Operations Manual DCS4 DCS5

Operating- and maintenance manual
Service manual
Spare parts lists
Clamshell grab – Model line DCS

Clamshell grab
Table of contents:
Part 1. Operating manual ..................................................................................................... 3

1.1 Product identification: ................................................................................................. 3
1.2 Terms of guarantee: ................................................................................................... 4
1.3 General safety instructions: ........................................................................................ 5
1.4 Product information: ................................................................................................... 6
1.4.1 Assembly: ............................................................................................................ 6
1.4.2 Product description: ............................................................................................. 6
1.4.3 Design features: .................................................................................................. 6
1.4.4 Plug system: ........................................................................................................ 6
1.4.5 Measures / Technical data: .................................................................................. 7
1.4.6 Recommended Hydraulic fluids: .......................................................................... 7
1.4.7 Employment: ........................................................................................................ 8
1.5 Transport / Storage: ................................................................................................... 9
1.6 Installation and initiation: .......................................................................................... 10
1.6.1 Positions of the hydraulic connectors at the rotator: .......................................... 11
Part 2. Service manual ...................................................................................................... 12
2.1 Inspection: ............................................................................................................... 12
2.1.1 Items of daily inspection: ................................................................................... 12
2.1.2 Items of weekly inspection: ................................................................................ 12
2.2 Maintenance............................................................................................................. 13
2.2.1 Items of daily maintenance / after 8 operating hours: ........................................ 13
Part 3. Spare parts lists: .................................................................................................... 14
3.1 DCS05 / Z-Z05 with AG 5-2 ..................................................................................... 14
3.1.1 DCS05 / Z-Z05 - Grab cpl. - Spare parts ........................................................... 14
3.1.2 DCS05 / Z-Z05 - Grab cpl. - Picture................................................................... 15
3.1.3 DCS05 / Z-Z05 - Cylinder - Picture/spare parts ................................................. 16
3.2 DCS1 / Z-Z1 with AG 5-2 ......................................................................................... 17
3.2.1 DCS1 / Z-Z1 - Grab cpl. - Spare parts ............................................................... 17
3.2.2 DCS1 / Z-Z1 - Grab cpl. - Picture....................................................................... 18
3.2.3 DCS1 / Z-Z1 - Cylinder - Picture/spare parts ..................................................... 19
3.3 DCS2 / Z-Z2 with AG 5-2 ......................................................................................... 20
3.4 DCS3 / Z-Z3 with TH609H-2-G3/4” .......................................................................... 23
3.5 DCS4 / Z-Z4 with AB1000-30-PV ............................................................................. 26
3.5.3 DCS4 / Z-Z4 - Cylinder - Spare parts................................................................. 29
3.5.4 DCS4 / Z-Z4 - Cylinder - Picture ....................................................................... 30
3.6 DCS5 / Z-Z5 with AB1500-31-PV ............................................................................. 31
3.6.3 DCS5 / Z-Z5 - Cylinder - Spare parts................................................................. 33
3.6.4 DCS5 / Z-Z5 - Cylinder - Picture ....................................................................... 34
2
Clamshell grab
Part 1. Operating manual

1.1 Product identification:
Position of identification data
1
1. Serial number – rotator
(on identification plate – rotator)
2
2. Serial number – grab

(stamped onto frame) 3
3. Identification plate - grab
Explanation of identification plate
Contact postal address
Max. lifting capacity – grab
Max. working pressure - turning
Max. oil amount - turning
Max. working pressure – griffin
Max. oil amount – griffin
Max. weight of carrier machine
Trader- / customer number

Identification information:
Type designation – grab:
Serial number – grab:
Serial number – rotator:
Type designation – carrier machine:
Day of delivery:
Trader information:
Name: Branch:
Address:
Customer number:
Phone: Fax:
E-Mail: Contact person:
3
Clamshell grab
1.2 Terms of guarantee:

A) Guarantee period
Prodem offers a guarantee period of 12 months after delivery of the product.
B) Guarantee extent
The guarantee shall include all parts showing defects which are traceable to material or production faults.
C) Guarantee completion
a) Guarantee claims must be submitted to Prodem in writing (see D Guarantee notification).
b) Defective parts, replaced within the scope of the guarantee, shall remain the property of the HGT. Upon request they
must be delivered immediately to the manufacturer for the purpose of guarantee claim settlement (see E Allocation).
c) Spare/replacement parts must be ordered from Prodem on account.
d) After the investigation by Prodem, an evaluation and a written statement are made and if necessary a credit note of
the resulted costs.
D) Guarantee notification
Guarantee claims must be submitted to PRODEM in writing within 4 weeks after the damage or fault has occurred and
must include the following information:
 Type identification number of PRODEM product
 Factory and, where necessary, rotator ID number
 Denotation of the defective part ( if possible with PRODEM - spare part number )
 Date and kind of the damage
 Possible cause of damage (photographs as required)
 Information about deployment and carrier machine ( digger / crane )
E) Allocation
Defective parts must be made available free of charge for PRODEM min. 6 weeks after guarantee notification for
investigation of the defect. Defective parts which are not returned to PRODEM/and/or are not made available for the
investigation are excluded from the guarantee.
F) Guarantee exclusion
The following shall be excluded from the guarantee:
 Damage incurred by improper assembly of machine parts and/or hydraulic components, as a result of improper
use or maintenance or damage incurred during transport.
 Defects which are traceable to repairs carried out by a non-authorised third party.
 Defects incurred by the use of foreign spare parts.
 Damage to parts subject to normal wear, such as e.g.: sleeve bearings, hoses, bolts etc.
 Secondary damage traceable to the delayed replacement of wearable parts.
If repairs are carried out independently by the owner on machine parts during the guarantee period without the prior
consent of the manufacturer (PRODEM), guarantee and/or liability claims shall become void.
G) Guarantee claims
Guarantee claims shall only relate to the possible cost-free delivery of replacement parts. Travel and wage costs shall be
subject to negotiation.
We reserve ourselves to adapt assembly/disassembly hours in individual cases on a necessary measure. To customer
service expenditures the following, firm sentences apply:
 Assembly/disassembly by mechanic
 Travel expenses of mechanic, vehicle included
H) Special arrangements
Special arrangements according to the specified points 1-5 are to be submitted in writing before conclusion of the sales
contract and be confirmed by PRODEM in writing. Later special arrangements cannot be considered.
I) Contact – guarantee: PRODEM
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Clamshell grab
1.3 General safety instructions:

Please observe the following items before assembling or operating this machine component:
1. First read this operating manual thoroughly!

Should unclear points or questions arise when reading through this operating manual, please
consult you supplier in the first instance.
2. Check whether your carrier machine if suitable for this product!
3. Acquaint yourself with the safety regulations applicable at your place of

Work!
4. If you do not comply with the information and instructions given in this operating manual, all
guarantee and/or liability claims shall be excluded.
The grab is constructed according to the present state of technology and complies with the currently
applicable safety regulations. Unforeseeable factors may, however, affect the safety of the grab.
It is therefore extremely important to precisely adhere to the safety regulations.
Safety rules:
1. Any damage to the grab must be repaired immediately by a qualified technician.

If necessary, the assistance of the supplier or manufacturer must be called upon.
2. The grab must only be deployed for carrying out tasks for which it is intended.
3. Unauthorised persons must keep clear of the working area of the carrier machine and
the grab.
4. Observe all safety regulations applicable at your place of work.
5. Protection or safety devices must not be removed. In the event of damage or loss these must be replaced
immediately.
6. When assembling or disassembling the grab, ensure that all connections and attachments are secured in
accordance with the regulations.
7. When repositioning the machine, ensure that the grab is in a safe position. Secure the grab e.g. with
chains in order to prevent all uncontrolled movements.
8. When carrying out repairs, only use original replacement parts. If foreign parts are used, the safety of
the grab can no longer be guaranteed.
9. Also observe the additional safety regulations given in this operating manual.
Safety regulations are only effective provided these are known and understood.
Please consult your supplier if questions arise.
5
Clamshell grab
1.4 Product information:
1.4.1 Assembly:
Suspension
Rotator
Frame
Cylinder
Clamshell carrier
Clamshell
Exchange teeth
1.4.2 Product description:

Special clamshell grabs for hydraulic excavator use as excavating and dredging of grown soil, pulling ditches
and cable pits, shipping bulk materials.
1.4.3 Design features:

- Multi-functional clamshell grab for oscillating use
- Clamshell with clamshell carrier exchangeable within the entire line of products
- Rotator with endless hydraulic rotation
- Hose protection for rotator connection
- Exchange teeth out of high density resistant steel 400 HB
Control unit
(Frame with connector and hydraulic unit)
Socket pin - frame
Socket pin - cylinder
Clamshell carrier with clamshell
1.4.4 Plug system:

The Clamshell grabs of the series DCS2 – DCS5 are equipped with a plug system, which makes it possible to quick
change the clamshell with clamshell carrier and synchronisation steering element.
Only the two lower cylinder socket pins and the frame socket pin are to be detached in order to change the clamshell.
This economical solution makes a versatile employment, with only one control unit and with the most different clamshell
sizes and clamshell forms, possible for the customer.
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Clamshell grab
1.4.5 Measures / Technical data:
Model DCS05 DCS1 DCS2 DCS3 DCS4 DCS5
Excavator weight class t 1–2 1–4 4,5 – 8 9 – 12 13 – 21 22 – 30

Max. lifting capacity clamshell t 1 1 2 2 4 6
Max. lifting capacity rotator t 2 4 4 10 10 15
Measure A mm 865 885 1230 1695 2100 2380
Measure B mm 670 630 890 1340 1610 1790
Measure C mm 700 840 1180 1295 1490 1730
Measure D mm 790 950 1305 1410 1700 2000
Cut width E mm 280-400 300-500 270-600 300-800 300-1000 400-1200
3
Max. bulk density t/m 2 2 2 2 3 3
Max. closing pressure kN 20 24 27 40 67 95
Max. working pressure griffin bar 250 250 300 350 350 350
Max. working pressure turning bar 250 250 300 320 320 320
Hydraulic connection griffin M18x1,5 M18x1,5 M18x1,5 G3/4 G3/4 G3/4
Hydraulic connection turning M18x1,5 M18x1,5 M18x1,5 G1/2 G1/2 G1/2
Max. oil consumption griffin l/min 25 25 50 60 90 120
Max. oil consumption turning l/min 20 20 20 20 25 25
1.4.6 Recommended Hydraulic fluids:

Hydraulic fluid H-LP e.g.: Mineral oil HLP46
Hydraulic fluid HE ES e.g.: Panolin HLP Synth 32/46/68
Synthetic ester oils Ukabiol HE46
DEA ECONA E46
Agip Arnica S46
Hydraulic fluid HE TG e.g.:
Plant oils Ukabiol HY 32
Brennrag HV32
Hydraulic fluids HFC, HFD, HFA, and HFB are not recommended!
Filter designs for min. oil purity according to DIN ISO 4406. Class 18/16/13
Recommended lubricating greases:

Lubricating grease e.g.: ESSO - MULTI-PURPOSE GREASE (Moly)
ESSO - Joint grease 2-083
Lubricating grease e.g.: AVIA - AVIALITH 2 F (water-resistant)
7
Clamshell grab
1.4.7 Employment:
Operating regulations:
1. Take care to comply with the regulations for operating the carrier machine and the functions necessary for working
with the grab.
2. Ensure that all persons keep well clear of the working area of the carrier machine and the grab.
3. Only use the grab to carry out work for which it is designed:
 Excavating and shipping
4. Do not use the clamshell grab for:

 Hammering
 Striking
 Tamping
 Crushing – The rotary function is not a crushing device!
 Coiling – Rotation device is for positioning the grab!
 Moving of containers and waggons!
! In the event of improper use all guarantee and / or liability claims shall become void.
Grab is designed for free oscillating

employment!
Load admission only in vertical grab
axle!
Do not pull loads with

the grab!
8
Clamshell grab
1.5 Transport / Storage:

The transportation and lifting or lowering of the grab must be carried out using the tools provided for this
purpose.
Transport:
- Grab installed at the carrier machine (Pict.1):
The grab is determined to the transportation claw of the excavator and secured (see
operating manual of the excavator)
- The grab is transported in open position (Pict. 2):
Place the grab on an even, stable surface (! sharp knives) and take precautions to prevent it
from tipping over and slipping. The same is valid during the storage of the grab.
- The grab is transported/stored in horizontal position (Pict. 3):
Stabilize the grab under the rotator while storing. Take precautions to prevent it from tipping
over and slipping during the transport.
Pict. 1 Pict. 2
Pict. 3
! Before longer storage the grab must be cleaned and maintenance
completely first. An oil exchange is recommended before any further
employment! Seals and hoses age, become useless and have to be
exchanged in time.
Lifting / moving
Always lift the grab at the connection point provided (Pict. 4). Pict. 4
! The following checks must be carried out after each transport:

 Visual check for transport damages
 Check grab for missing parts (see spare parts list)
 Check firm seat of screws, bolts and safety devices
 Check for leaks in the hydraulic system
If any defects are detected the grab must be repaired immediately by a qualified technician before
employment.
9
Clamshell grab
1.6 Installation and initiation:

The carrier machine must fulfil the following requirements:
1. The carrier machine must be fitted with a safe hydraulic unit.

In order to realise the two basic functions (rotation and opening/closing) of the grab,
two separate hydraulic circuits are necessary.
2. Make yourself acquainted with the hydraulic connection layout for the carrier machine.
Errors in the operating logistics must not endanger the safety of the functions.
4. The adapter unit (adapter/suspension/connector) between the carrier machine and the grab must be
designed for the working load of the grab.
! Only use original parts.
5. The working load of the excavator must match the grab type (see 1.4.5 Excavator weight class).
6. Connection values (pressures, delivery volumes) must be checked in advance for compliance with the
correct specifications (see 1.4.5 Technical data)
! Never change the pressure and volume settings of safety valves without the permission of the
manufacturer.
- Check whether the connection hoses (excavator - grab) have the correct length and are appropriate
for the grab operating pressure.
- Ensure that the correct hoses and connectors are used (Table 1). Take care to follow the supplier’s
specifications.
! Improper connectors and/or incorrect hose connections may lead to malfunctioning and damage
to the grab.
Attachment:
- Attach the adapter/suspension to the admission on the excavator arm using the stud bolt (Pict. 1/2).
Follow thereby the instructions of the supplier of the carrier machine.
- Attach the hoses to the rotator according to their respective functions.
Consider thereby the connection symbols next to the screw threads on the rotator (Pict. 3).
! Ensure absolute cleanliness when attaching all hydraulic hoses. Dirt will damage your hydraulic
system.
Pict. ½
10
Clamshell grab
1.6.1 Positions of the hydraulic connectors at the rotator:
DCS05 – DCS2 DCS3 – DCS4 DCS5
Pict. 3
Thread sizes (Internal threads in the rotator)
Connecting thread DCS05 DCS1 DCS2 DCS3-S DCS4 DCS5
R1  rotate left M18x1,5 M18x1,5 M18x1,5 G1/2 G1/2 G1/2

R2  rotate right M18x1,5 M18x1,5 M18x1,5 G1/2 G1/2 G1/2
GS  close grab M18x1,5 M18x1,5 M18x1,5 G3/4 G3/4 G3/4
GO  open grab M18x1,5 M18x1,5 M18x1,5 G3/4 G3/4 G3/4
Table 1
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Clamshell grab
Part 2. Service manual

2.1 Inspection:
Acquaint yourself with the safety regulations applicable at your place of work first.
Inspection
During maintenance and inspection work the grab must be placed on a stable and even surface.
a) Place the grab on the ground

b) Switch off the motor of the carrier machine
c) Remove the starter key from the carrier machine
d) Block the machine
e) Ensure that the hydraulic system is depressurized
f) During inspection/maintenance work place a sign in the machine cabin reading
“Do not start / operate”
2.1.1 Items of daily inspection:

- Visual check whether any parts are missing
- Visual check whether any parts are loose (screws, bolts and safety devices etc.)
- Visual check for leaks in the hydraulic system (connectors, hoses, cylinders etc.)
- Visual check for signs of mechanical damage (cracks, deformations etc.)
2.1.2 Items of weekly inspection:

Check the grab for signs of wear
- Play in the bearings (steering element, clamshell, cylinder, adapter)
- Exchange teeth
- Stops opening  limit - opening min. lifting cylinder assembly dimension (Table 1 - measure E)
- Exchange teeth  limit - closing max. lifting cylinder assembly dimension (Table 1 - measure E)
In case of noticeable wear or other defects contact your supplier immediately and arrange for parts to be
replaced or repaired.
Assembly Opening / E min. Closing / E max.

dimensions
DCS05 80 mm 290 mm
DCS1 80 mm 290 mm
DCS2 365 mm 520 mm
DCS3 565 mm 815 mm
DCS4 670 mm 1015 mm
DCS5 780 mm 1195 mm
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Clamshell grab
2.2 Maintenance
2.2.1 Items of daily maintenance / after 8 operating hours:

- All bearings (Pict. 2) should be lubricated at least 1x daily and/or after 8 operating hours with multi-
purpose grease
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Clamshell grab
Part 3. Spare parts lists:
A – Replacement part / E – Spare part / S – Set / V – Wearing part

Ma= Torque
= Description of adhesive:
Secured with medium strength screw adhesive
(e.g. Loctite 638)
3.1 DCS05 / Z-Z05 with AG 5-2
3.1.1 DCS05 / Z-Z05 - Grab cpl. - Spare parts

Item Pc. Designation Group Order-No.
1 1 rotator E 3007000119
2 1 frame E 2002001001
3 2 steering E 2004001001
4 1 clamshell with steering – 280 E 2006001010
clamshell with steering – 300 E 2006001011
5 4 pin – frame/clamshell V 3009035005
6 4 pin – cylinder/clamshell V 3009035004
7 4 pin – steering V 3009020001
8 4 bush – frame/clamshell V 5003002103
9 4 bush – cylinder retainer V 5003002108
10 4 bush – steering V 5003002001
11 4 bolt A 5001001014
12 4 washer A 5001002084
13 4 bolt A 5001001008
14 4 spring pin A 5001005005
15 8 grease nipple A 5003001001
16 1 bush set ( items 5 – 15 ) S 2013001001
17 2 hose A 5002010238
18 2 threaded adapter ( W ) A 5002001041
19 2 threaded adapter ( E ) A 5002001015
20 2 threaded adapter ( SW ) A 5002001089
21 4 threaded adapter ( VSTI ) A 5002001217
22 1 hydraulic set ( items 17 – 20 ) S 2010001001
23 4 bolt – rotator/frame A 5001001211
24 4 washer A 5001002083
25 4 nut A 5001006002
26 3 tooth V 5004001002
27 6 bolt V 5001001003
28 6 nut V 5001006004
50 1 cylinder E 2011001000
51 2 retainer E 2001001001
52 2 washer A 5001002021
53 2 nut A 5001006005
70 1 hose protection E 3005000001

71 4 bolt A 5001001102
72 4 washer A 5001002060
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Clamshell grab
3.1.2 DCS05 / Z-Z05 - Grab cpl. - Picture
15
Clamshell grab
3.1.3 DCS05 / Z-Z05 - Cylinder - Picture/spare parts
50 1 cylinder E 2011001000
1 1 cylinder barrel E 2011001001

2 1 piston rod E 2011001002
3 1 piston E 2011001003
4 1 guide nut E 2011001004
5 2 set screw (! secured with screw adhesive) A 5001007001
6 2 guide band V 5002006002
7 1 rod seal V 5002005002
8 1 rod seal V 5002005001
9 1 scraper V 5002007003
10 1 o-ring V 5002004004
11 1 support ring V 5002014002
12 1 piston seal V 5002003006
13 1 seal set ( items 6 – 12 ) S 2011001005
16
Clamshell grab
3.2 DCS1 / Z-Z1 with AG 5-2

1 1 rotator E 3007000119
2 1 frame E 2002001001
3 2 steering E 2004001001
4 1 clamshell with steering – 300 E 2006001001

5 4 pin – frame/clamshell V 3009035005

6 4 pin – cylinder/clamshell V 3009035004
7 4 pin – steering V 3009020001
8 4 bush – frame/clamshell V 5003002103
9 4 bush – cylinder retainer V 5003002108
10 4 bush – steering V 5003002001
11 4 bolt A 5001001014
12 4 washer A 5001002084
13 4 bolt A 5001001008
14 4 spring pin A 5001005005
16 1 bush set ( items 5 – 15 ) S 2013001001
17 2 hose A 5002010238
20 2 threaded adapter ( SW ) A 5002001089
21 4 threaded adapter ( VSTI ) A 5002001217
24 4 washer A 5001002083
25 4 nut A 5001006002
26 tooth V 5004001002
27 bolt ( 2 pc./tooth ) V 5001001003
28 nut ( 2 pc./tooth ) V 5001006004
50 1 cylinder E 2011001000
51 2 retainer E 2001001001
52 2 washer A 5001002021
53 2 nut A 5001006005

71 4 bolt A 5001001102
72 4 washer A 5001002060
17
Clamshell grab
18
Clamshell grab

50 1 cylinder E 2011001000

2 1 piston rod E 2011001002
3 1 piston E 2011001003
4 1 guide nut E 2011001004
6 2 guide band V 5002006002
7 1 rod seal V 5002005002
8 1 rod seal V 5002005001
9 1 scraper V 5002007003
10 1 o-ring V 5002004004
12 1 piston seal V 5002003006
13 1 seal set ( items 6 – 12 ) S 2011001005
19
Clamshell grab
3.3 DCS2 / Z-Z2 with AG 5-2


2 1 rotator E 3007000119
3 1 frame E 2002002001
4 1 clamshell carrier E 2003002001
5 1 steering E 2004002001
6 1 clamshell with teeth and clamshell carrier – 270 S 2007002001
clamshell with teeth and clamshell carrier – 300 S 2007002002
7 2 pin – cylinder/frame V 3009035003

8 6 pin - clamshell pivot/cylinder/clamshell V 3009035002
9 2 pin – steering V 3009035001
10 1 pin – frame/clamshell carrier V 3009040001
11 2 bush – steering V 5003002102
12 4 bush - frame/clamshell carrier V 5003002101
13 1 folding split pin A 5001004103
14 8 split pin V 5001004003
17 1 bush set ( items 7 – 16 ) S 2013002001
18 4 hose A 5002010201
20 2 threaded adapter ( T ) A 5002001048
22 4 threaded adapter ( plug ) A 5002001217
24 tooth V 5004001003
25 bolt ( 2 pc./tooth ) V 5001001203
26 nut ( 2 pc./tooth ) V 5001006006
28 4 washer A 5001002083
29 4 washer A 5001002060
30 4 bolt – hose protection A 5001001102
50 2 cylinder E 2011002000
70 2 piston rod protection E 2012002001
71 4 bolt – piston rod protection / cylinder A 5001001007
72 4 washer A 5001002085
20
Clamshell grab
21
Clamshell grab

50 2 cylinder E 2011002000

2 1 piston rod E 2011002002
3 1 piston E 2011002003
4 1 guide nut E 2011002004
5 2 pivot bearing V 5003003002
6 2 locking ring A 5003004002
8 2 guide band V 5002006002
9 1 rod seal V 5002005004
10 1 rod seal V 5002005003
11 1 scraper V 5002007002
12 1 o-ring V 5002004004
14 1 piston seal V 5002003003
15 2 piston guide ring V 5002003005
16 2 bush V 5003002101
17 1 seal set ( items 8 – 15 ) S 2011002005
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Clamshell grab
3.4 DCS3 / Z-Z3 with TH609H-2-3/4”

1 1 adapter E 3004000001
2 1 rotator E 3007000078
3 1 cross-brace E 2002003005
4 1 clamshell carrier E 2003003001
5 1 steering E 2004003001
6 1 oil distributor E 3014000028
7 1 clamshell with teeth and clamshell carrier – 300 E 2007003026
clamshell with teeth and clamshell carrier – 400 E 2007003027
8 4 pin – cylinder V 3009050002

9 4 pin – pivot V 3009050006
10 4 bush – clamshell carrier V 5003002304
11 2 pin – steering V 3009040008
12 2 bush – steering V 5003002104
13 1 pin - cross-brace / clamshell carrier V 3009045003
16 6 split pin V 5001004004
17 2 split pin V 5001004005
18 1 bush set ( Pos. 8 – 17 ) S 2013003002
19 6 fitting ( E ) A 5002001016
20 2 fitting ( T ) A 5002001049
21 4 fitting ( W ) A 5002001042
22 4 fitting A 5002001219
23 4 flexible hose A 5002010301
24 1 hydraulic set ( Pos.19 – 23 ) S 2010003005
25 6 screw – rotator/adapter A 5001001310
26 6 washer V 5001002063
27 8 screw – rotator/ cross-brace A 5001001224
28 8 washer V 5001002083
29 4 clamping sleeve A 5001005001
30 5 screw – oil distributor A 5001001001
31 5 washer A 5001002084
32 2 gasket - oil distributor V 5002004001
33 1 pin – adapter V 3009070001
34 1 split pin – adapter V 5001004001
35 1 washer – adapter A 5001002001
36 1 nut – adapter A 5001006001
37 tooth V 5004001039
38 screw ( 3 pc. / tooth ) V 5001001326
39 nut ( 3 pc. /Zahn ) V 5001006003
40 2 fitting A 5002001219
41 2 fitting A 5002001220
50 2 cylinder E 2011003000

71 4 Piston rod protection / cylinder A 5001001002
72 4 spring washer A 5001008001
23
Clamshell grab
24
Clamshell grab

50 2 cylinder E 2011003000

2 1 piston rod E 2011003002
3 1 piston E 2011003003
4 1 guide nut E 2011003004
8 2 guide band V 5002006001
9 1 rod seal V 5002005001
10 1 rod seal V 5002005002
11 1 scraper V 5002007001
12 1 o-ring V 5002004004
14 1 piston seal V 5002003003
16 1 seal set ( items 8 – 15 ) S 2011003005
25
Clamshell grab
3.5 DCS4 / Z-Z4 with TH609HV-2-GV
1 1 connector E 3004000001
2 1 rotator E 3007000078
3 1 frame E 2002004012
4 1 clamshell carrier ( E= 300 – 600 ) E 2003004001
clamshell carrier ( E= 700 – 1000 ) E 2003004002
5 1 steering E 2004004001
6 1 oil manifold E 3014000105

8 1 pin – connector V 3009070001

9 1 split pin – connector V 5001004001
10 1 washer – connector A 5001002001
11 1 nut – connector A 5001006001
12 8 pin – pivot / cylinder V 3009050002
13 2 pin – steering V 3009050001
14 1 pin – frame / clamshell carrier V 3009060001
15 6 split pin V 5001004004
16 2 bush – steering V 5003002302
21 1 bush set ( items 12 – 20 ) S 2013004001
22 4 hose A 5002010301
28 4 clamping sleeve A 5001005001

29 8 bolt – rotator / frame A 5001001210
30 8 washer V 5001002083
31 8 nut A 5001006002
32 6 bolt – connector A 5001001301
33 6 washer V 5001002063
34 5 bolt – oil manifold / rotator A 5001001001
35 9 washer A 5001002084
36 2 seal ring – oil manifold / rotator V 5002004001
26
Clamshell grab
Size 300
39 3 tooth V 5004001013
40 3 bolt V 5001001402
41 6 nut V 5001006009
42 3 bolt V 5001001401
Size 400 - 1000

39 tooth V 5004001001
40 bolt ( 3 pc. / tooth ) V 5001001302
41 nut ( 3 pc. / tooth ) V 5001006003
50 2 cylinder E 2011004000

71 4 bolt – piston rod protection / cylinder A 5001001002
27
Clamshell grab
28
Clamshell grab
3.5.3 DCS4 / Z-Z4 - Cylinder - Spare parts

50 2 cylinder E 2011004000

2 1 piston rod E 2011004002
3 1 piston E 2011004003
4 1 guide nut E 2011004004
7 2 set screw (! Secured with screw adhesive !) A 5001007001
8 2 guide band V 5002006001
9 1 rod seal V 5002005002
10 1 rod seal V 5002005001
11 1 scraper V 5002007001
12 1 o-ring V 5002004002
14 1 piston seal V 5002003001
16 1 seal set ( items 8 - 15 ) S 2011004005
29
Clamshell grab
3.5.4 DCS4 / Z-Z4 - Cylinder - Picture
30
Clamshell grab
3.6 DCS5 / Z-Z5 with IR20-5HPL

1 1 connector E 3004000072
2 1 rotator E 3007000111
3 1 frame E 2002005005
4 1 clamshell carrier ( E= 400 – 800 ) E 2003005001
clamshell carrier ( E= 1000 – 1200 ) E 2003005002
5 1 steering E 2004005001

7 1 pin – connector V 3009070001

8 1 split pin – connector V 5001004001
9 1 washer - connector A 5001002001
10 1 nut - connector A 5001006001
11 6 bolt – connector A 5001001409
12 12 washer A 5001002064
13 6 bolt – rotator / frame A 5001001407
14 8 pin – pivot / cylinder V 3009060004

15 2 pin - steering V 3009050009
16 1 pin – frame / clamshell carrier V 3009080002
18 2 bush - steering V 5003002303
19 6 split pin V 5001004008
20 2 split pin V 5001004004
22 1 clip A 5001004202
23 1 cotter pin V 5001004201
25 1 bush set ( items 14 – 24 ) S 2013005001
26 4 hose A 5002010301

40 tooth V 5004001001
41 bolt ( 3 pc. / tooth ) V 5001001307
42 nut ( 3 pc. / tooth ) V 5001006003
50 2 cylinder E 2011005100
31
Clamshell grab
32
Clamshell grab
3.6.3 DCS5 / Z-Z5 - Cylinder - Spare parts
50 2 cylinder E 2011005100

2 1 piston rod E 2011005102
3 1 piston E 2011005103
4 1 guide nut E 2011005004
5 1 piston seal V 5002003011
6 1 piston guiding ring V 5002003012
7 1 o-ring V 5002004010
9 1 scraper V 5002007006
10 1 rod seal V 5002005007
11 1 rod seal V 5002005008
12 2 guide band V 5002006005
15 8 bolt A 5001001601
16 1 set screw (! secured with screw adhesive !) A 5001007007
18 1 protecting tube E 2011005006
19 1 seal set ( items 5-12 ) S 2011005105
33
Clamshell grab
3.6.4 DCS5 / Z-Z5 - Cylinder - Picture
34

Operations Manual DCS4 DCS5

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Operations Manual DCS4 DCS5

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Operating- and maintenance manual

Clamshell grab – Model line DCS

Part 1. Operating manual ..................................................................................................... 3

Part 1. Operating manual

2. Serial number – grab

3. Identification plate - grab

Explanation of identification plate

Contact postal address

Max. lifting capacity – grab

Max. working pressure - turning

Max. oil amount - turning

Max. working pressure – griffin

Max. oil amount – griffin

Max. weight of carrier machine

Trader- / customer number

Type designation – grab:

Serial number – grab:

Serial number – rotator:

Type designation – carrier machine:

E-Mail: Contact person:

1.2 Terms of guarantee:

I) Contact – guarantee: PRODEM

1.3 General safety instructions:

1. First read this operating manual thoroughly!

2. Check whether your carrier machine if suitable for this product!

3. Acquaint yourself with the safety regulations applicable at your place of

1. Any damage to the grab must be repaired immediately by a qualified technician.

4. Observe all safety regulations applicable at your place of work.

Please consult your supplier if questions arise.

1.4 Product information:

1.4.2 Product description:

1.4.3 Design features:

Socket pin - frame

Socket pin - cylinder

Clamshell carrier with clamshell

1.4.4 Plug system:

1.4.5 Measures / Technical data:

Model DCS05 DCS1 DCS2 DCS3 DCS4 DCS5

Excavator weight class t 1–2 1–4 4,5 – 8 9 – 12 13 – 21 22 – 30

1.4.6 Recommended Hydraulic fluids:

Recommended lubricating greases:

4. Do not use the clamshell grab for:

Grab is designed for free oscillating

Do not pull loads with

1.5 Transport / Storage:

! The following checks must be carried out after each transport:

1.6 Installation and initiation:

1. The carrier machine must be fitted with a safe hydraulic unit.

1.6.1 Positions of the hydraulic connectors at the rotator:

DCS05 – DCS2 DCS3 – DCS4 DCS5

Thread sizes (Internal threads in the rotator)

Connecting thread DCS05 DCS1 DCS2 DCS3-S DCS4 DCS5

R1  rotate left M18x1,5 M18x1,5 M18x1,5 G1/2 G1/2 G1/2

Part 2. Service manual

a) Place the grab on the ground

2.1.1 Items of daily inspection:

2.1.2 Items of weekly inspection:

Assembly Opening / E min. Closing / E max.

2.2.1 Items of daily maintenance / after 8 operating hours:

Part 3. Spare parts lists:

A – Replacement part / E – Spare part / S – Set / V – Wearing part

3.1 DCS05 / Z-Z05 with AG 5-2

3.1.1 DCS05 / Z-Z05 - Grab cpl. - Spare parts