Friday, November 22, 2019

Mailhelp@pcmfluidpower.co.uk                                                   Phone pic +44 (0)1327 842808

logo2

D19                                                                                                 

PCM STABILISER PADS

Quality Statement

 

PCM stabiliser pads are produced from recycled high molecular weight polyethylene produced to various DIN standards. This material is made only from new production remainders, and when reprocessed has the same properties as material produced from new raw material. Re granulation intensive mixing ensures an even distribution of colour through the stabiliser pad and gives an attractive mottled finish. The material is tough, resists abrasion, had good elasticity and elongation. This means that the stabiliser pad will deform rather than compress, shear or otherwise break. The illustration of a pad under test demonstrates this.

 

The deformation of a stabiliser pad is an indication that its working load is being exceeded and therefore alerts the operator to take appropriate action.

 

Full technical specification is available on request and is provided as a matter of course with any stabiliser pads supplied.

 

Having carried out extensive product testing, ‘cheap’ stabiliser pads made from secondary recycled materials are not a product PCM would offer. Our tests show that such products can permanently deform under much less imposed load than the PCM stabiliser pads, and that in some circumstances the stabiliser foot can penetrate the material of the cheap pads and in one alarming test, the pad material disintegrated due to lack of granular cohesion.

 

D15                                                                                                                                                                                

READ BEFORE OPERATION

 

GRAB / CLAMSHELL BUCKET INFORMATION

  1. The Grab/Clamshell Bucket is built according to the EC Machinery Directive 89/392 as modified with the EC norms 91/368 and 93/44 and to the European Norm EN 292 1st / 2nd part.

    Fitting information Operation

  2. The grab bucket should be fitted to a loader crane of suitable capacity, using suitably rated link and rotator.

  3. The grab bucket should be fitted by a suitably qualified person.

  4. High tensile (at least 10.9 grade) 16mm attachment bolts should be used to attach the grab to the rotator mounting plate, and the shoulders of the bolts should extend through the rotator and bucket mounting hole. Set screws (i.e threaded to the head) should not be used.

  5. When fitted, the working pressure on the grab during operation must not exceed 200 bar when closing, 20 bar when opening. The lower opening pressure is to ensure that damage does not occur to the compensating mechanism, if the bucket is prevented from fully opening by, for example, the sides of an excavation or skip.

  6. When used for the handling of particularly abrasive material it is recommended that the bucket is fitted with optional “bolt-on” cutting edges.

  7. After fitting and pressure checking, the bucket should be operated a few times fully open and fully closed, so as to operate the respective relief valves, in order to purge any air out of the system.

    Safety Information

    In addition to the maintenance information, the following safety information may be considered in addition to the normal safe operation of a loader crane without attachments.

  8. Do not attempt to overload the bucket by forcing down into a pile of material.

  9. Do not attempt to slew the bucket with the rotator while in contact with the ground or material.

  10. Never stand under the bucket, or allow others to stand under the bucket while loader crane is in operation.

  11. Never attempt to grease or otherwise work on the bucket if the loader crane is operative

  12. Do not attempt to lift items by clamping between the cutting edges.

  13. Do not attach chains or slings to the bucket, unless fitted with approved and tested attachment points.

    Maintenance Information

  1. All maintenance must be carried out with the equipment secured and with the operating machinery switched off.

  2. All maintenance should be carried out by skilled, trained personnel only.

  3. Grease suitably all joints DAILY and in case of occasional use only, grease joints prior to use. Only use synthetic lithium based, extreme pressure grease with a consistency of NLGI 2.

  4. Nuts, bolts, pins, plugs and bushes should be checked at regular intervals.

  5. Hose lines, hose connections and fittings should be checked at regular intervals.

  6. Always use original spare parts.

    General Warranty Terms – (full Terms and Conditions available on request)

  1. The company will make good by repair or replacement (at the company’s option) defects in goods supplied or manufactured by the company, which under proper use occur within 12 months of the supply date, which will be deemed to be the invoice date.

  2. The product warranty is strictly limited to defects in material and manufacturing and does not include damage caused by incorrect mounting, improper fitment, modifications, misuse, abuse, over-loading, etc.

  3. Any claim for warranty arising from improper fitment, alteration, modification or unsuitable purpose will be rejected.

  4. Validation of warranty claims will be assessed by the company by examination and testing at the company’s premises.

  5. The company shall not be liable for any loss or damage consequential to a warranty claim by a customer.

     
     

    IMPORTANT

    If you require any further advice or assistance, please contact your supplier.

 

D13                                                                                        

Important – Please Read

 

Safety Notice - Stabiliser Pads

Polyethylene pads are produced to spread loads imposed by stabiliser jacks upon the surface on which they are deployed.

Their methods of use are included in the training programmes for equipment operator licensing and therefore stabiliser pads should only be used by qualified operators. See LOLAR regulations for further information.

    • Pad choice should be made taking into account the type of duty and conditions likely to be encountered during operations.
    • Pads should not be used to bridge voids.
    • Pads should not be used on brittle surfaces such as manhole covers and drain grating.
    • Pads should not be used to impose loads beyond the minimum required distance from the edge of excavations, river banks, sea walls and similar hazardous situations.
    • Pads which become deformed should be replaced.
    • Pad deformation is an indication that a higher specification pad may be required.
    • Pad lifting handles should be regularly checked for security and wear and replaced if necessary.
    • Pads should be stored away from heat sources likely to exceed 80°.

Some stabiliser pad sizes over 600 x 600 x 60 exceed the safe lifting load for one person and therefore require alternative methods of lifting.

Full material specification is available from PCM by request.

 




D14                                                                                       

Important – Please Read

 

Lorry Loader Crane Mounting Studs and Weldable Drilled Blocks

General

The mounting on vehicles of lorry loader cranes should only be carried out by suitably qualified personnel and according to the recommended methods of the particular crane manufacturer.

The crane mounting studs supplied are a high quality, high tensile product specifically manufactured for loader crane mounting applications with rolled threads in 42 cr MO54 material, hardened and tempered. This material can be cut to length using normal methods, except abrasive discs which may cause local heating of the stud. The studs must not be heated or welded to during or after installation. The unused centre part of the thread should be painted with a non etch type primer prior to installation. In no circumstances should the studs be electro-plated or dip plated.

Nuts supplied with mounting studs are high tensile steel, hardened and tempered. In no circumstances should ordinary commercial grade items be used in their place.

When tightening the nuts, the appropriate torque should be applied to a single nut which should then be locked with an additional nut whilst holding the previously torqued nut.

Suitable washers or bridging pieces should be used where required, across slots and oversize holes.

Most cranes now require an 8 stud mounting pattern and older cranes should be upgraded to this pattern if possible.

Weldable drilled blocks are manufactured from BS 43 A material commonly referred to as “mild steel”. They are designed to have sufficient length to hole size ratio to ensure that when correctly welded the attachment has a suitable safety margin in relation to the ultimate stud strength. It is essential that the specification of the material to which the block is to be welded is known and that a suitable welding procedure is carried out. Attention should be paid to the weld fillet size and the welding position. Mounting blocks are end faced to provide an accurate 90 degree to length face for the securing nuts. Therefore it is important that the blocks are carefully positioned and welded. Tightening nuts up on an “out of true” surface will impose extra stress on the nut and stud, and must be avoided.

The table gives a guide to the maximum recommended torque of the different sizes of nuts and stud and this must not be exceeded. The torque settings should be checked after the loader crane has been proof load tested. If any significant tightening is required then it should be checked that the stud is of the required size for the application.

In service, nuts should be occasionally checked for security but if it is found that significant tightening is required the cause of this should be investigated and if the stud elongation is suspected, the reason for this must be identified and rectified. Elongated studs and nuts should be discarded and never used for the re-mounting of lorry loader cranes.

Maximum Recommended Tightening Torque – Threads Lubricated

Stud Size Max Torque Nm
18mm 125
20mm 175
22mm 250
24mm 350
27mm 500
30mm 600
33mm 1000
36mm 1250
39mm 1600

 

D12              PTO / Pump Fitment              

Please check that your order is complete and that no damage in transit has occurred. Please inform your supplier immediately of any shortages or damage.

Hydraulic equipment can cause death, personal injury and property damage.

The equipment should be fitted and commissioned by a suitably qualified person.

PTOs

  1. Any specific instructions for the particular PTO are supplied. If you do not have these, please contact us. In addition to good fitting practice the following points are drawn to your attention.

  2. Check sufficient backlash between PTO gear and gearbox gear on side mounted PTOs. Insufficient backlash will typically cause whining and rapid wear resulting in both damage to PTO and gearbox.

  3. Backlash should be set to the instructions specific to the type of PTO being fitted, and should be to the manufacturer’s instructions. As a further guide, no unit should ever be run with zero backlash or a backlash so great as to cause rattling, normally evident if the backlash is greater than around 0.40mm. Backlash is expressed as a measurement of the radial movement of the PTO gear measured at the outer end of the gear teeth.

  1. Do not use more than 3 soft gaskets to achieve clearance. If more clearance is required insert metal shim gasket.

  1. Fixing studs should be secured using “loctite” or similar locking compound.

  1. Function including engage / disengage should be checked before the pump is fitted.

  1. On a rear mounted PTO take extra care to ensure that any quillshaft supplied is correct for length, engagement into gearbox spline or drive gear, and engagement into oil pump if fitted.

  2. The air supply to the PTO should normally be at the full vehicle system pressure (?-?) taken from manufacturers recommended supply points. This is especially important on clutch type PTO’s as any unsuitably low pressure will cause major damage to the clutch pack. Always check the manufacturer’s minimum and maximum pressure instructions. Air must not contain contaminates such as oil or water.

Pumps

  1. Check pump rotation

  2. Before fitting the pump, lightly grease the pump shaft up to the pump seal.

  3. On applications where water or other contaminates may enter the PTO/Pump joint, fit a gasket

  4. Always bleed the pump before use, either by means of the bleed plug if provided, or by allowing oil to exit the pressure port before coupling outlet pipe.

  5. Certain pump types may require pre-filling with oil – check additional instructions.

  6. If a pump is replacing a failed unit take into account residual contamination and take steps such as oil and filter changing.

  7. Do not start the PTO / Pump under load.

  8. Check that relief valves have not been adjusted to compensate for a previously worn pump.

  9. If in doubt, always back off the relief valve before running the pump

  10. Always pressure check, by means of a suitable gauge, the system pressure before the equipment is put into service.

    IF IN DOUBT ASK YOUR SUPPLIER

Hydraulic Fluids

Although not highly aggressive, hydraulic fluids may contain compounds dangerous to eyes and mucous membrane. Emergency procedures should be followed if fluid contamination occurs to eyes or internally. Medical assistance must be immediately sought in these instances. Prolonged exposure of outer skin may lead to skin complaints and should be avoided. Used oil may contain carcinogens.

Pressure Hazards

Vehicle hydraulic systems may run up to pressures of 500 bar. Fluid at this level of pressure can penetrate skin if near high pressure leaks or component failure. Penetration of contaminates in to the sub skin layer can be fatal. Fluid injection accidents are extremely serious and immediate emergency medical assistance must be sought. Suitable protective equipment must be worn when working on live hydraulic systems.

Heat Hazards

Faulty hydraulic systems can heat fluid which, being under pressure, can attain temperatures far in excess of its atmospheric boiling point and contact with components at these temperatures can cause burns. Contact with the fluid at these temperatures will cause scalding burn injuries. Immediate medical attention must be sought.

Mechanical Hazards

Hydraulic systems can store energy in the form of pressure (e.g. in hoses or accumulators) or potentially by the imposition of force due to the relative position of components and the effect of gravity or other energy storage mechanism on these components. Therefore, before any work is undertaken on hydraulic equipment, these forces must be eliminated by neutralizing the equipment.

Equipment can be neutralised by:

  1. Bleeding off under control any residual pressure.

  2. By blocking or otherwise supporting components.

  3. By returning equipment to at rest or neutral positions.

    Equipment such as tipping bodies, loader crane booms, tail lifts and excavator booms present obvious hazards in this category.

 






PCM Footer