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Instructions on the correct use of the hydraulic cutter

Caution!

K

Fig. 11

Ensure  that  the  carrier  is
positioned  on  firm  ground.  If
this  is  not  the  case,  the  car
rier  may  fall  over.

Caution!

K

Fig. 12

When  working  on  floors/
roofs,  ensure  that  they  are
strong  enough  to  bear  the
weight  of  the  carrier.
Danger  of  collapse!

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Содержание CombiCutter CC 1501

Страница 1: ...Operating instructions CombiCutter hydraulic cutter CC 1501 CC 2100 and CC 4000 Valid from 07 2003 GB T Id Nr 3363 0028 88 CC 2100 ...

Страница 2: ......

Страница 3: ... 2100 CC 4000 E Atlas Copco Construction Tools GmbH Atlas Copco Construction Tools GmbH P O Box 102152 D 45021 Essen Helenenstrasse 149 D 45143 Essen Federal Republic of Germany Telephone 49 201 633 0 Telefax 49 201 633 2281 Telefax Customer Support 49 201 633 1352 ...

Страница 4: ...n to the safety regula 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...

Страница 5: ...ed below CAUTION Please note The marked text provides instructions on the correct use of the hydraulic tool aimed at avoiding incorrect operation or errors during work The marked text provides safety regula tions and instructions aimed at avoiding damage to equipment WARNING The marked text provides safety regula tions and instructions aimed at avoiding accidents and possible injuries ...

Страница 6: ...draulic cutter 16 8 2 2 Mounting the hydraulic cutter on the carrier 17 9 Operating the hydraulic cutter 18 9 1 Media consumables 18 9 1 1 Mineral hydraulic fluids 18 9 1 2 Environment friendly fluids 18 9 2 Start up 19 9 3 Functional test 19 9 4 Limitations when cutting steel 20 9 5 Instructions on the correct use of the hydraulic cutter 20 9 6 Underwater applications 27 10 Care and maintenance o...

Страница 7: ...tter jaw CC 1501 S single 39 10 7 11 Presentation Cutter jaw CC 2100 S single 40 10 7 12 Presentation Cutter jaw CC4000 S single 40 10 8 Maintenance schedule 41 10 9 Lubricant recommendations 43 10 9 1 Presentation Lubrication points on the hydraulic cutters CC 1501 CC 2100 and CC 4000 43 11 Troubleshooting 44 11 1 Hydraulic cutter does not work 44 11 2 Insufficient breaking force 44 11 3 Hydrauli...

Страница 8: ...table below ÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂ Cutter model ÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂ Carrier weight class CC 1501 CC 2100 CC 4000 15 25 t 22 35 t 35 50 t Check the pressure relief valve for the cutter circuit on the hydraulic system to ensure it is set exactly to the reference value Caution Collect any oil which runs out and dispose of it correctly The oil can be very hot risk of burns Cutter operati...

Страница 9: ...reventive checks listed Dismounting the hydraulic cutter Dismounting the hydraulic cutter requires the presence of an assistant who must be instructed by the carrier driver The carrier driver and assistant should agree beforehand on clear hand signals Observe the carrier manufacturer s safety regulations When putting the carrier out of operation the carrier manufacturer s instructions shall apply ...

Страница 10: ...ed onto the cutter below the lifting lug These data should be quoted in all correspondence especially when ordering spare parts so as to clearly identify the cutter Fig 1 CC 2100 Nameplate 2 1 Scope of supply The general scope of supply for a Atlas Copco CombiCutter includes H hydraulic cutter H operating manual H spare parts list H info sheet H special accessories as ordered e g hydraulic convers...

Страница 11: ...ld these nameplates be lost or defaced replacements can be ordered from your dealer Atlas Copco Construction Tools The following information must be provided Part ident no ser no of the tool and date of delivery from the delivery note 1 Name and address of manufacturer 2 Model 3 Serial no 4 Part ident no 5 Max permissible operating pressure 6 Year of manufacture of product group 7 Weight of produc...

Страница 12: ...n capability o 360 hydraulisch Oil flow rate for rotating mechanism l min to 15 to 30 to 30 Operating pressure for rotating mechanism bar 130 220 Two piece blade for cutting steel N mm2 370 see Section 9 4 Blade length mm 350 380 350 380 525 525 Connecting thread hydraulic motor Non soldered coupling with cutting ring DIN 2353 or 24o conical seal M 20 x 1 5 Connecting thread hydraulic cylinder Non...

Страница 13: ...g the carrier with the hydraulic cutter mounted the carrier manufacturer s safety regulations shall apply 6 Transportation and storage Caution When lifting the hydraulic cutter use only the lug provided and sufficiently powerful lifting equipment Ropes and lug must be in good condition The hydraulic cutter should be deposited on a wooden support of sufficient size and strength Collect any oil whic...

Страница 14: ...g cylinder pin main bearing pin cutter jaw single cutter tooth cutter blades Table of dimensions a b CC 1501 U CC 2100 U 2150 1400 1925 790 850 c 1300 CC 4000 U 2079 1740 1130 CC 1501 S CC 2100 S CC 4000 S 1927 2556 2462 1300 1400 1740 385 400 490 14 7 Main components Fig 2 shows the components of the hydraulic cutter and their designations ...

Страница 15: ...ion of the existing hydraulic equipment by Atlas Copco s Customer Support or an authorised dealer will determine the extent of retrofitting required 8 1 3 Checking existing hydraulic facility for cutter operation Examination by Atlas Copco s Customer Support or an authorised dealer will determine whether the hydraulic facility is suitable for cutter operation regardless of whether a Atlas Copco or...

Страница 16: ... Allen key size 22 CC 2100 Allen key size 22 Tools required See Fig 4 CC 4000 Allen key size 27 Caution Use only the Allen screws included in supply When transporting the cutter use only the transport lug provided and sufficiently powerful lifting equipment Note for anyone using this operating manual Figures marked with do not correspond exactly to the CC 1501 CC 2100 and CC 4000 cutter models but...

Страница 17: ...to the adapter in such a way that the bores in the stick adapter are aligned Insert stick pin and secure as shown in Fig 5 K Fig 5 To fit the toggle pin extend the shovel cylinder and position the toggle by hand until the bores are aligned with those in the adapter Insert toggle pin and secure Caution K Fig 6 Agree on clear hand signals with assistants Never use your fingers to check whether the p...

Страница 18: ... determining whether the hydraulic tool can be run on fluids of this kind it is imperative to know the name and exact type of the fluid involved The manufacturers provide data sheets for each type with characteristic data such as components base viscosity temperature limits compatibility etc Max oil temperature 60oC Before using fluids of this kind it is imperative to enquire with the carrier manu...

Страница 19: ...unctional test rotating clockwise and anticlockwise The cutter can be rotated either by using the carrier function rotate cutter or mechanically by pushing one of the cutter jaws against a firm object When rotating the cutter mechanically ports A and B se page 13 must be closed using the screw plugs included in supply Connection via rotate cutter function Ensure that the existing hoses for this fu...

Страница 20: ...60 mm 220 mm 300 mm 240 mm 320 mm 400 mm 400 mm 150 150 20mm 160 160 22mm 160 160 22mm 200 200 24mm 250 250 24mm 250 250 24mm F 7 x Ø28 mm 9 x Ø28 mm 10 x Ø28 mm 10 x Ø28 mm 18 x Ø28 mm 20 x Ø28 mm 9 5 Instructions on the correct use of the hydraulic cutter The hydraulic pulverizer may only be used for the applications described Refer to section 5 The following examples show how to use the hammer ...

Страница 21: ...er Caution K Fig 11 Ensure that the carrier is positioned on firm ground If this is not the case the car rier may fall over Caution K Fig 12 When working on floors roofs ensure that they are strong enough to bear the weight of the carrier Danger of collapse ...

Страница 22: ... the top down wards Large chunks of the bro ken material may other wise fall onto the cutter or carrier and cause dam age If necessary larger elements should be se cured beforehand Caution KFig 13 Warning K Fig 14 Change the hydraulic cut ter s point of attack in good time Wherever possible demolition should be started on narrower faces ...

Страница 23: ...e boom extended to the side This will re strict the carrier s stability and may cause it to fall over Warning K Fig 16 Never support the weight of the carrier on the hydraulic cutter so as to shift the car rier to the side Warning K Fig 17 Never lift or transport loads with the hydraulic cutter ...

Страница 24: ... 18 Never move the boom or the cutter when demolition is in progress This will cause serious damage to the hydraulic cutter Warning K Fig 19 Never rotate the hydraulic cutter when demolition is in progress This will cause serious damage to the hydraulic cutter and the boom ...

Страница 25: ...hydraulic cutter Warning K Fig 20 Never hack or pound with the hydraulic cutter since this will cause serious dam age to the cutter Warning K Fig 21 Never use the hydraulic cutter as a crowbar since this will cause serious dam age to the cutter ...

Страница 26: ...hen demolition is in progress Bending movements of this nature will cause serious damage to the hydraulic cutter Warning K Fig 23 Never pull at girders sup ports and walls with the hy draulic cutter This will damage both the hy draulic cutter and the adap ter The carrier may also be come unstable and fall over ...

Страница 27: ...material The hydraulic cutter is not de signed for this kind of work 9 6 Underwaterapplications The hydraulic cutter must never be used for underwater applications Use for other special applications e g in high temperatures breaking highly abrasive material etc also requires prior consultation with Atlas Copco s Customer Support ...

Страница 28: ...s are factory set to the oil flow rate required for cutter rotation They settings must not be adjusted Risk of injury 10 2 Maintenance work 10 2 1 Maintenance work to be performed by the carrier driver H All lubrication points must be adequately greased Ensure that grease lubrication is refreshed at least once a day Suitable lubricating greases are listed in the lubricant recommendations Section 1...

Страница 29: ... new blades always use new fastening screws Use only genuine Atlas Copco fastening screws Q Warning Missing blades must be replaced immediately Working without blades causes serious damage to the blade seat on the cutter jaw Repairing the blade seat is highly time consuming and expensive Q Caution When removing the blades it is imperative that a copper drift be used to knock them out The blades ar...

Страница 30: ...aded ring until the clearance between the blades is almost 0 mm 6 Use the special tool see table 7 Refit the locking pin in the threaded ring on the side to which the jaw has been moved One of the threaded ring s locating bores must be flush with those in the cover Under no circumstances should the threaded ring be tightened further to allow the locking pin to be fitted 8 By tightening the other t...

Страница 31: ...Fig 26 S S A B Distance between points A and B 0 05 to 0 1 mm cutter jaw single cutter jaw double threaded ring 1 threaded ring 2 cap locking pin 31 Setting the blade clearance ...

Страница 32: ...etainer bolt can only be unscrewed by mechanically damaging the nut or the bolt Warning Missing teeth must be replaced immediately Working without teeth causes serious damage to the tooth support and the cutter jaw Repairing the cutter jaws is highly time consuming and thus expensive Fig 27 Unscrew bolt ...

Страница 33: ...must first be welded in place before hard facing Before welding the cutter jaw in question must be removed from the cutter and fitted components such as blades and teeth removed In order to achieve the best possible results the following welding regulations must be observed Welding instructions Welding filler VDG Mo Ni Wire electrode 8 Ni Mn Mo 35 Shield gas CO2 M 21 DIN 32526 Preheating for weldi...

Страница 34: ... CO2 M 21 DIN 32526 Interpass temperature max 160 o C Preheating temperature for welding MAX 100 o C Interpass temperature max 200 o C Annealing to eliminate hydrogen 1 hour at 150 o 200 o Welding filler DIN 8555 MSG 1 GZ 250 Dura EA 250 SG DIN 8555 MSG 1 GZ 60 Dura EA 600 SG Shield gas CO2 M 21 DIN 32526 Cooling under cover Fig 28 to 39 shows the zone which is armoured by hard facing The number o...

Страница 35: ...r EA 600 SG 3 layer EA 600 SG 3 layer Hard facing must not protrude Warning Only the welding filler indicated may be used 10 7 3 Presentation Cutter jaw CC 1501 S double Fig 30 Hard facing EA 600 SG Hard facing lengthwiseweld beads EA 250 SG Hard facing lengthwiseweld beads EA 250 SG Warning Only the welding filler indicated may be used Hard facing must not protrude ...

Страница 36: ...d facing must not protrude Warning Only the welding filler indicated may be used 10 7 5 Presentation Cutter jaw CC 2100 U double Fig 32 EA 250 SG 1 layer EA 250 SG 1 layer EA 600 SG 3 layer EA 600 SG 3 layer Hard facing must not protrude Bottom pass EA 600 SG continuous on top of that 2 layer pattern EA 600 SG Warning Only the welding filler indicated may be used ...

Страница 37: ...ude EA 600 SG 1 layer 37 10 7 6 Presentation Cutter jaw CC 2100 S double Fig 33 20 13 10 40 260 Hard facing lengthwiseweld beads EA 250 SG Hard facing lengthwiseweld beads EA 250 SG Hard facing must not protrude Hard facing 2 layer pattern EA 600 SG Warning Only the welding filler indicated may be used Hard facing EA 600 SG 10 7 7 Presentation Cutter jaw CC4000 U single ...

Страница 38: ...facing must not protrude Bottom pass EA 600 SG conC tinuous on top of that 2 layer pattern EA 600 SG 10 7 9 Presentation Cutter jaw CC 4000 S double Fig 36 Scharf kantig 24 50 314 Warning Only the welding filler indicated may be used Hard facing EA 600 SG Hard facing lengthwiseweld beads EA 250 SG Hard facing must not protrude Hard facing lengthwiseweld beads EA 250 SG Hard facing 2 layer pattern ...

Страница 39: ...layer on cutter jaws S single Preheating temperature for buffer layer 100 o C Welding filler DCMS IG wire electrode EN 12070 G CrMo1Si W Nr 17339 Shield gas M 21 DIN EN 439 Interpass temperature 100 o 180 o C Preheating temperature for welding 100 o C Interpass temperature 100 o 200 o C Welding filler EN 12072 G 13 4 CN 13 4 IG wire electrode Fa Böhler Shield gas CO2 M 21 DIN 32526 Cooling under c...

Страница 40: ...cing CN 13 4 IG 40 10 7 11 Presentation Cutter jaw CC 2100 S single Fig 38 When hard facing leave an area apC prox 40 mm dia around the bore free Hard facing must not protrude Hard facing CN 13 4 IG Hard facing CN 13 4 IG Hard facing CN 13 4 IG Warning Only the welding filler indicated may be used 10 7 12 Presentation Cutter jaw CC4000 S single ...

Страница 41: ...spanner size 24 100 20 Cutter blades 4 daily CC 1501 CC 2100 Allen key 530 30 Cutter blades 4 daily CC 2100 CC 4000 Allen key size 17 530 30 Cutter jaws set ting blade clear ance 5 as required CC 1501 CC 2100 CC 4000 jaw spanner size 55 special tool see Section 10 4 340 10 max blade clear ance 2 mm CC 1501 Allen key size 14 290 15 Ball bearing slewing gear K 6 weekly CC 2100 Allen key size 10 150 ...

Страница 42: ...Bild 40 4 5 1 6 3 2 A B CC 2100 42 ...

Страница 43: ...ccordance with the maintenance schedule on page 41 of the manual with the exception of the lubrication points on the 4 point bearing which require lubrication once per month Recommended lubricant Atlas Copco cutter grease part ident no 3362 2635 19 supplied in 500 g cartridges For the lubrication points on the 4 point bearing KP2K greases must be used i e lithium base saponified mineral oils NLGI ...

Страница 44: ...ientbreaking force ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ Cause ÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂ Remedy ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ By Operating pressure too low con nections for lines A and B mixed up Connect up lines A and B correctly Carrier driver Operating pressure too low Correct operating pressure Workshop or Atlas Copco Customer Support 11 3 ...

Страница 45: ...relief valve Correct carrier engine speed Cor rect pump pilot system if available Carrier driver or Atlas Copco Customer Support Pressure relief valve defective Fit new pressure relief cartridge Atlas Copco Customer Support Oil level in tank too low Top up oil Carrier driver or workshop 11 6 Oil leaks from hydraulic ports ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂ Cause ÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂÂÂÂÂ ÂÂÂÂÂÂÂÂ...

Страница 46: ...utes Ensure all hoses are facing upwards Seal off all open hose connections Cover up the hydraulic hammer to protect it against the weather Caution Please note The hydraulic oil can become very hot Risk of burns Collect any oil which runs out and dispose of it correctly Clear hand signals must be agreed on beforehand with assistants Keep your hands well clear of the carrier boom when the stick and...

Страница 47: ... Limitations when cutting steel 20 H Lubricant recommendations 43 M H Main components 14 H Maintenance schedule 41 H Maintenance work 28 H Maintenance work to be performed by the car rier driver 28 H Mechanical attachment 16 H Media consumables 18 H Mineral hydraulic fluids 18 H Mounting the hydraulic cutter on the carrier 17 O H Oil leaks from hydraulic ports 45 H Operating temperature too high 4...

Страница 48: ...tion Tools GmbH Helenenstrasse 149 S 45143 Essen P O Box 10 21 52 S 45021 Essen Federal Republic of Germany Telephone 49 201 633 0 Telefax 49 201 633 2281 Telefax Customers Support 49 201 633 1352 Internet www hydraulic attachments com ...

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