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Epiroc ER 100 L, Safety And Operating Instructions Manual

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Epiroc ER 100 L Safety And Operating Instructions Manual Download Page 78

Safety and operating instructions

78

© Anbaufräsen PC GmbH | 3390 5221 01 | 2020-09-07

Original Instructions

Type

ER 2000-1L

ER 2000-2L

ER 2000-3L

Carrier weight class

1

35 - 50 t (77162 - 1100231 lbs)

Service weight

2

1800 kg (3968 lbs)

Weight without adapter

3

1500 kg (3307 lbs)

Dimensions
Total length
Length of cutter drum
Diameter of cutter drum

1500 mm (59.06 in.)

600 mm (23.62 in.)
720 mm (28.35 in.)

Nominal power

160 kW (215 hp)

Oil flow rate idling, max.

410 l/min (108.3 gal (US)/min)

Oil flow rate, recommended at 200 bar (2900 psi)

300 l/min

(79.3 gal (US)/min)

340 l/min

(89.8 gal (US)/min)

390 l/min

(103.0 gal (US)/

min)

Operating pressure, max.

350 bar (5075 psi)

Rotational speed, recommended

75 rpm

68 rpm

65 rpm

Pick speed

2.8 m/s (9.1 fps)

2.6 m/s (8.5 fps)

2.4 m/s (7.9 fps)

Number of picks

28

Pick shaft diameter

30 mm (1.18 in.)

Maximum cutting force at 350 bar (5075 psi)

61.9 kN

(13916 lbf)

77.2 kN

(17355 lbf)

93.0 kN

(20907 lbf)

Maximum torque at 350 bar (5075 psi)

22.3 kNm

(16448 ft lbs)

27.8 kNm

(20504 ft lbs)

33.5 Nm

(24708 ft lbs)

Maximum rock hardness

80 MPa (11603 psi)

Gear oil volume

4.5 l (1.19 gal)

Oil volume hydraulic motor

6 l (1.59 gal)

Hydraulic connections (Drum cutter)
Pressure / tank line
Leakage oil line

M42x2
M30x2

Hose lines (inside diameter)
Pressure / tank line
Leakage oil line

25 mm (0.98 in.)
20 mm (0.79 in.)

1

 Weight applies to standard carriers only. Any variations must be agreed with Anbaufräsen PC GmbH and / or the car-

rier manufacturer.

2

 Drum cutter including adapter plate of medium size. Please note that the working weight can be considerably higher,

depending on the adapter plate.

3

 Drum cutter including rotatable upper part. Accessory parts such as the adapter plate are not included.

Summary of Contents for ER 100 L

Page 1: ...ER L 100 250 400 450 600 700 1100 1500 2000 Safety and operating instructions Longitudinal Drum Cutters Anbaufräsen PC GmbH 3390 5221 01 2020 09 07 Original Instructions ...

Page 2: ......

Page 3: ...ectrical shock precautions 13 2 12 Falling stones precautions 13 2 13 Emissions precautions 14 2 14 Handling machines precautions 14 2 15 Repair precautions 15 2 15 1 Maintenance works not allowed by the manufacturer 15 2 16 Changes to the hydraulic attachment precautions 15 2 17 Environmental pollution precautions 15 3 Overview 16 3 1 Equipment description 16 3 2 Function 16 3 3 Modules 17 3 4 Si...

Page 4: ...illing auger 37 5 6 8 Specification of soil classes for earth rock drilling 37 6 Operation 38 6 1 Preparations before starting 39 6 2 Commissioning 39 6 2 1 Checks during commissioning 39 6 3 Switching the drum cutter on and off 40 6 4 Functional test 40 6 5 Correct operation 41 6 5 1 Operating the drilling auger 41 6 6 Prohibited operation 42 6 6 1 Cylinder end positions 42 6 6 2 Moving the carri...

Page 5: ...roubleshooting 63 8 1 Faults table 63 8 2 Cutter drum does not turn is blocked 64 8 3 Cutter drum turns too slowly 64 8 4 Drum cutter stops moving with light pressure 65 8 5 Unusual oscillation of the cutter drum 65 8 6 Round attack picks do not turn 65 8 7 Unusually loud gear noise 65 8 8 Unusually loud noise from the hydraulic motor 65 8 9 Overpressure cover for the hydraulic motor deformed oil ...

Page 6: ...aulic shear systems 82 13 3 Hydraulic settings explanation for following diagrams 83 13 4 Hydraulic settings ER 100 L 84 13 5 Hydraulic settings ER 250 L 86 13 6 Hydraulic settings ER 400 L ER 450 L ER 600 L 88 13 7 Hydraulic settings ERL 700 89 13 8 Hydraulic settings ERL 1100 ER 1500 L 90 13 9 Hydraulic settings ER 2000 L 92 14 EC Declaration of Conformity EC Directive 2006 42 EC 94 ...

Page 7: ...Contents Anbaufräsen PC GmbH 3390 5221 01 2020 09 07 Original Instructions 7 ...

Page 8: ...str 3 D 36469 Bad Salzungen OT Hämbach Tel 49 3695 851 09 0 Fax 49 3695 851 0999 1 1 About these Safety and Operating Instructions The aim of these Instructions is to familiarise you with the safe and effective operation of the hydraulic attach ment You will also find instructions for regular mainte nance activities for the hydraulic attachment in this docu ment Please read these Instructions care...

Page 9: ...he product Ensure if applicable that any received amendment is in corporated in the instructions Hand over the Safety and operating instructions if ever you lend rent out or sell the hydraulic attachment All safety regulations listed in this manual comply with the laws and regulations of the European Union Also observe the additional national regional regulations Hydraulic attachment operation out...

Page 10: ...therwise the operational safety of the hydraulic attachment is not guaranteed Personnel carrier operator maintenance personnel must receive instructions from the operator regularly For the purpose of improved traceability the provision of in structions must be recorded 2 3 Intended use Only attach the drum cutter to a hydraulic carrier of a suitable load bearing capacity Read the carrier manu fact...

Page 11: ... Falling carrier If the load bearing capacity of the carrier used is insuffi cient the carrier will not be stable It can topple over and cause injuries and damage Using a carrier whose load bearing capacity is too high will greatly burden the hydraulic attachment causing it to wear faster u Only attach the hydraulic attachment to a hydraulic carrier of a suitable load bearing capacity u The carrie...

Page 12: ...e any hydraulic lines through the carrier s cab u Only use hydraulic lines which comply with the fol lowing quality requirements Hydraulic hoses with 4 reinforcement steel wires 4SP and 4SH according to DIN EN 856 Hydraulic hoses with high tensile steel wire braid 1SN and 2SN according to DIN EN 853 Hydraulic pipes seamless cold drawn steel pipes to DIN EN 10305 2 9 Media consumables precautions W...

Page 13: ...ill lead to an electric shock resulting in serious injury or death The hydraulic attachment is not electrically insulated u Never work in the vicinity of electric circuits or other sources of electricity u Make sure that there are no hidden circuits in the work area u Check wiring diagrams 2 12 Falling stones precautions DANGER Fragments flying around Fragments of material which come loose while o...

Page 14: ...ior to all work check the drum cutter to ensure that all surfaces have cooled to the ambient temperature 2 14 Handling machines precautions WARNING Injuries due to incorrect operation Incorrect operation can result in severe injuries and may cause considerable damage to property u Carry out all operating steps in accordance with these Safety and operating instructions u Prior to starting work ensu...

Page 15: ... manufacturer u Modifications that entail new hazards may require a new procedure for assessing conformity WARNING Injuries due to the use of incorrect spare parts The use of incorrect or defective spare parts can result in risks to personnel as well as damage malfunctioning or a total failure of the drum cutter u Only use original parts or accessories approved by the manufacturer u If there are a...

Page 16: ...Transport lug 3 2 Function The operation of a drum cutter is described in a simpli fied version below The drum cutter is an attachment for hydraulic carriers The cutter drum is powered by the hydraulic motor of the drum cutter The round attack picks are attached to the cutter drum at a defined angle A rotating motion of the cutter drum facilitates the cutting process and thus re duces the size of ...

Page 17: ...ition Transport lug The transport lug G serves as an anchor point for the lifting gear when transporting the drum cutter The transport lug is an eyebolt and can be unscrewed after transportation After removal of the transport lug the thread must be protected from dirt and damage by a blank plug Drive hydraulic motor intermediate bracket The drum cutter is fastened to a suitable adapter plate on th...

Page 18: ... The drilling auger C can be mounted on the longitudi nal drum cutter as an accessory part To do so the cutter drum must be disassembled and the drilling auger mounted onto the drive shaft via appropriate auger adapter B In addition a pivot adapter A is mounted between the carrier stick and the intermediate bracket The complete drilling auger has a drilling head D to loosen the material and the au...

Page 19: ...ates and labels 3 4 1 Signs The warning symbol and the book symbol indicate that the Safety and Operating Instruc tions must be read prior to use of the hydraulic attachment and in particular the chapter on Safety 3 4 2 Name plate A Model B Year of construction of hydraulic attachment C Max hydraulic pressure D Weight of hydraulic attachment E Serial number F Name and address of manufacturer G The...

Page 20: ...he hazardous area is in the direct vicinity of the drum cutter Whilst operating the drum cutter the minimum dis tance around the carrier is 15 m 50 ft When cutting reinforced concrete the minimum dis tance around the carrier is 50 m 165 ft 3 7 Removing the packaging n Remove all the packaging material n Dispose of it in accordance with the applicable provi sions n Check that the delivery is comple...

Page 21: ... mm 1 50 in 45 0 mm 1 77 in 12 0 mm 0 47 in Retainer sleeve ER 450 L 22 0 mm 0 87 in 56 5 mm 2 22 in 38 0 mm 1 50 in 42 0 mm 1 65 in 12 0 mm 0 47 in Knock on retainer ER 600 L 22 0 mm 0 87 in 56 5 mm 2 22 in 38 0 mm 1 50 in 46 0 mm 1 81 in 15 0 mm 0 59 in Knock on retainer ERL 700 22 0 mm 0 87 in 56 5 mm 2 22 in 38 0 mm 1 50 in 42 0 mm 1 65 in 12 0 mm 0 47 in Knock on retainer ERL 1100 30 0 mm 1 1...

Page 22: ...Type A B C D E F ER 100 L x x x ER 250 L x x x ER 400 L x x x ER 450 L x x x x ER 600 L x x x x ERL 700 x x x x ERL 1100 x x x ER 1500 L x x x ER 2000 L x x x A Knock out tool B Knock out tool for stuck picks optional C Mounting tool for knock on retainer D Dismantling tool for knock on retainer E Dismantling tool for Quick snap retainer F Puller for retainer sleeve picks ...

Page 23: ...ght of the hydraulic attachment u Only lift and secure the hydraulic attachment with lift ing gear ropes chains shackles etc with the right load bearing capacity for the weight to be lifted u Make sure that there is nobody near or under the suspended hydraulic attachment 4 1 Transport using a crane The drum cutter is equipped with transport lugs for lifting by crane n Secure the hydraulic attachme...

Page 24: ...mbly stand with the hydraulic at tachment n Transport the assembly stand with the hydraulic at tachment to the location provided for 4 3 Transport using a truck Always transport the drum cutter whilst secured to the assembly stand WARNING Hydraulic attachment tipping over slipping The hydraulic attachment slipping or tipping over and falling from the loading area of a lorry may cause serious injur...

Page 25: ... class HLP 32 or higher In summer and in hot climates oils of viscosity class HLP 68 or higher should be used In all other respects the regulations of the carrier manu facturer are to be taken into consideration Optimum viscosity range 30 60 cSt Max start viscosity 2000 cSt Max oil temperature 80 C Special conditions apply to using the hydraulic attach ment at low temperatures see chapter Low ambi...

Page 26: ...ssure of the tank line is at least 5 bar 73 psi above the pressure of the hydraulic motor s case drain line The pressure in the leakage oil line is of 3 bar 44 psi maximum during operation The cabin of the carrier must be protected by means of suitable measures e g armoured glass against damage due to flying rock The cabin of the carrier must allow an adequate view of the working area Lighting wit...

Page 27: ...ome loose if the fastening screws are not designed for local high loads u Only use the Allen screws of strength category 8 8 and the pairs of lock washers included in the delivery to attach the adapter plate or the base plate n Place the drum cutter on the assembly stand within the range of the carrier n Apply Anti Seize to the Allen screw threads A be fore inserting them The contact faces of the ...

Page 28: ...onnel u Do not undertake unauthorised first installation WARNING Unexpected movement Sudden movements of the carrier may cause serious in jury u Secure the carrier such that it cannot move unex pectedly u Observe the carrier manufacturer s instructions NOTICE Damage due to incorrect oil pressure setting Incorrect oil pressure setting can result in severe dam age to property and the environment u B...

Page 29: ...o be damaged u Only use hydraulic lines of the rated sizes as in structed see chapter Technical Specifications u Check the rated size of the hydraulic lines on existing hydraulic installations All supply and return lines for the hydraulic oil must have a sufficient inside diame ter and wall thickness u Route all hydraulic hoses in a torsion free manner n Switch off the carrier n Depressurise the h...

Page 30: ...he shut off valve on the left side of the boom n Remove the end cap from the shut off valve on the boom and save for future use n Unscrew the end cap from the pressure line and save for future use n Connect the pressure line to the shut off valve fitting of the supply line on the left side of the boom n Clean the area around the shut off valve on the right side of the boom n Remove the end cap fro...

Page 31: ...ting a hydraulic hose see chapter Depressuris ing the hydraulic system WARNING Hot parts The cutter drums hoses pipes and fittings become very hot during operation Touching them may lead to burns u Never touch hot parts u If you have to carry out activities where you have to touch the parts wait for them to cool down first n Position the drum cutter carefully on the assembly stand n Close all shut...

Page 32: ... elements and adhere to the specified thread tightening torques u Prior to a restart do the following Ensure that all replacement work is executed and completed in accordance with the specifications and instructions given in this manual Ensure that no one is present in the hazardous area Ensure that all covers and safety devices are in stalled and that they work correctly WARNING Injury by impacts...

Page 33: ...L with the required tightening torque L Type Tightening torque ER 100 L 120 Nm 89 ft lbs Type Tightening torque ER 250 L 300 Nm 221 ft lbs ER 400 L 300 Nm 221 ft lbs ER 450 L 300 Nm 221 ft lbs ER 600 L 560 Nm 413 ft lbs ER 1500 L 950 Nm 701 ft lbs ER 2000 L 1400 Nm 1033 ft lbs n Place the facing screws in the disassembly screw holes and tighten them n Position the clamping sleeves in the intermedi...

Page 34: ...the notches of the hexagon of the drive shaft Q O P 4 Switch off the carrier and safeguard against a restart 5 Fix the fastening screws P and nuts O and tighten as required 5 6 3 Mount pivot adapter Actual details may differ Note When attaching a drilling auger it is necessary to mount a pivot adapter to the drum cutter instead of the adapter plate You need an assistant to attach the pivot adapter...

Page 35: ...king area with sufficient bearing strength n Switch off the carrier n Secure the carrier such that it cannot move unexpect edly n Unscrew the two screw connections on the tipping safeguard U and remove tipping safeguard U U 5 6 4 Dismount pivot adapter You need an assistant to remove the pivot adapter n Place the drum cutter horizontal on a level working area with sufficient bearing strength withi...

Page 36: ...ceiver and screw into the disassembly screw aper tures By tightening the fastening screws N into the disas sembly screw apertures the hexagonal receiver will slowly push up from the intermediate flange n Remove the hexagonal receiver M n Remove the facing screws from the disassembly screw apertures of the intermediate flange J n Remove the fastening screws L from the intermedi ate flange and screw...

Page 37: ...15 of silt clay with a par ticle size smaller than 0 06 mm 0 002 in containing at most 30 of boulders larger than 63 mm 2 5 in each having a maximum volume of 0 01 m 0 0006 in organic soil with lit tle water e g strong peat Class 4 Soil medium hard to excavate Mixtures of sand gravel silt clay with more than 15 of their particles smaller than 0 06 mm 0 002 in cohesive soil with low or medium plast...

Page 38: ... ensure that no parts are still moving u When in the hazardous area wear closely fitting clothes with a minimal tear strength WARNING Hot parts The cutter drums hoses pipes and fittings become very hot during operation Touching them may lead to burns u Never touch hot parts u If you have to carry out activities where you have to touch the parts wait for them to cool down first WARNING Lung disease...

Page 39: ...property u Prior to every cutting process check the compressive strength of the cutting material u Never exceed the max compressive strength of the cutting material permissible during cutting work see chapter Technical specifications Depending on the material being cut round attack picks will wear at different rates A particularly high wear rate should be expected working in the following material...

Page 40: ...h on or off the drum cutter when working at full capacity u Never switch off the drum cutter from full idling speed n Switch the hydraulic attachment on and off as de scribed in the carrier s operating instructions n When leaving the driver s cab set the safety switch lever for the electrical hydraulic attachment installa tion to the OFF position Carry out the above actions to prevent any unin ten...

Page 41: ...rotating cutter drum to the cut ting material slowly in order to avoid stalling n Always apply slight pressure to the drum cutter when cutting Always ensure that the cutter drum does not come to a standstill n With lateral cutting movements with the boom al ways ensure that no strong forces are applied to the carrier n Never switch the drum cutter on or off when in con tact with the cutting materi...

Page 42: ...k and bucket cylinder are in one of their end positions These end positions have damping fa cilities the hydraulic cylinder may be damaged by prolonged use while in its end positions 6 6 2 Moving the carrier n Never relocate the carrier sideways by placing the hydraulic attachment on the ground to lift the carrier This would seriously damage the hydraulic attach ment 6 6 3 Lifting Transporting n N...

Page 43: ...ctions 43 6 6 4 Impacting chopping n Do not use the hydraulic attachment to impact or chop to destroy material This would seriously damage the hydraulic attach ment 6 7 Activities after use n After use carry out all activities specified in the main tenance schedule to perform after every shift ...

Page 44: ...mponents with linear movement can cause serious injury u Prior to all maintenance work on moving parts switch off the machine and safeguard it against being switched back on Wait until all parts have come to a standstill u When in the hazardous area wear closely fitting clothes with a minimal tear strength WARNING Risk of death due to unauthorised switching on An unauthorised switching on of the p...

Page 45: ...out exclu sively by the manufacturer If such maintenance activi ties are required consult the authorized Customer cen ter Dealer in your area in order to ensure that they pro ceed safely The following maintenance activities are not allowed by the manufacturer Repairs to the gear and hydraulic motor Replacing wear sleeves and pick boxes Welding work on the cutter drums Welding work on the gear hous...

Page 46: ...cracks Check hydraulic lines for leaks and damage Check the pipe clamp receiver on the carrier during shift approximately every 30 minutes Cutter drum drilling head drilling auger Check if all round attack picks exist Check the round attack picks for wear Check the head lengths and carbite tip of all round attack picks for even wear after shift Clean drum cutter weekly Check the bolted connections...

Page 47: ...cks laying on the ground 4 Depressurise the hydraulic system according to the manufacturer s safety and operating instructions for the carrier 5 You must wait at least another 60 minutes until the pressure has been relieved through leakages 6 When you have made sure that no more pressure is present in the hydraulic system you must disconnect the hydraulic connection to the carrier Close the shut o...

Page 48: ... or replace worn bolts 7 8 Change gear oil The following maintenance activities are carried out in the workshop WARNING Risk of injury due to a failure to ob serve the minimum clearances A lack of space for assembly when changing the oil on the drum cutter inside buildings can lead to accidents u When working on the drum cutter inside buildings al ways ensure sufficient space for assembly WARNING ...

Page 49: ...ew A n Allow the oil to fully drain off n Clean the oil drain plug B and opening with a cotton cloth Note The oil drain plug B and oil filler screw A are fitted with a magnet that attracts metal filings n Check the oil drain plug B for metal particles if nec essary remove n Screw in the oil drain plug B and tighten using an Allen key n Dispose of used oil in accordance with the applicable environm...

Page 50: ...lay of more than 0 3 times the pick shaft diameter have the pick box or the wear sleeve immediately replaced Contact the authorized Customer Center dealer in your area 7 10 Replace round attack picks n You must replace the round attack picks if the tungsten carbide tip is worn if the head lengths of the round attack picks are dif ferent in case of cracks between the shaft and the head DANGER Risk ...

Page 51: ...ainer 1 Place the dismantling tool A with the semi circular opening onto the opening of the knock on re tainer B A B 2 Remove the knock on retainer B with a forceful hammer blow onto the dismantling tool A 3 Pull round attack pick out of the pick box 4 Clean the pick box 5 Insert a new round attack pick 6 Place a new knock on retainer B in the mounting tool C Note The retainer of the mounting tool...

Page 52: ...rface F directed to the cutter drum E F 2 Grip the puller E firmly in the hand 3 Give the impact surface F of the puller E a forceful blow with a hammer The round attack pick will loosen from the pick box 4 Pull round attack pick out of the pick box 5 Clean the pick box 6 Place a new round attack pick G in the notch of the puller The tip of the pick must point in the direction of the impact surfac...

Page 53: ...rved tip of the puller tool into the hole in the quick snap ring I I 2 Grip the puller tool firmly in the hand and pull it up wards see arrow The quick snap retainer loosens from the shaft of the round attack pick 3 Pull round attack pick out of the pick box 4 Clean the pick box 5 Slide a new round attack pick J into the pick box K see arrow I J K 6 Position the new quick snap retainer I with the ...

Page 54: ...k picks Long nose pliers curved 1 Remove both retaining rings L from the pick shaft one after another using long nose pliers M L M 2 Pull round attack pick out of the pick box 3 Clean the pick box 4 Insert a new round attack pick 5 Place a new retaining ring L on the pick shaft N and rotate the retaining ring opening downwards ar row L N 6 Attach the second retaining ring L and rotate the re taini...

Page 55: ...ocedures with heavy parts using suitable lifting gear u If lifting procedures require the application of physical force personnel should always lift in pairs u Wear protective gloves and safety footwear 7 11 1 Disassemble cutter drum ER 100 L ER 2000 L Actual details may differ n Disassemble the drum cutter from the carrier see chapter Removing the hydraulic attachment from the carrier and place o...

Page 56: ...r drum ERL 700 ERL 1100 Actual details may differ n Place the drum cutter on a level working area with sufficient bearing strength Note Do not remove the drum cutter from the carrier n Switch off the carrier n Secure the carrier such that it cannot move unexpect edly n Remove the fastening screws I and nuts H H E I n Place the cutter drum E on a pallet for further use and secure against rolling of...

Page 57: ...ces 7 11 3 1 Assemble cutter drum ER 100 L ER 2000 L n Disassemble the drum cutter from the carrier see chapter Removing the hydraulic attachment from the carrier and place on a level working area with sufficient bearing strength n Remove the adapter plate n Lift the drum cutter using suitable lifting equipment and suspend on a crane Observe the weight see chapter Technical Specifications n Place ...

Page 58: ...33 ft lbs 7 11 3 2 Assemble cutter drum ERL 700 ERL 1100 Actual details may differ Note The drum cutter is attached to the carrier n Place the cutter drum on a level working area with sufficient bearing strength n Switch on the carrier and push the hexagon of the drive shaft fully into the cutter drum E The holes of the cutter drum E must flush with the notches of the hexagon of the drive shaft n ...

Page 59: ...k of death due to use of old parts Using old parts old hydraulic hoses screws or retainers can lead to accidents which may in turn result in severe injuries u Only use new parts u Only use original parts Note When working on the hydraulic circuit always have suitable oil receiver tanks available and collect oil for environmental reasons Note When changing the hydraulic hoses always use the manufac...

Page 60: ...90 Nm 288 ft lbs Rotatable upper part fixing bolts in case of repair Allen key 10 mm 0 39 in 100 Nm 74 ft lbs 14 mm 0 55 in 180 Nm 133 ft lbs Cutter drum fixing bolts if necessary Allen key 10 mm 0 39 in 120 Nm 89 ft lbs 14 mm 0 55 in 300 Nm 221 ft lbs Overpressure cover fixing bolts in case of repair open ended wrench 17 mm 0 67 in 45 Nm 33 ft lbs 19 mm 0 75 in 75 Nm 55 ft lbs Hydraulic ports pre...

Page 61: ...75 in 700 Nm 516 ft lbs Rotatable upper part fixing bolts in case of repair Allen key 14 mm 0 55 in 180 Nm 133 ft lbs Cutter drum fixing bolts if necessary Allen key 14 mm 0 55 in 300 Nm 221 ft lbs 17 mm 0 67 in 560 Nm 413 ft lbs Overpressure cover fixing bolts in case of repair open ended wrench 19 mm 0 75 in 75 Nm 55 ft lbs 30 mm 1 18 in 400 Nm 295 ft lbs Hydraulic ports pressure line and tank l...

Page 62: ...7 in 1500 Nm 1106 ft lbs Rotatable upper part fixing bolts in case of repair Allen key 19 mm 0 75 in 700 Nm 516 ft lbs 17 mm 0 67 in 500 Nm 369 ft lbs Cutter drum fixing bolts if necessary Allen key 19 mm 0 75 in 950 Nm 701 ft lbs 19 mm 0 75 in 1400 Nm 1033 ft lbs Overpressure cover fixing bolts in case of repair open ended wrench 30 mm 1 18 in 400 Nm 295 ft lbs Hydraulic ports pressure line and t...

Page 63: ...ly stacked or scattered parts and tools can cause accidents u If parts have been removed ensure that these are assembled correctly reattach all fixing elements and adhere to the specified thread tightening torques u Prior to a restart ensure the following Ensure that all troubleshooting work is carried out and completed in accordance with the specifications and instructions in this manual Ensure t...

Page 64: ...ed Customer Center Dealer in your area Dismantle gear or drive Replace damaged parts Authorized Customer Center Dealer in your area Check valve installed inverted Install check valve as per hydraulic installation plan version 1 Workshop Hydraulic couplings of the hoses are blocked or excavator valve on boom not completly opened Check hydraulic couplings Open excavator valve Carrier driver 8 3 Cutt...

Page 65: ... In case of difficult work cutting as phalt consult the authorized Cus tomer Center Dealer in your region Workshop 8 7 Unusually loud gear noise Cause Remedy By Damage to internal gear parts Consult the authorized Customer Center Dealer in your region and re place gear Authorized Customer Center Dealer in your area 8 8 Unusually loud noise from the hydraulic motor Cause Remedy By Air inclusions in...

Page 66: ...stallation version 1 or 2 and measure oil pressure Workshop 8 10 Oil leaking at the cutter drum area Cause Remedy By Slide ring seals on output shaft dam aged high pressure seal between hy draulic motor and gear leaking Change set of slide ring seals Change high pressure seal between hydraulic motor and gear Authorized Customer Center Dealer in your area 8 11 Behaviour following fault elimination ...

Page 67: ...c attachment for repairs NOTICE Mixed hydraulic oil Never mix mineral and non mineral hydraulic oils Even small traces of mineral oil mixed in with non mineral oil can result in damage to both the hydraulic attachment and the carrier Non mineral oil loses its biodegradability u Only use one type of hydraulic oil n Always specify which hydraulic oil has been used when sending in the hydraulic attac...

Page 68: ...e of the stor age site Duration of storage Climate range Moderate Tropical Coastal 3 months A B C 6 months B C D 12 months C C D 24 months C D D Explanation to the measures specified in the table per taining to storage A No special maintenance measures necessary Apply plugs and closures B Fill hydraulic motor with hydraulic oil C Rinse hydraulic motor with preservation agent D Fill hydraulic motor...

Page 69: ...er the water table or water supplies u Collect any such consumables which may escape u Dispose of them in accordance with the applicable environmental regulations 11 1 Drum cutter n Switch off the drum cutter and secure against a restart n Remove the drum cutter from the carrier see chapter Removing the hydraulic attachment from the car rier n Remove the adapter plate see chapter Removing the hydr...

Page 70: ...r of picks 32 Pick shaft diameter 20 mm 0 79 in Maximum cutting force at 350 bar 5075 psi 14 0 kN 3147 lbf 15 7 kN 3530 lbf 16 9 kN 3799 lbf Maximum torque at 350 bar 5075 psi 2600 Nm 1918 ft lbs 2900 Nm 2139 ft lbs 3120 Nm 2301 ft lbs Maximum rock hardness 35 MPa 5076 psi Gear oil volume 0 25 l 0 07 gal Oil volume hydraulic motor 1 l 0 26 gal Hydraulic connections Drum cutter Pressure tank line L...

Page 71: ... Pick shaft diameter 20 mm 0 79 in Maximum cutting force at 350 bar 5075 psi 17 5 kN 3934 lbf 21 75 kN 4890 lbf 26 0 kN 5845 lbf Maximum torque at 350 bar 5075 psi 3500 Nm 2582 ft lbs 4350 Nm 3208 ft lbs 5200 Nm 3835 ft lbs Maximum rock hardness 35 MPa 5076 psi Gear oil volume 1 2 l 0 32 gal Oil volume hydraulic motor 1 5 l 0 40 gal Hydraulic connections Drum cutter Pressure tank line Leakage oil ...

Page 72: ...40 Pick shaft diameter 20 mm 0 79 in Maximum cutting force at 350 bar 5075 psi 43 50 kN 9779 lbf 52 00 kN 11690 lbf Maximum torque at 350 bar 5075 psi 8700 Nm 6417 ft lbs 10400 Nm 7671 ft lbs Maximum rock hardness 40 MPa 5802 psi Gear oil volume 1 2 l 0 32 gal Oil volume hydraulic motor 2 l 0 53 gal Hydraulic connections Drum cutter Pressure tank line Leakage oil line M24x1 5 M22x1 5 Hose lines in...

Page 73: ...30 Pick shaft diameter 22 mm 0 87 in Maximum cutting force at 350 bar 5075 psi 38 70 kN 8700 lbf 46 20 kN 10386 lbf Maximum torque at 350 bar 5075 psi 8700 Nm 6417 ft lbs 10400 Nm 7671 ft lbs Maximum rock hardness 40 MPa 5802 psi Gear oil volume 1 2 l 0 32 gal Oil volume hydraulic motor 2 l 0 53 gal Hydraulic connections Drum cutter Pressure tank line Leakage oil line M24x1 5 M22x1 5 Hose lines in...

Page 74: ... 42 Pick shaft diameter 22 mm 0 87 in Maximum cutting force at 350 bar 5075 psi 32 50 kN 7306 lbf 38 90 kN 7891 lbf Maximum torque at 350 bar 5075 psi 8700 Nm 6417 ft lbs 10400 Nm 7671 ft lbs Maximum rock hardness 45 MPa 6527 psi Gear oil volume 3 3 l 0 87 gal Oil volume hydraulic motor 2 l 0 53 gal Hydraulic connections Drum cutter Pressure tank line Leakage oil line M24x1 5 M22x1 5 Hose lines in...

Page 75: ...cks 30 Pick shaft diameter 22 mm 0 87 in Maximum cutting force at 350 bar 5075 psi 52 00 kN 11690 lbf Maximum torque at 350 bar 5075 psi 11700 Nm 8630 ft lbs Maximum rock hardness 45 MPa 6527 psi Gear oil volume 4 l 1 06 gal Oil volume hydraulic motor 3 l 0 79 gal Hydraulic connections Drum cutter Pressure tank line Leakage oil line M42x2 M30x2 Hose lines inside diameter Pressure tank line Leakage...

Page 76: ...ks 26 Pick shaft diameter 30 mm 1 18 in Maximum cutting force at 350 bar 5075 psi 70 0 kN 15737 lbf 78 0 kN 17535 lbf 93 6 kN 21042 lbf Maximum torque at 350 bar 5075 psi 17 5 kNm 12907 ft lbs 19 5 kNm 14382 ft lbs 23 4 kNm 17259 ft lbs Maximum rock hardness 60 MPa 8702 psi Gear oil volume 4 l 1 06 gal Oil volume hydraulic motor 5 l 1 32 gal Hydraulic connections Drum cutter Pressure tank line Lea...

Page 77: ...s 24 Pick shaft diameter 30 mm 1 18 in Maximum cutting force at 350 bar 5075 psi 45 6 kN 10251 lbf 51 5 kN 11579 lbf 57 3 kN 12881 lbf 68 8 kN 15467 lbf Maximum torque at 350 bar 5075 psi 15 5 kNm 11432 ft lbs 17 5 kNm 12907 ft lbs 19 5 kNm 14382 ft lbs 23 4 kNm 17259 ft lbs Maximum rock hardness 80 MPa 11603 psi Gear oil volume 4 5 l 1 19 gal Oil volume hydraulic motor 5 l 1 32 gal Hydraulic conn...

Page 78: ...m s 7 9 fps Number of picks 28 Pick shaft diameter 30 mm 1 18 in Maximum cutting force at 350 bar 5075 psi 61 9 kN 13916 lbf 77 2 kN 17355 lbf 93 0 kN 20907 lbf Maximum torque at 350 bar 5075 psi 22 3 kNm 16448 ft lbs 27 8 kNm 20504 ft lbs 33 5 Nm 24708 ft lbs Maximum rock hardness 80 MPa 11603 psi Gear oil volume 4 5 l 1 19 gal Oil volume hydraulic motor 6 l 1 59 gal Hydraulic connections Drum cu...

Page 79: ...31 89 in 350 mm 13 78 in 80 mm 3 15 in 1260 mm 49 61 in 350 mm 13 78 in 80 120 160 mm 3 15 4 72 6 30 in Rotational speed 50 110 rpm 40 80 rpm 40 80 rpm 40 80 rpm Oil flow optimal3 30 60 l min 7 93 15 85 gal US min 40 75 l min 10 57 19 81 gal US min 75 150 l min 19 81 39 63 gal US min 75 150 l min 19 81 39 63 gal US min Torque max 4 3120 Nm 2301 ft lbs 5200 Nm 3835 ft lbs 10400 Nm 7671 ft lbs 10400...

Page 80: ...mm 23 62 in 80 120 160 mm 3 15 4 72 6 30 in 1250 mm 49 21 in 660 mm 25 98 in 120 160 mm 4 72 6 30 in Rotational speed 50 90 rpm 50 70 rpm 50 70 rpm 30 60 rpm Oil flow optimal3 105 170 l min 27 74 23 78 gal US min 200 300 l min 52 83 79 25 gal US min 200 300 l min 52 83 79 25 gal US min 200 360 l min 52 83 95 10 gal US min Torque max 4 11700 Nm 8630 ft lbs 23400 Nm 17259 ft lbs 23400 Nm 17259 ft lb...

Page 81: ... H I Parts not included in the scope of delivery Parts included in the scope of delivery HP high pressure LP low pressure A Pressure line High pressure HP 350 bar 5075 psi max Q X l min Y gal min B Leakage oil line Leakage oil pressure 3 bar 43 5 psi max C Additional leakage oil filter D Tank line filter E Oil tank F Oil pump G Valve block H Hydraulic motor I Check valve 8 bar 116 psi J Tank line ...

Page 82: ... D E F G I B H Parts not included in the scope of delivery Parts included in the scope of delivery A Pressure line High pressure HP 350 bar 5075 psi max Q X l min Y gal min B Leakage oil line Leakage oil pressure 3 bar 43 5 psi max C Additional leakage oil filter D Oil tank E Oil pump F Tank G Valve block H Hydraulic motor I Tank line Low pressure LP 15 bar 217 5 psi min ...

Page 83: ... operated simultaneously at maximum operating pressure and maximum oil flow rate other wise the permissible nominal power is exceeded The drum cutter must be operated within the recommended power range The higher the operating pressure the higher the cutting force and torque The higher the oil flow the higher the rotational speed and pick speed 2 maximum permissible motor load The combination of o...

Page 84: ... 180 20 40 60 80 140 100 60 60 100 140 80 60 40 20 180 0 4 20 0 120 160 40 0 350 300 250 200 150 100 50 100 0 80 0 100 50 100 150 200 250 300 350 0 2 0 1 20 0 5 1 5 2 5 40 60 80 200 0 8 1 6 1 2 2 0 2 4 2 8 M kN m p bar Q l min n rpm M kN m p bar Q l min P n rpm M kN m p bar Q l min P 60 100 140 20 180 120 160 40 80 200 n rpm 20 kW 3 0 k W 2 1 20 kW 3 0 k W 2 1 20 kW 3 0 k W 2 1 ER 100 4L ER 100 2L...

Page 85: ...60 100 140 20 180 120 160 40 80 200 n rpm 1800 4 0 h p 2 27 hp 1 P 4 0 h p 2 27 hp 1 P 100 140 20 180 120 160 40 60 0 0 80 200 1000 2000 n rpm M ft lbs 25 1000 2000 3000 4000 5000 0 5 10 15 20 p psi Q gal min 4 0 h p 2 2 7 h p 1 P 0 0 40 160 120 2400 1200 180 20 140 100 60 80 n rpm M ft lbs 25 1000 2000 3000 4000 5000 0 5 10 15 20 p psi Q gal min ER 100 4L ER 100 2L ER 100 3L ...

Page 86: ...75 0 5 1 5 2 5 3 5 3 5 2 5 1 5 0 5 75 25 0 120 40 0 350 300 250 200 150 100 50 50 100 0 80 4 5 1 0 2 0 3 0 4 0 4 0 3 0 2 0 1 0 80 0 100 50 50 100 150 200 250 300 350 0 40 120 0 25 75 20 60 100 5 0 n rpm M kN m p bar Q l min P 160 80 40 120 n rpm M kN m p bar Q l min P n rpm M kN m p bar Q l min P 4 5 k W 2 3 0 k W 1 4 5 k W 2 3 0 k W 1 4 5 k W 2 3 0 k W 1 ER 250 2L ER 250 3L ER 250 4L ...

Page 87: ...8 1000 2000 n rpm M ft lbs p psi Q gal min P 160 80 1500 120 40 0 0 80 3000 n rpm M ft lbs 24 12 1000 2000 3000 4000 5000 0 6 18 p psi Q gal min P 4000 2000 80 0 0 40 120 20 60 100 n rpm M ft lbs 24 12 1000 2000 3000 4000 5000 0 6 18 p psi Q gal min P 6 0 h p 2 4 0 h p 1 ER 250 4 L 6 0 h p 2 4 0 h p 1 6 0 h p 2 4 0 h p 1 ER 250 2 L ER 250 3 L ...

Page 88: ...0 0 6000 0 3000 10 30 50 n rpm M ft lbs p psi Q gal min 80 100 60 40 20 65 kW 2 45 kW 1 9 0 h p 2 6 0 h p 1 9 0 h p 2 6 0 h p 1 65 kW 2 45 kW 1 80 0 100 150 50 50 100 150 200 250 300 350 0 20 40 60 100 2 6 8 4 0 1 3 5 7 9 25 75 125 175 10 30 50 70 90 110 90 70 50 30 10 175 125 75 25 9 7 5 3 1 0 4 8 6 2 100 60 40 20 0 350 300 250 200 150 100 50 50 150 100 0 80 10 n rpm M kN m p bar Q l min P P P n ...

Page 89: ...89 13 7 Hydraulic settings ERL 700 0 0 0 Q gal min M ft lbs 1000 p psi 2000 3000 4000 5000 20 40 60 10000 5000 7500 2500 7 0 k W 2 4 7 k W 1 9 4 h p 2 6 3 h p 1 0 100 150 200 50 50 100 150 200 250 300 350 0 20 40 60 100 10 80 8 6 4 2 12 0 n rpm 0 20 40 60 100 80 n rpm M kN m p bar Q l min P P ERL 700 ...

Page 90: ...0 0 20 30 40 50 60 15 5 10 90 100 20 100 90 10 5 15 60 50 40 30 20 0 350 300 250 200 150 100 50 10 50 300 250 200 150 100 350 0 70 80 110 80 0 350 100 150 200 250 300 50 50 100 150 200 250 300 350 0 20 40 60 100 120 8 4 12 16 n rpm M kN m p bar Q l min P n rpm M kN m p bar Q l min P n rpm M kN m p bar Q l min P n rpm M kN m p bar Q l min P 1 1 0 k W 2 7 8 k W 1 1 1 0 k W 2 7 8 k W 1 1 1 0 k W 2 7 ...

Page 91: ... 45 60 75 90 15 1000 2000 3000 4000 5000 p psi Q gal min P 0 50 0 0 7500 15000 n rpm M ft lbs 30 45 60 75 90 15 1000 2000 3000 4000 5000 p psi Q gal min P 0 100 50 7500 15000 60 40 0 0 80 n rpm M ft lbs 30 45 60 75 90 15 1000 2000 3000 4000 5000 p psi Q gal min P 0 20 1 5 0 h p 2 1 0 5 h p 1 1 5 0 h p 2 1 0 5 h p 1 1 5 0 h p 2 1 0 5 h p 1 1 5 0 h p 2 1 0 5 h p 1 ER 1500 3L ERL 1100 3 ER 1500 0L ER...

Page 92: ...0 80 12 4 90 100 110 2 6 10 14 18 90 4 12 80 70 60 50 40 30 20 8 20 28 24 0 16 350 300 250 200 150 100 50 10 50 300 250 200 150 100 350 400 450 0 0 450 400 350 100 150 200 250 300 50 10 50 100 150 200 250 300 350 20 0 30 35 25 10 20 30 40 50 60 70 15 5 n rpm M kN m p bar Q l min P n rpm M kN m p bar Q l min P n rpm M kN m p bar Q l min P 0 0 0 24 100 kW 1 160 kW 2 100 kW 1 160 kW 2 100 kW 1 160 kW...

Page 93: ...5 1000 2000 3000 4000 5000 p psi Q gal min 0 12000 80 60 40 20 6000 0 18000 0 n rpm M ft lbs 120 105 30 45 60 75 90 15 1000 2000 3000 4000 5000 p psi Q gal min 0 0 120 105 30 45 60 75 90 15 1000 2000 3000 4000 5000 0 7000 14000 n rpm M ft lbs p psi Q gal min 0 75 50 25 100 P P P 135 hp 1 215 hp 2 135 hp 1 215 hp 2 135 hp 1 215 hp 2 ER 2000 1L ER 2000 3L ER 2000 2L ...

Page 94: ...udinal drum cutter ER 100 2L ER 450 1L ER 1500 0L ER 100 3L ER 450 2L ER 1500 1L ER 100 4L ER 600 1L ER 1500 2L ER 250 2L ER 600 2L ER 1500 3L ER 250 3L ERL 700 ER 2000 1L ER 250 4L ERL 1100 1 ER 2000 2L ER 400 1L ERL 1100 2 ER 2000 3L ER 400 2L ERL 1100 3 Following harmonised standards were applied n EN ISO 12100 n EN 474 1 Technical Documentation authorised representative Roger Dähne Anbaufräsen...

Page 95: ......

Page 96: ...Anbaufräsen PC GmbH 3390 5221 01 2020 09 07 Any unauthorized use or copying of the contents or any part thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings ...

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