Atlas Copco DC 200, DC 1000, DC 400, DC 1200, DC 2000 Safety And Operating Instructions Manual
...
Safety and operating instructions
Transverse Drum Cutters
DC 200
DC 400
DC 600
DC 1000
DC 1200
DC 2000
DC 2100
DC 2900
Valid from serial number
DEQ161115
DEQ140244
DEQ140245
DEQ140246
DEQ161163
DEQ132047
DEQ140172
DEQ161168
DC
200, 400, 600, 1000, 1200, 2000, 2100, 2900
© Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
Contents
Introduction .................................................................................................................................................... 7
About these Safety and Operating Instructions .................................................................................... 7
Safety instructions ......................................................................................................................................... 8
Signal words ............................................................................................................................................. 8
Qualification .............................................................................................................................................. 9
Intended use .............................................................................................................................................. 9
Use other than intended ........................................................................................................................... 9
Protective equipment ............................................................................................................................. 10
Carrier, precautions ................................................................................................................................ 10
Transport, precautions ........................................................................................................................... 10
Hydraulic installation, precautions ....................................................................................................... 11
Media/consumables, precautions .......................................................................................................... 11
Explosion and fire, precautions ............................................................................................................ 12
Electrical shock, precautions ................................................................................................................ 12
Falling stones, precautions ................................................................................................................... 12
Emissions, precautions ......................................................................................................................... 13
Handling machines, precautions .......................................................................................................... 13
Repair, precautions ................................................................................................................................ 14
Maintenance works not allowed by Atlas Copco ................................................................................. 14
Changes to the hydraulic attachment, precautions ............................................................................ 14
Environmental pollution, precautions .................................................................................................. 15
Overview ....................................................................................................................................................... 16
Equipment description ........................................................................................................................... 16
Function ................................................................................................................................................... 16
Modules ................................................................................................................................................... 16
Signs / labels ........................................................................................................................................... 18
Name plate .......................................................................................................................................... 18
Labels .................................................................................................................................................. 19
Applications ............................................................................................................................................ 19
Working area and hazardous area ........................................................................................................ 19
Removing the packaging ....................................................................................................................... 20
Scope of delivery .................................................................................................................................... 20
Standard round attack picks ................................................................................................................ 21
Transport ...................................................................................................................................................... 22
Transport using a crane ......................................................................................................................... 22
Transport using a forklift truck .............................................................................................................. 23
Transport using a truck .......................................................................................................................... 23
Installation .................................................................................................................................................... 24
Media/consumables ................................................................................................................................ 24
Mineral hydraulic oil ............................................................................................................................. 24
Non-mineral hydraulic oil ..................................................................................................................... 24
Gear oil ................................................................................................................................................ 24
Preconditions for the carrier ................................................................................................................. 24
Preconditions for adapter plate ............................................................................................................. 25
Manufacturing the adapter plate ........................................................................................................... 25
Attaching the hydraulic attachment to the carrier ............................................................................... 26
Mechanical mounting aspects ............................................................................................................. 26
First installation .................................................................................................................................... 27
Making the hydraulic connections ........................................................................................................ 28
Mechanical mounting aspects ............................................................................................................. 29
Removing the hydraulic attachment from the carrier ......................................................................... 30
Operation ...................................................................................................................................................... 31
DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900 Contents
© Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
3
Preparations before starting .................................................................................................................. 32
Commissioning ....................................................................................................................................... 33
Checks during commissioning ............................................................................................................. 33
Switching the transverse drum cutter on and off ................................................................................ 33
Functional test ........................................................................................................................................ 33
Correct operation .................................................................................................................................... 34
Prohibited operation ............................................................................................................................... 35
Cylinder end positions ......................................................................................................................... 35
Moving the carrier ................................................................................................................................ 35
Lifting/Transporting .............................................................................................................................. 35
Impacting/chopping .............................................................................................................................. 36
Activities after use .................................................................................................................................. 36
Turning the transverse drum cutter ...................................................................................................... 36
Maintenance ................................................................................................................................................. 38
Maintenance works not allowed by Atlas Copco ................................................................................. 39
Maintenance schedule ........................................................................................................................... 40
Depressurising the hydraulic system ................................................................................................... 41
Cleaning ................................................................................................................................................... 41
Checking bolted connections ................................................................................................................ 41
Checking the hydraulic attachment and adapter plate for cracks ..................................................... 42
Checking the adapter plate bolts for wear ........................................................................................... 42
Change gear oil ....................................................................................................................................... 42
Oil change intervals ............................................................................................................................. 42
Preparation .......................................................................................................................................... 42
Drain off gear oil .................................................................................................................................. 42
Fill up gear oil ...................................................................................................................................... 43
Check the round attack picks ................................................................................................................ 44
Replace round attack picks ................................................................................................................... 44
Replace round attack pick with knock on retainer ............................................................................... 45
Replace round attack pick with retaining sleeve .................................................................................. 46
Replace round attack picks with quick snap retainer ........................................................................... 47
Replace round attack picks with retaining ring .................................................................................... 48
Replace cutter drums ............................................................................................................................. 49
Disassemble cutter drums ................................................................................................................... 49
Assemble cutter drums ........................................................................................................................ 50
Assemble and disassemble rotatable upper part ................................................................................ 52
Disassemble rotatable upper part ........................................................................................................ 52
Assemble rotatable upper part ............................................................................................................. 52
Checking hydraulic lines ....................................................................................................................... 53
Checking and cleaning the hydraulic oil filter of the carrier .............................................................. 53
Replace hydraulic hoses ........................................................................................................................ 54
Actions following maintenance ............................................................................................................. 54
Bolt connections/ Tightening torques .................................................................................................. 55
Troubleshooting ........................................................................................................................................... 57
Faults table .............................................................................................................................................. 57
Cutter drums do not turn / are blocked ................................................................................................ 58
Cutter drums turn too slowly ................................................................................................................. 58
Transverse drum cutter stops moving with light pressure ................................................................ 58
Unusual oscillation of the cutter drums ............................................................................................... 59
Round attack picks do not turn ............................................................................................................. 59
Unusually loud gear noise ..................................................................................................................... 59
Unusually loud noise from the hydraulic motor .................................................................................. 59
Overpressure cover for the hydraulic motor deformed, oil leak on sealing surface, oil leak at the
pressure limiting valve ........................................................................................................................... 60
Behaviour following fault elimination ................................................................................................... 60
Repair ............................................................................................................................................................ 61
Contents DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900
4 © Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
Sending in the hydraulic attachment for repairs ................................................................................. 61
Storage .......................................................................................................................................................... 62
Transverse drum cutter .......................................................................................................................... 62
Short storage ....................................................................................................................................... 62
Long storage ........................................................................................................................................ 62
Cutter drums ........................................................................................................................................... 62
Round attack picks ................................................................................................................................. 62
Disposal ........................................................................................................................................................ 63
Transverse drum cutter .......................................................................................................................... 63
Hydraulic hoses ...................................................................................................................................... 63
Hydraulic oil ............................................................................................................................................ 63
Gear oil .................................................................................................................................................... 63
Technical specifications .............................................................................................................................. 64
Appendix ................................................................................................................................................. 66
Hydraulic installation version 1 for hydraulic hammer ......................................................................... 66
Hydraulic installation version 2 for hydraulic shear systems ............................................................... 67
Hydraulic settings DC 200 ................................................................................................................... 68
Hydraulic settings DC 400 ................................................................................................................... 69
Hydraulic settings DC 600 ................................................................................................................... 70
Hydraulic settings DC 1000 ................................................................................................................. 71
Hydraulic settings DC 1200 ................................................................................................................. 72
Hydraulic settings DC 2000 ................................................................................................................. 73
Hydraulic settings DC 2100 ................................................................................................................. 74
Hydraulic settings DC 2900 ................................................................................................................. 75
EC Declaration of Conformity (EC Directive 2006/42/EC) ........................................................................ 76
DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900 Contents
© Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
5
Introduction
Thank you for choosing an Atlas Copco product!
We have been working according to a customeroriented approach since 1873. Our innovative and
ergonomic solutions help our customers lower
costs and achieve better business results.
Atlas Copco has a worldwide, comprehensive
sales and service network of Customer Centers
and dealers. Our professionals are specialists with
a thorough product knowledge and considerable
application experience.
This allows us to offer our customers effective
service and know-how throughout the world,
enabling them to achieve greater operating
efficiency.
Construction Tools GmbH
P.O. Box: 102152
Helenenstraße 149
D - 45021 Essen
Tel.: +49 201 633-0
About these Safety and
Operating Instructions
The aim of these Instructions is to familiarise you
with the safe and effective operation of the
hydraulic attachment. You will also find instructions
for regular maintenance activities for the hydraulic
attachment in this document.
Please read these Instructions carefully prior to the
first attachment and use of the hydraulic
attachment.
The different designation of the texts means as
follows:
►
Action step in a safety instruction
♦
Action step
1.
2.
Established operation process
A
B
C
Explanation of the elements of a drawing
•
•
•
Listing
Symbols used in illustrations have the following
meanings:
permitted operation
prohibited operation
DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900 Safety and operating instructions
© Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
7
Safety instructions
This is the safety alert symbol. It is used to alert you to
potential personal injury hazards. Obey all safety
messages that follow this symbol to avoid possible
injury or death.
Read these Safety and operating instructions and
specifically all safety instructions before using the
hydraulic attachment. This will:
•
prevent the risk of injuries and fatal accidents
for yourself and others,
•
protect the hydraulic attachment and other
property against material damage,
•
protect the environment against environmental
damage.
Follow all instructions in these Safety and
operating instructions.
Store these Safety and operating instructions in
the document compartment of the carrier cab.
Anyone
•
transporting,
•
installing or removing,
•
operating,
•
maintaining,
•
repairing,
•
storing or
•
disposing of
the hydraulic attachment must have read and
understood 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 incorporated 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 Instructions before attaching the
hydraulic attachment to the carrier and operating it.
Observe all instructions.
Signal words
The signal words Danger, Warning, Caution, and
Notice are used as follows in these Safety and
operating instructions:
DANGER indicates a hazardous situation
which, if not avoided, will result in
death or serious injury.
WARNING indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
CAUTION indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
NOTICE The signal word NOTICE is used
to address practices related to
possible property damage but not
related to personal injury.
Safety and operating instructions DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900
8 © Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
Qualification
Transporting the hydraulic attachment is only
permitted if carried out by people who:
•
are authorised to operate a crane or a forklift
truck according to the applicable national
provisions,
•
know all the relevant national/regional safety
provisions and accident prevention rules,
•
have read and understood the safety and
transport chapter of these Safety and operating
instructions.
First installation and commissioning of the
hydraulic attachment is only permitted if carried out
by people who:
•
are authorised by Construction Tools GmbH,
•
know all the relevant national/regional safety
provisions and accident prevention rules,
•
have read and understood these Safety and
operating instructions.
Installing, maintaining, storing and disposing of
the hydraulic attachment are only permitted if
carried out by people who:
•
know all the relevant national/regional safety
provisions and accident prevention rules,
•
have read and understood these Safety and
operating instructions.
Operating the hydraulic attachment is only
permitted if carried out by qualified carrier drivers.
Carrier drivers are qualified if they:
•
have been trained to operate a carrier
according to the national regulations,
•
know all the relevant national/regional safety
provisions and accident prevention rules,
•
have read and understood these Safety and
operating instructions.
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 hydraulic attachment
is not guaranteed.
Personnel (carrier operator, maintenance
personnel) must receive instructions from the
operator regularly. For the purpose of improved
traceability, the provision of instructions must be
recorded.
Intended use
Only attach the transverse drum cutter to a
hydraulic carrier of a suitable load-bearing
capacity. Read the carrier manufacturer's Safety
and operating instructions before attaching the
transverse drum cutter to the carrier and operating
it. Observe all instructions.
The transverse drum cutter is intended exclusively
for mounting on a hydraulic excavator or, following
agreement with the Atlas Copco Customer Center/
dealer in your area, with another carrier.
The transverse drum cutter serves exclusively to
cut:
•
Rock
•
Concrete (reinforced and non-reinforced)
•
Asphalt
•
Frozen soil
•
Ice
Furthermore, the transverse drum cutter is suitable
for cutting ditches and tunnels. The transverse
drum cutter can be used to a depth of 30 m under
water.
When cutting with the transverse drum cutter,
check the compressive strengths of the rock to be
cut (see chapter Technical specifications).
Intended use also includes adhering to all
specifications contained in this manual.
Any further use which exceeds or is contrary to the
intended use is considered inappropriate use.
Use other than intended
Misusing the transverse drum cutter or the boom
can lead to dangerous situations.
•
Do not use the transverse drum cutter in areas
with a risk for explosions.
•
Do not cut any materials other than those
mentioned in chapter Intended use.
•
Do not carry out any impacting work.
•
Do not operate the transverse drum cutter if
picks are broken.
•
Do not use the transverse drum cutter as a
device for lifting people or materials.
•
Do not use the transverse drum cutter as a
surface for carrying or transporting machines,
materials or tools.
•
Do not use the transverse drum cutter to take
the weight of the carrier.
Claims of any kind as a result of damages arising
from misuse are excluded.
DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900 Safety and operating instructions
© Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
9
Protective equipment
Personal protective equipment must comply with
the applicable health and safety regulations.
Always wear the following personal protective
equipment:
•
protective helmet
•
safety glasses with side protectors
•
protective gloves
•
protective shoes
•
warning vest
•
Light respiratory protection
•
Protective work clothing
Protective work clothing is tight-fitting work
clothing with low resistance to tearing, with tight
sleeves and without projecting parts. It is
primarily used to protect against entanglement
by moving machine parts. Do not wear rings,
chains or other jewellery.
Carrier, precautions
WARNING Falling carrier
If the load-bearing capacity of the carrier used is
insufficient, 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.
►
Only attach the hydraulic attachment to a
hydraulic carrier of a suitable load-bearing
capacity.
►
The carrier must remain stable at all times.
►
Read the carrier manufacturer's Safety and
operating Instructions before attaching the
hydraulic attachment to the carrier and
operating it. Observe all instructions.
Transport, precautions
WARNING Risk of death due to suspended
loads
When lifting loads these can swing out and fall.
This can result in serious injuries or even death.
►
Never stand underneath or in the swinging
range of suspended loads.
►
Only move loads under supervision.
►
Only use approved lifting equipment and lifting
gear with sufficient load bearing capacity.
►
Do not use worn lifting gear (ropes, belts,
chains, shackles etc.).
►
Do not place lifting gear such as ropes and
belts on sharp edges or corners, do not knot
these or twist them.
►
When leaving the workplace, set down the load.
WARNING Injury due to swivelling load
When transporting the load by crane it can swivel
and cause severe injuries and considerable
damage to property.
►
Ensure that no personnel, objects or obstacles
are located in the swivel range of the load.
Safety and operating instructions DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900
10 © Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
Hydraulic installation,
precautions
WARNING Hydraulic pressure too high
If the hydraulic pressure is too high, the parts of
the hydraulic attachment will be exposed to
excessively high loads. Parts can break loose or
burst causing serious injuries.
►
Lay the drain line of the pressure relief valve
directly in the tank to ensure the safe
functioning of the pressure relief valve!
►
The pressure relief valve must be set at the
maximum static pressure.
►
The pressure relief valve setting must be
checked to ensure that the maximum static
pressure (see chapter Technical specifications)
of the hydraulic installation is not exceeded at
any time. Attach a lead seal to the pressure
relief valve.
►
Prior to their first use, the safety facilities on the
hydraulic installation must be checked by a
professional/authorised monitoring body for
their quality (CE mark etc.), suitability and
proper functioning.
►
If any significant changes are made to the
hydraulic installation, a new acceptance
inspection is to be carried out in accordance
with the relevant national safety provisions.
WARNING Hot hydraulic oil squirting out
The hydraulic system is under high pressure.
Hydraulic lines may spring a leak or burst.
Hydraulic oil squirting out can lead to serious
injury.
►
When attaching the hydraulic attachment do not
route any hydraulic lines through the carrier's
cab.
►
Only use hydraulic lines which comply with the
following quality requirements:
Hydraulic hoses with 4 reinforcement steel
wires 4SP and 4SH according to DIN EN 856,
Hydraulic hoses with high tensile steel wire
braid 1SN and 2SN according to DIN EN 853,
Hydraulic pipes, seamless cold-drawn steel
pipes to DIN EN 10305.
Media/consumables,
precautions
WARNING Hot hydraulic oil under high
pressure
Hydraulic oil will squirt out under high pressure if
there is a leakage. The jet of oil might penetrate
people's skin and cause permanent damage. Hot
hydraulic oil can cause burns.
►
Never use your hands to find leaks.
►
Always keep your face away from a possible
leak.
►
If hydraulic oil has penetrated your skin consult
a doctor immediately.
WARNING Hydraulic oil spills
Spilt hydraulic oil can make a floor slippery. If
people slip they can be injured. Hydraulic oil is
environmentally harmful and must not penetrate
the ground or enter the water table or water
supplies.
►
Make sure not to spill any hydraulic oil.
►
Immediately clean the floor if you have spilt
hydraulic oil.
►
Observe all safety and environmental protection
provisions when handling hydraulic oil.
WARNING Skin infections/diseases due to
oil and grease
Hydraulic oil and grease can cause rashes (or
even eczema) if they come into contact with the
skin.
►
Avoid all skin contact with hydraulic oil and
grease.
►
Use a suitable skin protection product.
►
Always wear safety gloves when working with
hydraulic oil or grease.
►
Immediately clean any skin that has been
contaminated by oil or grease with water and
soap.
DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900 Safety and operating instructions
© Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
11
Explosion and fire,
precautions
DANGER Explosion and fire
Explosions cause serious injury or death.
If the hydraulic attachment encounters explosives
in operation, it may cause an explosion.
►
Never operate the hydraulic attachment in the
direct vicinity of explosives.
►
Make sure that no explosives are hidden in the
ground.
►
Check gas line position plans of the complete
construction area.
DANGER Explosion and fire
Operating the hydraulic attachment may create
sparks which ignite highly flammable gases.
This may lead to fire or an explosion.
►
Never work in an environment with highly
flammable substances.
►
Make sure that there are no hidden sources of
gas in the work area.
►
Check gas line position plans of the complete
construction area.
DANGER Explosion and fire
Dust-rich air can form an explosive atmosphere
which may ignite when operating the hydraulic
attachment.
This may lead to fire or an explosion.
►
Never operate the hydraulic attachment in an
explosion-hazard atmosphere.
►
Always provide sufficient ventilation when
working in buildings or in a confined area.
Electrical shock, precautions
DANGER Electrical shock
Any contact of the hydraulic attachment with
electric circuits or other sources of electricity will
lead to an electric shock, resulting in serious injury
or death. The hydraulic attachment is not
electrically insulated.
►
Never work in the vicinity of electric circuits or
other sources of electricity.
►
Make sure that there are no hidden circuits in
the work area.
►
Check wiring diagrams.
Falling stones, precautions
DANGER Fragments flying around
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 objects falling from a great height
can also cause serious damage.
During hydraulic attachment operation the danger
zone is considerably greater than during the
excavation operation due to fragments of stone
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 secured in a suitable manner
through corresponding measures.
►
Secure the danger zone.
►
Ensure that no persons are within a distance of
15 metres during cutting work.
►
Ensure that no persons are within a distance of
50 metres during cutting work on reinforced
steel.
►
Stop the hydraulic attachment immediately if
anyone enters the danger zone.
►
Close the windscreen and the side windows of
the driver's cab.
Safety and operating instructions DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900
12 © Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
Emissions, precautions
WARNING Noise hazard
Operating the hydraulic attachment creates a loud
noise. Long term high sound pressure level can
affect your hearing.
►
Wear suitable hearing protection.
WARNING Lung disease
Dust may be generated when operating the
hydraulic attachment. If dust from rocks or silica
dust, produced when operating the hydraulic
attachment on rocks, concrete, asphalt or other
such materials, is inhaled this may lead to silicosis
(dust lungs, a severe lung disease). Silicosis is a
chronic disease which may lead cancer and death.
►
Wear a suitable breathing mask.
WARNING Vibration hazards
When working with the transverse drum cutter
severe vibrations can occur and may cause
considerable significant injuries and chronic
damage to health.
►
Operate the transverse drum cutter with a
constant load, in order to minimise existing
vibrations.
►
Avoid abrupt starting up or stopping of the
cutter drums.
WARNING Risk of death if exhaust gases
are not vented
When working in buildings or tunnels, exhaust
gases from the carrier (diesel motor) can collect
and cause poisoning or even death.
►
Effectively vent exhaust gases from buildings or
tunnels using a ventilation system.
►
Keep the cabin doors of the carrier closed.
WARNING Hot surfaces
The cutter drums of the transverse drum cutter can
become very hot in operation. Skin contact with hot
surfaces results in severe burns to the skin.
►
Always wear heat-resistant protective work
clothes and protective gloves, when working in
close proximity to hot surfaces.
►
Prior to all work, check the transverse drum
cutter to ensure that all surfaces have cooled to
the ambient temperature.
Handling machines,
precautions
WARNING Injuries due to incorrect
operation
Incorrect operation can result in severe injuries
and may cause considerable damage to property.
►
Carry out all operating steps in accordance with
these Safety and operating instructions.
►
Prior to starting work, ensure that:
•
All covers and safety devices are installed
and are fully functional.
•
No persons are in the hazardous area.
►
Never switch off any safety devices during
operations or bridge these.
WARNING Injuries due to unclean
workplace
A dirty workplace can cause accidents and may
result in severe injuries.
►
Always keep the accesses to the carrier cabin
clean.
►
Always keep the cabin windows clean.
►
Do not leave parts or objects lying around the
working area.
WARNING Injuries due to missed
inspection and repair work
Disregarding or neglecting daily inspections can
result in serious accidents and lead in turn to the
severe injuries associated with them.
►
Carry out all daily inspections before and after
work.
►
Report any faults or damage to maintenance
personnel immediately and instruct them to
repair them.
►
Only restart the carrier once the fault or
damage has been repaired.
WARNING Narcotics, alcohol and drugs
Narcotics, alcohol and medicinal drugs make their
users less alert and affect their ability to
concentrate. Negligence and incorrectly assessing
a situation can result in serious injury or death.
►
Never work on or with the hydraulic attachment
when under the influence of narcotics, alcohol
or drugs which affect your alertness.
►
Never allow other people who are under the
influence of narcotics, alcohol or drugs which
affect their alertness to work on or with the
hydraulic attachment.
DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900 Safety and operating instructions
© Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
13
Repair, precautions
Maintenance work must be conducted exclusively
by authorised and trained maintenance personnel.
Maintenance works not allowed by Atlas
Copco
Some maintenance activities must be carried out
exclusively by Atlas Copco. If such maintenance
activities are required, consult the Atlas Copco
customer center/Dealer in your area in order to
ensure that they proceed safely.
The following maintenance activities are not
allowed by Atlas Copco:
•
Repairs to the gear
•
Replacing wear sleeves and pick boxes
•
Welding work on the cutter drums
•
Welding work on the gear housing
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.
►
Never carry out any changes to the hydraulic
attachment or the adapter plate.
►
Only use original parts or accessories approved
by Atlas Copco.
►
Modifications that entail new hazards may
require a new procedure for assessing
conformity.
WARNING Injuries due to the use of
incorrect spare parts
The use of incorrect or defective spare parts can
result in risks to personnel as well as damage,
malfunctioning or a total failure of the transverse
drum cutter.
►
Only use original parts or accessories approved
by Atlas Copco.
►
If there are any questions, consult the Atlas
Copco Customer Center/dealer in your area.
Safety and operating instructions DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900
14 © Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
Environmental pollution,
precautions
NOTICE Environmental pollution due to hydraulic
oil
Hydraulic oil is permanently environmentally
harmful. Escaped hydraulic oil will lead to
groundwater and soil contamination. Organisms
may die.
►
Collect any hydraulic oil which escapes to avoid
environmental pollution. For minor volumes use
an absorbing medium (in case of an emergency
use soil). In case of major leakages contain the
hydraulic oil. It must not drain off and penetrate
the ground or enter the water table or water
supplies.
►
Collect contaminated absorbing medium or soil
in a watertight box/container and close it tight.
►
Contact an authorized waste management
company.
►
Dispose of all contaminated material in
accordance with the applicable environmental
regulations.
DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900 Safety and operating instructions
© Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
15
Overview
Equipment description
The illustration gives an overview of the main parts
and components of the hydraulic attachment.
Actual details may differ.
D
E
F
A
B
C
A. Gear housing
B. Round attack pick
C. Pick box
D. Cutter drum
E. Transport lug
F. Rotatable upper part
Function
The operation of a transverse drum cutter is
described in a simplified version below:
The transverse drum cutter is an attachment for
hydraulic carriers. The cutter drums are powered
by the hydraulic motor and the gear of the
transverse drum cutter. The round attack picks are
attached to the cutter drums at a defined angle. A
rotating motion of the cutter drums facilitates the
cutting process and thus reduces the size of the
rock.
Modules
Cutter drums
The transverse drum cutter is equipped with one
left and one right cutter drum. These cutter drums
are fastened by means of screws and special
clamping sleeves directly to the drive shafts. A
certain number of pick boxes are attached to the
surface of the cutter drums. These hold the round
attack picks in position.
The cutter drums can be designed with charging
spirals (see arrow).
Safety and operating instructions DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900
16 © Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
Transport lug
E
The transport lug (E) serves as an anchor point for
the lifting gear when transporting the transverse
drum cutter.
Rotatable upper part
The transverse drum cutter is fastened to a
suitable adapter plate on the carrier boom via the
rotatable upper part. The rotatable upper part is
bolted to the adapter plate. Additionally, the
transverse cutter drum can be rotated via the
rotatable upper part relative to the axis of the
boom.
Gear housing
The gear housing contains a spur gear driven by a
hydraulic motor. The gear's drive shafts turn the
cutter drums. The hydraulic motor transfers the
drive moment through the gear to the cutter drums.
Round attack picks
The round attack picks are made of steel and have
a brazed tungsten carbide tip. The round attack
picks are held in the pick boxes.
The appearance of the round attack picks may
deviate from the image shown here.
DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900 Safety and operating instructions
© Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
17
Pick boxes
The pick boxes are welded onto the cutter drums
for holding round attack picks. Some pick boxes
may have a wear sleeve, which can be exchanged.
Signs / labels
WARNING Missing warnings
The name plate and the labels on the hydraulic
attachment contain important information about the
hydraulic attachment and for personal safety. A
missing warning can lead to overlooking or
misinterpretation of possible risks and cause
personal hazards. The signs and labels must
always be clearly legible.
►
Immediately replace any defective name plates
and labels.
►
Use the spare parts list to order new name
plates and labels.
Name plate
A B C D E F G H
Construction Tools GmbH
A. Model
B. Year of construction of hydraulic attachment
C. Max. hydraulic pressure
D. Weight of hydraulic attachment
E. Serial number
F. Name and address of manufacturer
G. The warning symbol and the book symbol
indicate that the Safety and Operating
Instructions must be read prior to use of the
hydraulic tool and in particular the chapter on
Safety.
H. The CE symbol indicates that the hydraulic
attachment was produced in conformity with
CE. You can find further information about this
in the enclosed EC Declaration of Conformity.
Safety and operating instructions DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900
18 © Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
Labels
A
A. Danger zone
Danger zone
No persons should be within the
danger zone. 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
objects falling from a great height
can also cause serious damage.
Applications
The transverse drum cutter is suitable for use in
trenching and tunnelling, for demolition and
renovation works, quarrying and in special
underground engineering.
Working area and hazardous
area
B
A
A. Working area for operating personnel
B. Hazardous area when working with the
transverse drum cutter
•
The working area for the operating personnel is
in the cabin of the carrier.
•
The hazardous area is in the direct vicinity of
the transverse drum cutter.
•
Whilst operating the transverse drum cutter, the
minimum distance around the carrier is 15
metres.
•
When cutting reinforced concrete, the minimum
distance around the carrier is 50 metres.
DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900 Safety and operating instructions
© Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
19
Removing the packaging
◆
Remove all the packaging material.
◆
Dispose of it in accordance with the applicable
provisions.
◆
Check that the delivery is complete.
◆
Check the delivery for visual damage.
◆
If any defects are found, consult the Atlas
Copco Customer Center/dealer in your area.
Scope of delivery
The transverse drum cutter is delivered complete
with:
•
Transverse drum cutter including rotatable
upper part
•
Safety and operating instructions
•
Spare parts list
•
EC Declaration of Conformity
•
Hoses:
- Pressure line
- Tank line including precharge valve
- Leakage oil line
•
Overpressure cover plate including O-ring and
screws
•
Set of standard round attack picks including
retainers (see table below)
•
Set of tools for round attack pick assembly and
disassembly (see table below)
Safety and operating instructions DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900
20 © Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
Standard round attack picks
Ø
T
L
H
L
S
Ø
H
Ø
S
Type Ø
S
Shaft diameter
L
S
Shaft length
Ø
H
Head diameter
L
H
Head length
Ø
T
Tip diameter
Locking system
DC 200 11.4 mm (0.45 in.) 26.0 mm (1.02 in.) 24.0 mm (0.94 in.) 28.0 mm (1.10 in.) 11.5 mm (0.45 in.) Knock on retainer
DC 400 20.0 mm (0.79 in.) 41.0 mm (1.61 in.) 38.0 mm (1.50 in.) 45.0 mm (1.77 in.) 12.0 mm (0.47 in.) Retainer sleeve
DC 600 22.0 mm (0.87 in.) 56.5 mm (2.22 in.) 38.0 mm (1.50 in.) 42.0 mm (1.65 in.) 12.0 mm (0.47 in.) Knock on retainer
DC 1000 25.0 mm (0.98 in.) 78.5 mm (3.09 in.) 60.0 mm (2.36 in.) 64.0 mm (2.52 in.) 17.0 mm (0.67 in.) Quick snap retainer
DC 1200 25.0 mm (0.98 in.) 78.5 mm (3.09 in.) 60.0 mm (2.36 in.) 64.0 mm (2.52 in.) 17.0 mm (0.67 in.) Quick snap retainer
DC 2000 30.0 mm (1.18 in.) 80.0 mm (3.15 in.) 70.0 mm (2.76 in.) 75.0 mm (2.95 in.) 17.0 mm (0.67 in.) Quick snap retainer
DC 2100 30.0 mm (1.18 in.) 80.0 mm (3.15 in.) 70.0 mm (2.76 in.) 75.0 mm (2.95 in.) 17.0 mm (0.67 in.) Quick snap retainer
DC 2900 30.0 mm (1.18 in.) 80.0 mm (3.15 in.) 70.0 mm (2.76 in.) 75.0 mm (2.95 in.) 19.0 mm (0.75 in.) Quick snap retainer
Set of tools for round attack pick
Type A B C D E F
DC 200
DC 400 x x x
DC 600 x x x x
DC 1000 x x x
DC 1200 x x x
DC 2000 x x x
DC 2100 x x x
DC 2900 x x x
A. Knock out tool
B. Knock out tool for stuck picks
C. Mounting tool for knock on retainer
D. Dismantling tool for knock on retainer
E. Puller tool for quick snap retainers
F. Puller for retainer sleeve picks
Special accessories as ordered:
•
e.g. adapter plate with Allen screws and pairs of lock washers
•
e.g. base plate to construct an adapter plate with Allen screws and pairs of lock washers
•
e.g. hydraulic fittings for the carrier
DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900 Safety and operating instructions
© Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
21
Transport
WARNING Hoist tipping over / hydraulic
attachment falling
The hydraulic attachment is heavy. The hoist/lifting
equipment and/or hydraulic attachment tipping
over or falling may cause serious injury and
material damage.
►
Only transport the hydraulic attachment with
lifting equipment with the right load-bearing
capacity for the weight of the hydraulic
attachment.
►
Only lift and secure the hydraulic attachment
with lifting gear (ropes, chains, shackles etc.)
with the right load-bearing capacity for the
weight to be lifted.
►
Make sure that there is nobody near or under
the suspended hydraulic attachment.
Transport using a crane
The transverse drum cutter is equipped with
transport lugs, for lifting by crane.
◆
Secure the hydraulic attachment with ropes or
chains as shown in the following illustration.
◆
Slowly lift the hydraulic attachment.
Ensure that the transverse drum cutter hangs
straight, if applicable observe any eccentric
centre of gravity.
◆
Place the transverse drum cutter on the
assembly stand.
Safety and operating instructions DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900
22 © Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
Transport using a forklift
truck
Always transport the transverse drum cutter whilst
secured to the assembly stand.
WARNING Hydraulic attachment tipping
over
The hydraulic attachment tipping off the fork of the
forklift truck or the assembly stand may cause
serious injury.
►
Place the hydraulic attachment on the assembly
stand.
►
Strap the hydraulic attachment to the assembly
stand using suitable strapping, as shown in the
illustration below.
►
Move the forks of the forklift truck under the
assembly stand so that the centre of gravity is
between the prongs.
◆
Move the forks of the forklift truck under the
assembly stand so that the hydraulic
attachment cannot tip over.
◆
Slowly lift the assembly stand with the hydraulic
attachment.
◆
Transport the assembly stand with the hydraulic
attachment to the location provided for.
Transport using a truck
Always transport the transverse drum cutter whilst
secured to the assembly stand.
WARNING Hydraulic attachment tipping
over / slipping
The hydraulic attachment slipping or tipping over
and falling from the loading area of a lorry may
cause serious injury.
►
Place the hydraulic attachment on the assembly
stand.
►
Strap the hydraulic attachment to the assembly
stand using suitable strapping (see illustration
in chapter Transport using a forklift truck).
►
Place the assembly stand with the hydraulic
attachment on an anti-slip mat.
►
Secure the hydraulic attachment to the loading
area with ropes or chains; use any available
transport lugs.
◆
Secure the hydraulic attachment on the
assembly stand and the loading surface as
shown in the following illustration.
◆
Observe all the applicable national/regional
regulations on securing loads.
DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900 Safety and operating instructions
© Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
23
Installation
WARNING Hot hydraulic oil squirting out
The hydraulic system is under high pressure. If
hydraulic connections come loose or are
disconnected, hydraulic oil will squirt out under
high pressure. Hydraulic oil squirting out can lead
to serious injury.
►
Depressurise the hydraulic system before
connecting or disconnecting the hydraulic
circuits of the hydraulic attachment (see chapter
Depressurising the hydraulic system).
WARNING Risk of death due to defective
first installation and commissioning
Faults during the first installation or commissioning
can lead to life-threatening situations and may
cause considerable damage to property.
►
Have the first installation and commissioning
exclusively conducted by authorised specialist
personnel.
►
Do not undertake unauthorised first installation
and commissioning.
Media/consumables
The following consumables are used when
operating the hydraulic attachment:
Mineral hydraulic oil
All hydraulic oil brands prescribed by the carrier
manufacturer are also suitable for use when
operating the hydraulic attachment.
However, the oil should comply with viscosity class
HLP 32 or higher.
In summer and in hot climates, oils of viscosity
class HLP 68 or higher should be used.
In all other respects the regulations of the carrier
manufacturer are to be taken into consideration.
Optimum viscosity range = 30 - 60 cSt
Max. start viscosity = 2000 cSt
Max. oil temperature = 80 °C
Special conditions apply to using the hydraulic
attachment at low temperatures (see chapter Low
ambient temperature).
◆
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.
Non-mineral hydraulic oil
NOTICE Mixed hydraulic oil
Never mix mineral and non-mineral hydraulic oils!
Even small traces of mineral oil mixed in with nonmineral oil can result in damage to both the
hydraulic attachment and the carrier. Non-mineral
oil loses its biodegradability.
►
Only use one type of hydraulic oil.
If you are using non-mineral oil it is imperative that
the name of the oil in use be indicated when
returning the hydraulic attachment for repair.
In order to protect the environment or on technical
grounds, hydraulic oils are currently being used
which are not classified as HLP mineral oils.
Before using hydraulic oils of this kind it is
imperative to ask the carrier manufacturer whether
operations with such fluids are possible.
Our hydraulic attachments are basically designed
for use with mineral oils. Consult the Atlas Copco
Customer Center/Dealer in your area before using
other hydraulic oils approved by the carrier
manufacturer. Following initial assembly and after
any workshop repairs, our hydraulic attachments
are subjected to a test run on a test bed powered
by mineral oil.
Gear oil
Media /
consumables
Temperature range Part number
AC Fluid Traction
Gear 100
-15 to +40 °C
5 l (1.32 gal)
4812 0082 71
20 l (5.28 gal)
4812 0082 72
209 l (55.21 gal)
4812 0082 73
AC Fluid Gearbox
100
-20 to +30 °C
5 l (1.32 gal)
4812 0082 74
20 l (5.28 gal)
4812 0082 75
209 l (55.21 gal)
4812 0082 76
Preconditions for the carrier
The carrier must fulfil the following criteria in order
that a transverse drum cutter can be attached to it:
•
A complete hydraulic hammer or shearer line
right to the end of the carrier boom must be
available.
•
The motor's pressure line is set to max. 350
bar.
•
The pressure of the tank line is at least 5 bar
above the pressure of the case drain line.
Safety and operating instructions DC 200, 400, 600, 1000, 1200, 2000, 2100, 2900
24 © Construction Tools GmbH | 3390 5192 01 | 2016-12-01
Original instructions
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