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HB-1000 Hydraulic Breaker Operations Manual

1. 5 Install two lifting eyes Lift spacer with wear plate and breaker out of housing m X AZ NN AZ NA 727 Page 101 Workshop COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION 1000 Disassembly and assembly 7 Remove pad DISASSEMBLING THE PIN MOUNTED SIDE PLATES Warning The breaker must be secured from falling down in either direction when handling it Check that the lifting capacity of the hoist you are using is sufficient for the job 1 Remove the tool and disconnect the breaker from the carrier 2 Remove hydraulic hoses COPYRIGHT O 2015 SANDVIK MINING AND CONSTRUCTION Workshop Page 1025 Disasse mbly and assembly HB 1000 4 Remove side plates ASSEMBLING THE HOUSING AND VIBRATION DAMPENING 1 Check all parts for cracks and excessive wear 2 Measure thickness of pads and buffer If measured thicknesses are smaller than specified or any cracks are noticed parts must be replaced Note Pads must be replaced as a pair Set housing to vertical position 4 Install pad 9 Page 103 Workshop COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION 1000 Disassembly and assembly 6 Lower breaker into housing Check clearance by moving breaker from side to side 7 8 Install spacer screw 9 Install buffer 10 Connect hose couplings to breaker COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Workshop Page DX Disasse mbly and
2. Original instructions Lee ie SERVICE MANUAL Unlimited EYDRAULC HAMMER HB 1000 Contents DAO PERO MSN 3 11 OM irccsicuisderaincstaasrdeddincecgceinceccsecdstadcdutacadddudctetaenSatedadataced deatatetaentatacadasatebadestids 4 1 2 Safety and environmental instructions 2 11221 8 159 94161 26 1 4 Safety during operation Nearest eee 38 1 5 Transportation storage and setting up eese eere eee 45 1 6 Breaker installation and removal sise 48 15 0 21 62 11 10 1 isnt 51 2 LUBRICATION 63 2 1 GhEaSING ecco euenit ddnde ned neo deed tende eode 64 22 MVOTAUNC OI nn st ere des 62 OM Yi iler 67 2 21 68 3 2 Releasing pressure from the 71 3 3 Inspection of pressure in the low pressure accumulator 72 3 4 Recharging the low pressure accumulator cesses eese 76 aD ase NINO AITO TOON ssn E 80 3 6 Removal and installation
3. 0030004 4 Install cap B to the charging device 5 Pull the handle C out and leave it in this position Close the discharge valve D on the charging device by turning the knob COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 74 Inspection of pressure the low HB 1000 6 Tighten the recharge valve to the filling plug on the breaker from E If the recharge valve does not easily fit to the breaker connect first adapter by one end F to the breaker and then the recharge valve E to other end of adapter G 7 Pushin the handle C on the charging device Observe the pressure gauge reading on the charging device If the pressure in the accumulator is not in specification recharge it according specification 8 Pull out the handle C on the charging device Open the discharge valve D on the charging device by turning the knob 10 Remove the recharging device from the breaker 11 Install the flange plug on the filling plug making sure that no dirt enters the valve Tighten the flange plug with an allen key to specified torque 12 Install shield plate to housing and tighten mounting screws to specified torque Page 75 Maintenance COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Recharging the low pressure HB 1000 4 RECHARGING THE LOW PRESSURE ACCUMULATOR ACCUMULATOR PRECHARGE PRESSURE See the precharge pressure on the table in inspection of pressure in the low pressure ac
4. 3 Grease at least every three hours of use In dry applications such as demolition of concrete apply grease more frequently The tool shaft inside the bushing must never be dry 4 When installing a new tool liberally coat the upper 1 3 of the tool with grease before inserting 5 Failure to comply will cause seizures and excessive wear of the tool and the tool bushing Excessive wear of the tool bushing misaligns the tool and the piston and will cause severe damage to the interior parts of the breaker COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Lubrication Page 64 1000 Greasing the breaker 1 1 RECOMMENDED GREASES For tool lubrication use a grease that meets the following criteria No dropping point or very high over 250 C 480 F Maximum service temperature at least 150 C 300 F Minimum working temperature below lowest ambient temperature Additives molybdenum disulfide MoS graphite or equivalent Penetration 0 2 NLGI No reaction with hydraulic oils Water resistant Good adhesion with steel Wear gloves when handling the grease containers If you get grease onto your skin washitaway with water Page 65 Lubrication COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Hydraulic oil HB 1000 2 HYDRAULIC OIL It is essential that the viscosity of the oil at operating temperature is within specifications The correct oil viscosity is a guarantee for proper lubricati
5. Workshop Page 120 Service tools HB 1000 Name Specification Grease gun Flowmeter 20 150 l min Flowmeter 70 350 l min Pressure gauge 40 bar Page 121 Workshop COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Steel Unlimited Inc 452 W Valley Blvd Rialto CA 92376 USA 48 8 14105 24 192 105 48 8 14105 33 124 266
6. Use of non authorized spare parts may cause an uncontrolled risk to user health and is thus prohibited MANAGING WORK RELATED HAZARDS All mechanical equipment can be hazardous if handled without due care or correct maintenance Most accidents involving equipment handling are caused by failure to observe basic safety rules or precautions Because it is impossible to anticipate every possible circumstance that might involve a potential hazard the warnings in this manual and on the equipment are not all inclusive Safety is not just a matter of responding to the warnings All the time you are working with your attachment you must pay attention to the hazards there might be and how to avoid them COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page 7 Safety and environ mental instructions HB 1000 The user must always perform a local risk assessment before starting a task This assessment also known as a Real Time Hazard Analysis ensures that the user stops and thinks about what she or he is going to do before starting to work Perform Real Time Hazard Analysis on site at least daily before starting up Determine escape route for emergency situation Identify potential hazards that could impact you your colleague the environment your product and or work method while you are performing the task Assess the risks and implement the actions needed to eliminate or reduce the risk Make sure that you do n
7. against pinhole leaks Use cardboard to check on a pinhole leak Stay clear from hot surfaces Wear proper PPE Wait for hydraulic oil inside the breaker to cool down before disassembly or service Oil inside the breaker may be extremely hot Do not handle hydraulic hoses connect disconnect while oil is hot Use approved PPE Flying fragments are an extreme hazard while driving in the tool retaining pin or other pins Use approved eye protection Use proper tools Use approved PPE Plug pressure and return line before washing the breaker to prevent water and dirt from entering into the breaker Pressurized air and or water can cause debris and or hot water to be blown out This can result in personal injury When pressurized air and or pressure water is used for cleaning wear protective clothing protective shoes and eye protection Eye protection includes safety glasses or a protective face shield The maximum air pressure for cleaning purposes must be below 205 kPa 30 psi The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi 3 12 FIELD REPAIR Place carrier on stable level ground before starting any installation service or maintenance on the product Release internal pressure from breaker and accumulator before service disassembly or scrapping Charge accumulator with nitrogen only Use approved PPE Do not attempt to lift turn or move heavy parts manually A sudden change of balance may resu
8. assembly HB 1000 11 Install shield plate and hose guides 12 Install mounting bracket 13 Grease mounting bracket screws and install them Torque them to specified setting 14 Install breaker to carrier ASSEMBLING THE PIN MOUNTED SIDE PLATES Check all parts for cracks and excessive wear Grease threads and bearing surfaces of spacer screws and lock washers Install side plates spacer screws and lock washers Torque screws crosswise to specified setting Install mounting bracket Grease screws with lock washers and nuts and install them Torque screws to specified setting Install hydraulic hoses O e eS ue des Install breaker to carrier Page 105 Workshop COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION 1000 Disassembly and assembly 1 3 DISASSEMBLING AND ASSEMBLING THE BREATHER TORQUES ADJUSTMENTS AND LUBRICANTS A BA050092 Item Specification Breather A 250 Nm Item Lubricant Breather thread and Thread bearing surface grease DISASSEMBLING THE BREATHER Warning The hydraulic pressure insidethe breaker must always be released before removing any of the plugs or valves 1 Set breaker vertically on floor Prevent breaker to fall down COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Workshop Page 1065 Disasse mbly and assembly HB 1000 2 Remove breather and O ring ASSEMBLING THE BREATHER 1 Check and dry all parts
9. at all time Special care should be given to dust noise and vibration related regulation Ignorance is no excuse for not following national law Familiarize yourself with the national safety legislation SITE SPECIFIC SAFETY REGULATIONS Site specific regulations must not contradict national safety regulations Site specific regulations should address issues like transportation of product or equipment access to site personal protective equipment PPE and working hours Site specific regulations should also cover the case of an incident occuring what to do who to contact and other questions Site specific regulations must be followed at all time in the same way as national safety regulations PERIODIC SAFETY INSPECTIONS It is important to thoroughly inspect the product before use to make sure it is safe to operate Look for defects and damage before any operation so that problems can be reported and fixed The operator is responsible to Check the breaker in accordance with the requirements of the operator s manual before during and after use and operation Safety features such as labels safeguards and others should be checked frequently and repaired immediately if damaged Respiratory silica dust is a hazard which requires special attention Regularly clean your working environment properly to minimize the dust level in the air PERIODIC MAINTENANCE Periodic maintenance is an essential procedure to ensure and
10. kg 400 950 bpm 90 140 bar 13 15 bar 75mm 0 0 5 5 mm BSPP internal 1 2 Return line connection T BSPP internal 1 2 Pressure line size minimum inner diameter Return line connection minimum inner diameter 12 5 mm eee Carrier weight 6 10t Specifications are subject to change without prior notice Including breaker standard tool and standard bracket Including breaker standard tool and standard bracket Depends on hydraulic parameters oil flow and pressure Operating pressure 50 bar Check carrier s lifting capacity especially with mounting bracket COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Specifications Page 92 DR 1000 Breaker specifications 1 2 MAIN DIMENSIONS 1073 1451 105 130 105 023 12 pcs BAO40002 y hs 93 Maintenance COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Breaker specifications HB 1000 1 3 MAIN DIMENSIONS 733 9 326 500 AS os 260 ie D ol 1 11 DL 1 I I ao 699 883 918 987 1582 Bec p 595 160 227 BAO40008 COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Specifications Page 214 1000 Breaker specifications 1 4 MOUNTING BRACKET Recommended minimum plate thickness is 20 mm After welding check flatness of the plate and mill sur
11. maintain safety and performance of the breaker Follow given instructions for maintenance and inspection of the breaker Regular inspections are especially important where hydraulic hoses are concerned NOTICE Poor quality of hydraulic oil lack of lubrication or too wide clearance between tool and tool bushing may destroy internal parts of the breaker COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page Safety and environ mental instructions HB 1000 PERSONAL PROTECTIVE EQUIPMENT PPE GENERAL HAZARD Lack of approved PPE may cause severe injury or death Wear approved PPE approved respirator approved hard hat approved ear protection approved safety boots approved safety gloves approved safety glasses Operators and anyone in the vicinity of the breaker MUST wear approved personal protective equipment PPE Proper PPE includes but is not restricted to Approved ear protection Approved respirative protection Approved eye protection Approved safety boots Approved hard hat Approved protective gloves Approved high visibility vest Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment Confine long hair Special conditions may require the use of additional PPE as specified in safe working procedures 2 3 INTENDED USE Intended use of machinery This hydraulic breaker is to be used as an attachment on a carrier in demolitio
12. may disable safety features and must not be applied If modifications and corrections that affect the maintenance operation safety and usability of the product are made without the written permission of the manufacturer the manufacturer is not responsible for any incidents resulting in death injury or property damage brought about by such modifications and corrections Should you consider a modification or correction necessary please ask your local dealer to contact the manufacturing and design team of the equipment Page 22 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety and environ mental instructions If a modification or correction as described above has been implemented without the manufacturing factory s permission its effect on warranty liability will be considered case by case Thus a warranty application may be rejected altogether 2 5 HAZARD ZONE DANGER ZONE CRUSHING HAZARD Getting caught by machinery movement may cause severe injury or death Keep yourself and bystanders out of hazard zone for host machine During installation check it may be required to be temporarily in the hazard zone Use approved PPE Take extreme care against flying objects Keep yourself and bystanders out of the hazard zone Stop operation immediately if bystanders enter the hazard zone There are several different hazard zone levels for this equipment The risks for bystanders in hazard zo
13. of lower tool bushing 84 ETE T CIO OLET 87 PEE 91 4 1 Breaker SD cifICallolis AEN reote Uoc eee 92 4 2 TOOL SD CHICATIONS en be a bd hne ad au 96 NOR RS AO PS 97 5 1 Disassembly and 100 52 Service tOOlS nein eere toes a ene E Det 119 COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page 3 Introduction INTRODUCTION THIS DOCUMENT This data transfer document is arranged to provide necessary product information for Steel Unlimited documentation team when designing their manuals Document contains information of the equipment and its safe operation It also contains maintenance information technical specifications and service instructions GENERAL HAZARD Faulty handling practice may cause death or severe injury READ UNDERSTAND and FOLLOW the instructions of the operator s MANUAL and safety LABELS Information for use consist of this manual the safety labels on the machinery the carrier manual and other information for proper and safe use of this machinery Instructions are an essential and integral part of the product Always keep them available for users Store
14. suitable seating in cab Steel Unlimited strongly recommends to use breaker only on carriers equipped with ROPS FOPS Visually check that all parts and bolts of the breaker are in place Check the tool retaining pins on a regular basis Check the tightness of the bracket bolts on a regular basis Flying fragments are an extreme hazard while driving in the tool retaining pin or other pins Use approved eye protection Use proper tools Use approved PPE Stop the engine when use is not required Make sure that proper ventilation of exhaust gases is available when engine is running Check the mounting pin locking mechanism on the carrier to pin mounted breaker or a mounting bracket for the bracket mounted breaker a regular basis Respiratory Silica Dust will cause severe injury or death Always wear an approved respirator Use vertical steel bars a separate plastic net or a plastic window for operator cab protection Use an air conditioned cab in high temperature applications metallurgical or similar as well as at high ambient temperature In high reach or similar bad ergonomy applications rest tense muscles at regular intervals This breaker is for professional use only Special conditions such as radioactive asbestos chemical poisonous or biological hazard environment require unconditional use of hazard specific methods and protective measures 3 8 TRAPPED PRESSURE IN HYDRAULIC SYSTEM Unreleased trapped pressure can cause s
15. the breaker must always be released before making any adjustments or repairs when the breaker is connected to the carrier There may also be pressurized oil trapped inside the breaker even if the breaker is disconnected from the carrier Release the hydraulic pressure according to the following instructions before opening any plugs or valve covers 1 Stopthe carrier engine 2 Operate the boom and breaker controls to release any pressure trapped inside the hoses Sa Wait 10 minutes for oil pressure to drop inside the breaker Close breaker inlet and outlet lines If you use quick couplers the disconnection automatically closes the breaker lines If the breaker line includes ball valves make sure that they are closed Warning This procedure does not release the pressure from the pressure accumulators Read the instructions dealing with the accumulator before disassembling the breaker Warning When you are inspecting or releasing the pressure from the pressure accumulators use safety glasses and cloves There can be oil in the accumulator and oil can spray out with gas Page 71 Maintenance COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Inspection of pressure in the low 3 INSPECTION OF PRESSURE IN THE LOW PRESSURE ACCUMUL ATOR LOCATION OF ACCUMULATORS The breaker has one accumulator a low pressure accumulator A The low pressure accumulator A is inside the back head The low p
16. the danger of breathing or inhaling dust Failure to comply will result in serious injury or death The related safety label on the breaker and the text on the label are shown below DUST HAZARD Breathing dust will cause death or severe injury Always wear approved respirator COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page 3 Safety during operation HB 1000 DANGER DUST HAZARD Breathing dust will cause death or severe injury Always wear approved respirator R010349 4 3 FLYING FRAGMENTS IN OPERATION Protect bystanders against flying chips of rock Do not operate the breaker or the carrier if people without proper PPE are near the equipment The safe distance for unprotected people is approx 40 m 130 ft The breaker must be stopped immediately when the operator observes people without proper PPE to come any closer than this Where there is need to work at closer distance to unprotected people or structures erect safety barriers that can stop flying fragments Also erect safety barriers if unprotected bystanders may be crossing through the hazard zone reasonably foreseeable misuse Protect yourself against flying chips of rock Flying objects or debris can cause serious injury or death To prevent injury to your eyes or to your ears wear eye protection and hearing protection when you operate the machine The European standard EN 474 1 on safety of earth moving machinery requires th
17. 7 Page 50 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION HB 1000 Breaker installation and removal 7 OPERATION 7 1 UNDERWATER USE d ii E i F 9 x AN s D Chasse 7 T j SI S om gt gt a Les Lig E n C 5 ia 0 c 1 A 4 s TED za v ora E a C1 ET A FX F L Cr 0010081 Do notusethe breaker under water If the seals get damaged in underwater use oil may escape into the environment such as rivers lakes or groundwater reservoirs Only a minor amounts of hydraulic oil is required to completely spoil drinking water for a very long time The strong pressure waves may damage the breaker if the space between piston and tool is filled with water If underwater use damages the seals water will enter the hydraulic circuit of the carrier This will result in expensive damage to equipment 7 2 IDLE STROKES Operating the breaker so that there is no material to be broken piston strikes to the hydraulic brake Constant idle strokes have a deteriorating effect on the breaker and the side plates These will then wear out quicker Vibration caused by constant idle strokes will damage the carrier structures and cause additional fatigue to the operator 7 3 BLANK FIRING Stop the breaker the moment the subject material is broken Operating the breaker piston without material under the tool is cal
18. 80 dB A could cause hearing impairment Wear approved hearing protectors 4 5 HIGH PRESSURE PINHOLE LEAKAGE Fine jets of hydraulic fluid at high pressure can penetrate the skin causing serious allergic reaction and gangrene A high pressure jet of hydraulic fluid may penetrate your skin and cause severe injury or death Do not touch fine jets of hydraulic fluid at high pressure Do not use your fingers to check for hydraulic fluid leaks Do not put your face close to suspected leaks Always hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid leak If fluid is injected into your skin you must get treatment immediately Seek treatment from a doctor who is familiar with this type of injury During breaker operation keep people away from the hydraulic hoses J Page 42 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety during operation Hydraulic fluid at system pressure may cause injury Before disconnecting or connecting hydraulic hoses stop the carrier engine and operate the controls to release pressure trapped in the hoses Make sure to let the hydraulic fluid cool down to ambient temperature before disconnecting the hoses Always use leakproof containers when you drain fluids Do not pour waste onto the ground down a drain or into any source of water Improper disposal of waste can threaten the environment Pote
19. Do not allow unauthorized personnel on the equipment During operation the tip of the tool may get extremely hot Do not operate the breaker near flammable liquids Page 38 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety during operation 4 2 AIRBORNE POLLUT ION DUSTHAZARD Breathing dust will cause death or severe injury Always wear approved respirator Protect yourself and bystanders from airborne pollution Breathing or inhaling dust particles will cause death or severe injury Always work with a respirator approved by the respirator manufacturer for the job you are doing It is essential that the respirator that you use protects you from the tiny dust particles which cause silicosis and which may cause other serious lung diseases Do not use the equipment until you are sure your respirator is working properly This means you must check the respirator to make sure that it is clean that its filter has been changed and to otherwise make sure the respirator will protect you in the way it is meant to Make sure the dust suppression system in your equipment is working properly If the dust suppression system is not working properly stop working immediately Always make sure dust has been cleaned off your boots and clothes when you leave your shift The smallest particles of dust are the most harmful They may be so fine that you can not see them Remember you must protect yourself from
20. ERSONAL PROTECTIVE EQUIPMENT PPE SYMBOLS Personal Protective Equipment PPE symbols have the same layout as mandatory action symbols and are mandatory where applicable PPE symbols specify the protective measure which must be taken to eliminate a hazard pointed out in the safety message This is not a matter of choice or judgement but an undisputible instruction J Page 10 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Wear Approved Respirator Wearing an approved respirator is mandatory in equipment operation Wear Approved Hard Hat Approved hard hat is mandatory in equipment handling Wear Approved Safety Gloves Approved safety gloves are mandatory in equipment handling HAZARD SYMBOLS Safety and environmental instructions Wear Approved Ear Protection Approved ear protection is mandatory in equipment handling Wear Approved Safety Boots Approved safety boots are mandatory in equipment handling Wear Approved Eye Protection Approved safety glasses are mandatory in equipment handling Hazard symbols indicate the nature of a possible hazard Hazard symbols are indicated by a yellow triangle with black symbols and black frames COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page 11 Safety and environmental instructions General Hazard This symbol is used where the hazard is not easily specified Hanging Loads Hazard related to lifti
21. G PREVENTION CRUSHING HAZARD Moving or falling equipment objects or parts may cause severe injury or death Keep yourself and bystanders out of hazard zone Never mount or dismount the breaker to or from the carrier with the breaker in vertical position and supported by tool in ground only The breaking action of the tool will make even relatively hard ground extremely unstable Make sure that the carrier is able to properly support the load of the product in all directions and in all working situations Stability is an issue especially in long reach applications COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page 9 Safety section HB 1000 Support the breaker properly when you perform work beneath the breaker Do not depend on the hydraulic cylinders in order to support the breaker A breaker can fall if a control lever is moved or if a hydraulic line breaks Also a breaker can fall if a hydraulic cylinder drifts Whenever there are breaker control linkages the clearance in the linkage area changes with movement of the breaker Stay clear of all rotating parts and all moving parts Unless you are instructed otherwise never attempt adjustments while the machine is moving or while the engine is running During storage and transportation make sure that the load is secured in a proper way Use proper pallets and make sure the ground is able to support the load 3 5 REMOVAL FROM PACKAGE amp INSTALLATIO
22. N Clean ice snow water oil or grease spills from the floor to prevent slipping tripping or falling Use approved safety boots Dispose properly recycle of spill oil and grease Make sure that lighting conditions are good enough to allow for safe working Use proper and approved lifting accessories for lifting of parts heavier than 20 kg Do not attempt to lift turn or move heavy parts manually A sudden change of balance may result in unexpected movement of equipment Visually check that all parts and bolts of the breaker are in place Check the breaker weight from the serial label on breaker Check weight of the mounting bracket and tool as well Sudden movement of parts which were stuck but become loose may cause crushing of body parts Beware of sharp edges of parts Beware of noise from pneumatic or other tools Wear approved PPE Make sure that the carrier lifting and transport equipment has proper capacity to carry the weight of the product Secure the product properly during transportation Follow proper transportation practice Secure the product properly during installation Always keep the breaker in horizontal position while mounting to carrier Agree with your colleagues on site on the use of hand signals Do not assume any knowledge of signals Place the carrier on stable level ground before starting any installation service or maintenance on equipment Do not climb on the product There is always hazard zone ar
23. OOL CONTACT AREA Remove the tool and wipe excessive grease off BREAKER CONTROL VALVE DOES NOT OPEN When operating the breaker control valve check that the pressure line pulsates this indicates the breaker control valve is opening If the valve does not operate check the operating means mechanical connections pilot pressure or electrical control RELIEF VALVE IN HYDRAULIC CIRCUIT OPENS AT A LOW PRESSURE BREAKER OPERATING PRESSURE IS NOT REACHED Check the installation Check the relief valve operation Adjust the relief valve in hydraulic circuit Measure the high pressure in the breaker inlet line EXCESSIVE BACK PRESSURE IN RETURN LINE Check the installation Check the size of the return line LEAKAGE FROM PRESSURE TO RETURN THE CARRIER HYDRAULIC CIRCUIT Check the installation Check the pump and the other hydraulic components FAILURE IN BREAKER VALVE OPERATION Service the breaker TOO HIGH PRECHARGE PRESSURE OF THE GAS PISTON ACCUMULATOR Check the precharge pressure and adjust it to a correct value If there spray oil out from the accumulator service the breaker PISTON FAILURE Service the breaker Page 87 Maintenance COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Troubleshooting HB 1000 7 2 THE BREAKER OPERATES IRREGULARLY BUT THE BLOW HAS FULL POWER NOT ENOUGH FEED FORCE FROM EXCAV ATOR Refer to the correct working methods RELIEF VALVE IN HYDRAULIC CIRCUIT OPENS AT A LOW PRESSURE BREAKER O
24. PERATING PRESSURE IS NOT REACHED Check the installation Check the relief valve operation Adjust the relief valve in hydraulic circuit Measure the high pressure in the breaker inlet line FAILURE IN BREAKER VALVE OPERATION Service the breaker 7 3 THE BREAKER OPERATES IRREGULARLY AND BLOW HAS NO POWER THE WORKING METHOD IS NOT CORRECT Refer to the correct working methods RELIEF VALVE IN HYDRAULIC CIRCUIT OPENS AT A LOW PRESSURE BREAKER OPERATING PRESSURE IS NOT REACHED Check the installation Check the relief valve operation Adjust the relief valve in the hydraulic circuit Measure the high pressure in the breaker inlet line GAS PRESSURE IN THE GAS PISTON ACCUMULATOR TOO LOW Check the pressure and fill the gas piston accumulator the correct prefill pressure FAILURE IN BREAKER VALVE OPERATION Service the breaker 7 4 IMPACT RATE SLOWS DOWN OIL HAS OVERHEATED OVER 80 176 F Check for a fault in the oil cooling system or an internal leak in the breaker Check the hydraulic circuit of the carrier Check the line size Assemble an extra oil cooler HYDRAULIC OIL VISCOSITY TOO LOW Check hydraulic oil EXCESSIVE BACK PRESSURE IN RETURN LINE Check the installation Check the size of the return line COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 88 1000 Troubleshooting RELIEF VALVE IN HYDRAULIC CIRCUIT OPENS AT A LOW PRESSURE BREAKER OPERATING PRESSURE IS NOT REACHED C
25. R TOOL REMOVAL BA030122 Item Wear limit Tool diameter worn out 73 mm BA030150 Item Wear limit Tool retaining pin worn out 27 mm Item Lubricant Tool and tool retaining pins Tool grease OF TOOL Warning The hydraulic pressure inside the breaker must always be released before removing the tool After operating the breaker wait 10 minutes for oil pressure to drop inside the breaker COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 80 1000 Removal of tool Warning Use caution when you remove the breaker tool The tool can be very hot after the tool has been in operation When you remove the breaker tool wear protective gloves 1 Position the breaker on level ground 2 Putthe carrier transmission in neutral Make sure the parking brake is engaged Stop the engine 4 Remove the plugs from the breaker housing 5 Remove the retaining pin from the front head using the drift pin and the breaker Page 81 Maintenance COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Removal of tool HB 1000 6 Remove the tool retaining pin from the front head using the drift pin and the breaker 8 If necessary use a suitable lifting device to remove the tool Refer to tool specification for the weight of the tool 9 Inspect the breaker tool and the lower tool bushing for wear 10 Refer to specifications for the wear limit for the tool and the lower
26. TION NOT CORRECT FOR BREAKER Refer to the recommended use and the correct working methods ROUGH OPERATING PRACTICES Refer to the recommended use and the correct working methods TOOL DOES NOT GET ENOUGH LUBRICANT Refer to the recommended use and the correct working methods TOO LONG TOOL Use the shortest tool possible Refer to the recommended use and the correct working methods RAPID WEAR OF TOOL Refer to the recommended use and the correct working methods 7 7 FURTHER ASSIST ANCE FURTHER ASSISTANCE If you need further assistance prepare to answer the following questions when calling your dealer Model and serial number Working hours and service history Carrier model Installation Oil flow operating pressure and return line pressure if known Application Has the product operated normally before COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 90 SPECIFICA TIONS Page 91 Maintenance COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Breaker specifications HB 1000 1 BREAKER SPECIFICATIONS TECHNICAL SPECIFICATIONS Description Minimum working weight 2 Breaker weight Minimum working weight 3 Breaker weight Impact rate Operating pressure Pressure relief setting min Pressure relief setting max Oil flow range Low pressure Back pressure max Input power max Tool diameter Pressure line connection P 420 kg 345 kg 380 kg 345
27. TION Operation Page 57 Operation HB 1000 If the ambient temperature is below 20 C 4 F preheat the breaker and the tool before you start to operate the breaker Warm up the hydraulic oil of the excavator to 30 C 40 80 F 105 F This allows you to avoid breaking the membrane and the tool These components will remain warm during operation of the breaker When the hydraulic oil temperature exceeds 80 C 176 F you may add an auxiliary oil cooler When you operate the breaker at temperatures above 80 C 176 F the life of the seals will be reduced When you operate the breaker in ambient temperatures above 30 C 86 F you can use an oil with higher viscosity The use of oil with higher viscosity can improve the life of the breaker when you operate the breaker in high ambient temperatures Refer to the Owner s Manual of the carrier for more information 7 9 PROPER FEED FORCE Push the breaker firmly down Too little feed will cause vibration to the boom the carrier and the operator Too much feed force will cause the front of the tracks to rise in the air When the material breaks suddenly the carrier will fall down causing excessive vibrations to the operator and the carrier 7 10 ALIGNMENT OF THE TOOL Apply feed force along the axis of the tool and not in an angle to the material Operating with a tilted tool will cause heavy seizure and premature failure of the tool and the piston Ste
28. ase the weight of the attachment more than the lifting capacity of the carrier allows A too light bracket may not be able to support the breaker properly Faulty bracket geometry may lead to contact and expensive damage to the boom cylinders Mount or dismount the breaker to or from the boom only while the breaker is in a horizontal position If the breaker is in a standing position it may fall over due to insufficient support from ground or due to sudden movement of the boom Tighten the bracket bolts to the proper torque value When measuring breaker operating pressure you are in the breaker s hazard zone Stay clear of moving equipment Use proper PPE Failure to comply could result in serious injury or death Page 46 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Transportation storage and setting HB 1000 After maintenance or a long period of storing fill the breaker with oil Lift the breaker off the ground and press the breaker s operating switch and drive oil through the breaker for a couple of minutes T Aa cona 2909 9275 E FC WE FE vies et BAD 3t COPYRIGHT O 2015 SANDVIK MINING AND CONSTRUCTION Operation Page 27 1000 Breaker installation and removal 6 BREAKER INSTALLATION AND REMOVAL 6 1 PREPARING FOR INSTALLATION Before you install the breaker verify the setup of the hydraulic system for the carrier or perform the following st
29. assembly HB 1000 DISASSEMBLING THE FRONT HEAD 1 Set front head upside down on floor 2 Remove retaining pins 3 Remove lower tool bushing a ER 4 Remove retaining pins 5 Remove upper tool bushing ASSEMBLING THE FRONT HEAD 1 Clean and dry all parts carefully Check all parts for cracks and excessive wear See wear limits for upper tool bushing in specifications 2 Apply thread grease on outer surface of upper tool bushing Lubricate inner surface of upper tool bushing with tool grease Page 117 Workshop COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION 1000 Disassembly and assembly 3 Install upper tool bushing and retaining pins Note bushing direction 4 Apply thread grease on contact surface of lower tool bushing and front head Install lower tool bushing retaining pins Note bushing direction 5 Lubricate inner surfaces of lower tool bushing with tool grease COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Workshop Page 118 Service tools HB 1000 2 SERVICE TOOLS 2 1 SPECIAL SERVICE TOOLS Item Name Part no Qty Picture Kit Accumulator charging 166460 1 kit incl parts 1 2 1 2 1 Accumulator charging 953511 1 1 1 A kit incl parts 1 1 1 4 RE 11 Filling valve 954076 ANA 1 3 Pressure gauge 25 bar 953990 1 4 gauge 100 bar 954075 amp 12 14 Ww Name Part Qty Picture Pres
30. at adequate operator s protection such as bullet proof glass mesh guard or an equivalent protection is used on carriers equipped with a breaker Always make sure the machine is equipped with a flying object guard When measuring breaker operating pressure you are working in the breaker s hazard zone Stay clear of moving equipment Use proper PPE Failure to comply could result in serious injury or death The safety label on the breaker is shown below FLYING OBJECTS HAZARD Fragments fly up to 40 m 130 ft and could cause death or severe injury Stop operation when a person enters hazard zone 7 Page 40 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety during operation Wear approved personal protective equipment FLYING OBJECTS HAZARD Fragments fly up to 40 m 130 ft and could cause death or severe injury Stop operation when a person enters hazard zone Wear approved personal protective equipment 010350 4 4 NOISE breaker in operation creates high noise level Always wear ear protection to prevent personal injury The safety label on the breaker is shown below NOISE HAZARD Continuous exposure to noise above 80 dB A will cause hearing impairment Wear approved hearing protectors COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page 41 Safety during operation HB 1000 NOISE HAZARD Continuous exposure to noise above
31. at hand Advise site manager when you leave site Agree with your colleagues on site on the use of hand signals Do not assume any knowledge of signals Wear approved PPE approved safety boots approved safety gloves approved safety glasses approved ear protection approved hard hat If your PPE is not functioning properly get new PPE equipment Only operate the product when in fit condition Beware of sharp edges of parts Common sense is the most important part of safety in standard breaker applications 2 1 SAFETY LABELS This section includes explanations of safety symbols and labels used on the breaker and in information for use SIGNAL WORDS The following signal words and symbols are used to identify safety messages in these instructions The signal word DANGER in white font on red background together with a safety alert symbol indicates a hazardous situation which if not avoided will result in death or serious injury J Page 8 Operation COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION HB 1000 Safety and environmental instructions DANGER DO10097 The signal word WARNING in black font on orange background together with a safety alert symbol indicates a hazardous situation which if not avoided could result in death or serious injury D010098 The signal word NOTICE indicates a situation which if not avoided could result in damage to property or environment A NOTICE situation will not i
32. carefully Install O ring to breather Grease breathers thread and install it p e 5 Torque breather to specified setting Page 107 Workshop COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION 1000 Disassembly and assembly 1 4 DISASSEMBLING AND ASSEMBLING THE TIE RODS TORQUES ADJUSTMENTS AND LUBRICANTS s A e 9 9 BADSO104 Item Specificatio n Tie rod A 590 Nm Item Lubricant Tie rod threads and Thread bearing surfaces tie rod nuts DISASSEMBLING THE TIE RODS 1 Set breaker vertically on floor Prevent breaker to fall down 2 Mark each tie rod and its tie rod nuts as pairs Mark also each tie rod s location on breaker 3 Open tie rod nuts crosswise COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Workshop Page 108 Disasse mbly and assembly HB 1000 4 Remove tie rod nuts tie rods and washers ASSEMBLING THE TIE RODS 1 2 Check and dry all parts carefully Use crack detecting equipment to check if there are cracks in rod threads If cracks are detected change tie rod and its nuts Also change diagonal tie rod and nuts Grease threads and bearing surfaces of tie rods tie rod nuts washers and back head Install tie rods tie rod nuts and washers Check each tie rod has correct nuts as it is pair Also check location of each tie rod in breaker is same as before disassembly Use torque wrench to tighten tie rods in small steps cro
33. ctions which have disappeared been damaged painted over come loose or do not meet the legibility requirements for safe viewing distance must be replaced before operating the product If a safety label is attached to a part that is replaced install a new safety label on the replacement part If this manual is available in your language then the safety labels should be available in the same language There are several specific safety labels on this breaker Please become familiarized with all safety labels The location of the safety labels is shown in the illustration below When you clean the safety labels use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the safety labels Solvents gasoline or harsh chemicals could loosen the adhesive that secures the safety labels Loose adhesive will allow the safety label to fall COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page 13 1000 Safety and environ mental instructions DANGER DUST HAZARD Breathing dust will cause death or severe injury FLYING OBJECTS HAZAR Fragmanta up te 40 130 ft and could cause death or sever injury Stop operation when a porson enters hazard zor Vinar approved porsonal protective equipment Always wear approved respirato IGNORING INSTRUCTIONS HAZARD Faulty handling practice could caus death or sovore injury Read and follow the instructions in the ope
34. cumulator Item Torque Flange plug 25 Nm COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 76 1000 Recharging the low pressure RECHARGING THE LOW PRESSURE ACCUMULATOR HIGH PRESSURE HAZARD Use only Nitrogen N2 for charging accumulators The use of other gases may cause accumulators to explode Failure to comply could result in serious injury or death 1 Place the breaker in a horizontal position with the low pressure accumulator recharging point faced upwards During recharging the piston may move unexpectedly Make sure the tool is fully extracted and that no people or equipment are near the end of the tool 2 Remove the flange plug from the filling plug on the breaker with an allen key 4 Page 77 Maintenance COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Recharging the low pressure HB 1000 3 Pull the handle C out and leave it in this position otherwise gas leaks out of the accumulator Open the discharge valve D on the charging device by turning the knob 4 Tighten the recharge valve to the filling plug on the breaker from E If the recharge valve does not easily fit to the breaker connect first adapter by one end F to the breaker and then the recharge valve E to the other end of the adapter G Remove the cap B from the charging device 6 Connect the hose of nitrogen gas bottle to charging device at A Carefully
35. d Use of this breaker is specifically prohibited if Operator has not read and understood this manual Operator has not read and understood operator s manual for the carrier safety feature of the equipment is defeated for whatever reason Operator has not performed Real Time Hazard Analysis RTHA of the site and is not aware of escape route for emergency situation Operator is without proper and approved personal protective equipment People are in hazard zone of breaker breaker is outside the technical limits as described in the technical specification This applies especially to carrier weight hydraulic oil pressure and oil flow WARNING breaker or lifting eye on breaker must not be used to lift external loads WARNING breaker must not be used in intoxicated condition alcohol drugs when tired or when otherwise in unfit condition fever or illness Foreseeable misuse COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page 21 Safety and environ mental instructions HB 1000 Foreseeable misuse may be due to carelessness or to pressure to keep product running at any time Reasonably foreseeable misuse is extremely likely to cause considerable damage to people or property Examples of such behavior are Operating the product outside limits of use Do not use the product on carrier with insufficient lifting capacity Do not operate the product under water Do not operate the product outs
36. draulic breaker place the carrier on a level stable surface If the carrier must be placed on a slope or on a rough surface be careful during the operation Never operate the hydraulic breaker when you cannot see the hydraulic breaker Always position the carrier so that you can see the hydraulic breaker and the area of work NOTICE Do not use the dropping force of the hydraulic breaker to break rocks or other hard objects This will cause high vibration level to operator and cause structural damage to the breaker and carrier Steel Unlimited considers this a faulty operation technique that is not covered by warranty NOTICE Do not use the sides or back of the hydraulic breaker to move rocks or other hard objects Doing this can cause damage not only to the breaker but to the stick or boom cylinder NOTICE Do not operate the breaker with any of the cylinders fully retracted or extended Doing this can cause structural damage to the carrier resulting in reduced machine life 1 Before you start the hydraulic breaker close the front window 2 Only use the hydraulic breaker to break rocks concrete and other hard objects Before you start hydraulic breaker operation place the carrier on a level stable surface If the carrier must be placed on a slope or on a rough surface be careful during the operation 7 Page 52 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Operation Set the carrier s drive to neut
37. e product Place the carrier on stable level ground before starting any installation service or maintenance on the product Do not climb on the product There is always a hazard zone around the product Use a proper working platform for safe access Where working platforms are used make sure to place this on level and stable ground Keep yourself and bystandersoutof the hazard zone of thecarrier Beware of heavy vibration Do not touch a vibrating breaker or pulsating hoses Vibration makes it extremely difficult to take off hands Use a plastic spiral over hoses to protect against pinhole leaks Use cardboard to check on a pinhole leak Wear proper PPE Visually check that all parts and bolts of the breaker are in place Check the tool retaining pins on a regular basis Check the tightness of the bracket bolts on a regular basis Flying fragments are an extreme hazard while driving in the tool retaining pin or other pins Use approved eye protection Use proper tools Use approved PPE Place the boom in proper position to allow for an ergonomic way of connecting the hoses Check the hose ends for proper connection on a regular basis Use only suitable bolts with proper capacity for the mounting of the breaker COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page 31 Safety section HB 1000 Always check the breaker function and installation outdoors Stop the engine when use is not required Make sure that proper vent
38. e to collect all oil in a proper container and to dispose of it properly 1 OUT 010013 6 Open the pressure line and tank line valves on boom 7 Checkthatoil flow operating pressure and return line pressure are within specification COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page 49 Operation HB 1000 6 3 REMOVING THE BREAKER 1 Move the carrier and the breaker to solid clean ground 2 Lower the boom and the breaker to the ground placing the breaker on solid and level wooden blocks Do not place yourself or other people under the breaker or the boom at any instance Sudden unexpected movements of boom may crush your limbs 3 Stop the engine Turn off the main switch Move the controls to release trapped pressure 4 Close the pressure line and tank line valves on the boom to prevent oil from leaking to the ground 5 Disconnect the hoses Do not to let oil inside the breaker housing Make sure to collect all the oil in a proper container and to dispose of it properly Plug the hoses and pipeline ends immediately in order to prevent dust from entering the system 6 Remove the mounting bracket or mounting pins Take care not to be hit by released pins or links 8 i nn kV L M A e AQ TT YY d _ 10045
39. ed Warning This procedure does not release the pressure from the pressure accumulators Read the instructions dealing with the accumulator before disassembling the breaker Warning Release the pressure from the pressure accumulators before disassembling the breaker When you are releasing the pressure from the pressure accumulators use safety glasses and cloves There can be oil in the accumulator and oil can spray out with gas COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Specifications Page 98 Disasse mbly and assembly HB 1000 1 2 REMOVING THE HOUSING AND SIDE PLATES SPECIFICATIONS FOR THE HOUSING AND SIDE PLATES 050014 050167 Item Specification Mounting bracket screws 340 Nm A Spacer mountingscrews 1200 Nm B Shield plate mounting 70 Nm screws C Pin mounted side plate 1180 Nm mounting screws D Page 99 Workshop COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION 1000 Disassembly and assembly DISASSEMBLING THE HOUSING AND VIBRATION DAMPENING Warning The breaker must be secured from falling down in either direction when handling it Check that the lifting capacity of the hoist you are using is sufficient for the job 1 Remove the tool and disconnect the breaker from the carrier 2 Remove mounting bracket COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Workshop Page 100 Disasse mbly and assembly HB 1000 4 Remove buffer and spacer screw
40. el Unlimited considers this a faulty operation technique that is not covered by warranty Move the breaker carefully towards the rock Dropping the breaker will cause high vibration level to operator and cause damage to breaker and host machine 7 11 OPERATION PRECAUTION Do not operate the breaker continuously in one place The tip of the tool will heat get soft and wear extremely fast Steel Unlimited considers this a faulty operation technique that is not covered by warranty Always begin breaking the material at an edge trying to remove reasonably sized pieces This is the most efficient way to operate the breaker Do not operate the breaker at more than fifty percent 50 engine speed Raising the engine speed more than necessary does not increase breaker force 7 Page 58 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Operation With high engine speed hydraulic oil temperature will rise and internal components will be damaged Especially during winter time warm up the hydraulic oil of the carrier to 30 40 C 80 F 105 F before breaker operation 7 12 STOPPING OPERATION Before leaving the carrier always lower the boom so that the carrier is stable Never leave the machine with the engine running Always engage the parking breaks before leaving the controls Stop operation immediately if the hoses of the breaker vibrate excessively Stop operation immediately if hydraulic oil
41. el Unlimited dealer about changing the hydraulic fluid The breakers are test run at the factory with in standard hydraulic oil and will have small quantities of oil inside Consult your carrier manufacturer for proper quality requirements contamination oxidation moisture of the hydraulic fluids whether it be special fluids or hydraulic oil COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 66 MAIN I ENANCE Page 67 Lubrication COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Routine maintenance HB 1000 1 ROUTINEMAINTENANCE This Steel Unlimited breaker is built to last and will provide years of trouble free operation provided it is properly used and maintained 1 1 INSPECTION AND MAINTENANCE BY THE OPERATOR HIGH PRESSURE PINHOLE LEAK HAZARD A high pressure jet of hydraulic fluid may penetrate your skin and cause severe injury or death Do nottouch fine jets of hydraulic fluid at high pressure Do not use your fingers to check for hydraulic fluid leaks Do not put your face close to suspected leaks NOTICE Accumulated grease and oil on a work tool is a fire hazard NOTICE Remove debris with steam cleaning or high pressure water at any time a significant quantity of oil is spilled on the breaker COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 68 1000 Routine maintenance Before starting the breaker be sure to inspect the breaker referr
42. eps Verify the setting of the relief valve for the auxiliary system If the pressure is not correct adjust the relief valve to the proper pressure setting Verify the back pressure of the return flow of the hydraulic system Refer to the Specifications section for the proper specifications for your machine For more information consult your Steel Unlimited dealer Remove the lifting eye from the breaker housing and put bolt in place before starting operation If the lifting eye is left in its place heavy vibration will create cracks in housing Page 48 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Installation and removal HB 1000 6 2 INSTALLING THE BREAKER Warning Installing the breaker to the carrier or removing the breaker from the carrier is not allowed by one person only Warning The breaker must be secured from falling down in either direction when handling it Check that the lifting capacity of the hoist you are using is sufficient for the job 1 Move the carrier to the breaker taking care not to hit any bystanders 2 Lower the boom carefully towards the breaker Do not place yourself or other people under the breaker or the boom at any instance Sudden unexpected movements of boom may crush your limbs Mount the breaker on the boom Take care not to be hit by pins or links 4 Tighten the bracket bolts to the proper torque value Remove protective caps Connect the hoses Make sur
43. erating the breaker with the carrier s cylinders either fully extended or fully extracted will cause damage to the cylinders COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page 61 Operation HB 1000 7 17 STARTING THE BREAKER AFTER MAINTENANCE OR LONG BREAK OF WORKING After the maintaining or long period of storing fill the breaker with oil Lift the breaker off the ground and press the breaker operating switch and drive oil through the breaker for a couple of minutes SS WT F ru af LL P L c RES AS POO Mo ROM 54265 BA Cer 1 Page 62 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION LUBRICATION COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Lubrication Page 63 Greasing the breaker HB 1000 1 GREASING THE BREAKER While the breaker is mounted on the carrier apply down pressure on the tool Failure to apply down pressure may allow the grease to enter between the tool and the piston The subsequent impact of the piston on the grease will generate an extremely high pressure and destroy internal parts of the breaker Pump grease into the grease fittings as indicated on the breaker to apply a proper amount of grease inside tool bushings 1 With the breaker mounted on the carrier apply down pressure to the tool in vertical position 2 Fillthe cavity with proper grease Use an NLGI NO 2 grease for proper lubrication
44. ey all local safety instructions 3 2 PACKING TRANSPORTATION AND STORAGE Stay clear of hot surfaces Wear approved PPE Use proper and approved lifting accessories for lifting of parts heavier than 20 kg Do not attempt to lift turn or move heavy parts manually A sudden change of balance may result in unexpected movement of equipment Check breaker weight from the serial label on breaker Check weight of the mounting bracket and tool as well Especially with pin mount breaker check the combined weight of the breaker and quick hitch mounting bracket Make sure that the carrier the lifting and the transport equipment have proper capacity to carry the weight of the product During transport secure other parts such as hoses tools and tool box properly so that these cannot move uncontrolled Secure the product properly during transportation and storage Follow proper transportation practices Short term storage in horizontal position only Store the product horizontally on level ground which is able to support the load Store and transport the product on pallet with proper load capacity Do not stack products or pallets with products on top of each other COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page 7 Safety section HB 1000 3 3 PRESSURIZED GAS IN ACCUMULATOR HIGH PRESSURE HAZARD Faulty handling of pressurized accumulator will cause death or severe injury READ WORKSHOP MANUAL before disassembl
45. f the housing Refer to the Operation and Maintenance Manual of the carrier for additional information on transporting the carrier COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page 5 1000 Transportation storage and setting 5 2 STORAGE Observe the following points when the breaker is stored In this way the vital parts of the attachment are protected from rust and the machine is ready to beinstalled whenever necessary Make sure the storage area is dry Remove the tool from the hydraulic breaker Protect the lower end of the piston the tool and the tool bushings well with grease everywhere within the hydraulic breaker Seal the connections with clean plugs to prevent oil leakage dirt from getting into couplings Store the product in the vertical position Make sure the product can not fall 5 3 SETTING UP Verify that the breaker is compatible with the carrier Consult your Steel Unlimited dealer for more information Verify that all parts you have specified are delivered Verify that the mounting bracket standard or quick hitch is the correct mounting bracket for the carrier and the breaker Verify that the oil hoses are specified for maximum pressure relief setting If the carrier is equipped with a quick hitch mounting bracket consult the operating manual of the quick hitch bracket before you attempt to mount the breaker An excessively heavy bracket may incre
46. face as needed Maximum acceptable deviation from flatness is 1 mm Page 95 Specifications COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Tool specifications HB 1000 2 TOOL SPECIFICATIONS BA040005 Tool Part no Length Weight Diameter Chisel A 60 0619 750 mm 24 kg 75 mm Moil point B 60 0620 25 kg 75mm Pyramid C 60 0621 750 23 kg 75 mm Sbe O 9015 SANDVIK MINING AND CONSTRUCTION Specifications Page 96 W ORKSHOP Page 97 Workshop COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Disasse mbly assembly 1 DISASSEMBLY AND ASSEMBLY 1 1 RELEASING HYDRAULIC PRESSURE FROM BREAKER RELEASING PRESSURE Warning The hydraulic pressure inside the breaker must always be released before making any adjustments or repairs when the breaker is connected to the carrier There may also be pressurized oil trapped inside the breaker even if the breaker is disconnected from the carrier Release the hydraulic pressure according to the following instructions before opening any plugs or valve covers 1 Stopthe carrier engine 2 Operate boom and breaker controls to release any pressure trapped inside hoses Wait at least 10 minutes for oil pressure to drop inside the breaker 4 Close breaker inlet and outlet lines If quick couplers are used disconnection automatically closes breaker lines If breaker line includes ball valves please make sure that they are clos
47. heck the installation Check the relief valve operation Adjust the relief valve in hydraulic circuit Measure the high pressure in the breaker inlet line LEAKAGE FROM PRESSURE TO RETURN EXCAVA TOR HYDRAULIC CIRCUIT Check the installation GAS PRESSURE IN THE GAS PISTON ACCUMULATOR TOO LOW OR TOO HIGH Check the pressure and fill the gas piston accumulator the correct prefill pressure FAILURE IN BREAKER VALVE OPERATION The breaker must be serviced 7 5 OIL OVERHEATS APPLICATION NOT CORRECT FOR BREAKER Refer to the recommended use and the correct working methods THE CARRIER OIL COOLER IS DIRTY Check and clean the oil cooler COOLING CAPACITY OF THE CARRIER OIL COOLER IS TOO SMALL Assemble an extra oil cooler RELIEF VALVE IN HYDRAULIC CIRCUIT OPENS AT A LOW PRESSURE BREAKER OPERATING PRESSURE IS NOT REACHED Check the installation Check the relief valve operation Adjust the relief valve in hydraulic circuit Measure the high pressure in the breaker inlet line HYDRAULIC OIL VISCOSITY TOO LOW Check hydraulic oil LEAKAGE FROM PRESSURE TO RETURN IN THE CARRIER HYDRAULIC CIRCUIT Check the installation Check the pump and the other hydraulic components INTERNAL OIL LEAK IN THE BREAKER Service the breaker EXCESSIVE BACK PRESSURE IN RETURN LINE Check the installation Page 89 Maintenance COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Troubleshooting HB 1000 7 6 RECURRENT TOOL FAILURE APPLICA
48. ide other limits of use Always perform site and equipment inspection before operation RTHA Non professional operation Do not operate equipment without proper training Do not operate if you are not in fit condition Operating broken equipment NOTICE Stop immediately when you observe failure on structures or hydraulic leak Foreseeable misuse is not an acceptable excuse to cause considerable damage to equipment environment or people Liability Steel Unlimited will not accept any liability for injury to personnel or damage to equipment caused by unauthorized use negligence of user obligations or unauthorized modification of this breaker 2 4 MODIFICATIONS AND CORRECTIONS TO THE PRODUCT All modifications and corrections not authorized in the maintenance manuals or which may affect the maintenance operation safety and availability of the product need to be approved in writing by the manufacturer before implementation Approval requires a careful risk assessment taking into consideration the known risks and any new risks that the modifications may cause Changes and modifications without proper risk assessment elimination or reduction of risk and without appropriate safety measures may lead to death serious personal injuries or damage to property Unauthorized modifications may add additional weight to the equipment This may affect stability during lifting and stability of the carrier Unauthorized modifications
49. ilation of exhaust gases is available when the engine is running Check the mounting pin locking mechanism on the carrier for a pin mounted breaker or the mounting bracket for a bracket mounted breaker on a regular basis Clear all obstacles that are in the path of the machine Beware of hazards such as wires and ditches Check the stability of the level where you are working Falling down a level with carrier will cause severe injury or death Know the width of your equipment in order to maintain proper clearance when you operate the equipment near fences or near boundary obstacles Be aware of high voltage power lines and power cables that are buried If the machine comes in contact with these hazards serious injury or death may occur from electrocution Be aware of water and sewage pipelines that are buried 3 7 OPERATION Make sure that the lighting conditions are good enough to allow for safe working Move carefully on site to avoid tripping slipping or falling Use approved safety boots Secure the product properly during transportation Follow proper transportation practice Store and transport the product on pallet with proper load capacity Make sure that carrier lifting and transport equipment has proper capacity to carry the weight of the product The breaker or the lifting eye on the breaker must not be used to lift external loads Place the carrier on a stable level ground before starting any installation service
50. im plates under the lifting eye or rotating lifting eyes to avoid unfavorable load direction on lifting eye Do not use the lifting eye on the impact unit for lifting of complete breaker Do not use the breaker or the breaker s tool for lifting of objects In most cases the safe lifting capacity of the carrier is extensively utilized with the weight of breaker bracket and tool Page 26 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety section Safety instructions for lifting Below are some common Safety instructions concerning lifting operations In addition to this always observe the national standards for machines and lifting tackles strictly Note that the list below is not all inclusive Always ensure that the procedure you choose is safe for yourself and bystanders not lift load over people Allow nobody to go under the hoisted load Do not lift people and never ride the hoisted load Avoid side pull of the load Make sure you take up the slack slowly Start and stop carefully Lift load a few centimeters and verify it before proceeding Make sure the load is well balanced Check for any loose items Never leave the suspended load unattended Maintain load control at all times Never lift a load heavier than the rated capacity Inspect all lifting equipment before use Do not use twisted or damaged lifting equipment Protect the lifting equipment from sharp corners Ob
51. ing to the below list Tighten all loose bolts nuts and fasteners to proper torque and replace damaged or missing ones Inspect the bracket mounting bolts the tie rods and the accumulator bolts Tightenloose hose and pipe fittings Inspect for visible damage to hoses and leakages on hoses and pipes Check also the hydraulic flanges for proper torque Inspect the pipes for the breaker and the oil hoses If you are using a greasing device check that as well Breaker oil leaks Inspect the connections of the back head and the cylinder Inspect the clearance between the front head and the tool If leakage occurs at hydraulic hose connections tighten or replace the fittings Other leakages require workshop service Do not operate the breaker as this will cause expensive damage to the internal parts piston cylinder Inspect the tool and bushing for abnormal wear and cracks Replace tool when it is worn out Inspect the lower tool bushing for wear and replace if required Steel Unlimited strongly recommends the use of original tools which are designed to be compatible with internal breaker parts This 18 one important means for long service life of breaker Grease the tool each day at startup and 10 pumps every 3 hours using the manual grease pump Inspect the hydraulic oil level and the degree of contamination Too little oil may cause a oil heating problem Contaminated oil will destroy the pump of the carrier Fol
52. is visible along the tool shaft seal failure 7 13 UNDERWATER OPERATION D010047 Never use the breaker under water Water between the tool and the piston will destroy the breaker Oil will leak into the surroundings and pollute the water Water will leak into the hydraulic circuit of the breaker and destroy the carrier 7 14 BENDING THE TOOL Do not use the tool to move boulders around The lower part of the housing is designed for moving boulders COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page 59 Operation HB 1000 Lom MM p E 2 We un 0010048 Do not use the tool as lever when it has penetrated into concrete rock or hard ground The force applied will bend and or break the tool Steel Unlimited considers this a faulty operation technique that is not covered by warranty 7 15 NEVER USE BREAKER OR TOOL FOR LIFTING The breaker and the tool are not designed to be a lifting tool The recommended carrier weight classification is limited by the carrier s ability to carry a load at end of the boom without falling over Never use the breaker or the tool to lift loads Failure to comply can cause severe injury or death Page 60 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation HB 1000 0010050 7 16 CARRIER CYLINDERS IN END POSITION Do not operate the carrier with cylinders in either end position Op
53. led blank firing Also excessive prying of the tool may prevent contact between the piston and the tool and cause blank firing sign of this is when breaker recoil sound becomes extremely rapid during operation Blank firing will destroy major components of the breaker starting from the tool and the tool retaining pin Continuous blank firing will destroy the front head the piston and the tie rods COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page 51 Operation HB 1000 Steel Unlimited considers this a faulty operation technique that is not covered by warranty 7 4 PENETRATIVE BREAKING In penetrative breaking a moil tool or a chisel tool is forced inside the material Penetrative breaking is more effective in the following materials soft material layered material plastic material and low abrasive material breakers with a higher rate of impact BPM are ideal for penetrative breaking 7 5 IMPACT BREAKING With impact breaking the material is broken by transferring very strong mechanical stress waves from the tool into the material Impact breaking is most effective in hard brittle and very abrasive materials The high impact energy of the big breakers makes them ideal for impact breaking The use of a chisel tool in hard material will cause the sharp edge to wear very quickly 7 6 OPERATING TECHNIQUES Only use the hydraulic breaker to break rocks concrete and other hard objects Before you start the hy
54. low instructions of the carrier manufacturer Inspect the breaker body and housing for missing rubber plugs Replace where missing Check the overall condition of the breaker and the hydraulic system Perform all repairs before the breaker is put into service Check safety signs and labels Replace them when the they are damaged or missing or you cannot read them Page 69 Lubrication COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Routine maintenance HB 1000 1 2 INSPECTION AND MAINTENANCE BY THE DEALER Note The times given refer to the carrier hours while the attachment is installed EVERY 600 HOURS OR ONCE A YEAR This service is recommended to be done by your local dealer after 600 operating hours or at least once a year Neglecting the annual service can cause severe damage to the breaker Your local dealer will reseal the breaker replace the accumulator membranes and replace safety decals as needed Contact your local dealer for more informationaboutannual servicing During this maintenance you should do the following tasks Checkallhydraulic connections m Check that the hydraulic hoses do not rub against anything any boom position Replace and inspect the hydraulic oil filters of the carrier COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 70 1000 Releasing pressure from the breaker 2 RELEASING PRESSURE FROM THE BREAKER Warning The hydraulic pressure inside
55. lt in unexpected movement of equipment While changing the tool make sure not to leave fingers hands or other body parts between the tool and the ground or the product Stay clear from hot surfaces Wear approved PPE Secure the product properly during field service Always keep the breaker in horizontal position Beware of unexpected boom movement Do not climb on the product There is always a hazard zone around the product Use proper working platform for safe access Flyingfragments are extreme hazard while driving in toolretaining or other pins Useapprovedeye protection Usepropertools Useapproved PPE Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page 35 Safety section HB 1000 Unless you are instructed otherwise never attempt adjustments while the machine is moving or while the engine is running Stay clear of all rotating parts and all moving parts Before welding on the breaker while it is mounted on the carrier disconnect the carrier alternator and battery Note that welding on breaker tools will renderthem useless Use all cleaning solutions with care Never put maintenance fluids into glass containers Drain all liquids into a suitable container 3 13 DISMOUNTING Make sure that carrier lifting and transport equipment have pro
56. n trenching quarrying or mining applications Page 20 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety and environ mental instructions Designed environmental conditions This breaker is designed to operate in standard environmental conditions with the following restrictions ambient temperature for use of breaker is 20 80 C WARNING Use of breaker in explosive atmosphere gasoline fumes coal dust is strictly prohibited The tool in contact with the material to be broken will create sparks which could ignite an explosive atmosphere NOTICE Useof breaker under wateris strictly prohibited Properties of the materials to be processed This breaker reduces the fragment size of concrete rock hard or frozen ground asphalt metallurgical slag or similar material and has been designed exclusively for this application WARNING Special conditions with for example radioactive asbestos chemical poison or biological hazards require unconditional use of hazard specific methods and protective measures Under such special conditions methods and precautions must be reviewed in co operation with the local and national authorities Operation may only commence when approval has been granted Prohibited use of machinery Any use of this breaker not permitted as intended use outside the designed environmental conditions or on unsuitable materials to be processed is prohibite
57. n the information for use Hazard Zone any space around the breaker or the carrier in which a person can be exposed to a hazard Bystander any person in hazard zone who is not handling the breaker Real Time Hazard Analysis RTHA review of site before starting to work in order to identify potential hazards that could impact users bystanders or environment COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page 7 Safety and environmental instructions HB 1000 2 SAFETY AND ENVIRONMENTAL INSTRUCTIONS Safety is the result of attitude Proper attitude includes Realize the hazards related to what you do whether it be operation or maintenance Don t ever take hazards lightly Follow all local laws and regulations Leave special work to the specialist Special conditions such as radioactive asbestos chemical poisonous or biological hazard environment require unconditional use of hazard specific methods and protective measures Read understand and follow the instructions of this manual Read understand and follow the instructions of carrier manual If this language version is not proper ask for a translation of this manual Communicate Tell other people what you are about to do so that they do not place you or themselves at risk Installation or other maintenance related work must never be done alone Always keep people informed of what you are doing when and where Keep mobile phone always
58. ne I are related to crushing by breaker carrier boom or other heavy equipment This hazard zone is within 5 meters 15 ft of the machinery COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page nc Safety and environ mental instructions HB 1000 Do10085 Nobody is allowed in hazard zone I during breaker operation WARNING It is user s obligation to stop the breaker operation immediately if bystanders come into hazard zone I The risks to bystanders in hazard zone II are related to noise dust flying fragments of rock pressurized oil from hydraulic hose failure or others This hazard zone is 40 m 130 ft from the breaker for each single one of these hazards It is user obligation to stop breaker operation immediately when people come into hazard zone II Where required make sure that site access is restricted by barriers or fences This will frequently be necessary in road construction or demolition applications Page 24 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety and environ mental instructions Do1o085 Hazard zone III is related to the stability of the carrier It is user s obligation to ensure that the stability of carrier is proper in all working directions especially when the boom is sideways to the undercarriage COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page 25 Safety section HB 1000 3 SAFETY SECTION This safety section explains
59. ng of equipment or parts during transportation service or other working phases High Pressure HB 1000 Airborne Pollution Hazard related to inhalation of silica dust as well as fumes or other hazardous substances Flying Fragments Hazard related to flying fragments of rock or other debris during operation maintenance washing or other Crushing Hazard Hazard related to related to crushing pressurized parts or due to e g moving product Crushing of Hands Hazard related to crushing of hand product COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Page 12 Operation HB 1000 Safety and environmental instructions LABELS ON THE PRODUCT GENERAL HAZARD Unawareness of hazards may cause death or severe injury Replace all safety labels which are lost damaged or otherwise not legible Safety labels communicate the following four things The severity level of the risk with the signal word DANGER or WARNING nature of the hazard that is the type of hazard high pressure dust consequence of interaction with the hazard How to avoid the hazard You must ALWAYS follow the instructions of the safety messages and symbols of the product safety labels and the instructions set forth in the manuals to avoid death or severe injury Keep the safety labels clean and visible at all times Check the condition of safety labels daily Safety labels and instru
60. ntain flammable fluid Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page v Safety during operation HB 1000 4 SAFETY DURING OPERATION 4 1 PROPER OPERATING PRACTICE Only operate the breaker while you are in the seat of the carrier The seat belt must be fastened while you operate the carrier Only operate the controls while the engine is running Wear protective glasses while you operate the carrier and while you operate the breaker While you operate the breaker slowly in an open area check for proper operation of all controls and all protective devices Before you move the carrier ensure that no one will be endangered Carry the breaker low to the ground Do not go close to the edge of a cliff an excavation or an overhang Maintain control of the carrier while you operate the breaker Operating the equipment beyond its design limits can cause damage to people or equipment Know the maximum operating dimensions of your carrier when the breaker is installed Ensure that there is adequate clearance between the tool and any stationary objects when you are maneuvering the machine Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals Confirm your understanding of the signs with the other personnel before starting Accept hand signals from one person only
61. ntially harmful fluids should be disposed of according to local regulations 4 6 ASBESTOS RADIOACTIVE OR POISONOUS APPLICATIONS Protect yourself and bystanders from asbestos radioactive or poisonous airborne pollution Stop immediately working on the site when you suspect that asbestos radioactive or poisonous material is on the site unexpectedly Advise the site supervisor and authorities on your findings If you are aware of asbestos radioactive or poisonous material on site follow all local laws and regulations for this application Use gas masks and other proper personal protective equipment Use proper personal protective equipment including pressurized suits It is essential that you protect yourself and people in your surrounding from the tiny dust particles which cause asbestosis and other serious lung diseases Do not use the breaker until you are sure the respirators are working properly This means you must check the respirator to make sure that it is clean that its filter has been changed and to otherwise make sure the respirator will protect in the way it is meant to Equipment components which may contain asbestos fibers are brake pads brake bands lining material clutch plates and some gaskets The asbestos that is used in these components is usually bound in a resin or sealed in some way Normal handling is not hazardous COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page Safety during ope
62. nvolve a specific hazard to people GENERAL SAFETY SYMBOL This general safety symbol identifies important safety messages in this manual When you see this symbol be alert your safety is involved Carefully read and understand the message that follows and inform other users Generalhazard symbol SYMBOLS FOR MANDATORY ACTIONS Mandatory Actions are indicated by white symbols on a blue background Mandatory action symbols specify the action which must be taken to eliminate a hazard pointed out in the hazard symbol COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page 9 Safety environmental instructions HB 1000 Read the Manual It Pin HoleLeakage Safety Read Workshop ismandatorytoread Testing forleakof Distance Manual operator s manual pressurized fluid Mandatory to Mandatorytoread must always keep safety workshop involveatestpiece distance from instructions for cardboard or equipment safe practice and similar proper product settings SYMBOLS FOR PROHIBITED ACTIONS Prohibited Actions are indicated by a red circle with a red diagonal line across the circle The action which is prohibited is always in black Prohibited action symbols advise on the action which must be avoided This is not a matter of choice or judgement but an undisputible instruction Pin Hole Hazard Do Hazard Zone not use hand for Prohibited to bein testing hydraulic hazard zone Keep leaks Out P
63. on properties between the piston and the cylinder Poor viscosity will cause piston and cylinder to seize and leads to due time a total failure of breaker internal parts Refer to the Operation and Maintenance Manual of the carrier Bear in mind that Hydraulic oil degrades quickly in breaker applications and must be replaced more frequently than in digging applications The operating temperature of the hydraulic oil may vary considerable in Summer and in winter plastic parts of the carrier and the breaker such as seals have a limit to the temperature in which they perform properly Only operate the breaker within the oil temperature range given in specifications If the temperature has a tendency to rise above allowed level reduce heat buildup The easiest way to do this is to install larger diameter pressure and return lines on the carrier If this is not sufficient install an additional cooler Warranty will not apply if the seals are miscoloured due to overheating Contaminated oil is as dangerous as low viscosity oil Contaminated oil will also damage the hydraulic pump of the carrier Consult your carrier manufacturer on proper filter change intervals and oil change intervals Follow the instructions and procedures given For special hydraulic fluids as a rule of thumb any fluid suitable for the carrier will be suitable for your Steel Unlimited breaker Steel Unlimited recommends consulting with your Ste
64. onsiders this a faulty operation technique that is not covered by warranty COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page 53 Operation HB 1000 eet 056 x 5 See eee LE IER co ET ES ENIM 010096 8 Use the carrier s boom to press the breaker firmly against the object Do not pry the breaker with the boom Correct force is applied when the carrier starts to feel light Too little feed will cause vibration to the boom the carrier and the operator Too much feed force will cause the front of the tracks to rise in the air When the material breaks suddenly the carrier will fall down causing excessive vibrations to the operator and the carrier 9 Startthe breaker 10 When the breaker tool penetrates the object do not allow the breaker tool to move outward from the breaker Keep boom down pressure on the breaker 11 Do not operate the breaker while you move the breaker from one area to another area 12 Do not operate the breaker in one spot for more than 15 seconds at a time If the object does not break stop operation and change the position of the tool 54 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Operation When you operate the breaker too long in one location stone dust forms under the tool Stone dust dampens the effect of impact on the object Stone dust also produces heat Stone dust can cause the point of the
65. open the valve on the nitrogen bottle and adjust the gas flow to minimum Rapid opening of the valve on the nitrogen bottle may blow the seals in the breaker Rapid opening or overcharging may also damage the gauge on charging device 8 Close the discharge valve D and push in the handle C on the charging device and charge the accumulator to 2 3 bar above the specified charging pressure Observe the pressure gauge reading on the charging device Shut the nitrogen bottle valve 9 Wait ten minutes for the nitrogen gas pressure to stabilize in the accumulator If the gas pressure do not stabilized contact your authorized workshop 10 Adjust the pressure inside the accumulator to correct setting by carefully opening the discharge valve D 11 When the proper pressure level is reached close the discharge valve D and release the handle C 12 Release the nitrogen pressure from the hose by opening the discharge valve D on the charging device slowly 13 Remove the recharging device from the breaker COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 78 1000 Recharging the low pressure 14 Install the flange plug on the filling plug making sure that no dirt enters the valve Tighten the flange plug with an allen key to the specified torque Page 79 Maintenance COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Removal of tool HB 1000 5 REMOVAL OF TOOL WEAR LIMITS AND LUBRICANTS FO
66. or before service disassembly or scrapping Drain the hydraulic breaker of fluids before scrapping Use approved PPE Page 36 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety section Plastic wear plates foam rubber and rubber seals vibration dampening elements plugs parts should be deposited at dump Do not burn Obey all local regulations in the disposal of liquids Improperly disposal of waste can threaten the environment Always use leak proof containers when you drain fluids Do not pour waste onto the ground down a drain or into any source of water Recycle all metal parts of the breaker as standard scrap recycling 3 16 FLAMMABLELIQUIDS All fuels most lubricants and some coolant mixtures are flammable Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire Fire may cause personal injury and property damage Remove all flammable materials such as fuel oil and debris from the breaker Do not allow any flammable materials to accumulate on the breaker Store fuels and lubricants in properly marked containers away from unauthorized persons Store oily rags and any flammable materials in protective containers Do not smoke in areas that are used for storing flammable materials Do not operate the breaker near any flame Do not weld on lines or on tanks that contain flammable fluids Do not flame cut lines or tanks that co
67. or maintenance on the product Do not climb on the product There is always a hazard zone around the product Use proper working platform for safe access If you use a working platform make sure to place this on level and stable ground Perform Real Time Hazard Analysis on site at least daily before starting up Determine an escape route for emergency situations Agree with your colleagues on site on the use of hand signals Do not assume any knowledge of signals Always keep people informed of what you are doing when and where Keep a mobile phone always at hand Inform the site manager when you leave the site Keep yourself and bystanders out of hazard zone forthe carrier With tractor backhoe loader do not ever drive while boom and breaker are outside wheel width sideways Driving with the breaker in this transport position may cause severe damage to pedestrians or passing cars Page 32 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety section Use of breaker in explosive atmosphere gasoline fumes coal dust is strictly prohibited Beware of heavy vibration Do not touch a vibrating breaker or pulsating hoses Vibration makes it extremely difficult to take off hands Use a plastic spiral over hoses to protect against pinhole leaks Use cardboard to check on a pinhole leak Stay clear from hot surfaces Wear proper PPE Extended exposure to whole body vibration may damage your health Install
68. ot damage or make the product unsafe by the method of operation or maintenance you choose Review site before using the breaker Heavy load of equipment or vibration of breaker work may cause structures walls roofing bridges floors to collapse Keep yourself and bystanders out of hazard zone WARNING This breaker may be operated or maintained only by a person skills needed for safe and proper operation or maintenance Only competent persons may carry out operation and other tasks The employer must Provide training and orientation Validate training methods Verify competence and skills Monitor and evaluate user performance regularly WARNING This breaker is for professional use only Especially in equipment rental applications the renting company must make sure that the user has demonstrated the necessary skills and knowledge for safe and proper operation and maintenance of both carrier and breaker Workshop service Workshop service disassembly assembly of this breaker must be performed by trained and authorized personnel Consult your nearest Steel Unlimited dealer or distributor for further information Page 18 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION who has received proper training and has demonstrated that he or she has the 1000 Safety and environ mental instructions NATIONAL SAFETY REGULATIONS It is the responsibility of the user to follow national safety regulations
69. ound the product Use proper working platform for safe access Where working platforms are used make sure to place them on level and stable ground Page 30 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety section During installation check it may berequired to be temporarily in the hazard zone of the breaker Use approved PPE Take extreme care against flying objects Flying fragments are an extreme hazard while driving in the tool retaining pin or other pins Use approved eye protection Use proper tools Use approved PPE Check the tool retaining pins on a regular basis Check the tightness of the bracket bolts on a regular basis Place the boom in a proper position to allow for ergonomic way of connecting hoses Check hose ends for proper connection on a regular basis Use only suitable bolts with proper capacity for mounting of breaker Always check the breaker function and installation outdoors Stop the engine when use is not required Make sure that proper ventilation of exhaust gases is available when the engine is running Check the mounting pin locking mechanism on the carrier for the pin mounted breaker or mounting bracket for a bracket mounted breaker on a regular basis 3 6 BEFORE USE AND NEW USERS Secure the product properly during transportation Follow proper transportation practice Make sure that carrier lifting and transport equipment has proper capacity to carry the weight of th
70. per capacity to carry the weight of the product Keep yourself and bystanders out of hazard zone during lifting Never place load over people Never ride a load Do not use self made repaired or damaged lifting accessories Apply lifting accessories properly and securely Secure the product properly during transportation Follow proper transportation practice While changing the tool make sure not to leave fingers hands or other body parts between the tool and the ground or the product Oil inside the breaker may be extremely hot Do not handle hydraulic hoses connect disconnect while oil is hot Stay clear from hot surfaces Use approved PPE Secure the product properly during field service Always keep the breaker in horizontal position Beware of unexpected boom movement Do not climb on the product There is always a hazard zone around the product Use proper working platform for safe access 3 14 WORKSHOP SERVICE Workshop service must be performed at a trained and Steel Unlimited approved workshop Non professional service is a severe risk for the staff performing the service Non professional service is a safety risk for the operator as well with a high risk of material damage which may become extremely expensive 3 15 SCRAPPING While removing the tool make sure not to leave fingers hands or other body parts between the tool and the ground or the product Release the internal pressure from the breaker and the accumulat
71. ral 4 Setthe engine speed to the recommended engine RPM Note Stop the hydraulic breaker operation immediately if any of the hydraulic hoses are flexing excessively This indicates that the accumulator is punctured Consult your Steel Unlimited dealer for the necessary repairs 5 Place the tool against the object at a 90 working angle Avoid small irregularities on the object Irregularities will break easily Irregularities will cause idle strokes blank firing Irregularities will cause incorrect working angles 0010075 UF ee ms ped 6 Keep the breaker tool perpendicular to the surface at all times Keep the feed force and the breaker tool aligned If the object moves or the object s surface breaks correct the working angle immediately 7 Stop operation the moment the subject material is broken Do not allow the breaker to fall into the object and make idle strokes blank firing when the object breaks NOTICE Frequent idle strokes blank firing have a deteriorating effect on the breaker Do not operate the breaker without proper down pressure against the object NOTICE Also excessive prying of the tool may prevent contact between the piston and the tool and cause blank firing A sign of this is when the breaker recoil sound becomes extremely rapid during operation NOTICE Blank firing will destroy major components of the breaker starting from tool and tool retaining pin Steel Unlimited c
72. ration cleaning troubleshooting maintenance and disposal of machinery Safe working procedures are needed for each phase In case you need more detailed instructions do not hesitate to contact your Steel Unlimited representative Page 16 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety and environ mental instructions Protective measures which must be taken by the user based on the information for use Use of personal protective equipment PPE Provision and use of additional safeguards Use vertical steel bars separate plastic net or plastic window for operator cab protection Regular training on site safety and safe working procedures Other particular issues which should be known to the user are Site organization and supervision Workplace safety including safe working procedures Permit to work systems All near miss incidents and accidents must be reported to Steel Unlimited without delay where a Steel Unlimited breaker has been involved The following safety guidelines apply for each person working with the breaker or in the vicinity of the breaker Every single person is responsible for their own safety and for the safety of her or his colleagues In case of violation of any safety guidelines or regulations every single person is responsible to warn the others and the responsible supervisor WARNING Authorized spare parts are listed on a spare parts list
73. ration HB 1000 If dust that may contain asbestos is present follow the basic guidelines below Never use compressed air for cleaning Avoid brushing materials that contain asbestos Avoid grinding materials that contain asbestos Use a wet method in order to clean up asbestos materials Use exhaust ventilation on permanent machining jobs Wear an approved respirator if there is no other way to control the dust Comply with applicable rules and regulations for the work place In the United States use Occupational Safety and Health Administration OSHA requirements Obey environmental regulations for the disposal of asbestos Stay away from areas that might have asbestos particles in the air Dispose of waste properly Failure to comply will result in serious injury or death 7 Page 44 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Transportation storage and setting HB 1000 5 TRANSPORTATION STORAGE AND SETTING UP 5 1 TRANSPORT POSITION The transportation and parking positions are shown in the illustration When moving with the breaker ensure that it is not too close and does not point at the cabin window aN eS pua y fO RTS PAPE Ter E m JEU Ts Seat x ae 10010084 When moving the breaker without the mounting bracket install plate or a beam to the housing to prevent the breaker from falling out o
74. rator s manual NOISE HAZARD Continuous exposure to noise above BO dB A could cause hearing impairment Wear approved hearing HIGH PRESSURE HAZARD improper handling of pressurized accumulator will cause death s vene injury Road workshop manual before disassembly Release prossure bibori dis assemblty Recharge with nitragen Mp anty S Hydraulic Hammer Version Serial NHurnber Hammer weight Min vearking weight Operating pr ssure CHI flow Manufactured Wu hunted Dutt Sand Mining and Constructor Oy Adress B 15170 Lahi Fran 50010 Page 14 Operation COPYRIGHT O 2018 SANDVIK MINING AND CONSTRUCTION Safety and environ mental instructions HB 1000 Model DUST HAZARD asc Ed HIGH PRESSURE HAZARD Version Of injury Improper handling of pressurized IGNORING Serial Number Hydraulic Hammer DANGER DANGER SU Always wear approved d INSTRUCTIONS HAZARD Hammer weight Faulty handling practice could Min working weight Read workshop manual betare cause death or severe injury Operating pressure die Read and follow the instructi Release pressure before sr cesar eel flow L opera manwal disassembly Manufactured Recharge with nitrogen N only FLYING OBJECTS HAZARD Fragments fly up to 40 m 130 ft and could cause death or severe injury Stop operation when a person enters hazard zone Wear appro
75. ressure accumulator A is a piston type accumulator and needs recharging base on specification B 4 o a 030002 COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 72 Inspection of pressure the low HB 1000 030152 Item Precharge pressure Low pressure accumulator A 14 bar Item Torque Flange plug 25 Nm Shield plate mounting screws 70 Nm INSPECTION OF PRESSURE IN THE LOW PRESSURE ACCUMULATOR HIGH PRESSURE HAZARD Use only Nitrogen N2 for charging accumulators The use of other gases may cause accumulators to explode Failure to comply could result in serious injury or death Inspect pressure in the low pressure accumulator after two weeks Page 73 Maintenance COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Inspection of pressure in the low If pressure in the low pressure accumulator needs recharging more than every week contact an authorized workshop If there spray oil out from the accumulator when you are inspecting it service the breaker 1 Place the breaker in a horizontal position with the low pressure accumulator recharging point faced upwards During inspection the piston may move unexpectedly Make sure the tool is fully extracted and that no people or equipment are near the end of the tool 2 Remove shield plate from the housing 3 Removethe flange plug from the filling plug on breaker with an allen key
76. rt of the training material during orientation Following these instructions helps minimize maintenance cost and downtime and optimize reliability and life of the product IDENTIFICATION The model and serial number are shown on the serial number plate Check that the model corresponds to the one given on the cover of this manual It is important to make correct reference to the serial number of the breaker when making repairs or ordering spare parts Identification of the serial number is the only proper means of maintaining and identifying parts for a specific breaker COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Operation Page 5 HB 1000 Introduction 1 4 MANUFACTURER This hydraulic breaker has been manufactured by For maintenance and service of this hydraulic breaker contact your nearest Steel Unlimited representative Dealer and distributor information may be found at www steelunlimited com 1 5 CE MARK AND DECL ARATION OF CONFORMITY The CE mark is located on the serial number plate of the breaker 1 6 VALIDITY OF MANUAL This manual contains safety information operation instructions transportation information lubrication information and maintenance information in accordance with the hydraulic breaker design at the time it was delivered from factory This manual and especially its safety information as well as the EC declaration of conformity and statement of compliance are valid only if no una
77. ssary use fine emery cloth or grinding agent Clean and oil all parts 2 Lubricate and install seals and wiper to cylinder 3 Install parallel pin to front head 4 Lower cylinder to front head Page 113 Workshop COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION 1000 Disassembly and assembly 5 Oiland install distributor and steering ring to cylinder 6 7 8 Oil piston and lift it to cylinder COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Workshop Page 114 Disasse mbly and assembly HB 1000 9 Install seal carrier to cylinder 10 Install O ring to back head 11 Install parallel pin to cylinder 12 Lower back head to cylinder Page 115 Workshop COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION 1000 Disassembly and assembly 1 6 DISASSEMBLING AND ASSEMBLING THE FRONT HEAD TORQUES ADJUSTMENTS AND LUBRICANTS 050152 Item Specification Grease nipple A Item Thrust ring min lenght B Upper tool bushing max diameter C Item All seals and O rings Contact surfaces between bushings and front head Contact surfaces between cylinder and front head Inside tool bushings 33 Nm Locking fluid medium locking force Wear limit 16 5 mm 76 8 mm Lubricant O ring grease Thread grease Thread grease Tool grease COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Workshop Page 116 Disasse mbly and
78. sswise to specified tightening torque Page 109 Workshop COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION 1000 Disassembly and assembly 1 5 DISASSEMBLING AND ASSEMBLING THE BODY PARTS TORQUES ADJUSTMENTS AND LUBRICANTS 050114 Item Specification Filling plug A 375 Nm Flange plug B 25 Nm Flange plug in cylinder 50 Nm Item Lubricant All seals and O rings O ring grease Contact surfaces between Anticorrosion back head and cylinder agent e g CRC 3 36 Contact surfaces between Thread cylinder and front head grease All parts especially piston Hydraulic oil DISASSEMBLING THE BODY PARTS 1 Set breaker vertically on floor Prevent breaker to fall down 2 Lift back head out of cylinder 3 Remove parallel pin from cylinder COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Workshop Page 0 Disasse mbly and assembly HB 1000 4 Remove O ring from back head 7 Remove slide ring from cylinder Page Workshop COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION 1000 Disassembly and assembly 8 Remove O rings from slide ring 10 Lift cylinder out from front head 11 Remove parallel pin from front head COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Workshop Page 125 Disasse mbly and assembly HB 1000 12 Remove seals and wiper from cylinder ASSEMBLING THE BODY PARTS 1 Checkall parts for wear and damage If nece
79. sure gauge assembly 60 41787 bar and 250 bar if ff N j 1 M l 1 N al s 3 2 2 Adapter for French nitrogen 901311 1 bottle R050073 Name Part no Qty Picture Drift pins Drift pin D15 5 400369 Drift pin D20 400595 1 R050072 S y x sr Page 119 Workshop COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Service tools HB 1000 Service tools Name Part no Qty Picture Lifting eyes Lifting eye M12 Lifting eye M16 Lifting eye M20 90624 2 2 STANDARD SERVICE TOOLS Name Specification Torque wrench Torque wrench Torque wrench Ratchet handle Extension Extension Sliding T handle Adapter Adapter Adapter Combination spanner Combination spanner Combination spanner Combination spanner Hex socket Hex socket Hex socket Hex socket Hex socket Allen type screw socket Allen type screw socket Pry bars Lifting chain Breaker Breaker Breaker Screwdriver Screwdriver Oil can COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 150 700 Nm 3 4 20 200 Nm 1 2 15 Nm 1 2 1 2 L 125 mm 1 2 L 200 mm 1 2 3 4 3 4 gt 1 2 1 2 gt 3 4 3 4 gt 1 13 mm 27 mm 36 mm 46 mm 13 mm 1 2 14 mm 1 2 27 mm 1 27 36 mm 3 4 46 mm 3 4 5 mm 1 2 10 mm 1 2 400 mm Plastic 1000 g Ball headed 680 g 2000 g 6x150 mm 8x250 mm 0 5
80. the work related risks and gives instructions for proper protective measures against hazards which may occur on any site Read and understand the protective measures listed in this safety section before using the breaker 3 1 LIFTING LIFTING HAZARD Faulty lifting practice may cause severe injury or death Keep yourself and bystanders out of hazard zone during lifting Never place load over people Never ride a load Check breaker weight from the serial label on breaker Check weight of mounting bracket and tool as well Especially with pin mount breaker check the combined weight of the breaker and quick hitch mounting bracket Make sure that carrier lifting and transport equipment has proper capacity to carry the weight of the product Faulty lifting procedures or faulty lifting equipment may cause injury or death Use proper and approved lifting accessories for lifting of parts heavier than 20 kg Do not attempt to lift turn or move heavy parts manually Apply lifting accessories properly and securely Make sure that the lifting eye is properly fastened into the fixture Where required remove dirt from threaded lifting eye holes and lifting eye thread Do not use self made repaired or damaged lifting accessories Make sure that the lifting eye is proper and approved for complete the breaker weight especially where the mounting bracket is applied Lifting eyes are not to be side loaded during a lifting operation Use sh
81. this manual in the operator s compartment in the literature holder or seat back literature storage area for easy user access at any time Keep all information for use clean and in good condition If necessary ask for a translation of information for use The related safety label on the breaker and the text on the label are shown below IGNORINGINSTRUCTIONSHAZARD Faulty handling practice could cause death or severe injury Read and follow the instructions in the operator s manual Page 4 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION HB 1000 Introduction IGNORING INSTRUCTIONS HAZARD Faulty handling practice could cause death or severe injury _ Read and follow the instructions in the operators manual R010348 1 2 THE PURPOSE OF INSTRUCTIONS The purpose of these instructions is to promote intended safe proper and economical use of this breaker These instructions assist the user in identifying avoiding and preventing hazardous situations and related consequences Always follow these instructions along with any instructions given in local laws and regulations any orders given by local authorities and all protective measures specific for the site such as safe working procedures Replace the operator s manual immediately if lost damaged or unreadable For replacement copies contact Steel Unlimited representative Use the instructions set forth in the information for use as a pa
82. tool bushings If you have to replace the lower tool bushing see the removal and the installation of the lower tool bushing INSTALLATION OF TOOL 1 Clean the tool 2 Apply tool grease to the tool COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 82 1000 Removal of tool 3 Install the tool 4 Apply grease to the tool retaining pin 5 Install the tool retaining pin 6 Apply grease to the retaining pin 7 Install the retaining pin 8 Install the plugs to housing Page 83 Maintenance COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Removal and installation of lower tool 6 REMOVAL AND INSTALLATION OF LOWER TOOL BUSHING WEAR LIMITS AND LUBRICANTS FOR LOWER TOOL BUSHING BAO30123 Item Wear limit Tool bushing inner diameter worn 78 mm out Item Lubricant Contact surfaces of front head Thread grease REMOVAL AND INSTALLATION OF LOWER TOOL BUSHING 1 Remove the tool Refer to section Removal of tool for information on the removal procedure 2 Clean the inside of the tool bushing Inspect the inside bore of the tool bushing for wear COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 84 Removal and installation of lower tool HB 1000 3 You must replace the tool bushing if the tool bushing has too much wear Refer to specification for the dimensions A a BAD30013 4 Ifyou have to replace the lower
83. tool to become deformed 0010077 Note Listen to the breaker s sound while you are using the breaker If the sound is thinner and the breaker s impact is less efficient the tool is misaligned with the object Also there is not enough down force on the tool Realign the tool and press the breaker firmly against the object 13 Do not strike and do not pry with the tool at the same time The tool may snap off The tool may be bent by stones inside hard ground or frozen ground Be careful and stop striking if you find sudden resistance under the tool Lo ci T E a Sa Oo PL a 010082 Do not use the tool to move boulders around lower part of the housing is designed for moving boulders Do not use a tool as a lever when it has penetrated into concrete rock or hard ground The force applied will bend and or break the tool COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page 55 Operation HB 1000 14 Do not operate the breaker with the carrier s boom cylinder stick cylinder or bucket cylinders fully retracted or fully extended Structural damage to the carrier will result _ q EE We es Do10079 Tn 15 When you operate the breaker make sure that the breaker does not make contact with the carrier s boom or hydraulic lines 16 Preheat the tool before you start to operate the breaker in temperatures that are belo
84. tool bushing remove the breaker from the housing Refer to section Removing housing and side plates for information on the removal procedure 5 Remove the retaining pins from the front head 6 Remove the lower tool bushing from the front head 7 Clean and dry the lower tool bushing Apply thread grease on outer surfaces of the lower tool bushing Lubricate inner surfaces of the lower tool bushing with tool grease 8 Install the lower tool bushing 9 Install the retaining pins Page 85 Maintenance COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Removal and installation of lower tool 10 Install the breaker to the housing Refer to section Removing housing and side plates for information on the installation procedure 11 Install the tool Refer to section Installation of tool for information on the installation procedure COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION Maintenance Page 86 Troubleshooting HB 1000 7 TROUBLESHOOTING 7 1 THE BREAKER DOES NOT START PRESSURE OR RETURN LINES CLOSED Check the operation of the quick couplings in breaker line Open the breaker line ball valves if closed PRESSURE AND RETURN HOSES INSTALLED BACKWARDS Swap the pressure and return hoses PISTON IS IN ITS LOWER HYDRAULIC BRAKE Keep the breaker control valve open and force the tool against an object The tool head will push the piston out of its brake area GREASE BETWEEN PISTON AND T
85. udden machine movement or attachment movement Use caution if you disconnect hydraulic lines or fittings High pressure oil that is released can cause a hose to whip High pressure oil that is released can cause oil to spray Oil may be hot after prolonged operation If you use a lubrication system make sure to relieve all pressure before any lines fittings or related items are disconnected Before disconnecting or connecting hydraulic hoses stop the carrier engine and operate controls to release pressure trapped in the hoses COPYRIGHT 02015 SANDVIK MINING AND CONSTRUCTION Operation Page 33 Safety section HB 1000 Pressure can be trapped in the hydraulic circuit long after the engine has been stopped The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly Wait at least 10 minutes to ensure that the pressure has been relieved from the system before disconnecting any hoses pipes or other components Failure to comply could result in a serious injury or death 3 9 HOT SUBSTANCES Hot oil and hot components can cause personal injury Do not allow hot oil to contact the skin Also do not allow hot components to contact the skin Relieve all pressure in the air system in the hydraulic system or in the lubrication system before any lines fittings or related items are disconnected Metal parts such as valves or body parts may have the same temperature as the h
86. ures for the most severe risks Information for Use the information in this manual the safety labels on breaker and other information on for example the delivery package This provides protective measures and advice on proper methods for transportation installation operation and maintenance of the breaker Intended Use use of this breaker in accordance with the instructions provided in information for use Prohibited Use any use of this breaker which is not intended use Especially the use which is specifically prohibited in information for use Reasonably Foreseeable Misuse use ofthe breaker in a way not intended but which may result from readily predictable human behaviour User any person handling the breaker whether it be transportation installation operation scheduled maintenance scrapping or other Harm physical injury or damage to health This is always in relationship to people not to equipment or property Hazard potential source of harm Risk the combination of the probability of occurrence of harm and the severity of that harm Protective Measure the measure intended to achieve risk reduction The protective measures are implemented by the designer where possible and by the user where design measures are not sufficient for safe operation Protective measures for the user are given in the information for use User Obligations protective measures which must be taken by the user based o
87. uthorized changes to the product are made Some illustrations in this publication show details that can be different from your breaker Guards and covers may have been removed for illustrative purposes Continuing improvement and advancement of product design may have caused changes to your breaker which are not included in this publication Whenever a question arises regarding your breaker or this manual please consult your dealer for the latest available information 7 COPYRIGHT NOTICE This publication is copyright of Sandvik Mining and Construction Oy Breakers Lahti Finland Sandvik Mining and Construction Breakers Lahti Finland 2015 It must not be copied reproduced or otherwise made available in full or in part to any third party without our prior written consent All Rights Reserved 1 8 DEFINITIONS Breaker the product described in this manual Page 6 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Introduction Tool the wear part which is in direct contact with the rock Carrier the base machine onto which the breaker is mounted and which supplies the operating power and controls with which the breaker is operated This Manual this one complete book which contains vital information for transportation handling and storage as well as installation operation and maintenance of the breaker Safety Label label applied on the breaker advising on protective meas
88. ved personal NOISE HAZARD Continuaus exposure to noise above could cause hearing impairment Wear approved hearing prabecbors 50010010 Page 15 Operation COPYRIGHT 2015 SANDVIK MINING ANDCONSTRUCTION Safety and environ mental instructions HB 1000 2 2 USER OBLIGATIONS GENERAL HAZARD Improper installation operation or maintenance could cause death or severe injury This product may be used or maintained only by a person who has received proper training and has demonstrated that he or she has the competence and the skills needed for safe and proper operation or maintenance The safe use of a product depends on among other things a combination of design and construction measures taken by the manufacturer skills of operators and protective measures taken by the user It is important to pass the information for use on to any subsequent user of this breaker Steel Unlimited prohibits in connection with the access to the breaker the consumption possession and distribution of intoxicants and narcotics any kind of legal or illegal drugs items which are in conjunction with any of these firearms and unapproved explosives Warning Only operate the product when in fit condition Do not handle the product in intoxicated condition alcohol drugs tired or otherwise unfit condition fever or illness Safety information covers transport installation use settings ope
89. w 20 C 4 F Use a torch in order to heat the tool until the tool is at least 0 C 32 F Do not heat the tool to a temperature that is greater than 100 C 200 F 17 Do not use the breaker to sweep the ground of debris This may damage the breaker and the housing will wear out more quickly 18 The breaker and the tool are not designed to be a lifting tool The recommended carrier weight classification is limited by the carrier s ability to carry a load at boom s end without falling over Do not use the breaker or the breaker tool for lifting Failure to comply could cause severe injury or death Page 56 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Operation Ll Inu Y T V Vira m Tap Uo E n x ric M on A SIE ri DOo10080 19 Keep the tool shank well greased during operation 7 7 NOISE The operation of a breaker near areas that are sensitive to noise can cause noise pollution Follow these basic rules to avoid unnecessary noise Keep the tool at 90 to the material Keep the force of the feed in line with the tool Replace the parts or fix the parts that are worn out damaged or loosened This will extend the life of the breaker The noise level of the breaker will be reduced 7 8 OPERATING TEMPERA TURERANGE The recommended operating temperature range is 20 C to 80 C 4 F to 176 F COPYRIGHT 02015 SANDVIK MINING AND CONSTRUC
90. y Recharge with NITROGEN N2 only Before for example an air freight as well as before any workshop service of the breaker depressurize the accumulator Use only nitrogen for recharging the accumulators The use of other gas may cause accumulators to explode Failure to comply can result in serious injury or death The accumulator charging device does not have any pressure relief valve Shut gas the bottle valve when the gauge shows the correct charging pressure Do not disassemble the breaker before releasing gas pressure from the accumulators and oil pressure from the breaker Failure to comply could result in serious injury or death The safety label on or near the accumulator is shown below HIGH PRESSURE HAZARD Improper handling of pressurized accumulator will cause death or severe injury Read workshop manual before disassembly Release pressure before disassembly Recharge with nitrogen N only Page 28 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety section HIGH PRESSURE HAZARD Improper handling of pressurized accumulator will cause death or severe injury Read workshop manual before disassembly Helease pressure before disassembly r Recharge with nitrogen only 010357 3 4 CRUSHING PREVENTION amp CUTTIN
91. ydraulic oil The working end of the tool may get extremely hot during operation Make sure the tool has had time to cool down before starting to handle it 3 10 CONTAINING FLUID SPILLAGE Ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the equipment Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Use tools and equipment that are suitable for containing and collecting fluids Improperly disposing of waste can threaten the environment Always use leakproof containers when you drain fluids Do not pour waste onto the ground down a drain or into any source of water Obey all local regulations for the disposal of liquids 3 11 CLEANING AND SERVICE Replace all damaged lost or otherwise illegible safety labels Clean ice snow water oil or grease spills from the floor to prevent slipping tripping or falling Use approved safety boots Dispose properly recycle of spill oil and grease Do not climb on the product There is always a hazard zone around the product Use proper working platform for safe access Page 34 Operation COPYRIGHT 2015 SANDVIK MINING AND CONSTRUCTION 1000 Safety section Beware of heavy vibration Do not touch a vibrating breaker or pulsating hoses Vibration makes it extremely difficult to take off hands Use a plastic spiral over hoses to protect

HB-1000 Hydraulic Breaker Operations Manual

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