connected with
operating the equipment for its intended use. It is recommended to read periodically the
instructions.
• The instructions manual is not meant to replace the professional experience of the operator.
The Instructions Manual
• This instructions manual is an integral part of the equipment machine and must always
accompany it until its demolition. Keep the manual always with the equipment.
• In case it is damaged or lost, replace it immediately by requesting the manufacturer to issue a
new copy, by providing the manufacturer the model, type, serial number and year of production.
• In case the equipment is sold, the manual must accompany the equipment.
• As the main objective of the manufacturer is the constant improvement of the quality, technical
features are subject to modifications without any information.
• The user can request information and updates that, once given, become integral part of the
instructions manual.
EQUIPMENT USE AND MAINTENANCE
6
Page
of
29
2

Cases that manufacturer is not responsible
The manufacturer is not responsible in the following cases:
• Improper usage of the equipment or usage of the equipment by personnel who is not qualified
nor professional;
• Specific national law not respected;
• Incorrect installation;
• Defects in the excavator hydraulic supply line;
• Periodic maintenance not done;
• Modifications or changes unauthorized;
• Use of non-original spare parts;
• Total or partial non-observation of the instructions;
• Exceptional unexpected events.
DEFINITIONS:
Machine = Hydraulic excavator on which the PDO crusher is mounted
Equipment = PDO crusher
Operator = Person who is professionally qualified to use the equipment
EQUIPMENT USE AND MAINTENANCE
7
Page
of
29
2

3 General Technical Description
Equipment General Features
The equipment is a crushing unit composed of two closing simultaneous jaws that are operated by
two double effect hydraulic cylinders. The jaws are fixed on a strong frame and the cylinders
directly act on them.
The equipment, considering the vibrations from the excavator (excavator’s weight and the material
weight) and the necessity to guarantee the correct idraulic pressure, has to be assembled to
excavator specified in the following point. The application on a different excavator must be verified
in order guarantee the stability e safetyness of the assembly.
Note well: The application of the equipment on an excavator not proper can cause great risks to
the operator, caused by:
- loss of stability of the ecxcavator with the risk to capsize;
- possibility of unforeseen movements of the excavator boom or the equipment;
- falling or launching of material parts being crushed;
- yielding or bursting of the hydraulic circuit, with launching of high pressure liquid and
mechanical parts.
Excavator Data
The stability of the excavator is related to the weight of the excavator and the weight of the
assembled equipment to the excavator boom. An excessive length of the boom or a too low weight
of the excavator compared to the equipment assembled to the boom can determine unstablenees
of the excavator and its capsize.
Regardless of the hydraulic circuit, there should not be any values higher that those suggested. In
case the pressure should be higher than the values given for the equipment, limitation valves must
be placed on the hydraulic lines set to the given values.
TECHNICAL DESCRIPTION
8
Page
of
29
3

4 General Instructions
All these phases must be carried out by professional qualified personnel who must control that all
the security rules are respected.
Transportation
• The equipment is made of one whole part (see paragraph 11.1) and is not supplied with
detachable parts which can be transported separately.
• In case of transportation of the equipment detached from the excavator, it is recommended to
use a pallet on which the equipment will lie with the jaws open without material between them.
Proceed therefore with dismounting (see paragraph 5.5), tie the equipment tightly to the pallet
with strong self-tightening belts or similar.
• After the equipment is fixed to the pallet, it can be loaded on a truck. All the operations of
loading and unloading must be done with the engine off and the brakes on. The equipment must
be well fixed on the truck with strong belts.
• Do not transport the equipment with material between the jaws.
• Particular care towards the hydraulic circuit and hoses must be always given.
Movement
•
In case the equipment is to be lifted, a chain suitable to lift up minimum 0,15 tons must be used,
fixed to the lifting positions on the reinforced side. The chains must not form an angle above A°
= 90°.See drawing.
•
During the movements use care in order avoid violent movements.
Stockage
In case the equipment is stored, there is no need of particular care. After dismounting the
equipment as described in specific paragraph and placed it on a pallet by using a proper machine,
stock the equipment in a dry, clean and covered area without placing anything on top of it.
GENERAL WARNINGS
9
Page
of
29
4

5. Installation
ATTENTION:
• Before starting these operations, make sure that the working area is clean and in order.
• Personal safety equipments: it is recommendable that for all operations, personal safety
equipments are to be used such as: overall, safety glasses, working gloves, dust-mask, helmet,
anti-noise caps, safety shoes, etc.
• Before starting the equipment please make sure that the equipment is complete and in case of
doubts contact the manufacturer. Packaging must be removed using maximum care in order to
avoid injuries.
Control Devices
The equipment does not have its own devices.
Before starting the equipment, make sure that the excavator is provided with the two hydraulic
circuits suitable to feed the motor of the equipment (jaw actioning cylinder and rotation motor**)
with respective bi-directional control devices placed in the cabin.
Hydraulic Connection
The excavator must be provided with one or two hydraulic circuits having three control positions
with automatic return and an electric circuit, depending on the models.
For the connection, refer to the schemes attached to this manual.
ATTENTION:
• The control devices must have three positions with automatic return in the central position when
the operator has finished the operations. Moreover, it must not be possible to block the control
device in a position different from the standby position.
• The hydraulic system must have the above technical features, otherwise please carry out the
needed modifications.
** PDO 100 model excluded
Hydraulic Hoses Connection
It is absolutely obligatory to stop the equipment and down load the hydraulic pressure
completely before starting any operation.
The hydraulic hoses, both input and output, must have a quick coupling with oil retainer.
Pay careful attention when moving the hoses to avoid any rubbles entering the hoses and
causing damages to the internal parts. Proceed then with connecting the equipment to the
excavator.
Equipment Disassembly
In case the equipment is needed to be dismounted from the excavator proceed in the following
way:
• Place the equipment on the flat ground in order to avoid it from moving.
• Stop the excavator and download the hydraulic oil pressure.
• Disconnect the hydraulic hoses which connect the equipment to the excavator.
 Remove with caution the pins from the attachments of the adapting plate.
INSTALLATION
10
Page
of
29
5

6. Equipment start-up
Protection devises cannot be applied to the equipment, all the area in the ray of action is to be
considered dangerous and for this reason it is absolutely forbidden to use the equipment before
having prevented the access to the work area to people or animals, therefore it is necessary to
fence the worksite.
Preliminary inspection
Before starting the crushing operation, a general inspection of the equipment must be done.
• Move away from the working area of the equipment any person or animal.
• Make sure that in case there are valves mounted on the excavator boom, they are open.
• With extreme caution the operator on the excavator must proceed with the different movements
of the crusher in order to verify that the equipment is functioning well by opening closing and
rotating the equipment.
• All these operations must be done with extreme caution.
Equipment use
After having done all the operations verify that the equipment does not have any damages :
1. position the equipment on the flat ground and make sure it is stable,
2. switch off the engine of the excavator and remove the key from the control panel,
3. download the hydraulic pressure,
4. wait for the oil temperature to cool down,
5. before approaching the equipment make sure to have all the personal safety equipment,
6. proceed with extreme caution and attention with the visual control of the complete equipment.
ATTENTION:
• Before and after the usage, the equipment must be controlled, all the mobile parts must intact,
bolts, screws, hoses etc. and in case any are damaged, proceed to their replacement.
• Verify the status of the metal case, wear, damages etc.
• Verify the status of the bearings, shaft and bushes.
• Verify that the pressure supplied is not above the maximum required and if necessary install a
pressure control valve to down load.
• The hydraulic connection must be done using components ideal to withdraw the maximum
working pressure allowed by the law.
• Do not use the equipment when the oil temperature exceeds 80°, serious damages can be
provoked to the equipment; in case you have worked in these conditions control immediately the
cylinders and the distributor.
• Verify there are not any oil leakages, in case there are, do not enter in contact, as it is in
pressure and very hot.
After the first usage, the bolts must be checked to make sure they are fastened, this control must
be done frequently during the first days.
EQUIPMENT START-UP
11
Page
of
29
6

7 Equipment use
Preliminary
The equipment is studied for the demolition of:
• Non-reinforced structures
• Reinforced concrete e cutting of rebars
The structures to be demolished must not danger through the presence of liquids or gas in
pressure, corrosives or instable, without electricity, without the structure tensioned with high
resistant cables.
The operator must verify that the above are not present on the worksite.
Other operations of demolition/crushing non specified in this manual must be planned by the
jobsite manager.
Your attention is required for the following points:
- The equipment must be used only by qualified personeel who has read this manual, who is
authorized to use the equipment and has experience in use and functioning of the
equipment. Toread this manual periodicallu is suggested.
- The operator’s knowledge of the control devises is fundamentalin order to use the
excavator and the equipment.
- Avoid any type of work that can mean non-staqbility of the excavator or the assembly of the
excavator-equipment.
Materials to be worked on
Please see the table 1 for the largest dimensions of the masses, instead regarding the materials to
be worked please see the following limitations:
-The equipment can be used to demolish reinforced concrete or prestressed concrete, with a cubic
resistance of RBK<55N/mm2. It can be also used for materials such as natural stone, cement
bricks or similur, having a resistance below value here specificed.
-The bladesm of the crusher can be used to cut iron rebars, alluminium and copper bonds having a
max load of below 750 N/mm2 and hardness below 230HB.
Usage
In order to carry out these operations the operator must:
-position the excavator near the mas to be worked on;
-the operation of crushing the masses in reinforced concrete produces the launching the materials
on all the area below the material being crushed, for a radius of serverl meters, area which must
be cleared from materials or other things that can get damaged;
-the operation of cutting metallic masses determines the falling of heavy pieces and the launching
of smaill parts, on all the area below the mass, for a radius of serveral meters, area that must be
cleared from materials or other things that can get damaged;
-position the crusher in such a way that the material is palced between the jaws, taking care that
the jaws are perpendicular to the side of the material, in order to avoid actions that can damage
the crusher movments;
-proceed in closing the jaws with care, verifing that the crushing and or the cutting operation is
proceeding in way regular way, without producing large pieces closed between the jaws;
EQUIPMENT USE
12
Page
of
29
7

-interrupt the operation e proceed in removing the material, in order to avoid forming accumulation
of unstable material in the working area.
USAGE NOT PERMITTED
All the operations listed below can mean serious damages to the equipment and to the safety of
the operator. Therefore these operations are totally prohibited, in case of contrary the warrantee on
the equipment and the responsibility of the manufacturer will decline.
-The equipment must not be used on a different excavator as the one suggested, and must be
verified before the usage.
-The equipment nust not be used for operations or materials which are not the ones indicated.
-The equipment must not be used by personeel which is not properly prepared.
-The equipment must not be used in worksites different from those indicated, referred to the
temperature and humitidy.
-The equipment must not be used in dangerous worksites, in presence of gas, vapor, aggressive
climate, corrosive, esplosive, danger of fire, due to the over heating from the working procedures.
-The equipment must not be used in case of unstable or leaning ground.
-The equipment must not be used to crush water pipelines, pressure lines, gas lines, electrical
lines, before having verified that there isn’t any electricity or dangerous residuals.
-Crushing operations must not be done near dangerous elements (tanks with pressure, pressure
lines, high tension electrical llines, in case the safety distances do not guarantee that these
elements can be damaged by falling parts due to the crushing operation.
-The equipment must not be used to compact, tear or pull materials.
-Do not rotate the crusher with material in between the jaws, the rotation allows the operator to
place the equipment in the ideal position for the demolition process.
-It is forbidden to use the equipment to crush material that can slide and cause danger such as:
- round materials,
- on either end of a beam,
-This material or similar pieces can also cause damages to the jaws.
-It is forbidden to use the equipment to lift or transport people.
-It is forbidden to move above people with material between the jaws.
-During the demolition do not move the excavator.
-Make sure that the excavator is always on solid ground and not tilting in order to be stable. In
case of an unstable situation of the excavator due to the weight of the material being crushed,
open the jaws immediately and free the material.
-Do not use the equipment or move in case the operator does not have a full view of the working
field.
-It is forbidden to bring and maintain the equipment at the maximum pressure trying to demolish or
cut a concrete structure positioned on the bottom of the jaws, or between the blades. In case such
situation accruse, imeediately remove the pressure and appraise whether you can proceed with
the demilition in gradual way or whether the equipment used is understaffed for the type of usage
(application)
EQUIPMENT USE
13
Page
of
29
7

8 Maintenance and Inspections
The operations of maintenance and inspections are necessary in order to keep the technical
performance and safety features designed by the manufacturer during the life time of the
equipment.
Before the usage, make sure to have all the individual protections.
The person responsible of the maintenance and inspection must always be professionally
qualified and follow all the instructions in this manual.
Place the equipment on clean and solid surface and stop the excavator and remove the key
from the control panel.
Download the hydraulic oil pressure completely.
Wait for the oil to cool.
Every 40 hours in normal working conditions, proceed to the greasing as to point n.1 with
LOCTITE HEAVY DUTY ANTI SIEZE grease or similar. During particular crushing operations
service every 8 hours.
PARTS DRAWING PDO 100
Verify with the same frequency of the greasing inspections: the connection of the equipment to
the excavator and verify that the bush housings are not damaged.
Verify the clearance between the rods and the bushes, in case the clearance exceeds 0,6mm
replace the damaged components.
Verify the structure of the equipment and the cylinder rods.
Verify the bolt tightening.
Verify the conditions of the blades.
Verify that there are not any leakages in the hydraulic system (hoses, couplings, seals).
In order to avoid that the properties of the steel of the equipment do not place the equipment
near strong heat or welding procedures.
The manufacturer is not responsible for damages caused by modifications done to the
equipment if not approved by the it’s technical department.
Proceed with all service operations in a clean and illuminated workshop.
In case any hydraulic or mechanical parts are to be replaced, only original parts are to be used.
These are supplied by Socomec SpA specifying the product code, model, year of production
and serial number of the equipment.
MAINTENANCE AND INSPECTIONS
14
Page
of
29
8

Technical Support
Socomec SpA, based in Medesano (Parma-Italy), can solve any problem regarding the usage,
service and repair of the equipment.
Socomec SpA can supply the details of the nearest Authorized Dealer to you for any repair etc.
It is fundamental to refer to an Authorized Dealer for technical support.
Instructions to Scrap the Equipment
In order to scrap the equipment, all the hydraulic oil must be sealed in a container and delivered to
an authorized company for its’ disposal. The oil must be separated from the metal parts. The metal
scrap can be given to any metal scrap yard, the oil nmust be given to specialized disposal refuses
companies.
Warranty
The manufacturer assures the customer a warranty term which is foreseen in the contract of
purchase.
The customer will lose his rights on warranty, if he does not comply with the terms of payment
(even only once), or if the breakdowns are caused by the customer himself, his employees or
others, through: an improper installation (if not made by the manufacturer), inexperience in
handling the machine, improper use, bad maintenance, modifications, changes or tampering made
without an authorization by the manufacturer.
The warranty declines if non-original spare parts are used by the customer.
All those parts subject to wear and tear, are excluded from warranty.
The warranty, which the manufacturer must grant by law, is limited to the replacement or repair of
the parts damaged by the manufacturer himself and this at his own choice.
The report on possible faults must be done by the customer, within 8 days, by registered letter. No
compensation for damages is due to the customer.
The faulty parts must be sent to the supplier’s factory, carriage free, in order to be inspected and
eventually changed or repaired under warranty.
Where the installation is made by the manufacturer, any damage caused to the customer or
others, during the installation, falls on the customer’s responsability.
MAINTENANCE AND INSPECTIONS
15
Page
of
29
8

9 Problems and Solutions
Problem Cause Solution
Equipment does not work
•
Oil flow is not enough
or missing.
--------------------------------
•
Valves on the
excavator boom are
closed.
--------------------------------
•
Something is
blocking the cylinder
stroke.
• Verify the excavator pump and replace
if necessary.
---------------------------------------------------------
• Open the valves.
---------------------------------------------------------
• Remove the obstruction and verify
possible damages.
Equipment does not rotate.
•
The idraulic motor
could be broken.**
--------------------------------
•
The pressure in the
hydraulic circuit is too
low or too high.
--------------------------------
• Excessi
ve friction in
the rotating group.
--------------------------------
•
Crushed pieces can
block the jaws.
• Check che components.
---------------------------------------------------------
• Verify that the hydrauic pressure is
within the limits indicated in Tab.1
---------------------------------------------------------
• Grease the rotating group.
---------------------------------------------------------
• Remove the pieces that do not allow the
movement.
Equipment does not crush.
•
Hydraulic system is
damaged.
--------------------------------
•
Material to crush is
too hard.
--------------------------------
•
Hydraulic pressure is
too low.
• Verify the hydraulic system.
----------------------------------------------------------
•
Free the material and try crushing
smaller pieces.
----------------------------------------------------------
• Verify the hydraulic system.
** PDO model excluded
PROBLEMS AND SOLUTIONS
16
Page
of
29
9

10 Protection Against Mechanical Risks
General Instructions
During the use of the equipment, crushed pieces can fall and damage the hydraulic hoses
with eventual oil leakages. ATTENTION.
During the use of the equipment, crushed material can be launched away from the working
position. ATTENTION.
During the use of the equipment, the jaws can be damaged and material can be launched
away from the working position. ATTENTION.
During the usage the motor can be damaged with the loss of control of the equipment.
IT IS FORBIDDEN FOR ANYONE TO STOP IN THE EXCAVATOR WORKING AREA.
ATTENTION.
USE ALWAYS PROTECTION DEVISES DURING THE USAGE.
DO NOT APPROACH THE EQUIPMENT UNLESS THE EXCAVATOR IS STOPPED AND
THE HYDRAULIC OIL PRESSURE IS DOWNLOADED.
Thanks to the shrewdness and attention in the design, the equipment doesn’t present any
further risks in case the OPERATOR FOLLOWS ALL THE INSTRUCTIONS STATED IN
THIS MANUAL.
Materials and Products
In manufacturing the equipment, material which is not harmful has been used.
Risks during Use
The equipment parts are resistant and studied for a normal use and have been chosen with
regards to the different temperatures, lifetime and for abrasive materials.
Risks of Stability


The equipment must be attached on an excavator with technical features that fit with the
equipment’s weight and technical details. The equipment has been designed in order to avoid
problems to the excavator stability.


Follow all the instructions in this manual.
Risks related to Angles and Surfaces


The equipment parts are without angles and without rugged surfaces which can cause injuries.
Risks due to Noise Level


The noise level of the equipment registered during the crushing process does not exceed 80 db
(A), therefore no protections are needed.


The use of personal hearing protection is anyway recommended.
PROTECTIONS AGAINST MECHANICAL RISKS
17
Page
of
29
10

Risks due to Dust Pollution
During the crushing process dust pollution is released. Proper dust and other protections must
be used during the crushing process and, if possible, use water to reduce dust pollution.
Protections
Protections on the equipment for its’ specific use cannot be applied.
The control devises in the excavator cabin are used for the equipment also.
•IT IS FORBIDDEN FOR ANYONE TO STOP IN THE EQUIPMENT WORKING AREA.
PROTECTIONS AGAINST MECHANICAL RISKS
18
Page
of
29
10

3
11 Technical Features
MODEL
PDO 100
WEIGHT IN WORKING CONDITIONS
kg 110
A
mm 260
B
mm 220
C
mm 60
D
mm 840
E
mm 20
CYLINDER FORCE
ton. 20
CRUHING FORCE
ton. 18
CUTTING FORCE
ton 40
MAXIMUM PRESSURE
bar 210
WORKING PRESSURE
bar 180
OIL FLOW
lt/min.
10 - 20
ROTATION
H Libero
ROTATION PRESSURE
bar --
ROTATION OIL FLOW
lt/min.
--
EXCAVATOR WEIGHT
ton 0,8 – 2
DEMOLITION HOSES DIAMETER (EN 853 - 2SN)
G 1/2"
TECHNICAL FEATURES
19
Page
of
29
11

4
11.1 Hydraulic circuit PDO 100
ACCELERATING
VALVE
DISTRIBUTOR
TECHNICAL FEATURES
20
Page
of
29
11