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Summary of Contents for Atlas Copco HB 2000
- Page 1 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Hydraulic breakers Valid from serial number HB 2000 DEQ130141 HB 2000 DP DEQ130141 HB 2500 DEQ130141 HB 2500 DP DEQ130141 © Construction Tools GmbH | 3390 5090 01 | 2016-05-23...
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Page 3: Table Of Contents
HB 2000, 2000 DP, 2500, 2500 DP Contents Contents Introduction ..............................7 About these Safety and Operating Instructions ..................7 Safety instructions ............................8 Signal words ............................. 8 Qualification .............................. 9 Intended use .............................. 9 Use other than intended ........................... 9 Protective equipment .......................... - Page 4 Contents HB 2000, 2000 DP, 2500, 2500 DP Removal ............................... 28 Installation ............................28 Working tool ............................29 Selecting the right working tool ......................29 Installation ............................30 Removal ............................... 31 Operation ..............................32 Initial operation and operation after long storage ................32 Preparations before starting ........................
- Page 5 HB 2000, 2000 DP, 2500, 2500 DP Contents Checking the fastening screws ......................53 Checking the gas pressure ........................53 Checking the hydraulic lines ......................... 54 Checking and cleaning the hydraulic oil filter ..................54 Checking the adapter plate and the breaker box for cracks and/or wear ......... 54 Checking the adapter plate bolts for wear ...................
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Page 7: Introduction
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Introduction Symbols used in illustrations have the following meanings: Thank you for choosing an Atlas Copco product! permitted operation We have been working according to a customer- oriented approach since 1873. Our innovative and ergonomic solutions help our customers lower costs and achieve better business results. -
Page 8: Safety Instructions
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Safety instructions Signal words The signal words Danger, Warning, Caution, and This is the safety alert symbol. It is used to alert you to Notice are used as follows in these Safety and potential personal injury hazards. -
Page 9: Qualification
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Qualification Intended use Transporting the hydraulic attachment is only Only attach the hydraulic breaker to a hydraulic permitted if carried out by people who: carrier of a suitable load-bearing capacity. -
Page 10: Protective Equipment
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Protective equipment Transport, precautions Personal protective equipment must comply with WARNING Risk of death due to suspended the applicable health and safety regulations. loads Always wear the following personal protective When lifting loads these can swing out and fall. -
Page 11: Hydraulic Installation, Precautions
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Hydraulic installation, Special parts, precautions precautions HP-accumulator WARNING Hydraulic pressure too high DANGER Danger of explosions If the hydraulic pressure is too high, the parts of The HP-accumulator of the hydraulic breaker is the hydraulic attachment will be exposed to filled with nitrogen (N 2 ). -
Page 12: Media/Consumables, Precautions
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Media/consumables, Explosion and fire, precautions precautions WARNING Hot hydraulic oil under high DANGER Explosion and fire pressure Explosions cause serious injury or death. Hydraulic oil will squirt out under high pressure if If the working tool hits explosives, an explosion there is a leakage. -
Page 13: Electrical Shock, Precautions
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Electrical shock, precautions Emissions, precautions DANGER Electrical shock WARNING Noise hazard Any contact of the hydraulic attachment with Operating the hydraulic attachment creates a loud electric circuits or other sources of electricity will noise. -
Page 14: Handling Machines, Precautions
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Handling machines, Changes to the hydraulic precautions attachment, precautions WARNING Narcotics, alcohol and drugs WARNING Changes to the hydraulic attachment Narcotics, alcohol and medicinal drugs make their users less alert and affect their ability to Changes to the hydraulic attachment or the concentrate. -
Page 15: Environmental Pollution, Precautions
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Environmental pollution, precautions NOTICE Environmental pollution due to hydraulic Hydraulic oil is permanently environmentally harmful. Escaped hydraulic oil will lead to groundwater and soil contamination. Organisms may die. Collect any hydraulic oil which escapes to avoid ►... -
Page 16: Overview
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Overview L. StartSelect valve M. Pressure line »P« N. Non-return valve of percussion compartment ventilation O. The swivel joint covers protect the swivel joints. Function The operation of a hydraulic breaker is described in a greatly simplified version below: The pressure line »P«... -
Page 17: Signs / Labels
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Signs / labels Labels Sound Power The label states the WARNING Missing warnings guaranteed sound power level The name plate and the labels on the hydraulic in accordance with EC attachment contain important information about the directive 2000/14/EC. -
Page 18: Applications
Hydraulic breaker • Underwater applications* Demolition, Deepening shipping channels • Test gauge lower wear bush * only after consulting the Atlas Copco Customer Center/ Safety and Operating instructions • Dealer in your area Spare parts list • Guarantee EC Declaration of Conformity •... -
Page 19: Transport
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Transport WARNING Hydraulic breaker falling The lifting eye may fail and cause the hydraulic breaker to fall. This may cause serious injury and WARNING Hoist tipping over / hydraulic material damage. -
Page 20: Transport Using A Crane
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Transport using a crane Transport using a forklift truck ◆ 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 21: Transport Using A Truck
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions 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. -
Page 22: Installation
Our hydraulic attachments are basically designed for use with mineral oils. Consult the Atlas Copco Construction Tools GmbH also supplies base Customer Center/Dealer in your area before using plates to manufacture adapter plates alternatively other hydraulic oils approved by the carrier to the adapter plates supplied. -
Page 23: Installing The Adapter Plate
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions ◆ NOTICE Adapter plate cracking Align the adapter plate (D) to the hydraulic breaker as shown. The adapter plate may crack if it is not designed for the high load. -
Page 24: Attaching The Hydraulic Attachment To The Carrier
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Attaching the hydraulic attachment to the carrier Mechanical mounting aspects You need an assistant to attach the hydraulic attachment to the carrier. ◆ Agree on hand signals with your assistant, to... - Page 25 HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions NOTICE Total damage to the hydraulic Tighten loosen screw connections (see chapter ► attachment Bolt connections / Tightening torques). Immediately replace a defective swivel joint ► Polluted hydraulic lines and connections may cover.
- Page 26 Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP NOTICE Piston seizure The hydraulic breaker must always be filled-up with hydraulic oil after every mounting to the carrier, repair, and carrier’s oil change. The percussion piston may seize if there is no lubrication oil film between percussion piston and cylinder.
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Page 27: Removing The Hydraulic Attachment From The Carrier
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Removing the hydraulic Only move the boom very slowly and in a ► controlled manner while an assistant is within attachment from the carrier the danger zone. Always keep sight of your assistant. -
Page 28: Dustprotector
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP DustProtector Push the sealing lip of the wiper inwards with your thumb. This pushes the wiper out of the wiper sleeve ring groove. ◆ Place the hydraulic breaker on timber support Installation blocks. -
Page 29: Working Tool
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Working tool Selecting the right working tool The standard available working tools are shown. The different cutter geometries may influence the production result, depending on the actual use. WARNING Unexpected movement... -
Page 30: Installation
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP ◆ Installation Remove the screws (Z), washers (Y), plate (X), and plugs (E). ◆ Place the hydraulic breaker on timber support ◆ Use a break pin punch and a hammer to drive blocks. -
Page 31: Removal
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Removal ◆ 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 32: Operation
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Operation NOTICE Damage due to idling strokes If the percussion piston carries out a hammer action without hitting the working tool, it is carrying WARNING Components bursting out an idling stroke. If this happens it will lead to Components of the swivel joint may burst. -
Page 33: Preparations Before Starting
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions ◆ Preparations before starting Put the working tool on the material to be broken. Switching the hydraulic WARNING Falling carrier breaker on and off A carrier falling or tipping over due to the surface not being level may cause serious injury and material damage. -
Page 34: Functional Test
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Functional test Correct operation Always carry out a functional test before putting the hydraulic attachment into use to check that all Working angle hydraulic lines and connections are tight and that ◆... -
Page 35: Advance
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Low ambient temperature Ambient temperature below 0 °C: Advance NOTICE The working tool may break Select the distance marked with "V“ such that the fragment is released within 30 seconds. If this is... -
Page 36: Prohibited Operation
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Prohibited operation Moving objects ◆ Never use the hydraulic attachment to move debris. This would damage the hydraulic attachment. Lifting/Transporting WARNING Falling load The lifted object can fall and cause serious injuries or death. -
Page 37: Blank Firing Of The Working Tool
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Blank firing of the working tool Cylinder end positions The working tool "blank fires" if the percussion ◆ Avoid operating the hydraulic attachment when energy is transferred to the retainer bars instead of the carrier stick and bucket cylinder is in one of to the material to be broken. -
Page 38: Working With Safety Equipment
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Working with safety AutoControl System equipment The AutoControl System is a combination of a pressure-maintaining and reversing valve. The AutoControl System protects the breaker from Underwater applications damage if blank firing occurs. -
Page 39: Startselect System Autostop/Autostart
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions StartSelect System AutoStop/ WARNING Jets of hot hydraulic oil can escape AutoStart The hydraulic system is under high pressure. If hydraulic connections come loose or are disconnected, hydraulic oil will squirt out under The StartSelect System enables you set the start high pressure. -
Page 40: Poweradapt
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP PowerAdapt PowerAdapt protects the hydraulic breaker against hydraulic overloads and switches it off if the hydraulic input energy is too high. An overload occurs when the hydraulic breaker is operated while the delivery rate and the pressure from the carrier are too high. -
Page 41: Maintenance
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Maintenance WARNING Unexpected movement Sudden movements of the carrier may cause serious injury. The maintenance activities are carried out by the carrier driver. Secure the carrier so that it cannot move ►... -
Page 42: Maintenance Schedule
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Maintenance schedule during a shift Monitor the filling level of the grease cartridge of the ContiLube ® II lubrication system and immediately replace an empty cartridge. Monitor the lubricant film on the shaft of the working tool. -
Page 43: Depressurising The Hydraulic System
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Depressurising the hydraulic disconnect the quick-release couplings, so that no hydraulic oil can flow back from the carrier. system Case 2: If no facility for measuring the pressure is present... -
Page 44: Cleaning
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP 3. When you have made sure that no more Lubrication pressure is present in the hydraulic system, you must disconnect the hydraulic connection to the carrier device. Close the shut-off valves... -
Page 45: Automatic Lubrication
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Automatic lubrication ContiLube ® II operation The hydraulic breaker is lubricated automatically Please remember the following: by the ContiLube ® II. The ContiLube ® II (C) is self-venting, i.e. the •... -
Page 46: Manual Lubrication
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Manual lubrication Chisel paste filling device Manual lubrication is required if the automatic Construction Tools GmbH offers a device for lubrication system fails to work. refilling empty cartridges. This can be mounted on a 15-kg or 45-kg hobbock to fill empty cartridges ◆... -
Page 47: Checking The Tensioning Bolts
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Checking the tensioning Checking the working tool bolts WARNING Hot working tool WARNING Rupturing washers become The tip of the working tool gets very hot during projectiles operation. Touching it may lead to burns. -
Page 48: Checking The Retainer Bars
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Checking the percussion piston impact surface ◆ Check the percussion piston impact surface whenever replacing the working tool, but at least once every 100 operating hours to make sure it is not chipped and has no visible cracks. -
Page 49: Checking The Wear Bushes And Impact Ring
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Checking the wear bushes and impact ring The wear bushes can be checked after removing the working tool. You can check the diameter using the enclosed test gauge. The diameter measured must not exceed the maximum permissible diameter D max (measuring point see below). -
Page 50: Checking And Cleaning The Dustprotector System
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP ◆ Checking and cleaning the Remove the floating ring (E), counter ring (D) and guide ring (F) (see chapter DustProtector/ DustProtector system Removal). ◆ Clean the space in front of the flexible wiper (A) of all loose dust. -
Page 51: Piston Accumulator
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Piston accumulator Checking the pressure in the piston accumulator Check the gas pressure in the piston accumulator The pressure in the piston accumulator is monthly, and in cases of decreasing power or measured at the filling valve (G). -
Page 52: Release The Pressure From The Piston Accumulator
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP ◆ Release the pressure from the piston Connect the filling hose end (H) to the minimess connection (C) of the pressure relief accumulator valve (D). ◆ Release gas from the piston accumulator to ◆... -
Page 53: Hp-Accumulator
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions HP-accumulator - cracks/fissures, - distortion/deformation, - corrosion, - thread damage to the threaded bores. As safety−related components, high pressure accumulators are subject to special safety ◆ If broken or missing connecting screws are regulations. -
Page 54: Checking The Hydraulic Lines
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP 4. Connect the pressure gauge to the HP- Checking the hydraulic lines accumulator via the pressure line »P«. 5. Close the tank line »T«. ◆ Before starting your work shift, always carry out... -
Page 55: Checking The Adapter Plate Bolts For Wear
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions If the wear rails have worn severely, this may cause damage to the basic body of the breaker box. Checking the adapter plate bolts for wear ◆ Carry out this visual check whenever the hydraulic attachment has been removed from the carrier. -
Page 56: Bolt Connections/Tightening Torques
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP 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. HB 2000 HB 2500... - Page 57 HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions © Construction Tools GmbH | 3390 5090 01 | 2016-05-23 Original instructions...
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Page 58: Troubleshooting
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Troubleshooting The hydraulic breaker does not start Cause Remedy Pressure and tank lines swapped Check the laying of the pressure and tank lines and Carrier driver connect correctly (see chapter Making the hydraulic connections ) -
Page 59: Hydraulic Breaker Operates Too Slowly
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Hydraulic breaker operates too slowly Cause Remedy Insufficient hydraulic oil delivery volume Check the engine speed and/or mode stage of the carrier Carrier driver and the operation pressure and adjust... -
Page 60: Impact Rate Too High And Impact Force Too Low
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Impact rate too high and impact force too low Cause Remedy No gas in piston accumulator Check the gas pressure and fill the piston accumulator Carrier driver (see chapter Filling/topping up the piston accumulator) -
Page 61: Oil Or Grease Escapes From The Contilube ® Ii
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Oil or grease escapes from the ContiLube ® II Cause Remedy Connecting fittings are loose Check the connecting fittings and tighten Workshop (see chapter Bolt connections/Tightening torques) Operating temperature too high... -
Page 62: Repair
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP Repair WARNING Risk of injury Nonprofessional disassembly and assembly of the hydraulic breaker may lead to serious injury and property damage. Never pull the percussion unit out of the ►... -
Page 63: Storage
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Storage Hydraulic oil is environmentally harmful and must not penetrate the ground or enter the water table or water supplies. WARNING Hydraulic breaker / working tool Collect any hydraulic oil which escapes. -
Page 64: Working Tool
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP check any parts liable to corrosion • (percussion piston, cylinder, control) for corrosion damage. • rework or replace corroded parts. replace all sealing elements. • Working tool ◆ Grease the working tool with chisel paste to prevent it from corroding. -
Page 65: Disposal
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Disposal Chisel paste and grease cartridges NOTICE Environmental damage due to consumables ◆ Dispose of chisel paste and not completely emptied grease cartridges in accordance with Hydraulic oil and chisel paste are environmentally the applicable regulations. -
Page 66: Technical Specifications
3363 1168 57 3363 1168 59 1) Weights apply to standard carriers only. Any variances must be agreed with Atlas Copco and/or the carrier manufacturer prior to attachment 2) Hydraulic breaker incl. breaker box, working tool and adapter plate of medium size. -
Page 67: Noise Declaration Statement
HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions Noise declaration statement HB 2000, HB 2000 DP HB 2500, HB 2500 DP Sound pressure 1 dB(A) Sound power 2 dB(A) 1 Sound pressure level according to EN ISO 3744 in accordance with directive 2000/14/EC at 10 metres distance. -
Page 68: Ec Declaration Of Conformity (Ec Directive 2006/42/Ec)
Safety and operating instructions HB 2000, 2000 DP, 2500, 2500 DP 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 97/23/EC (Pressure Equipment Directive), and the harmonised standards mentioned below. - Page 69 HB 2000, 2000 DP, 2500, 2500 DP Safety and operating instructions 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 97/23/EC (Pressure Equipment Directive), and the harmonised standards mentioned below.
- Page 72 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. www.atlascopco.com...
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