Maintenance

Operation

Maintenance

Maintenance

The maintenance activities are carried out by the carrier driver.

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.

  1. Immediately switch off the hydraulic attachment and the carrier if you detect any leaks in the hydraulic circuits.

  2. Depressurise the hydraulic system (see chapter Depressurising the hydraulic system).

  3. Repair any leaks before operating the hydraulic attachment again.

WARNING

Hot hydraulic oil squirting out

The hydraulic system is under high pressure. Hydraulic oil escaping out can lead to serious injury.

  1. Immediately switch off the hydraulic attachment and the carrier if you detect any leaks in the hydraulic circuits.

  2. Do not inspect for possible leaks with your fingers or other parts of the body, but use a piece of cardboard instead, holding it up to the suspected leakage site.

  3. Examine the cardboard for traces of liquid.

  4. Depressurise the hydraulic system (see chapter Depressurising the hydraulic system).

  5. Repair any leaks before operating the hydraulic attachment again.

WARNING

Hot parts

The hydraulic cylinder, hoses, pipes and fittings become very hot during operation. Touching them may lead to burns.

  1. Never touch hot parts.

  2. If you have to carry out activities where you have to touch the parts, wait for them to cool down first.

WARNING

Accidental start

If the hydraulic attachment is started by accident this may lead to serious injury.

  1. Follow the instructions in the Operating Instructions of the carrier to prevent the hydraulic attachment starting by accident.

WARNING

Unexpected movement

Sudden movements of the carrier may cause serious injury.

  1. Secure the carrier such that it cannot move unexpectedly.

  2. Observe the carrier manufacturer’s instructions.

NOTICE

Environmental damage due to hydraulic oil

Hydraulic oil is environmentally harmful and must not penetrate the ground or enter the water table or water supplies.

  1. Collect any hydraulic oil which escapes.

  2. Dispose of it in accordance with the applicable environmental regulations.

Maintenance schedule

prior to shift

Check the hydraulic concrete buster and adapter plate for cracks.

Check hydraulic lines for leaks and damage.

Check the pipe clamp receiver on the carrier.

Check cutter jaws, cutter blades, and tips for wear. If necessary to reface cutter jaws, to turn or to replace cutter blades, to reface tips, consult your Epiroc contact person.

Check the cutting edges of the blades for wear every 8 operating hours, max. 3 mm (0.12 in.) radius.

Check fixing bolts at the cutter blades (visual check), if necessary tighten.

Lubricate cylinder pin bearings at all cutter cylinder lubrication nipples.

Lubricate main bolt bearing at all cutter jaw lubrication nipples.

daily

Check the bolted connections at the adapter plate and tighten as required.

weekly

Check the bolted connections at the hydraulic lines and tighten as required.

Check the bolted connections at the four point bearing and tighten as required.

monthly

Lubricate four point bearing.

after the first 50 operating hours

Change hydraulic oil filter cartridge.

every 500 operating hours

Check oil filter cartridge, replace if necessary.

if necessary

Replace bent and damaged pipes.

Replace damaged hoses.

Check wear at the adapter plate bolts.

Change cutter jaws.

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 attachment even after you have disconnected the quick-release couplings or closed the shut-off valves.

The hydraulic attachment can only be depressurised using the hydraulic system of the carrier, by allowing hydraulic oil to drain to the tank via the return connection.

Depending on the type of hydraulic attachment, 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.

Observe the following steps in order to depressurise the hydraulic attachment:

  1. 1.
    Ensure that the hydraulic oil in the hydraulic attachment 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. 2.
    The hydraulic attachment 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.
  3. 3.
    Open the cutter jaws completely.
  4. 4.
    Place the hydraulic attachment horizontal on the ground.
  5. 5.
    Close the cutter jaws briefly, just enough to see a movement of the cutter jaws.
  6. 6.
    Depressurise the hydraulic system according to the manufacturer's safety and operating instructions for the carrier.
  7. 7.
    You must wait at least another 30 minutes until the pressure has been relieved through leakages.
  8. 8.
    Measure the pressure with a suitable gage at both measurement connections at the hydraulic attachment.
  9. 9.
    If residual pressure is still present, wait until the pressure has been completely relieved.
  10. 10.
    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.

Cleaning

NOTICE

Environmental damage due to polluted water

Hydraulic oil and cutter grease are environmentally harmful and must not penetrate the ground or enter the water table or water supplies.

  1. Collect the water used for cleaning if it has been contaminated by hydraulic oil and cutter grease.

  2. Dispose of the water in accordance with the applicable regulations to avoid environmental hazards.

Preparations

Hydraulic concrete buster attached:

  1. 1.
    Place the hydraulic concrete buster on the opened cutter jaws.

    All parts are thus accessible for cleaning.

  2. 2.
    Secure the carrier such that it cannot move unexpectedly.

Hydraulic concrete buster not attached:

  1. 1.
    Plug up all hydraulic ports.

Procedure

  1. 1.
    Use a pressure cleaner to remove dirt from the hydraulic attachment.

Lubrication

Lubricate bolts

Lubrication interval: prior to every shift.

  1. 1.
    Close the hydraulic concrete buster.
  2. 2.
    Place the hydraulic concrete buster vertically on the closed cutter jaws.
  3. 3.
    Secure the carrier so that it cannot move unexpectedly.
  4. 4.
    Only use cutter grease for lubrication.
  5. 5.
    Place the grease gun on the lubrication nipples of the cylinder eyes (A).
  6. 6.
    Inject 4 to 6 strokes of cutter grease per lubrication nipple.
  7. 7.
    Place the grease gun on the lubrication nipples of the cutter jaws (B).
  8. 8.
    Inject 4 to 6 strokes of cutter grease per lubrication nipple.

Lubricating the four point bearing

Lubrication interval: every 14 days

  1. 1.
    Place the hydraulic attachment vertically on the cutter jaws.
  2. 2.
    Secure the carrier such that it cannot move unexpectedly.
  3. 3.
    Only use cutter grease for lubrication.
  4. 4.
    Place the grease gun on the lubrication nipple (A) of the four point bearing.
  5. 5.
    Inject 4 strokes of cutter grease per lubrication nipple.

WARNING

Unexpected movement

Movements of the carrier and the hydraulic attachment may cause serious injury. Persons who are within the danger zone (within the reach of the carrier and the hydraulic attachment) can get injured or killed.

  1. Secure the danger zone.

  2. Stop the hydraulic attachment immediately if anyone enters the danger zone.

  1. 1.
    Clear the danger zone.
  2. 2.
    Switch the carrier on.
  3. 3.
    Lift the hydraulic attachment and let it hang vertically.
  4. 4.
    Turn the hydraulic attachment about 45°.
  5. 5.
    Place the hydraulic attachment vertically on the cutter jaws.
  6. 6.
    Secure the carrier such that it cannot move unexpectedly.
  7. 7.
    Place the grease gun on the lubrication nipples (A) of the four point bearing.
  8. 8.
    Again inject 4 strokes of cutter grease per lubrication nipple.

Checking the hydraulic concrete buster and adapter plate for cracks

  1. 1.
    Secure the carrier such that it cannot move unexpectedly.
  2. 2.
    Check all the hydraulic concrete buster and adapter plate load-bearing parts and welds for cracks prior to every shift.
  3. 3.
    Ensure repair or refinishing in good time to prevent greater damage.

Checking hydraulic concrete buster for wear

  1. 1.
    Secure the carrier such that it cannot move unexpectedly.

WARNING

Parts of the body or whole bodies may be sheared or crushed

Cutter jaws may close unexpectedly and shear or crush parts of the body or whole bodies.

  1. Ensure that there is nobody between the cutter jaws.

  1. 1.
    Secure the carrier such that it cannot move unexpectedly.
  2. 2.
    Prior to starting work, check cutter jaws, cutter blade and tips of tooth for wear.
  3. 3.
    Replace cutter blades and tips of tooth in good time to prevent greater damage (see Chapter Turning or changing cutter blades and Changing tip of tooth).

NOTICE

Damage to blade seat of cutter jaw

Working without cutter blades causes serious damage to the blade seat on the cutter jaw.

  1. Replace the missing cutter blades immediately (see Chapter Turning or changing cutter blades).

NOTICE

Damage to cutter jaw

Working with worn out tips of tooth causes serious damage to the cutter jaws.

  1. Reface the worn out tips of tooth immediately (see Chapter Hardfacing the cutter jaws).

Checking hydraulic lines

  1. 1.
    Secure the carrier such that it cannot move unexpectedly.
  2. 2.
    Perform a visual inspection of all lines (pipes and hoses) from the pump to the hydraulic attachment and back to the tank, before starting work.
  3. 3.
    Tighten loose bolted connections and hose clamps to the torque required (see Chapter Bolted connections / tightening torques).
  4. 4.
    Replace damaged pipes and/or hoses.

Checking bolted connections

  1. 1.
    Secure the carrier such that it cannot move unexpectedly.
  2. 2.
    Check all bolted connections regularly for tight fit (see Chapter Bolted connections / Tightening torques).
  3. 3.
    Tighten loose bolted connections and hose clamps to the torque required (see Chapter Bolted connections / Tightening torques).

Checking the adapter plate bolts for wear

  1. 1.
    Carry out this visual check whenever the hydraulic attachment has been removed from the carrier.
  2. 2.
    Check the adapter plate bolts for excessive wear such as cracks, pitting or severe erosion.
  3. 3.
    Rework or replace worn bolts.

Checking and cleaning the hydraulic oil filter of the carrier

An oil filter must be integrated in the return circuit of the hydraulic system. The maximum mesh width allowed for the oil filter is 50 microns; it must have a magnetic separator.

  1. 1.
    Secure the carrier such that it cannot move unexpectedly.
  2. 2.
    Change the oil filter cartridge after the first 50 operating hours.
  3. 3.
    Check the oil filter every 500 operating hours and replace if it is necessary.

Turning or changing the cutter blades

  1. 1.
    Turn the cutter blade if the cutting edge is worn and the contact face is undamaged.
  2. 2.
    Change the cutter blade if the contact face is damaged or if the cutter blade shows any other damage.
  3. 3.
    Use new, original fixing bolts when you attach new cutter blades.

Removing the cutter blades

  1. 1.
    Open the cutter jaws completely.
  2. 2.
    Place the hydraulic concrete buster horizontal on the ground.

WARNING

Parts of the body or whole bodies may be sheared or crushed

Cutter jaws may close unexpectedly and shear or crush parts of the body or whole bodies.

  1. Ensure that there is nobody between the cutter jaws.

  1. 1.
    Perform work while outside the open cutter jaws, not between them.
  2. 2.
    Disconnect the hydraulic supply to the hydraulic concrete buster by shutting the shut-off valves of the lines »Open« (Connection »A«) and »Close« (Connection »B«) at the boom.
  3. 3.
    Secure the carrier such that it cannot move unexpectedly.
  4. 4.
    Hold the Allen screws (A) with an Allen key to stop them turning.
  5. 5.
    Loosen the hexagon nuts (D) with a socket wrench and ratchet.
  6. 6.
    Remove the Allen screws (A) and the hexagon nuts (D).
  7. 7.
    Lever the cutter blade (B) out of the blade seat using a screw driver or thin chisel.
  8. 8.
    Remove the shims (C).
  9. 9.
    Check the blade seat of the cutter jaw.

Checking the blade seat

The blade seat should not have any severe damage since this means the support of the cutter blade (B) is not ensured. Damage to the blade seat may lead to fracture of the cutter blade (B).

  1. 1.
    If you notice damaged blade seats, please consult your Epiroc contact person.

Checking cutter blades

If you turn the cutter blade (B), the surfaces contacting the blade seat should not have any major unevenness. Unevenness causes damage to the blade seat.

  1. 1.
    Change the cutter blade (B) if the contact surface (E) is damaged or if the cutter blade (B) has other damage.
  2. 2.
    Check the cutting edges of the blades for wear every 8 operating hours.

    The cutting edges may be worn to a maximum radius (R max.) of 3 mm (0.12 in.).

  3. 3.
    Change the cutter blade if the cutting edges are worn above the maximum radius (R max.) of 3 mm (0.12 in.).
  4. 4.
    Turn the cutter blade if the cutting edge is worn and the contact surface is undamaged.
  5. 5.
    Replace damaged Allen screws (A) and hexagon nuts (D).

Fitting cutter blades

If the inspection of the blade seat does not show any defects or if it has been reworked, fitting of the cutter blade (B) can begin.

  1. 1.
    Clean the blade seat.
  2. 2.
    Insert the cutter blade (B).
  3. 3.
    Push the Allen screws (A) through the free drilled holes.
  4. 4.
    Screw the hexagon nuts (D) on.
  5. 5.
    Hold the hexagon nuts (D) with a box wrench to stop them turning.
  6. 6.
    Tighten the Allen screws (A) to the torque required (see chapter Bolt connections / Tightening torques).
  7. 7.
    Turn the hydraulic concrete buster to the other side to turn or change the other cutter blade. Thus you can avoid being between the open cutter jaws.
  8. 8.
    Open the shut-off valves of the lines »Open« (Connection »A«) and »Close« (Connection »B«) at the boom.
  9. 9.
    Lift the hydraulic concrete buster using the carrier.
  10. 10.
    Turn the hydraulic concrete buster 180°.
  11. 11.
    Place the hydraulic concrete buster horizontal on the ground.
  12. 12.
    Work through all the steps as previously described in this chapter and observe the safety instructions.

Checking and correcting the blade clearance

  1. 1.
    Secure the carrier to prevent any unexpected movements prior to measuring or correcting the blade clearance.

Checking the blade clearance

  1. 1.
    Open the cutter jaws completely.

WARNING

Parts of the body or whole bodies may be sheared or crushed

Cutter jaws may close unexpectedly and shear or crush parts of the body or whole bodies.

  1. Ensure that there is nobody between the cutter jaws.

  1. 1.
    Perform work while outside the open cutter jaws, not between them.
  2. 2.
    Close the cutter jaws until the pair of cutter blades overlaps.
  3. 3.
    Secure the carrier to prevent any unexpected movements.
  4. 4.
    Measure the blade clearance with a feeler gauge (leaf gauge).
  5. 5.
    The blade clearance must be corrected if it is greater than 1.5 mm (0.06 in.).

Correcting the blade clearance

Shims are required to correct the blade clearance. These are not included in the hydraulic concrete buster scope of delivery. They must be purchased separately. The order number can be seen in the list of spare parts.

WARNING

Metal fragments expelled at high velocity

The cutter blades are made of hardened steel. If the cutter blade pairs come in contact with each other when the cutter jaws close, fragments may be expelled as projectiles and cause serious injuries and damage property.

  1. Wear safety glasses when making adjustments to the blade clearance.

  2. Only shim the blade pairs so there is minimum blade clearance when the cutter jaws close.

  1. 1.
    Always underlay overlapping pairs of blades with shims evenly. The blade protrusion »d1« at the cutter jaw (single) and (double) must be the same.
  2. 2.
    Open the cutter jaws completely.

WARNING

Parts of the body or whole bodies may be sheared or crushed

Cutter jaws may close unexpectedly and shear or crush parts of the body or whole bodies.

  1. Ensure that there is nobody between the cutter jaws.

  1. 1.
    Perform work while outside the open cutter jaws, not between them.
  2. 2.
    Disconnect the hydraulic supply to the hydraulic concrete buster by shutting the shut-off valves of the lines »Open« (Connection »A«) and »Close« (Connection »B«) at the boom.
  3. 3.
    Secure the carrier such that it cannot move unexpectedly.
  4. 4.
    Hold the Allen screws (A) with an Allen key to stop them turning.
  5. 5.
    Loosen the hexagon nuts (D) with a socket wrench and ratchet.
  6. 6.
    Remove the Allen screws (A) and the hexagon nuts (D).
  1. 1.
    Lever the cutter blade (B) out of the blade seat using a screw driver or thin chisel.
  2. 2.
    Push shims (C) between cutter blade (B) and blade seat.
  3. 3.
    Fit the cutter blade (B).
  4. 4.
    Push the Allen screws (A) through the free drilled holes.
  5. 5.
    Screw the hexagon nuts (D) on.
  6. 6.
    Hold the hexagon nuts (D) with a box wrench to stop them turning.
  7. 7.
    Tighten the Allen screws (A) to the torque required (see chapter Bold connections / Tightening torques).
  1. 1.
    Re-check the blade clearance (see chapter Correcting the blade clearance).
  2. 2.
    Repeat this procedure until the blade clearance is less than 1.5 mm (0.06 in.).

Bolt connections / Tightening torques

The bolt connections of hydraulic concrete busters are subjected to very high loads.

  1. 1.
    Tighten any loose connections without exceeding the recommended tightening torques.

Connection point

Interval

Type of spanner / size

Tightening torque

Adapter plate*

(fixing bolts)

A

daily

Socket spanner / 24 mm (0.95 in.)

215 Nm (159 ft lbs)

Four point bearing

B

weekly

Allen key / 8 mm (0.32 in.)

70 Nm (52 ft lbs)

Base plate

(fixing bolts)

C

daily

Allen key / 17 mm (0.67 in.)

600 Nm (443 ft lbs)

Cap nut

D

in case of a repair

open-ended wrench / 65 mm (2.56 in.)

50 Nm (37 ft lbs)

Cutter blades

E

prior to shift

Allen key / 8 mm (0.32 in.)

97 Nm (72 ft lbs)

Cylinder rod protection

(fixing bolts)

F

daily

Allen key / 14 mm (0.55 in.)

200 Nm (148 ft lbs)

Hydraulic hose »Turn«

G

weekly

open-ended wrench / 19 mm (0.75 in.)

26 Nm (19 ft lbs)

Hydraulic hose »Open / Close«

H

weekly

open-ended wrench / 24 mm (0.95 in.)

63 Nm (47 ft lbs)

*

Treat the threads of the Allen screws with Anti-seize prior to screwing them in.

The contact face of the screw head and the lock washers must not be lubricated.

 

**

Lubricate thread with hydraulic oil before screwing in (Threads of stainless steel fittings must be lubricated with EO-NIROMONT).

Screw until handtight.

Then tighten according to chart.

Tightening torques are based on lubricated carbon steel zinc plated components and counterpart made of steel.