Safety instructions
| This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. |
Read these Overhaul instructions and the Safety and operating instructions of the hydraulic attachment. In particular read all safety instructions before reparing the hydraulic attachment. This will: |
prevent the risk of injuries and fatal accidents for yourself and others,
protect the hydraulic attachment and other property against material damage,
protect the environment against environmental damage.
Follow all instructions in these Repair manual.
Signal words
The signal words Danger, Warning, Caution, and Notice are used as follows in these Overhaul instructions:
DANGER | indicates a hazardous situation which, if not avoided, will result in death or serious injury. |
WARNING | indicates a hazardous situation which, if not avoided, could result in death or serious injury. |
CAUTION | indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. |
NOTICE | The signal word NOTICE is used to address practices related to possible property damage but not related to personal injury. |
Qualification
Repairing the hydraulic attachment is only permitted if carried out by professionals trained by Construction Tools GmbH.
These professionals must have read and understood these Overhaul instructions and the Safety and operating instructions. They must follow all safety instructions and guidelines for repair. Otherwise the operational safety of the hydraulic attachment is not guaranteed.
Welding of the hydraulic attachment is only permitted if carried out by qualified welders who:
have been trained to operate MIG welding equipment according to the national regulations.
know all the relevant national/regional safety provisions and accident prevention rules.
Protective equipment
Personal protective equipment must comply with the applicable health and safety regulations.
- 1.Do not work wearing jewelry or with loose long hair. Moving machine parts could catch your hair or jewelry causing serious injury.
- 2.Wear comfortable, close-fitting work clothes. The moving machine parts can snag loose clothing and cause serious injury.
Always wear the following personal protective equipment:
protective helmet
safety glasses with side protectors
protective gloves
protective shoes
warning vest
hearing protection
Hydraulic installation, precautions
WARNING
Hot hydraulic oil squirting out
The hydraulic system is under high pressure. If hydraulic connections come loose, hydraulic oil will squirt out under high pressure. Hydraulic oil squirting out can lead to serious injury.
Immediately switch off the hydraulic attachment and the carrier if you detect any leaks in the hydraulic circuits.
Depressurise the hydraulic system (see chapter Depressurising the hydraulic system).
Special parts, precautions
Piston accumulator
DANGER
Danger of explosions
The integrated piston accumulator is filled with nitrogen (N2). Filling it with any other gas may trigger an explosion and lead to serious, possibly fatal, injuries.
Only fill the piston accumulator with nitrogen (N2).
WARNING
Component coming loose abruptly
The piston accumulator is under pressure, even when the hydraulic system has been depressurised. The filling valve might come loose unexpectedly and cause injuries.
Never unscrew the filling valve »G« from the pressurised piston accumulator.
Media/consumables, precautions
WARNING
Hot hydraulic oil under high pressure
Hydraulic oil will squirt out under high pressure if there is a leakage. The jet of oil might penetrate people's skin and cause permanent damage. Hot hydraulic oil can cause burns.
Never use your hands to find leaks.
Always keep your face away from a possible leak.
If hydraulic oil has penetrated your skin consult a doctor immediately.
WARNING
Hydraulic oil spills
Spilt hydraulic oil can make a floor slippery. If people slip they can be injured. Hydraulic oil is environmentally harmful and must not penetrate the ground or enter the water table or water supplies.
Make sure not to spill any hydraulic oil.
Immediately clean the floor if you have spilt hydraulic oil.
Observe all safety and environmental protection provisions when handling hydraulic oil.
WARNING
Skin infections/diseases due to oil and grease
Hydraulic oil and grease can cause rashes (or even eczema) if they come into contact with the skin.
Avoid all skin contact with hydraulic oil and grease.
Use a suitable skin protection product.
Always wear safety gloves when working with hydraulic oil or grease.
Immediately clean any skin that has been contaminated by oil or grease with water and soap.
Environmental pollution, precautions
NOTICE
Environmental pollution due to hydraulic oil
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 environmental pollution. For minor volumes use an absorbing medium (in case of an emergency use soil). In case of major leakages contain the hydraulic oil. It must not drain off and penetrate the ground or enter the water table or water supplies.
Collect contaminated absorbing medium or soil in a watertight box/container and close it tight.
Contact an authorized waste management company.
Dispose of all contaminated material in accordance with the applicable environmental regulations.
Heavy parts, precautions
WARNING
Heavy parts falling
The main parts of the hydraulic breaker are heavy. Unsuitable lifting attachments (e.g. ring or eye bolts) may fail and cause heavy parts to fall. Falling parts may cause serious injury.
Never pull the percussion unit out of the breaker box. Dismounting the percussion unit is only permitted if carried out by professionals trained by Construction Tools GmbH. These professionals must follow all safety instructions and guidelines for repair.
These professionals are only permitted to repair the percussion unit if they use the sling gears prescribed by Construction Tools GmbH when:
- removing the complete percussion unit.
- mounting or dismounting parts of the percussion unit.
Changes to the hydraulic attachment, precautions
WARNING
Changes to the hydraulic attachment
Changes to the hydraulic attachment or the adapter plate may lead to serious injury.
Never carry out any changes to the hydraulic attachment or the adapter plate.
Only use original parts or accessories approved by Epiroc.
Modifications that entail new hazards may require a new procedure for assessing conformity.
Workshop requirements
All parts of the percussion unit are vulnerable to dirt, the hydraulic breaker should always be disassembled and assembled in a place that is:
Separate from all grinding, welding or other particle- generating activities.
Thoroughly cleaned and free of dust and dirt.
Disposal
All waste products must be treated and scrapped in such a way that the greatest possible portion of the material can be recycled and any negative influence on the environment is kept as low as possible.
- 1.Dispose of all waste products in line with all applicable regulations or consult an authorised and specialised recycling company.
NOTICE
Environmental damage due to consumables
Hydraulic oil and chisel paste are environmentally harmful and must not penetrate the ground or enter the water table or water supplies.
Collect any such consumables which may escape.
Dispose of them in accordance with the applicable environmental regulations.
Depressurising the hydraulic system
Even when you have switched off the carrier, a considerable residual pressure can still be present in the hydraulic system.
A residual pressure can still be present in the hydraulic breaker even after you have disconnected the quick-release couplings or closed the shut-off valves.
The hydraulic breaker can only be depressurised using the hydraulic system of the carrier, by allowing hydraulic oil to drain to the tank via the return connection.
If the hydraulic breaker is fitted with a high-pressure accumulator, it can take longer to relieve the pressure in the hydraulic system to the tank, since a larger volume of oil has to be drained away.
Depending on the type of hydraulic breaker, the internal leaks, the oil temperature, the type of hydraulic oil and the design of the hydraulic installation of the carrier, the time required to relieve the pressure can vary.
Depending on the hydraulic system of the carrier you will have to consider using various measures in order to depressurise the hydraulic system.
Case 1: If measurement connections are present in the supply pipe to the hydraulic breaker, with which the depressurised state can be checked using a suitable gage. In order to depressurise the hydraulic breaker you must observe the following steps:
- 1.The hydraulic breaker must be connected to the hydraulic system of the carrier device, i.e. the hydraulic hoses must be connected up and the respective shut-off valves in the supply pipe and in the connection to the tank must be opened.
- 2.Depressurise the hydraulic system according to the manufacturer's safety and operating instructions for the carrier.
- 3.Measure the pressure with a suitable gage at a measurement connection in the supply pipe to the hydraulic breaker.
- 4.If residual pressure is still present, wait until the pressure has been completely relieved.
- 5.When you have made sure that no more pressure is present in the hydraulic system, you must disconnect the hydraulic connection to the carrier. Close the shut-off valves or disconnect the quick-release couplings, so that no hydraulic oil can flow back from the carrier.
Case 2: If no facility for measuring the pressure is present in the supply pipe to the hydraulic breaker and the return pipe is connected to the tank without an intermediate valve connection, you must observe the following steps in order to depressurise the hydraulic breaker:
- 1.Ensure that the hydraulic oil in the hydraulic breaker and in the carrier has a temperature of at least 0 °C (32 °F). If necessary, pre-heat it to at least 0 °C (32 °F).
- 2.The hydraulic breaker must be connected to the hydraulic system of the carrier, i.e. the hydraulic hoses must be connected up and the respective shut-off valves in the supply pipe and in the connection to the tank must be opened.
- 3.Depressurise the hydraulic system according to the manufacturer's safety and operating instructions for the carrier.
- 4.You must wait at least another 30 minutes until the pressure has been relieved through leakages.
Only after this period of time will there be no more residual pressure present in the hydraulic system of the hydraulic breaker.
- 5.When you have made sure that no more pressure is present in the hydraulic system, you must disconnect the hydraulic connection to the carrier. Close the shut-off valves or disconnect the quick-release couplings, so that no hydraulic oil can flow back from the carrier.
Case 3: If no facility for measuring the pressure is present in the supply pipe to the hydraulic breaker and the return pipe is connected to the tank via intermediate valves, which for example close off or pressurise the return pipe, you must observe the following steps in order to depressurise the hydraulic breaker:
- 1.The hydraulic breaker must be connected to the hydraulic system of the carrier, i.e. the hydraulic hoses must be connected up and the respective shut-off valves in the supply pipe and in the connection to the tank must be opened.
- 2.Depressurise the hydraulic system according to the safety and operating instructions from the carrier manufacturer, and where appropriate, those of the manufacturer of the hydraulic installation for the attachment.
- 3.When you have made sure that no more pressure is present in the hydraulic system, you must disconnect the hydraulic connection to the carrier device. Close the shut-off valves or disconnect the quick-release couplings, so that no hydraulic oil can flow back from the carrier.