Atlas Copco PP 100 Safety And Operating Instructions Manual

Safety and operating instructions

Hydraulic power packs

100

Contents

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

About the Safety and operating instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Safety signal words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Personal precautions and qualifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Drugs, alcohol or medication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation, precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Operation, precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Maintenance, precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Storage, precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Design and function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Main parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Data plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Caution: fill with oil before use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Electrical hazard label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Water pressure label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Electrical connection label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Quick-release couplings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Hoses and connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Connecting hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Connecting new hydraulic hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Disconnecting hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Hose length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Water connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Electrical connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Lifting the power pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Preparation before starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Start and stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Power on demand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Emergency stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Reinforced cooling and power reduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

When taking a break. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Hydraulic oil refill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Every day. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Every 300 hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Original instructions

ContentsPP 100

Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Machine data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Noise declaration statement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Advanced Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Service data download. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Diagnostic files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

EC Declaration of Conformity (EC Directive 2006/42/EC). . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Original instructions

PP 100Contents

Introduction

Thank you for choosing a product from Atlas Copco. Since 1873, we have been committed to finding new and better ways of fulfilling our customers' needs. Through the years, we have developed innovative and ergonomic product designs that have helped customers improve and rationalize their daily work.

Atlas Copco has a strong global sales and service network, consisting of customer centers and distributors worldwide. Our experts are highly trained professionals with extensive product knowledge and application experience. In all corners of the world, we can offer product support and expertise to ensure that our customers can work at maximum efficiency at all times.

For more information please visit: www.atlascopco.com

Construction Tools PC AB Box 703 391 27 Kalmar Sweden

About the Safety and operating instructions

The aim of the instructions is to provide you with knowledge of how to use the power pack in an efficient, safe way. The instructions also give you advice and tell you how to perform regular maintenance on the power pack.

Before using the power pack for the first time you must read these instructions carefully and understand all of them.

Original instructions

Safety and operating instructionsPP 100

Safety instructions

To reduce the risk of serious injury or death to yourself or others, read and understand the Safety and operating instruction before installing, operating, repairing, maintaining, or changing accessories on the machine.

Post this Safety and operating instruction at work locations, provide copies to employees, and make sure that everyone reads the Safety and operating instruction before operating or servicing the machine. For professional use only.

In addition, the operator or the operator's employer must assess the specific risks that may be present as a result of each use of the machine.

Safety signal words

The safety signal words Danger, Warning and Caution have the following meanings:

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

DANGER

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

CAUTION

Personal precautions and qualifications

Only qualified and trained persons may operate or maintain the machine. They must be physically able to handle the bulk, weight, and power of the tool. Always use your common sense and good judgement.

Personal protective equipment

Always use approved protective equipment. Operators and all other persons in the working area must wear protective equipment, including at a minimum:

● Protective helmet

● Hearing protection

● Impact resistant eye protection with side protection

● Respiratory protection when appropriate

● Protective gloves

● Proper protective boots

● Appropriate work overall or similar clothing (not

loose-fitting) that covers your arms and legs.

Drugs, alcohol or medication

WARNING Drugs, alcohol or medication

Drugs, alcohol or medication may impair your judgment and powers of concentration. Poor reactions and incorrect assessments can lead to severe accidents or death.

► Never use the machine when you are tired or

under the influence of drugs, alcohol or medication.

► No person who is under the influence of drugs,

alcohol or medication may operate the machine.

Installation, precautions

DANGER Electrical hazard

The machine is not electrically insulated. There is a risk of electrical shocks if the electrical cable is not treated correctly. If the machine is not connected correctly, serious injuries or death may result.

► See section "Operation, precautions" for more

information regarding electrical hazards.

WARNING Hydraulic oil at high pressure

Thin jets of hydraulic oil under high pressure can penetrate the skin and cause permanent injury.

► Immediately consult a doctor if hydraulic oil has

penetrated the skin.

► Never use your fingers to check for hydraulic fluid

leaks.

► Keep your face away from any possible leaks.

► Never operate the machine without covers.

WARNING Hydraulic oil

Spilled hydraulic oil can cause burns, accidents due to slippery conditions and will also harm the environment.

► Take care of all spilled oil and handle it according

to your safety and environmental regulations.

► Never dismount the hydraulic machine when the

hydraulic oil is hot.

CAUTION Skin eczema

Hydraulic oil can cause eczema if it comes in contact with the skin.

► Avoid getting hydraulic oil on your hands.

► Always use protective gloves when working with

hydraulic oil.

► Wash hands after contact with hydraulic oil.

Original instructions

PP 100Safety and operating instructions

CAUTION Moving parts

Risk for crushed hands and fingers.

► Never check bores or passages with hands or

fingers.

Operation, precautions

DANGER Fire hazard

If a fire starts in the machine, it can cause injury.

► If possible use an ABE-class powder extinguisher,

otherwise use a BE-type carbon dioxide fire extinguisher.

DANGER Explosion hazard

When working on certain materials and when using certain materials in machine parts, sparks and ignition can occur. Explosions will lead to severe injuries or death.

► Never operate the machine in any explosive

environment.

► Never use the machine near flammable materials,

fumes or dust.

► Make sure that there are no undetected sources

of gas or explosives.

DANGER Electrical hazard

The machine is not electrically insulated. If the machine is not connected correctly, serious injuries or death may result.

► Never place the power pack in a position where it

risks being drowned by water.

► Ensure that the machine is earthed and that the

earth connection has been checked at regular intervals for correct functionality. Operation of the machine without an earth connection presents a risk of fatal accident.

► Use a DC-sensitive residual current circuit breaker

(RCCB) protected supply. The RCCB must be checked for correct functionality according to the specifications from the manufacturer.

► Never modify the electrical plug or socket.

► Check that the mains voltage corresponds with

the information stated on the data plate on the machine.

► Only cerified technicians are allowed to service

the electrical motor. Do not open any of the motor covers. Unauthorized service work on the motor might lead to power pack malfunction and possibly serious injuries or death.

DANGER Electrical cable hazard

There is a risk of electrical shocks if the electrical cable is not treated correctly, this can lead to serious injuries or death.

► Never move the machine by dragging the electrical

cable.

► Disconnect the cable only by pulling the socket,

never pull the electrical cable.

► Do not expose the electrical cable to heat, oil, and

sharp edges.

► Make sure the electrical cable is not pinched in

doors, fences or similar.

► Check that the electrical cable, extension cable,

and cable plug are intact and in good condition. Never connect a damaged electrical cable to the machine.

► Never touch the electrical cable if it becomes

damaged while working. Disconnect the main supply and then disconnect the electrical plug from the socket.

WARNING Whipping hose

Hoses under pressure can whip uncontrollably if the hose connection becomes loose. A whipping hose can cause severe injuries. To reduce this risk:

► Turn of the power pack before loosening the

connection of a hose.

► Check that the hose and the connections are not

damaged.

► Never carry or drag the machine by the hoses.

WARNING Abuse hazard

Never abuse or strike the power pack. This may cause machine breakdown.

► Never strike or abuse the equipment.

► Make sure that the frame is clean and free of oil.

► Never rest on the power pack.

► Never throw objects on the power pack.

WARNING Cover protection

The covers of the power pack must be in place. Thin jets of hydraulic oil under high pressure can penetrate the skin and cause permanent injury.

► Never operate the machine without covers.

► Immediately consult a doctor if hydraulic oil has

penetrated the skin.

Original instructions

Safety and operating instructionsPP 100

WARNING Dust and fume hazard

Dusts and/or fumes generated or dispersed when using the machine may cause serious and permanent respiratory disease, illness, or other bodily injury (for example, silicosis or other irreversible lung disease that can be fatal, cancer, birth defects, and/or skin inflammation).

Some dusts and fumes created by drilling, breaking, hammering, sawing, grinding and other construction activities contain substances known to the State of California and other authorities to cause respiratory disease, cancer, birth defects, or other reproductive harm. Some examples of such substances are:

● Crystalline silica, cement, and other masonry

products.

● Arsenic and chromium from chemically-treated

rubber.

● Lead from lead-based paints.

Dust and fumes in the air can be invisible to the naked eye, so do not rely on eye sight to determine if there is dust or fumes in the air.

To reduce the risk of exposure to dust and fumes, do all of the following:

► Operate and maintain the machine as

recommended in the safety and operating instructions.

► Read the attached machine's safety and operating

instructions.

WARNING Overheated power pack

The power pack can become overheated and cause burns.

► Never turn off the cooling water.

WARNING Falling power pack

If the power pack tips over and fall, it may cause serious injury.

► Place the power pack in a safe position where it

cannot fall and cause damage.

WARNING Slipping, tripping and falling

hazards

There is a risk of slipping or tripping or falling, for example tripping on the hoses or on other objects. Slipping or tripping or falling can cause injury. To reduce this risk:

► Always make sure that no hose or other object is

in your way or in any other person's way.

► Always make sure you are in a stable position with

your feet as far apart as your shoulders width and keeping a balanced body weight.

WARNING Slipping hazard

There is a risk of slipping on spilled oil, it may cause serious injury. To reduce this risk:

► Wipe immediately up spilled oil from the ground.

► Make sure that the frame is clean and free of oil.

WARNING Involuntary start

Involuntary start of the machine may cause injury.

► Keep your hands away from the start and stop

device until you are ready to start the machine.

► Learn how the machine is switched off in the event

of an emergency.

► Stop the machine immediately in all cases of

power supply interruption.

WARNING Noise hazard

High noise can cause permanent loss of hearing and other problems such as tinnitus (ringing, buzzing, whistling or humming in the ears). To reduce risk and prevent an unnecessary increase of noise levels:

► Operate and maintain the machine as

recommended in these instructions.

► Read the attached machine's safety and operating

instructions.

WARNING Nominal pressure

If the maximum nominal pressure for the hydraulic machine is exceeded, it can result in material damage and personal injury.

► Always run the hydraulic machine with a tool (in

this case, only RD 100) that does not require a continuously higher pressure than the stated nominal pressure. See section "Technical data".

Maintenance, precautions

WARNING Machine modification

Any machine modification may result in bodily injuries to yourself or others.

► Never modify the machine. Modified machines are

not covered by warranty or product liability.

► Always use original parts and accessories.

► Change damaged parts immediately.

► Replace worn components in good time.

WARNING Accessory hazards

Accidental engagement of accessories during maintenance or installation can cause serious injuries, when the power source is connected.

► Never inspect, clean, install, or remove

accessories while the power source is connected.

Original instructions

PP 100Safety and operating instructions

Storage, precautions

♦

Keep the machine and tools in a safe place, out of the reach of children and locked up.

Original instructions

Safety and operating instructionsPP 100

+ 19 hidden pages

Atlas Copco PP 100 Safety And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual