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Chicago Pneumatic CP 1150, Operating Instructions Manual, Page: 48 / 56

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Chicago Pneumatic CP 1150 Operating Instructions Manual Download Page 48

4

8

11.6

Oil  leaks  between  cylinder  cover  and  cylinder

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Cause

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Remedy

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ÂÂÂÂÂÂÂÂÂÂÂ

by

Tie  rods 

/

  nuts  for  tensioning  bolts

loose

Tighten  tie  rods 

/

  Nuts

Workshop

S

eals  defecti

v

e

Replace  seals

(see  spare  parts  lists)

Workshop

11.7

Oil  leaks  from  parts  of  hydraulic  system  for  breaker  (Screw  coup
lings,  hoses  etc.)

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Cause

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Remedy

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by

S

crew  couplings  loose; 

flange  connections  on 

v

al

v

e  loose

Tighten  screw  couplings;  if

necessary  replace  defecti

v

e  parts;

check  hydraulic  system  for

breaker,  replace  defecti

v

e  parts

Note:

  use  only  genuine  spares

E

x

ca

v

ator  dri

v

er  or  workshop

11.8

Oil  leaks  from  working  tool

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Cause

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Remedy

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by

Through  intrusion  of  dust  lower

piston  seals  are  defecti

v

e

Dismantle  hydraulic  breaker;  re

place  seals;  a

v

oid  possible  e

x

cessi

v

e  lubrication  of  working  tool

Workshop

11.9

Oil  leaks  from  high−pressure  accumulator

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ÂÂÂÂÂÂÂÂÂÂÂ

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Cause

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Remedy

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by

Fi

x

ing  screws  for  highpressure

accumulator  loose

Replace 

O

ring  a.  back

−

up  ring

(CP 

11

50

:

  parts 

111

  + 

11

2)

K

(CP 

16

50

:

  parts  43  +  44)

K

(CP  2250

:

  parts 

11

+

1

2)

K

(CP  3050,  CP  4250

:

parts  35  +  3

6

)

K

Tighten  fi

x

ing  screws

Workshop

K

Part  nos.  refer  to 

v

alid  spare  parts  lists

Summary of Contents for CP 1150

Page 1: ...No 3390 5053 01 AIB 2007 05 04 Copyright 2007 www chicagopneumatic com Operating instructions for hydraulic breaker TM CP 550 CP 750 CP 1150 CP 1650 CP 2250 CP 3050 CP 4250 ...

Page 2: ......

Page 3: ...ker CP 550 CP 750 CP 1150 CP 1650 CP 2250 CP 3050 CP 4250 E Chicago Pneumatic Any unauthorized use or copying of contents or any part thereof is prohibited This applies in particular to to trademarks model denominations part numbers and drawings ...

Page 4: ...he excavator hydraulic aspects 18 6 5 Switching the hydraulic breaker on off from the carrier 19 6 6 Dismounting the hydraulic breaker from the excavator for short or lengthy periods of non use 19 6 6 1 Dismounting from excavator 19 7 Storage 20 7 1 Hydraulic breaker 20 7 1 1 Short storage 20 7 1 2 Long storage 20 7 1 3 How to proceed after more than twelve months storage 20 7 1 4 Working tool 21 ...

Page 5: ...ing the impact face of the percussion piston 36 10 5 6 Checking the breaker box for wear and cracks and checking the adapter for cracks 36 10 5 7 Screw couplings CP 550 and CP 750 37 10 5 8 Screw couplings CP 1150 38 10 5 9 Screw couplings CP 1650 39 10 5 10 Screw couplings CP 2250 CP 3050 and CP 4250 40 10 5 11 Checking pressure in piston accumulator and refilling if required 42 10 5 12 Checking ...

Page 6: ...egula tions which are listed at the beginning of this man ual and repeated in the relevant sections Responsibility for the observation of these safety regulations lies at all times with the operator All safety regulations listed in this manual comply with the laws and regulations of the European Union Additional national regulations have also been taken into consideration wherever applicable Hydra...

Page 7: ...he valid local statutes and regula tions shall apply Please observe any other more stringent national regional regulations and legisla tion Explanation of the symbols used in this operating instructions To emphasise their importance certain points in the operating instructions are marked with symbols which are described below DANGER Note The marked text provides instructions on the correct use of ...

Page 8: ...uirements are to be observed e g in Germany an authorized person inspection body is to inspect and certify the system on site before put ting it into use Fitting and removing the working tool Always wear protective glasses when fitting or re moving the working tool since metal splinters may fly off when hammering out the locking bolts The working tool should only be fitted in the way de scribed in...

Page 9: ...rative that all bolts be replaced If any significant changes are made to the hy draulic system a new acceptance inspection is to be carried out in accordance with the relevant national safety provisions Note Check the pressure accumulator in accordance with the national safety provisions We recommend five yearly maintenance intervals Dismounting the hydraulic breaker Dismounting the hydraulic brea...

Page 10: ...roup max operating pressure Year of construction of product group Atlas Copco Construction Tools EssenGermany Made in Germany Type Ser No Deliv wt P max Year The CE nameplate contains information on the unit breaker and breaker box All weights indicated refer to the weight of this unit When selecting hoists and suspension aids for trans porting the unit the weights of the working tool and adapter ...

Page 11: ...truction Demolition tearing up trenching foundation work Mining and quarrying Primary breaking bench leveling reducing mineral raw materials and rocks tunnel construction Under normal circumstances the hydraulic breaker is operated from the driver s cab of the carrier Please refer to Sections 2 and 6 5 4 2 Scope of supply The scope of supply of a hydraulic breaker generally includes Hydraulic brea...

Page 12: ...or assemblies CP 550 and CP 750 CP 550 CP 750 CE nameplate CE name plate cylindercover cylinder hammerbox lower hammer part The graphic shows only a general view of the main components Details may vary on different breaker models working tool ...

Page 13: ... CP 1650 CP 1650 CE name plate CP 1150 CE nameplate working tool hammer box cylinder cover The graphic shows only a general view of the main components Details may vary on different breaker models cylinder High pressure accumulator lower hammer part ...

Page 14: ...CP 4250 hammer box cylinder cylinder cover lower hammer part CP 2250 CP 3050 CP 4250 Sealing flange CE name plate working tool The graphic shows only a general view of the main components Details may vary on different breaker models High pressure accumulator ...

Page 15: ...echnical grounds hydraulic oils are currently being used which are not classified as HLP mineral oils Before using hydraulic oils of this kind it is imperative to ask the carrier manufacturer whether operations with such hydraulic oils are possible Our tools are basically designed for use with mineral oils Before using other hydraulic oil types which have been approved by the carrier manufacturer ...

Page 16: ...e breaker box with two screws referring to Sec tion 6 3 Then fit all screws The required sizes for the Allen keys are shown below Apply anti seize to the threads of the cylindrical bolts before screwing them in The contact face of the bolt head and the locking rings must be free of lubricant ÂÂÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂÂÂ Model ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ Type of spanner size CP 550 CP ...

Page 17: ... whether the bores are flush To mount the hydraulic breaker carefully lower the stick of the boom into the adapter An assistant di rects the movement of the stick until the bores in the stick are flush with those in the adapter Then insert the stick pin and lock Stick Adapter Stick pin Hydraulic breaker Lift up the hydraulic breaker Extend the shovel cylinder until the bore in the toggle is flush ...

Page 18: ...eturn oil flow The pressure relief overflow line must run direct from the pressure relief valve to the tank to ensure the reliable functioning of the valve Do not run any hydraulic lines for attachment of the hydraulic breaker through the driver s cab Hydraulic lines may spring a leak or even burst re leasing hot hydraulic oil CP 2250 Unscrew the blank flanges from ports P and T and put them in th...

Page 19: ...n use 6 6 1 Dismounting from excavator Unless otherwise stipulated the hydraulic breaker is dismounted in reverse order to mounting Before mounting dismounting the hydraulic tool and or any maintenance work on the hydraulics of the hydraulic tool carrier the hydraulic system must be depressurized For safety reasons the carrier must be switched off before performing the following work Lay the hydra...

Page 20: ...e filling hose in the filling valve to let the gas escape CAUTION Environmental damage due to hydraulic oil Hydraulic oil is environmentally harmful and must not penetrate the ground or the water Collect any hydraulic oil which runs out and dispose of it in accordance with the applicable regulations to avoid environmental hazards Oil may run out when pushing the percussion piston up H Remove the c...

Page 21: ... Working tool H Grease the working tool with chisel paste to pre vent it corroding H Store the working tool in a dry properly ventilated room H Store the working tool so that it cannot topple over or roll down ...

Page 22: ...ble tools The working tools must be adequately cooled during remachining using a suitable coolant Never weld or flame cut the working tools The high temperatures involved will modify the micro structure of the tool 8 1 1 Working tools for hydraulic breakers CP 550 ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ Designation ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ Application Standard des...

Page 23: ...23 8 1 3 Working tools for hydraulic breakers CP 1150 CP 4250 Moilpoint Universal use Flat chisel cross cut Mining foundations trenching demolition Blunt tool Mining breaking oversizes demolition ...

Page 24: ...al chips may fly off when the locking pins are hammered out Insert an ejector drift screwdriver or similar object into the bore in the lower breaker part and push in as far as it will go see diagram Push up retaining pin from below with screwdriver or similar object and pull it out the rest of the way by hand Note Retaining pins are wear parts Remove the protective cap from the bore for the workin...

Page 25: ...and using the screw to pull out the bar Remove the dust cap from the working tool bore and put it in the toolbox for safekeeping Clean away any dirt adhering to the working tool in the insertion zone then thoroughly lubricate the shaft of the working tool and the bushes with chisel paste Clean away any dirt adhering to the working tool in the insertion zone then thoroughly lubricate the shaft of t...

Page 26: ...hout first ap plying contact pressure since this could cause dam age to the carrier Stop the hydraulic breaker immediately as soon as persons are in the danger zone The danger zone during the breaker operation is consider ably greater than during the excavation oper ation on account of fractions of stones and pieces of steel flying around and for this rea son the danger zone must depending on the ...

Page 27: ...breaker being transferred to the material being broken Excessive rocking will however cause bending strains resulting in damage to the working tool and the hydraulic breaker 9 5 Never drive the working tool into the ground If the advance step is too large or the breaker is not rocked to allow dust to escape the working tool will be driven into the material without breaking it suffi ciently The tip...

Page 28: ...plication 9 9 Using the hydraulic breaker in or under water The hydraulic breaker must never be used in or under water without prior conversion In order to avoid damage to the hydraulic breaker Chicago Pneumatics has developed a special con necting kit for underwater applications containing all necessary components incl safety equipment to keep water out of the lower breaker part by means of compr...

Page 29: ...he carrier and the hydraulic breaker are left out in the open the carrier and all equipment must be warmed up before the hydraulic breaker can be started up The excavator manufacturer s regula tions must be observed in full Ensure that the hydraulic oil in the carrier is at least at 0 C The hydraulic breaker cannot be started up until the oil temperature is over 0 C Please observe the excavator ma...

Page 30: ...e note that working tools may still be very hot at the point cutting edge even after work has stopped For preference chisel paste should be used for lubri cation 5 10 shots from a hand held grease gun are sufficient Lubricating interval approximately every 2 5 hours per shift The required lubricant level has been reached when grease starts to emerge from the bores for the retai ning pins or from t...

Page 31: ...ergency lubrication 10 2 3 Operating the CP Lube Please observe the following information H CP Lube is self bleeding i e the system requires no additional bleeding H The cartridge is made of transparent recyclable plastic PE so the lubricant level in the cartridge can be monitored at all times from the driver s cab by observing the position of the piston which is red H The piston end of the cartri...

Page 32: ... can be recycled CP Lube rear side CP 750 rear side CP Lube CP 1150 CP Lube rear side CP 1650 CL CP Lube rear side CP 2250 CP 3050 CP 4250 10 3 1 Filling device for the chisel paste The Chicago Pneumatics offers a filling device to re fill emptied cartridges which is fitted on a 45 kg grease container and allows empty cartridges to be refilled as required 500 g cartidges for CP Lube in a carton of...

Page 33: ...ica tion fitted check level replace cart ridge if necessary H Check hydraulic lines for leaks H Check spring dowel sleeve at the retaining pin have not come loose H Check wear to lower wear bushes H Replace dam aged hoses H Check pipe clamps on carrier H Tensioning bolts Visual check and or sound check by metallic hitting of the upper hexagons washers thru the service openings of breaker box H Che...

Page 34: ...atest after 100 operating hours If the shaft of the tool has worn down to below the permissible minimum ÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂ Model ÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂ Minimum diameter D CP 550 CP 750 CP 1150 CP 1650 CP 2250 CP 3050 CP 4250 77 mm 97 mm 111 mm 131 mm 145 mm 160 mm 175 mm Any burring on the working tool must be smoothed off carefully D ...

Page 35: ...nside diameter The measured diameter must not exceed the maxi mum dimension ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ Model ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ j template ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ max permiss ible diam CP 550 CP 750 CP 1150 CP 1650 CP 2250 CP 3050 CP 4250 80 100 115 135 150 165 180 83 mm 103 mm 120 mm 140 mm 155 mm 170 mm 185 mm CP 750 CP 4250 When the lower wear bushing is replaced the inside diamet...

Page 36: ... face of the percussion piston has to be checked for wear or damage every time the working tool is changed and at latest every 100 operating hours Once the working tool has been removed shine a torch onto the impact face If chipping or wear is detected do not resume work with the hy draulic breaker and inform the Chicago Pneumatic Customer Center dealer in your region 10 5 6 Checking the breaker b...

Page 37: ...ons CP Lube 5 weekly Socket and jaw spanners of varying sizes Screw plug Perc chamber ventilation 6 in case of re pair Jaw spanner size 41 200 Nm K Apply anti seize to the threads of the cylindrical bolts before screwing them in The contact face of the bolt head and the locking rings must be free of lubricant The tie rods are only accessible when the breaker has been removed from the hammer box No...

Page 38: ...anner size 41 200 Nm Filling valve G Screw plug 5 in case of repair Socket spanner size 22 130 Nm Allen key size 5 20 Nm Connections P and T 6 weekly Jaw spanner size 46 160 Nm Connection CL 7 weekly Jaw spanner size 27 200 Nm Jaw spanner size 14 20 Nm Hose connections CP Lube 7 weekly Socket and jaw spanners of varying sizes High pressure accumulator 8 weekly Allen key size 14 350 Nm K Apply anti...

Page 39: ...ize 30 Connection CL 9 weekly Jaw spanner size 27 200 Nm Jaw spanner size 14 20 Nm Hose connections CP Lube 9 weekly Socket and jaw spanners of varying sizes K Apply anti seize to the threads of the cylindrical bolts before screwing them in The contact face of the bolt head and the locking rings must be free of lubricant Note Tensioning bolts Visual check and or sound check by metallic hitting of ...

Page 40: ...kly Socket and jaw spanners of varying sizes K Apply anti seize to the threads of the cylindrical bolts before screwing them in The contact face of the bolt head and the locking rings must be free of lubricant KK Only possible when adapter has been removed Note Tensioning bolts Visual check and or sound check by metallic hitting of the upper hexagons washers thru the service ope nings of breaker b...

Page 41: ...n CP 3050 and CP 4250 the connec tion points 6 and 7 are on the sides of the cylinder cover Tensioning bolts Visual check and or sound check by metallic hitting of the upper hexagons washers thru the service openings of breaker box 9 CP 2250 CP 3050 CP 4250 View X without hammer box ...

Page 42: ...ed pressure in the piston accumulator is as follows ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ Model ÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂ at operating pressure 60 70 C no contact pres sure to the working tool ÂÂÂÂÂ ÂÂÂÂÂ ÂÂÂÂÂ ÂÂÂÂÂ Minimum gas pres sure ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ ÂÂÂÂÂÂ Required gas pressure CP 550 CP 750 CP 1150 CP 1650 CP 2250 CP 3050 CP 4250 14 0 bar 9 5 bar 5 2 bar 5 3...

Page 43: ... on the nitrogen cylinder H Open the pressure relief valve fully to allow any residual gas to escape H Remove the pressure relief valve and if required the adapter G Minimess port Pressure gauge Nozzle Pressure relief valve gas cylinder valve Adapter CAUTION Only use the hose nozzle to relieve the pressure Never use nails screwdrivers or similar objects for this purpose as they will damage the fil...

Page 44: ...lines before starting work Carry out a visual check on all lines pipes and hoses from the pump to the hydraulic breaker and back to the tank Tighten any loose screw couplings and hose clamps Damaged pipes hoses must be replaced 10 5 14 Checking the adapter bolts for wear This visual check is only possible when the hydraulic breaker has been dismounted from the excavator If excessive wear is detect...

Page 45: ...ccumula tor too high Check pressure in piston accumu lator reset to correct value Excavator driver Oil level in tank too low Refill oil Excavator driver Defective screw couplings block ing pressure or return line Replace defective coupling halves Workshop Electrical equipment for breaker hydraulics defective Check electrical equipment for breaker hydraulics Workshop Magnet on switch on valve defec...

Page 46: ...g hydraulic breaker axis Correct boom direction deburr working tool check wear to work ing tool and wear bushes Excavator driver Inside diameter of return line too small Change inside diameter Refer to Section 13 Technical specifications Workshop Return pressure too high Check and lower return pressure Chicago Pneumatic Customer Center dealer in your region Hydraulic oil returns to tank via valve ...

Page 47: ...ÂÂÂÂÂ Remedy ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ by No gas in piston accumulator Fill piston accumulator Excavator driver O rings defective CP 550 parts 9 and 12 K CP 750 part 103 K CP 1150 parts 120 and 126 K CP 1650 parts 17 and 51 K CP 2250 parts 18 and 20 K CP 3050 and CP 4250 parts 28 and 42 K Replace O rings Workshop K parts nos refer to valid spare parts lists 11 5 Oil leaks from ports P an...

Page 48: ...ulic system for breaker replace defective parts Note use only genuine spares Excavator driver or workshop 11 8 Oil leaks from working tool ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ Cause ÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂ Remedy ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ by Through intrusion of dust lower piston seals are defective Dismantle hydraulic breaker re place seals avoid possible ex cessive lubric...

Page 49: ...speed Reset pump Excavator driver Chicago Pneumatic Customer Center dealer in your region High outside temperature and no oil cooler fitted Fit oil cooler Workshop or Chicago Pneumatic Customer Center dealer in your region Pressure relief valve defective or valve with a bad characteristic curve Fit new type tested pressure relief cartridges or a more precise pres sure limiting valve Workshop 12 Di...

Page 50: ...t 170 190 190 160 Working tool diameter mm 80 100 115 135 Piston accumulatorKKK Minimum gas pressure bar Required gas pressure bar 14 0 17 3 9 5 11 9 5 2 7 0 5 3 8 2 Sound pressure level measured Lp dB A r 10 m 87 90 90 87 Sound power levelKKKK garanteed LWA dB A 116 120 120 117 Connecting thread on ports P and T up to SN 299 M 36 x 2 24 concial seal from SN 300 on M 26 x 1 5 24 concial seal M 36 ...

Page 51: ...essure relief valve for breaker circuit 200 200 Working tool diameter mm 150 165 180 Piston accumulatorKKK Minimum gas pressure bar Required gas pressure bar 12 0 15 5 12 5 16 0 8 6 11 5 Sound pressure level measured Lp dB A r 10 m 91 93 92 Sound power levelKKKK garanteed LWA dB A 121 122 122 Connecting thread on ports P and T Connection flange SAE 1 1 4 6000 psi 1 5 8 12 UNF JIC Konus 37 Inside d...

Page 52: ... adapter bolts 44 H Checking the breaker box for wear and cracks and checking the adapter for cracks 36 H Checking the hydraulic lines 44 H Checking the impact face of the percussion piston 36 H Checking the retainer bars CP 1150 CP 4250 36 H Checking the retaining pin for wear 36 H Checking the wear bushes 35 H Checking the working tool for wear 34 H CP 550 and CP 750 24 D H Dismounting from exca...

Page 53: ...from high pressure accumulator 48 H Oil leaks from parts of hydraulic system for brea ker 48 H Oil leaks from ports P and T 47 H Oil leaks from working tool 48 H Oil or grease leaks from CP Lube 49 H Operating temperature too high 49 H Operating the breaker 29 H Operating the CP Lube 31 H Operating the hydraulic breaker 26 R H refilling if required 42 H Removing the tool 25 S H Scope of supply 11 ...

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