Ac550 - Ac4250 Operators Manual 3390502393

Operating instructions for hydraulic breaker

550 750 1150 1650 2250 3050 4250

AIB 2007−05−04

© Copyright 2007 www.atlascopco.com

No. 3390 5023 93

Operating instructions for hydraulic breaker 550 750 1150 1650 2250 3050 4250

E Atlas Copco Construction Tools GmbH Any unauthorized use or copying of contents or any part thereof is prohibited.This applies in particular to to trademarks, model denominations, part numbers and drawings.

Table of contents 1 2 3

4

5

6

7

8

9

4

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accident prevention regulations Explanation of the symbols used in this operating instructions . . . . . . . . . . . . . . . . CE markings (EC machinery directive 98/37/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 7 10

3.1

CE sticker product groups A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

3.2 3.3

CE sticker product groups B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sticker for guaranteed sound level power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 11

General informations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

4.1

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

4.2

Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

5.1

Main components or assemblies 550 and 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

5.2

Main components or assemblies 1150 and 1650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

5.3

Main components or assemblies 2250, 3050 and 4250 . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

6.1 6.1.1 6.1.2 6.1.3 6.1.4

Media/consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mineral hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non−mineral hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 15 15 15 16

6.2

Attaching the adapter to the hydraulic breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

6.3 6.4

Mounting the hydraulic breaker on the excavatormechanical aspects . . . . . . . . . . . . . . Mounting the hydraulic breaker on the excavator−hydraulic aspects . . . . . . . . . . . . . . . .

17 18

6.5

Switching the hydraulic breaker on/off from the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

6.6

Dismounting the hydraulic breaker from the excavator for short or lengthy periods of nonuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

7.1 7.1.1 7.1.2 7.1.3 7.1.4

20 20 20 20 20

Hydraulic breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Long storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to proceed after more than twelve months’ storage . . . . . . . . . . . . . . . . . . . . . . . . . . Working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting/removing the working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

8.1 8.1.1 8.1.2 8.1.3 8.2 8.2.1 8.2.2 8.3

21 21 21 22 23 23 24 25

Selecting the right working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working tools for hydraulic breakers 550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working tools for hydraulic breakers 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working tools for hydraulic breakers 1150  4250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fitting the tool (After breaker delivery to the site) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550 and 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1150  4250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting up the hydraulic breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

9.1

Starting up the hydraulic breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

9.2

Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

9.3

Angle of attack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

9.4 9.5

Breaker rocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Never drive the working tool into the ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 26

9.6

Never lever with the breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

9.7

Never use as a sledgehammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

10

11

9.8

Never use for transport purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

9.9

Using the hydraulic breaker in or under water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

9.10

Hydraulic breaker used in Tunnelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

9.11

Working in high outside temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

9.12

Working in low outside temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

9.13

Operating the breaker with the cylinders fully extended or retracted . . . . . . . . . . . . . . . .

28

Maintenance work to be performed by the excavator driver . . . . . . . . . . . . . . . . . . . .

29

10.1

Manual lubricating of the working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

10.2 10.2.1

Automatic lubrication using of the hydraulic breaker of the 750, 1150, 1650, 2250, 3050 and 4250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic lubrication using ContiLube® II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 30

10.2.2

Changing the lubricant cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

10.2.3

Operating the ContiLube® II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

10.3

Manual lubrication without or upon failure of ContiLube® II . . . . . . . . . . . . . . . . . . . . . . .

31

10.3.1

Filling device for the chisel paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

10.4

Care and maintenance timetable − Work to be performed by excavator driver . . . . . . .

32

10.5

Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

10.5.1

Checking the working tool for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

10.5.2

Checking the wear bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34

10.5.3

Checking the retaining pin for wear (550 and 750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

10.5.4

Checking the retainer bars for wear (1150  2350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

10.5.5

Checking the impact face of the percussion piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

10.5.6

Checking the hammer box for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

10.5.7

Screw couplings 550 and 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

10.5.8

Screw couplings 1150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37

10.5.9

Screw couplings 1650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

10.5.10 Screw couplings 2250, 3050 and 4250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

10.5.11 Checking pressure in piston accumulator and refilling if required . . . . . . . . . . . . . . . . . . .

41

10.5.12 Checking that the highpressure accumulator is in perfect working order . . . . . . . . . . . .

43

10.5.13 Checking the hydraulic lines before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

10.5.14 Checking the adapter bolts for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

10.5.15 Checking and cleaning the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

11.1

Breaker does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

11.2

Impact rate of hydraulic breaker too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

11.3

Impact force too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

11.4

Impact rate too high and impact force too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

11.5

Oil leaks from ports »P« and »T« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

11.6

Oil leaks between cylinder cover and cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

11.7

Oil leaks from parts of hydraulic system for breaker (Screw couplings, hoses etc.) . . .

47

11.8

Oil leaks from working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

11.9

Oil leaks from high−pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

11.10

Oil or grease leaks from ContiLube® II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

11.11

Operating temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

12

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

13

Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 5

1

Foreword

Please read this operating manual before using your hydraulic breaker for the first time so as to avoid errors and breakdowns through incorrect usage.

It is important that all safety instructions be ob served. These safety instructions are listed at the beginning of the manual and repeated in the rel evant sections of the manual.

The operating manual includes:

Responsibility for observation of these safety in structions lies at all times with the operator, i.e. with you.

H important safety instructions H operating instructions for the hydraulic breaker H maintenance instructions for the hydraulic breaker H aids to troubleshooting The operating manual describes how to handle the hydraulic breaker on site and should therefore al ways be kept in the document compartment in the carrier cab.

6

All safety instructions are in line with the valid laws and regulations of the European Union. National provisions have also been taken into account where applicable. When using the breaker outside the European Union, the national laws and regulations of the country of use shall apply. Please note that reliable operation of the hydraulic breaker can only be guaranteed if genuine spare parts are used. We wish you every success with your hydraulic breaker.

2

Accident prevention regulations

To avoid the risk of injury, please observe the following instructions. Familiarise yourself with the operating manual and the applicable regulations before starting work with the hydraulic breaker.When using hydraulic break ers in states of the European Union, the regulations contained in the EC machinery directive 98/37/EC must be observed and followed, as must all appli cable national accident prevention regulations.In countries outside the European Union, the valid local statutes and regulations shall apply.

CAUTION Read and un derstand oper ator’s manual before operate this machine.

Explanation of the symbols used in this operating instructions To emphasise their importance, certain points in the operating instructions are marked with symbols, which are described below.

Danger a b

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

c

WARNING

a b

Indicates an potentially hazardous situation which, if not avoided, could result in death or serious injury.

c

CAUTION

a b

Indicates an potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

c

CAUTION

a b

Used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

c

Please note for the right side of the labels: Section a: Identify the hazard. Section b: What can happen. Section c: Define prohibitive actions.

7

Before mounting/dismounting the hydraulic tool and/or any maintenance work on the hy draulics of the hydraulic tool/carrier the hy draulic system must be depressurized. When using or transporting the carrier with the hy draulic breaker attached, the instructions included in the operating manual supplied by the carrier manufacturer must also be observed. Do not run any hydraulic lines for attachment of the hydraulic breaker through the driver’s cab! Hydrau lic lines may spring a leak or even burst! During operations, the hydraulic oil becomes very hot. Mounting the hydraulic breaker: Mounting the hydraulic breaker requires the pres ence of an assistant, who must be instructed by the carrier driver. The carrier driver and assistant should agree beforehand on clear hand signals. For transport purposes, use only the lugs provided and hoisting equipment of sufficient capacity. The hydraulic breaker should only be mounted on an excavator with sufficient load capacity. Please refer to the table in section 12. Carriers below this weight class will not provide the required degree of stability and could even fall over during breaker use, causing injury and damage. Carriers above this weight class may apply excess ively high mechanical loads to the attachment. When attaching the adapter use only the special steel Allen screws included in supply. Check the nominal width of the hydraulic lines on existing hydraulic systems. It is important that sup ply and return lines for the hydraulic oil are ad equately dimensioned. Keep your hands away from bores and fitting sur faces when mounting the hydraulic breaker, es pecially when the carrier boom is moving. Collect any oil which runs out and dispose of it in accordance with the applicable statutory provisions to avoid environmental hazards. When putting into use hydraulic breakers with high−pressure accumulators the applicable national requirements are to be observed, e.g. in Germany an authorized person/inspection body is to inspect and certify the system on site before putting it into use.

8

If you have any questions regarding hydraulic power or the adaptation of same, please call our Aftermarket Department. The threads on the hydraulic breaker ports and the corresponding hose connectors must be clean and free of damage. The safety facilities on the hydraulic system must be checked by a professional/authorised persons for their quality (CE mark etc.), suitability and proper functioning prior to their first use. By check ing the setting of and, where possible, attaching a lead seal to the pressure limiting valve, it can be guaranteed that the system’s working pressure, laid down in accordance with chapter 12, Technical Specifications, can never be exceeded. If this setting is tampered with, the operating permit for the unit will be withdrawn. Fitting and removing the working tool: Always wear protective glasses when fitting or re moving the working tool, since metal splinters may fly off when breakering out the locking bolts. The working tool should only be fitted in the way described in this operating manual. Never use your fingers to check whether the re cesses on the working tool shaft are aligned to the slots for the retainer bars. Operating the hydraulic breaker: Close the front screen/splinter guard on the driver’s cab to protect the driver from flying rock splinters during breaker operations. Wear ear protectors The national regulations of the country of use as regards excavator operations with percussive tools shall apply. Guaranteed sound power level The LWA guaranteed sound power level is an upper limit, indication of which is mandatory under EU directive 2000/14/EC. The guaranteed sound power levels are listed in section 12, Technical Specifica tions.

Do not start up the hydraulic breaker until both carrier and hydraulic breaker are in the correct posi tion. Stop the hydraulic hammer immediately as soon as persons are in the danger zone. The danger zone during the hammer operation is considerably greater than during the excavation operation − on account of fractions of stones and pieces of steel flying around − and for this reason, the danger zone must, depending on the type of material to be worked on, be enlarged correspondingly, or the danger zone must be secured in a suitable manner through corresponding measures.

WARNING Flying objects Danger of eye injury. Wear safety glasses.

CAUTION Burn hazard Hot surface. Do NOT touch. The hydraulic breaker heats up during operation. Monitor the oil temperature The temperature of the hydraulic oil must never ex ceed 80°C (176°F). If higher temperatures are measured in the tank, the hydraulic system and/or the pressure−relief valve have to be checked. Observe the excavator manufacturer’s safety re gulations. WARNING! With regard to excavator operation when working with an attached hydraulic breaker, please refer to Section 6.5. The hydraulic breaker is only to be used for the ap plications described.

Maintenance and repairs: The piston accumulator integrated in the hydraulic breaker is pressurised. Before dismantling the hy draulic breaker it is essential that all gas be bled off. The same applies to removal of the filling valve »G« (see Section 10.5.11). When filling the piston accumulator, ensure noone is in the vicinity of the working tool. If the tool has jammed, the increase in pressure in the piston accumulator may cause it to spring out suddenly. The piston accumulator should only be filled with nitrogen from the green nitrogen cylinder. Ensure that no other gas, e.g. air or oxygen, gets into the piston accumulator.

DANGER Explosion hazard Compressed gas. ONLY use nitrogen (N2) Before replacing the pressure accumulator, the hy draulic system must be fully depressurised. If one of the expansion bolts on the highpressure accumulator should break, it is imperative that all bolts be replaced. If any significant changes are made to the hy draulic system, a new acceptance inspection is to be carried out in accordance with the rel evant national safety provisions. Note Check the pressure accumulator in accordance with the national safety provisions. We recommend five− yearly maintenance intervals. Dismounting the hydraulic breaker: Dismounting the hydraulic breaker from the carrier requires the presence of an additional assistant who must be instructed by the carrier driver. The carrier driver and assistant should agree before hand on clear hand signals. When using the excavator or putting it out of oper ation, the safety instructions of the excavator manu facturer must be observed. Keep your hands away from bores and fitting sur faces when dismounting the hydraulic breaker, es pecially when the carrier boom is moving. Collect any oil which runs out and dispose of it in accordance with the applicable statutory provisions to avoid environmental hazards. Secure the hydraulic breaker after dismounting so that it cannot fall over.

9

3

CE markings (EC machinery directive 98/37/EC)

A Product group:

Hydraulic breaker (without hammer box)

B Product group:

Hydraulic breaker with hammer box

CE sticker

CE sticker

LWA sticker rear side of breaker box, below upper flange

3.1

CE sticker product groups A

1 2 3 4 5 6

3.2

7

Name and address of manufacturer Model Serial no. Part ident. no. max. operating pressure Year of construction of product group Weight of product group

CE sticker product groups B

Atlas Copco Construction Tools Essen Germany Type Ser. No. Deliv. wt P max Year

Made in Germany

The CE nameplate contains information on the unit "breaker and breaker box". All weights indicated refer to the weight of this unit. When selecting hoists and suspension aids for transporting the unit, the weights of the working tool and adapter may also have to be considered.

10

1. 2. 3. 4. 5. 6. 7.

Name and address of manufacturer Model Serial no. Weight of product group max. operating pressure Year of construction of product group

3.3

Sticker for guaranteed sound level power In accordance with EU directive 2000/14/EC, hy draulic breakers used within the EU must bear a marking legible from the outside stating the sound power level guaranteed by the manufacture.

4

General informations

4.1

Applications

The hydraulic breaker is an attachment suitable for mounting on hydraulicpowered excavators. Applications in the construction industry:

face extraction, rock levelling, reducing mineral raw materials and rock.

demolition, surface breaking, trenching, foundations.

Under normal circumstances the hydraulic breaker is operated from the driver’s cab of the carrier. Please refer to Sections 2 and 7.4.

Applications in mining, quarrying, tunnelling and in the rock products industry:

Hydraulic breaker, operating instructions, spare parts list and EC declaration of conformity.

4.2

Scope of supply

The scope of supply of a hydraulic breaker gen erally includes: Hydraulic breaker, operating instructions, spare parts list and EC declaration of conformity. Accessories: Mounting tool, hoses and service box according to the order. Special accessories: e. g. adapter, hydraulic adap ter kit for the excavator according to the order.

11

5

Main components

5.1

Main components or assemblies 550 and 750 550

750

CE sticker

cylinder cover

CE sticker cylinder

lower hammer part

hammer box

working tool

The graphic shows only a general view of the main components. Details may vary on different breaker models

12

5.2

Main components or assemblies 1150 and 1650

1150

1650

CE sticker

CE sticker cylinder cover High−pressure accumulator cylinder

hammer box

lower hammer part

working tool

The graphic shows only a general view of the main components. Details may vary on different breaker models

13

5.3

Main components or assemblies 2250, 3050 and 4250

2250, 3050, 4250

High−pressure accumulator

cylinder cover cylinder

hammer box Sealing flange lower hammer part

working tool

The graphic shows only a general view of the main components. Details may vary on different breaker models.

14

CEname plate

6

Installation

6.1

Media/consumables

The following media/consumables are required to operate the hydraulic breaker:

6.1.1

Mineral hydraulic oil

All hydraulic oil brands prescribed by the carrier manufacturer are suitable for hydraulic breakers. The oil should however correspond to viscosity class HLP 32 or higher. In summer and in hotter climates, oils of viscosity class HLP 68 or higher should be used.

The mesh width of this filter should not exceed 50 micrometers and a magnetic separator must be fit ted.

CAUTION Property damage

In all other respects the regulations of the carrier manufacturer are to be considered.

Hydaulic oil must never overheat.

Optimum viscosity range Max. initial viscosity Max. oil temperature

Monitor the oil temperature.

= 30  60 cSt = 2.000 cSt = 80°C (176°F)

Please refer to Section 9.12. for lowtemperature hydraulic breaker applications. Check the oil filter in the return line to the hydraulic system.

6.1.2

The temperature of the hydraulic oil must never ex ceed 80°C (176°F). If higher temperatures are measured in the tank, the hydraulic system and/or the pressure−relief valve have to be checked.

Non−mineral hydraulic oil

In order to protect the environment or on technical grounds, hydraulic oils are currently being used which are not classified as HLP mineral oils. Before using hydraulic oils of this kind it is impera tive to ask the carrier manufacturer whether oper ations with such hydraulic oils are possible. Our tools are basically designed for use with min eral oils. Before using other hydraulic oil types which have been approved by the carrier manufac turer, Atlas Copco Customer Center / dealer in your region must always be consulted. Following initial assembly and after any workshop repairs, our tools are subjected to a test run on a test bed powered by mineral oil. Note When returning tools for repair, it is imperative that the name of the oil in use be indicated if you are using non−mineral oil.

CAUTION Property damage Mixed hydraulic oil can result in damage. Never mix hydaulic oil. Never mix mineral and non−mineral hydraulic oils! Even small traces of mineral oil mixed in with non−min eral hydraulic oil can result in damage to both hy draulic attachment and carrier.

CAUTION Property damage Mixed hydraulic oil is no longer biodegradable. Never mix hydaulic oil. Non−mineral oil is no longer biodegradable if it is con taminated with mineral oil. Contaminated non−mineral oil must be disposed of as special waste in accord ance with the applicable statutory regulations for envi ronmental protection.

ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ 6.1.3

Grease

Grease type

Pt.−Id.−No.

Chisel paste

3363 0949 10

Always observe the relevant safety regulations when handling oils and greases.

15

6.1.4

Gas

Normal nitrogen, 99.8% pure. Use only nitrogen to fill the piston accumulator and ensure that no other gas, e.g. air, oxygen, is used. The nitrogen for the piston accumulator is in the green gas cylinder. Use of other gases could result in an explosion.

DANGER Explosion hazard Compressed gas. ONLY use nitrogen (N2)

6.2

Attaching the adapter to the hydraulic breaker

Lay the hydraulic breaker on squared beams or a pallet within reach of the excavator boom with the service window of the hammer box facing upwards. Insert the elastic pad in the hammer box, ensuring it is the right way round, and fix the adapter to the breaker box with two screws (ref. to Section 8.2)

Then fit all screws. The required sizes for the Allen keys are shown below. Apply anti−seize to the threads of the cylindrical bolts before screwing them in. The contact face of the bolt head and the locking rings must be free of lubricant.

ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Model

Type of spanner − size

550, 750

Allen key 17 / 390 Nm

1150, 1650, 2250

Allen key 22 / 1500 Nm

3050, 4250

Allen key 27 / 2300 Nm

DANGER

WARNING

Crush hazard

Crush hazard

Breaker can fall down. Block the breaker.

Boom moves uncontrolled. Keep clear of this area.

Only the specialsteel Allen screws included in supply should be used to attach the adapter. For transport purposes use only the lug(s) provided. The hydraulic breaker is heavy and difficult to move. Screw Pair of locking rings

CAUTION Pitch points Danger of hands injury.

Elastic pad

Keep hands clear.

Adapter

16

6.3

Mounting the hydraulic breaker on the excavator mechanical aspects

An adapter is required when mounting the hydraulic breaker on the excavator. This adapter varies ac cording to excavator model and must be ordered separately.

When placing an order please provide the following information: H excavator make H excavator model and year built H boom type

During breaker mounting, the carrier should only be operated from the driver’s cab. To mount the hydraulic breaker, carefully lower the stick of the boom into the adapter. An assistant di rects the movement of the stick until the bores in the stick are flush with those in the adapter. Then insert the stick pin and lock.

DANGER Crush hazard Excavator can fall down. Observe mass ratio excavator/ breaker.

Stick Hydraulic breaker

WARNING Flying objects Danger of eye injury.

Stick pin

Wear safety glasses.

Adapter

Lift up the hydraulic breaker. Extend the shovel cy linder until the bore in the toggle is flush with those in the adapter. Insert toggle pin and lock.

CAUTION Pitch points Danger of hands injury. Keep hands clear.

Stick Shovel cylinder

WARNING

Adapter

Crush hazard

Marking: Stiel Stick

Boom moves uncontrolled. Toggle

Keep clear of this area.

Toggle pin

CAUTION Warning! After mounting the breaker, carefully extend and retract the shovel cylinder to its full extent in each case. It is important that the cylinder can be fully extended and retracted without any difficult. If prob lems are encountered, please consult our After market Department.

Property damage Adapter can hit the stick. Rework or chan− ge the adapter.

17

6.4

Mounting the hydraulic breaker on the excavator− hydraulic aspects

Before mounting/dismounting the hydraulic tool and/or any maintenance work on the hydraulics of the hydraulic tool/carrier the hydraulic sys tem must be depressurized.

Oil leckages

The excavator must have a hydraulic system suit able for breaker operations.

Contamination of the ground.

Check the nominal width of the hydraulic lines on existing hydraulic systems. All feed and return lines for the hydraulic oil must have a sufficient inside diameter. Refer to Section 13, Technical specificati ons.

Collect any oil and dispose of it correctly.

Use only hoses/pipes which satisfy the following quality criteria: Hydraulic hoses with 4 wire spiral layers to DINEN854. Hydraulic pipes: seamless, cold drawn steel pipes to DINEN10305. The safety facilities on the hydraulic system must be checked by a professional/authorised persons for their quality (CE mark etc.), suitability and proper functioning prior to their first use. By checking the setting of and, where possible, attaching a lead seal to the pressure limiting valve, it can be guaranteed that the system’s working pressure, laid down in accordance with chapter 13, Technical Specifica tions, can never be exceeded.

CAUTION

2250: Unscrew the blank flanges from ports »P« and »T« and put them in the toolbox for safekeeping. Fasten the hose flanges to the hydraulic breaker using the fastening bolts. (Tightening torques see section 10.5.10) 550, 750, 1150, 1650, 3050 and 4250:

Hoses

Screw caps

The return line from the breaker must run direct to the oil tank in order to guarantee a reliable return oil flow.

Port »T«

The pressure−relief overflow line must run direct from the pressure−relief valve to the tank to ensure the reliable functioning of the valve. Do not run any hydraulic lines for attachment of the hydraulic breaker through the driver’s cab! Hydraulic lines may spring a leak or even burst, re leasing hot hydraulic oil.

DANGER Crush hazard Breaker can move. Stop engine and BLEED OFF breaker circuits.

Port »P«

The graphic may vary for different breaker models

Unscrew the caps from ports/blind flanges »P« and »T« and keep them. The pressure port »P« is marked in red. Check the connecting threads on the hydraulic breaker ports and the corresponding hose con nectors to ensure they are undamaged. Sand or other foreign bodies in the threads must be cleaned away. Screw the hoses to the ports. (Tightening torques see section 10.5.7  10.5.10) all types: If you come to the conclusion that the system does not comply with the requirements listed above, the hydraulic breaker must not be operated. For rea sons of safety, you should absolutely contact the Atlas Copco Customer Center / dealer in your re gion. When connecting or reconnecting the hydraulic lines, the carrier must be secured in such a way that automatic startup of the hydraulic breaker is reliably avoided.

18

6.5

Switching the hydraulic breaker on/off from the carrier

After the proper attachment of the hydraulic breaker to the carrier, the hydraulic breaker can be operated using the carrier’s hydraulic system. All functions for normal excavator operations remain intact. The hy draulic breaker is switched on and off using electri cal and hydraulic signals. For further details please contact the carrier manufacturer or the Atlas Copco Customer Center / dealer in your region.

6.6

When leaving the driver’s cab, the safety switch for the electrical/hydraulic breaker operation system must be set to the "OFF" position. So as to reliably prevent any unintended start−up of the hydraulic breaker.

Dismounting the hydraulic breaker from the excavator for short or lengthy periods of nonuse

Unless otherwise stipulated, the hydraulic breaker is dismounted in reverse order to mounting.

DANGER

Collect any oil which runs out and dispose of it in accordance with the applicable statutory provisions to avoid environmental hazards. Unscrew the hoses from the boom and seal them with appropriate caps.

Explosion hazard Pressurized vessel. Stop engine and BLEED OFF breaker circuit. Before mounting/dismounting the hydraulic tool and/or any maintenance work on the hydraulics of the hydraulic tool/carrier the hydraulic sys tem must be depressurized. For safety reasons, the carrier must be switched off before performing the following work.

WARNING Flying objects Danger of eye injury. Wear safety glasses. Unlock the toggle and stick pins and knock out the pins using a steel rod and a breaker.

WARNING Flying objects Danger of eye injury. Wear safety glasses. Wear protective glasses when fitting and removing the working tool. Lay the hydraulic breaker flat on the ground.

CAUTION Oil leakages Contamination of the ground. Collect any oil which runs out and dispose of it in accor dance with the applicable sta tutory provi sions to avoid environmental hazards.

Agree on hand signals with the assistant.

CAUTION Pitch points Danger of hands injury. Keep hands clear. Keep your hands away from bores and fitting sur faces when dismounting the hydraulic breaker. Do not touch any parts when the boom is moving.

19

7

Storage DANGER

Oil may run out when pushing the percussion piston up.

Crush hazard

H Remove the covers from the connection hoses.

Breaker can fall down. Block the breaker.

H Slide the percussion piston into its upper stroke position. H Slide the percussion piston retainer into the ap erture for the working tool. H Install the retainer bars / retaining pin.

7.1

Hydraulic breaker

The percussion piston has now been locked in its upper stroke position.

The hydraulic breaker must be stored in an upright position to avoid its seals being damaged.

H Seal the connection hoses with the covers.

7.1.1

H Seal the aperture for the working tool with the cover.

Short storage

H Proceed as follows in the case of storage for less than eight weeks: H Remove the hydraulic breaker from the carrier (see chapter 6.6). H Store the hydraulic breaker in a dry, properly ventilated room. H If you can only store the hydraulic breaker in the open air, cover it with plastic sheeting or tarpau lins to protect it against the weather. H Store the hydraulic breaker in an upright position and such that it cannot topple over.

7.1.2

Long storage

Proceed as follows if storage is expected to be for more than eight weeks: H Remove the hydraulic breaker from the carrier (see chapter 6.6). H Remove the working tool (see chapter 8.3). H Grease the working tool with chisel paste to pre vent it corroding. H Grease the wear bushes. H Depressurise the piston accumulator (see chapter 10.5.11). H Leave the filling hose in the filling valve to let the gas escape.

CAUTION Oil leakages Contamination of the ground. Collect any oil which runs out and dispose of it in accor dance with the applicable sta tutory provi sions to avoid environmental hazards.

20

H Pull the filling hose out of the filling valve. H Store the hydraulic breaker in a dry, properly ventilated room. H Store the hydraulic breaker in an upright position and such that it cannot topple over.

7.1.3

How to proceed after more than twelve months’ storage

The following measures are required to prevent pre mature hydraulic breaker failure, after it has been stored for over twelve months: H Disassemble the hydraulic breaker as described in the Repair Manual. H Check any parts liable to corrosion (percussion piston, cylinder, control) for corrosion damage. H Rework or replace corroded parts. H Replace all sealing elements.

7.1.4

Working tool

H Grease the working tool with chisel paste to pre vent it corroding. H Store the working tool in a dry, properly venti lated room. H Store the working tool so that it cannot topple over or roll down.

8

Fitting/removing the working tool

8.1

Selecting the right working tool

The standard working tools available for the hy draulic breaker are depicted below. The different tip geometries will influence production performance depending on the type of job. Please refer to the following table for application recom−mendations.

Sharp tips will produce better results. Resharpening is possible using suitable tools.

Note Only genuine working tools may be used. If other makes of working tools are used, the warranty will cease to apply.

Never weld or flamecut the working tools.

The working tools must be adequately cooled dur ing remachining using a suitable coolant.

The high temperatures involved will modify the mi crostructure of the tool.

ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ 8.1.1

Working tools for hydraulic breakers 550 Designation

Application

Standard designs

Moil point

Ø80 Universal use

Flat chisel cross−cut

Mining, foundations, trenching, demolition

8.1.2

160

Spade transverse

Road surface (asphalt)

Working tools for hydraulic breakers 750

Moilpoint

Ø100 Universal use

Flat chisel cross−cut

200

Spade transverse

Mining, foundations, trenching, demolition

Road surface (asphalt)

21

8.1.3

Working tools for hydraulic breakers 1150  4250

Moilpoint Universal use

Flat chisel cross−cut

Blunt tool

22

Mining, foundations, trenching, demolition

Mining, breaking oversizes, demolition

8.2

Fitting the tool (After breaker delivery to the site)

8.2.1

550 and 750

In general the working tool is not fitted when the breaker is delivered. For fitting move the hydraulic breaker into horizontal position using the excavator boom and deposit it on a support (e.g. squared beams).

DANGER Crush hazard Breaker can move. Stop engine and BLEED OFF breaker circuits. For safety reasons, the carrier must be switched off before performing the following work.

Always wear protective glasses when fitting or re moving the working tool, since metal splinters may fly off when breakering out the locking pins. Never use your fingers to check whether the re cesses on the working tool shaft are aligned to the slots for the retainer bars. Remove all additional plugs in the lower area of the breaker box. Insert an ejetor drift, srewdriver or similar object into the bore in the lower hammer part and push in as far as it will go (see diagram). Push up retaining pin from below with screwdriver or similar object and pull it out the rest of the way by hand. Remove the protective cap from the bore for the working tool and put it in the tool box for safekeep ing. Lubricate the shank of the working tool and the bushes thoroughly using our chisel paste.

WARNING Flying objects Danger of eye injury. Wear safety glasses.

CAUTION

Insert the working tool, turning it until the retaining bars slip easily into the oblong holes. Knock the locking pins back into place and insert the sealing plugs. Clean away any dirt adhering to the working tool in the insertion zone, then thoroughly lubricate the shaft of the working tool and the bushes with chisel paste. (A cartridge of chisel paste is contained in the toolbox for firsttime fitting).

Pitch points

The retainer bars are also to be lubricated. Then insert the working tool, turning it until the re tainer bars slide easily into the slots.

Danger of hands injury.

The working tool should only be fitted in the way described here.

Keep hands clear.

retaining pin

ejector drift

23

8.2.2

1150  4250

In general the working tool is not fitted when the breaker is delivered. For fitting move the hydraulic breaker into horizontal position using the excavator boom and deposit it on a support (e.g. squared beams).

DANGER

Never use your fingers to check whether the re cesses on the working tool shaft are aligned to the slots for the retainer bars. Always wear protective glasses when fitting or re moving the working tool, since metal splinters may fly off when breakering out the locking pins. Remove all additional plugs in the lower area of the breaker box.

Crush hazard Breaker can move.

Knock the locking pins for the retainer bars out of the lower hammer part using the drift contained in the toolbox.

Stop engine and BLEED OFF breaker circuits.

Remove both sealing plugs from the retainer bar slots.

For safety reasons, the carrier must be switched off before performing the following work.

Remove the retainer bars by turning a screw into the M12 thread provided and using the screw to pull out the bar. Remove the dust cap from the working tool bore and put it in the toolbox for safekeeping.

WARNING

Danger of eye injury.

Clean away any dirt adhering to the working tool in the insertion zone, then thoroughly lubricate the shaft of the working tool and the bushes with chisel paste. (A cartridge of chisel paste is contained in the toolbox for firsttime fitting).

Wear safety glasses.

The retainer bars are also to be lubricated. Then insert the working tool, turning it until the re tainer bars slide easily into the slots.

Flying objects

The working tool should only be fitted in the way described here. Fit the working tool. To do this, turn the working tool until the retainer bars slide easily into the slots.Re place the sealing plugs and drive the locking pins for the retainer bars back into position.

CAUTION Pitch points Danger of hands injury. Keep hands clear.

Retainer bars

Sealing plug

Locking pins Working tool

24

8.3

Removing the tool CAUTION

Removal of the working tool for whatever reason is effected in reverse order to fitting, observing the specific features of the individual breaker models. Please note that the tip of the working tool may re main hot for some after use.

Burn hazard Hot surface. Do NOT touch.

9

Starting up the hydraulic breaker

9.1

Starting up the hydraulic breaker

First of all, precautionary measures should be taken to rule out the risk of accidents:

WARNING Flying objects Danger of eye injury. Wear safety glasses. H Close the front screen / splinter guard on the driver’s cab to avoid injury from flying rock splin ters. H Wear ear protection to prevent hearing impair ment. Anyone in the immediate vicinity of breaker operations should also wear ear protec tion. H Move the excavator into operating position.

H Do not start up the hydraulic breaker until the breaker is in position. H Now start up the hydraulic breaker using the foot or hand switch. Never try to break with the breaker without first applying contact pressure since this could cause damage to the carrier. H Stop the hydraulic breaker immediately as soon as persons are in the danger zone. The danger zone during the breaker operation is considerably greater than during the excava tion operation − on account of fractions of stones and pieces of steel flying around − and for this reason, the danger zone must, depending on the type of material to be worked on, be enlarged correspondingly, or the danger zone must be secured in a suit able manner through corresponding measu res.

DANGER Stay clear of this area when ma chine is ON.

25

9.2

Advance

The advance distance (marked »V«) should be such that the rock breaks within 30 seconds at the most. If this is not the case, reduce the amount of advance or reposition the breaker at a different point of attack.

Advancing in large steps will not improve working results. Advancing in small steps is more effective.

Advance

V

9.3

Angle of attack

The working tool should always be positioned at rightangles to the working surface. If this is not the case, the hydraulic breaker will wear more quickly and in the long term will suffer damage.

9.4

Breaker rocking

Rock the breaker gently (no more than approx. 5o) during breaking to allow the dust to escape from beneath the tip of the working tool. If dust is allowed to build up, it will act as a cushion to prevent the full impact energy of the breaker being transferred to the material being broken. Excessive rocking will, however, cause bending strains resulting in damage to the working tool and the hydraulic breaker.

9.5

Never drive the working tool into the ground

If the advance step is too large, or the breaker is not rocked to allow dust to escape, the working tool will be driven into the material without breaking it sufficiently. The tip of the working tool will glow red hot and lose its hardness. Operating in this way is not allowed!

26

9.6

Never lever with the breaker

Never attempt to use the hydraulic breaker as a crowbar, as this will cause the working tool to break. Operating in this way is not allowed!

9.7

Never use as a sledgehammer

Before starting up, rest the breaker on the ground. Never attempt to use the breaker and the excavator boom as a sledgehammer to break material. Operating in this way is not allowed!

9.8

Never use for transport purposes

The hydraulic breaker is not designed to lift or trans port loads. Unsuitable application!

9.9

Using the hydraulic breaker in or under water

The hydraulic breaker must never be used in or under water without prior conversion. If water were to penetrate the percussion chamber, each blow would create a pressure wave. These pressure waves would cause irreparable damage to the stripper and seals on the hydraulic breaker, and in addition the lower percussion piston zone would rust. Water could also penetrate the carrier’s hy draulic system.

Please always contact the Atlas Copco Customer Center / dealer in your region before starting work in or under water.

In order to avoid damage to the hydraulic breaker, Atlas Copco Construction Tools has developed a special connecting kit for underwater applications containing all necessary components incl. safety equipment to keep water out of the lower hammer part by means of compressed air.

27

9.10

Hydraulic breaker used in Tunnelling

Do not use the hydraulic breaker for tunnelling in volving overhead, horizontal or floor work before taking preventative measures!

Please always contact the Atlas Copco Customer Center / dealer in your region before starting work in or under water.

Penetration by dust, stone fragments and/or water can lead to malfunctions during operation and may even cause the hydraulic breaker to stop working.

9.11

Working in high outside temperatures

The temperature of the hydraulic oil must be moni tored to ensure it does not exceed 80°C (176°F). If higher temperatures are measured in the tank, oil cooler must be fitted, and/or installation and pres sure−relief valve have to be checked.

9.12

Only use hydraulic oils of sufficient viscosity. In summer and in tropical climates, the minimum re quirement is a hydraulic oil of type HLP 68.

Working in low outside temperatures

For temperatures down to 20°C (68°F) below freezing there are no special regulations. At temperatures below minus 20°C (−4°F), the carrier must be warmed up prior to use in the way described by the excavator manufacturer. In the majority of cases, carriers and attachments are kept in protected or even heated areas when not in use. However, if the carrier and the hydraulic breaker are left out in the open, the carrier and all equipment must be warmed up before the hydraulic breaker can be started up. The excavator manufacturer’s regulations must be observed in full. Ensure that the hydraulic oil in the carrier is at least at 0°C (32°F). The hydraulic breaker cannot be started up until the oil temperature is over 0°C (32°F). Please observe the excavator manufacturer’s re gulations. During operations, leave the excavator engine and pumps running even during breaks.

CAUTION

Note The hydraulic breaker and excavator will not oper ate to full capacity until the oil temperature has re ached at least 60°C (140°F).

CAUTION Property damage Sealings could break. Prewarm car− rier and brea− ker. Feeding hot hydraulic oil to an extremely cold hy draulic breaker will cause internal stresses in the unit resulting in its failure. If the breaker is used without preheating the oil: H the breaker seals may fracture H he diaphragm in the highpressure accumulator may tear

Property damage Tool could break at temperatures of below 0°C (32°F). Preheat the tool slowly and gradually.

9.13

Operating the breaker with the cylinders fully extended or retracted

Operating the breaker with the shovel/stick cylin ders fully extended or retracted must be avoided at all costs. These end positions are equipped with damping functions; continuous operation at full ex tension/retraction can result in damage to the hy draulic cylinders. Remedy: reposition carrier and/or boom.

28

CAUTION Property damage Piston rod can stuck. Do NOT operate in the dead cent− res of cylinder.

10

Maintenance work to be performed by the excavator driver

10.1

Manual lubricating of the working tool

The working tool must be lubricated regularly during operation. The required lubrication interval depends on the type of application and the amount of dust involved.

550

For lubrication purposes, the hydraulic breaker should be stood vertically on the working steel and contact pressure applied to avoid overgreasing/fill ing up the percussion chamber. Remove the plug. Place the grease gun on the lu brication nipple and apply grease. Replace plug.

grease nipple in lower hammer part

CAUTION Burn hazard Hot surface. Do NOT touch. Please note that working tools may still be very hot at the point/cutting edge even after work has stopped. For preference, chisel paste should be used for lubrication. 510 shots from a handheld grease gun are sufficient. Lubricating interval: approximately every 2−5 hours per shift. The required lubricant level has been reached when grease starts to emerge from the bores for the re taining pins or from the insertion bore for the work ing steel. For preference, only genuine chisel paste should be used for lubrication.Genuine chisel paste is avail able in fully self−emptying standard cartridges. Fully emptied cartridges can be recycled. 500 g cartidges for ContiLube® II in a carton of 30 pieces, part ident. no. 3363 0949 10 Manual grease gun for cardridges: part ident. no. 3363 0345 67

29

10.2

Automatic lubrication using of the hydraulic breaker of the 750, 1150, 1650, 2250, 3050 and 4250

10.2.1 Automatic lubrication using ContiLube® II Hydraulic breakers 750, 1150, 1650, 2250, 3050 and 4250 are equipped with the ContiLube® II auto matic lubrication unit as standard.

ContiLube® II is attached near the service opening on the upper part of the breaker box.

10.2.2 Changing the lubricant cartridge The diagrams below depict the logical steps involved in preparing and fitting a new cartridge. H Open the cartridge by taking off the cap and, on sealed cartridges, by cutting off the seal above the cone (Fig. 1) Important: Do not cut off or damage the cone itself!

H Screw the cartridge into the bore provided in the pump unit as far as it will go. The ContiLube® II is now ready for operation (Fig. 3).

H Depress the cartridge piston with your thumb until lubricant emerges from the threaded end (Fig. 2). Fig. 2

Fig. 1 Seal

Fig. 3

Metering screw

Cone

Lubrication nipple for emergency lubrication

10.2.3 Operating the ContiLube® II Please observe the following information: H ContiLube® II is selfbleeding, i.e. the system requires no additional bleeding. H The cartridge is made of transparent, recyclable plastic (PE), so the lubricant level in the car tridge can be monitored at all times from the driver’s cab by observing the position of the pis ton, which is red. H The piston end of the cartridge must never be sealed off, as this would render delivery imposs ible. H The amount of lubricant delivery per stroke can be set using the metering screw, allowing the unit to be adapted to differing requirements. Turn the screw clockwise = smaller delivery per stroke Turn the screw anticlockwise = greater delivery per stroke

30

H Once the cartridge is empty, the pump unit must be sealed off to prevent water or dust penetra tion. Close the unit with a dust cap or simply leave the empty cartridge in position until a new cartridge is available. H Emergency lubrication is possible via the lu− brication nipple on the front of the ContiLube® II. See chapter 10.2.2, Fig. 3. H The connections for hoses used to operate the ContiLube® II unit must be checked once a week to ensure they have not come loose.

10.3

Manual lubrication without or upon failure of ContiLube® II

Manual lubrication is necessary if the automatic lu brication fails. For manual lubrication, stand the hy draulic breaker upright on the working tool and apply contact pressure. Lubricating intervals: approximately every 25 hours. 5 to 10 shots from a grease gun are suffi cient.

1650

For preference, only genuine chisel paste should be used for lubrication. Genuine chisel paste is available in fully self−empty ing standard cartridges. Fully emptied cartridges can be recycled. rear side ContiLube® II ContiLube® II

2250 3050 4250

rear side

ContiLube® II 750 CL ContiLube® II rear side

rear side

1150

10.3.1 Filling device for the chisel paste The Atlas Copco Construction Tools offers a filling device to refill emptied cartridges, which is fitted on a 45 kg grease container and allows empty car tridges to be refilled as required. 500 g cartidges for ContiLube® II in a carton of 30 pieces, part ident. no. 3363 0949 10 Manual grease gun for cardridges: part ident. no. 3363 0345 67

Manual grease gun for cardridges: part ident. no. 3363 0345 67 15 kg grease container: part ident. no. 3362 2639 00 45 kg grease container: part ident. no. 3362 2632 75 For further information on this subject please con tact the Atlas Copco Customer Center / dealer in your region.

31

10.4

Care and maintenance timetable Work to be performed by excavator driver

ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ During the shift

H Lubricate work ing tool with breaker upright and contact pressure applied

Daily

Weekly

H Tighten screw H Check screw couplings (during couplings first 50 operating hours)

H Check hydraulic Intervals: lines for leaks appr. all 25 hours. 5 to 10 shots with the grease gun.

H Check spring do wel sleeve at the retaining pin have not come loose

H Check pipe H Check locking clamps on carrier pins on retainer bars for tight fit

When changing tool, but latest every 100 opera− ting hours

H Check wear to working tool

H Replace bent and squashed pipes

H Check wear to lower wear bu shes

H Replace dam aged hoses

H Check impact face of per cussion piston for wear/ da mage

H Check pressure in piston accu mulator

H Check impact If automatic lubrica H Tensioning bolts: H Check function Visual check of plugs face of working tion fitted, check and/ or sound tool for damage level, replace cart− check by metallic H Check adapter ridge if necessary hitting of the and breaker box H Check working upper hexagons/ for cracks tool for burring washers through the service open H The connections H Check retainer ings of breaker for hoses used to bars/pins for bur box operate the Con ring tiLube® II unit must be checked to ensure they have not come loose.

32

As required

H Check adapter bolts for wear

10.5

Check

10.5.1 Checking the working tool for wear Check the working tool for wear each time the tool is changed and at the latest after 100 operating hours. If the shaft of the tool has worn down to below the permissible minimum.

D

ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Model

550 750 1150 1650 2250 3050 4250

Minimum diameter D 77 mm / 3.03 in. 97 mm / 3.82 in. 111 mm / 4.38 in. 131 mm / 5.16 in. 145 mm / 5.71 in. 160 mm / 6.30 in. 175 mm / 6.89 in.

Any burring on the working tool must be smoothed off carefully.

33

10.5.2 Checking the wear bushes Note The wear bushes and buffer ring must be replaced in a suitablyequipped workshop. Before fitting new parts, remove any grease residues inside the lower breaker part.

upper wear bush

The inside diameter of the following wear bush has to be checked every time the working tool is changed and at the latest every 100 operating hours: 550: 750  4250:

wear bush lower wear bush

If the diameter has enlarged due to wear, the wear bush must be replaced. A template is included in the delivery to check the inside diameter.

550

The measured diameter must not exceed the maxi mum dimension.

ÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Model

550 750 1150 1650 2250 3050 4250

j template

max. permissible diam.

80 100 115 135 150 165 180

83 mm / 3.27 in 103 mm / 4.06 in 120 mm / 4.72 in 140 mm / 5.51 in 155 mm / 6.10 in 170 mm / 6.69 in 185 mm / 7.28 in

750  4250: When the lower wear bushing is replaced, the in side diameter of the upper wear bushing must be checked. If the diameter has enlarged due to wear, the wear bush and the buffer ring, if existing, must be re placed.

34

lower hammer part

wear bush

buffer ring

lower wear bush

750

upper wear bush

lower wear bush lower ham mer part

1150 1650 2250 3050 4250

10.5.3 Checking the retaining pin for wear (550 and 750) The retaining pin must be checked every time the working tool is changed. If excessive wear is de tected, e. g. sharp edges, notches or dents, the re taining pin must be replaced.

carefully. All sealing plugs for the retaining pins must also be checked. All plugs, which are located in the lower hammer part, must be undamaged and in place.

Burrs on the retaining pin should be smoothed off

10.5.4 Checking the retainer bars for wear (1150  2350) Both retainer bars must be checked each time the tool is changed. If excessive wear is detected (e.g. sharp edges, notches, noticeable indentations) the retainer bars must be replaced. Any burring on the retainer bars must be smoothed off carefully.

The two seal plugs for the retainer bars should also be examined to ensure they are not damaged. It is only possible to check and replace the seal plugs, which are located opposite to each other, after the percussion mechanism has been removed from the hammer box.

10.5.5 Checking the impact face of the percussion piston The impact face of the percussion piston has to be checked for wear or damage every time the working tool is changed and at latest every 100 operating hours. Once the working tool has been removed,

shine a torch onto the impact face. If chipping or wear is detected, do not resume work with the hy draulic breaker and inform the Atlas Copco Cus tomer Center / dealer in your region.

10.5.6 Checking the hammer box for wear Heavily worn hammer boxes must be replaced so as to avoid further damage to the lower hammer part. The wear strips attached at the lower end of the hammer box can be replaced if required. The pro cedure is described in the relevant repair manuals. Note If the wear strips are heavily worn, the guiding sy stem for the percussion unit can get out of function.

Wear strip

35

10.5.7 Screw couplings 550 and 750 On percussive tools such as hydraulic breakers, the screw couplings are subjected to particularly high loads. During the first 50 operating hours the screw couplings on the breaker must be checked daily, thereafter once a

week. Tighten any loose connections without exceeding the prescribed tightening torque.The following screws/ couplings must be checked:

ÓÓÓÓÓÓÓÓÓ ÓÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Connection point

Part no.

Interval

550

750

Type of spanner ...... size ...... Nm

AdapterK

1

daily

Nuts for tensioning boltsKK

2

weekly

Allen key size 17 / 390 Nm Torque wrench / Power wrench size 41

Filling valve »G« Screw plug

3

in case of repair

size 50

Socket spanner size 22 / 130 Nm Allen key size 5 / 20 Nm

Connections »P« and »T«

4

weekly

Jaw spanner / 90 Nm up to SN 299: size 36 from SN 300 on: size 27

Connection »CL«

5

weekly

−

Jaw spanner size 14 20 Nm

Hose connections ContiLube® II

5

weekly

−

Socket and jaw span ners of varying sizes

Screw plug (Perc. chamber ventilation)

6

in case of repair

K

Jaw spanner size 41 120 Nm

Jaw spanner size 41 200 Nm

Apply anti−seize to the threads of the cylindrical bolts before screwing them in. The contact face of the bolt head and the locking rings must be free of lubricant.

1 2

The tie rods are only accessible when the breaker has been removed from the hammer box.

G

Note Tensioning bolts: Visual check and/or sound check by metallic hitting of the upper hexagons/washers thru the service openings of breaker box.

3 T

4

P

KK

Tightening the tensioning bolts for 550 H Pre−tighten nuts in diagonally opposed pairs to 200Nm, H then tighten in diagonally opposed pairs by a further 60° (1 side of hexagonal head), H then tighten in diagonally opposed pairs by a further 90° (1 ½ sides of hexagonal head).

550

1 2

KK

Tightening the tensioning bolts for 750 H Pre−tighten nuts in diagonally opposed pairs to 200Nm, H then tighten in diagonally opposed pairs by a further 120° (2 sides of hexagonal head), H then finish tighten in diagonally opposed pairs by 210° (3 ½ sides of the hexagonal head).

3 G T

L

6

P P

CL

4 5

4 750

36

10.5.8 Screw couplings 1150 On percussive tools such as hydraulic breakers, the screw couplings are subjected to particularly high loads. During the first 50 operating hours the screw couplings on the breaker must be checked daily, thereafter once a week (except of tie rods and high−

pressure accumulator). Tighten any loose connec tions without exceeding the prescribed tightening torque. The following screws/couplings must be checked:

ÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Connection point

Partno.

Interval

1150

Type of spanner......size.....Nm

AdapterK

1

daily

Allen key size 22 / 1500 Nm

Tensioning boltsKKK

2

sound check weekly

Torque wrench / Power wrench size 55

Allen screwKK (valve cover/control valve)

3

in case of repair

Allen key size 14 / 200 Nm

Screw plug (Perc. chamber ventilation)

4

in case of repair

Spanner size 41 / 200 Nm

Filling valve »G« Screw plug

5

in case of repair

Socket spanner size 22 / 130 Nm Allen key size 5 / 20 Nm

Connections »P« and »T«

6

weekly

Jaw spanner size 46 / 160 Nm

Connection »CL«

7

weekly

Jaw spanner size 27 / 200 Nm Jaw spanner size 14 / 20 Nm

Hose connections ContiLube® II

7

weekly

Socket and jaw spanners of varying sizes

8

weekly

Allen key size 14 / 350 Nm

High−pressure accumulator K

Apply anti−seize to the threads of the cylindrical bolts before screwing them in. The contact face of the bolt head and the locking rings must be free of lubricant.

1150 1

KK

Only possible when adapter has been removed

Note Tensioning bolts: Visual check and/or sound check by metallic hitting of the upper hexagons/washers thru the service openings of breaker box.

X

8

2

KKK Tightening

the tensioning bolts for 1150 H Pre−tighten nuts in diagonally opposed pairs to 500Nm, H then tighten in diagonally opposed pairs by a further 60° (1 side of hexagonal head), H then finish tighten in diagonally opposed pairs by 120° (2 sides of the hexagonal head).

3

4

P

G T

CL

5

7 6 View X (without hammer box)

37

10.5.9 Screw couplings 1650 On percussive tools such as hydraulic breakers, the screw couplings are subjected to particularly high loads. During the first 50 operating hours the screw couplings on the breaker must be checked daily, thereafter once a week (except of tie rods and high−

pressure accumulator). Tighten any loose connec tions without exceeding the prescribed tightening torque. The following screws/couplings must be checked:

ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓ ÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Connection point

Part no.

Interval

1650

Type of spanner ...... size ..... Nm

AdapterK

1

daily

Allen key size 22 / 1500 Nm

Tensioning boltsKK

2

sound check weekly

Torque wrench / Power wrench size 55

Allen screw (valve cover/control valve)

3

in case of repair

Spanner size 30 / 380 Nm

Screw plug (Perc. chamber ventilation)

4

in case of repair

Jaw spanner size 41 / 200 Nm

Filling valve »G« Screw plug

5

in case of repair

Socket spanner size 22 / 130 Nm Allen key size 5 / 20 Nm

Connections »P« and »T«

6

weekly

Jaw spanner size 50 / 400 Nm

Port »F« for impact rate switching

7

weekly

Jaw spanner size 30 / 200 Nm

High−pressure accumulatorKKK (connecting screws)

8

weekly

Socket spanner size 30

Connection »CL«

9

weekly

Jaw spanner size 27 / 200 Nm Jaw spanner size 14 / 20 Nm

Hose connections 9 weekly ContiLube® II K Apply anti−seize to the threads of the cylindrical bolts before screwing them in. The contact face of the bolt head and the locking rings must be free of lubricant. Note Tensioning bolts: Visual check and/or sound check by metallic hitting of the upper hexagons/washers thru the service openings of breaker box. K Tightening the tensioning bolts for 1650 H Pre−tighten nuts in diagonally opposed pairs to 500 Nm, H then tighten in diagonally opposed pairs by a further 120° (2 side of hexagonal head), H then finish tighten in diagonally opposed pairs by 90° (1 ½ sides of the hexagonal head). KK Tightening the expansion bolts on high−pressure accumulator 1650 1. Treat the threads and HeliCoil thread inserts for the expansion bolts with an anti−seize agent. 2. Treat the surfaces between the bolt head, was her, and high−pressure accumulator cover with anti−seize agent. 3. Place on the high−pressure accumulator, and tighten the expansion bolts by hand in a cross wise fashion. 4. Pretighten the expansion bolts to 100 Nm, pro ceeding in a crosswise fashion, 5. then tighten each bolt through 30° in a crosswise fashion, 6. finally tighten each bolt again through 60° in a crosswise fashion.

38

Socket and jaw spanners of varying sizes 1650

1 X

3

2

8

5

F P CL

T V

P

6

9

7 4

9

6

View X (without hammer box)

10.5.10 Screw couplings 2250, 3050 and 4250 On percussive tools such as hydraulic breakers, the screw couplings are subjected to particularly high loads. During the first 50 operating hours the screw couplings on the breaker must be checked daily, thereafter once a week (except of tie rods and high−

pressure accumulator). Tighten any loose connec tions without exceeding the prescribed tightening torque. The following screws/couplings must be checked:

ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Connection point

Part no.

Interval

2250

3050

4250

Type of spanner......size.....Nm

Allen key size 22 / 1500 Nm

AdapterK

1

daily

Tensioning boltsKKK

2

sound check weekly

Allen (valve cover/ control valve)

3

in case of repair

Allen key size 17 / 380 Nm

Screw plug (Perc. chamber ventilation)

4

in case of repair

Spanner size 41 / 200 Nm

Filling valve »G« Screw plug

5

in case of repair

Socket spanner size 22 / 130 Nm Allen key size 5 / 20 Nm

Connections »P« and »T«

6

weekly

−

Jaw spanner size 50/55 / 400 Nm

Allen screws for flanges

7

weekly

Allen key size 12 / 130 Nm

Allen key size 10 / 80 Nm

High−pressure accumulatorKKKK (connecting screws)

8

weekly

Allen key size 14 / 350 Nm

Socket spanner size 30

Hose connections ContiLube® II

9

weekly

screwKK

K

KK

Allen key size 27 / 2360 Nm

Slugging ring spanner size 55 size 55

size 65

Socket and jaw spanners of varying sizes

Apply anti−seize to the threads of the cylindrical bolts before screwing them in. The contact face of the bolt head and the locking rings must be free of lubricant.

KKKK

Only possible when adapter has been removed

2.

Note Tensioning bolts: Visual check and/or sound check by metallic hitting of the upper hexagons/washers thru the service openings of breaker box.

1.

3.

4.

KKK Tightening

the tensioning bolts for 2250 H Pre−tighten nuts in diagonally opposed pairs to 500 Nm, H then tighten in diagonally opposed pairs by a further 120° (2 sides of hexagonal head), H then finish tighten in diagonally opposed pairs by 120° (2 sides of the hexagonal head).

size 75

5. 6.

Tightening the expansion bolts on high−pres sure accumulator 3050 and 4250 Treat the threads and HeliCoil thread inserts for the expansion bolts with an anti−seize agent. Treat the surfaces between the bolt head, was her, and high−pressure accumulator cover with anti−seize agent. Place on the high−pressure accumulator, and tighten the expansion bolts by hand in a cross wise fashion. Pretighten the expansion bolts to 100 Nm, pro ceeding in a crosswise fashion, then tighten each bolt through 30° in a crosswise fashion, finally tighten each bolt again through 60° in a crosswise fashion.

KKK Tightening

the tensioning bolts for 3050 and 4250 H Pre−tighten nuts in diagonally opposed pairs to 500 Nm, H then tighten in diagonally opposed pairs by a further 120° (2 sides of hexagonal head), H then finish tighten in diagonally opposed pairs by 180° (3 sides of the hexagonal head).

39

2250 3050 4250 1

Tensioning bolts: Visual check and/or sound check by metallic hitting of the upper hexagons/washers thru the service openings of breaker box.

9

2

3

X

T 8

CL G

P

6

7

5

4

View X (without hammer box)

On 3050 and 4250 the connection points 6 and 7 are on the sides of the cylinder cover.

The graphic may vary for different breaker models.

40

10.5.11 Checking pressure in piston accumulator and refilling if required For checking the piston accumulator of the hy draulic breaker you need: 1 nitrogen filling device 1 pressure gauge 1/4", 025 bar (0−400 psi), test class 1.6 1 nitrogen cylinder 1 adapter, country specific These items should be on hand at all times to allow the following checking and maintenance work to be performed. CHECKING If the performance of the hydraulic breaker starts to drop, the gas pressure in the breaker’s piston accu mulator should be checked. The piston accumulator does not need to be refilled until the gas pressure has dropped to the minimum level or below.

550, 750 Port for test pressure gauge

G

T

L P

CL

P

The graphic may vary for different breaker models.

1150

Note The pressure should be checked at an operating temperature of 6070°C (140160°F). Lay the hydraulic breaker flat to check the pressure. Do not apply contact pressure to the working tool. Unscrew the plug from filling valve »G« and connect up the pressure gauge.

Port for test pressure gauge

G

Read off the pressure. The required pressure in the piston accumulator is as follows:

ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Model

550 750 1150 1650 2250 3050 4250

at operating temperature 6070°C (140160°F) + no contact pressure to the working tool!

Minimum gas pressure bar / psi

Required gas pressure bar / psi

14.0 / 203 9.5 / 138 5.2 / 75 5.3 / 77 12.0 / 174 12.5 / 181 8.6 / 125

17.3 / 251 11.9 / 173 7.0 / 102 8.2 / 119 15.5 / 225 16.0 / 232 11.5 / 167

1650 Port for test pressure gauge

G F P

T CL

P

FILLING / REFILLING Note If a country specific adapter is required it has to be fitted between nitrogen cylinder and pressurerelief valve. Preparations: H Connect the pressurerelief valve to the nitrogen cylinder. H Connect one nozzle of the filling hose to the Minimess port on the pressurerelief valve. H Close the pressurerelief valve

V

2250 3050 4250 G

Port for test pressure gauge

41

H Open the valve on the nitrogen cylinder H Unscrew the plug from filling valve »G«. H Press the free nozzle on the filling hose into the filling valve »G«. Filling the piston accumulator: H Slowly open the pressurerelief valve to allow the nitrogen to flow into the piston accumulator. The pressure increase can be read on the pres sure gauge. H Close the pressurerelief valve when the pres sure in the piston accumulator has reached the required level +10%. H Pull the filling hose out of filling valve »G«. Checking and lowering pressure: H Remove the filling hose from the pressurerelief valve and connect it to the pressure gauge. H Press the free nozzle of the filling hose back into filling valve »G« and read off the pressure. H The pressure in the piston accumulator can be lowered to the required reading by repeatedly pushing in and pulling out the hose nozzle. After filling: H Screw the plug back onto filling valve »G« to close it. H Close the valve on the nitrogen cylinder H Open the pressurerelief valve fully to allow any residual gas to escape. H Remove the pressurerelief valve and if required the adapter. Pressure Minimess port gauge

Nozzle

G gas cylinder valve

42

Pressure− relief valve Adapter

WARNING! Only use the hose nozzle to relieve the pressure. Never use nails, screwdrivers or similar objects for this purpose as they will damage the filling valve. Use only nitrogen from the green gas cylinder to fill the piston accumulator. Never use any other gas, e.g. air or oxygen.

DANGER Explosion hazard Compressed gas. Stop engine, BLEED OFF gas chamber. When filling the piston accumulator, ensure noone is in the vicinity of the working tool. If the tool has jammed, the increase in pressure in the piston accumulator may cause it to spring out suddenly. Before removing the complete filling valve »G«, the piston accumulator must be completely depressur ized. To this end unscrew the valve plug and de press the valve piston in the filling valve using the nozzle of the filling hose. This will allow the nitrogen to escape safely from the cylinder cover of the hydraulic breaker.

10.5.12 Checking that the highpressure accumulator is in perfect working order (1150, 1650, 2250, 3050, 4200) If the normally motionless pressure hose to the breaker (port »P«) starts to jerk violently, there is a problem with the highpressure accumulator.

DANGER Explosion hazard Pressurized vessel.

Switch off the hydraulic breaker immediately and replace the highpressure accumulator.

Stop engine and BLEED OFF breaker circuit. Before mounting/dismounting the hydraulic tool and/or any maintenance work on the hydraulics of the hydraulic tool/carrier the hydraulic sys tem must be depressurized. Check the pressure accumulator in accordance with the national safety provisions. We recommend five− yearly maintenance intervals.

10.5.13 Checking the hydraulic lines before starting work Carry out a visual check on all lines (pipes and hoses) from the pump to the hydraulic breaker and back to the tank. Tighten any loose screw couplings

and hose clamps. Damaged pipes/hoses must be replaced.

10.5.14 Checking the adapter bolts for wear This visual check is only possible when the hy draulic breaker has been dismounted from the ex cavator. If excessive wear is detected (cracks,

notches, noticeable indentations etc.) the screws must be replaced.

10.5.15 Checking and cleaning the hydraulic oil filter A new oil filter cartridge should be fitted for the first time after 50 operating hours. Thereafter the oil filters should be checked every 500 operating hours and changed if necessary.

43

11

Troubleshooting

11.1

Breaker does not start

ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Cause

Remedy

by

Pressure and return lines mixed up

Connect breaker hoses correctly

Excavator driver

Check valve in pressure and/or re turn lines closed

Open check valve

Excavator driver

Gas pressure in piston accumula tor too high

Check pressure in piston accumu lator, reset to correct value

Excavator driver

Oil level in tank too low

Refill oil

Excavator driver

Defective screw couplings block ing pressure or return line

Replace defective coupling halves

Workshop

Electrical equipment for breaker hydraulics defective

Check electrical equipment for breaker hydraulics

Workshop

Magnet on switchon valve defective

Replace magnet

Workshop

Check excavator engine speed; check operating pressure

Excavator driver or Atlas Copco Customer Center / dealer in your region

Operating pressure too low

44

11.2

Impact rate of hydraulic breaker too low

ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ Cause

Remedy

by

Inadequate hydraulic oil delivery

Correct excavator engine speed; check operating pressure; check setting on carrier

Excavator driver

Loose coupling in pressure or return line

Check coupling, tighten if necessary

Excavator driver

Check valve in pressure or return line partially closed

Open check valve

Excavator driver

Flow resistance too high on oil filter or oil cooler

Check oil filter/cooler, clean or replace

Excavator driver

Gas pressure in piston accumulator too high

Check gas pressure in piston accumulator, bleed off if necessary

Excavator driver

Working tool jams in lower hammer part Note: contact pressure must be applied along hydraulic breaker axis

Correct boom direction; deburr working tool; check wear to work ing tool and wear bushes

Excavator driver

Inside diameter of return line too small

Change inside diameter, note the minimum inside diameter refer to Section 13, Technical spe cifications

Workshop

Return pressure too high

Check and lower return pressure

Atlas Copco Customer Center / dealer in your region

Hydraulic oil returns to tank via valve section. Not permitted!

Note: hydraulic oil must return di rect to tank or to filter

Atlas Copco Customer Center / dealer in your region or workshop

Diaphragm in highpressure accumulator defective (1150, 1650, 2250, 3050, 4250) Note: hose at port »P« jerks vio lently

Replace highpressure accumulator. Note: Observe the national safety regulations

Workshop

Temp. of hydraulic oil in tank above 80°C

Check oil level in hydraulic tank and top up if required

Excavator driver

Hydraulic oil pressure too low

Check pressure, modify if necess ary; fit new type−tested pressure relief cartridges where necessary

Workshop

45

11.3

Impact force too low

ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ Cause

Remedy

by

Gas pressure too low

Fill piston accumulator

Excavator driver

Delivery rate from hydraulic system pump inadequate

Check pump characteristics with measuring device and compare with original specifications; if necessary replace pump

11.4

Checking: Atlas Copco Customer Center / dealer in your region Replacing: Aftermarket Depart ment of excavator manufacturer

Impact rate too high and impact force too low

ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ

K

Cause

Remedy

by

No gas in piston accumulator

Fill piston accumulator

Excavator driver

Orings defective (550 parts 9 and 12)K (750 part 103)K (1150 parts 120 and 126)K (1650 parts 17 and 51)K (2250 parts 18 and 20)K (3050 and 4250 parts 28 and 42)K

Replace Orings

Workshop

parts nos refer to valid spare parts lists

11.5

Oil leaks from ports »P« and »T«

ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Cause

Remedy

by

Threaded connections between connecting flange and breaker hose are loose 2250

Tighten threaded connections

Excavator driver

Cap nuts loose

Tighten cap nuts

Excavator driver

CL hose connection on port »P« for ContiLube® II (or plug if ContiLube® II not fitted) loose

Tighten hose connections Tighten plug

Excavator driver

46

11.6

Oil leaks between cylinder cover and cylinder

ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ

11.7

Cause

Remedy

by

Tie rods loose

Tighten tie rods

Workshop

Seals defective

Replace seals (see spare parts lists)

Workshop

Oil leaks from parts of hydraulic system for breaker (Screw couplings, hoses etc.)

ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ Cause

Remedy

by

Screw couplings loose; flange connections on valve loose

Tighten screw couplings; if necessary replace defective parts; check hydraulic system for breaker, replace defective parts Note: use only genuine spares

Excavator driver or workshop

11.8

Oil leaks from working tool

ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Cause

Remedy

by

Lower piston seals defective

Dismantle hydraulic breaker; re place seals; avoid possible ex cessive lubrication of working tool

Workshop

11.9

Oil leaks from high−pressure accumulator

ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ

K

Cause

Remedy

by

Fixing screws for highpressure accumulator loose

Replace Oring a. back−up ring (1150: parts 111 + 112)K (1650: parts 43 + 44)K (2250: parts 11+12)K (3050, 4250: parts 35 + 36)K Tighten fixing screws

Workshop

Part nos. refer to valid spare parts lists

47

11.10 Oil or grease leaks from ContiLube® II

ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ Cause

Remedy

by

Screw couplings are loose

Tighten screw couplings

Workshop

11.11 Operating temperature too high

ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Cause

Remedy

by

Oil level in tank too low

Refill oil

Excavator driver or Workshop

Excavator pump delivery too high; oil is constantly returned to the tank via the pressurerelief valve

Correct excavator engine speed

Excavator driver

Reset pump

Atlas Copco Customer Center / dealer in your region

High outside temperature and no oil cooler fitted

Fit oil cooler

Workshop or Atlas Copco Cus tomer Center / dealer in your re gion

Pressurerelief valve defective or valve with a bad characteristic curve

Fit new type−tested pressure relief cartridges or a more precise pres sure−limiting valve

Workshop

12

Disposal CAUTION!

Dispose of the hydraulic breaker and the hydraulic oil in accordance with the applicable statutory provi sions on environmental protection.

48

H Put the hydraulic breaker out of operation and disassemble it as described in sections 8.3 and 6.6. H Dispose of the hydraulic breaker in line with all applicable regulations or consult an authorised and specialised recycling company.

13

Technical specifications

ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓÓÓ ÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Model

Service

weightK [kg]

[lbs]

Recommended carrier class [t] [lbs] Impact rateKK [min1] Dimensions (excl. working tool) Length [mm] [inch] Width [mm] [inch] Depth [mm] [inch] Oil flow rate [l/min] [US gal/min] Operating pressure [bar] [psi] Max. static pressure [bar] [psi] (to be set on pressure− relief valve for breaker circuit) Working tool diameter [mm] [inch] Piston accumulatorKKK gas pressure Minimum [bar/psi] Required [bar/psi] Sound pressure level measured [Lp dB (A)] r = 10 m Sound power levelKKKK garanteed [LWA dB (A)]

Connecting thread on ports »P« and »T«

Inside diameter: Hoses [mm]

Pipes K KK KKK KKKK

[mm]

550

750

1150

1650

560 1235

850 1874

1250 2756

1600 3528

9−15 19.800−33.000 590  1100

12−18 26.500−40.000 420  750

14−22 30.100−48.500 350 − 600

18−34 40.000−75.000 360 − 540

1190 46.80 410 16.14 560 22.05 70 − 100 18.5 − 26.4

1366 54.37 410 16.14 560 22.05 80  110 21.1 − 31.7

1579 62.16 495 19.48 630 24.80 90  120 23.8 − 31.7

1664 65.51 495 19.49 648 25.51 130 − 170 34.35 − 44.91

120 − 150 1740 − 2175

140  170 2030 − 2465

140  170 2030 − 2465

120 − 140 1740 − 2030

170 2465

200 2900

190 2755

160 2320

80 3.15

100 3.94

115 4.53

135 5.32

14.0/203 17.3/251

9.5/138 11.9/173

5.2/75 7.0/102

5.3/77 8.2/119

87

90

90

87

116

120

120

117

M 36 x 2 24° concial seal

M 42 x 2 24° concial seal

BSP 1" DIN 2999

up to SN 299: M 36 x 2 / 24° concial seal from SN 300 on: M 26 x 1,5 24° concial seal

up to SN 299: 20 / (0.79 inch) from SN 300 on: 18 / (0.71 inch) up to SN 299: 20 / (0.79 inch) from SN 300 on: 16 / (0.63 inch)

20 / (0.79 inch)

25 (1 inch)

20 / (0.79 inch)

25 (1 inch)

Hydraulic breaker incl. breaker box, working tool and medium sized adapter. Depending on the oil flow rate at operating temperature of 60 to 70°C and no contact pressure to the working tool measuring process based on directive 2000/14/EC

49

ÓÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓ ÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓÓ Model

2250

3050

4250

Service weightK [kg] [lbs]

2150 4741

3000 6615

4120 9085

Recommended carrier class [t] [lbs]

26 − 40 57.300 − 88.200

32 − 50 70.600 − 110.300

42 − 75 92.600 − 165.400

280 − 550

280 − 540

270 − 530

1946 76.61 650 25.59 700 27.56

2205 86.81 670 26.38 800 31.50

2359 92.87 670 26.38 800 31.50

140  180 36.99 − 47.56

210  270 55.48 − 71.33

250 − 320 66.05 − 84.54

Impact rateKK

[min1]

Dimensions (excl. working tool) Length [mm] [inch] Width [mm] [inch] Depth [mm] [inch] Oil flow rate [l/min] [US gal/min] Operating pressure

[bar] [psi]

Max. static pressure

[bar] [psi] (to be set on pressure−relief valve for breaker circuit) Working tool diameter

160  180 2320 − 2610

160  180 2330 − 2610

200 2900

200 2900

150 5.91

165 6.50

180 7.09

12.0/174 15.5/225

12.5/181 16.0/232

8.6/125 11.5/167

Sound pressure level measured [Lp dB (A)] r = 10 m

91

93

92

Sound power levelKKKK garanteed [LWA dB (A)]

121

122

122

[mm] [inch]

Piston accumulatorKKK gas pressure Minimum [bar/psi] Required [bar/psi]

Connecting thread on ports »P« and »T« Inside diameter: Hoses [mm] Pipes [mm] K KK KKK KKKK

50

Connection flange SAE 1 1/4 − 6000 psi

1 5/8−12 UNF JIC Konus 37°

25 (1") 25 (1")

30 / (1.18 inch) 30 / (1.18 inch)

Hydraulic breaker incl. breaker box, working tool and medium sized adapter. Depending on the oil flow rate at operating temperature of 60 to 70°C and no contact pressure to the working tool measuring process based on directive 2000/14/EC

Index A

F

H Accident prevention regulations, 7

H Filling device for the chisel paste, 31

H Applications, 11 H Attaching the adapter to the hydraulic hammer, 16

G H General informations, 11

H Automatic lubrication using ContiLube® II, 30 H Automatic lubrication using of the hydraulic breaker of the 750, 1150, 1650, 2250, 3050 and 4250, 30

H H Hammer does not start, 44 H How to proceed after more than twelve months’ storage, 20

C H Care and maintenance, 32 H CE markings, 10

I H Impact force too low, 46

H CE sticker product groups B, 10 H Changing the lubricant cartridge, 30 H Checking −

Adapter bolts, 43

−

Hammer box, 35

−

Hydraulic filter, 43

−

Hydraulic lines, 43

−

Retainer bars, 35

−

Working tool, 33

H Checking pressure in piston accumulator and refilling if required, 41 H Checking that the high−pressure accumulator is in perfect , 43 H Checking the impact face of the percussion piston, 35 H Checking the retainer bars for wear (1150 − 2350), 35 H Checking the wear bushes , 34

H Impact rate of hydraulic hammer too low, 45 H Impact rate too high and impact force too low, 46

L H Long storage, 20

M H Main components, 12 H Main components or assemblies 1150 and 1650, 13 H Main components or assemblies 2250, 3050 and 4250, 14 H Main components or assemblies 550 and 750, 12 H Maintenance work to be performed by the exca vator driver, 29 H Manual lubricating of the working tool, 29

D

H Manual lubrication without or upon failure of ContiLube® II, 31

H Dismounting the hydraulic breaker from the ex cavator for short or lengthy periods of non−use, 19

H Mineral hydraulic oil, 15 H Mounting, Hydraulic aspects, 18

H Disposal, 48 H DustProtector , 24

H Mounting the hydraulic hammer on the excava tor−, 17

51

N

S

H Never drive the working tool into the ground, 26

H Scope of supply, 11

H Never lever with the hammer, 27

H Screw couplings 1150, 37

H Never use as a sledgehammer, 27

H Screw couplings 1650, 38

H Never use for transport purposes, 27

H Screw couplings 2250, 3050 and 4250, 39

H Non−mineral hydraulic oil, 15

H Screw couplings 550 and 750, 36 H Selecting the right working tool, 21

O H Oil leaks between cylinder cover and cylinder, 47

H Short storage, 20 H Starting up the hydraulic breaker, 25

H Oil leaks from high−pressure accumulator, 47 H Sticker for guaranteed sound level power, 11 H Oil leaks from parts of hydraulic system for ham mer (Screw couplings, hoses etc.), 47

H Storage, 20 −

H Oil leaks from ports »P« and »T«, 46

Hydraulic breaker, 20

H Oil leaks from working tool, 47

H Switching on from the carrier, 19 , 23

H Oil or grease leaks from ContiLube® II, 48

H Symbols, 7

H Operating, 15 −

Advance, 26

T

−

Angle of attack, 26

H Technical specifications, 49

−

Hammer rocking, 26

−

Media/consumables, 15

−

Starting up, 25

H Operating media/consumables −

Gas, 16

−

Grease, 15

H Operating temperature too high, 48 H Operating the breaker with the cylinders fully extended or retracted, 28 H Operating the ContiLube® II, 30

H Troubleshooting, 44

W H Working −

In high outside temperatures, 28

−

In low outside temperatures, 28

−

In or under water, 27

−

In tunnel application, 28

H Working tool, Fitting, 21 H Working tools, 21

P H Piston accumulator, Filling, 41

52

H Working tools for hydraulic breakers 1150 − 4250, 22

53

54

55

Atlas Copco Construction Tools GmbH Helenenstrasse 149 S 45143 Essen P. O. Box 10 21 52 S 45021 Essen Federal Republic of Germany Telephone +49 201 633 − 0 Internet: www.atlascopco.com

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