Operating instructions

for hydraulic breaker

550
750
1150
1650
2250
3050
4250

AIB
20070504
Copyright 2007 No. 3390 5023 93
www.atlascopco.com
 Operating instructions for hydraulic breaker

550
750
1150
1650
2250
3050
4250

E Atlas Copco Construction Tools GmbH

Any unauthorized use or copying of contents or any part thereof is
prohibited.This applies in particular to to trademarks, model denominations,
part numbers and drawings.
Table of contents
1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Accident prevention regulations
Explanation of the symbols used in this operating instructions . . . . . . . . . . . . . . . . 7
3 CE markings (EC machinery directive 98/37/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 CE sticker product groups A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 CE sticker product groups B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Sticker for guaranteed sound level power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 General informations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Scope of supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.1 Main components or assemblies 550 and 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Main components or assemblies 1150 and 1650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Main components or assemblies 2250, 3050 and 4250 . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1 Media/consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1.1 Mineral hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1.2 Nonmineral hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1.3 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1.4 Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.2 Attaching the adapter to the hydraulic breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.3 Mounting the hydraulic breaker on the excavatormechanical aspects . . . . . . . . . . . . . . 17
6.4 Mounting the hydraulic breaker on the excavatorhydraulic aspects . . . . . . . . . . . . . . . . 18
6.5 Switching the hydraulic breaker on/off from the carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.6 Dismounting the hydraulic breaker from the excavator for short or
lengthy periods of nonuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.1 Hydraulic breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.1.1 Short storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.1.2 Long storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.1.3 How to proceed after more than twelve months storage . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.1.4 Working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8 Fitting/removing the working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1 Selecting the right working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1.1 Working tools for hydraulic breakers 550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1.2 Working tools for hydraulic breakers 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
8.1.3 Working tools for hydraulic breakers 1150  4250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8.2 Fitting the tool (After breaker delivery to the site) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.2.1 550 and 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.2.2 1150  4250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.3 Removing the tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9 Starting up the hydraulic breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.1 Starting up the hydraulic breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9.2 Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.3 Angle of attack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.4 Breaker rocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.5 Never drive the working tool into the ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
9.6 Never lever with the breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.7 Never use as a sledgehammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4
 9.8 Never use for transport purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.9 Using the hydraulic breaker in or under water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
9.10 Hydraulic breaker used in Tunnelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.11 Working in high outside temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.12 Working in low outside temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9.13 Operating the breaker with the cylinders fully extended or retracted . . . . . . . . . . . . . . . . 28
10 Maintenance work to be performed by the excavator driver . . . . . . . . . . . . . . . . . . . . 29
10.1 Manual lubricating of the working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.2 Automatic lubrication using of the hydraulic breaker of
the 750, 1150, 1650, 2250, 3050 and 4250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.2.1 Automatic lubrication using ContiLube II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.2.2 Changing the lubricant cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.2.3 Operating the ContiLube II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.3 Manual lubrication without or upon failure of ContiLube II . . . . . . . . . . . . . . . . . . . . . . . 31
10.3.1 Filling device for the chisel paste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.4 Care and maintenance timetable Work to be performed by excavator driver . . . . . . . 32
10.5 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.5.1 Checking the working tool for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10.5.2 Checking the wear bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.5.3 Checking the retaining pin for wear (550 and 750) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.5.4 Checking the retainer bars for wear (1150  2350) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.5.5 Checking the impact face of the percussion piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.5.6 Checking the hammer box for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.5.7 Screw couplings 550 and 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.5.8 Screw couplings 1150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
10.5.9 Screw couplings 1650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.5.10 Screw couplings 2250, 3050 and 4250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.5.11 Checking pressure in piston accumulator and refilling if required . . . . . . . . . . . . . . . . . . . 41
10.5.12 Checking that the highpressure accumulator is in perfect working order . . . . . . . . . . . . 43
10.5.13 Checking the hydraulic lines before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.5.14 Checking the adapter bolts for wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.5.15 Checking and cleaning the hydraulic oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11.1 Breaker does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
11.2 Impact rate of hydraulic breaker too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
11.3 Impact force too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.4 Impact rate too high and impact force too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.5 Oil leaks from ports P and T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11.6 Oil leaks between cylinder cover and cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.7 Oil leaks from parts of hydraulic system for breaker (Screw couplings, hoses etc.) . . . 47
11.8 Oil leaks from working tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.9 Oil leaks from highpressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
11.10 Oil or grease leaks from ContiLube II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11.11 Operating temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
13 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5
1 Foreword
Please read this operating manual before using
your hydraulic breaker for the first time so as to
avoid errors and breakdowns through incorrect
usage.
The operating manual includes:
H important safety instructions
H operating instructions for the hydraulic breaker
H maintenance instructions for the hydraulic
breaker
H aids to troubleshooting
The operating manual describes how to handle the
hydraulic breaker on site and should therefore al
ways be kept in the document compartment in the
carrier cab.
6
It is important that all safety instructions be ob
served. These safety instructions are listed at the
beginning of the manual and repeated in the rel
evant sections of the manual.
Responsibility for observation of these safety in
structions lies at all times with the operator, i.e.
with you.
All safety instructions are in line with the valid laws
and regulations of the European Union. National
provisions have also been taken into account
where applicable.
When using the breaker outside the European
Union, the national laws and regulations of the
country of use shall apply.
Please note that reliable operation of the hydraulic
breaker can only be guaranteed if genuine spare
parts are used.
We wish you every success with your hydraulic
breaker.
2 Accident prevention regulations
To avoid the risk of injury, please observe the
following instructions. CAUTION
Familiarise yourself with the operating manual and
the applicable regulations before starting work with
the hydraulic breaker.When using hydraulic break Read and un
ers in states of the European Union, the regulations derstand oper
contained in the EC machinery directive 98/37/EC ators manual
must be observed and followed, as must all appli before operate
cable national accident prevention regulations.In this machine.
countries outside the European Union, the valid
local statutes and regulations shall apply.
Explanation of the symbols used in this operating instructions
To emphasise their importance, certain points in the operating instructions are marked with symbols, which
are described below.

Danger Indicates an imminently hazardous situation

a which, if not avoided, will result in death or
b serious injury.
c

WARNING
Indicates an potentially hazardous situation
a
which, if not avoided, could result in death or
b
serious injury.
c

CAUTION Indicates an potentially hazardous situation

a which, if not avoided, may result in minor or
b moderate injury.
c

CAUTION
Used without the safety alert symbol indicates
a a potentially hazardous situation which, if not
b
avoided, may result in property damage.
c

Please note for the right side of the labels:

Section a: Identify the hazard.
Section b: What can happen.
Section c: Define prohibitive actions.

7
Before mounting/dismounting the hydraulic
tool and/or any maintenance work on the hy
draulics of the hydraulic tool/carrier the hy
draulic system must be depressurized.
When using or transporting the carrier with the hy
draulic breaker attached, the instructions included
in the operating manual supplied by the carrier
manufacturer must also be observed.
Do not run any hydraulic lines for attachment of the
hydraulic breaker through the drivers cab! Hydrau
lic lines may spring a leak or even burst! During
operations, the hydraulic oil becomes very hot.
Mounting the hydraulic breaker:
Mounting the hydraulic breaker requires the pres
ence of an assistant, who must be instructed by the
carrier driver. The carrier driver and assistant
should agree beforehand on clear hand signals.
For transport purposes, use only the lugs provided
and hoisting equipment of sufficient capacity.
The hydraulic breaker should only be mounted on
an excavator with sufficient load capacity. Please
refer to the table in section 12.
Carriers below this weight class will not provide the
required degree of stability and could even fall over
during breaker use, causing injury and damage.
Carriers above this weight class may apply excess
ively high mechanical loads to the attachment.
When attaching the adapter use only the special
steel Allen screws included in supply.
Check the nominal width of the hydraulic lines on
existing hydraulic systems. It is important that sup
ply and return lines for the hydraulic oil are ad
equately dimensioned.
Keep your hands away from bores and fitting sur
faces when mounting the hydraulic breaker, es
pecially when the carrier boom is moving.
Collect any oil which runs out and dispose of it in
accordance with the applicable statutory provisions
to avoid environmental hazards.
When putting into use hydraulic breakers with
highpressure accumulators the applicable
national requirements are to be observed, e.g. in
Germany an authorized person/inspection body
is to inspect and certify the system on site before
putting it into use.
8
If you have any questions regarding hydraulic
power or the adaptation of same, please call our
Aftermarket Department.
The threads on the hydraulic breaker ports and the
corresponding hose connectors must be clean and
free of damage.
The safety facilities on the hydraulic system must
be checked by a professional/authorised persons
for their quality (CE mark etc.), suitability and
proper functioning prior to their first use. By check
ing the setting of and, where possible, attaching a
lead seal to the pressure limiting valve, it can be
guaranteed that the systems working pressure, laid
down in accordance with chapter 12, Technical
Specifications, can never be exceeded.
If this setting is tampered with, the operating permit
for the unit will be withdrawn.
Fitting and removing the working tool:
Always wear protective glasses when fitting or re
moving the working tool, since metal splinters may
fly off when breakering out the locking bolts.
The working tool should only be fitted in the way
described in this operating manual.
Never use your fingers to check whether the re
cesses on the working tool shaft are aligned to the
slots for the retainer bars.
Operating the hydraulic breaker:
Close the front screen/splinter guard on the drivers
cab to protect the driver from flying rock splinters
during breaker operations.
Wear ear protectors
The national regulations of the country of use as
regards excavator operations with percussive tools
shall apply.
Guaranteed sound power level
The LWA guaranteed sound power level is an upper
limit, indication of which is mandatory under EU
directive 2000/14/EC. The guaranteed sound power
levels are listed in section 12, Technical Specifica
tions.
Do not start up the hydraulic breaker until both
carrier and hydraulic breaker are in the correct posi
tion.
Stop the hydraulic hammer immediately as soon as
persons are in the danger zone. The danger zone
during the hammer operation is considerably
greater than during the excavation operation on
account of fractions of stones and pieces of steel
flying around and for this reason, the danger zone
must, depending on the type of material to be
worked on, be enlarged correspondingly, or the
danger zone must be secured in a suitable manner
through corresponding measures.
WARNING
Flying objects
Danger of
eye injury.
Wear safety
glasses.
CAUTION
Burn hazard
Hot surface.
Do NOT touch.
The hydraulic breaker heats up during operation.
Monitor the oil temperature
The temperature of the hydraulic oil must never ex
ceed 80C (176F). If higher temperatures are
measured in the tank, the hydraulic system and/or
the pressurerelief valve have to be checked.
Observe the excavator manufacturers safety re
gulations.
WARNING!
With regard to excavator operation when working
with an attached hydraulic breaker, please refer to
Section 6.5.
The hydraulic breaker is only to be used for the ap
plications described.
Maintenance and repairs:
The piston accumulator integrated in the hydraulic
breaker is pressurised. Before dismantling the hy
draulic breaker it is essential that all gas be bled off.
The same applies to removal of the filling valve G
(see Section 10.5.11).
When filling the piston accumulator, ensure noone
is in the vicinity of the working tool. If the tool has
jammed, the increase in pressure in the piston
accumulator may cause it to spring out suddenly.
The piston accumulator should only be filled with
nitrogen from the green nitrogen cylinder. Ensure
that no other gas, e.g. air or oxygen, gets into the
piston accumulator.
DANGER
Explosion hazard
Compressed
gas.
ONLY use
nitrogen (N2)
Before replacing the pressure accumulator, the hy
draulic system must be fully depressurised.
If one of the expansion bolts on the highpressure
accumulator should break, it is imperative that all
bolts be replaced.
If any significant changes are made to the hy
draulic system, a new acceptance inspection is
to be carried out in accordance with the rel
evant national safety provisions.
Note
Check the pressure accumulator in accordance with
the national safety provisions. We recommend five
yearly maintenance intervals.
Dismounting the hydraulic breaker:
Dismounting the hydraulic breaker from the carrier
requires the presence of an additional assistant
who must be instructed by the carrier driver. The
carrier driver and assistant should agree before
hand on clear hand signals.
When using the excavator or putting it out of oper
ation, the safety instructions of the excavator manu
facturer must be observed.
Keep your hands away from bores and fitting sur
faces when dismounting the hydraulic breaker, es
pecially when the carrier boom is moving.
Collect any oil which runs out and dispose of it in
accordance with the applicable statutory provisions
to avoid environmental hazards.
Secure the hydraulic breaker after dismounting so
that it cannot fall over.
9
3 CE markings
(EC machinery directive 98/37/EC)
A Product group: Hydraulic breaker B Product group: Hydraulic breaker with
(without hammer box) hammer box

CE sticker

CE sticker

LWA sticker
rear side of breaker
box, below upper flange

3.1 CE sticker product groups A

1. Name and address of manufacturer

1
2. Model
2 3. Serial no.
3 4. Part ident. no.
4 7 5. max. operating pressure
5 6. Year of construction of product group
6 7. Weight of product group

3.2 CE sticker product groups B

Name and address of manufacturer

Atlas Copco Construction Tools
Essen Germany Model
Type Serial no.
Ser. No. Weight of product group
Deliv. wt
P max Made in Germany max. operating pressure
Year Year of construction of product group

The CE nameplate contains information on the unit

"breaker and breaker box". All weights indicated
refer to the weight of this unit.
When selecting hoists and suspension aids for
transporting the unit, the weights of the working tool
and adapter may also have to be considered.

10
3.3 Sticker for guaranteed sound level power
In accordance with EU directive 2000/14/EC, hy
draulic breakers used within the EU must bear a
marking legible from the outside stating the sound
power level guaranteed by the manufacture.

4 General informations
4.1 Applications
The hydraulic breaker is an attachment suitable for
mounting on hydraulicpowered excavators.
Applications in the construction industry:
demolition, surface breaking, trenching,
foundations.
Applications in mining, quarrying, tunnelling and in
the rock products industry:
face extraction, rock levelling, reducing mineral raw
materials and rock.
Under normal circumstances the hydraulic breaker
is operated from the drivers cab of the carrier.
Please refer to Sections 2 and 7.4.
Hydraulic breaker, operating instructions, spare
parts list and EC declaration of conformity.

4.2 Scope of supply

The scope of supply of a hydraulic breaker gen
erally includes:
Hydraulic breaker, operating instructions, spare
parts list and EC declaration of conformity.
Accessories: Mounting tool, hoses and service box
according to the order.
Special accessories: e. g. adapter, hydraulic adap
ter kit for the excavator according to the order.

11
5 Main components
5.1 Main components or assemblies 550 and 750

550 750

CE sticker

cylinder cover

CE sticker
cylinder

lower hammer part

hammer box

working tool

The graphic shows only a general view of the main components.

Details may vary on different breaker models

12
5.2 Main components or assemblies 1150 and 1650

1150 1650

CE sticker

CE sticker

cylinder cover
Highpressure
accumulator

cylinder

hammer box

lower hammer part

working tool

The graphic shows only a general view of the main components.

Details may vary on different breaker models

13
5.3 Main components or assemblies 2250, 3050 and 4250

2250,
3050,
4250 CEname
plate

Highpressure
accumulator

cylinder cover

cylinder

hammer box

Sealing flange

lower hammer part

working tool

The graphic shows only a general view of the main components.

Details may vary on different breaker models.

14
6 Installation
6.1 Media/consumables
The following media/consumables are required to operate the hydraulic breaker:

6.1.1 Mineral hydraulic oil

All hydraulic oil brands prescribed by the carrier The mesh width of this filter should not exceed 50
manufacturer are suitable for hydraulic breakers. micrometers and a magnetic separator must be fit
ted.
The oil should however correspond to viscosity
class HLP 32 or higher.
CAUTION
In summer and in hotter climates, oils of viscosity
class HLP 68 or higher should be used. Property damage
In all other respects the regulations of the carrier Hydaulic oil
manufacturer are to be considered. must never
overheat.
Optimum viscosity range = 30  60 cSt
Max. initial viscosity = 2.000 cSt Monitor the oil
Max. oil temperature = 80C (176F) temperature.

Please refer to Section 9.12. for lowtemperature The temperature of the hydraulic oil must never ex
hydraulic breaker applications. ceed 80C (176F). If higher temperatures are
Check the oil filter in the return line to the hydraulic measured in the tank, the hydraulic system and/or
system. the pressurerelief valve have to be checked.

6.1.2 Nonmineral hydraulic oil

In order to protect the environment or on technical
grounds, hydraulic oils are currently being used CAUTION
which are not classified as HLP mineral oils.
Property damage
Before using hydraulic oils of this kind it is impera
tive to ask the carrier manufacturer whether oper Mixed hydraulic
ations with such hydraulic oils are possible. oil can result in
damage.
Our tools are basically designed for use with min
eral oils. Before using other hydraulic oil types Never mix
which have been approved by the carrier manufac hydaulic oil.
turer, Atlas Copco Customer Center / dealer in your
region must always be consulted. Following initial Never mix mineral and nonmineral hydraulic oils!
assembly and after any workshop repairs, our tools Even small traces of mineral oil mixed in with nonmin
are subjected to a test run on a test bed powered eral hydraulic oil can result in damage to both hy
by mineral oil. draulic attachment and carrier.

Note CAUTION
When returning tools for repair, it is imperative that
the name of the oil in use be indicated if you are Property damage
using nonmineral oil.
Mixed hydraulic
oil is no longer
biodegradable.
Never mix
hydaulic oil.
Nonmineral oil is no longer biodegradable if it is con
taminated with mineral oil. Contaminated nonmineral
oil must be disposed of as special waste in accord
ance with the applicable statutory regulations for envi
ronmental protection.

6.1.3 Grease

Grease type Pt.Id.No.

Always observe the relevant safety regulations
when handling oils and greases.
Chisel paste 3363 0949 10

15
6.1.4 Gas
Normal nitrogen, 99.8% pure.
Use only nitrogen to fill the piston accumulator and DANGER
ensure that no other gas, e.g. air, oxygen, is used.
The nitrogen for the piston accumulator is in the Explosion hazard
green gas cylinder. Use of other gases could result
in an explosion. Compressed
gas.
ONLY use
nitrogen (N2)

6.2 Attaching the adapter to the hydraulic breaker

Lay the hydraulic breaker on squared beams or a
pallet within reach of the excavator boom with the
service window of the hammer box facing upwards.
Insert the elastic pad in the hammer box, ensuring it
is the right way round, and fix the adapter to the
Then fit all screws. The required sizes for the Allen
keys are shown below.
Apply antiseize to the threads of the cylindrical
bolts before screwing them in.
The contact face of the bolt head and the locking

breaker box with two screws (ref. to Section 8.2) rings must be free of lubricant.

Model
550, 750

Type of spanner size

Allen key 17 / 390 Nm
1150, 1650, 2250 Allen key 22 / 1500 Nm
3050, 4250 Allen key 27 / 2300 Nm

DANGER WARNING

Crush hazard Crush hazard

Breaker can Boom moves
fall down. uncontrolled.
Block the Keep clear of
breaker. this area.

Only the specialsteel Allen screws included in supply should be used to attach the adapter.
For transport purposes use only the lug(s) provided.
The hydraulic breaker is heavy and difficult to move.

Screw CAUTION
Pair of
locking rings Pitch points
Danger of
hands injury.
Elastic pad
Keep hands
clear.

Adapter

16
6.3 Mounting the hydraulic breaker on the excavator
mechanical aspects
An adapter is required when mounting the hydraulic When placing an order please provide the following
breaker on the excavator. This adapter varies ac information:
cording to excavator model and must be ordered H excavator make
separately. H excavator model and year built
H boom type

During breaker mounting, the carrier should only be operated from the drivers cab.
To mount the hydraulic breaker, carefully lower the
stick of the boom into the adapter. An assistant di DANGER
rects the movement of the stick until the bores in
the stick are flush with those in the adapter. Then Crush hazard
insert the stick pin and lock.
Excavator can
fall down.
Observe mass
ratio excavator/
breaker.
Stick
Hydraulic WARNING
breaker
Flying objects
Danger of
eye injury.
Wear safety
Adapter
Stick pin glasses.

Lift up the hydraulic breaker. Extend the shovel cy CAUTION

linder until the bore in the toggle is flush with those
in the adapter. Insert toggle pin and lock. Pitch points
Danger of
hands injury.
Keep hands
Stick clear.
Shovel
cylinder WARNING
Adapter Crush hazard
Marking: Boom moves
Stiel uncontrolled.
Stick
Toggle Keep clear of
this area.
Toggle pin
CAUTION
Warning!
Property damage
After mounting the breaker, carefully extend and
retract the shovel cylinder to its full extent in each
Adapter can hit
case. It is important that the cylinder can be fully
the stick.
extended and retracted without any difficult. If prob
lems are encountered, please consult our After Rework or chan
market Department. ge the adapter.

17
6.4 Mounting the hydraulic breaker on the excavator
hydraulic aspects
Before mounting/dismounting the hydraulic tool
and/or any maintenance work on the hydraulics CAUTION
of the hydraulic tool/carrier the hydraulic sys
tem must be depressurized. Oil leckages
The excavator must have a hydraulic system suit Contamination
able for breaker operations. of the ground.
Check the nominal width of the hydraulic lines on Collect any oil
existing hydraulic systems. All feed and return lines and dispose of
for the hydraulic oil must have a sufficient inside it correctly.
diameter. Refer to Section 13, Technical specificati
ons.
2250:
Use only hoses/pipes which satisfy the following
Unscrew the blank flanges from ports P and T
quality criteria:
and put them in the toolbox for safekeeping.
Hydraulic hoses with 4 wire spiral layers to
DINEN854. Fasten the hose flanges to the hydraulic breaker
Hydraulic pipes: seamless, cold drawn steel pipes using the fastening bolts. (Tightening torques see
to DINEN10305. section 10.5.10)
The safety facilities on the hydraulic system must 550, 750, 1150, 1650, 3050 and 4250:
be checked by a professional/authorised persons
for their quality (CE mark etc.), suitability and proper
functioning prior to their first use. By checking the
setting of and, where possible, attaching a lead seal Screw
to the pressure limiting valve, it can be guaranteed Hoses caps
that the systems working pressure, laid down in
accordance with chapter 13, Technical Specifica
tions, can never be exceeded.
The return line from the breaker must run direct to
the oil tank in order to guarantee a reliable return oil Port
flow. T
The pressurerelief overflow line must run direct Port
from the pressurerelief valve to the tank to ensure P
the reliable functioning of the valve.
Do not run any hydraulic lines for attachment of the
hydraulic breaker through the drivers cab!
Hydraulic lines may spring a leak or even burst, re The graphic may vary for different breaker models
leasing hot hydraulic oil.

Unscrew the caps from ports/blind flanges P and

DANGER T and keep them. The pressure port P is
marked in red.
Crush hazard
Check the connecting threads on the hydraulic
Breaker can breaker ports and the corresponding hose con
move. nectors to ensure they are undamaged. Sand or
Stop engine and other foreign bodies in the threads must be cleaned
BLEED OFF away.
breaker circuits. Screw the hoses to the ports. (Tightening torques
see section 10.5.7  10.5.10)
all types:
If you come to the conclusion that the system does
not comply with the requirements listed above, the
hydraulic breaker must not be operated. For rea
sons of safety, you should absolutely contact the
Atlas Copco Customer Center / dealer in your re
gion.
When connecting or reconnecting the hydraulic
lines, the carrier must be secured in such a way
that automatic startup of the hydraulic breaker is
reliably avoided.

18
6.5 Switching the hydraulic breaker on/off from the carrier
After the proper attachment of the hydraulic breaker When leaving the drivers cab, the safety switch for
to the carrier, the hydraulic breaker can be operated the electrical/hydraulic breaker operation system
using the carriers hydraulic system. All functions for must be set to the "OFF" position.
normal excavator operations remain intact. The hy So as to reliably prevent any unintended startup of
draulic breaker is switched on and off using electri the hydraulic breaker.
cal and hydraulic signals. For further details please
contact the carrier manufacturer or the Atlas Copco
Customer Center / dealer in your region.

6.6 Dismounting the hydraulic breaker from the excavator for short or
lengthy periods of nonuse
Unless otherwise stipulated, the hydraulic breaker is Collect any oil which runs out and dispose of it in
dismounted in reverse order to mounting. accordance with the applicable statutory provisions
to avoid environmental hazards.
DANGER Unscrew the hoses from the boom and seal them
with appropriate caps.
Explosion hazard
Pressurized WARNING
vessel.
Flying objects
Stop engine and
BLEED OFF Danger of
breaker circuit. eye injury.

Before mounting/dismounting the hydraulic tool Wear safety

and/or any maintenance work on the hydraulics
of the hydraulic tool/carrier the hydraulic sys
tem must be depressurized.
For safety reasons, the carrier must be switched
off before performing the following work.
glasses.
Unlock the toggle and stick pins and knock out the
pins using a steel rod and a breaker.

WARNING
Flying objects
Danger of
eye injury.

Wear safety
glasses.

Wear protective glasses when fitting and removing

the working tool.
Lay the hydraulic breaker flat on the ground.

CAUTION
Oil leakages
Agree on hand signals with the assistant.
Contamination
of the ground. CAUTION
Collect any oil Pitch points
which runs out
and dispose of Danger of
it in accor hands injury.
dance with the
applicable sta Keep hands
tutory provi clear.
sions to avoid
environmental Keep your hands away from bores and fitting sur
hazards. faces when dismounting the hydraulic breaker.
Do not touch any parts when the boom is moving.

19
7 Storage
Oil may run out when pushing the percussion piston
DANGER up.
H Remove the covers from the connection hoses.
Crush hazard
H Slide the percussion piston into its upper stroke
Breaker can position.
fall down.
Block the H Slide the percussion piston retainer into the ap
erture for the working tool.
breaker.
H Install the retainer bars / retaining pin.

7.1 Hydraulic breaker
The hydraulic breaker must be stored in an upright
position to avoid its seals being damaged.
7.1.1 Short storage
H Proceed as follows in the case of storage for
less than eight weeks:
H Remove the hydraulic breaker from the carrier
(see chapter 6.6).
H Store the hydraulic breaker in a dry, properly
ventilated room.
H If you can only store the hydraulic breaker in the
open air, cover it with plastic sheeting or tarpau
lins to protect it against the weather.
H Store the hydraulic breaker in an upright position
and such that it cannot topple over.
7.1.2 Long storage
Proceed as follows if storage is expected to be for
more than eight weeks:
H Remove the hydraulic breaker from the carrier
(see chapter 6.6).
H Remove the working tool (see chapter 8.3).
H Grease the working tool with chisel paste to pre
vent it corroding.
H Grease the wear bushes.
H Depressurise the piston accumulator
(see chapter 10.5.11).
H Leave the filling hose in the filling valve to let the
gas escape.
CAUTION
The percussion piston has now been locked in its
upper stroke position.
H Seal the connection hoses with the covers.
H Seal the aperture for the working tool with the
cover.
H Pull the filling hose out of the filling valve.
H Store the hydraulic breaker in a dry, properly
ventilated room.
H Store the hydraulic breaker in an upright position
and such that it cannot topple over.
7.1.3 How to proceed after more than
twelve months storage
The following measures are required to prevent pre
mature hydraulic breaker failure, after it has been
stored for over twelve months:
H Disassemble the hydraulic breaker as described
in the Repair Manual.
H Check any parts liable to corrosion (percussion
piston, cylinder, control) for corrosion damage.
H Rework or replace corroded parts.
H Replace all sealing elements.
7.1.4 Working tool
H Grease the working tool with chisel paste to pre
vent it corroding.

H Store the working tool in a dry, properly venti

Oil leakages lated room.
Contamination
of the ground. H Store the working tool so that it cannot topple
over or roll down.
Collect any oil
which runs out
and dispose of
it in accor
dance with the
applicable sta
tutory provi
sions to avoid
environmental
hazards.

20
8 Fitting/removing the working tool
8.1 Selecting the right working tool
The standard working tools available for the hy Sharp tips will produce better results. Resharpening
draulic breaker are depicted below. The different tip is possible using suitable tools.
geometries will influence production performance
depending on the type of job. Please refer to the The working tools must be adequately cooled dur
following table for application recommendations. ing remachining using a suitable coolant.

Note Never weld or flamecut the working tools.

Only genuine working tools may be used. If other The high temperatures involved will modify the mi
makes of working tools are used, the warranty will crostructure of the tool.
cease to apply.

8.1.1 Working tools for hydraulic breakers 550

Designation Application

Standard designs

80
Moil point Universal use

Flat chisel
crosscut Mining, foundations, trenching, demolition

Spade
160

transverse Road surface (asphalt)

8.1.2 Working tools for hydraulic breakers 750

Moilpoint 100
Universal use

Flat chisel
crosscut
Mining, foundations, trenching, demolition

Spade
transverse Road surface (asphalt)
200

21
8.1.3 Working tools for hydraulic breakers 1150  4250

Moilpoint
Universal use

Flat chisel
crosscut
Mining, foundations, trenching, demolition

Blunt
tool Mining, breaking oversizes, demolition

22
8.2 Fitting the tool (After breaker delivery to the site)
8.2.1 550 and 750
In general the working tool is not fitted when the Always wear protective glasses when fitting or re
breaker is delivered. For fitting move the hydraulic moving the working tool, since metal splinters may
breaker into horizontal position using the excavator fly off when breakering out the locking pins.
boom and deposit it on a support (e.g. squared
beams). Never use your fingers to check whether the re
cesses on the working tool shaft are aligned to the
slots for the retainer bars.
DANGER
Remove all additional plugs in the lower area of the
Crush hazard breaker box.

Breaker can Insert an ejetor drift, srewdriver or similar object into

move. the bore in the lower hammer part and push in as
far as it will go (see diagram). Push up retaining pin
Stop engine and from below with screwdriver or similar object and
BLEED OFF pull it out the rest of the way by hand.
breaker circuits.
Remove the protective cap from the bore for the
For safety reasons, the carrier must be switched working tool and put it in the tool box for safekeep
off before performing the following work. ing.
Lubricate the shank of the working tool and the
bushes thoroughly using our chisel paste.
WARNING Insert the working tool, turning it until the retaining
bars slip easily into the oblong holes.
Flying objects
Knock the locking pins back into place and insert
Danger of the sealing plugs.
eye injury.
Clean away any dirt adhering to the working tool in
Wear safety the insertion zone, then thoroughly lubricate the
glasses. shaft of the working tool and the bushes with chisel
paste. (A cartridge of chisel paste is contained in
the toolbox for firsttime fitting).
CAUTION The retainer bars are also to be lubricated.
Then insert the working tool, turning it until the re
Pitch points tainer bars slide easily into the slots.
Danger of The working tool should only be fitted in the way
hands injury. described here.

Keep hands
clear.

retaining pin

ejector drift

23
8.2.2 1150  4250
In general the working tool is not fitted when the Never use your fingers to check whether the re
breaker is delivered. For fitting move the hydraulic cesses on the working tool shaft are aligned to the
breaker into horizontal position using the excavator slots for the retainer bars.
boom and deposit it on a support (e.g. squared Always wear protective glasses when fitting or re
beams). moving the working tool, since metal splinters may
fly off when breakering out the locking pins.
DANGER Remove all additional plugs in the lower area of the
breaker box.
Crush hazard
Knock the locking pins for the retainer bars out of
Breaker can the lower hammer part using the drift contained in
move. the toolbox.
Stop engine and Remove both sealing plugs from the retainer bar
BLEED OFF slots.
breaker circuits.
Remove the retainer bars by turning a screw into
For safety reasons, the carrier must be switched the M12 thread provided and using the screw to pull
off before performing the following work. out the bar.
Remove the dust cap from the working tool bore
and put it in the toolbox for safekeeping.
WARNING
Clean away any dirt adhering to the working tool in
the insertion zone, then thoroughly lubricate the
Flying objects
shaft of the working tool and the bushes with chisel
Danger of paste. (A cartridge of chisel paste is contained in
eye injury. the toolbox for firsttime fitting).

Wear safety The retainer bars are also to be lubricated.

Then insert the working tool, turning it until the re
glasses. tainer bars slide easily into the slots.
The working tool should only be fitted in the way
CAUTION described here.
Fit the working tool. To do this, turn the working tool
Pitch points until the retainer bars slide easily into the slots.Re
place the sealing plugs and drive the locking pins
Danger of for the retainer bars back into position.
hands injury.
Keep hands
clear.

Retainer bars Sealing plug

Locking pins
Working
tool

24
8.3 Removing the tool
Removal of the working tool for whatever reason is CAUTION
effected in reverse order to fitting, observing the
specific features of the individual breaker models. Burn hazard
Please note that the tip of the working tool may re
main hot for some after use.
Hot surface.

Do NOT touch.

9 Starting up the hydraulic breaker

9.1 Starting up the hydraulic breaker
First of all, precautionary measures should be taken H Do not start up the hydraulic breaker until the
to rule out the risk of accidents: breaker is in position.
H Now start up the hydraulic breaker using the foot
or hand switch.
WARNING Never try to break with the breaker without first
applying contact pressure since this could cause
Flying objects damage to the carrier.
Danger of H Stop the hydraulic breaker immediately as
eye injury. soon as persons are in the danger zone. The
danger zone during the breaker operation is
Wear safety considerably greater than during the excava
glasses. tion operation on account of fractions of
stones and pieces of steel flying around
and for this reason, the danger zone must,
H Close the front screen / splinter guard on the depending on the type of material to be
drivers cab to avoid injury from flying rock splin worked on, be enlarged correspondingly, or
ters. the danger zone must be secured in a suit
H Wear ear protection to prevent hearing impair able manner through corresponding measu
ment. Anyone in the immediate vicinity of res.
breaker operations should also wear ear protec
tion.
H Move the excavator into operating position. DANGER

Stay clear of
this area
when ma
chine is ON.

25
9.2 Advance
The advance distance (marked V) should be Advancing in large steps will not improve working
such that the rock breaks within 30 seconds at the results.
most. If this is not the case, reduce the amount of
advance or reposition the breaker at a different Advancing in small steps is more effective.
point of attack.

Advance

9.3 Angle of attack

The working tool should always be positioned at
rightangles to the working surface. If this is not the
case, the hydraulic breaker will wear more quickly
and in the long term will suffer damage.

9.4 Breaker rocking

Rock the breaker gently (no more than approx. 5o)
during breaking to allow the dust to escape from
beneath the tip of the working tool. If dust is allowed
to build up, it will act as a cushion to prevent the full
impact energy of the breaker being transferred to
the material being broken.
Excessive rocking will, however, cause bending
strains resulting in damage to the working tool and
the hydraulic breaker.

9.5 Never drive the working tool into the ground

If the advance step is too large, or the breaker is
not rocked to allow dust to escape, the working tool
will be driven into the material without breaking it
sufficiently. The tip of the working tool will glow red
hot and lose its hardness.
Operating in this way is not allowed!

26
9.6 Never lever with the breaker
Never attempt to use the hydraulic breaker as a
crowbar, as this will cause the working tool to break.
Operating in this way is not allowed!

9.7 Never use as a sledgehammer

Before starting up, rest the breaker on the ground.
Never attempt to use the breaker and the excavator
boom as a sledgehammer to break material.
Operating in this way is not allowed!

9.8 Never use for transport purposes

The hydraulic breaker is not designed to lift or trans
port loads.
Unsuitable application!

9.9 Using the hydraulic breaker in or under water

The hydraulic breaker must never be used in or Please always contact the Atlas Copco Customer
under water without prior conversion. Center / dealer in your region before starting work
in or under water.
If water were to penetrate the percussion chamber,
each blow would create a pressure wave. These
pressure waves would cause irreparable damage to
the stripper and seals on the hydraulic breaker, and
in addition the lower percussion piston zone would
rust. Water could also penetrate the carriers hy
draulic system.
In order to avoid damage to the hydraulic breaker,
Atlas Copco Construction Tools has developed a
special connecting kit for underwater applications
containing all necessary components incl. safety
equipment to keep water out of the lower hammer
part by means of compressed air.

27
9.10 Hydraulic breaker used in Tunnelling
Do not use the hydraulic breaker for tunnelling in Please always contact the Atlas Copco Customer
volving overhead, horizontal or floor work before Center / dealer in your region before starting work
taking preventative measures! in or under water.
Penetration by dust, stone fragments and/or water
can lead to malfunctions during operation and may
even cause the hydraulic breaker to stop working.

9.11 Working in high outside temperatures

The temperature of the hydraulic oil must be moni
tored to ensure it does not exceed 80C (176F). If
higher temperatures are measured in the tank, oil
cooler must be fitted, and/or installation and pres
surerelief valve have to be checked.
Only use hydraulic oils of sufficient viscosity. In
summer and in tropical climates, the minimum re
quirement is a hydraulic oil of type HLP 68.

9.12 Working in low outside temperatures

For temperatures down to 20C (68F) below Note
freezing there are no special regulations. The hydraulic breaker and excavator will not oper
At temperatures below minus 20C (4F), the ate to full capacity until the oil temperature has re
carrier must be warmed up prior to use in the way ached at least 60C (140F).
described by the excavator manufacturer. In the
majority of cases, carriers and attachments are kept CAUTION
in protected or even heated areas when not in use.
However, if the carrier and the hydraulic breaker are Property damage
left out in the open, the carrier and all equipment
must be warmed up before the hydraulic breaker Sealings could
can be started up. The excavator manufacturers break.
regulations must be observed in full. Prewarm car
Ensure that the hydraulic oil in the carrier is at least rier and brea
at 0C (32F). ker.
The hydraulic breaker cannot be started up until the
oil temperature is over 0C (32F). Feeding hot hydraulic oil to an extremely cold hy
draulic breaker will cause internal stresses in the
Please observe the excavator manufacturers re
unit resulting in its failure.
gulations.
If the breaker is used without preheating the oil:
During operations, leave the excavator engine and
pumps running even during breaks. H the breaker seals may fracture
H he diaphragm in the highpressure accumulator
CAUTION may tear

Property damage
Tool could break
at temperatures of
below 0C (32F).
Preheat the
tool slowly and
gradually.

9.13 Operating the breaker with the cylinders fully extended or retracted
Operating the breaker with the shovel/stick cylin
ders fully extended or retracted must be avoided at CAUTION
all costs. These end positions are equipped with
damping functions; continuous operation at full ex Property damage
tension/retraction can result in damage to the hy
draulic cylinders. Piston rod can
Remedy: reposition carrier and/or boom. stuck.
Do NOT operate
in the dead cent
res of cylinder.

28
10 Maintenance work to be performed by the excavator driver
10.1 Manual lubricating of the working tool
The working tool must be lubricated regularly during
operation. The required lubrication interval depends 550
on the type of application and the amount of dust
involved.
For lubrication purposes, the hydraulic breaker
should be stood vertically on the working steel and
contact pressure applied to avoid overgreasing/fill
ing up the percussion chamber.
Remove the plug. Place the grease gun on the lu
brication nipple and apply grease. grease nipple in lower
Replace plug. hammer part

CAUTION
Burn hazard

Hot surface.

Do NOT touch.

Please note that working tools may still be very hot

at the point/cutting edge even after work has
stopped.
For preference, chisel paste should be used for
lubrication. 510 shots from a handheld grease gun
are sufficient. Lubricating interval: approximately
every 25 hours per shift.
The required lubricant level has been reached when
grease starts to emerge from the bores for the re
taining pins or from the insertion bore for the work
ing steel.
For preference, only genuine chisel paste should be
used for lubrication.Genuine chisel paste is avail
able in fully selfemptying standard cartridges.
Fully emptied cartridges can be recycled.
500 g cartidges for ContiLube II
in a carton of 30 pieces,
part ident. no. 3363 0949 10
Manual grease gun for cardridges:
part ident. no. 3363 0345 67

29
10.2 Automatic lubrication using of the hydraulic breaker of
the 750, 1150, 1650, 2250, 3050 and 4250
10.2.1 Automatic lubrication using ContiLube II
Hydraulic breakers 750, 1150, 1650, 2250, 3050 ContiLube II is attached near the service opening
and 4250 are equipped with the ContiLube II auto on the upper part of the breaker box.
matic lubrication unit as standard.

10.2.2 Changing the lubricant cartridge

The diagrams below depict the logical steps involved in preparing and fitting a new cartridge.
H Open the cartridge by taking off the cap and, on H Screw the cartridge into the bore provided in the
sealed cartridges, by cutting off the seal above pump unit as far as it will go.
the cone (Fig. 1) The ContiLube II is now ready for operation
Important: Do not cut off or damage the cone (Fig. 3).
itself!
H Depress the cartridge piston with your thumb
until lubricant emerges from the threaded end
(Fig. 2).

Fig. 1 Fig. 2 Fig. 3

Metering screw
Seal
Cone

Lubrication nipple
for emergency
lubrication

10.2.3 Operating the ContiLube II

Please observe the following information:

H ContiLube II is selfbleeding, i.e. the system
requires no additional bleeding.
H The cartridge is made of transparent, recyclable
plastic (PE), so the lubricant level in the car
tridge can be monitored at all times from the
drivers cab by observing the position of the pis
ton, which is red.
H Once the cartridge is empty, the pump unit must
be sealed off to prevent water or dust penetra
tion. Close the unit with a dust cap or simply
leave the empty cartridge in position until a new
cartridge is available.
H Emergency lubrication is possible via the lu
brication nipple on the front of the ContiLube II.

H The piston end of the cartridge must never be See chapter 10.2.2, Fig. 3.
sealed off, as this would render delivery imposs
ible. H The connections for hoses used to operate the
ContiLube II unit must be checked once a
H The amount of lubricant delivery per stroke can week to ensure they have not come loose.
be set using the metering screw, allowing the
unit to be adapted to differing requirements.
Turn the screw clockwise = smaller delivery
per stroke
Turn the screw anticlockwise = greater delivery
per stroke

30
10.3 Manual lubrication without or upon failure of ContiLube II
Manual lubrication is necessary if the automatic lu
brication fails. For manual lubrication, stand the hy
draulic breaker upright on the working tool and 1650
apply contact pressure.
Lubricating intervals: approximately every 25
hours. 5 to 10 shots from a grease gun are suffi
cient.
For preference, only genuine chisel paste should be
used for lubrication.
Genuine chisel paste is available in fully selfempty
ing standard cartridges. Fully emptied cartridges
can be recycled.
rear side
ContiLube II

ContiLube II

2250
rear side 3050
4250

ContiLube II
750
CL

ContiLube II

rear side

rear side

1150

10.3.1 Filling device for the chisel paste

The Atlas Copco Construction Tools offers a filling Manual grease gun for cardridges:
device to refill emptied cartridges, which is fitted on part ident. no. 3363 0345 67
a 45 kg grease container and allows empty car
tridges to be refilled as required. 15 kg grease container:
part ident. no. 3362 2639 00
500 g cartidges for ContiLube II
in a carton of 30 pieces, 45 kg grease container:
part ident. no. 3363 0949 10 part ident. no. 3362 2632 75
Manual grease gun for cardridges: For further information on this subject please con
part ident. no. 3363 0345 67 tact the Atlas Copco Customer Center / dealer in
your region.

31
10.4 Care and maintenance timetable
Work to be performed by excavator driver

When changing

During the shift



Daily Weekly
tool, but latest
every 100 opera
As required

ting hours

H Lubricate work H Tighten screw H Check screw H Check wear to H Replace bent
ing tool with couplings (during couplings working tool and squashed
breaker upright first 50 operating pipes
and contact hours)
pressure applied

Intervals: H Check hydraulic H Check spring do H Check wear to H Replace dam
appr. all 25 hours. lines for leaks wel sleeve at the lower wear bu aged hoses
5 to 10 shots with retaining pin shes
the grease gun. have not come
loose

H Check pipe H Check locking H Check impact H Check pressure

clamps on carrier pins on retainer face of per in piston accu
bars for tight fit cussion piston mulator
for wear/ da
mage

If automatic lubrica H Tensioning bolts: H Check function H Check impact H Check adapter
tion fitted, check Visual check of plugs face of working bolts for wear
level, replace cart and/ or sound tool for damage
ridge if necessary check by metallic H Check adapter
hitting of the and breaker box H Check working
upper hexagons/ for cracks tool for burring
washers through
the service open H The connections H Check retainer
ings of breaker for hoses used to bars/pins for bur
box operate the Con ring
tiLube II unit
must be checked
to ensure they
have not come
loose.

32
10.5 Check

10.5.1 Checking the working tool for wear

Check the working tool for wear each time the tool
is changed and at the latest after 100 operating
hours. If the shaft of the tool has worn down to D
below the permissible minimum.

Model Minimum diameter D

550 77 mm / 3.03 in.

750 97 mm / 3.82 in.
1150 111 mm / 4.38 in.
1650 131 mm / 5.16 in.
2250 145 mm / 5.71 in.
3050 160 mm / 6.30 in.
4250 175 mm / 6.89 in.

Any burring on the working tool must be smoothed

off carefully.

33
10.5.2 Checking the wear bushes
Note upper wear
The wear bushes and buffer ring must be replaced bush
in a suitablyequipped workshop. Before fitting new
parts, remove any grease residues inside the lower
breaker part.
The inside diameter of the following wear bush has
to be checked every time the working tool is
changed and at the latest every 100 operating
hours:
550: wear bush
750  4250: lower wear bush
lower
wear bush lower wear
If the diameter has enlarged due to wear, the wear hammer part
bush must be replaced. bush

A template is included in the delivery to check the

inside diameter.
550 750
The measured diameter must not exceed the maxi
mum dimension.

buffer upper wear
bush

Model j template max. permissible ring
diam.
550 80 83 mm / 3.27 in
750 100 103 mm / 4.06 in
1150 115 120 mm / 4.72 in lower wear
1650 135 140 mm / 5.51 in bush
2250 150 155 mm / 6.10 in
3050 165 170 mm / 6.69 in lower ham
4250 180 185 mm / 7.28 in mer part 1150
1650
750  4250:
2250
3050
When the lower wear bushing is replaced, the in 4250
side diameter of the upper wear bushing must be
checked.
If the diameter has enlarged due to wear, the wear
bush and the buffer ring, if existing, must be re
placed.

34
10.5.3 Checking the retaining pin for wear (550 and 750)
The retaining pin must be checked every time the carefully.
working tool is changed. If excessive wear is de
tected, e. g. sharp edges, notches or dents, the re All sealing plugs for the retaining pins must also be
taining pin must be replaced. checked. All plugs, which are located in the lower
hammer part, must be undamaged and in place.
Burrs on the retaining pin should be smoothed off

10.5.4 Checking the retainer bars for wear (1150  2350)

Both retainer bars must be checked each time the
tool is changed. If excessive wear is detected (e.g.
sharp edges, notches, noticeable indentations) the
retainer bars must be replaced.
Any burring on the retainer bars must be smoothed
off carefully.
The two seal plugs for the retainer bars should also
be examined to ensure they are not damaged. It is
only possible to check and replace the seal plugs,
which are located opposite to each other, after the
percussion mechanism has been removed from the
hammer box.

10.5.5 Checking the impact face of the percussion piston

The impact face of the percussion piston has to be shine a torch onto the impact face. If chipping or
checked for wear or damage every time the working wear is detected, do not resume work with the hy
tool is changed and at latest every 100 operating draulic breaker and inform the Atlas Copco Cus
hours. Once the working tool has been removed, tomer Center / dealer in your region.

10.5.6 Checking the hammer box for wear

Heavily worn hammer boxes must be replaced so

as to avoid further damage to the lower hammer
part.
The wear strips attached at the lower end of the
hammer box can be replaced if required. The pro
cedure is described in the relevant repair manuals.
Note
If the wear strips are heavily worn, the guiding sy
stem for the percussion unit can get out of function.

Wear
strip

35
10.5.7 Screw couplings 550 and 750
On percussive tools such as hydraulic breakers, the week. Tighten any loose connections without exceeding
screw couplings are subjected to particularly high loads. the prescribed tightening torque.The following screws/
During the first 50 operating hours the screw couplings on couplings must be checked:

the breaker must be checked daily, thereafter once a

Connection point Part no. Interval 550 750

Type of spanner ...... size ...... Nm

AdapterK 1 daily Allen key size 17 / 390 Nm

Torque wrench / Power wrench

Nuts for tensioning boltsKK 2 weekly
size 41 size 50

Filling valve G in case of Socket spanner size 22 / 130 Nm

3
Screw plug repair Allen key size 5 / 20 Nm

Jaw spanner / 90 Nm
Jaw spanner size 41
Connections P and T 4 weekly up to SN 299: size 36 120 Nm
from SN 300 on: size 27

Jaw spanner size 14

Connection CL 5 weekly
20 Nm

Hose connections Socket and jaw span

5 weekly
ContiLube II ners of varying sizes

Screw plug in case of Jaw spanner size 41

6
(Perc. chamber ventilation) repair 200 Nm
K Apply antiseize to the threads of the cylindrical
bolts before screwing them in. 1
The contact face of the bolt head and the locking
rings must be free of lubricant.
2
The tie rods are only accessible when the breaker
has been removed from the hammer box. G 3
Note
T 4
Tensioning bolts:
Visual check and/or sound check by metallic hitting P
of the upper hexagons/washers thru the service
openings of breaker box.
KKTightening the tensioning bolts for 550
H Pretighten nuts in diagonally opposed pairs to 550
200Nm,
H then tighten in diagonally opposed pairs by a
further 60 (1 side of hexagonal head),
H then tighten in diagonally opposed pairs by a 1
further 90 (1 sides of hexagonal head).
2
KKTightening the tensioning bolts for 750
H Pretighten nuts in diagonally opposed pairs to 3
200Nm, G
H then tighten in diagonally opposed pairs by a
further 120 (2 sides of hexagonal head), T
4
L
H then finish tighten in diagonally opposed pairs by 6 P CL 5
210 (3 sides of the hexagonal head). P

750

36
10.5.8 Screw couplings 1150
On percussive tools such as hydraulic breakers, the
screw couplings are subjected to particularly high
loads. During the first 50 operating hours the screw
couplings on the breaker must be checked daily,
thereafter once a week (except of tie rods and high
pressure accumulator). Tighten any loose connec
tions without exceeding the prescribed tightening
torque.
The following screws/couplings must be checked:

Connection point Partno. Interval 1150

Type of spanner......size.....Nm
AdapterK 1 daily Allen key size 22 / 1500 Nm
sound check
Tensioning boltsKKK 2 Torque wrench / Power wrench size 55
weekly
Allen screwKK in case of
3 Allen key size 14 / 200 Nm
(valve cover/control valve) repair
Screw plug in case of
4 Spanner size 41 / 200 Nm
(Perc. chamber ventilation) repair
Filling valve G in case of Socket spanner size 22 / 130 Nm
5
Screw plug repair Allen key size 5 / 20 Nm
Connections P and T 6 weekly Jaw spanner size 46 / 160 Nm
Jaw spanner size 27 / 200 Nm
Connection CL 7 weekly
Jaw spanner size 14 / 20 Nm
Hose connections
7 weekly Socket and jaw spanners of varying sizes
ContiLube II
Highpressure accumulator
8 weekly Allen key size 14 / 350 Nm

K Apply antiseize to the threads of the cylindrical

bolts before screwing them in. 1150
The contact face of the bolt head and the locking
rings must be free of lubricant.
1
KK Only possible when adapter has been removed
Note
Tensioning bolts: X
Visual check and/or sound check by metallic hitting
of the upper hexagons/washers thru the service
openings of breaker box.
8 2
KKK Tightening 3
the tensioning bolts for 1150
H Pretighten nuts in diagonally opposed pairs to
500Nm,
H then tighten in diagonally opposed pairs by a
4
further 60 (1 side of hexagonal head),
H then finish tighten in diagonally opposed pairs by
120 (2 sides of the hexagonal head).
G
P
T
5
CL
7

6
View X
(without hammer box)

37
10.5.9 Screw couplings 1650
On percussive tools such as hydraulic breakers, the
screw couplings are subjected to particularly high
loads. During the first 50 operating hours the screw
couplings on the breaker must be checked daily,
pressure accumulator). Tighten any loose connec
tions without exceeding the prescribed tightening
torque.
The following screws/couplings must be checked:

thereafter once a week (except of tie rods and high

Connection point

Part

no.
Interval 1650

Type of spanner ...... size ..... Nm

AdapterK 1 daily Allen key size 22 / 1500 Nm
sound check
Tensioning boltsKK 2 Torque wrench / Power wrench size 55
weekly
Allen screw in case of
3 Spanner size 30 / 380 Nm
(valve cover/control valve) repair
Screw plug in case of
4 Jaw spanner size 41 / 200 Nm
(Perc. chamber ventilation) repair
Filling valve G in case of Socket spanner size 22 / 130 Nm
5
Screw plug repair Allen key size 5 / 20 Nm
Connections P and T 6 weekly Jaw spanner size 50 / 400 Nm
Port F for impact rate
7 weekly Jaw spanner size 30 / 200 Nm
switching
Highpressure accumulatorKKK
8 weekly Socket spanner size 30
(connecting screws)
Jaw spanner size 27 / 200 Nm
Connection CL 9 weekly
Jaw spanner size 14 / 20 Nm
Hose connections
9 weekly Socket and jaw spanners of varying sizes
ContiLube II
K Apply antiseize to the threads of the cylindrical
bolts before screwing them in. 1650
The contact face of the bolt head and the locking
rings must be free of lubricant.
Note
Tensioning bolts:
Visual check and/or sound check by metallic hitting
of the upper hexagons/washers thru the service 1
openings of breaker box. X
K Tightening the tensioning bolts for 1650
H Pretighten nuts in diagonally opposed pairs to
500 Nm, 3
H then tighten in diagonally opposed pairs by a
further 120 (2 side of hexagonal head),
H then finish tighten in diagonally opposed pairs by 2 5
8
90 (1 sides of the hexagonal head).
KK Tightening the expansion bolts on highpressure
accumulator 1650
1. Treat the threads and HeliCoil thread inserts for F
the expansion bolts with an antiseize agent.
2. Treat the surfaces between the bolt head, was P T
V 7
her, and highpressure accumulator cover with CL
antiseize agent.
6 P 4
3. Place on the highpressure accumulator, and
tighten the expansion bolts by hand in a cross
wise fashion.
4. Pretighten the expansion bolts to 100 Nm, pro 9 9 6
ceeding in a crosswise fashion, View X
5. then tighten each bolt through 30 in a crosswise (without hammer box)
fashion,
6. finally tighten each bolt again through 60 in a
crosswise fashion.

38
10.5.10 Screw couplings 2250, 3050 and 4250
On percussive tools such as hydraulic breakers, the
screw couplings are subjected to particularly high
loads. During the first 50 operating hours the screw
couplings on the breaker must be checked daily,
pressure accumulator). Tighten any loose connec
tions without exceeding the prescribed tightening
torque.
The following screws/couplings must be checked:

thereafter once a week (except of tie rods and high

Part

Connection point
no.
Interval 2250 3050 4250

Type of spanner......size.....Nm
Allen key size 22 /
AdapterK 1 daily Allen key size 27 / 2360 Nm
1500 Nm

sound check Slugging ring spanner size 55

Tensioning boltsKKK 2
weekly size 55 size 65 size 75
Allen screwKK
in case of
(valve cover/ 3 Allen key size 17 / 380 Nm
repair
control valve)
Screw plug
in case of
(Perc. chamber 4 Spanner size 41 / 200 Nm
repair
ventilation)
Filling valve G in case of Socket spanner size 22 / 130 Nm
5
Screw plug repair Allen key size 5 / 20 Nm
Connections P and
6 weekly Jaw spanner size 50/55 / 400 Nm
T
Allen screws for Allen key size 12 /
7 weekly Allen key size 10 / 80 Nm
flanges 130 Nm
Highpressure
Allen key size 14 /
accumulatorKKKK 8 weekly Socket spanner size 30
350 Nm
(connecting screws)
Hose connections
9 weekly Socket and jaw spanners of varying sizes
ContiLube II
K Apply antiseize to the threads of the cylindrical KKKK Tightening the expansion bolts on highpres
bolts before screwing them in. sure accumulator 3050 and 4250
The contact face of the bolt head and the locking 1. Treat the threads and HeliCoil thread inserts for
rings must be free of lubricant. the expansion bolts with an antiseize agent.
KK Only possible when adapter has been removed 2. Treat the surfaces between the bolt head, was
her, and highpressure accumulator cover with
Note antiseize agent.
Tensioning bolts: 3. Place on the highpressure accumulator, and
Visual check and/or sound check by metallic hitting tighten the expansion bolts by hand in a cross
of the upper hexagons/washers thru the service wise fashion.
openings of breaker box.
4. Pretighten the expansion bolts to 100 Nm, pro
KKK Tighteningthe tensioning bolts for 2250 ceeding in a crosswise fashion,
H Pretighten nuts in diagonally opposed pairs to 5. then tighten each bolt through 30 in a crosswise
500 Nm, fashion,
H then tighten in diagonally opposed pairs by a 6. finally tighten each bolt again through 60 in a
further 120 (2 sides of hexagonal head), crosswise fashion.
H then finish tighten in diagonally opposed pairs by
120 (2 sides of the hexagonal head).
KKK Tighteningthe tensioning bolts for 3050 and
4250
H Pretighten nuts in diagonally opposed pairs to
500 Nm,
H then tighten in diagonally opposed pairs by a
further 120 (2 sides of hexagonal head),
H then finish tighten in diagonally opposed pairs by
180 (3 sides of the hexagonal head).

39
 2250
3050
4250

Tensioning bolts:
Visual check and/or sound check by metallic
hitting of the upper hexagons/washers thru
the service openings of breaker box.

9 2 3

T
8

CL
G

6 7 5 4

View X
(without hammer box)

On 3050 and 4250 the connection

points 6 and 7 are on the sides of the
cylinder cover.

The graphic may vary for different breaker models.

40
10.5.11 Checking pressure in piston accumulator and refilling if required
For checking the piston accumulator of the hy
550, 750
draulic breaker you need:
1 nitrogen filling device
1 pressure gauge 1/4", 025 bar (0400 psi), Port for test
test class 1.6 pressure gauge
G
1 nitrogen cylinder
1 adapter, country specific
These items should be on hand at all times to allow
the following checking and maintenance work to be L T
performed. The graphic may vary for
P CL
CHECKING different breaker models.
P
If the performance of the hydraulic breaker starts to
drop, the gas pressure in the breakers piston accu
mulator should be checked. The piston accumulator
does not need to be refilled until the gas pressure
has dropped to the minimum level or below.
1150
Note
The pressure should be checked at an operating
temperature of 6070C (140160F).
Lay the hydraulic breaker flat to check the pressure.
Do not apply contact pressure to the working tool.
Port for test
Unscrew the plug from filling valve G and connect G pressure gauge
up the pressure gauge.
Read off the pressure.
The required pressure in the piston accumulator is

as follows:

at operating temperature
6070C (140160F) 1650

+ no contact pressure to the Port for test pressure gauge

working tool!
Model

Minimum gas Required gas G

pressure pressure
F

bar / psi bar / psi

550 14.0 / 203 17.3 / 251 P T

750 9.5 / 138 11.9 / 173 V
CL
1150 5.2 / 75 7.0 / 102
1650 5.3 / 77 8.2 / 119
2250 12.0 / 174 15.5 / 225 P
3050 12.5 / 181 16.0 / 232
4250 8.6 / 125 11.5 / 167

FILLING / REFILLING
2250
Note 3050
If a country specific adapter is required it has to be 4250
fitted between nitrogen cylinder and pressurerelief
valve. G
Preparations:
H Connect the pressurerelief valve to the nitrogen
cylinder.
H Connect one nozzle of the filling hose to the Port for test
Minimess port on the pressurerelief valve. pressure gauge
H Close the pressurerelief valve

41
H Open the valve on the nitrogen cylinder
H Unscrew the plug from filling valve G.
H Press the free nozzle on the filling hose into the
filling valve G.
Filling the piston accumulator:
H Slowly open the pressurerelief valve to allow
the nitrogen to flow into the piston accumulator.
The pressure increase can be read on the pres
sure gauge.
H Close the pressurerelief valve when the pres
sure in the piston accumulator has reached the
required level +10%.
H Pull the filling hose out of filling valve G.
Checking and lowering pressure:
H Remove the filling hose from the pressurerelief
valve and connect it to the pressure gauge.
H Press the free nozzle of the filling hose back into
filling valve G and read off the pressure.
H The pressure in the piston accumulator can be
lowered to the required reading by repeatedly
pushing in and pulling out the hose nozzle.
After filling:
H Screw the plug back onto filling valve G to
close it.
H Close the valve on the nitrogen cylinder
H Open the pressurerelief valve fully to allow any
residual gas to escape.
H Remove the pressurerelief valve and if required
the adapter.
WARNING!
Only use the hose nozzle to relieve the pressure.
Never use nails, screwdrivers or similar objects for
this purpose as they will damage the filling valve.
Use only nitrogen from the green gas cylinder to fill
the piston accumulator. Never use any other gas,
e.g. air or oxygen.
DANGER
Explosion hazard
Compressed
gas.
Stop engine,
BLEED OFF
gas chamber.
When filling the piston accumulator, ensure noone
is in the vicinity of the working tool.
If the tool has jammed, the increase in pressure in
the piston accumulator may cause it to spring out
suddenly.
Before removing the complete filling valve G, the
piston accumulator must be completely depressur
ized. To this end unscrew the valve plug and de
press the valve piston in the filling valve using the
nozzle of the filling hose.
This will allow the nitrogen to escape safely from
the cylinder cover of the hydraulic breaker.

Pressure Minimess port

gauge

Nozzle

Pressure
relief valve
G
gas cylinder valve Adapter

42
10.5.12 Checking that the highpressure accumulator is in perfect
working order (1150, 1650, 2250, 3050, 4200)
If the normally motionless pressure hose to the
breaker (port P) starts to jerk violently, there is a DANGER
problem with the highpressure accumulator.
Explosion hazard
Switch off the hydraulic breaker immediately and
replace the highpressure accumulator. Pressurized
vessel.
Stop engine and
BLEED OFF
breaker circuit.

Before mounting/dismounting the hydraulic tool

and/or any maintenance work on the hydraulics
of the hydraulic tool/carrier the hydraulic sys
tem must be depressurized.
Check the pressure accumulator in accordance with
the national safety provisions. We recommend five
yearly maintenance intervals.

10.5.13 Checking the hydraulic lines before starting work

Carry out a visual check on all lines (pipes and and hose clamps. Damaged pipes/hoses must be
hoses) from the pump to the hydraulic breaker and replaced.
back to the tank. Tighten any loose screw couplings

10.5.14 Checking the adapter bolts for wear

This visual check is only possible when the hy notches, noticeable indentations etc.) the screws
draulic breaker has been dismounted from the ex must be replaced.
cavator. If excessive wear is detected (cracks,

10.5.15 Checking and cleaning the hydraulic oil filter

A new oil filter cartridge should be fitted for the first time after 50 operating hours. Thereafter the oil filters
should be checked every 500 operating hours and changed if necessary.

43
11 Troubleshooting
11.1 Breaker does not start

Cause Remedy by

Pressure and return lines

Connect breaker hoses correctly Excavator driver
mixed up

Check valve in pressure and/or re

Open check valve Excavator driver
turn lines closed

Gas pressure in piston accumula Check pressure in piston accumu

Excavator driver
tor too high lator, reset to correct value

Oil level in tank too low Refill oil Excavator driver

Defective screw couplings block

Replace defective coupling halves Workshop
ing pressure or return line

Electrical equipment for breaker Check electrical equipment for

Workshop
hydraulics defective breaker hydraulics

Magnet on switchon valve

Replace magnet Workshop
defective

Check excavator engine speed; Excavator driver or

Operating pressure too low check operating pressure Atlas Copco Customer Center /
dealer in your region

44
11.2 Impact rate of hydraulic breaker too low

Cause Remedy by

Correct excavator engine speed;

Inadequate hydraulic oil delivery check operating pressure; Excavator driver
check setting on carrier

Loose coupling in pressure or Check coupling, tighten

Excavator driver
return line if necessary

Check valve in pressure or return

Open check valve Excavator driver
line partially closed

Flow resistance too high on oil Check oil filter/cooler, clean or

Excavator driver
filter or oil cooler replace

Check gas pressure in piston

Gas pressure in piston
accumulator, bleed off if Excavator driver
accumulator too high
necessary

Working tool jams in lower

hammer part Correct boom direction; deburr
Note: contact pressure must be working tool; check wear to work Excavator driver
applied along hydraulic breaker ing tool and wear bushes
axis

Change inside diameter, note the

Inside diameter of return line too minimum inside diameter
Workshop
small refer to Section 13, Technical spe
cifications

Atlas Copco Customer Center /

Return pressure too high Check and lower return pressure
dealer in your region

Hydraulic oil returns to tank via

Note: hydraulic oil must return di Atlas Copco Customer Center /
valve section.
rect to tank or to filter dealer in your region or workshop
Not permitted!

Diaphragm in highpressure
Replace
accumulator defective
highpressure accumulator.
(1150, 1650, 2250, 3050, 4250) Workshop
Note: Observe the national safety
Note: hose at port P jerks vio
regulations
lently

Temp. of hydraulic oil in tank Check oil level in hydraulic tank

Excavator driver
above 80C and top up if required

Check pressure, modify if necess

Hydraulic oil pressure too low ary; fit new typetested pressure Workshop
relief cartridges where necessary

45
11.3 Impact force too low

Cause Remedy by

Gas pressure too low Fill piston accumulator Excavator driver

Checking: Atlas Copco Customer

Delivery rate from hydraulic
system pump inadequate
Check pump characteristics with
Center / dealer in your region
measuring device and compare
with original specifications; if
Replacing: Aftermarket Depart
necessary replace pump
ment of excavator manufacturer

11.4 Impact rate too high and impact force too low

Cause Remedy by

No gas in piston accumulator Fill piston accumulator Excavator driver

Orings defective
(550 parts 9 and 12)K
(750 part 103)K
(1150 parts 120 and 126)K
Replace Orings Workshop
(1650 parts 17 and 51)K
(2250 parts 18 and 20)K
(3050 and 4250
parts 28 and 42)K

K parts nos refer to valid spare parts lists

11.5 Oil leaks from ports P and T

Cause Remedy by

Threaded connections between

connecting flange and breaker Tighten threaded connections Excavator driver
hose are loose 2250

Cap nuts loose Tighten cap nuts Excavator driver

CL hose connection on port P

Tighten hose connections
for ContiLube II (or plug if Excavator driver
Tighten plug
ContiLube II not fitted) loose

46
11.6 Oil leaks between cylinder cover and cylinder

Cause Remedy by

Tie rods loose Tighten tie rods Workshop

Replace seals
Seals defective Workshop
(see spare parts lists)

11.7 Oil leaks from parts of hydraulic system for breaker

(Screw couplings, hoses etc.)

Cause Remedy by

Tighten screw couplings; if

necessary replace defective parts;
Screw couplings loose;
check hydraulic system for Excavator driver or workshop
flange connections on valve loose
breaker, replace defective parts
Note: use only genuine spares

11.8 Oil leaks from working tool

Cause Remedy by

Dismantle hydraulic breaker; re

Lower piston seals defective place seals; avoid possible ex Workshop
cessive lubrication of working tool

11.9 Oil leaks from highpressure accumulator

Cause Remedy by

Replace Oring a. backup ring

(1150: parts 111 + 112)K
Fixing screws for highpressure (1650: parts 43 + 44)K
Workshop
accumulator loose (2250: parts 11+12)K
(3050, 4250: parts 35 + 36)K
Tighten fixing screws

K Part nos. refer to valid spare parts lists

47
11.10 Oil or grease leaks from ContiLube II

Cause
Remedy by

Screw couplings are loose Tighten screw couplings Workshop

11.11 Operating temperature too high

Cause Remedy by

Excavator driver
Oil level in tank too low Refill oil
or Workshop

Excavator pump delivery too high;
oil is constantly returned to the
tank via the pressurerelief valve
Excavator driver
Correct excavator engine speed
Atlas Copco Customer Center /
Reset pump
dealer in your region

Workshop or Atlas Copco Cus

High outside temperature and no
Fit oil cooler tomer Center / dealer in your re
oil cooler fitted
gion

Pressurerelief valve defective or Fit new typetested pressure relief

valve with a bad characteristic cartridges or a more precise pres Workshop
curve surelimiting valve

12 Disposal
H Put the hydraulic breaker out of operation and
disassemble it as described in sections 8.3 and
CAUTION! 6.6.

H Dispose of the hydraulic breaker in line with all

applicable regulations or consult an authorised
Dispose of the hydraulic breaker and the hydraulic and specialised recycling company.
oil in accordance with the applicable statutory provi
sions on environmental protection.

48
13 Technical specifications

Model 550 750 1150 1650

Service weightK [kg] 560 850 1250 1600
[lbs] 1235 1874 2756 3528
Recommended
carrier class [t] 915 1218 1422 1834
[lbs] 19.80033.000 26.50040.000 30.10048.500 40.00075.000
Impact rateKK [min1] 590  1100 420  750 350 600 360 540
Dimensions
(excl. working tool)
Length [mm] 1190 1366 1579 1664
[inch] 46.80 54.37 62.16 65.51
Width [mm] 410 410 495 495
[inch] 16.14 16.14 19.48 19.49
Depth [mm] 560 560 630 648
[inch] 22.05 22.05 24.80 25.51
Oil flow rate [l/min] 70 100 80  110 90  120 130 170
[US gal/min] 18.5 26.4 21.1 31.7 23.8 31.7 34.35 44.91
Operating
pressure [bar] 120 150 140  170 140  170 120 140
[psi] 1740 2175 2030 2465 2030 2465 1740 2030
Max. static
pressure [bar] 170 200 190 160
[psi] 2465 2900 2755 2320
(to be set on pressure
relief valve for breaker
circuit)
Working tool
diameter [mm] 80 100 115 135
[inch] 3.15 3.94 4.53 5.32
Piston accumulatorKKK
gas pressure
Minimum [bar/psi] 14.0/203 9.5/138 5.2/75 5.3/77
Required [bar/psi] 17.3/251 11.9/173 7.0/102 8.2/119
Sound pressure level
measured [Lp dB (A)] 87 90 90 87
r = 10 m
Sound power levelKKKK
116 120 120 117
garanteed [LWA dB (A)]
up to SN 299:
M 36 x 2 /
Connecting thread on 24 concial seal M 36 x 2 M 42 x 2 BSP 1"
ports P and T from SN 300 on: 24 concial seal 24 concial seal DIN 2999
M 26 x 1,5
24 concial seal

Inside diameter: up to SN 299:

Hoses [mm] 20 / (0.79 inch) 20 / (0.79 inch) 25 (1 inch)
from SN 300 on:
18 / (0.71 inch)
up to SN 299:
20 / (0.79 inch)
Pipes [mm] from SN 300 on: 20 / (0.79 inch) 25 (1 inch)
16 / (0.63 inch)

K Hydraulic breaker incl. breaker box, working tool and medium sized adapter.
KK Depending on the oil flow rate
KKK at operating temperature of 60 to 70C and no contact pressure to the working tool
KKKK measuring process based on directive 2000/14/EC

49


Model 2250 3050 4250

Service weightK [kg] 2150 3000 4120

[lbs] 4741 6615 9085

Recommended
carrier class [t] 26 40 32 50 42 75
[lbs] 57.300 88.200 70.600 110.300 92.600 165.400

Impact rateKK [min1] 280 550 280 540 270 530

Dimensions
(excl. working tool)
Length [mm] 1946 2205 2359
[inch] 76.61 86.81 92.87
Width [mm] 650 670 670
[inch] 25.59 26.38 26.38
Depth [mm] 700 800 800
[inch] 27.56 31.50 31.50

Oil flow rate [l/min] 140  180 210  270 250 320
[US gal/min] 36.99 47.56 55.48 71.33 66.05 84.54

Operating
pressure [bar] 160  180 160  180
[psi] 2320 2610 2330 2610

Max. static
200 200
pressure [bar]
2900 2900
[psi]
(to be set on pressurerelief
valve for breaker circuit)

Working tool
diameter [mm] 150 165 180
[inch] 5.91 6.50 7.09

Piston accumulatorKKK
gas pressure
Minimum [bar/psi] 12.0/174 12.5/181 8.6/125
Required [bar/psi] 15.5/225 16.0/232 11.5/167

Sound pressure level

measured [Lp dB (A)] 91 93 92
r = 10 m

Sound power levelKKKK

121 122 122
garanteed [LWA dB (A)]

Connection
Connecting thread on ports flange 1 5/812 UNF
P and T SAE 1 1/4 JIC Konus 37
6000 psi

Inside diameter:
Hoses [mm] 25 (1") 30 / (1.18 inch)
Pipes [mm] 25 (1") 30 / (1.18 inch)

K Hydraulic breaker incl. breaker box, working tool and medium sized adapter.
KK Depending on the oil flow rate
KKK at operating temperature of 60 to 70C and no contact pressure to the working tool
KKKK measuring process based on directive 2000/14/EC

50
Index
A F
H Accident prevention regulations, 7 H Filling device for the chisel paste, 31

H Applications, 11

H Attaching the adapter to the hydraulic hammer,

G
16 H General informations, 11
H Automatic lubrication using ContiLube II, 30

H Automatic lubrication using of the hydraulic H

breaker of the 750, 1150, 1650, 2250, 3050 and
H Hammer does not start, 44
4250, 30
H How to proceed after more than twelve months
C storage, 20

H Care and maintenance, 32

I
H CE markings, 10
H Impact force too low, 46
H CE sticker product groups B, 10
H Impact rate of hydraulic hammer too low, 45
H Changing the lubricant cartridge, 30
H Checking H Impact rate too high and impact force too low,
46
Adapter bolts, 43
Hammer box, 35
L
Hydraulic filter, 43
H Long storage, 20
Hydraulic lines, 43
Retainer bars, 35
M
Working tool, 33
H Main components, 12
H Checking pressure in piston accumulator and
H Main components or assemblies 1150 and 1650,
refilling if required, 41
13
H Checking that the highpressure accumulator is
H Main components or assemblies 2250, 3050 and
in perfect , 43
4250, 14
H Checking the impact face of the percussion
H Main components or assemblies 550 and 750,
piston, 35
12
H Checking the retainer bars for wear (1150
2350), 35 H Maintenance work to be performed by the exca
vator driver, 29
H Checking the wear bushes , 34
H Manual lubricating of the working tool, 29

D H Manual lubrication without or upon failure of

ContiLube II, 31
H Dismounting the hydraulic breaker from the ex
cavator for short or lengthy periods of nonuse, H Mineral hydraulic oil, 15
19
H Mounting, Hydraulic aspects, 18
H Disposal, 48
H Mounting the hydraulic hammer on the excava
H DustProtector , 24 tor, 17

51
N S
H Never drive the working tool into the ground, 26 H Scope of supply, 11

H Never lever with the hammer, 27 H Screw couplings 1150, 37

H Never use as a sledgehammer, 27 H Screw couplings 1650, 38
H Never use for transport purposes, 27 H Screw couplings 2250, 3050 and 4250, 39
H Nonmineral hydraulic oil, 15
H Screw couplings 550 and 750, 36

H Selecting the right working tool, 21

O
H Oil leaks between cylinder cover and cylinder, H Short storage, 20
47
H Starting up the hydraulic breaker, 25
H Oil leaks from highpressure accumulator, 47
H Sticker for guaranteed sound level power, 11
H Oil leaks from parts of hydraulic system for ham
mer (Screw couplings, hoses etc.), 47 H Storage, 20

H Oil leaks from ports P and T, 46 Hydraulic breaker, 20

H Oil leaks from working tool, 47 H Switching on from the carrier, 19 , 23

H Oil or grease leaks from ContiLube II, 48 H Symbols, 7

H Operating, 15
Advance, 26 T
Angle of attack, 26 H Technical specifications, 49
Hammer rocking, 26
H Troubleshooting, 44
Media/consumables, 15
Starting up, 25
H Operating media/consumables W
H Working
Gas, 16
In high outside temperatures, 28
Grease, 15
In low outside temperatures, 28
H Operating temperature too high, 48
In or under water, 27
H Operating the breaker with the cylinders fully
In tunnel application, 28
extended or retracted, 28
H Operating the ContiLube II, 30 H Working tool, Fitting, 21

H Working tools, 21
P
H Working tools for hydraulic breakers 1150
H Piston accumulator, Filling, 41 4250, 22

52
53
54
55
Atlas Copco Construction Tools GmbH
Helenenstrasse 149 S 45143 Essen
P. O. Box 10 21 52 S 45021 Essen
Federal Republic of Germany
Telephone +49 201 633 0
Internet: www.atlascopco.com

Your partner: