HB Series

HB 3100, 3100 DP, 3600, 3600 DP, 4100, 4100 DP, 4700, 4700 DP
Safety and operating instructions

Hydraulic breakers
© Construction Tools GmbH | 3390 5203 01 | 2019-08-06

Original Instructions
Contents
Table of Contents
1 Introduction ................................................................................................................................ 8
1.1 About these Safety and Operating Instructions............................................................................................... 8
2 Safety instructions..................................................................................................................... 9
2.1 Signal words........................................................................................................................................................ 9
2.2 Qualification ...................................................................................................................................................... 10
2.3 Intended use ...................................................................................................................................................... 10
2.4 Use other than intended ................................................................................................................................... 10
2.5 Protective equipment........................................................................................................................................ 11
2.6 Carrier, precautions .......................................................................................................................................... 11
2.7 Transport, precautions ..................................................................................................................................... 11
2.8 Hydraulic installation, precautions ................................................................................................................. 12
2.9 Special parts, precautions ............................................................................................................................... 12
2.9.1 HP-accumulator............................................................................................................................................... 12
2.9.2 Piston accumulator .......................................................................................................................................... 12
2.10 Media/consumables, precautions.................................................................................................................... 13
2.11 Explosion and fire, precautions....................................................................................................................... 13
2.12 Electrical shock, precautions .......................................................................................................................... 14
2.13 Falling stones, precautions.............................................................................................................................. 14
2.14 Emissions, precautions.................................................................................................................................... 14
2.15 Handling machines, precautions..................................................................................................................... 14
2.16 Repair, precautions........................................................................................................................................... 15
2.17 Changes to the hydraulic attachment, precautions....................................................................................... 15
2.18 Environmental pollution, precautions............................................................................................................. 15
3 Overview ................................................................................................................................... 16
3.1 Equipment description ..................................................................................................................................... 16
3.2 Function ............................................................................................................................................................. 16
3.3 Signs / labels ..................................................................................................................................................... 17
3.3.1 Name plate ...................................................................................................................................................... 17
3.3.2 Labels .............................................................................................................................................................. 17
3.3.3 Signs................................................................................................................................................................ 17
3.4 Applications....................................................................................................................................................... 18
3.5 Guarantee .......................................................................................................................................................... 18
3.6 Removing the packaging.................................................................................................................................. 18
3.7 Scope of delivery .............................................................................................................................................. 18
4 Transport .................................................................................................................................. 19
4.1 Transport using a crane ................................................................................................................................... 20
4.2 Transport using a forklift truck........................................................................................................................ 20
4.3 Transport using a truck .................................................................................................................................... 21
5 Installation ................................................................................................................................ 22
5.1 Media/consumables .......................................................................................................................................... 22
5.1.1 Mineral hydraulic oil......................................................................................................................................... 22
© Construction Tools GmbH | 3390 5203 01 | 2019-08-06 3

Contents
5.1.2 Non-mineral hydraulic oil ................................................................................................................................. 22

5.1.3 Grease............................................................................................................................................................. 22
5.1.4 Gas .................................................................................................................................................................. 22
5.2 Manufacturing the adapter plate...................................................................................................................... 23
5.3 Installing the adapter plate............................................................................................................................... 23
5.4 Attaching the hydraulic attachment to the carrier ......................................................................................... 24
5.4.1 Mechanical mounting aspects ......................................................................................................................... 24
5.4.2 Making the hydraulic connections ................................................................................................................... 24
5.5 Removing the hydraulic attachment from the carrier.................................................................................... 26
5.5.1 Dismantling the hydraulic connections ............................................................................................................ 26
5.5.2 Mechanical disassembly.................................................................................................................................. 26
5.6 Removing the adapter plate ............................................................................................................................. 26
5.7 DustProtector .................................................................................................................................................... 27
5.7.1 Removal .......................................................................................................................................................... 27
5.7.2 Installation ....................................................................................................................................................... 27
5.8 Working tool ...................................................................................................................................................... 28
5.8.1 Selecting the right working tool........................................................................................................................ 28
5.8.2 Installation ....................................................................................................................................................... 29
5.8.3 Removal .......................................................................................................................................................... 30
6 Operation .................................................................................................................................. 31
6.1 Initial operation and operation after long storage ......................................................................................... 31
6.2 Preparations before starting ............................................................................................................................ 32
6.3 Switching the hydraulic breaker on and off ................................................................................................... 32
6.4 Functional test................................................................................................................................................... 32
6.5 Correct operation .............................................................................................................................................. 33
6.5.1 Working angle.................................................................................................................................................. 33
6.5.2 Advance........................................................................................................................................................... 33
6.5.3 Impact time ...................................................................................................................................................... 33
6.5.4 High ambient temperature ............................................................................................................................... 34
6.5.5 Low ambient temperature................................................................................................................................ 34
6.6 Prohibited operation ......................................................................................................................................... 35
6.6.1 Lifting/Transporting.......................................................................................................................................... 35
6.6.2 Impacting ......................................................................................................................................................... 35
6.6.3 Moving objects................................................................................................................................................. 35
6.6.4 Levering........................................................................................................................................................... 35
6.6.5 Blank firing of the working tool......................................................................................................................... 36
6.6.6 Cylinder end positions ..................................................................................................................................... 36
6.7 Working with safety equipment ....................................................................................................................... 37
6.7.1 Underwater applications .................................................................................................................................. 37
6.7.2 Usage in tunnels.............................................................................................................................................. 37
6.7.3 Hot applications ............................................................................................................................................... 37
6.8 AutoControl System ......................................................................................................................................... 37
6.8.1 AutoControl in daily use................................................................................................................................... 37
6.8.2 AutoControl in special applications.................................................................................................................. 37
6.9 Intelligent Protection System (IPS) ................................................................................................................. 37
6.10 PowerAdapt ....................................................................................................................................................... 38
7 Maintenance ............................................................................................................................. 39
7.1 Maintenance schedule...................................................................................................................................... 40
7.2 Depressurising the hydraulic system ............................................................................................................. 41
7.3 Cleaning ............................................................................................................................................................. 42
4 © Construction Tools GmbH | 3390 5203 01 | 2019-08-06

Contents
7.3.1 Preparations .................................................................................................................................................... 42

7.3.2 Procedure ........................................................................................................................................................ 42
7.4 Lubrication......................................................................................................................................................... 42
7.4.1 Checking the lubricant film .............................................................................................................................. 42
7.4.2 Automatic lubrication ....................................................................................................................................... 43
7.4.3 Replacing the lubricant cartridge ..................................................................................................................... 43
7.4.4 ContiLube® II operation................................................................................................................................... 43
7.4.5 Manual lubrication ........................................................................................................................................... 44
7.4.6 Chisel paste filling device ................................................................................................................................ 44
7.5 Checking the tensioning bolts......................................................................................................................... 45
7.6 Checking the working tool ............................................................................................................................... 45
7.7 Checking the retainer bars............................................................................................................................... 46
7.8 Checking the percussion piston impact surface ........................................................................................... 46
7.9 Checking the wear bushes and impact ring ................................................................................................... 47
7.10 Checking and cleaning the DustProtector system ........................................................................................ 48
7.11 Piston accumulator........................................................................................................................................... 49
7.11.1 Checking the pressure in the piston accumulator............................................................................................ 50
7.11.2 Release the pressure from the piston accumulator ......................................................................................... 50
7.11.3 Filling / topping up the piston accumulator ...................................................................................................... 50
7.12 HP-accumulator................................................................................................................................................. 51
7.12.1 Visual check .................................................................................................................................................... 51
7.12.2 Checking the fastening screws........................................................................................................................ 52
7.12.3 Checking the gas pressure.............................................................................................................................. 52
7.13 Checking the hydraulic lines ........................................................................................................................... 53
7.14 Checking and cleaning the hydraulic oil filter................................................................................................ 53
7.15 Checking the adapter plate and the breaker box for cracks and/or wear.................................................... 53
7.16 Checking the adapter plate bolts for wear...................................................................................................... 53
7.17 Bolt connections / Tightening torques ........................................................................................................... 54
8 Troubleshooting....................................................................................................................... 57
8.1 The hydraulic breaker does not start .............................................................................................................. 57
8.2 Hydraulic breaker operates too slowly ........................................................................................................... 57
8.3 Impact force too low ......................................................................................................................................... 58
8.4 Impact rate too high and impact force too low .............................................................................................. 58
8.5 Oil leaks from ports »P« und »T« .................................................................................................................... 59
8.6 Oil escapes between the cylinder cover and the cylinder ............................................................................ 59
8.7 Oil escapes from parts of the hydraulic breaker installation (connecting fittings, hoses etc.) ................ 59
8.8 Oil escapes from the working tool .................................................................................................................. 59
8.9 Oil escapes from the high pressure accumulator.......................................................................................... 59
8.10 Oil or grease escapes from the ContiLube® II ............................................................................................... 60
8.11 Operating temperature too high ...................................................................................................................... 60
8.12 Pressure line »P« flails violently ..................................................................................................................... 60
9 Repair ........................................................................................................................................ 61
9.1 Sending in the hydraulic attachment for repairs ........................................................................................... 61
10 Storage...................................................................................................................................... 62
10.1 Hydraulic breaker.............................................................................................................................................. 62
10.1.1 Short storage ................................................................................................................................................... 62

Contents
10.1.2 Long storage.................................................................................................................................................... 62

10.1.3 How to proceed after more than twelve months‘ storage ................................................................................ 62
10.2 Working tool ...................................................................................................................................................... 63
10.3 Grease cartridges.............................................................................................................................................. 63
11 Disposal .................................................................................................................................... 64
11.1 Hydraulic breaker.............................................................................................................................................. 64
11.2 Hydraulic hoses ................................................................................................................................................ 64
11.3 Hydraulic oil....................................................................................................................................................... 64
11.4 Chisel paste and grease cartridges................................................................................................................. 64
12 Technical specifications.......................................................................................................... 65
12.1 Noise declaration statement ............................................................................................................................ 67
13 EC Declaration of Conformity (EC Directive 2006/42/EC) .................................................... 68

Contents

1 Introduction 1.1 About these Safety and

Epiroc is a leading productivity partner for the mining, in- Operating Instructions
frastructure and natural resources industries. With cut- The aim of these Instructions is to familiarise you with
ting-edge technology, Epiroc develops and produces in- the safe and effective operation of the hydraulic attach-
novative drill rigs, rock excavation and construction ment. You will also find instructions for regular mainte-
equipment, and provides world-class service and con- nance activities for the hydraulic attachment in this docu-
sumables. ment.
The company was founded in Stockholm, Sweden, and Please read these Instructions carefully prior to the first
has passionate people supporting and collaborating with attachment and use of the hydraulic attachment.
customers in more than 150 countries.
In these instructions, the DustProtector version of the hy-
Construction Tools GmbH draulic breaker will be referred to by the abbreviation
P.O. Box: 102152 DP.
Helenenstraße 149 The different designation of the texts means as follows:
D - 45021 Essen
► Action step in a safety instruction
Tel.: +49 201 633-0
♦ Action step
1. Established operation process

2.
A Explanation of the elements of a drawing

B
C
• Listing
•
•
Symbols used in illustrations have the following mean-

ings:
permitted operation
prohibited operation

2 Safety instructions 2.1 Signal words

The signal words Danger, Warning, Caution, and Notice
This is the safety alert symbol. It is used to alert
are used as follows in these Safety and operating in-
you to potential personal injury hazards. Obey
all safety messages that follow this symbol to structions:
avoid possible injury or death.
DANGER indicates a hazardous situation
Read these Safety and operating instructions which, if not avoided, will result in
and specifically all safety instructions before us- death or serious injury.
ing the hydraulic attachment. This will:
WARNING indicates a hazardous situation
• prevent the risk of injuries and fatal accidents for which, if not avoided, could result in
yourself and others, death or serious injury.
• protect the environment against environmental dam-
CAUTION indicates a hazardous situation
age. which, if not avoided, could result in
• protect the hydraulic attachment and other property minor or moderate injury.
against material damage,
NOTICE The signal word NOTICE is used to
Follow all instructions in these Safety and operating in- address practices related to possible
structions. property damage but not related to
personal injury.
Store these Safety and operating instructions in the doc-
ument compartment of the carrier cab.
Anyone
• transporting,
• installing or removing,
• operating,
• maintaining,
• repairing,
• storing or
• disposing of
the hydraulic attachment must have read and under-
stood these Safety and operating instructions.
These Safety and operating instructions belong to the
hydraulic attachment. Keep it for the life of the 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 outside the European
Union is subject to the laws and regulations valid in the
country of use. Please observe any other, more stringent
regional regulations and legislation.
Read the carrier manufacturer's Safety and operating In-
structions before attaching the hydraulic attachment to
the carrier and operating it. Observe all instructions.

2.2 Qualification 2.3 Intended use

Transporting the hydraulic attachment is only permitted Only attach the hydraulic breaker to a hydraulic carrier of
if carried out by people who: a suitable load-bearing capacity.
• are authorised to operate a crane or a forklift truck Only use the hydraulic breaker function of the device to
according to the applicable national provisions, break or fragment concrete, stone and rocks.
• know all the relevant national/regional safety provi-
Using the hydraulic breaker in and under water, in tun-
sions and accident prevention rules,
nels, under the ground and for hot applications is only
• have read and understood the safety and transport
possible if it has been fitted out with special safety equip-
chapter of these Safety and operating instructions.
ment.
Installing, maintaining, storing and disposing of the
Intended use also implies observing all instructions in
hydraulic attachment are only permitted if carried out by
these Safety and operating instructions.
people who:
• know all the relevant national/regional safety provi-
sions and accident prevention rules, 2.4 Use other than intended
• have read and understood these Safety and operat-
ing instructions. Never operate the hydraulic breaker in an environment
where there is a risk of explosions. Explosions will result
Operating the hydraulic attachment is only permitted if
in serious injury or death.
carried out by qualified carrier drivers. Carrier drivers are
qualified if they: Never use the hydraulic breaker
• have been trained to operate a carrier according to • to transport or lift objects. The lifted object can fall
the national regulations, and cause serious injuries or death.
• know all the relevant national/regional safety provi- • as a sledge hammer. This will damage the hydraulic
sions and accident prevention rules, breaker, the working tool and the carrier.
• have read and understood these Safety and operat- • as a crowbar. This can cause the working tool to
ing instructions. break.
• to push debris. This damages the hydraulic breaker.
Testing the hydraulic installation is only permitted if
carried out by professionals. Professionals are people
who are authorised to approve a hydraulic installation for
operation according to the national regulations.
Repairing the hydraulic attachment is only permitted if
carried out by professionals trained by Construction
Tools GmbH. These professionals must have read and
understood these Safety and operating instructions.
They must follow all safety instructions and guidelines
for repair. Otherwise the operational safety of the hy-
draulic attachment is not guaranteed.

2.5 Protective equipment 2.7 Transport, precautions

Personal protective equipment must comply with the ap- WARNING Risk of death due to suspended loads
plicable health and safety regulations.
When lifting loads these can swing out and fall. This can
n Do not work wearing jewelry or with loose long hair. result in serious injuries or even death.
Moving machine parts could catch your hair or jew- u Never stand underneath or in the swinging range of
elry causing serious injury. suspended loads.
n Wear comfortable, close-fitting work clothes. The u Only move loads under supervision.
moving machine parts can snag loose clothing and u Only use approved lifting equipment and lifting gear
cause serious injury. with sufficient load bearing capacity.
u Do not use worn lifting gear (ropes, belts, chains,
Always wear the following personal protective equip- shackles etc.).
ment: u Do not place lifting gear such as ropes and belts on
• protective helmet sharp edges or corners, do not knot these or twist
• safety glasses with side protectors them.
• protective gloves u When leaving the workplace, set down the load.
• protective shoes WARNING Injury due to swivelling load
• warning vest
When transporting the load by crane it can swivel and
• hearing protection
cause severe injuries and considerable damage to prop-
erty.
2.6 Carrier, precautions u Ensure that no personnel, objects or obstacles are
located in the swivel range of the load.
WARNING 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 carrier must remain stable at all times.
u Read the carrier manufacturer's Safety and operating
Instructions before attaching the hydraulic attach-
ment to the carrier and operating it. Observe all in-
structions.

2.8 Hydraulic installation, 2.9 Special parts, precautions

precautions
2.9.1 HP-accumulator
WARNING Hydraulic pressure too high
If the hydraulic pressure is too high, the parts of the hy- DANGER Danger of explosions
draulic attachment will be exposed to excessively high The HP-accumulator of the hydraulic breaker is filled
loads. Parts can break loose or burst causing serious in- with nitrogen (N2). Filling it with any other gas may trig-
juries. ger an explosion and lead to serious, possibly fatal, in-
u Lay the drain line of the pressure relief valve directly juries.
in the tank to ensure the safe functioning of the pres- u Only fill the HP-accumulator with nitrogen (N2).
sure relief valve! u Do not carry out any welding and soldering work to
u The pressure relief valve must be set at the maxi- the HP-accumulator.
mum static pressure. u Check the HP-accumulator in accordance with the
u The pressure relief valve setting must be checked to national safety provisions.
ensure that the maximum static pressure (see chap-
WARNING Component coming loose abruptly
ter Technical specifications) of the hydraulic instal-
Risk of bursting
lation is not exceeded at any time. Attach a lead seal
to the pressure relief valve. The HP-accumulator is under pressure, even when the
u Prior to their first use, the safety facilities on the hy- hydraulic system has been depressurised. Screw con-
draulic installation must be checked by a profes- nections might come loose unexpectedly and cause in-
sional/authorised monitoring body for their quality juries.
(CE mark etc.), suitability and proper functioning. u Never unscrew the cover or the upper shell from a
u If any significant changes are made to the hydraulic pressurised HP-accumulator.
installation, a new acceptance inspection is to be u Never carry out mechanical processing to the HP-ac-
carried out in accordance with the relevant national cumulator.
safety provisions.
WARNING Hot hydraulic oil squirting out 2.9.2 Piston accumulator

The hydraulic system is under high pressure. Hydraulic DANGER Danger of explosions
lines may spring a leak or burst. Hydraulic oil squirting
The integrated piston accumulator is filled with nitrogen
out can lead to serious injury.
(N2). Filling it with any other gas may trigger an explo-
u When attaching the hydraulic attachment do not lay
sion and lead to serious, possibly fatal, injuries.
any hydraulic lines through the carrier's cab.
u Only fill the piston accumulator with nitrogen (N2).
u Only use hydraulic lines which comply with the fol-
lowing quality requirements: WARNING Component coming loose abruptly
- Hydraulic hoses with 4 reinforcement steel wires The piston accumulator is under pressure, even when
according to DIN EN 856 4SH, the hydraulic system has been depressurised. The filling
- Hydraulic pipes, seamless cold-drawn steel pipes valve might come loose unexpectedly and cause in-
according to DIN EN 10305 juries.
u Never unscrew the filling valve »G« from the pres-
surised piston accumulator.

2.10 Media/consumables, 2.11 Explosion and fire,

precautions precautions
WARNING Hot hydraulic oil under high pressure DANGER Explosion and fire
Hydraulic oil will squirt out under high pressure if there is Explosions cause serious injury or death. If the working
a leakage. The jet of oil might penetrate people's skin tool hits explosives, an explosion may be the result.
and cause permanent damage. Hot hydraulic oil can u Never operate the hydraulic breaker in the direct
cause burns. vicinity of explosives.
u Never use your hands to find leaks. u Make sure that no explosives are hidden in the rocks
u Always keep your face away from a possible leak. and stones.
u If hydraulic oil has penetrated your skin consult a u Check gas line position plans of the entire construc-
doctor immediately. tion area.
WARNING Hydraulic oil spills DANGER Explosion and fire

Spilt hydraulic oil can make a floor slippery. If people slip Operating the hydraulic breaker may create sparks
they can be injured. Hydraulic oil is environmentally which ignite highly flammable gases. This may lead to
harmful and must not penetrate the ground or enter the fire or an explosion.
water table or water supplies. u Never work in an environment with highly flammable
u Make sure not to spill any hydraulic oil. substances.
u Immediately clean the floor if you have spilt hydraulic u Make sure that there are no hidden sources of gas in
oil. the work area.
u Observe all safety and environmental protection pro- u Check gas line position plans of the entire construc-
visions when handling hydraulic oil. tion area.
WARNING Skin infections/diseases due to oil and DANGER Explosion and fire
grease Dust-rich air can form an explosive atmosphere which
Hydraulic oil and grease can cause rashes (or even may ignite when operating the hydraulic breaker. This
eczema) if they come into contact with the skin. may lead to fire or an explosion.
u Avoid all skin contact with hydraulic oil and grease. u Never use the hydraulic breaker in an explosive at-
u Use a suitable skin protection product. mosphere.
u Always wear safety gloves when working with hy- u Always provide sufficient ventilation when working in
draulic oil or grease. buildings or in a confined area.
u Immediately clean any skin that has been contami-
nated by oil or grease with water and soap.

2.12 Electrical shock, precautions 2.14 Emissions, precautions

DANGER Electrical shock WARNING Noise hazard
Any contact of the hydraulic attachment with electric cir- Operating the hydraulic attachment creates a loud noise.
cuits or other sources of electricity will lead to an electric Long term high sound pressure level can affect your
shock, resulting in serious injury or death. The hydraulic hearing.
attachment is not electrically insulated. u Wear suitable hearing protection.
u Never work in the vicinity of electric circuits or other
WARNING Lung disease
sources of electricity.
u Make sure that there are no hidden circuits in the Dust may be generated when operating the hydraulic at-
work area. tachment. If dust from rocks or silica dust, produced
u Check wiring diagrams. when operating the hydraulic attachment on rocks, con-
crete, asphalt or other such materials, is inhaled this
may lead to silicosis (dust lungs, a severe lung disease).
2.13 Falling stones, precautions Silicosis is a chronic disease which may lead cancer and
death.
WARNING Fragments flying around u Wear a suitable breathing mask.
Fragments of material which come loose while operating
the hydraulic attachment may be flung away and can
cause serious injury if people are hit by them. Small ob- 2.15 Handling machines,
jects falling from a great height can also cause serious
precautions
damage.
During hydraulic attachment operation the danger zone WARNING Narcotics, alcohol and drugs
is considerably greater than during the excavation oper- Narcotics, alcohol and medicinal drugs make their users
ation due to fragments of stone and pieces of steel flying less alert and affect their ability to concentrate. Negli-
around, and for this reason the danger zone must, de- gence and incorrectly assessing a situation can result in
pending on the type of material to be worked on, be en- serious injury or death.
larged correspondingly, or secured in a suitable manner u Never work on or with the hydraulic attachment when
through corresponding measures. under the influence of narcotics, alcohol or drugs
u Secure the danger zone. which affect your alertness.
u Stop the hydraulic attachment immediately if anyone u Never allow other people who are under the influ-
enters the danger zone. ence of narcotics, alcohol or drugs which affect their
u Close the windscreen and the side windows of the alertness to work on or with the hydraulic attach-
driver's cab. ment.

2.16 Repair, precautions 2.18 Environmental pollution,

WARNING Heavy parts falling precautions
The main parts of the hydraulic breaker are heavy. Un- NOTICE Environmental pollution due to hydraulic oil
suitable lifting attachments (e.g. ring or eye bolts) may
Hydraulic oil is permanently environmentally harmful. Es-
fail and cause heavy parts to fall. Falling parts may
caped hydraulic oil will lead to groundwater and soil con-
cause serious injury.
tamination. Organisms may die.
u Never pull the percussion unit out of the breaker box.
u Collect any hydraulic oil which escapes to avoid envi-
Dismounting the percussion unit is only permitted if
ronmental pollution. For minor volumes use an ab-
sorbing medium (in case of an emergency use soil).
Tools GmbH. These professionals must follow all
In case of major leakages contain the hydraulic oil. It
safety instructions and guidelines for repair.
must not drain off and penetrate the ground or enter
u These professionals are only permitted to repair the the water table or water supplies.
percussion unit if they use the sling gears prescribed
u Collect contaminated absorbing medium or soil in a
by Construction Tools GmbH when:
watertight box/container and close it tight.
- removing the complete percussion unit.
u Contact an authorized waste management company.
- mounting or dismounting parts of the percussion
u Dispose of all contaminated material in accordance
unit.
with the applicable environmental regulations.
2.17 Changes to the hydraulic

attachment, precautions
WARNING Changes to the hydraulic attachment
Changes to the hydraulic attachment or the adapter
plate may lead to serious injury.
u Never carry out any changes to the hydraulic attach-
ment or the adapter plate.
u Only use original parts or accessories approved by
Epiroc.
u Modifications that entail new hazards may require a
new procedure for assessing conformity.
WARNING Changes to the HP-accumulator

Changes to the HP-accumulator may lead to serious in-
jury.
u Never carry out any changes to the HP-accumulator.
u Any modification will result in immediate invalidation
of the operating licence.

J. The working tool is retained in the lower breaker

3 Overview part.
K. The percussion piston is guided in the cylinder.
L. Pressure line »P«
3.1 Equipment description
M. Non-return valve of percussion compartment venti-
The illustration gives an overview of the main parts and lation
components of the hydraulic attachment. Actual details N. The swivel joint covers protect the swivel joints.
may differ.
A
3.2 Function
The operation of a hydraulic breaker is described in a
greatly simplified version below:
N
The pressure line »P« supplies oil at the operating pres-
B sure of the carrier to the hydraulic breaker. The tank line
M »T« returns the oil to the tank of the carrier. The HP-ac-
C
D cumulator compensates pressure variations in the hy-
draulic system.
E
The percussion piston moves up and down in the cylin-
der. When the percussion piston is in its lower position, it
L
impacts the working tool. The percussion energy is
N transferred to the material to be broken via the working
tool.
F
K
H G
A. The hydraulic breaker is connected to the carrier by

the adapter plate. The adapter plate is not included
in the scope of supply of the hydraulic breaker.
B. Tank line »T«
C. Automatic lubrication system ContiLube® II
D. The cylinder cover houses the nitrogen gas (N2)
filled piston accumulator and the control mechanism.
E. The HP-accumulator compensates pressure varia-
tions in the hydraulic system.
F. The breaker box protects the percussion unit.
G. Working tool aperture protective cap
H. The working tool can be replaced as required. The
working tool is not included in the scope of supply of
the hydraulic breaker.
I. The DustProtector system prevents dust from en-
tering the percussion compartment (only on the
DP version).

3.3 Signs / labels 3.3.2 Labels
WARNING Missing warnings Sound Power
The name plate and the labels on the hydraulic attach- The label states the guaranteed
ment contain important information about the hydraulic sound power level in accordance
WA with EC directive 2000/14/EC.
attachment and for personal safety. A missing warning
xxx dB
can lead to overlooking or misinterpretation of possible
risks and cause personal hazards. The signs and labels
must always be clearly legible.
u Immediately replace any defective name plates and
labels. Transport warning
u Use the spare parts list to order new name plates
and labels. Never lift the hydraulic breaker
by the transport safety device.
This was not designed for lifting
and might break, causing the hy-
3.3.1 Name plate draulic breaker to fall
Lubrication symbol
The label identifies a lubrication

point.
Gas pressure
A. Model The label indicates that the gas

Gasdruck nur bei betriebswarmem Hammer prüfen!
Only check the gas pressure
when the hammer is at operating temperature! pressure can only be checked if
B. Year of construction of hydraulic attachment Ne contrôler la pression d´azote que si le marteau
est à température de service!
Controllare la pressione del gas solo a mortello the breaker has reached operat-
a temperature d´esercizio!
C. Max. permissible operating pressure ¡Controlar la presión del gas sólo con el martillo
a temperatura de régimen!
ing temperature.
D. Weight of hydraulic attachment
E. Serial number
F. Name and address of manufacturer 3.3.3 Signs
G. The warning symbol and the book symbol indicate
that the Safety and Operating Instructions must be The warning symbol and the
book symbol indicate that the
read prior to use of the hydraulic attachment and in
Safety and Operating Instruc-
particular the chapter on Safety. tions must be read prior to use of
H. The CE symbol indicates that the hydraulic attach- the hydraulic attachment and in
ment was produced in conformity with CE. You can particular the chapter on Safety.
find further information about this in the enclosed EC
Declaration of Conformity.
I. The EAC symbol means that the machine is EAC
approved.

3.4 Applications 3.6 Removing the packaging

n Remove all the packaging material.
Field Type of application
n Dispose of it in accordance with the applicable provi-
General construction work Trenchwork for utilities,
foundation work sions.
Demolition Heavily reinforced con- n Check that the delivery is complete.

crete, demolition of power
stations and bridges n Check the delivery for visual damage.
Rock mining / breaking Primary breaking n If any defects are found, consult the Epiroc Customer
Center / dealer in your area.
Secondary breaking,
bench leveling foundation
work
Tunneling*, mining* Bench levelling 3.7 Scope of delivery

Tunnel driving The hydraulic breaker is delivered complete with:
• Hydraulic breaker
High temperature applica- Breaking up slag
tions* • Test gauge lower wear bush
• Safety and Operating instructions
Underwater applications* Demolition, Deepening
shipping channels • Spare parts list
• EC Declaration of Conformity
* only after consulting the Epiroc Customer Center /
Dealer in your area Accessories as ordered:
• Working tool
• Hoses
3.5 Guarantee • Service box
The guarantee or product liability will be invalidated by Special accessories as ordered:

the following: • e.g. adapter plate with Allen screws and pairs of lock
• Use other than intended washers
• Maintenance work not being carried out or being • e.g. base plate to construct an adapter plate with
carried out incorrectly Allen screws and pairs of lock washers
• The use of incorrect consumables • e.g. hydraulic fittings for the carrier
• The use of non-approved parts • e.g. piston retainer
• Damage due to wear • e.g. calliper upper wear bush
• Damage due to improper storage
• Changes not carried out by or in consultation with
the manufacturer

A
4 Transport
WARNING Hoist tipping over / hydraulic attach-
ment falling B
The hydraulic attachment is heavy. The hoist/lifting
equipment and/or hydraulic attachment tipping over or
falling may cause serious injury and material damage.
u Only transport the hydraulic attachment with lifting
● the material is worn up to the checkpoints (A, B).
equipment with the right load-bearing capacity for the
weight 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.
WARNING Percussion unit falling

The percussion unit slides out of the breaker box if not Use permitted
secured by the adapter plate or the transport safety de-
vice. The falling percussion unit may cause serious in-
jury and material damage.
u Never transport a hydraulic breaker without mounted
adapter plate or transport safety device.
u Immediately mount the transport safety device after
removal of the adapter plate.
u The percussion unit must not move in the breaker
box even if the transport safety device is mounted. A Use prohibited
sliding percussion unit can destroy the transport ● the lifting eye is bent.
safety device. ● you detect cracks in the lifting eye or the weld
u Replace a missing elastic pad, if necessary e.g. with seam.
a wooden block. This keeps the percussion unit fixed u Contact the authorized Customer Center / Dealer in
in the breaker box during transport. your area if the lifting eye is worn in any way.
u Immediately replace a defective transport safety de-
vice. Use the spare parts list to order a new transport
safety device. If not in use save the transport safety
device for future use.
WARNING Hydraulic breaker falling

The lifting eye may fail and cause the hydraulic breaker
to fall. This may cause serious injury and material dam-
age.
u Check the lifting eye before you lift the hydraulic
breaker. Never lift the hydraulic breaker with the lift-
ing eye if:
● the checkpoints (A) are worn and not protruding
anymore
or
● the checkpoints (B) are worn and not recessed
anymore.

4.1 Transport using a crane 4.2 Transport using a forklift

n Secure the hydraulic attachment with ropes or chains truck
as shown in the following illustration.
WARNING Hydraulic attachment tipping over
The hydraulic attachment tipping off the fork of the forklift
truck or the pallet may cause serious injury.
u Place the hydraulic attachment on a pallet.
u Strap the hydraulic attachment to the pallet using
suitable strapping, as shown in the illustration below.
u Move the fork of the forklift truck under the pallet so
that the centre of gravity is between the prongs.
n Move the fork of the forklift truck under the pallet so

that the hydraulic attachment cannot tip over.
n Slowly lift the hydraulic attachment.
n Place the hydraulic attachment on timber support

blocks.
n Slowly lift the pallet with the hydraulic attachment.
n Transport the pallet with the hydraulic attachment to

the location provided for.

4.3 Transport using a truck

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
injury.
u Place the hydraulic attachment on a pallet.
u Strap the hydraulic attachment to the pallet using
suitable strapping (see illustration in chapter Trans-
port using a forklift truck).
u Place the pallet with the hydraulic attachment on an
anti-slip mat.
u Secure the hydraulic attachment to the loading area
with ropes or chains; use any available transport
lugs.
n Secure the hydraulic attachment on the pallet and the
loading surface as shown in the following illustration.
n Observe all the applicable national/regional regula-

tions on securing loads.

5 Installation 5.1.2 Non-mineral hydraulic oil

NOTICE Mixed hydraulic oil
WARNING Hot hydraulic oil squirting out
Never mix mineral and non-mineral hydraulic oils! Even
The hydraulic system is under high pressure. If hydraulic small traces of mineral oil mixed in with non-mineral oil
connections come loose or are disconnected, hydraulic can result in damage to both the hydraulic attachment
oil will squirt out under high pressure. Hydraulic oil and the carrier. Non-mineral oil loses its biodegradability.
squirting out can lead to serious injury. u Only use one type of hydraulic oil.
u Depressurise the hydraulic system before connecting
If you are using non-mineral oil it is imperative that the
or disconnecting the hydraulic circuits of the hy-
name of the oil in use be indicated when returning the
draulic attachment (see chapter Depressurising the
hydraulic attachment for repair.
hydraulic system).
In order to protect the environment or on technical
NOTICE Environmental damage due to hydraulic oil
grounds, hydraulic oils are currently being used which
Hydraulic oil is environmentally harmful and must not are not classified as HLP mineral oils.
penetrate the ground or enter the water table or water
Before using hydraulic oils of this kind it is imperative to
supplies.
ask the carrier manufacturer whether operations with
u Collect any hydraulic oil which escapes.
such fluids are possible.
u Dispose of it in accordance with the applicable envi-
ronmental regulations. Our hydraulic attachments are basically designed for use
with mineral oils. Consult the Epiroc Customer Center /
Dealer in your area before using other hydraulic oils ap-
5.1 Media/consumables proved by the carrier manufacturer. Following initial as-
sembly and after any workshop repairs, our hydraulic at-
The following consumables are used when operating the
tachments are subjected to a test run on a test bed pow-
hydraulic attachment:
ered by mineral oil.
5.1.1 Mineral hydraulic oil

5.1.3 Grease
All hydraulic oil brands prescribed by the carrier manu-
n When handling oils and greases observe the safety
facturer are also suitable for use when operating the hy-
instructions that apply to these products.
draulic attachment.
However, the oil should comply with viscosity class
Media / consumables Part number
HLP 32 or higher.
Chisel paste 3363 1223 56 (Bio)
In summer and in hot climates, oils of viscosity class
(for ContiLube® II) 3363 0912 00
HLP 68 or higher should be used.
Parker O-Lube
In all other respects the regulations of the carrier manu-
facturer are to be taken into consideration.
Optimum viscosity range = 30 - 60 cSt 5.1.4 Gas

Max. start viscosity = 2000 cSt Normal nitrogen, purity degree 99.8 %
Max. oil temperature = 80 °C Media / consumables Part number
Special conditions apply to using the hydraulic attach- Nitrogen bottle 2 l 3363 0345 04
ment at low temperatures (see chapter Low ambient Nitrogen bottle 5 l 3363 0345 06
temperature).
n Check the oil filter!
An oil filter must be integrated in the tank line of the
hydraulic system. The maximum mesh width allowed
for the oil filter is 50 microns; it must have a magnetic
separator.

5.2 Manufacturing the adapter WARNING Hands and fingers being cut off or hurt
Bores and surfaces can act like a pair of scissors and
plate
cut off or hurt parts of your body.
Construction Tools GmbH also supplies base plates to u Never use your fingers to check bores or fitting sur-
manufacture adapter plates alternatively to the adapter faces.
plates supplied.
n Align the adapter plate (D) to the hydraulic breaker as
NOTICE Adapter plate cracking shown.
The adapter plate may crack if it is not designed for the
high load. A
u Take not only the weight of the hydraulic attachment B
but also the crowd force of the carrier, possible vibra-
tion etc. into account when dimensioning the adapter
plate. C
u Ensure that the design conforms to the state of the
art. D
u Have the web plates welded to the adapter plate
base plate by a qualified welding specialist.
The base plate is made of the material EN10025-S355
J2G3.
n Have the web plates designed and manufactured or
procure web plates to fit your carrier.
n Ensure that the web plates are welded to the base

plate side marked "TOP". n Fit a pair of lock washers (B) onto every screw.
n Tighten the Allen screws (A) with an Allen key.

The adapter plate must not strike in any position during
operation of the hydraulic attachment. n Tighten the Allen screws (A) with the required tight-
Construction Tools GmbH does not design, manufacture ening torque.
or sell web plates for adapter plates.
Type Key size Tightening torque
HB 3100 / 27 mm 2300 Nm (1696 ft lbs)

5.3 Installing the adapter plate HB 3100 DP (1.06 in.)
NOTICE The adapter plate can come loose HB 3600 / 27 mm 2300 Nm (1696 ft lbs)
The adapter plate can come loose if the fastening HB 3600 DP (1.06 in.)
screws are not designed for local high loads. HB 4100 / 27 mm 2300 Nm (1696 ft lbs)
u Only use the Allen screws of strength category 8.8 HB 4100 DP (1.06 in.)
and the pairs of lock washers included in the delivery
HB 4700 / 27 mm 2300 Nm (1696 ft lbs)
to attach the adapter plate or the base plate. HB 4700 DP (1.06 in.)
n Place the hydraulic breaker on timber support blocks
within the range of the carrier. The breaker box ser-
vice opening must be facing upwards.
n Remove the transport safety device which keeps the

elastic pad (C) and the percussion unit in the breaker
box.
n Apply Anti-Seize to the Allen screw threads (A) be-

fore inserting them.
The contact faces of the screw head and the lock
washers (B) must not be lubricated.

5.4 Attaching the hydraulic

attachment to the carrier
5.4.1 Mechanical mounting aspects

You need an assistant to attach the hydraulic attachment
to the carrier.
n Agree on hand signals with your assistant, to enable
him to help you placing the carrier in the proper posi-
tion to attach the hydraulic attachment.
n Lower the stick of the carrier into the holder provided

on the adapter plate.
WARNING Injury by impacts

A sudden movement of the carrier may cause your as-
n Extend the bucket cylinder (E) until the bore in the
sistant to be hit and injured by the boom or the hydraulic
linkage (F) links up with the bore in the adapter
attachment.
plate (B).
u Only move the boom very slowly and in a controlled
manner while an assistant is within the danger zone. n Install the linkage bolt (G) and lock it.
u Always keep sight of your assistant.
n Carefully move the bucket cylinder (E) into both end
WARNING Hands and fingers being cut off or hurt positions.
Bores and surfaces can act like a pair of scissors and
The adapter plate must not be stopped by mechanical
cut off or hurt parts of your body.
stops in either position. Consult the Epiroc Customer
u Never use your fingers to check bores or fitting sur-
Center/Dealer in your area if the adapter plate is stopped
faces.
by a mechanical stop.
n Let your assistant instruct you until the bores in the
adapter plate (B) and in the stick (A) are properly
aligned. 5.4.2 Making the hydraulic connections
NOTICE Faulty hydraulic installation
n Install the stick bolt (C) and lock it.
The carrier must have a suitable hydraulic installation to
operate the hydraulic attachment. Improperly installed
lines and incorrectly rated sizes may cause the oil to
heat up and the hydraulic attachment to be damaged.
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 hydraulic system according to the

n Lift the hydraulic attachment (D). manufacturer's safety and operating instructions for
the carrier.
n If no quick couplings are used, close all shut-off

valves in the installation at the boom.

NOTICE Total damage to the hydraulic attachment WARNING Components bursting

Polluted hydraulic lines and connections may enable Components of the swivel joint may burst. Metal parts
sand, fragments of material and dirt to penetrate the hy- may become projectiles and cause serious injuries and
draulic attachment and damage it completely. damage property.
u Clean the hydraulic lines and connections before u Always check the swivel joint covers are fitted prop-
connecting the hydraulic hoses. Lay all hydraulic erly when attaching the hydraulic breaker to the car-
hoses so that they are torsion-free. rier.
n Install the pressure and tank hoses. u Tighten loosen screw connections (see chapter Bolt
connections / Tightening torques).
n Connect the pressure and tank hoses.
u Immediately replace a defective swivel joint cover.
n Remove the caps from the ports »P« and »T« and
save them for future use.
The pressure port »P« has been marked with red
paint as an extra reference.
n Check that the ports and connections on the hy-

draulic breaker and/or on the hydraulic hoses are not
damaged.
n Replace any damaged connections.
n Connect the pressure hose to port »P«, making sure

it is torsion-free.
n Connect the tank hose to port »T«, making sure it is

torsion-free.
WARNING Hydraulic hose flailing about

Pressurised hydraulic hoses will flail about if a bolted
n If no quick couplings are used, open the shut-off connection comes loose or becomes loosened. A hy-
valves in the installation at the boom. draulic hose flailing about may cause serious injuries.
u Tighten the fastening screws with the right tightening
n Switch on the carrier.
torque.
n Let the hydraulic oil run through the carrier oil filter for Tightening torque (see chapter Bolt connections /
approx. three minutes to make sure that the hoses Tightening torques).
are clean.
n Switch off the carrier.
n Depressurise the hydraulic system according to the

manufacturer's safety and operating instructions for
the carrier.
n If no quick couplings are used, close all shut-off

valves in the installation at the boom.
n Disconnect the pressure and tank hoses.

WARNING Hot parts

The percussion unit, the working tool, 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 Close all shut-off valves in the installation at the
boom if no quick couplings are used.
n Disconnect the hose lines to and from the hydraulic

attachment at the boom side.
n Close off all open hose ends.
5.5.2 Mechanical disassembly

n You need an assistant to remove the hydraulic at-
tachment.
n Agree on hand signals with your assistant, to enable

him to help you move the boom.
5.5 Removing the hydraulic WARNING Injury by impacts

A sudden movement of the carrier may cause your as-
attachment from the carrier sistant to be hit and injured by the boom or the hydraulic
n Place the hydraulic attachment on timber support attachment.
blocks. u Only move the boom very slowly and in a controlled
manner while an assistant is within the danger zone.
5.5.1 Dismantling the hydraulic WARNING Metal chips shooting off
connections
When hammering out bolts, chips may shoot off and
WARNING Unexpected movement cause serious eye injuries.
u Wear safety glasses when hammering out the bolts.
Sudden movements of the carrier may cause serious in-
jury. n Remove the bolt locks from the stick and linkage
u Secure the carrier such that it cannot move unex- bolts.
pectedly.
n Drive out the linkage bolt with a steel arbor and a
u Observe the carrier manufacturer’s instructions.
hammer.
WARNING Hydraulic hose flailing about
n Switch on the carrier.
Pressurised hydraulic hoses will flail about when bolted
connections have come loose or have been loosened. A n Retract the bucket cylinder.
hydraulic hose flailing about may cause serious injuries. n Drive out the stick bolt with a steel arbor and a ham-
u Depressurise the hydraulic system before discon- mer.
necting a hydraulic hose (see chapter Depressuris-
ing the hydraulic system). n Move the carrier stick out of the adapter plate.
5.6 Removing the adapter plate

n Loosen the fastening screws of the adapter plate.

n Lift the adapter plate with a suitable lifting equipment n Remove the guide ring (F), floating ring (E) and
and put it down on timber support blocks. counter ring (D) of the DustProtector system.
n Lock the elastic pad with the transport safety device. n Remove the wiper (A).
n Save the fastening screws and the pairs of lock

To make the wiper (A) easier to remove: Push the seal-
washers for future use. ing lip of the wiper inwards with your thumb. This pushes
the wiper out of the wiper sleeve ring groove.
5.7 DustProtector 5.7.2 Installation

n Place the hydraulic breaker on timber support blocks.
n Before installing the DustProtector, install the working
tool (see chapter Working tool/Installation).
WARNING Unexpected movement
n Manually push the wiper (A) over the working tool
and let it click into place in the wiper sleeve ring
jury.
groove.
u Secure the carrier such that it cannot move unex-
pectedly. n Use a tool (hammer handle) to push on the wiper (A)
u Observe the carrier manufacturer’s instructions. at several points.
WARNING Metal chips shooting off n Use your thumbs to push the wiper into place along
When hammering out bolts, chips may shoot off and its circumference.
cause serious eye injuries. n Apply chisel paste to the guide ring (F), floating
u Wear safety glasses when hammering out the bolts. ring (E) and counter ring (D).
F n Install the floating ring (E) and counter ring (D) in the
E
guide ring (F).
D n Push the rings over the working tool and install them
in the lower part of the breaker box.
n Turn the guide ring (F) so that the apertures in the

C breaker box and the guide ring are lined up.
n Drive the lock bolts (C) into place using a pin punch
B and a hammer.
n Seal the apertures in the breaker box with the

plugs (B).
A
5.7.1 Removal
n Remove the working tool (see chapter Working tool/
Removal) before removing the DustProtector.
n Remove the plugs (B) from the breaker box.
n Drive out the lock bolts (C) of the DustProtector using

a pin punch and a hammer.

5.8 Working tool 5.8.1 Selecting the right working tool

The standard available working tools are shown. The dif-
WARNING Unexpected movement
ferent cutter geometries may influence the production re-
Sudden movements of the carrier may cause serious in- sult, depending on the actual use. Please consult the fol-
jury. lowing table for recommended uses.
pectedly. Conical moil point
u Observe the carrier manufacturer’s instructions. Suitable for universal use
WARNING Metal chips shooting off Very good penetration
Even splitting effect distribution
When hammering out bolts, chips may shoot off and
No torsion effect
cause serious eye injuries.
u Wear safety glasses when hammering out the bolts.
Pyramidal moil point
WARNING Heavy working tool
Suitable for universal use
The working tool is heavy; if it falls it may cause serious
injury. Lifting the working tool without suitable lifting Very good penetration
equipment may lead to physical injury. Even splitting effect distribution
u Lift the working tool with lifting equipment designed Slight torsion effect
for the weight of the working tool.
WARNING Hands and fingers being cut off or hurt Chisel and spade
Bores and surfaces can act like a pair of scissors and Mining, demolition work, ground
cut off or hurt parts of your body. work, foundations
u Never use your fingers to check bores or fitting sur- Very good splitting effect distri-
faces. bution
u Do not reach into the aperture in the lower breaker Very good penetration
part or between the working tool and the lower Torsion effect
breaker part.
Blunt tool
Mining, block holing, demolition

work
Very good energy transfer

Optimum in-cutting effect
No torsion effect

5.8.2 Installation n Remove the screws (Z), washers (Y), plate (X), and
plugs (E).
n Use a pin punch and a hammer to drive the bolt (G)
NOTICE The working tool may break for the retainer bars (D) out of the lower breaker
There is an increased risk of the working tool breaking if part (F) from the side.
it has not been stored in frostfree conditions. n Remove the two plugs (C) from the slotted holes for
u Store the working tool in a frostfree environment for the retainer bars (D).
one day before installing it. or
n Screw one screw (M 12) into the bore on the front
u Heat up the working tool for several hours, e.g. with
a heating blanket, until it has warmed up thoroughly. side of the retainer bars.
Z n Pull out the retainer bars by the screw.

X Y
Retainer bar and wiper removed:
C
If the retainer bars and the wiper (only on hydraulic
D
breakers with DustProtector) have been removed, pro-
A E ceed as follows:
n Clean the insertion area of the working tool (A).
F
n Grease the insertion area of the working tool (A) with
chisel paste.
H n Grease both retainer bars (D) with chisel paste.
n Install the working tool (A).
n Put the retainer bars (D) in place.
n Turn the working tool (A) until the retainer bars (D)
G slide into place in the slotted holes of the lower
breaker part (F).
Wiper installed (only hydraulic breakers with DustProtec-
tor): n Remove the screw from the retainer bars (D).
When installing the working tool for the first time after it n Install the sealing plugs (C).
has been delivered, you first have to remove the
wiper (H) from the DustProtector. n Drive the bolt (G) into place using a pin punch and a
hammer.
n Remove the wiper (H) from the DustProtector (see
chapter DustProtector/Removal). n Install the plate (X), washers (Y), screws (Z), and the
plugs (E).
NOTICE Damage to the wiper
n If the hydraulic breaker is a DustProtector type, install
If the wiper is not removed it will bend back when in- the wiper (H) (see chapter DustProtector/In-
stalling the working tool. The wiper can then no longer stalling).
be used.
u Remove the wiper before installing the working tool.
Retainer bar installed:
When installing the working tool for the first time after it
has been delivered, you must remove the protective cap
and the retainer bars.
n Remove the protective cap from the aperture for the
working tool.
n Store the protective cap for future use.

5.8.3 Removal
WARNING The working tool suddenly comes

loose
A clamped working tool is still under the pressure of the
piston accumulator. When the working tool is loosened,
it will partly jump out of the hydraulic breaker; this may
lead to serious injury.
u Never position yourself directly in front of the in-
stalled working tool.
WARNING Hot working tool

The tip of the working tool gets very hot during opera-
tion. Touching it may lead to burns.
u Never touch the hot working tool.
u If you have to carry out any activities, wait for the
working tool to cool down first.
n Remove the screws (Z), washers (Y), plate (X), and
plugs (H).
Y
X Z
D
F G
C
B
n Use a pin punch and a hammer to drive the bolt (B)

for the retainer bars (C) out of the lower breaker
part (A) from the side.
n Remove the two plugs (D) from the slotted holes for
the retainer bars.
n Screw one screw (M 12) into the bore on the front

side of the retainer bars.
n Pull out the retainer bars by the screw.
n Pull the working tool (G) out of the lower breaker part.
n If the hydraulic breaker is a DustProtector type, re-

move the wiper (F) (see chapter DustProtector/Re-
moval).

NOTICE Damage due to idling strokes

6 Operation
If the percussion piston carries out a hammer action
WARNING Components bursting without hitting the working tool, it is carrying out an idling
Components of the swivel joint may burst. Metal parts stroke. If this happens it will lead to hydraulic peak pres-
may become projectiles and cause serious injuries and sures which may damage the seals of the hydraulic
damage property. breaker and the carrier.
u Never operate the hydraulic breaker without attached u Do not allow the percussion piston to carry out idling
swivel joint covers. strokes for a prolonged period of time.

The hydraulic system is under high pressure. If hydraulic 6.1 Initial operation and operation
connections come loose, hydraulic oil will squirt out un- after long storage
der high pressure. Hydraulic oil squirting out can lead to
serious injury. Prior to first use and after more than eight weeks storage
u Immediately switch off the hydraulic attachment and of the hydraulic breaker, the pressure in the piston accu-
the carrier if you detect any leaks in the hydraulic cir- mulator must be checked.
cuits. n Remove the protective cap from the aperture for the
u Depressurise the hydraulic system (see chapter De- working tool.
pressurising the hydraulic system).
n Remove the retainer bars.
u Repair any leaks before operating the hydraulic at-
tachment again. n Check the pressure in the piston accumulator without
exerting pressure (see chapter Piston accumulator).
WARNING Hot parts
The percussion unit, the working tool, hoses, pipes and n Fill up the piston accumulator or release the pressure
fittings become very hot during operation. Touching from the piston accumulator until the piston accumu-
them may lead to burns. lator has reached the minimum gas pressure (see
u Never touch hot parts. chapter Piston accumulator). Use the tabular value
u If you have to carry out activities where you have to at ambient temperature, not at operating temperature
touch the parts, wait for them to cool down first. in this case.
NOTICE Environmental damage due to hydraulic oil n Install the hydraulic breaker (see chapter Installa-
tion).
Hydraulic oil is environmentally harmful and must not
penetrate the ground or enter the water table or water n Operate the hydraulic breaker until the operating tem-
supplies. perature 60 – 70 °C (140 – 158 °F) has been
u Collect any hydraulic oil which escapes. reached.
n Follow all instructions as described in the chapter
ronmental regulations.
Operation.
NOTICE Hydraulic oil too hot
n Check the pressure in the piston accumulator without
The temperature of the hydraulic oil must not exceed
exerting pressure of the working tool (see chapter
80 °C (176 °F). Higher temperatures will damage the
Piston accumulator).
seals of the hydraulic breaker and the diaphragm of the
HP-accumulator. n Fill up the piston accumulator to the required gas
u The temperature of the hydraulic oil must be moni- pressure (see chapter Piston accumulator).
tored.
u Shut off the carrier and the hydraulic breaker if you
measure an increased temperature in the tank.
u Check the hydraulic installation and the pressure re-
lief valve.

6.2 Preparations before starting 6.3 Switching the hydraulic

WARNING Falling carrier breaker on and off
A carrier falling or tipping over due to the surface not be- After properly attaching the hydraulic attachment to the
ing level may cause serious injury and material damage. carrier, the hydraulic attachment can be operated using
u Always observe great care when moving the carrier. the carrier‘s hydraulic system. All functions for normal
u Do not use the hydraulic attachment until the carrier carrier operation remain intact.
is positioned stably. The hydraulic attachment is switched on and off using
WARNING Fragments flying around electrical and hydraulic signals.
Fragments of material which come loose while operating If you have any questions about electric / hydraulic com-
the hydraulic attachment may be flung away and can mands, consult the carrier manufacturer and / or the
cause serious injury if people are hit by them. Small ob- Epiroc Customer Center / Dealer in your area.
jects falling from a great height can also cause serious n Switch the hydraulic attachment on and off, as de-
damage. scribed in the carrier‘s operating instructions.
During hydraulic attachment operation the danger zone n When leaving the driver’s cab, set the safety switch/
is considerably greater than during the excavation oper-
lever for the electrical / hydraulic attachment installa-
ation due to fragments of stone and pieces of steel flying
tion to the „OFF“ position.
around, and for this reason the danger zone must, de-
pending on the type of material to be worked on, be en- Carry out the above actions to prevent any unintended
larged correspondingly, or secured in a suitable manner start-up of the hydraulic attachment.
through corresponding measures.
u Secure the danger zone.
u Stop the hydraulic attachment immediately if anyone 6.4 Functional test
enters the danger zone.
Always carry out a functional test before putting the hy-
u Close the windscreen and the side windows of the
draulic attachment into use to check that all hydraulic
driver's cab.
lines and connections are tight and that the hydraulic at-
The preparations required prior to starting the hydraulic tachment works without any problems.
attachment depend on the ambient temperature:
n Prepare the hydraulic attachment so that you can
• Ambient temperature below 0 °C (32 °F) (see chap-
start using it.
ter Low ambient temperature).
• Ambient temperature above 30 °C (86 °F) (see n Carry out a couple of test impacts on the material to
chapter High ambient temperature). be broken.
The oil temperature in the hydraulic attachment must be n Check the hydraulic lines and make sure that the hy-
between 0 °C (32 °F) and +80 °C (176 °F) when operat- draulic attachment works without any problems.
ing the breaker.
n Immediately switch off the hydraulic attachment if oil
The full capacity of the hydraulic attachment can be
escapes from the hydraulic lines or if other defects in
achieved when the oil temperature is approx.
functioning occur.
60 °C (140 °F).
n Depressurise the hydraulic system (see chapter De-
n Make sure that there are no people in the danger
zone.
n Only use the hydraulic attachment again after having
n Start the carrier as instructed by the carrier manufac-
repaired all leaks and operating defects.
turer.
n Let the carrier heat up until the operating temperature

prescribed by the carrier manufacturer has been
reached.
n Put the carrier in its working position.
n Put the working tool on the material to be broken.

Larger swing angles would lead to bending loads and

6.5 Correct operation
damage to the working tool and the hydraulic
breaker.
6.5.1 Working angle
n Always position the tool so that it hits the material to
6.5.2 Advance
be broken at a right angle.
Select the distance marked with "V“ such that the frag-
ment is released within 30 seconds. If this is not the
case decrease the advance or apply the tool again to an-
other location.
Excessive advances do not improve the working result.
The working tool will then penetrate the material without
90° a satisfactory breaking result. The tip of the working tool
then becomes hot and loses its hardness. Work step by
step to achieve the optimum work result.
n Start near the edge of the material to be broken and
If you do not do this, the hydraulic breaker will wear work your way back to its centre.
faster and damage will occur after a while.
n Slightly swing the hydraulic breaker to and fro when 6.5.3 Impact time
carrying out the hammer impacts, but never swing it
through more than approx. 5°. n Never apply the hydraulic breaker to the same point
for more than 30 seconds.
-5˚ +5˚
90° 30 s
This swing action enables any dust under the tip or

the cutter of the working tool to escape. Otherwise a n If the material fails to break, apply the tool to a new
layer of dust is created which would prevent the full location.
percussion energy being transferred to the material to
be broken. The tip of the working tool then becomes
hot and loses its hardness.

6.5.4 High ambient temperature The temperature of the hydraulic oil of the carrier must
be at least 0 °C (32 °F).
n Only use hydraulic oils of sufficient viscosity.
n Start the hydraulic attachment when the temperature
In summer and in tropical climates, the minimum re-
has risen to 0 °C (32 °F).
quirement is a hydraulic oil of type HLP 68.
n During operations, leave the carrier engine and
pumps running even during breaks.
6.5.5 Low ambient temperature
Ambient temperature below 0 °C (32 °F):
NOTICE The working tool may break
There is an increased risk of the working tool breaking if
it has not been stored in frostfree conditions.
u Store the working tool in a frostfree environment for
one day before installing it. or
u Heat up the working tool for several hours, e.g. with
a heating blanket, until it has warmed up thoroughly.
Additional instructions when working at an ambient
temperature of below -20 °C (-4 °F):
You must heat up the hydraulic attachment and the car-
rier when working at ambient temperatures of below
-20 °C (-4 °F). Preferably park the carrier and the hy-
draulic attachment in a heated, sheltered space while
not in use.
NOTICE Hydraulic oil too cold
Operating the hydraulic breaker while the hydraulic oil is
still cold will damage the seals of the hydraulic breaker
and the diaphragm in the HP-accumulator.
u Do not operate the hydraulic breaker until the tem-
perature of the hydraulic oil is at least 0 °C (32 °F).
n Start the carrier as instructed by the carrier manufac-
turer.
n Let the carrier heat up until the operating temperature

prescribed by the carrier manufacturer has been
reached.
NOTICE Damage to hydraulic parts

If a hydraulic breaker which has not reached operating
temperature is operated with hot hydraulic oil this will
lead to tensions and the hydraulic breaker will stop work-
ing.
u Do not fill the hydraulic system with hot hydraulic oil.
NOTICE Damage due to idling strokes
If the percussion piston carries out a hammer action
without hitting the working tool, it is carrying out an idling
stroke. If this happens it will lead to hydraulic peak pres-
sures which may damage the seals of the hydraulic
breaker and the carrier.
u Do not allow the percussion piston to carry out idling
strokes for a prolonged period of time.

6.6 Prohibited operation 6.6.3 Moving objects

n Never use the hydraulic attachment to move debris.
6.6.1 Lifting/Transporting This would damage the hydraulic attachment.
WARNING Falling load

The lifted object can fall and cause serious injuries or
death.
u Never lift or transport loads with the hydraulic attach-
ment.
The hydraulic attachment was not constructed to lift or
transport loads. The hydraulic attachment will be dam-
aged by such use.
6.6.4 Levering
n Never use the working tool for crowbar-type applica-
tions.
6.6.2 Impacting
n Do not use the hydraulic breaker as a sledge ham-
mer to demolish the material.
This might cause the working tool to break. Listen to
the sound of the hydraulic breaker – it changes when
stresses occur between the working tool and the
wear bush.
This will damage the hydraulic breaker, the working

tool and the carrier.

6.6.5 Blank firing of the working tool 6.6.6 Cylinder end positions
The working tool "blank fires" if the percussion energy is n Avoid operating the hydraulic attachment when the
transferred to the retainer bars instead of to the material carrier stick and bucket cylinder is in one of its end
to be broken. This happens when the working tool positions.
breaks through the material or slips off it, e.g.: when
working on thin concrete slabs or layers of loose rocks.
Blank firing of the working tool subjects the hydraulic
breaker and the carrier to increased loads. Blank firing of
the working tool generates a typical metallic sound.
n Try to avoid blank firing of the working tool by:
– observing the material to be broken to identify

whether there is any risk of the working tool break-
ing through the material or slipping off it.
– listening to the sound of the hydraulic breaker.

You can hear a metallic twang when the working
tool is blank firing.
n Stop the hydraulic breaker when blank firing occurs.
These end positions have damping facilities; the hy-

draulic cylinder may be damaged by prolonged use
while in its end positions.
n Reposition the carrier so that you do not have to work

with the cylinder in its end positions.

6.7 Working with safety 6.8 AutoControl System

equipment The AutoControl System is a combination of a pressure-
maintaining and reversing valve. The AutoControl Sys-
tem protects the breaker from damage if blank firing oc-
6.7.1 Underwater applications curs. The pressure-maintaining valve makes sure that
Using the hydraulic breaker in and under water is possi- the hydraulic breaker switches correctly in all operating
ble if it has been fitted out with special safety equipment. situations. It enables up to 30 % energy to be recovered
A special connection kit for underwater use was devel- when working on hard rock. The reversing valve auto-
oped to avoid damage to the hydraulic breaker. It con- matically switches over the hydraulic breaker to a shorter
tains all the necessary components including the safety stroke to reduce the single-impact energy.
facilities to keep the interior of the lower breaker part
free from water by using external compressed air. Spe-
6.8.1 AutoControl in daily use
cific documentation, has been drawn up, including oper-
ating instructions and a spare parts list, for underwater The system works automatically without any manual in-
usage. tervention by the carrier operator and automatically ad-
justs to the conditions of use. If the situation requires a
n Before using the hydraulic breaker in or under water,
high single blow energy, the system produces a full
consult the Epiroc Customer Center / Dealer in your stroke and a high single blow energy.
area.
6.8.2 AutoControl in special applications

6.7.2 Usage in tunnels For special applications, e.g. work with very little percus-
Using the hydraulic breaker for tunnelling with overhead sion, the AutoControl System can be blocked mechani-
operations and horizontal applications or for river bed cally at a high impact rate with a reduced single-impact
excavation/slope construction is possible if it has been energy.
fitted out with special safety equipment. Dust and stone For further information, please contact the Epiroc Cus-
particles and/or water penetrating the hydraulic breaker tomer Center / Dealer in your area.
can lead to operating failures and can even cause the
hydraulic breaker to malfunction completely. Preventa-
tive measures to protect the hydraulic breaker have 6.9 Intelligent Protection System
been collected in separate documentation.
(IPS)
n Before using the hydraulic breaker for tunnelling
The “Intelligent Protection System (IPS)” automatically
work, consult the Epiroc Customer Center / Dealer in
controls the start-up and shut-off behaviour of the hy-
your area.
draulic breaker. The hydraulic breaker always starts in
the “AutoStart” mode, i. e. the breaker starts operating
without exerting pressure on the working tool. If “Auto-
6.7.3 Hot applications Control” triggers a long piston stroke, “IPS” will automati-
Using the hydraulic breaker in a hot environment is pos- cally switch over to the “AutoStop” mode and shuts off
sible if it has been fitted out with special safety equip- the hydraulic breaker. If the hydraulic breaker continues
ment. to work in the short piston stroke mode after having been
started, “IPS” will stay in the “AutoStart” mode.
n Before using the hydraulic in a hot environment, con-
sult the Epiroc Customer Center / Dealer in your
area.

6.10 PowerAdapt
PowerAdapt protects the hydraulic breaker against hy-
draulic overloads and switches it off if the hydraulic input
energy is too high.
An overload occurs when the hydraulic breaker is oper-
ated while the delivery rate and the pressure from the
carrier are too high. The carrier driver can correct this by
reducing the engine speed or setting a lower mode stage
on the carrier.
Adjusting the delivery rate:
n Start the carrier.
n Set the maximum speed and the highest mode stage.
n Switch on breaker operation.
If the hydraulic breaker fails to work:

n Lower the speed or the mode stage and restart the
hydraulic breaker.
n Repeat this until the hydraulic breaker works continu-

ously without failures.
The oil volume can be increased after the heat-up

phase.
The advantage of PowerAdapt is that manual adjustment
puts the maximum percussion energy at your disposal,
without overloading the hydraulic breaker.
Hydraulic adjustment of the carrier to enable working
with the hydraulic breaker is still necessary, in spite of
using PowerAdapt. PowerAdapt is not a pressure-relief
valve.

7 Maintenance WARNING Unexpected movement

The maintenance activities are carried out by the carrier
jury.
driver.
WARNING Hot hydraulic oil squirting out pectedly.
The hydraulic system is under high pressure. If hydraulic u Observe the carrier manufacturer’s instructions.
connections come loose, hydraulic oil will squirt out un- NOTICE Environmental damage due to hydraulic oil
der high pressure. Hydraulic oil squirting out can lead to Hydraulic oil is environmentally harmful and must not
serious injury. penetrate the ground or enter the water table or water
u Immediately switch off the hydraulic attachment and supplies.
the carrier if you detect any leaks in the hydraulic cir- u Collect any hydraulic oil which escapes.
cuits.
u Depressurise the hydraulic system (see chapter De- ronmental regulations.
tachment again.

The hydraulic system is under high pressure. Hydraulic
oil escaping out can lead to serious injury.
u Immediately switch off the hydraulic attachment and
the carrier if you detect any leaks in the hydraulic cir-
cuits.
u Do not inspect for possible leaks with your fingers or
other parts of the body, but use a piece of cardboard
instead, holding it up to the suspected leakage site.
u Examine the cardboard for traces of liquid.
u Depressurise the hydraulic system (see chapter De-
tachment again.
WARNING Hot parts

The percussion unit, the working tool, 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 Accidental start

If the hydraulic attachment is started by accident this
may lead to serious injury.
u Follow the instructions in the Operating Instructions
of the carrier to prevent the hydraulic attachment
starting by accident.

7.1 Maintenance schedule

during a shift Monitor the filling level of the grease cartridge of the ContiLube® II lubrication sys-
tem and immediately replace an empty cartridge.
Monitor the lubricant film on the shaft of the working tool.
Manual lubrication of the working tool approx. every 2 hours.
daily Check the bolted connections at the adapter plate and tighten as required.
Check the hydraulic lines for leaks.
Check that the pipe clamps on the carrier are tight.
Check the screw connections of the swivel joint covers and tighten as required.
Replace damaged swivel joint covers.
during and after the first 50 oper- Tighten the screw connections daily during the first 50 operating hours.
ating hours Replace the oil filter cartridges after the first 50 operating hours.
Check the fill pressure of the HP-accumulator during the first operating week.
weekly Visual check of the tensioning bolts through the service openings placed at the top
of the breaker box's rear side.
Check the screw connections and tighten as required.
Check the pins in the retainer bars.
Check that the plugs of the retainer bars are in place and are not damaged. Re-
place any damaged plugs.
Check the adapter plate and the breaker box for cracks.
In normal use: Clean and grease the DustProtector system.
Check the connecting fittings of the ContiLube® II system for leaks.
Visual check of the HP-accumulator.
monthly Check the pressure in the piston accumulator.
after the first three operating Check the fill pressure of the HP-accumulator.
month
every 500 operating hours Check the oil filter and replace as required.
when replacing the working tool, Check the working tool for wear.
and at least every 100 operating Check the lower and upper wear bush for wear.
hours Check that the piston impact surface is not chipped.
Check that the working tool impact surface is not chipped.
Check the working tool for burrs.
Check the retainer bar for burrs.
when performing regular replace- Replace the o-rings on the fastening screws of the HP-accumulator.
ment of all hydraulic breaker
seals, and at least every 1000
carrier operating hours
annual Check the fill pressure of the HP-accumulator.
if necessary Replace bent and damaged pipes.

Replace damaged hoses.
Check the pressure in the piston accumulator.
In case of dusty conditions: Clean and grease the DustProtector system.
Check the adapter plate bolts for wear.

Case 2: If no facility for measuring the pressure is

7.2 Depressurising the hydraulic
present in the supply pipe to the hydraulic breaker and
system the return pipe is connected to the tank without an inter-
mediate valve connection, you must observe the follow-
Even when you have switched off the carrier, a consider-
ing steps in order to depressurise the hydraulic breaker:
able residual pressure can still be present in the hy-
draulic system. 1. Ensure that the hydraulic oil in the hydraulic breaker
A residual pressure can still be present in the hydraulic and in the carrier has a temperature of at least 0 °C.
breaker even after you have disconnected the quick-re- If necessary, pre-heat it to at least 0 °C.
lease couplings or closed the shut-off valves. 2. The hydraulic breaker must be connected to the hy-
The hydraulic breaker can only be depressurised using draulic system of the carrier, i.e. the hydraulic hoses
the hydraulic system of the carrier, by allowing hydraulic must be connected up and the respective shut-off
oil to drain to the tank via the return connection. valves in the supply pipe and in the connection to the
tank must be opened.
If the hydraulic breaker is fitted with a high-pressure ac-
cumulator, it can take longer to relieve the pressure in 3. Depressurise the hydraulic system according to the
the hydraulic system to the tank, since a larger volume manufacturer's safety and operating instructions for
of oil has to be drained away. the carrier.
Depending on the type of hydraulic breaker, the internal 4. You must wait at least another 30 minutes until the
leaks, the oil temperature, the type of hydraulic oil and pressure has been relieved through leakages.
the design of the hydraulic installation of the carrier, the
time required to relieve the pressure can vary. Only after this period of time will there be no more
residual pressure present in the hydraulic system of
Depending on the hydraulic system of the carrier you will the hydraulic breaker.
have to consider using various measures in order to de-
pressurise the hydraulic system. 5. When you have made sure that no more pressure is
present in the hydraulic system, you must disconnect
Case 1: If measurement connections are present in the
the hydraulic connection to the carrier. Close the
supply pipe to the hydraulic breaker, with which the de-
shut-off valves or disconnect the quick-release cou-
pressurised state can be checked using a suitable gage.
plings, so that no hydraulic oil can flow back from the
In order to depressurise the hydraulic breaker you must
carrier.
observe the following steps:
1. The hydraulic breaker must be connected to the hy- Case 3: If no facility for measuring the pressure is
draulic system of the carrier device, i.e. the hydraulic present in the supply pipe to the hydraulic breaker and
hoses must be connected up and the respective shut- the return pipe is connected to the tank via intermediate
off valves in the supply pipe and in the connection to valves, which for example close off or pressurise the re-
the tank must be opened. turn pipe, you must observe the following steps in order
to depressurise the hydraulic breaker:
2. Depressurise the hydraulic system according to the
manufacturer's safety and operating instructions for 1. The hydraulic breaker must be connected to the hy-
the carrier. draulic system of the carrier, i.e. the hydraulic hoses
must be connected up and the respective shut-off
3. Measure the pressure with a suitable gage at a mea-
valves in the supply pipe and in the connection to the
surement connection in the supply pipe to the hy- tank must be opened.
draulic breaker.
2. Depressurise the hydraulic system according to the
4. If residual pressure is still present, wait until the pres-
safety and operating instructions from the carrier
sure has been completely relieved. manufacturer, and where appropriate, those of the
5. When you have made sure that no more pressure is manufacturer of the hydraulic installation for the at-
present in the hydraulic system, you must disconnect tachment.
the hydraulic connection to the carrier. Close the 3. When you have made sure that no more pressure is
shut-off valves or disconnect the quick-release cou- present in the hydraulic system, you must disconnect
plings, so that no hydraulic oil can flow back from the the hydraulic connection to the carrier device. Close
carrier.

the shut-off valves or disconnect the quick-release

7.4 Lubrication
couplings, so that no hydraulic oil can flow back from
the carrier.
7.4.1 Checking the lubricant film
The lubricant film on the shaft of the working tool must
7.3 Cleaning be checked during the work shift.
NOTICE Environmental damage due to polluted water n Let the hydraulic breaker hang freely from the carrier
Hydraulic oil and chisel paste are environmentally harm- boom.
ful and must not penetrate the ground or enter the water
table or water supplies. When the working tool is hanging from the retainer bars,
the lubricant film on the shaft of the working tool be-
u Collect the water used for cleaning if it has been con-
comes visible. There must be an even film of lubricant
taminated by hydraulic oil and chisel paste.
on the entire shaft.
u Dispose of the water in accordance with the applica-
ble regulations to avoid environmental hazards.
7.3.1 Preparations
Hydraulic breaker installed:
n Place the breaker on the working tool and exert a
slight pressure.
This prevents water penetrating the percussion pis-
ton.
Hydraulic breaker not installed, working tool re-

moved:
n Plug up all hydraulic ports.
n Seal the aperture for the working tool with the protec-
tive cap. n Increase the lubricant supply if the film of lubricant
comes away or dry spots can be seen:
– Automatic lubrication: increase the lubricant sup-

7.3.2 Procedure
ply via the metering screw of the ContiLube® II.
NOTICE Damage to the hydraulic breaker
– Manual lubrication: increase the lubrication inter-
Water can penetrate the percussion chamber via the val and the number of strokes from the manual
percussion chamber ventilation non-return valve. This grease gun.
may cause the percussion piston to rust which may re-
sult in damage to the seals and the cylinder.
NOTICE Damage due to excessive lubrication
u Never direct the pressure cleaner jet onto the per-
cussion chamber non-return valve. Excessive lubrication may damage the hydraulic breaker
and the carrier. The impact surface of the working tool
n Use a pressure cleaner to remove dirt from the hy- must be free of grease.
draulic breaker. u Do not over-lubricate the working tool.
If the ContiLube® II automatic lubrication system has
been installed, a lubrication pulse is triggered whenever
the hydraulic breaker is switched on.
n Adjust the lubricant supply to your work method.

7.4.2 Automatic lubrication 7.4.4 ContiLube® II operation

The hydraulic breaker is lubricated automatically by the Please remember the following:
ContiLube® II. • The ContiLube® II (C) is self-venting, i.e. the system
The ContiLube® II has been installed near the service does not require you to vent it.
opening in the upper section of the breaker box. • The lubricant level in the transparent cartridge (E) of
recyclable PE plastic can always be checked from
Instructions on how to operate and maintain the Con-
the cab by looking at the position of the red piston.
tiLube® II is described in a seperate documentation.
• The piston side of the cartridge (E) must never be
n If you have questions how to use the ContiLube® II, sealed, otherwise no grease supply will be possible.
contact the Epiroc Customer Center / dealer in your • You can change the supply volume by adjusting the
area. metering screw (A), depending on the actual use.
• Tighten the screw clockwise = less grease
• Loosen the screw counter-clockwise = more grease
7.4.3 Replacing the lubricant cartridge
C
n Unscrew and remove the empty lubricant cartridge
and the old seal by turning counter clockwise. B
n Remove the cover from the new cartridge. Make sure
not to damage the sealing cone (A).
A
n Place the seal (B) on the cartridge.
D
The pump unit (C) must always be sealed to prevent the

ingestion of water and dust.
n Use your thumb to push the cartridge piston down
n Use a dust cover or leave the empty cartridge in the
until lubricant escapes from the screw thread.
pump until a new cartridge is available.
n Screw the cartridge until the stop into the guide hole
n Check the tightness of the connections of all hoses
of the grease pump.
for the ContiLube® II operation once a week.
The ContiLube® II is ready for use.
Emergency lubrication is possible via the grease nip-
ple (B) on the side of the ContiLube® II.

7.4.5 Manual lubrication 7.4.6 Chisel paste filling device

Manual lubrication is required if the automatic lubrication Construction Tools GmbH offers a device for refilling
system fails to work. empty cartridges. This can be mounted on a 15-kg or 45-
kg hobbock to fill empty cartridges as required.
n Place the hydraulic breaker at a right angle on the
working tool and exert pressure. Bio chisel paste
n Only use chisel paste for lubrication. 550-g Bio chisel paste cartridges packed per 12 car-
tridges:
n Put the manual grease gun on the grease nipple of
part number 3363 1223 56 for ContiLube® II
the emergency lubrication system and inject chisel
paste. 15-kg Bio chisel paste container,
part number 3363 1223 57
45-kg Bio chisel paste container,
Chisel paste
500-g chisel paste cartridges packed per 12 cartridges:
part number 3363 0912 00 for ContiLube® II
15-kg chisel paste container,
45-kg chisel paste container,
Manual grease gun for ContiLube® II cartridges:

Filling device for use with 15-kg containers:
Filling device for use with 45-kg containers:
For further information, please contact the Epiroc Cus-
• Lubrication interval: approx. every 2 hours tomer Center / Dealer in your area.
• Hydraulic breaker without DustProtector: 5 to 15
strokes from the manual grease gun
• Hydraulic breaker with DustProtector: 5 to 10
strokes from the manual grease gun

7.5 Checking the tensioning bolts 7.6 Checking the working tool
WARNING Rupturing washers become projectiles WARNING Hot working tool
Washers can rupture and cause serious injuries, if you The tip of the working tool gets very hot during opera-
hit the heads of the tensioning bolts or the washers. tion. Touching it may lead to burns.
u Never check the tensioning bolts by acoustic test, but u Never touch the hot working tool.
by visual test. u If you have to carry out any activities, wait for the
The visual check is only an indication. You can only working tool to cool down first.
check doubtless in a repair shop after removing the n Remove the working tool (see the chapter Disman-
adapter plate and the elastic pad. tling the working tool).
n Remove the covers of the service openings which are n Check the impact surface of the working tool for chips
placed at the top of the breaker box’s rear side. and cracks.
n Check the seat of the paint marks which are placed n Check the impact surface of the working tool for de-
on the heads of the tensioning bolts and washers. formation:
The paint marks have to be in your visual field. In other A = new working tool
cases, the respective tensioning bolt can be loose or B, C = worn working tool
broken. In this case act as follows:
n Dismount the adapter plate and the elastic pad (see
chapter Removing the adapter plate).
n Check the tensioning bolt for tight fit.
n Tighten the loose tensioning bolt with the torque re-

quired. (see chapter Bolt connections/Tightening
torques).
n Strip the old paint mark.
n Mark new the tighten tensioning bolt, the washer and

the cylinder cover with a colour cast of 10 mm width
vertically over all three parts. The paint mark shall be
seen in the centre of the service openings.
n Have broken tensioning bolts immediately replaced.
n If you have any questions about replacement of bro-

ken tensioning bolts, consult the Epiroc Customer
Center / Dealer in your area.
You can only check the front tensioning bolts, if you dis-
mount the adapter plate and the elastic pad (see chapter
Removing the adapter plate).
n Check the tensioning bolts weekly for tight fit.
n Replace the working tool if you detect chips, cracks

or deformations (B and C).
n Check the wear condition of the impact ring if you de-

tect deformations (B). Replace impact ring if neces-
sary.

n Check the shaft of the working tool for wear when-

7.8 Checking the percussion
ever replacing it, but at least once every 100 operat-
ing hours. piston impact surface
n Check the percussion piston impact surface when-
ever replacing the working tool, but at least once ev-
ery 100 operating hours to make sure it is not
chipped and has no visible cracks.
n Use an electric torch to illuminate the surface of the

dismantled working tool.
n Do not use the hydraulic breaker again if you have

found the surface to be chipped or cracked.
n Consult the Epiroc Customer Center / Dealer in your

area.
n Replace the working tool if the shaft has worn to the

minimum diameter Dmin stated below.
Type Dmin
HB 3100, HB 3100 DP 160 mm (6.30 in.)
HB 3600, HB 3600 DP 165 mm (6.50 in.)
HB 4100, HB 4100 DP 175 mm (6.89 in.)
HB 4700, HB 4700 DP 185 mm (7.28 in.)
7.7 Checking the retainer bars

n Check both retainer bars whenever replacing working
tools.
n Rework or replace the retainer bars if you find any

signs of wear, such as sharp edges, notches or se-
vere erosion.
n Deburr the retainer bars by careful grinding.
n Install the retainer bars in their reversed orientation if

they cannot be reworked anymore.
n Replace the retainer bars if both sides cannot be re-

worked anymore.
n Check both plugs for the retainer bars.

The plugs must not be damaged.

7.9 Checking the wear bushes

and impact ring A
The wear bushes can be checked after removing the
working tool. You can check the diameter using the en- B
closed test gauge. The diameter measured must not ex-
ceed the maximum permissible diameter Dmax (measur-
ing point see below).
A. impact ring
B. upper wear bush
C. lower wear bush
The upper wear bush and the impact ring must be re-
Type Size information Dmax placed in a workshop fitted out for this purpose.
on test gauge
n Replace the lower wear bush when its inside diame-
HB 3100 Ø 165 170 mm (6.69 in.) ter is greater than the maximum permissible diame-
HB 3100 DP ter.
HB 3600 Ø 170 175 mm (6.89 in.) n When replacing the lower wear bush check the inside
HB 3600 DP diameter of the upper wear bush using inside cal-
HB 4100 Ø 180 185 mm (7.28 in.) lipers (part number 3363 0949 52).
HB 4100 DP
n Replace the upper wear bush and the impact ring
HB 4700 Ø 190 195 mm (7.68 in.) when the inside diameter is greater than the maxi-
HB 4700 DP mum permissible diameter.
n Check the inside diameter of the lower and upper n Replace the impact ring if you find chips and cracks.
wear bush whenever replacing the working tool, but
at least once every 100 operating hours.
n Clean the area around the impact ring to enable a

visual check.
The lower wear bush can be replaced on site. Consult

the Epiroc Customer Center / Dealer in your area.
n Remove all remnants of lubricant from the inside of
the lower breaker part before installing new parts.

n Remove the floating ring (E), counter ring (D) and

7.10 Checking and cleaning the
guide ring (F) (see chapter DustProtector/Re-
DustProtector system moval).
An important factor for the DustProtector operation is n Clean the space in front of the flexible wiper (A) of all
that the floating ring which moves in a radial direction loose dust.
can follow the movements of the breaker and the work-
n Check the wiper (A) for damage.
ing tool.
If dust penetrates it, it may block up the available instal- n Replace the wiper (A) if it is damaged.
lation space and interfere with the DustProtector system
n Check the inside diameter of the floating ring (E) with
operation.
a suitable test gauge or with a inside calliper.
F
E Type Size information Dmax
on test gauge
D
HB 3100 DP Ø 165 170 mm (6.69 in.)
HB 3600 DP Ø 170 175 mm (6.89 in.)

C HB 4100 DP Ø 180 185 mm (7.28 in.)
HB 4700 DP Ø 190 195 mm (7.68 in.)
B The diameter measured must not exceed the maximum

permissible diameter Dmax.
n If it has eroded so much that its inside diameter has
A become too great, replace the floating ring (E).
n Clean and grease the floating ring (E), counter

ring (D) and guide ring (F) and install them again (see
chapter DustProtector / Installation).
B
n Regularly check that the floating ring (E) can move
freely.
NOTICE Environmental damage due to chisel paste

Chisel paste is environmentally harmful and must not
penetrate the ground or enter the water table or water
supplies.
u Dispose of chisel paste polluted by dust and of cloths
with chisel paste in accordance with the applicable
regulations to avoid environmental hazards.
Regular cleaning and greasing of the installed parts and
their holders safeguards their operation and improves
the availability of the hydraulic breaker.
The inspection frequency depends on how much dust is
generated:
Normal dust generation: once a week (assuming 40–50
hours of operation).
n Check more frequently if the floating ring (E) is stuck.

HB 4100, HB 4100 DP
7.11 Piston accumulator
The pressure in the piston accumulator is measured at
the filling valve (G). The piston accumulator is also filled
through this valve.
HB 3100, HB 3100 DP
The following accessories can be supplied:

1 nitrogen filling device
1 test pressure gauge ¼", 0-25 bar, test category 1.6
HB 3600, HB 3600 DP 1 nitrogen bottle
HB 4700, HB 4700 DP 1 adapter, country-specific

To enable the following inspection and maintenance ac-
tivities to be carried out, the equipment referred to above
has to be directly available at the location of use at all
times.

7.11.1 Checking the pressure in the piston 7.11.2 Release the pressure from the
accumulator piston accumulator
Check the gas pressure in the piston accumulator n Release gas from the piston accumulator to depres-
monthly, and in cases of decreasing power or failure of surise the piston accumulator or if the value mea-
the hydraulic breaker. Do not top up the piston accumu- sured is above the required gas pressure.
lator unless the gas pressure is equal to or less than the
minimum gas pressure. NOTICE Damage to the filling valve
Check the pressure in the piston accumulator when the Nails, screwdrivers or similar objects can damage the fill-
hydraulic breaker is at operating temperature 60 – 70 °C ing valve.
(140 – 158 °F). u Never use nails, a screwdriver or similar objects to
n Lay down the hydraulic breaker. release nitrogen gas from the piston accumulator.
Do not apply pressure to the working tool. n Push the hose end of the test pressure gauge into
the filling valve again.
This will cause gas to escape from the piston accu-
mulator.
n Repeat this until the required gas pressure has been

reached or until the piston accumulator is depressur-
ized.
n Install the threaded plug (A) in the filling valve (G).
7.11.3 Filling / topping up the piston

accumulator
n Remove the threaded plug (A) from the filling valve
»G«. WARNING Unexpected movement
n Push the hose end of the test pressure gauge (B) into If the working tool has got stuck, it might come loose un-
expectedly if the pressure in the piston accumulator is in-
the filling valve and note the pressure.
creased. The unexpected impact may lead to serious in-
n If the value measured is below the required gas pres- jury.
sure add nitrogen into the piston accumulator. u When filling the piston accumulator make sure that
there is nobody within the direct vicinity of the work-
The required pressure in the piston accumulator is: ing tool.
with an operating temperature 60 – 70 °C (140 – If a country-specific adapter (E) is required, it has to be

158 °F) and without exerting pressure! installed between the nitrogen bottle and the pressure
relief valve (D).
Type Minimum gas Required gas
pressure pressure n Connect the pressure relief valve (D) to the nitrogen
bottle.
HB 3100, 14.2 bar 16.7 bar
HB 3100 DP (206 psi) (242 psi)
HB 3600, 11.5 bar 14.0 bar

HB 3600 DP (167 psi) (203 psi)
HB 4100, 11.7 bar 14.2 bar

HB 4100 DP (170 psi) (206 psi)
HB 4700, 10.5 bar 13.0 bar

HB 4700 DP (152 psi) (189 psi)

n Close the pressure relief valve (D).

7.12 HP-accumulator
n Connect the filling hose end (H) to the minimess con-
Accumulators are pressure containers in the context of
nection (C) of the pressure relief valve (D). the European Pressure Equipment Directive 2014/68/
n Open the valve of the nitrogen bottle (F). EU.
As safety−related components, high pressure accumula-
n Remove the threaded plug (A) from the filling
tors are subject to special safety regulations.
valve (G).
Overhauling high pressure accumulators is only permit-
n Push the free filling hose end (H) into the filling
ted if carried out by professionals. Professionals are
valve (G).
people who are authorised to overhaul high pressure ac-
n Slowly open the pressure relief valve (D) to let the ni- cumulators according to national regulations.
trogen flow into the piston accumulator. Contact the Epiroc Customer Center / Dealer in your
area for a professional.
n Read out the pressure increase from the pressure
gauge (B). B
A
n Close the pressure relief valve (D) when the piston
accumulator has reached the required pressure
+10 %.
n Pull the filling hose out of the filling valve (G).
n Check the pressure in the piston accumulator and let C

gas escape until the required gas pressure has been D
reached.
n Install the threaded plug (A) in the filling valve (G)

and tighten it to the required tightening torque (see
chapter Bolt connections / Tightening torques).
n Close the nitrogen bottle valve (F).
A. Lower shell
B. Upper shell
C. Fastening screws
D. Connecting screws
WARNING Component coming loose abruptly

The HP-accumulator is under pressure, even when the
hydraulic system has been depressurised. Screw con-
nections and parts of the HP-accumulator might come
loose abruptly and cause injuries.
u Never unscrew the cover or the upper shell from a
pressurised HP-accumulator.
u Have the HP-accumulator checked in accordance
with the national / regional safety provisions.
7.12.1 Visual check

Once a week carry out a visual check of the HP-accumu-
lator.
In case of damages, safe, trouble-free operation is en-
sured only if the complete HP-accumulator is replaced.

n Immediately replace the complete HP-accumulator if The gas pressure changes with the gas temperature.
you detect: Before checking the gas pressure it is necessary to wait
until the temperature of the HP-accumulator has levelled
– cracks/fissures,
to about 20 °C (68 °F).
– distortion/deformation, The gas pressure can be checked by measuring the ve-
– corrosion, locity of the pressure drop in the hydraulic system. Use a
pressure gauge (measuring range ≥ 250 bar (3625 psi)).
– thread damage to the threaded bores.
1. Place the hydraulic breaker on timber support blocks.
n If broken or missing connecting screws are detected The breaker box service opening must be facing up-
the HP-accumulator shells needs to be checked for wards.
cracks, deformations and damage to the threaded 2. Depressurise the hydraulic system before discon-
bores by a professional. All connecting screws must necting a hydraulic hose (see chapter Depressuris-
be replaced. ing the hydraulic system).
n Never operate the hydraulic breaker if you detect any 3. Remove the cover of the service opening.
damage to the HP-accumulator.
4. Connect the pressure gauge to the HP-accumulator
The HP-accumulator can be replaced on site. Contact via the pressure line »P«.
the Epiroc Customer Center / Dealer in your area.
5. Close the tank line »T«.
You need an assistant to monitor the pressure
7.12.2 Checking the fastening screws gauge.
Once a week, check that the HP-accumulator fastening
WARNING Injury by impacts
screws are tight.
A sudden movement of the carrier may cause your
n Check that the fastening screws (C) are tight. assistant to be hit and injured by the boom or the hy-
n Tighten any loose fastening screws to the right tight- draulic attachment.
ening torques (see chapter Bolt connections / u Only move the boom very slowly and in a con-
Tightening torques). trolled manner while an assistant is within the
danger zone.
n If any of the HP-accumulator fastening screws are
broken, replace all fastening screws.
6. Switch on the hydraulic breaker at the lowest possi-
We recommend changing of the o-rings on the fastening ble engine rpm and mode level.
screws when the regular replacement of all hydraulic
7. Switch off the hydraulic breaker as soon as your as-
breaker seals is performed. The fastening screw o-rings
sistant indicates that the operating pressure (180 bar
need replacing at least after every 1000 carrier operating
(2610 psi)) is reached.
hours.
8. Open the tank line »T« a little and slowly release
pressure.
7.12.3 Checking the gas pressure
9. Watch the pressure gauge during the release proce-
After the first installation of the hydraulic breaker, the
dure. As soon as the gas pressure in the HP-accu-
gas pressure of the HP-accumulator must be checked at
mulator is reached, the indicator stops shortly and
least once during the first week.
then drops sharply to zero.
If no loss of gas is found, the second check is to be car-
ried out after three months. 10. Refilling is required if the gas pressure is lower than
50 bar (725 psi). Refilling must be performed by an
If no change in gas pressure is found at that stage, then
authorized person. Contact the Epiroc Customer
testing can be performed annually.
Center / dealer in your area.
Further checks, e.g. prior to installation and regular
checks, are to be carried out in accordance with national
regulations.

7.13 Checking the hydraulic lines 7.15 Checking the adapter plate
n Before starting your work shift, always carry out a vis- and the breaker box for cracks
ual check of all lines (pipes and hoses) from the
pump to the hydraulic attachment and from there to
and/or wear
the tank. n Check the adapter plate and the breaker box for
cracks every week.
n Tighten any loose screw connections or hose clamps.
n Have rework activities or repairs carried out in time to
n Replace damaged pipes and/or hoses.
avoid major damage.
n The wear rails (A) in the lower section of the breaker

7.14 Checking and cleaning the box can be replaced as required. Please consult the
Epiroc Customer Center / dealer in your area.
hydraulic oil filter
An oil filter must be integrated in the tank line of the hy-
draulic system. The maximum mesh width allowed for
the oil filter is 50 microns; it must have a magnetic sepa-
rator.
n Replace the oil filter cartridges after the first 50 oper-
ating hours.
n Check the oil filter every 500 operating hours and re-
place as required.
If the wear rails have worn severely, this may cause

damage to the basic body of the breaker box.
7.16 Checking the adapter plate

bolts for wear
n Carry out this visual check whenever the hydraulic at-
tachment has been removed from the carrier.
n Check the adapter plate bolts for excessive wear

such as cracks, pitting or severe erosion.
n Rework or replace worn bolts.

7.17 Bolt connections / Tightening torques

The bolt connections of hydraulic breakers are subjected to very high loads.
n Tighten any loose connections without exceeding the recommended tightening torques.
HB 3100 HB 3600 HB 4100 HB 4700

HB 3100 DP HB 3600 DP HB 4100 DP HB 4700 DP
Connection point Interval Type of Size / Torque

spanner
Adapter plate* A daily Allen key 27 mm (1.06 in.)

(fastening screws) 2300 Nm (1696 ft lbs)
Tensioning bolts** B weekly Torque 65 mm 75 mm 75 mm 75 mm

visual wrench/ (2.56 in.) (2.95 in.) (2.95 in.) (2.95 in.)
check power
wrench
Cover for control mecha- C in case of Allen key 17 mm (0.67 in.)

nism / control mechanism a repair 380 Nm (280 ft lbs)
(Allen screws / hexagon
head screws)
AutoControl System D in case of Allen key 22 mm (0.87 in.)

a repair 300 Nm (221 ft lbs)
PowerAdapt E in case of socket 24 mm (0.95 in.)

a repair spanner 300 Nm (221 ft lbs)
Filling valve »G« F in case of socket 22 mm (0.87 in.) / 130 Nm (96 ft lbs)
(threaded plug) a repair spanner 5 mm (0.20 in.) / 20 Nm (15 ft lbs)
Allen key
Ports »P« and »T« G weekly open-ended 55 mm (2.17 in.)

wrench 285 Nm (210 ft lbs)
HP-accumulator*** H weekly socket 30 mm (1.18 in.)

(Fastening screws) spanner
Flanges (Allen screws) I weekly Allen key 10 mm (0.39 in.)

80 Nm (59 ft lbs)
Percussion chamber venti- J in case of open-ended 41 mm (1.31 in.)

lation a repair wrench 200 Nm (148 ft lbs)
Swivel joint covers K daily Allen key 10 mm (0.39 in.)

(Allen screws) 85 Nm (63 ft lbs)
Hose connections - weekly Various open-ended spanners with different spanner sizes
ContiLube® II

* Apply anti-seize compound to the Allen screw threads before inserting them. The contact
faces of the screw head and the lock washers must not be lubricated.
**HB 3100 1. Pre-tighten the tensioning bolts to 500 Nm (369 ft lbs) crosswise,
**HB 4100 2. retighten 120° (2 hexagons) crosswise,
3. retighten 180° (3 hexagons) crosswise
2. retighten 150° (2.5 hexagons) crosswise,
3. retighten 120° (2 hexagons) crosswise,
***HB 3100 Tightening regulations for fastening screws on HP-accumulator:

***HB 3600 1. Treat the threads of the fastening screws and the threaded inserts with Anti-Seize
***HB 4100 agent.
***HB 4700 2. Treat the surfaces between the fastening screw head, washer, and HP-accumulator
upper shell with Anti-Seize agent.
3. Position on the HP-accumulator, and tighten the fastening screws by hand in a cross-
wise fashion.
4. Pre-tighten the fastening screws to 80 Nm (59 ft lbs), proceeding in a crosswise fash-
ion.
5. Tighten each fastening screw through 30° in a crosswise fashion.
6. Finally tighten each fastening screw again through 60° in a crosswise fashion.

Actual details may differ.

8 Troubleshooting
8.1 The hydraulic breaker does not start

Cause Remedy By
Pressure and tank lines swapped Check the laying of the pressure and Carrier driver
tank lines and connect correctly (see
chapter Making the hydraulic con-
nections )
Shut-off valve in pressure and/or tank Check the shut-off valve and open Carrier driver
line closed
Gas pressure in piston accumulator Check the gas pressure in the piston Carrier driver
too high accumulator and adjust it to the cor-
rect value (see chapter Checking the
pressure in the piston accumulator
and Release the pressure from the
piston accumulator)
Oil level in tank too low Check the oil level and top up oil Carrier driver
Defective couplings blocking pressure Check coupling and replace defective Workshop
and tank lines coupling halves
Faults in the electrical system of the Check the electrical system of the hy- Workshop
hydraulic breaker installation draulic breaker installation and clear
faults
Magnet on switch-on valve damaged Replace the magnet Workshop
Operating pressure too low Check the carrier engine speed, the Carrier driver or Epiroc Customer
pump delivery and the pressure relief Center / Dealer in your area
valve; check the operating pressure
Adjust settings and replace defective
parts if required
PowerAdapt active Check the engine speed and/or mode Carrier driver
stage of the carrier and lower as re-
quired (see chapter PowerAdapt)
8.2 Hydraulic breaker operates too slowly

Cause Remedy By
Insufficient hydraulic oil delivery vol- Check the engine speed and/or mode Carrier driver
ume stage of the carrier and the operation
pressure and adjust
The connecting fitting in the pressure Check the connecting fitting and Carrier driver
and tank line has come loose tighten
Shut-off valve in pressure and/or tank Check the shut-off valve and open Carrier driver
line partly closed
Flow resistance on oil filter or oil cooler Check the oil filter and oil cooler, Carrier driver
too high clean or renew them
Gas pressure in piston accumulator Check the gas pressure in the piston Carrier driver
too high accumulator and release some gas if
required (see chapter Checking the

Cause Remedy By
pressure in the piston accumulator

and Release the pressure from the
piston accumulator)
Working tool jams in the lower breaker Correct the direction of the carrier Carrier driver
part boom. The pressing force must act in
the axial direction of the hydraulic
breaker.
Check the shaft of the working tool
and deburr if required.
Check the working tool and the wear
bush for wear and replace if required
(see chapter Checking the working
tool and Checking the wear bushes
and impact ring)
Inside diameter of tank line too small Check the inside diameter and Workshop
change if required Observe the mini-
mum inside diameter! (see chapter
Technical specifications)
Return pressure too high Check and lower the return pressure Epiroc Customer Center / Dealer in
your area
Hydraulic oil return to the tank via a Connect the hydraulic oil return circuit Carrier driver or Epiroc Customer
valve section directly to the tank or filter Center / Dealer in your area
Diaphragm in high-pressure accumula- Replace the high-pressure accumula- Workshop

tor defective (Hose at port »P« is flail- tor
ing about wildly) Observe the national safety regula-
tions!
Hydraulic oil temperature in the tank Check the oil level in the hydraulic Carrier driver
higher than 80 °C (176 °F) tank and top up if required
Hydraulic oil pressure too low Check the pressure; adjust as re- Workshop
quired; Fit new type-tested pressure
relief cartridges where necessary
8.3 Impact force too low

Cause Remedy By
Gas pressure too low Check the gas pressure and fill the Carrier driver
piston accumulator (see chapter Fill-
ing / topping up the piston accu-
mulator)
The pump of the hydraulic installation Check the pump characteristic with a Checking: Epiroc Customer Center /
does not deliver sufficient oil measuring device and compare it to Dealer in your area
the original details; renew the pump if Replacing: by carrier manufacturer’s
required customer service
8.4 Impact rate too high and impact force too low
Cause Remedy By
No gas in piston accumulator Check the gas pressure and fill the Carrier driver
piston accumulator (see chapter Fill-
ing/topping up the piston accumu-
lator)

Cause Remedy By
O-rings defective Replace O-rings Workshop
8.5 Oil leaks from ports »P« und »T«

Cause Remedy By
Cap nuts loose Check the cap nuts and tighten (see Carrier driver
chapter Bolt connections/Tighten-
ing torques)
Hose connection CL to port »P« for Check the cap nuts and tighten Carrier driver
ContiLube® II or the plug is loose and Check the plugs and tighten (see
ContiLube® II has not been installed chapter Bolt connections/Tighten-
ing torques)
8.6 Oil escapes between the cylinder cover and the cylinder
Cause Remedy By
Tensioning bolts are loose Check the tensioning bolts and Workshop
tighten (see chapter Bolt connec-
tions/Tightening torques)
Seals damaged Replace the seals Workshop
8.7 Oil escapes from parts of the hydraulic breaker installation

(connecting fittings, hoses etc.)
Cause Remedy By
Connecting fittings are loose; flange Check the connecting fittings and Carrier driver or workshop
connections to the valve are loose tighten; replace any defective parts if
required (see chapter Bolt connec-
Check the hydraulic breaker installa-
tion and replace any damaged parts
Only use original parts!
8.8 Oil escapes from the working tool

Cause Remedy By
Lower piston seal defective Dismantle the hydraulic breaker Workshop

Replace the seals
8.9 Oil escapes from the high pressure accumulator

Cause Remedy By
The fastening screws of the high pres- Replace O-ring and back-up ring Workshop
sure accumulator are loose

Cause Remedy By
Tighten the fastening screws (see

chapter Bolt connections/Tighten-
ing torques)
Connecting screws of lower and upper Replace the HP- accumulator Workshop
shell are loose or broken Observe the national safety regula-
tions
8.10 Oil or grease escapes from the ContiLube® II

Cause Remedy By
Connecting fittings are loose Check the connecting fittings and Workshop
tighten (see chapter Bolt connec-
8.11 Operating temperature too high

Cause Remedy By
Oil level in tank too low Check the oil level and top up oil Carrier driver or workshop
Carrier pump delivery too high; a con- Check carrier engine speed and Carrier driver
stant volume of oil is squirted out of lower
the pressure relief valve
Check carrier settings and adjust Epiroc Customer Center / Dealer in
your area
Operation in high outside temperature Check oil temperature and install an Workshop or Epiroc Customer Cen-
without oil cooler oil cooler if required ter / Dealer in your area
Pressure relief valve defective or valve Fit new type-tested pressure relief Workshop
with poor characteristic cartridges or a more precise pres-
sure-limiting valve
8.12 Pressure line »P« flails violently

Cause Remedy By
There is a problem with the HP-accu- Immediately stop the hydraulic Workshop
mulator operation breaker.
The HP-accumulator needs to be
checked by a professional

9 Repair
WARNING Risk of injury
Nonprofessional disassembly and assembly of the hy-
draulic breaker may lead to serious injury and property
damage.
Dismounting the percussion unit is only permitted if
n For technical support contact the Epiroc Customer
Center / Dealer in your area.
9.1 Sending in the hydraulic

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 attachment to have it
repaired.

NOTICE Environmental damage due to hydraulic oil

10 Storage
Hydraulic oil is environmentally harmful and must not
WARNING Hydraulic breaker / working tool fall penetrate the ground or enter the water table or water
The hydraulic breaker and the working tool are heavy. If supplies.
they topple over or fall down from where they are stored, u Collect any hydraulic oil which escapes.
injury may be the result. u Dispose of it in accordance with the applicable envi-
u Store the hydraulic breaker and the tool so that they ronmental regulations.
cannot topple over or fall down. Oil may escape when pushing the percussion piston up.
n Remove the covers from the connection hoses.
10.1 Hydraulic breaker n Slide the percussion piston into its upper stroke posi-
The hydraulic breaker must be stored in an upright position.
tion to avoid its seals being damaged. n Slide the percussion piston retainer into the aperture
for the working tool.
10.1.1 Short storage n Install the retainer bar.
Proceed as follows in the case of storage for less than
eight weeks: The percussion piston has now been locked in its upper
stroke position.
n Remove the hydraulic breaker from the carrier (see
chapter Removing the hydraulic attachment from n Remove the filling hose from the filling valve.
the carrier). n Seal the connection hoses with the covers.
n Store the hydraulic breaker in a dry, properly venti- n Seal the aperture for the working tool with the protec-
lated room. tive cap.
n If you can only store the hydraulic breaker in the n Pull the filling hose out of the filling valve.
open air, cover it with plastic sheeting or tarpaulins to
protect it against the weather. n Store the hydraulic breaker in a dry, properly venti-
lated room.
n Store the hydraulic breaker in an upright position and
so that it cannot topple over. n Store the hydraulic breaker in an upright position and
so that it cannot topple over.
n Prior to reuse the hydraulic breaker follow the instruc-

10.1.2 Long storage tions as described in the chapter Initial operation
Proceed as follows if storage is expected to be for more and operation after long storage.
than eight weeks:
n Remove the hydraulic breaker from the carrier (see
chapter Removing the hydraulic attachment from
10.1.3 How to proceed after more than
the carrier). twelve months‘ storage
n Remove the working tool (see chapter Working tool/ WARNING Risk of injury
Removal). Nonprofessional disassembly and assembly of the hy-
n Grease the working tool with chisel paste to prevent it draulic breaker may lead to serious injury and property
damage.
corroding.
n Grease the wear bushes. Dismounting the percussion unit is only permitted if
n Depressurise the piston accumulator (see chapter
Release the pressure from the piston accumula-
tor).
The following measures are required to prevent prema-
n Leave the filling hose in the filling valve to let the gas
ture hydraulic breaker failure, after it has been stored for
escape.
over twelve months:

n Contact the Epiroc Customer Center / Dealer in your

area.
n Professionals trained by Construction Tools GmbH

will disassemble the hydraulic breaker properly and:
– check any parts liable to corrosion (percussion

piston, cylinder, control) for corrosion damage.
– rework or replace corroded parts.
– replace all sealing elements.
10.2 Working tool

n Grease the working tool with chisel paste to prevent it
from corroding.
n Store the working tool in a dry, properly ventilated

room.
n Store the working tool so that it cannot topple over or

roll down.
10.3 Grease cartridges

WARNING Fire and harmful vapors
Chisel paste can burn and cause serious fire. Harmful
vapors are generated when chisel paste is burnt.
u Never store grease cartridges near fire-propagating
or self-igniting substances.
u Do not expose the grease cartridges to direct sun-
light.
n Store the grease cartridges in a cool, properly venti-
lated room.

11 Disposal 11.2 Hydraulic hoses

NOTICE Environmental damage due to consumables n Drain the hydraulic oil from the hydraulic hoses and
collect it.
Hydraulic oil and chisel paste are environmentally harm-
ful and must not penetrate the ground or enter the water n Dispose of the hydraulic hoses in accordance with
table or water supplies. the applicable regulations to avoid environmental
u Collect any such consumables which may escape. hazards.
u Dispose of them in accordance with the applicable
environmental regulations.
11.3 Hydraulic oil
11.1 Hydraulic breaker n Collect any hydraulic oil that escapes.
n Remove the hydraulic breaker from the carrier (see n Dispose of it in accordance with the applicable envi-
chapter Removing the hydraulic attachment from ronmental regulations.
the carrier).
n Release the gas from the piston accumulator (see

chapter Release the pressure from the piston ac- 11.4 Chisel paste and grease
cumulator).
cartridges
n Remove the working tool (see chapter Working tool/
n Dispose of chisel paste and not completely emptied
Removal).
grease cartridges in accordance with the applicable
n Remove the adapter plate (see chapter Removing regulations.
the adapter plate).
n Completely emptied grease cartridges can be recy-
n Remove the hydraulic hoses from the hydraulic cled.
breaker.
n Clean the hydraulic breaker (see chapter Cleaning).
n Before disposal the HP-accumulator must be depres-

surised. This must be done by an authorized person.
Contact the Epiroc Customer Center / dealer in your
area.
n Dispose of the hydraulic breaker in line with all appli-

cable regulations or consult an authorised and spe-
cialised recycling company.

12 Technical specifications
HB 3100, HB 3100 DP HB 3600, HB 3600 DP
Carrier weight class1) 32 - 52 t 35 - 63 t

(70500 - 115000 lbs) (77000 - 139000 lbs)
Service weight2) 3100 kg (6800 lbs) 3600 kg (7900 lbs)

4)
Delivery weight (Standard version) 2522 kg (5560 lbs) 2965 kg (6540 lbs)
Delivery weight (DustProtector version)4) 2574 kg (5670 lbs) 3040 kg (6700 lbs)
Oil flow rate 210 - 270 l/min 240 - 300 l/min

(55.5 - 71.3 gal/min) (63.4 - 79.3 gal/min)
Operating pressure 160 - 180 bar

(2320 - 2610 psi)
Impact rate AutoControl

(280 - 560 blows/min)
Working tool diameter 165 mm (6.50 in.) 170 mm (6.69 in.)
Working length of working tool (Standard version) 675 mm (27 in.) 700 mm (28 in.)
Working length of working tool (DustProtector version) 630 mm (25 in.) 650 mm (26 in.)
Max. hydraulic input power 81 kW (108.6 hp) 90 kW (120.7 hp)
Back pressure acceptance8) 30 bar (435 psi)
Gas pressure HP- accumulator (20 °C (68 °F)) 60 bar (870 psi)
5)
Air pressure (min. gauge pressure in percussion chamber) 1.5 bar (22 psi)
Air flow (up to depth of 10 meters (33 ft))6) 5 m3/min (177 cfm)
Max static pressure (pressure relief valve on carrier) 200 bar (2900 psi)
Piston accumulator gas pressure (min, at operating tempera- 14.2 bar (206 psi) 11.5 bar (167 psi)
ture 60-70 °C (140-158 °F))7)
Piston accumulator gas pressure (max (optimum), at operating 16.7 bar (242 psi) 14.0 bar (203 psi)
temperature 60-70 °C (140-158 °F))7)
Hose inside diameter »P« 32 mm (1.3 in.)
Hose inside diameter »T« 32 mm (1.3 in.)
Start up mode IPS

1)
Weights apply to standard carriers only. Any variances must be agreed with Epiroc and/or the carrier manufacturer
prior to attachment
2)
Hydraulic breaker incl. breaker box, working tool and adapter plate of medium size. Please note that the service
weight can be considerably higher, depending on the adapter plate.
4)
Hydraulic breaker, breaker box and ContiLube® II without working tool and adapter plate
5)
Air pressure at pressure regulator has to be adjusted to 1.5 bar + 0.1 bar per meter depth (22 psi + 0.5 psi/ft depth)
6)
Air flow for depth of more than 10 meters (33 ft): Flow = 0.1 x depth [m] x flow up to 10 meters [m3/min] (0.0305 x
depth [ft] x flow up to 33 ft [cfm])
7)
Hydraulic breaker in horizontal position, no pressure applied to working tool
8)
Back pressure acceptance when breaker still runs regular but at significant reduced performance (oil flow)

HB 4100, HB 4100 DP HB 4700, HB 4700 DP
Carrier weight class1) 40 - 70 t 45 - 80 t

(88000 - 154000 lbs) (99000 - 176000 lbs)
Service weight2) 4100 kg (9000 lbs) 4700 kg (10400 lbs)
Delivery weight (Standard version)4) 3420 kg (7540 lbs) 3845 kg (8480 lbs)
Delivery weight (DustProtector version)4) 3516 kg (7750 lbs) 3930 kg (8660 lbs)
Oil flow rate 250 - 320 l/min 260 - 360 l/min

(66.0 - 84.5 gal/min) (68.7 - 95.1 gal/min)
Operating pressure 160 - 180 bar

(2320 - 2610 psi)
Impact rate AutoControl AutoControl

(280 - 550 blows/min) (280 - 540 blows/min)
Working tool diameter 180 mm (7.09 in.) 190 mm (7.48 in.)
Working length of working tool (Standard version) 750 mm (30 in.) 790 mm (31 in.)
Working length of working tool (DustProtector version) 705 mm (28 in.) 730 mm (29 in.)
Max. hydraulic input power 96 kW (128.7 hp) 108 kW (144.8 hp)
Back pressure acceptance8) 30 bar (435 psi)
Gas pressure HP- accumulator (20 °C (68 °F)) 60 bar (870 psi)
Air pressure (min. gauge pressure in percussion chamber)5) 1.5 bar (22 psi)
Air flow (up to depth of 10 meters (33 ft))6) 6 m3/min (212 cfm) 7.5 m3/min (265 cfm)
Max static pressure (pressure relief valve on carrier) 200 bar (2900 psi)
Piston accumulator gas pressure (min, at operating tempera- 11.7 bar (170 psi) 10.5 bar (152 psi)
ture 60 – 70 °C (140 – 158 °F))7)
Piston accumulator gas pressure (max (optimum), at operating 14.2 bar (206 psi) 13.0 bar (189 psi)
temperature 60 – 70 °C (140 – 158 °F))7)
Hose inside diameter »P« 32 mm (1.3 in.)
Hose inside diameter »T« 32 mm (1.3 in.)
Start up mode IPS

1)
Weights apply to standard carriers only. Any variances must be agreed with Epiroc and/or the carrier manufacturer
prior to attachment
2)
Hydraulic breaker incl. breaker box, working tool and adapter plate of medium size. Please note that the service
weight can be considerably higher, depending on the adapter plate.
4)
Hydraulic breaker, breaker box and ContiLube® II without working tool and adapter plate
5)
Air pressure at pressure regulator has to be adjusted to 1.5 bar + 0.1 bar per meter depth (22 psi + 0.5 psi/ft depth)
6)
Air flow for depth of more than 10 meters (33 ft): Flow = 0.1 x depth [m] x flow up to 10 meters [m3/min] (0.0305 x
depth [ft] x flow up to 33 ft [cfm])
7)
Hydraulic breaker in horizontal position, no pressure applied to working tool
8)
Back pressure acceptance when breaker still runs regular but at significant reduced performance (oil flow)

12.1 Noise declaration statement

HB 3100 HB 3600 HB 4100 HB 4700
HB 3100 DP HB 3600 DP HB 4100 DP HB 4700 DP
Sound pressure 1 dB(A) 91 93 94 97
Sound power 2 dB(A) 120 123 124 126

1
Sound pressure level according to EN ISO 3744 in accordance with directive 2000/14/EC at 10 metres distance.
2
Guaranteed sound power according to EN ISO 3744 in accordance with directive 2000/14/EC inclusive spread in pro-
duction.
These declared values were obtained by laboratory type testing in accordance with the stated directive or standards and
are suitable for comparison with the declared values of other tools tested in accordance with the same directive or stan-
dards. These declared values are not adequate for use in risk assessments and values measured in individual work
places may be higher. The actual exposure values and risk of harm experienced by an individual user are unique and de-
pend upon the way the user works, in what material the breaker is used, as well as upon the exposure time and the
physical condition of the user, and the condition of the breaker.
We, Construction Tools GmbH, cannot be held liable for the consequences of using the declared values, instead of val-
ues reflecting the actual exposure, in an individual risk assessment in a work place situation over which we have no con-
trol.

13 EC Declaration of Conformity (EC Directive 2006/42/EC)

We, Construction Tools GmbH, hereby declare that the machines listed below conform to the provisions of EC Directive
2006/42/EC (Machinery Directive) and 2000/14/EC, ANNEX V (Noise Directive) and 2014/68/EU (Pressure Equipment
Directive), and the harmonised standards mentioned below.
Hydraulic Breaker Guaranteed sound power level Measured sound power level
[dB(A)] [dB(A)]
HB 3100 120 119
HB 3100 DP 120 119
HB 3600 123 121
HB 3600 DP 123 121
HB 4100 124 122
HB 4100 DP 124 122
HB 4700 126 125
HB 4700 DP 126 125
Following harmonised standards were applied:

n EN ISO 12100
n EN ISO 3744
Technical Documentation authorised representative:

Stephan Schröer
Construction Tools GmbH
45143 Essen
Germany
General Manager:
Reiner Koch
Manufacturer:
Construction Tools GmbH
45143 Essen
Germany

© Construction Tools GmbH | 3390 5203 01 | 2019-08-06
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.
epiroc.com

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HB 3100, 3100 DP, 3600, 3600 DP, 4100, 4100 DP, 4700, 4700 DP

Safety and operating instructions

© Construction Tools GmbH | 3390 5203 01 | 2019-08-06

© Construction Tools GmbH | 3390 5203 01 | 2019-08-06 3

5.1.2 Non-mineral hydraulic oil ................................................................................................................................. 22

4 © Construction Tools GmbH | 3390 5203 01 | 2019-08-06

7.3.1 Preparations .................................................................................................................................................... 42

© Construction Tools GmbH | 3390 5203 01 | 2019-08-06 5

10.1.2 Long storage.................................................................................................................................................... 62

13 EC Declaration of Conformity (EC Directive 2006/42/EC) .................................................... 68

6 © Construction Tools GmbH | 3390 5203 01 | 2019-08-06

© Construction Tools GmbH | 3390 5203 01 | 2019-08-06 7

1 Introduction 1.1 About these Safety and

1. Established operation process

A Explanation of the elements of a drawing

Symbols used in illustrations have the following mean-

8 © Construction Tools GmbH | 3390 5203 01 | 2019-08-06

2 Safety instructions 2.1 Signal words

© Construction Tools GmbH | 3390 5203 01 | 2019-08-06 9

2.2 Qualification 2.3 Intended use

10 © Construction Tools GmbH | 3390 5203 01 | 2019-08-06

2.5 Protective equipment 2.7 Transport, precautions

© Construction Tools GmbH | 3390 5203 01 | 2019-08-06 11

2.8 Hydraulic installation, 2.9 Special parts, precautions

WARNING Hot hydraulic oil squirting out 2.9.2 Piston accumulator

12 © Construction Tools GmbH | 3390 5203 01 | 2019-08-06

2.10 Media/consumables, 2.11 Explosion and fire,

WARNING Hydraulic oil spills DANGER Explosion and fire

© Construction Tools GmbH | 3390 5203 01 | 2019-08-06 13

2.12 Electrical shock, precautions 2.14 Emissions, precautions

14 © Construction Tools GmbH | 3390 5203 01 | 2019-08-06

2.16 Repair, precautions 2.18 Environmental pollution,

2.17 Changes to the hydraulic

WARNING Changes to the HP-accumulator

© Construction Tools GmbH | 3390 5203 01 | 2019-08-06 15

J. The working tool is retained in the lower breaker

A. The hydraulic breaker is connected to the carrier by

16 © Construction Tools GmbH | 3390 5203 01 | 2019-08-06

3.3 Signs / labels 3.3.2 Labels

WARNING Missing warnings Sound Power

The label identifies a lubrication

A. Model The label indicates that the gas

© Construction Tools GmbH | 3390 5203 01 | 2019-08-06 17

3.4 Applications 3.6 Removing the packaging

Demolition Heavily reinforced con- n Check that the delivery is complete.

Tunneling*, mining* Bench levelling 3.7 Scope of delivery

The guarantee or product liability will be invalidated by Special accessories as ordered:

18 © Construction Tools GmbH | 3390 5203 01 | 2019-08-06

WARNING Percussion unit falling

WARNING Hydraulic breaker falling

© Construction Tools GmbH | 3390 5203 01 | 2019-08-06 19

4.1 Transport using a crane 4.2 Transport using a forklift

n Move the fork of the forklift truck under the pallet so

n Slowly lift the hydraulic attachment.

n Place the hydraulic attachment on timber support

n Slowly lift the pallet with the hydraulic attachment.

n Transport the pallet with the hydraulic attachment to

20 © Construction Tools GmbH | 3390 5203 01 | 2019-08-06

4.3 Transport using a truck

Tunneling, mining Bench levelling 3.7 Scope of delivery