Installation

Operation

Installation

Installation

WARNING

Hot hydraulic oil squirting out

The hydraulic system is under high pressure. If hydraulic connections come loose or are disconnected, hydraulic oil will squirt out under high pressure. Hydraulic oil squirting out can lead to serious injury.

  1. Depressurise the hydraulic system before connecting or disconnecting the hydraulic circuits of the hydraulic attachment (see chapter Depressurising the hydraulic system).

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.

NOTICE

Damage to the hydraulic attachment

Working with a hydraulic attachment mounted to a long reach boom may cause damage to the hydraulic attachment.

  1. Before working with a hydraulic attachment mounted to a long reach boom consult the Epiroc Customer Center / Dealer in your area.

Media/consumables

The following consumables are used when operating the hydraulic attachment:

Mineral hydraulic oil

All hydraulic oil brands prescribed by the carrier manufacturer are also suitable for use when operating the hydraulic attachment.

However, the oil should comply with viscosity class HLP 32 or higher.

In summer and in hot climates, oils of viscosity class HLP 68 or higher should be used.

In all other respects the regulations of the carrier manufacturer are to be taken into consideration.

Optimum viscosity range

= 30 - 60 cSt

Max. start viscosity

= 2000 cSt

Max. oil temperature

= 80 °C

Special conditions apply to using the hydraulic attachment at low temperatures (see chapter Low ambient temperature).

  1. 1.
    Check the oil filter!

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

Non-mineral hydraulic oil

NOTICE

Mixed hydraulic oil

Never mix mineral and non-mineral hydraulic oils! Even small traces of mineral oil mixed in with non-mineral oil can result in damage to both the hydraulic attachment and the carrier. Non-mineral oil loses its biodegradability.

  1. Only use one type of hydraulic oil.

If you are using non-mineral oil it is imperative that the name of the oil in use be indicated when returning the hydraulic attachment for repair.

In order to protect the environment or on technical grounds, hydraulic oils are currently being used which are not classified as HLP mineral oils.

Before using hydraulic oils of this kind it is imperative to ask the carrier manufacturer whether operations with such fluids are possible.

Our hydraulic attachments are basically designed for use with mineral oils. Consult the Epiroc Customer Center / Dealer in your area before using other hydraulic oils approved by the carrier manufacturer. Following initial assembly and after any workshop repairs, our hydraulic attachments are subjected to a test run on a test bed powered by mineral oil.

Grease

  1. 1.
    When handling oils and greases observe the safety instructions that apply to these products.

Media /consumables

Part number

Cutter grease

3363 0949 14

Manufacturing the adapter plate

Construction Tools GmbH also supplies base plates to manufacture adapter plates alternatively to the adapter plates supplied.

NOTICE

Adapter plate cracking

The adapter plate may crack if it is not designed for the high load.

  1. Take not only the weight of the hydraulic attachment but also the crowd force of the carrier, possible vibration etc. into account when dimensioning the adapter plate.

  2. Ensure that the design conforms to the state of the art.

  3. Have the web plates welded to the adapter plate base plate by a qualified welding specialist.

The base plate is made of the material EN10025-S355 J2G3.

  1. 1.
    Have the web plates designed and manufactured or procure web plates to fit your carrier.
  2. 2.
    Ensure that the web plates are welded to the base plate side marked "TOP".

The adapter plate must not strike in any position during operation of the hydraulic attachment.

Construction Tools GmbH does not design, manufacture or sell web plates for adapter plates.

Installing the adapter plate

NOTICE

The adapter plate can come loose

The adapter plate can come loose if the fastening screws are not designed for local high loads.

  1. Only use the Allen screws of strength category 8.8 and the pairs of lock washers included in the delivery to attach the adapter plate or the base plate.

  1. 1.
    Place the hydraulic attachment on timber support blocks within the range of the carrier.
  2. 2.
    Apply anti-seize compound to the hexagon head screw threads (D) before inserting them.

The contact faces of the screw head and the lock washers (C) must not be lubricated.

WARNING

Hands and fingers being cut off or hurt

Bores and surfaces can act like a pair of scissors and cut off or hurt parts of your body.

  1. Never use your fingers to check bores or fitting surfaces.

  1. 1.
    Align the adapter plate (F) to the upper part (E) of the hydraulic attachment as shown.

  2. 2.
    Fit a pair of lock washers (C) onto every hexagon head screw (D).
  3. 3.
    Put the hexagon head screws D) through the borings.
  4. 4.
    Fit a pair of lock washers (B) onto every hexagon head screw (D),
  5. 5.
    Screw the hexagon nuts (A) on.
  6. 6.
    Tighten the hexagon head screws (D)/hexagon nuts (A) with socket spanners to the tightening torque required.

Key size

Tightening torque

24 mm (0.95 in.)

215 Nm (159 ft lbs)

Attaching the hydraulic attachment to the carrier

Mechanical mounting aspects

You need an assistant to attach the hydraulic attachment to the carrier.

  1. 1.
    Agree on hand signals with your assistant, to enable him to help you place the carrier in the proper position to attach the hydraulic attachment.
  2. 2.
    Lower the stick of the carrier into the holder provided on the adapter plate.

WARNING

Injury by impacts

A sudden movement of the carrier may cause your assistant to be hit and injured by the boom or the hydraulic attachment.

  1. Only move the boom very slowly and in a controlled manner while an assistant is within the danger zone.

  2. Always keep sight of your assistant.

WARNING

Hands and fingers being cut off or hurt

Bores and surfaces can act like a pair of scissors and cut off or hurt parts of your body.

  1. Never use your fingers to check bores or fitting surfaces.

  1. 1.
    Let your assistant instruct you until the bores in the adapter plate (B) and in the stick (A) are properly aligned.
  2. 2.
    Install the stick bolt (C) and lock it.
  3. 3.
    Lift the hydraulic attachment (D).
  4. 4.
    Extend the bucket cylinder (E) until the bore in the linkage (F) aligns with the bore in the adapter plate (B).
  5. 5.
    Install the linkage bolt (G) and lock it.
  6. 6.
    Carefully move the bucket cylinder (E) into both end positions.

The adapter plate must not be stopped by the mechanical stops in either position. Consult the Epiroc Customer Center / Dealer in your area if the adapter plate is stopped by a mechanical stop.

Making the hydraulic connections

NOTICE

Faulty hydraulic installation

The carrier must have a suitable hydraulic installation to operate the hydraulic attachment. Improperly installed lines and incorrectly rated sizes may cause the oil to heat up and the hydraulic attachment to be damaged.

  1. Only use hydraulic lines of the rated sizes as instructed (see chapter Technical Specifications).

  2. Check the rated size of the hydraulic lines on existing hydraulic installations! All supply and return lines for the hydraulic oil must have a sufficient inside diameter and wall thickness.

  3. Route all hydraulic hoses in a torsion-free manner.

  1. 1.
    Switch off the carrier.
  2. 2.
    Depressurise the hydraulic system according to the manufacturer's safety and operating instructions for the carrier.
  3. 3.
    Close all shut-off valves in the installation at the boom, if no quick couplings are used.

NOTICE

Damage to hydraulic parts

Polluted hydraulic lines and connections may enable sand, fragments of material and dirt to penetrate the hydraulic attachment and damage the hydraulic parts.

  1. Clean the hydraulic lines and connections prior to connecting the hydraulic lines.

  1. 1.
    Have dirty hydraulic lines rinsed through by a specialist company.
  2. 2.
    Clean dirty hydraulic line connections with a suitable grease-dissolving universal cleaner.
  3. 3.
    Observe the cleaner manufacturer's information on safety and use.

Connecting hydraulic hoses for the functions »Open / Close«

  1. 1.
    Remove the cap nuts and plugs from the connections »A« and »B« at the upper part of the hydraulic hydraulic attachment and keep them in a safe place.

    The connection of function »Open« is marked with an »A«, the connection of function »Close« with a »B« at the edge of the connecting plate of the upper part.

  2. 2.
    Check that the connections on the hydraulic attachment and on the hoses are not damaged.
  3. 3.
    Change any damaged connections.
  4. 4.
    Fix the hoses to the connections »A« and »B«.

    When both input lines have the same operating pressures,

  5. 5.
    connect the two hoses at the boom torsion-free.

    If the two input lines have different operating pressures,

  6. 6.
    connect the hose connected to connection »B« torsion-free to the input line which has the higher operating pressure.
  7. 7.
    Connect the hose connected to connection »A« torsion-free to the input line which has the lower operating pressure.

WARNING

Hydraulic hose flailing about

Pressurised hydraulic hoses will flail about if a bolted connection comes loose or becomes loosened. A hydraulic hose flailing about may cause serious injuries.

  1. Tighten the fastening screws with the right tightening torque.

Tightening torque (see chapter Bolt connections / Tightening torques).

Connecting hydraulic hoses for the function »Turn«

  1. 1.
    Remove the cap nuts and plugs from the »Turn« connections and save them for future use.
  2. 2.
    Check that the connections on the hydraulic attachment and on the hoses are not damaged.
  3. 3.
    Replace damaged connections.
  4. 4.
    Fix the hoses to the connection for function »Turn«.

  5. 5.
    Connect both hoses for the function »Turn« at the boom, torsion-free.

WARNING

Hydraulic hose flailing about

Pressurised hydraulic hoses will flail about if a bolted connection comes loose or becomes loosened. A hydraulic hose flailing about may cause serious injuries.

  1. Tighten the fastening screws with the right tightening torque.

Tightening torque (see chapter Bolt connections / Tightening torques).

Removing the hydraulic attachment from the carrier

  1. 1.
    Place the hydraulic attachment on timber support blocks.

Dismantling the hydraulic connections

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.

WARNING

Hydraulic hose flailing about

Pressurised hydraulic hoses will flail about when bolted connections have come loose or have been loosened. A hydraulic hose flailing about may cause serious injuries.

  1. Depressurise the hydraulic system before disconnecting a hydraulic hose (see chapter Depressurising the hydraulic system).

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.

  1. 1.
    Close all shut-off valves in the installation at the boom if no quick couplings are used.
  2. 2.
    Disconnect the hose lines to and from the hydraulic attachment at the boom side.
  3. 3.
    Close off all open hose ends.

Mechanical disassembly

  1. 1.
    You need an assistant to remove the hydraulic attachment.
  2. 2.
    Agree on hand signals with your assistant, to enable him to help you move the boom.

WARNING

Injury by impacts

A sudden movement of the carrier may cause your assistant to be hit and injured by the boom or the hydraulic attachment.

  1. Only move the boom very slowly and in a controlled manner while an assistant is within the danger zone.

  2. Always keep sight of your assistant.

WARNING

Metal chips shooting off

When hammering out bolts, chips may shoot off and cause serious eye injuries.

  1. Wear safety glasses when hammering out the bolts.

  1. 1.
    Remove the bolt locks from the stick and linkage bolts.
  2. 2.
    Drive out the linkage bolt with a steel arbor and a hammer.
  3. 3.
    Switch on the carrier.
  4. 4.
    Retract the bucket cylinder.
  5. 5.
    Drive out the stick bolt with a steel arbor and a hammer.
  6. 6.
    Move the carrier stick out of the adapter plate.

Removing the adapter plate

  1. 1.
    Loosen the fastening screws of the adapter plate.
  2. 2.
    Lift the adapter plate with a suitable lifting equipment and put it down on timber support blocks.
  3. 3.
    Save the fastening screws and the pairs of lock washers for future use.