Operating Instructions Hydraulic Hammers HM 350 Eco V and HM 580 Eco (V)

Pt.Id.No. 3362 2630 15

Valid from: 09/2003 GB

Operating Instructions Hydraulic Hammers

HM 350 Eco V HM 580 Eco HM 580 Eco V

E Atlas Copco Construction Tools GmbH

Atlas Copco Construction Tools GmbH P. O. Box : 102152, D 45021 Essen Helenenstrasse 149, D 45143 Essen Federal Republic of Germany Telephone Telefax After Customer Support +49 201 633 0 +49 201 633 2281 +49 201 633 1352

Foreword
Please read these operating instructions before using the hydraulic hammer for the first time in order to avoid faults and breakdowns which may otherwise occur due to incorrect or inexpert usage. These operating instructions contain: H mportant safety regulations H operating instructions for the hydraulic hammer H maintenance instructions for the hydraulic hammer H aids to troubleshooting The operating instructions describe how to use the hammer on site and should therefore be kept in the document compartment of the excavator cab. Please pay careful attention to the safety regula tions which are listed at the beginning of this man ual and repeated in the relevant sections. Responsibility for the observation of these safety regulations lies at all times with the operator. All safety regulations listed in this manual comply with the laws and regulations of the European Union. Additional national regulations have also been taken into consideration wherever applicable. Hydraulic hammer operation outside the European Union is subject to the laws and regulations valid in the country of use. Please note that reliable operation of the hydraulic hammer can only be guaranteed if genuine spare parts are used. We wish you every success with your hydraulic hammer. Atlas Copco Construction Tools GmbH

All hydraulic hammers in this operating instructions can also be supplied with the additional ,, Vibrosilenced Plus noise damping system.

Explanation of the symbols used in this operating manual

Certain instructions in the operating manual are marked with symbols to emphasise their importance. The symbols used are described below:

The marked text provides instructions on the Please note! correct use of the hydraulic tool aimed at avoid ing incorrect operation or errors during work.

The marked text provides safety regulations Important! and instructions aimed at avoiding damage to equipment.

Caution!

The marked text provides safety regulations and instructions aimed at avoiding accidents and possible injuries.

Table of Contents
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Explanation of the symbols used in this operating manual . . . . . . . . . . . . . . . . . . . . . 1. 2. 3. 4. 5. 6. 7. Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accident Prevention Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CE markings (EU directive on machinery 98/37/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 7.2 7.3 7.4 Mounting the hydraulic hammer on the excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting the hydraulic hammer on the excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the hydraulic hammer to the excavators hydraulic system . . . . . . . . . . . . . Activating/deactivating the hydraulic hammer from the carrier . . . . . . . . . . . . . . . . . . . . .

4 5 8 8 11 12 12 13 14
14 15 16 18

8. 9.

Fitting the working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 Piston accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 19
19

10.

Operating the hydraulic hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 10.1.1 10.1.2 10.1.3 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 10.13 Operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mineral hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmentallyfriendly hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting up the hydraulic hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hammer rocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Never drive the working tool into the material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Never use as a crowbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Never use as a sledgehammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Never lift or transport loads with the hydraulic hammer . . . . . . . . . . . . . . . . . . . . . . . . . . . Never use in or under water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Hammer used in Tunnelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working in high outside temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working in low outside temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19
19 19 19 20 20 20 21 21 21 21 21 22 22 23 23 23

11.

Selecting the correct working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1 11.2 Working tools for hydraulic hammer model HM 350 Eco V . . . . . . . . . . . . . . . . . . . . . . . . Working tools for hydraulic hammer model HM 580 Eco (V) . . . . . . . . . . . . . . . . . . . . . . .

24
24 24 7

12.

Maintenance work to be carried out by the excavator driver . . . . . . . . . . . . . . . . . . . .

12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8 12.9 12.10 12.11 12.12 12.13 Lubricating the working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the working tool for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the retaining pin for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the hammer box/adapter for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the wear bushes and buffer ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening the screw connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking/topping up the pressure in the piston accumulator . . . . . . . . . . . . . . . . . . . . . . Checking the pressure accumulator is in perfect working order [Only on HM 580 Eco (V)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking hydraulic lines before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the adapter pins for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the adapter pins for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the hammer box for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and cleaning the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25
25 26 26 26 27 28 30 32 32 32 32 33 33

13. 14.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dismounting the hydraulic hammer from the excavator for short or lengthy periods of non use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.1 14.2 14.3 Dismounting the hammer from the excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short period of non use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lengthy period of non use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 39
39 39 40

15.

Care and maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

1.

Operating Conditions
The hydraulic hammer is generally operated from the drivers cab of the carrier. Please refer also to Sections 2. and 7.4

The hydraulic hammer is designed for attachment to hydraulic excavators and is suitable for the following applications: Extraction work, rock levelling, breaking up mineral raw materials and rock.

2.

Accident Prevention Regulations

Caution!

To exclude the possibility of injury to employees, please observe the following instructions. Before starting work: Please familiarise yourself with the operating instruc tions and the appropriate regulations before starting work with the hydraulic hammer. When using hydraulic hammers in the countries of the European Union, the regulations of the EC machinery guideline 98/37/EC and the national accident prevention regulations must be observed and followed. Likewise in countries outside of the European Union, the applicable statutes and regulations must be applied. Before mounting/dismounting the hydraulic tool and/or any maintenance work on the hydraulics of the hydraulic tool/carrier the hydraulic system must be depressurized. When using or transporting the excavator with the hydraulic hammer mounted, the operating instruc tions/manual provided by the excavator manufac turer must also be observed. Mounting the hydraulic hammer on the exca vator: When attaching the hydraulic hammer, an assistant is required who must be instructed by the excavator driver. All directions, signals etc. When lifting/transporting the hammer, use only the lugs provided and hoisting equipment with sufficient capacity. When attaching the hydraulic hammer, an assistant is required who must be instructed by the excavator driver. All directions, signals etc. must be agreed on beforehand. The hydraulic hammer should only be attached to an excavator with sufficient load capacity. Under normal circumstances, the hydraulic hammers HM 350 Eco V/HM 580 Eco (V) require carriers in the class indicated in the following table:

Hammer type Carrier weight class 8 15 tonnes 12 18 tonnes 12 18 tonnes HM 350 Eco V HM 580 Eco HM 580 Eco V If carriers are used with an insufficient load capacity, they may become unstable during hammer oper ation and fall over, causing injury and/or damage. If mounted on carriers above this upper weight limit, hammers may be subject to mechanical overload. Queries on the delivery required from the hydraulic system and adaptation of same to hammer oper ations should be addressed to our after sales ser vice. Only the special steel hexagonal socket head screws included in supply should be used to attach the adapter. Keep your hands well clear of bores and fitting areas when mounting the hydraulic hammer, especially when the boom is moving. If a hydraulic system is fitted, check the inside diameter of the hydraulic lines. All supply/ return lines for the hydraulic oil must have an adequate inside diameter. The connection threads on the hammer ports and the hydraulic hoses must be undamaged and free of sand or similar foreign bodies. Collect any oil which leaks out and dispose of it cor rectly. Check the pressure relief valve on the hydraulic sys tem for hammer operation. This valve, which pro tects the pressure accumulator, must be type tested and approved by the relevant authorities. It is set to a fixed value and then leaded. 9

Any tampering with this setting will result in immedi ate revocation of the operating permit for the sys tem. Before putting the hydraulic hammer with hydraulic accumulator into service, an accept ance inspection must be carried out and certifi cation provided by a our after sales service technician or another qualified specialist. Do not run any hydraulic lines through the drivers cab. These lines may spring a leak or even burst, and the hydraulic oil becomes very hot during oper ation. Fitting/ removing the working tool: Always wear protective glasses when fitting or re moving the working steel. Metal splinters may chip off when the locking pins are hammered out. Working tools should only be fitted as described in this operating manual. Never use your fingers to check the alignment of the recesses on the working tool to the oblong holes for the locking bars. Hammer operation: Close the front screen/splinter protection on the drivers cab to prevent possible injury from flying rock splinters during hammer operation. Ear protection: Ear protection must be made available and worn in accordance with regulations on the operation of excavators with percussive tools valid in the country of use. Guaranteed sound power level The LWA guaranteed sound power level is an upper limit, indication of which is mandatory under EU di rective 2000/14/EC. This level is measured by a defined method and contains additions to the measured sound power levels. It is therefore not comparable with previously stated noise levels (sound power level at a distance of 7 meters) or other values. The guaranteed sound power levels measured by this method are listed in the table below.

Stop the hydraulic hammer immediately if anyone moves into the danger zone, i.e. a radius of at least 7 metres around the hydraulic hammer. Depending on the application and the material greater distances may have to be observed or the site must be cor doned off. Danger by flying splinters! Do not touch any hot parts. The hydraulic hammer heats up during operation. Check the oil temperature constantly. The temperature of the hydraulic oil must never exceed 80oC; if higher temperatures are measured in the tank, an oil cooler must be fitted. Observe the excavator manufacturers safety regula tions. Operation of the excavator with a hydraulic hammer mounted: see Section 7.4 The hydraulic hammer may only be used for the applications described. Maintenance and repair work: If one of the tie rods on the hydraulic hammer breaks, it is imperative that all 4 tie rods be replaced. The hammers integrated piston accumulator is pressurised. Before dismantling the hydraulic hammer and before removing the complete filling valve G , the piston accumulator must be fully depressurised. (See Section 12.7) When filling the piston accumulator, make sure no one is in the vicinity of the working tool. If the tool has jammed, an increase in pressure in the piston accumulator may release it suddenly. Caution: risk of injury! The piston accumulator should only be filled with nitrogen (the nitrogen cylinder is green). Make sure no other gas (e.g. air or oxygen) is allowed into the piston accumulator. Caution: risk of explosion! Never open or repair the pressure accumulator. A defective pressure accumulator must be repaired by a specialist. (Only on HM 580 Eco/580 Eco V) Before repairing the pressure accumulator, depres surise the hydraulic system. An inspection must be carried out each time the pressure accumulator is repaired or modifica tions are made to the hydraulic system. During this inspection, the specialist will determine whether the pressure accumulator corresponds to the appropriate regulations governing pres surised vessels in the country of use. Have the pressure accumulator checked regularly, at the latest after five years, to ensure that it still corre sponds to the appropriate regulations for pressur ised vessels.

Hammer type The noise level LWA dB(A) K 113 118 114 HM 350 Eco V HM 580 Eco HM 580 Eco V K measuring process based on directive 2000/14/EC The hydraulic hammer should only be operated from the drivers seat. Exception: remote control of carrier. See Section 7.4. Do not start up the hydraulic hammer until both carrier and hydraulic hammer are in the correct posi tion. 10

Dismounting the hydraulic hammer: When dismounting the hydraulic hammer, an assist ant is required who must be instructed by the exca vator driver. Clear hand signals etc. must be agreed on beforehand. When handling the excavator or putting it out of ser vice, please observe the excavator manufacturers safety regulations.

Keep your hands well clear of bores and fitting areas when dismounting the hydraulic hammer, especially when the boom is moving. Collect any oil which leaks out and dispose of it cor rectly. Secure the hammer after removal so that it cannot fall over.

Important:
In order to avoid damage, please observe the following instructions. All hoses, pipes and fixing bolts must be checked visually for wear and tight fit each day before start ing work. Mounting the hydraulic hammer: If a hydraulic system is fitted, check the inside diam eter of the hydraulic lines. All supply/return lines for hydraulic oil must have an inside diameter of at least 20 mm. The hoses/pipes used for these lines must satisfy the following quality criteria: Hammer connection hoses: hydraulic hoses with 4 wire spiral inlays as per DIN standard 20023. Hydraulic pipes: steel tubing, seamless, cold drawn, as per DIN standard 2391, sheet 2, grade C. Check the connections on the hydraulic hammer and hammer hoses. The connection threads must be undamaged and free of sand or similar foreign bodies. Operating the hydraulic hammer: The hydraulic hammer is only suitable for the applications described in Section 1. Section 10 provides details on how to use the hydraulic hammer and also gives examples of the type of usage which is not allowed. Maintenance and repair work: The working tool must be lubricated regularly at the prescribed intervals during operation. Approx. 5 to 10 shots from the hand held grease gun are suffi cient. For preference, our chisel paste should be used, but the minimum requirement is for a high per formance friction bearing grease with molybdenum sulphide additives. The hydraulic hammer can also be equipped with a ContiLube II grease lubrication unit which permits virtually automatic lubrication. For further information on this subject please contact our after sales service. Dismounting the hydraulic hammer: Check the working tool for wear every time the tool is changed and at the latest every 100 operating hours. If the shank has worn down to below the minimum permissible diameter, the working tool must be replaced. Dismounting the hydraulic hammer and storage dur ing short or long periods of non use is described in Sections 14.2 and 14.3. 11 Check the screw couplings. For the first 50 operating hours, all screw couplings on the hydraulic hammer must be checked daily. After this, a weekly check is sufficient. Loose coup lings should be tightened without exceeding the pre scribed tightening torque. (See Section 12.6) Section 12 also describes how to check on the per cussion piston, the retaining bars, the adapter pins and the hammer box. The procedure for checking and if necessary topping up the piston accumulator pressure is described in Section 12.7. Check that the pressure accumulator is in perfect working order. (Only on HM 580 Eco/580 Eco V) If the pressurised oil line to port P on the hammer, which normally hangs still, starts to jerk violently, the pressure accumulators are not work Check the oil filter. The return line to the hydraulic system must be fitted with an oil filter with a mesh no greater than 50 micrometres and equipped with a magnetic separ ator. Clean the oil filter regularly. On new hydraulic hammers, the oil filter should be cleaned for the first time after 8 operating hours, for the second time after 50 operating hours and there after regularly every 500 operating hours. Information on the minimum permissible diameter and on remachining working tools is provided in Section 12.2.

3.

CE markings
(EU directive on machinery 98/37/EC)
Hydraulic hammer (excl. hammer box) B. Product group: Hydraulic hammer with hammer box

A. Product group:

Location on hammers intended for use with hammer box: Rear side of hammer (opposite side to ports P+T) Location on hammers with hammer holder/bracket: Side of hammer

Location: rear side of hammer box, below upper flange LWA sticker

Warning:
In according with EC directives CE nameplates must be affixed firmly and in a clearly visible position. Should these nameplates be lost or defaced, replacements can be ordered from your dealer/from Atlas Copco Con struction Tools. The following information must be provided: Part ident. no. of the tool/ser. no. and date of delivery (from the delivery note)

CE sticker product groups A and B 1 2 3 4 5 6 1. 2. 3. 4. 5. 6. 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

Sticker for guaranteed sound level power In accordance with EU directive 2000/14/EC, hy draulic hammers used within the EU must bear a marking legible from the outside stating the sound power level guaranteed by the manufacture. This level is certified by a notified body in accordance with the above directive and is documented on the EU declaration of conformity included in supply.

12

4.
Type

Technical Specifications
HM 350 Eco V HM 580 Eco (V)

Service weight K [ kg ] 535 900 Impact rate KK [ min
1

440 1000

370 820

Dimension without working tool Height Width Depth [ mm ] [ mm ] [ mm ] 1212 260 240 1381 400 560

Oil flow rate

[ l / min ]

60 100

70 120

Hydraulic oil pressure

[ bar ]

130 160

120 180

Max. static pressure [bar] (to be set on pressurerelief valve for hammer circuit)

180

200

Diameter of working tool

[ mm ]

90

100

Connecting thread ports P and T

M 36 x 2 with cutting ring DIN 2353 or 24o conical seal

Inside diameter Hoses Pipes

[ mm ] [ mm ]

20 20

K KK

Hydraulic hammer incl. hammer box, working tool and medium sized adapter Depending on operating conditions

5.

Scope of supply

The general scope of supply for hydraulic hammers includes the following: Hydraulic hammer, working tool, tool box. Special accessories (e.g. adapter, hydraulic adapter kit for the excavator) are provided in accordance with the order.

13

6.

Main components

The hydraulic hammer has the following main components or component assemblies:

adapter

cylinder cover high pressure accumulator (not on HM 350 Eco V) cylinder CE sticker on rear face of hammer box hammer box

lower hammer part

working tool

Please note:
The CE sticker contains information on the unit ,, hammer and hammer box . The weight indicated refers to the weight of this unit. When selecting suitable hoisting equipment and tackle to move the unit, it may be necessary to make addi tional provision for the weights of the working tool and the adapter. 14

7.
7.1

Attachment
Mounting the hydraulic hammer on the excavator

Lay the hydraulic hammer 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 hammer box with two screws (referring to Section 7.2 Then fit all screws. The required sizes for the Allen keys are shown below.

Model Type of spanner size Allen key 17 HM 350 Eco V HM 580 Eco HM 580 Eco V Tightening torques, see Section 12.6.

Caution!

Only the special steel Allen screws included in supply should be used to attach the adapter. For transport purposes use only the lug(s) provided. The hydraulic hammer is heavy and difficult to move.

screw

elastic pad

adapter

15

7.2

Mounting the hydraulic hammer on the excavator

A special kit is required to mount the hydraulic hammer on the excavator. This kit varies from one excavator model to another and must be ordered separately, indicating the following: H make of excavator H model / year built H boom type The excavators insertion pins are not required. They should be kept safely to allow subsequent remounting of the shovel. During mounting, the carrier must only be operated from the drivers seat. When mounting the hydraulic hammer, lower the stick of the boom carefully into the holder provided on the adapter. An assistant directs the movements of the stick until the bores in the adapter and the stick are flush. Insert stick pin and secure.

excavator stick hydraulic hammer

stick pin

adapter

Stand the hydraulic hammer vertically on the lower hammer part. Extend the shovel cylinder until the bore in the toggle is flush with that in the adapter. Insert toggle pin and secure.

excavator stick

shovel cylinder

adapter

marking

Stiel Stick

= Stiel

toggle pin

toggle

Important: After mounting the hydraulic hammer, extend and retract the shovel cylinder carefully as far as it will go. It is important that the hammer can be operated normally with this cylinder fully retracted or fully extended. If there are any problems in this respect, please contact after sales service. 16

Caution!
H The hydraulic hammer should only be mounted on an excavator with sufficient load capacity. If the excavator is too light, it may become unstable under load and fall over. H Hand signals must be agreed upon with the assistant beforehand. The assistant must be instructed by the excavator driver. H Keep your hands away from bores and fitting areas when mounting the hydraulic hammer. H Do not touch any parts when the boom is moving. H Never use your fingers to check the alignment of the bores.

7.3

Connecting the hydraulic hammer to the excavators hydraulic system

The excavator must have a hydraulic system suitable for hammer operation. Please note: If this is not the case, a genuine conversion kit must be fitted, for which there are separate instructions. Unscrew the screw caps from ports P and T and put them in the tool box for safekeeping. The pressure port P is marked in red. Screw the hoses firmly to the ports.

port P port T

hydraulic hoses
The graphic may vary for different hammer models

screw caps

Important: If the excavator has a suitable hydraulic system, check the nominal width of the hydraulic lines. All supply/return lines for the oil must have an inside diameter of at least 20 mm. The hoses/pipes used for these lines must satisfy the following quality criteria: Hydraulic hoses with 4 wire spiral inlays as per DIN standard 20023. Hydraulic pipes: steel tubing, seamless, cold drawn, as per DIN standard 2391, sheet 2, grade C. If you determine that the existing hydraulic system does not match these requirements, it is imperative that you contact our after sales service on safety grounds. Check the connections on the hydraulic hammer and the hammer hoses. The connecting threads must be undamaged. Clean any sand or similar foreign bodies from the connecting threads.

17

Caution!

Before mounting/dismounting the hydraulic tool and/or any maintenance work on the hydraulics of the hydraulic tool/carrier the hydraulic system must be depressurized. Screw the hoses tightly to the hydraulic hammer and to the connections on the side of the excavator stick. H Check that the pressure relief valve on the hydraulic system has been approved by the relevant author ities. H Set the pressure relief valve correctly. The pressure relief valve is set to the maximum permissible operating pressure of the hydraulic hammer and then leaded. Any tampering with this setting will immediately render the operating permit for the unit invalid. H Do not run any hydraulic lines through the drivers cab, since they may start to leak or even burst. The hydraulic oil becomes very hot during operation. When connecting up the hydraulic lines for the first time and then on each subsequent occasion, secure the carrier in such a way as to reliably prevent the hydraulic hammer from starting up on its own. Damaged hoses and pipes must be replaced in good time before they can cause damage or injury.If no our conversion kit has been used on the hydraulic system, check whether the hose ports on the excavator match the connections on the hammer hoses. Ports P and T have an M 36 x 2 metric connecting thread for compression pipe fittings with DIN 2353 cutting ring or 24o sealing cone. The hammer hoses can be connected up using either H screw nipples H stop cocks or H screw couplings with integrated non return valveon the stick of the excavator Screw the hoses tightly to the hydraulic hammer and to the connections on the side of the excavator stick.

The graphic may vary for different hammer models

18

7.4

Activating/deactivating the hydraulic hammer from the carrier

Integration of the genuine conversion kit in the carriers hydraulic system allows the hydraulic hammer to be powered by the carrier hydraulics. All normal excavator functions remain unaffected. During use, the hammer is activated and deactivated by electrical commands. When leaving the drivers cab, ensure that the safety switch for hammer electrics is set to ,, OFF so as to reliably prevent unintentional activation of the hammer. It is also possible to operate the carrier and hydraulic hammer by remote control. For further details on this point, please contact the carrier manufacturer and/or our after sales service.

8.

Fitting the working tool

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.

Using the excavator boom, move the hydraulic hammer into horizontal position.

Important!

Important: For preference, our chisel paste should be used for lubrication.

Lower the hydraulic hammer onto a suitable base. Insert an ejector drift, screwdriver 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. Please note: Retaining pins are wear parts. Replacement of these parts due to normal wear is not covered by the terms of the warranty. 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. The Insert the working tool, turning it until the retaining bars slip easily into the oblong holes.

Caution!

The working tool should only be fitted in the way described here. Never use your fingers to check the alignment of the recesses in the working tool to the oblong holes for the retaining bars. Always wear protective glasses when fitting/remov ing the working tool since metal chips may fly off when the locking pins are hammered out. Please note that the point/chisel edge of the working tool can still be very hot for a short time after use.

retaining pin

ejector drift

19

9.
9.1

Special technical features

Piston accumulator

The piston accumulator is located in the cylinder cover above the percussion piston and is filled with nitrogen. When the percussion piston is at upper dead centre, this nitrogen is subjected to maximum compression. The force arising from this compression acts on the face of the piston and drives it down. The piston accumulator provides around two thirds of the percussive power for the working stroke, the last third being provided by the excavator hydraulics. This design feature makes the percussive power of the hammer largely independent of fluctuations in the excavators hydraulic system during operation.

10.
10.1

Operating the hydraulic hammer

Operating media

The following media are required to operate the hydraulic hammer:

10.1.1 Mineral hydraulic fluids

All brand name hydraulic oils prescribed for use by the carrier manufacturer are suitable for running the hammers.The oil should, however, have a viscosity rating of at least HLP 32 or equivalent. In summer and in warmer climates, oils with a vis cosity rating of HLP 68 or higher should be used. In all other respects the regulations of the carrier manufacturer are to be considered. Optimum viscosity range Max. initial viscosity Max. oil temperature (for short period only) Important! When using the hydraulic hammer in low tempera tures, please refer to Section 10.12. Check the oil filter. Check that the oil temperature never exceeds 80oC. If higher temperatures are measured in the tank, an oil cooler must be fitted.
= = =

The return line to the hydraulic system must be fitted with an oil filter with a mesh no greater than 50 micrometres and equipped with a magnetic separ ator.

30 60 cSt 2000 cSt 80oC

Important!

10.1.2 Environmentallyfriendly hydraulic fluids

In order to protect the environment or on other technical grounds, fluids are now being used which do not belong to the HLP mineral oil group. These can be divided into three main groupings: H synthetic, water soluble fluids based on special polyglycols H synthetic fluids on an ester basis H fluids on a vegetable basis such as rapeseed oil, sunflower oil etc. To decide whether the hammer can be run on these fluids, it is essential to know the name and precise type of the fluid in question. Each of these fluids is provided by the manufacturer with a data sheet indi cating characteristic data such as constituents, basis, viscosity, temperature limits, compatibility etc. Before using such fluids, the manufacturer of your carrier must be consulted as to whether operation with fluids of this type is permitted. The hydraulic hammers are basically designed for use with mineral oils. Before using other fluids approved by the carrier manufacturer, always con 20 sult after sales service. After initial assembly, and following any repair work in the manufacturers fac tory, our hammers are subjected to a trial run and functional test using a facility operated with min eral oil. Even the smallest quantities of mineral oil mixed in with an environmentally friendly fluid during hammer drill operation may cause damage to tool and carrier alike. The environmentally friendly fluids also lose their special properties, such as biodegradabil ity and toxic behaviour. It should also be noted that mixed fluids such as these must be disposed of as special waste in line with legal requirements. If you wish or are obliged to operate your hammer with environmentally friendly fluids, consult us beforehand so that we can ensure the hydraulic tool is properly equipped for operation of this nature. It is essential to indicate the name of the fluid used when returning hammers for repair.

10.1.3 Greases

10.1.3 Gas
Pt.Id.Nr. Normal nitrogen, 99,8% pure The piston accumulator should only be filled with nitrogen. Make sure no other gas (e.g. air or oxy gen) is allowed into the piston accumulator.

Grease Chisel paste 3363 0660 65 When using oils and greases, always observe the relevant safety regulations for these products.

Caution!
Risk of explosion Only use nitrogen from the green gas cylinder to fill the piston accumulator.

10.2

Starting up the hydraulic hammer

H Do not start up the hydraulic hammer until the working tool is in contact with the rock to be broken and contact pressure is applied. In apply ing contact pressure, the front of the excavator may be raised slightly from the ground. H Now start up the hydraulic hammer using the foot or hand switch. Never try to break with the hammer without first applying contact pressure since this could cause damage to the carrier. H Switch off the hydraulic hammer immediately if anyone moves into the danger zone, i.e. within a radius of at least 7 metres around the hydraulic hammer. Depending on the application and the material greater distances may have to be observed or the site must be cordoned off. Danger by flying splinters!

Prior to starting up the hammer, precautionary measures must be taken to prevent the risk of acci dents. H The hydraulic hammer should only be operated from the drivers seat. H Close the front screen/splinter protection on the drivers cab to prevent possible injury from flying rock splinters. H Wear ear protection to avoid impairment to hear ing. Any workers in the immediate vicinity must also wear ear protection. H Move the excavator into the required position.

10.3

Advance

The distance V by which the hammer is advanced when work is in progress should be such that the rock breaks away after 30 seconds at the latest. If this is not the case, the advance must be either reduced or breaking restarted at a different point. Advancing by greater distances does not improve breaking performance. The best results are achieved by progressing in smaller steps.

advance

21

10.4

Angle of operation

The working tool should always be at right angles to the surface of the material. If not, the hydraulic hammer wears more quickly, eventually leading to damage.

H1802

10.5

Hammer rocking

Gently rocking the hydraulic hammer backwards and forwards (max. 5o) allows dust to escape which would otherwise dampen the penetrative force of the working tool. If this dust is allowed to remain, the tip of the working tool may glow red hot and become soft. However, rocking at angles greater than 5o will cause bending strain resulting in damage to the working tool and hydraulic hammer.
H1803

10.6

Never drive the working tool into the material

If the distance by which the hammer is advanced is too large and the hammer is not rocked to release the dust, the working tool will be driven into the material, causing the tip to glow red hot and become soft. Operating the hammer in this way is not allowed!

H1804

10.7

Never use as a crowbar

Using the hydraulic hammer as a crowbar may cause the working tool to break. Operating the hammer in this way is not allowed!

H1805

10.8

Never use as a sledgehammer

The hammer should always be put in contact with the material to be broken before starting up. Never use the hammer and boom to provide a sledge hammer function. Operating the hammer in this way is not allowed!

H1806

22

10.9

Never lift or transport loads with the hydraulic hammer

The hydraulic hammer is not designed to lift or transport loads. Non regulation usage!

H 5507

10.10

Never use in or under water

There is a separate document (part ident. no. 3361 8552 11) providing operating instructions and spare parts lists for underwater applications. Please always contact our after sales service before starting work in or under water. Phone: Fax: +49 201/633 1619 +49 201/633 1352

Using the hydraulic hammer in or under water is not allowed! If water penetrates the percussion chamber of the hydraulic hammer, a pressure wave builds up with each stroke which will damage the stripper and the seals of the hammer and cause the lower part of the percussion piston to rust. The hydraulic hammer 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 hammer, and in addition the lower percussion piston zone would rust. Water could also penetrate the carriers hy draulic system. In order to avoid damage to the hydraulic hammer, Atlas Copcok 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 com pressed air.

H 5508

23

10.11

Hydraulic Hammer used in Tunnelling

Do not use the hydraulic hammer for tunnelling involving overhead, horizontal or floor work before taking pre ventative measures! Penetration by dust, stone fragments and/or water can lead to malfunctions during operation and may even cause the hydraulic hammer to stop working. Consequently, preventative measures for protecting the hydraulic hammer in applications of this type are listed in a separate document. Please therefore contact the customer service department of tlas Copco before using the hammer for such work.

10.12

Working in high outside temperatures

Check the oil temperature constantly to ensure it does not exceed 80oC. If higher temperatures are measured in the tank, an oil cooler must be fitted. Only use hydraulic oils with adequate viscosity. In summer and in countries with a tropical climate, the mini mum requirement is a hydraulic oil with a viscosity rating of HLP 68.

10.13

Working in low outside temperatures

There are no special regulations for temperatures down to minus 20oC. At temperatures below minus 20oC, the hydraulic oil must be warmed up in the way recommended by the excavator manufacturer. In the majority However, if the carrier with hydraulic hammer has been left out in the open, the carrier and all equipment must be pre warmed before starting up the hydraulic hammer. The methods prescribed by the excavator manufacturer should be observed to the letter. Once this has been done, the boom should be raised, and with the hammers working tool hanging in the air, the hammer can be started repeatedly for short periods to warm up the percussion mechanism. The carriers hydraulic oil must have attained a temperature of at least 0oC; the hammer cannot be started up with the oil at a temperature below zero. Important! Leave the excavator motor and pumps running during breaks in work. Please note: The hydraulic hammer and excavator do not begin to perform at full capacity until an operating temperature of around 60oC has been reached. Important! Supplying hot hydraulic oil to a cold hydraulic hammer will cause stress which could lead to equipment failure. In addition, if the hammer is operated with cold hydraulic oil: H the seals in the hydraulic hammer may break H the diaphragm in the pressure accumulator may tear Observe the excavator manufacturers regulations.

Operating the hydraulic hammer with the cylinders fully extended or retracted
Operating the hammer with the shovel/stick cylinders fully extended or retracted must be avoided at all costs. These end positions are equip ped with damping functions; continuous operation at full extension/re traction can result in damage to the hydraulic cylinders. Remedy: reposition carrier and/or boom.

Warning!

24

11.

Selecting the correct working tool

The working tools should only be remachined on suitable equipment. Conical points and blunt tools can be remachined on a lathe with carbide tooling. Flat chisels can be sharpened on a shaping or mill ing machine. During remachining, the tool must be cooled thor oughly with liquid coolant. Never attempt to burn or weld the working tools. The high temperatures involved would cause the tools to fail.

Only use genuine working tools. Use of other tools renders the warranty invalid. Please note: When utilising long working tools, correct handling is of the utmost importance. The geometry of longer working tools makes them more susceptible to breakage. In such cases, the information provided in Section 10 Operating the hydraulic hammer should be followed closely.

11.1

Working tools for hydraulic hammer model HM 350 Eco V

Useful length [ mm ] Weight [ kg ] Part ident. no.

Moil point

90

Moil point

100

Flat chisel transverse

200

Description Standard designs: 450 38 3362 2655 65 Flat chisel transverse Special designs available on request. 450 39 3362 2684 45

11.2

Working tools for hydraulic hammer model HM 580 Eco (V)

Useful length [ mm ] Weight [ kg ] Part ident. no.

Description Standard designs: 560 56,4 3363 0687 05 Flat chisel transverse 560 58,4 3363 0687 07 510 60,7 3363 0689 07 Special designs available on request. Please note: Working tools are subject to wear in the normal course of operations. 25

12.
12.1

Maintenance work to be carried out by the excavator driver

Lubricating the working tool

The working tool must be lubricated regularly during operation. Depending on the type of application and the amount of dust involved, the hammer may require lubrication anything between twice and five times per shift. For lubrication purposes, the hydraulic hammer should be stood vertically on the working steel and contact pressure applied to avoid overgreasing/filling up the percussion chamber.

Caution!
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. 4 6 shots from a hand held grease gun are suffi cient. 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 working steel. The ContiLube II automatic lubrication system provides virtually automatic lubrication. 500 g cartridge, part ident. no. 3363 0660 65 for ContiLube II and manual grease gun (part ident. no. 3363 0345 67) Further information on this subject is available from after sales service on the following numbers: Phone: Fax: +49 201 / 633 1619 +49 201 / 633 1352

26

12.2

Checking the working tool for wear

Check the working tool for wear every time the steel is changed and at the latest every 100 operating hours. If the shank has been worn down to the mini mum diameter listed below, the working steel must be replaced. Please note: Working tools are wear parts.

Type Minimum diameter D 87 mm 97 mm 97 mm HM 350 Eco V HM 580 Eco HM 580 Eco V Burrs on the shank of the working steel and on the locking bolt should be smoothed off carefully.

12.3

Checking the retaining pin for wear

The retaining pin must be checked every time the working tool is changed. If excessive wear is detected, e.g. sharp edges, notches or dents, the retaining pin must be replaced. Please note: Retaining pins are wear parts. Burrs on the retaining pin should be smoothed off 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.

12.4

Checking the hammer box/adapter for cracks

The adapter and the hammer box must be checked daily for cracks in the material.

27

12.5

Checking the wear bushes and buffer ring

The inside diameter of the lower wear bush has to be checked every time the working tool is changed and at the latest every 100 operating hours. If this diameter has increased due to wear, both bushes and the buffer ring must be replaced. A template is provided in the toolbox to measure the diameter, which must not exceed the maximum per missible figure indicated below.

Model Max. permissible diameter 93 mm 103 mm 103 mm HM 350 Eco V HM 580 Eco HM 580 Eco V Please note: The wear bushes and buffer ring must be replaced in a suitably equipped workshop. Before fitting new parts, all residual lubricating grease must be removed from the interior of the lower hammer part. Please note: Wear bushes and buffer ring are wear parts. buffer ring upper wear bush lower hammer part lower wear bush

HM 350 Eco V

HM 580 Eco (V)

Please note: In the case of wear bushes which can be fitted in the lower hammer part without undercooling, the assembly spray with part identification no. 2267032 must be applied to the outside diameter prior to fitting. 28

12.6

Tightening the screw connections

The screw connections on percussive tools such as hydraulic hammers are subjected to particularly high stresses. All screw connections on the hydraulic hammer must be checked daily for the first 50 operating hours and thereafter once a week. Loose connections should be tightened without exceeding the specified tightening torque. The following couplings must be checked:

Connection point Part no. Interval Model Spanner required Tightening torque [Nm] Adapter 1 Weekly all Hexagon socket head spanner size 17 390 Nuts for Tensioning bolts L ) 2 As required HM 350 HM 580 Slugging ring spanner, size 46 size 50 Socket spanner size 22 Hexagon socket head spanner size 5 Double ended jaw spanner size 36 / 41 Face spanner
L

200 20 120

Connection G

Weekly

all

Connection P and T High pressure accumulator Locking pin Spring dowel sleeve Hose connections

Weekly

all

As required

HM 580

200

As required

all

Pin punch and impact tool Double ended jaw spanner size 36 / 41

As required

all

The tie rods are only accessible when the hammer has been removed from the hammer box Tightening the tensioning bolt for HM 350 Eco V H Pretighten nuts in diagonally opposed pairs to 200 Nm, H then tighten in diagonally opposed pairs by a further 60o ( 1 side of hexagonal head ), H then finish tighten in diagonally opposed pairs by 120o. ( 2 sides of the hexagonal head )

Tightening the tensioning bolt for HM 580 Eco (V) H Pretighten nuts in diagonally opposed pairs to 200 Nm, H then tighten in diagonally opposed pairs by a further 120o ( 2 sides of hexagonal head ), H then finish tighten in diagonally opposed pairs by 210o. ( 3 sides of the hexagonal head )

29

1 2 3

Diagram shows HM 580

30

12.7

Checking/topping up the pressure in the piston accumulator

test pressure gauge Minimess connection nozzle

The scope of supply for the hydraulic hammer includes: 1 nitrogen filling device 1 test pressure gauge 1/4", 0 25 bar, test class 1,6 1 nitrogen cylinder This equipment should be kept on site so as to be available at all times to perform the following checks and maintenance work. Testing: The length of the intervals between pressure checks depends on the on site conditions: Outside temperature Hydraulic fluid Duration of operations If the performance of the hydraulic hammer starts to drop off, it is advisable to check the pressure in the piston accumulator. The piston accumulator does not need to be topped up until the minimum per missible pressure level has been reached. Please note: Pressure testing should be performed with the hammer at an operating temperature of 60o to 70oC. To test the pressure, lay the hydraulic hammer on its side with no contact pressure on the working tool. Remove the screw plug from filling valve G and connect the test pressure gauge. Read off the pressure. The reference value for pressure in the piston accu mulator is:

G
gas cylinder valve

pressure relief valve

H Connect pressure relief valve to nitrogen cylinder

H Connect one nozzle of filling hose to Mini mess connection on pressure relief valve. H Close pressure relief valve. H Open valve on nitrogen cylinder. H Remove plug from filling valve G . H Press free nozzle of filling hose into filling valve G . Filling the piston accumulator: H Open pressure relief valve slowly allowing nitrogen into piston accumulator. Pressure increase can be read on pressure gauge. H Close pressure relief valve when required gas pressure + 10% has been reached. H Remove filling hose from filling valve G . Checking and reducing pressure: H Remove filling hose from pressure relief valve and connect to test pressure gauge. H Press free nozzle of filling hose back into filling valve G and read off pressure. H Pressure in piston accumulator is lowered by re peatedly pushing in/pulling out hose nozzle. After filling

Model at operating pressure 6070oC + no contact pressure to the working tool! Minimum gas pres sure Required gas pressure 12,0 bar 13,5 bar 13,5 bar HM 350 Eco V HM 580 Eco HM 580 Eco V 10 bar 11 bar 11 bar Filling/topping up All tools and parts required for filling are contained in the tool box. Preparations:

H Reclose filling valve G with screw plug. H Close valve on nitrogen cylinder. H Open pressure relief valve fully to allow residual pressure to escape. H Remove pressure relief valve. 31

Minimess connection pressure gauge

nozzle

pressure relief valve

gas cylinder valve

Important! Use only the hose nozzle to relieve the pressure: Never use nails, screwdrivers or similar objects since this would damage the filling valve. The piston accumulator should only be filled with nitrogen from the green nitrogen cylinder. Make sure no other gas (e.g. air or oxygen) is allowed into the piston accumulator: Caution: Risk of explosion! When filling the piston accumulator, make sure there is no one in the vicinity of the working tool. If the working tool has jammed, an increase in pres sure in the piston accumulator could release it suddenly. Caution: Risk of injury! Never remove the complete filling valve G while the piston accumulator is still under pressure. Before removing the complete filling valve G , the piston accumulator must be totally depressurised by unscrewing the screw plug and then pressing back the valve piston inside the filling valve using the open filling hose. In this way, the nitrogen is released harmlessly from the cylinder cover of the hydraulic hammer.

Caution!

32

12.8

Checking the pressure accumulator is in perfect working order [Only on HM 580 Eco (V)]
Never open or repair the pressure accumulator. A defective pressure accumulator must be repaired by a specialist. Before repairing a pressure accumulator, relieve the pressure in the hydraulic system. After repairing a pressure accumulator or making modifications to the hydraulic system, an inspection should always be carried out by a qualified expert to ensure that the pressure accumulator complies with the regulations governing pressurised vessels in the country of use. The pressure accumulator must be checked on a regular basis, at the latest every five years, to ensure that it complies with the regulations govern ing pressurised vessels in the country of use.

Before mounting/dismounting the hydraulic tool and/or any maintenance work on the hydraulics of the hydraulic tool/carrier the hydraulic system must be depressurized. If the pressurised oil line to port P on the hammer, which normally hangs still, starts to jerk violently, the pressure accumulator is not working properly. Shut off the hydraulic hammer immediately and replace the pressure accumulator.

Important!

12.9

Checking hydraulic lines before starting work

Carry out a visual check on all lines (pipes and hoses) from the pump to the hydraulic hammer and back into the tank. Tighten any loose screw connections and hose clamps. Replace any damaged pipes and/or hoses.

12.10

Checking the adapter pins for wear

This visual check can only be carried out when the hydraulic hammer is removed from the excavator. If the pins show signs of excessive wear, e.g. cracks, notches or dents, they must be replaced.

12.11

Checking the adapter pins for wear

This visual check can only be carried out when the hydraulic hammer is removed from the excavator. If the pins show signs of excessive wear, e.g. cracks, notches or dents, they must be replaced.

33

12.12 Checking the hammer box for wear

Heavily worn hammer boxes must be replaced in order to avoid subsequent damage to the lower hammer part.

12.13

Checking and cleaning the hydraulic oil filter

New oil filters must be cleaned for the first time after 50 operating hours. Thereafter, the filter should be checked every 500 operating hours and cleaned if necessary.

34

13.

Troubleshooting

Caution!
Before dismantling the hydraulic hammer, relieve the pressure in the piston accumulator by bleeding off the gas. Whenever one of the tie rods on the hydraulic hammer breaks, all 4 tie rods must be replaced.

Hydraulic hammer does not start Cause Remedy By
Pressure and return lines mixed up Shut off valve in pressure or re turn line closed Connect hammer hoses correctly Excavator driver Open shut off valve Excavator driver Gas pressure in piston accumula tor too high Check gas pressure in piston accumulator and set to correct value Top up oil Replace damaged screw coupling halves Check electrical system for hammer operation Excavator driver Oil level in tank too low Damaged screw couplings block ing pressure or return line Excavator electrics for hammer operation defective Magnet on switch on valve defec tive Excavator driver Workshop Workshop Replace magnet Workshop Operating pressure too low Check excavator motor speed; check operating pressure Excavator driver or Customer Support 35


Blow freqency of hammer too low
Cause Remedy By
Flow rate of hydraulic oil is insuffi cient Correct excavator motor speed; check operating pressure Excavator driver Coupling in pressure or return line has come loose Shut off valve in pressure or re turn line partly closed Gas pressure in piston accumula tor too low Working steel jams in lower hammer part. NB: Contact pressure must be applied in direction of hammer axis Temp. of hydraulic oil in tank above 80oC Flow resistance too high on oil filter or oil cooler Check coupling, tighten if necess ary Open shut off valve Check gas pressure in piston accumulator and top up if necess ary Correct boom direction; remove burrs from working steel; check degree of wear on working steel and wear bushes Check oil level in hydraulic tank and top up if required Check, clean or replace oil filter and oil cooler Change return line: min. inside diameter: hose = 20 mm pipe = 20 mm Check return pressure NB: Hammer return must always lead directly to tank or filter Check pressure, alter if red; if re quired, fit a new pressure relief cartridge Excavator driver Excavator driver Excavator driver Excavator driver Excavator driver Excavator driver Inside dia. of return line is too small Workshop Return pressure too high Hammer return to tank runs via a valve section. Not permitted! Customer Support Customer Support or workshop Hydraulic oil pressure too low Customer Support Diaphragm in high pressure accumulator (Model HM 580 Eco/HM 580 Eco V) defective. Indicated by: Hose to port P jerks violently Replace diaphragm in high pres sure accumulator; observe rel evant regulations in country of use Customer Support 36


Blow frequency and percussive power too low Cause Remedy By
Shut off valve in supply or return line only partly open Open shut off valve Excavator driver Coupling(s) in supply or return line defective Replace defective parts Check pump characteristics with measuring device and compare with original data; replace pump if necessary Workshop Delivery of pump on hydraulic sys tem inadequate Checking: Customer Support Replacement: after sales service of excavator manufacturer

Blow frequency too high and percussive power too low Cause Remedy By
No gas in piston accumulator Remove/dismantle hydraulic hammer Workshop Seal ring in upper seal area defec tive O ring defective HM 350 Eco V: part no.14K HM 580 Eco (V): part 20 no. 22K
K

Replace seal ring

Workshop

Replace O ring

Workshop

Part numbers; see relevant spare parts lists

37


Operating temperature too high
Cause Remedy
Top up oil

By

Oil level in tank too low

Excavator driver or workshop

Delivery of excavator pump too high; a constant amount of oil flows to the tank through the pressure relief valve High outside temperature and no oil cooler fitted Pressure relief valve defective

Reduce speed of motor Adjust pump

Excavator driver or Customer Support

Fit an oil cooler

Workshop or Customer Support

Fit new pressure relief cartridge

Customer Support

Oil leaks from ports P and T
Cause Remedy By
Cap nuts loose Tighten cap nuts Excavator driver

Oil leaks between cylinder and cylinder cover
Cause Remedy By
Hex. nuts on tie rods are loose Tighten hex. nuts Excavator driver 38


Oil leaks from parts of the hydraulic system for the hammer (screw couplings, hoses etc.)
Cause Remedy By
Screw couplings are loose; flange connections on valve are loose Tighten screw couplings; replace defective parts if required; check hydraulic system for hammer; replace defective parts Please note: Only use genuine spare parts Excavator driver

Oil leaks from working tool bore
Cause Remedy By
Lower piston seals damaged by dust penetration Dismantle hammer; replace seals; reduce intervals between lubrication Check wear. Please note: The permitted toler ances must not be exceeded; replace defective parts Workshop Wear tolerances for working tool/ wear bushes have been exceeded Excavator driver or workshop 39

14.

Dismounting the hydraulic hammer from the excavator for short or lengthy periods of non use
Dismounting the hammer from the excavator

14.1

Unless otherwise stated, the hydraulic hammer is dismounted in reverse order to mounting. Before mounting/dismounting the hydraulic tool and/or any maintenance work on the hydraulics of the hydraulic tool/carrier the hydraulic system must be depressurized. For safety reasons, the carrier must be shut down before performing the following work. Lay the hydraulic hammer flat on the ground. Unscrew the hoses from the excavator boom and seal the ends with the appropriate screw caps. Release the lock nuts from the toggle and stick pins and knock out the pins using a steel rod and a hammer.

Caution!
Collect any oil which leaks out and dispose of it cor rectly. All directions, signals etc. must be agreed on before hand with the assistant. Keep your hands well clear of bores and fitting areas when removing the hydraulic hammer. Do not touch any parts when the boom is moving. Always wear protective glasses when fitting or re moving the working steel.

14.2

Short period of non use

Lay the hammer flat on the ground. Cut off power to the hammer hydraulics on the excavator.

Important!
Observe the excavator manufacturers safety regulations when putting the excavator out of operation.

40

14.3

Lengthy period of non use

Please note: During lengthy periods of non use, the hydraulic hammer must be stored vertically with the bore for the working tool facing upwards. The hydraulic hammer should never be laid horizon tally for any length of time, since the fitted seals will become deformed and thus no longer effective.

If the hydraulic hammer is to be put out of service for longer than 14 days, the following maintenance work must be carried out: H Remove working tool H Bleed gas from piston accumulator H Open screw couplings on ports P and T H Using auxiliary tool (rod/pipe), push percussion piston into highest stroke position H Close screw couplings on ports P and T H Grease wear bushes thoroughly H Close off lower wear bush with dust cap H Remove adapter from hydraulic hammer

Caution!

Always wear protective glasses when fitting or removing the working tool. Several litres of oil will run out when the screw coup lings on ports P and T are opened. This oil must be collected and disposed of correctly. Secure the hammer during lengthy periods of non use so that it cannot fall over.

41

15.

Care and maintenance schedule

Work to be carried out by the excavator driver

During the shift Daily Weekly When changing tool, but latest every 100 opera ting hours As required H Lubricate the working tool hammer vertical, contact pressure applied 5 to 10 times per shift depending on re quirements. H Tighten screw couplings (during first 50 operating hours) H Tighten screw couplings H Check working tool for wear H Replace bent and squashed pipe lines H Check hydraulic lines for leaks H Check pipe clamps have not come loose H Check adapter pins for wear H Check impact face of working tool for chips H Check working tool for burrs H Check lower wear bush for wear H Check adapter and hammer box for cracks H Check dust collar (part 110), clean/re place if necessary H Check impact face of piston for dents H Replace any damaged hoses H Check pressure in piston accumula tor If an automatic grease lubrication unit is fitted, check lubricant level; if ; necessary replace cartridge or top up grease tank. 42

INDEX
A
H Accident Prevention Regulations, 8 H Activating/deactivating the hydraulic hammer from the carrier, 18 H Advance, 20 H Angle of operation, 21 H Attachment, 14 H Maintenance work to be carried out by the ex cavator driver, 25 H Mounting the hydraulic hammer on the excava tor, 14, 15

N
H Never drive the working tool into the material, 21 H Never lift or transport loads with the hydraulic hammer, 22 H Never use as a crowbar, 21 H Never use as a sledgehammer, 21 H Never use in or under water, 22

C
H H H H H H H H H H H H H Care and maintenance schedule, 41 CE markings, 11 Checking and cleaning the hydraulic oil filter, 33 Checking hydraulic lines before starting work, 32 Checking the adapter pins for wear, 32 Checking the hammer box for wear, 33 Checking the hammer box/adapter for cracks, 26 Checking the pressure accumulator is in perfect working order [Only on HM 580 Eco (V)], 32 Checking the retaining pin for wear, 26 Checking the wear bushes and buffer ring, 27 Checking the working tool for wear, 26 Checking/topping up the pressure in the piston accumulator, 30 Connecting the hydraulic hammer to the exca vators hydraulic system, 16

O
H Operating Conditions, 8 H Operating Media Environmentallyfriendly hydraulic fluids, 19 Gas, 20 Greases, 20 Mineral hydraulic fluids, 19 H Operating the hydraulic hammer, 19

P
H Piston accumulator, 19

S
H Scope of supply, 12 H Selecting the correct working tool, 24 H Dismounting the hydraulic hammer from the excavator for short or lengthy periods of non useg, 39 H Special technical features, 19 H Starting up the hydraulic hammer, 20

D
H Dismounting the hammer from the excavator, 39

F
H Fitting the working tool, 18

T H
H Hammer rocking, 21 H Hydraulic Hammer used in Tunnelling, 23 H Technical Specifications, 12 H Tightening the screw connections, 28 H Troubleshooting, 34

L
H Lengthy period of nonuse, 40 H Lubricating the working tool, 25

W
H Working in high outside temperatures, 23 H Working in low outside temperatures, 23 H Working tools for hydraulic hammer model HM 350 Eco V, 24 H Working tools for hydraulic hammer model HM 580 Eco (V), 24

M
H Main components, 13

43

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 Telefax +49 201 633 2281 Telefax Customer Support +49 201 633 1352 Internet: www.hydraulicattachments.com

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