Scrapped shipbreaking hydraulic shear woking in Batam
We have helped customers install our hydraulic shears in many countries across Asia, but the installation in Batam, Indonesia, was particularly impressive. This hydraulic shear is for scrapped shipbreaking jobs.
When the customer placed the order to us, the excavator they provided was a Kobelco SK330-8 excavator, which already had a spare valve for connecting hydraulic attachments. However, when our technicians arrived at the customer’s site, they had purchased a new SK330-10 excavator to install this dual-cylinder hydraulic shears. Unfortunately, the spare valve for the attachments were not installed on the excavator at the factory.
We have to contact Kobelco excavator dealers in Batam and Jakarta, but none of them had spare valves in stock. We were forced to order genuine Kobelco spare valves from the factory in China and have them airfreighted to Batam. Even with the delivery time, it would have taken about a week. After arranging the order from China, our technicians had to abandon the installation and return to Jakarta to await the arrival of the spare valves.
After about a week of waiting, the spare valve, flown from China to Batam, finally arrived at the customer’s scrap metal removal site. Our engineers then flew from Jakarta to Batam to continue the installation and commissioning of the hydraulic shears.
The installation of scrapped shipbreaking hydraulic shear
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Connect the main hydraulic lines.
Connect the hydraulic shears’ oil inlet pipe (high-pressure pipe) to the excavator’s P port (pressure oil outlet) and the return pipe to the T port (return oil port).
Inspect the newly installed spare hydraulic valve and confirm that the valve core function is activated.
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Secure the pipes.
Use welding, clamps, or cable ties to secure the pipes to the excavator boom to prevent friction with moving parts (such as the swing platform and cylinder).
Ensure that the pipe bend radius is greater than or equal to the minimum allowable value to prevent bends that could cause oil flow obstruction.
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Check for leaks.
Apply teflon tape or sealant (applies only to threaded connections) to the joints to prevent oil leaks.
Do not use damaged O-rings or seals.
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Connect the control signal cable.
If the accessory requires solenoid valve control (such as opening and closing a hydraulic shear), connect the solenoid valve control cable to the excavator cab and install a separate control box to control the opening and closing of the hydraulic shears.
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Adjust the pilot pressure.
Use the pressure reducing valve in the excavator’s hydraulic system to adjust the pilot valve pressure to the required pressure range for the hydraulic shears.
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Initial Startup Inspection
Start the engine and let it idle for 5 minutes. Observe the pipes for leaks or abnormal vibration.
Slowly operate the attachment control handle to check for smooth movement (avoid sudden high-pressure shocks).
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Bleeding and Refilling Oil
If the hydraulic shears are sluggish, there may be air in the pipes. Repeatedly operate the attachment several times to expel the air. Check the hydraulic oil level and refill with the same type of hydraulic oil if necessary.
After verifying that the hydraulic shears were functioning properly, our staff also provided on-site operator training on usage and maintenance.
Installation summary
The customer was very satisfied with the excavator mounted hydraulic dual-cylinder shears and our service. They have greatly improved the efficiency of scrap ship demolition and shortened the time. This efficiency improvement is accompanied by a significantly lower cost than manual oxygen cutting. Simply put, it directly reduces the cost per ton of scrap metal removed, increasing profits.
The customer even joked that the introduction of these excavator shears might displace up to 10 workers and put them out of work. Although the customer was kind and reluctant to lay off these workers, managing them remains a significant headache, and he will have to consider this issue, at least to make things easier.
We also feel bad about laying off these workers, but the development of intelligent machines is designed to replace the hard work of humans, rather than the harsh working environment. This allows humans to perform more valuable work in a better environment, thereby promoting further social development. With this in mind, we will further strengthen this hydraulic shears for sale in Indonesia.
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