Epiroc EC Series Safety And Operating Instructions Manual
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Epiroc EC Series Safety And Operating Instructions Manual

Hydraulic breaker
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EC
140T, 150T, 155T, 165T, 180T
Safety and operating instructions
Hydraulic breakers
© Construction Tools GmbH | 33905146 01 | 2019-09-05
Original Instructions

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  • Page 1 140T, 150T, 155T, 165T, 180T Safety and operating instructions Hydraulic breakers © Construction Tools GmbH | 33905146 01 | 2019-09-05 Original Instructions...

  • Page 3: Table Of Contents

    Contents Table of Contents 1 Introduction .......................... 8 About these Safety and Operating Instructions.................... 8 2 Safety instructions........................ 9 Signal words................................ 9 Qualification .............................. 10 Intended use .............................. 10 Use other than intended ........................... 10 Protective equipment............................ 11 Carrier, precautions ............................ 11 Transport, precautions ............................. 11 Hydraulic installation, precautions ......................... 12 Special parts, precautions .......................... 12 2.9.1 HP-accumulator............................... 12...
  • Page 4 Contents 5 Installation .......................... 24 Media/consumables ............................ 24 5.1.1 Mineral hydraulic oil............................ 24 5.1.2 Non-mineral hydraulic oil .......................... 24 5.1.3 Grease................................ 24 5.1.4 Gas .................................. 24 Manufacturing the adapter plate........................ 25 Installing the adapter plate.......................... 25 Attaching the hydraulic attachment to the carrier .................. 26 5.4.1 Mechanical mounting aspects .........................  26 5.4.2 Making the hydraulic connections ........................
  • Page 5 Contents 7.4.6 Manual lubrication ............................ 49 7.4.7 Chisel paste filling device .......................... 50 Checking the tensioning bolts......................... 50 Checking the working tool .......................... 51 Checking the retainer bars.......................... 51 Checking the percussion piston impact surface ................... 52 Checking the wear bushes and impact ring .................... 52 7.10 Piston accumulator............................ 53 7.10.1 Checking the pressure in the piston accumulator....................
  • Page 6 Contents 11.4 Chisel paste and grease cartridges......................... 68 12 Technical specifications...................... 69 12.1 Noise declaration statement .......................... 71 13 EC Declaration of Conformity (EC Directive 2006/42/EC) ............  72 © Construction Tools GmbH | 33905146 01 | 2019-09-05 Original Instructions...
  • Page 7 Contents © Construction Tools GmbH | 33905146 01 | 2019-09-05 Original Instructions...

  • Page 8: Introduction

    1.1 About these Safety and 1 Introduction Operating Instructions Epiroc is a leading productivity partner for the mining, in- frastructure and natural resources industries. With cut- The aim of these Instructions is to familiarise you with ting-edge technology, Epiroc develops and produces in-...

  • Page 9: Safety Instructions

    Safety and operating instructions 2.1 Signal words 2 Safety instructions The signal words Danger, Warning, Caution, and Notice This is the safety alert symbol. It is used to alert are used as follows in these Safety and operating in- you to potential personal injury hazards. Obey structions: all safety messages that follow this symbol to avoid possible injury or death.

  • Page 10: Qualification

    Safety and operating instructions 2.2 Qualification 2.3 Intended use Transporting the hydraulic attachment is only permitted Only attach the hydraulic breaker to a hydraulic carrier of if carried out by people who: a suitable load-bearing capacity. • are authorised to operate a crane or a forklift truck Only use the hydraulic breaker function of the device to according to the applicable national provisions, break or fragment concrete, stone and rocks.

  • Page 11: Protective Equipment

    Safety and operating instructions 2.5 Protective equipment 2.7 Transport, precautions Personal protective equipment must comply with the ap- WARNING Risk of death due to suspended loads plicable health and safety regulations. When lifting loads these can swing out and fall. This can n Do not work wearing jewelry or with loose long hair.

  • Page 12: Hydraulic Installation, Precautions

    Safety and operating instructions 2.8 Hydraulic installation, 2.9 Special parts, precautions precautions 2.9.1 HP-accumulator WARNING Hydraulic pressure too high DANGER Danger of explosions If the hydraulic pressure is too high, the parts of the hy- draulic attachment will be exposed to excessively high The HP-accumulator of the hydraulic breaker is filled loads.

  • Page 13: Media/Consumables, Precautions

    Safety and operating instructions 2.10 Media/consumables, 2.11 Explosion and fire, precautions precautions WARNING Hot hydraulic oil under high pressure DANGER Explosion and fire Hydraulic oil will squirt out under high pressure if there is Explosions cause serious injury or death. If the working a leakage.

  • Page 14: Electrical Shock, Precautions

    Safety and operating instructions 2.12 Electrical shock, precautions 2.14 Emissions, precautions DANGER Electrical shock WARNING Noise hazard Any contact of the hydraulic attachment with electric cir- Operating the hydraulic attachment creates a loud noise. cuits or other sources of electricity will lead to an electric Long term high sound pressure level can affect your shock, resulting in serious injury or death.

  • Page 15: Repair, Precautions

    Never carry out any changes to the hydraulic attach- ment or the adapter plate. u Only use original parts or accessories approved by Epiroc. u Modifications that entail new hazards may require a new procedure for assessing conformity. WARNING Changes to the HP-accumulator Changes to the HP-accumulator may lead to serious in- jury.

  • Page 16: Overview

    Safety and operating instructions E. Tank line »T« 3 Overview Pressure line »P« G. The breaker box protects the percussion unit. H. Working tool aperture protective cap 3.1 Equipment description The working tool can be replaced as required. The The illustration gives an overview of the main parts and working tool is not included in the scope of supply of components of the hydraulic attachment.

  • Page 17: Ec 150T

    Safety and operating instructions K. The percussion piston is guided in the cylinder. 3.1.2 EC 150T The cylinder cover houses the nitrogen gas (N filled piston accumulator and the control mechanism. A. The hydraulic breaker is connected to the carrier by the adapter plate.

  • Page 18: Ec 155T, Ec 165T, Ec 180T

    Safety and operating instructions K. The percussion piston is guided in the cylinder. 3.1.3 EC 155T, EC 165T, EC 180T The cylinder cover houses the nitrogen gas (N filled piston accumulator and the control mechanism. 3.2 Function The operation of a hydraulic breaker is described in a greatly simplified version below: The pressure line »P«...

  • Page 19: Signs / Labels

    Safety and operating instructions 3.3.2 Labels 3.3 Signs / labels Sound Power WARNING Missing warnings The label states the guaranteed The name plate and the labels on the hydraulic attach- sound power level in accordance ment contain important information about the hydraulic with EC directive 2000/14/EC.

  • Page 20: Applications

    Demolition Heavily reinforced con- crete, demolition of power n Check the delivery for visual damage. stations and bridges n If any defects are found, consult the Epiroc Customer Rock mining/breaking Primary breaking Center / dealer in your area. Secondary breaking,...

  • Page 21: Transport

    Safety and operating instructions 4 Transport WARNING Hoist tipping over / hydraulic attach- ment falling The hydraulic attachment is heavy. The hoist/lifting equipment and/or hydraulic attachment tipping over or falling may cause serious injury and material damage. u Only transport the hydraulic attachment with lifting ●...

  • Page 22: Transport Using A Crane

    Safety and operating instructions 4.1 Transport using a crane 4.2 Transport using a forklift truck n Secure the hydraulic attachment with ropes or chains as shown in the following illustration. WARNING Hydraulic attachment tipping over The hydraulic attachment tipping off the fork of the forklift truck or the pallet may cause serious injury.

  • Page 23: Transport Using A Truck

    Safety and operating instructions 4.3 Transport using a truck WARNING Hydraulic attachment tipping over / slipping The hydraulic attachment slipping or tipping over and falling from the loading area of a lorry may cause serious injury. u Place the hydraulic attachment on a pallet. u Strap the hydraulic attachment to the pallet using suitable strapping (see illustration in chapter Trans- port using a forklift truck).

  • Page 24: Installation

    Dispose of it in accordance with the applicable envi- Our hydraulic attachments are basically designed for use ronmental regulations. with mineral oils. Consult the Epiroc Customer Center / Dealer in your area before using other hydraulic oils ap- 5.1 Media/consumables proved by the carrier manufacturer.

  • Page 25: Manufacturing The Adapter Plate

    Safety and operating instructions 5.2 Manufacturing the adapter WARNING Hands and fingers being cut off or hurt Bores and surfaces can act like a pair of scissors and plate cut off or hurt parts of your body. Construction Tools GmbH also supplies base plates to u Never use your fingers to check bores or fitting sur- manufacture adapter plates alternatively to the adapter faces.

  • Page 26: Attaching The Hydraulic Attachment To The Carrier

    The adapter plate must not be stopped by mechanical cut off or hurt parts of your body. stops in either position. Consult the Epiroc Customer u Never use your fingers to check bores or fitting sur- Center/Dealer in your area if the adapter plate is stopped faces.
  • Page 27 Safety and operating instructions NOTICE Total damage to the hydraulic attachment 5.4.2.1 Flange connection Polluted hydraulic lines and connections may enable n Unscrew the blind flanges from the ports »P« and sand, fragments of material and dirt to penetrate the hy- »T«...
  • Page 28 Safety and operating instructions 5.4.2.2 Swivel joint connection WARNING Components bursting Components of the swivel joint may burst. Metal parts may become projectiles and cause serious injuries and damage property. u Always check the swivel joint covers are fitted prop- erly when attaching the hydraulic breaker to the car- rier.

  • Page 29: Removing The Hydraulic Attachment From The Carrier

    Safety and operating instructions 5.5 Removing the hydraulic WARNING Injury by impacts A sudden movement of the carrier may cause your as- attachment from the carrier sistant to be hit and injured by the boom or the hydraulic n Place the hydraulic attachment on timber support attachment.

  • Page 30: Working Tool

    Safety and operating instructions 5.7.1 Selecting the right working tool 5.7 Working tool The standard available working tools are shown. The dif- WARNING Unexpected movement ferent cutter geometries may influence the production re- Sudden movements of the carrier may cause serious in- sult, depending on the actual use.

  • Page 31: Installation

    Safety and operating instructions n Grease the insertion area of the working tool (A) with 5.7.2 Installation chisel paste. n Place the hydraulic breaker on timber support blocks. NOTICE Damage to percussion piston and working tool NOTICE The working tool may break The percussion piston hits the working tool at high There is an increased risk of the working tool breaking if speed.

  • Page 32: Removal

    Safety and operating instructions 5.7.3 Removal n Place the hydraulic breaker on timber support blocks. WARNING The working tool suddenly comes loose A clamped working tool is still under the pressure of the piston accumulator. When the working tool is loosened, it will partly jump out of the hydraulic breaker;...

  • Page 33: Operation

    Safety and operating instructions NOTICE Damage due to idling strokes 6 Operation If the percussion piston carries out a hammer action WARNING Components bursting without hitting the working tool, it is carrying out an idling stroke. If this happens it will lead to hydraulic peak pres- Components of the swivel joint may burst.

  • Page 34: Preparations Before Starting

    / or the the hydraulic attachment may be flung away and can Epiroc Customer Center / Dealer in your area. cause serious injury if people are hit by them. Small ob- jects falling from a great height can also cause serious n Switch the hydraulic attachment on and off, as de- damage.

  • Page 35: Correct Operation

    Safety and operating instructions Larger swing angles would lead to bending loads and 6.5 Correct operation damage to the working tool and the hydraulic breaker. 6.5.1 Working angle n Always position the tool so that it hits the material to 6.5.2 Advance be broken at a right angle.

  • Page 36: Low Ambient Temperature

    Safety and operating instructions n Start the hydraulic attachment when the temperature In summer and in tropical climates, the minimum re- quirement is a hydraulic oil of type HLP 68. has risen to 0 °C (32 °F). n During operations, leave the carrier engine and pumps running even during breaks.

  • Page 37: Moving Objects

    Safety and operating instructions 6.6.3 Moving objects 6.6.5 Blank firing of the working tool The working tool "blank fires" if the percussion energy is n Never use the hydraulic attachment to move debris. transferred to the retainer bars instead of to the material This would damage the hydraulic attachment.

  • Page 38: Cylinder End Positions

    Safety and operating instructions 6.6.7 Cylinder end positions 6.7 Stroke control valve n Avoid operating the hydraulic attachment when the The Stroke control valve enables you adjust the mode of carrier stick and bucket cylinder is in one of its end operation of the hydraulic breaker to the particular task.
  • Page 39 Safety and operating instructions EC 140T Marking »EP« on the cylinder cover = AutoStart n Turn the Stroke control valve (C) with an open-ended wrench through 90 degrees to the desired position. The mark (point) on the Stroke control valve must face the respective mark on the cylinder cover.
  • Page 40 Safety and operating instructions EC 150T Marking »EP« on the cylinder cover = AutoStart n Turn the Stroke control valve (C) with an open-ended wrench through 90 degrees to the desired position. The mark (point) on the Stroke control valve must face the respective mark on the cylinder cover.
  • Page 41 Safety and operating instructions EC 155T Marking »EP« on the cylinder cover = AutoStart n Turn the Stroke control valve (C) with an open-ended wrench through 90 degrees to the desired position. The mark (point) on the Stroke control valve must face the respective mark on the cylinder cover.
  • Page 42 Safety and operating instructions EC 165T Marking »EP« on the cylinder cover = AutoStart n Turn the Stroke control valve (C) with an open-ended wrench through 90 degrees to the desired position. The mark (point) on the Stroke control valve must face the respective mark on the cylinder cover.
  • Page 43 Safety and operating instructions EC 180T Marking »EP« on the cylinder cover = AutoStart n Turn the Stroke control valve (C) with an open-ended wrench through 90 degrees to the desired position. The mark (point) on the Stroke control valve must face the respective mark on the cylinder cover.

  • Page 44: Maintenance

    Safety and operating instructions 7 Maintenance WARNING Unexpected movement Sudden movements of the carrier may cause serious in- The maintenance activities are carried out by the carrier jury. driver. u Secure the carrier such that it cannot move unex- pectedly. WARNING Hot hydraulic oil squirting out u Observe the carrier manufacturer’s instructions.

  • Page 45: Maintenance Schedule

    Safety and operating instructions 7.1 Maintenance schedule during a shift Check the lubricant film on the shaft of the working tool approx. every 2 hours. Manual lubrication of the working tool approx. every 2 hours. ® Monitor the filling level of the grease cartridge of the ContiLube  II lubrication sys- tem and immediately replace an empty cartridge.

  • Page 46: Depressurising The Hydraulic System

    Safety and operating instructions Case 2: If no facility for measuring the pressure is 7.2 Depressurising the hydraulic present in the supply pipe to the hydraulic breaker and system the return pipe is connected to the tank without an inter- mediate valve connection, you must observe the follow- Even when you have switched off the carrier, a consider- ing steps in order to depressurise the hydraulic breaker:...

  • Page 47: Cleaning

    Safety and operating instructions the shut-off valves or disconnect the quick-release 7.4 Lubrication couplings, so that no hydraulic oil can flow back from the carrier. 7.4.1 Checking the lubricant film The lubricant film on the shaft of the working tool must 7.3 Cleaning be checked during the work shift.

  • Page 48: Manual Lubrication For Hydraulic Breakers Without Contilube® Ii

    If you have questions how to use the ContiLube ®  II, n Remove the plug from the breaker box. contact the Epiroc Customer Center / dealer in your area. n Put the manual grease gun on the grease nipple and inject chisel paste.

  • Page 49: Contilube® Ii Operation

    Safety and operating instructions 7.4.5 ContiLube® II operation 7.4.6 Manual lubrication Please remember the following: Manual lubrication is required if the automatic lubrication ® system fails to work. • The ContiLube  II  (C) is self-venting, i.e. the system does not require you to vent it. n Place the hydraulic breaker at a right angle on the •...

  • Page 50: Chisel Paste Filling Device

    3363 0946 69 Filling device for use with 45-kg containers: part number 3363 0664 11 For further information, please contact the Epiroc Cus- tomer Center / Dealer in your area. © Construction Tools GmbH | 33905146 01 | 2019-09-05...

  • Page 51: Checking The Working Tool

    Safety and operating instructions n Check the shaft of the working tool for wear when- 7.6 Checking the working tool ever replacing it, but at least once every 100 operat- ing hours. WARNING Hot working tool The tip of the working tool gets very hot during opera- tion.
  • Page 52 Use an electric torch to illuminate the surface of the dismantled working tool. n Do not use the hydraulic breaker again if you have found the surface to be chipped or cracked. n Consult the Epiroc Customer Center / Dealer in your area. Type Size information on test...

  • Page 53: Piston Accumulator

    Safety and operating instructions 7.10 Piston accumulator The pressure in the piston accumulator is measured at the filling valve (G). The piston accumulator is also filled through this valve. EC 140T EC 150T A. impact ring B. upper wear bush C. lower wear bush The upper wear bush and the impact ring must be re- placed in a workshop fitted out for this purpose.

  • Page 54: Checking The Pressure In The Piston Accumulator

    Safety and operating instructions EC 165T 7.10.1 Checking the pressure in the piston accumulator Check the gas pressure in the piston accumulator monthly, and in cases of decreasing power or failure of the hydraulic breaker. Do not top up the piston accumu- lator unless the gas pressure is equal to or less than the minimum gas pressure.

  • Page 55: Release The Pressure From The Piston Accumulator

    Safety and operating instructions n Close the pressure relief valve (D). 7.10.2 Release the pressure from the piston accumulator n Connect the filling hose end (H) to the minimess con- nection (C) of the pressure relief valve (D). n Release gas from the piston accumulator to depres- surise the piston accumulator or if the value mea- n Open the valve of the nitrogen bottle (F).

  • Page 56: Hp-Accumulator

    All connecting screws must cumulators according to national regulations. be replaced. Contact the Epiroc Customer Center / Dealer in your n Never operate the hydraulic breaker if you detect any area for a professional. damage to the HP-accumulator.

  • Page 57: Checking The Hydraulic Lines

    10. Refilling is required if the gas pressure is lower than 50 bar (725 psi). Refilling must be performed by an authorized person. Contact the Epiroc Customer Center / dealer in your area. 7.12 Checking the hydraulic lines...

  • Page 58: Bolt Connections / Tightening Torques

    Safety and operating instructions 7.16 Bolt connections / Tightening torques The bolt connections of hydraulic breakers are subjected to very high loads. Tighten any loose connections without exceeding the recommended tightening torques. EC 140T EC 150T Connection point Interval Type of spanner Size / Torque Adapter plate* A daily...
  • Page 59 Safety and operating instructions © Construction Tools GmbH | 33905146 01 | 2019-09-05 Original Instructions...
  • Page 60 Safety and operating instructions EC 155T EC 165T EC 180T Connection point Interval Type of spanner Size / Torque Adapter plate* A daily Allen key 22 mm 27 mm (1.06 in.) (0.87 in.) (fastening screws) 2300 Nm (1696 ft lbs) 1500 Nm (1106 ft lbs) Plate (Allen screws) B as required Allen key 10 mm (0.39 in.) / 85 Nm (63 ft lbs) Tensioning bolts**...
  • Page 61 Safety and operating instructions © Construction Tools GmbH | 33905146 01 | 2019-09-05 Original Instructions...

  • Page 62: Troubleshooting

    Replace the magnet Workshop Operating pressure too low Check the carrier engine speed, the Carrier driver or Epiroc Customer pump delivery and the pressure relief Center / Dealer in your area valve; check the operating pressure Adjust settings and replace defective parts if required 8.2 Hydraulic breaker operates too slowly...

  • Page 63: Impact Force Too Low

    (see chapter Technical specifications) Return pressure too high Check and lower the return pressure Epiroc Customer Center / Dealer in your area Hydraulic oil return to the tank via a Connect the hydraulic oil return circuit Carrier driver or Epiroc Customer...

  • Page 64: Oil Leaks From Ports "P" Und "T

    Safety and operating instructions 8.5 Oil leaks from ports »P« und »T« Cause Remedy Cap nuts loose Check the cap nuts and tighten (see Carrier driver chapter Bolt connections/Tighten- ing torques) Hose connection CL to port »P« for Check the cap nuts and tighten Carrier driver ®...

  • Page 65: Oil Or Grease Escapes From The Contilube® Ii

    Check carrier settings and adjust Epiroc Customer Center / Dealer in your area Operation in high outside temperature Check oil temperature and install an Workshop or Epiroc Customer Cen-...

  • Page 66: Repair

    Construction Tools GmbH. These professionals must follow all safety instructions and guidelines for repair. n For technical support contact the Epiroc Customer Center / Dealer in your area. 9.1 Sending in the hydraulic attachment for repairs...

  • Page 67: Storage

    Safety and operating instructions 10.2 Working tool 10 Storage n Grease the working tool with chisel paste to prevent it WARNING Hydraulic breaker / working tool fall from corroding. The hydraulic breaker and the working tool are heavy. If n Store the working tool in a dry, properly ventilated they topple over or fall down from where they are stored, room.

  • Page 68: Disposal

    Clean the hydraulic breaker (see chapter Cleaning). n Before disposal the HP-accumulator must be depres- surised. This must be done by an authorized person. Contact the Epiroc Customer Center / dealer in your area. n Dispose of the hydraulic breaker in line with all appli- cable regulations or consult an authorised and spe- cialised recycling company.

  • Page 69: Technical Specifications

    25 mm (0.98 in.) Start up mode Stroke control  Weights apply to standard carriers only. Any variances must be agreed with Epiroc and/or the carrier manufacturer prior to attachment.  Hydraulic breaker incl. breaker box, working tool, and adapter plate of medium size.
  • Page 70 32 mm (1.3 in.) Start up mode Stroke control  Weights apply to standard carriers only. Any variances must be agreed with Epiroc and/or the carrier manufacturer prior to attachment.  Hydraulic breaker incl. breaker box, working tool, and adapter plate of medium size.

  • Page 71: Noise Declaration Statement

    Safety and operating instructions 12.1 Noise declaration statement EC 140T EC 150T EC 155T EC 165T EC 180T Sound pressure 90 dB(A) 91 dB(A) 92 dB(A) 94 dB(A) 93 dB(A) Sound power 120 dB(A) 120 dB(A) 122 dB(A) 123 dB(A) 123 dB(A)  Sound pressure level according to EN ISO 3744 in accordance with Directive 2000/14/EC at 10 metres distance.

  • Page 72: Ec Declaration Of Conformity (Ec Directive 2006/42/Ec)

    Safety and operating instructions 13 EC Declaration of Conformity (EC Directive 2006/42/EC) We, Construction Tools GmbH, hereby declare that the machines listed below conform to the provisions of EC Directive 2006/42/EC (Machinery Directive) and 2000/14/EC, ANNEX V (Noise Directive) and 2014/68/EU (Pressure Equipment Directive), and the harmonised standards mentioned below.
  • Page 76 Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers, and drawings. epiroc.com...

This manual is also suitable for:

Ec140tEc150tEc155tEc165tEc180t

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