Safety and operating instructionsHydraulic breakers MB 750 MB 750 DP MB 750 HTL MB 1000 MB 1000 DP MB 1200 MB 1200 DP MB 1200 HTL MB 1500 MB 1500 DP
Valid from serial number 50 50 50
100 100
1800 1800 1800
50 50
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500, 1500 DP
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
ContentsIntroduction .................................................................................................................................................... 7
About these Safety and Operating Instructions .................................................................................... 7
Safety instructions ......................................................................................................................................... 8Signal words ............................................................................................................................................. 8Qualification .............................................................................................................................................. 9Intended use .............................................................................................................................................. 9Use other than intended ........................................................................................................................... 9Protective equipment ............................................................................................................................. 10Carrier, precautions ................................................................................................................................ 10Transport, precautions ........................................................................................................................... 10Hydraulic installation, precautions ....................................................................................................... 11Special parts, precautions ..................................................................................................................... 11
Piston accumulator .............................................................................................................................. 11Media/consumables, precautions ......................................................................................................... 12Explosion and fire, precautions ............................................................................................................ 12Electrical shock, precautions ................................................................................................................ 13Falling stones, precautions ................................................................................................................... 13Emissions, precautions ......................................................................................................................... 13Handling machines, precautions .......................................................................................................... 14Repair, precautions ................................................................................................................................ 14Changes to the hydraulic attachment, precautions ............................................................................ 14Environmental pollution, precautions .................................................................................................. 15
Overview ....................................................................................................................................................... 16Equipment description ........................................................................................................................... 16Function ................................................................................................................................................... 16Signs / labels ........................................................................................................................................... 17
Name plate .......................................................................................................................................... 17Labels .................................................................................................................................................. 17Signs .................................................................................................................................................... 17
Applications ............................................................................................................................................ 18Guarantee ................................................................................................................................................ 18Removing the packaging ....................................................................................................................... 18Scope of delivery .................................................................................................................................... 18
Transport ...................................................................................................................................................... 19Transport using a crane ......................................................................................................................... 20Transport using a forklift truck .............................................................................................................. 20Transport using a truck .......................................................................................................................... 21
Installation .................................................................................................................................................... 22Media/consumables ................................................................................................................................ 22
Non-mineral hydraulic oil ..................................................................................................................... 22Grease ................................................................................................................................................. 22Gas ...................................................................................................................................................... 22Mineral hydraulic oil ............................................................................................................................. 22
Manufacturing the adapter plate ........................................................................................................... 22Installing the adapter plate .................................................................................................................... 23Attaching the hydraulic attachment to the carrier ............................................................................... 24
Mechanical mounting aspects ............................................................................................................. 24Making the hydraulic connections ........................................................................................................ 24
Removing the hydraulic attachment from the carrier ......................................................................... 26Dismantling the hydraulic connections ................................................................................................ 26Mechanical disassembly ...................................................................................................................... 26
Removing the adapter plate ................................................................................................................... 26DustProtector .......................................................................................................................................... 27
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Contents
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Removal ............................................................................................................................................... 27Installation ............................................................................................................................................ 27
Working tool ............................................................................................................................................ 28Selecting the right working tool ............................................................................................................ 28Installation ............................................................................................................................................ 29Removal ............................................................................................................................................... 30
Operation ...................................................................................................................................................... 31Initial operation and operation after long storage ............................................................................... 31Preparations before starting .................................................................................................................. 32Switching the hydraulic breaker on and off ......................................................................................... 32Functional test ........................................................................................................................................ 33Correct operation .................................................................................................................................... 33
Working angle ...................................................................................................................................... 33Advance ............................................................................................................................................... 34Impact time .......................................................................................................................................... 34High ambient temperature ................................................................................................................... 34Low ambient temperature .................................................................................................................... 34
Prohibited operation ............................................................................................................................... 35Lifting/Transporting .............................................................................................................................. 35Impacting ............................................................................................................................................. 35Moving objects ..................................................................................................................................... 35Levering ............................................................................................................................................... 35Blank firing of the working tool ............................................................................................................. 36Cylinder end positions ......................................................................................................................... 36
Working with safety equipment ............................................................................................................. 37Underwater applications ...................................................................................................................... 37Usage in tunnels .................................................................................................................................. 37Hot applications ................................................................................................................................... 37
AutoControl System ............................................................................................................................... 37StartSelect System AutoStop/AutoStart ............................................................................................... 38
Maintenance ................................................................................................................................................. 40Maintenance schedule ........................................................................................................................... 41Depressurising the hydraulic system ................................................................................................... 42Cleaning ................................................................................................................................................... 43
Preparations ........................................................................................................................................ 43Procedure ............................................................................................................................................ 43
Lubrication .............................................................................................................................................. 43Checking the lubricant film ................................................................................................................... 43Automatic lubrication ........................................................................................................................... 44Replacing the lubricant cartridge ......................................................................................................... 44ContiLube® II operation ....................................................................................................................... 44Manual lubrication ................................................................................................................................ 45Chisel paste filling device .................................................................................................................... 45
Checking the tensioning bolts .............................................................................................................. 46Checking the working tool ..................................................................................................................... 46Checking the retainer bars .................................................................................................................... 47Checking the percussion piston impact surface ................................................................................. 47Checking the wear bushes and impact ring ......................................................................................... 48Checking and cleaning the DustProtector system .............................................................................. 49Piston accumulator ................................................................................................................................ 50
Checking the pressure in the piston accumulator ................................................................................ 50Release the pressure from the piston accumulator ............................................................................. 51Filling/topping up the piston accumulator ............................................................................................ 51
Checking the hydraulic lines ................................................................................................................. 52Checking and cleaning the hydraulic oil filter ..................................................................................... 52Checking the adapter plate and the breaker box for cracks and/or wear ......................................... 52
Contents MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
4 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Checking the adapter plate bolts for wear ........................................................................................... 52Bolt connections/ Tightening torques MB 750/DP, MB 1000/DP ........................................................ 53Bolt connections/ Tightening torques MB 1200/DP, MB 1500/DP ...................................................... 55
Troubleshooting ........................................................................................................................................... 57The hydraulic breaker does not start .................................................................................................... 57Hydraulic breaker operates too slowly ................................................................................................. 58Impact force too low ............................................................................................................................... 58Impact rate too high and impact force too low .................................................................................... 58Oil leaks from ports »P« und »T« .......................................................................................................... 59Oil escapes between the cylinder cover and the cylinder .................................................................. 59Oil escapes from parts of the hydraulic breaker installation (connecting fittings, hoses etc.)................................................................................................................................................................... 59Oil escapes from the working tool ........................................................................................................ 59Oil or grease escapes from the ContiLube® II ..................................................................................... 59Operating temperature too high ............................................................................................................ 60
Repair ............................................................................................................................................................ 61Sending in the hydraulic attachment for repairs ................................................................................. 61
Storage .......................................................................................................................................................... 62Hydraulic breaker ................................................................................................................................... 62
Short storage ....................................................................................................................................... 62Long storage ........................................................................................................................................ 62How to proceed after more than twelve months‘ storage .................................................................... 62
Working tool ............................................................................................................................................ 63Grease cartridges ................................................................................................................................... 63
Disposal ........................................................................................................................................................ 64Hydraulic breaker ................................................................................................................................... 64Hydraulic hoses ...................................................................................................................................... 64Hydraulic oil ............................................................................................................................................ 64Chisel paste and grease cartridges ...................................................................................................... 64
Technical specifications .............................................................................................................................. 65MB 750/DP, MB 1000/DP ......................................................................................................................... 65Noise declaration statement .................................................................................................................. 66MB 1200/DP, MB 1500/DP ....................................................................................................................... 67Noise declaration statement .................................................................................................................. 68
EC Declaration of Conformity (EC Directive 2006/42/EC) ........................................................................ 69
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
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© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
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IntroductionThank you for choosing an Atlas Copco product!We have been working according to a customer-oriented approach since 1873. Our innovative andergonomic solutions help our customers lowercosts and achieve better business results.Atlas Copco has a worldwide, comprehensivesales and service network of Customer Centersand dealers. Our professionals are specialists witha thorough product knowledge and considerableapplication experience.This allows us to offer our customers effectiveservice and know-how throughout the world,enabling them to achieve greater operatingefficiency.Construction Tools GmbHP.O. Box: 102152Helenenstraße 149D - 45021 EssenTel.: +49 201 633-0
About these Safety andOperating Instructions
The aim of these Instructions is to familiarise youwith the safe and effective operation of thehydraulic attachment. You will also find instructionsfor regular maintenance activities for the hydraulicattachment in this document.Please read these Instructions carefully prior to thefirst attachment and use of the hydraulicattachment.In these instructions, the DustProtector version ofthe hydraulic breaker will be referred to by theabbreviation DP. The different designation of the texts means asfollows:
► Action step in a safety instruction
♦ Action step
1.2.
Established operation process
ABC
Explanation of the elements of a drawing
•
•
•
Listing
Symbols used in illustrations have the followingmeanings:
permitted operation
prohibited operation
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
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Safety instructions
This is the safety alert symbol. It is used to alert you topotential personal injury hazards. Obey all safetymessages that follow this symbol to avoid possibleinjury or death.
Read these Safety and operating instructions andspecifically all safety instructions before using thehydraulic attachment. This will:
• prevent the risk of injuries and fatal accidentsfor yourself and others,
• protect the hydraulic attachment and otherproperty against material damage,
• protect the environment against environmentaldamage.
Follow all instructions in these Safety andoperating instructions.Store these Safety and operating instructions inthe document compartment of the carrier cab.Anyone• transporting,• installing or removing,• operating,• maintaining,• repairing,• storing or• disposing ofthe hydraulic attachment must have read andunderstood these Safety and operatinginstructions.These Safety and operating instructions belong tothe hydraulic attachment. Keep it for the life of theproduct. Ensure, if applicable, that any receivedamendment is incorporated in the instructions.Hand over the Safety and operating instructions ifever you lend, rent out or sell the hydraulicattachment.All safety regulations listed in this manual complywith the laws and regulations of the EuropeanUnion. Also observe the additional national/regional regulations.Hydraulic attachment operation outside theEuropean Union is subject to the laws andregulations valid in the country of use. Pleaseobserve any other, more stringent regionalregulations and legislation.Read the carrier manufacturer's Safety andoperating Instructions before attaching thehydraulic attachment to the carrier and operating it.Observe all instructions.
Signal words
The signal words Danger, Warning, Caution, andNotice are used as follows in these Safety andoperating instructions:
DANGER indicates a hazardous situationwhich, if not avoided, will result indeath or serious injury.
WARNING indicates a hazardous situationwhich, if not avoided, could resultin death or serious injury.
CAUTION indicates a hazardous situationwhich, if not avoided, could resultin minor or moderate injury.
NOTICE The signal word NOTICE is usedto address practices related topossible property damage but notrelated to personal injury.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
8 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Qualification
Transporting the hydraulic attachment is onlypermitted if carried out by people who:• are authorised to operate a crane or a forklift
truck according to the applicable nationalprovisions,
• know all the relevant national/regional safetyprovisions and accident prevention rules,
• have read and understood the safety andtransport chapter of these Safety and operatinginstructions.
Installing, maintaining, storing and disposing ofthe hydraulic attachment are only permitted ifcarried 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 onlypermitted 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 onlypermitted if carried out by professionals.Professionals are people who are authorised toapprove a hydraulic installation for operationaccording to the national regulations.Repairing the hydraulic attachment is onlypermitted if carried out by professionals trained byConstruction Tools GmbH. These professionalsmust have read and understood these Safety andoperating instructions. They must follow all safetyinstructions and guidelines for repair. Otherwisethe operational safety of the hydraulic attachmentis not guaranteed.
Intended use
Only attach the hydraulic breaker to a hydrauliccarrier of a suitable load-bearing capacity.Only use the hydraulic breaker function of thedevice to break or fragment concrete, stone androcks.Using the hydraulic breaker in and under water, intunnels, under the ground and for hot applicationsis only possible if it has been fitted out with specialsafety equipment.Intended use also implies observing all instructionsin these Safety and operating instructions.
Use other than intended
Never operate the hydraulic breaker in anenvironment where there is a risk of explosions.Explosions will result in serious injury or death.Never use the hydraulic breaker• to transport or lift objects.
The lifted object can fall and cause seriousinjuries or death.
• as a sledge hammer.This will damage the hydraulic breaker, theworking tool and the carrier.
• as a crowbar.This can cause the working tool to break.
• to push debrisThis damages the hydraulic breaker.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
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Protective equipment
Personal protective equipment must comply withthe applicable health and safety regulations.Always wear the following personal protectiveequipment:• protective helmet• safety glasses with side protectors• protective gloves• protective shoes• warning vest• hearing protection
Carrier, precautions
WARNING Falling carrierIf the load-bearing capacity of the carrier used isinsufficient, the carrier will not be stable. It cantopple over and cause injuries and damage.Using a carrier whose load-bearing capacity is toohigh will greatly burden the hydraulic attachmentcausing it to wear faster.► Only attach the hydraulic attachment to a
hydraulic carrier of a suitable load-bearingcapacity.
► The carrier must remain stable at all times.► Read the carrier manufacturer's Safety and
operating Instructions before attaching thehydraulic attachment to the carrier andoperating it. Observe all instructions.
Transport, precautions
WARNING Risk of death due to suspendedloadsWhen 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 knotthese or twist them.
► When leaving the workplace, set down the load.
WARNING Injury due to swivelling loadWhen transporting the load by crane it can swiveland cause severe injuries and considerabledamage to property.► Ensure that no personnel, objects or obstacles
are located in the swivel range of the load.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
10 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Hydraulic installation,precautions
WARNING Hydraulic pressure too highIf the hydraulic pressure is too high, the parts ofthe hydraulic attachment will be exposed toexcessively high loads. Parts can break loose orburst causing serious injuries.► Lay the drain line of the pressure relief valve
directly in the tank to ensure the safefunctioning of the pressure relief valve!
► The pressure relief valve must be set at themaximum static pressure.
► The pressure relief valve setting must bechecked to ensure that the maximum staticpressure (see chapter Technical specifications)of the hydraulic installation is not exceeded atany time. Attach a lead seal to the pressurerelief valve.
► Prior to their first use, the safety facilities on thehydraulic installation must be checked by aprofessional/authorised monitoring body fortheir quality (CE mark etc.), suitability andproper functioning.
► If any significant changes are made to thehydraulic installation, a new acceptanceinspection is to be carried out in accordancewith the relevant national safety provisions.
WARNING Hot hydraulic oil squirting outThe hydraulic system is under high pressure.Hydraulic lines may spring a leak or burst.Hydraulic oil squirting out can lead to seriousinjury.► When attaching the hydraulic attachment do not
lay any hydraulic lines through the carrier's cab.► Only use hydraulic lines which comply with the
following quality requirements:Hydraulic hoses with 4 reinforcement steelwires according to DIN EN 856 4SH,Hydraulic pipes, seamless cold-drawn steelpipes to DIN EN 10305.
Special parts, precautions
Piston accumulator
DANGER Danger of explosionsThe integrated piston accumulator is filled withnitrogen (N2). Filling it with any other gas maytrigger an explosion and lead to serious, possiblyfatal, injuries.► Only fill the piston accumulator with
nitrogen (N2).
WARNING Component coming looseabruptlyThe piston accumulator is under pressure, evenwhen the hydraulic system has beendepressurised. The filling valve might come looseunexpectedly and cause injuries.► Never unscrew the filling valve »G« from the
pressurised piston accumulator.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
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Media/consumables,precautions
WARNING Hot hydraulic oil under highpressureHydraulic oil will squirt out under high pressure ifthere is a leakage. The jet of oil might penetratepeople's skin and cause permanent damage. Hothydraulic 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 spillsSpilt hydraulic oil can make a floor slippery. Ifpeople slip they can be injured. Hydraulic oil isenvironmentally harmful and must not penetratethe ground or enter the water table or watersupplies.► 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 tooil and greaseHydraulic oil and grease can cause rashes (oreven eczema) if they come into contact with theskin.► 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 andsoap.
Explosion and fire,precautions
DANGER Explosion and fireExplosions cause serious injury or death.If the working tool hits explosives, an explosionmay be the result.► Never operate the hydraulic breaker in the
direct vicinity of explosives.► Make sure that no explosives are hidden in the
rocks and stones.► Check gas line position plans of the entire
construction area.
DANGER Explosion and fireOperating the hydraulic breaker may create sparkswhich ignite highly flammable gases. This maylead 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 entire
construction area.
DANGER Explosion and fireDust-rich air can form an explosive atmospherewhich may ignite when operating the hydraulicbreaker. This may lead to fire or an explosion.► Never use the hydraulic breaker in an explosive
atmosphere.► Always provide sufficient ventilation when
working in buildings or in a confined area.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
12 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Electrical shock, precautions
DANGER Electrical shockAny contact of the hydraulic attachment withelectric circuits or other sources of electricity willlead to an electric shock, resulting in serious injuryor death. The hydraulic attachment is notelectrically 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
WARNING Fragments flying aroundFragments of material which come loose whileoperating the hydraulic attachment may be flungaway and can cause serious injury if people are hitby them. Small objects falling from a great heightcan also cause serious damage.During hydraulic attachment operation the dangerzone is considerably greater than during theexcavation operation due to fragments of stoneand pieces of steel flying around, and for thisreason the danger zone must, depending on thetype of material to be worked on, be enlargedcorrespondingly, or secured in a suitable mannerthrough corresponding measures.► Secure the danger zone.► Stop the hydraulic attachment immediately if
anyone enters the danger zone.► Close the windscreen and the side windows of
the driver's cab.
Emissions, precautions
WARNING Noise hazardOperating the hydraulic attachment creates a loudnoise. Long term high sound pressure level canaffect your hearing.► Wear suitable hearing protection.
WARNING Lung diseaseDust may be generated when operating thehydraulic attachment. If dust from rocks or silicadust, produced when operating the hydraulicattachment on rocks, concrete, asphalt or othersuch materials, is inhaled this may lead to silicosis(dust lungs, a severe lung disease). Silicosis is achronic disease which may lead cancer and death.► Wear a suitable breathing mask.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
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Handling machines,precautions
WARNING Narcotics, alcohol and drugsNarcotics, alcohol and medicinal drugs make theirusers less alert and affect their ability toconcentrate. Negligence and incorrectly assessinga situation can result in serious injury or death.► Never work on or with the hydraulic attachment
when under the influence of narcotics, alcoholor drugs which affect your alertness.
► Never allow other people who are under theinfluence of narcotics, alcohol or drugs whichaffect their alertness to work on or with thehydraulic attachment.
Repair, precautions
WARNING Heavy parts fallingThe main parts of the hydraulic breaker are heavy.Unsuitable lifting attachments (e.g. ring or eyebolts) may fail and cause heavy parts to fall.Falling parts may cause serious injury.► Never pull the percussion unit out of the
breaker box. Dismounting the percussion unit isonly permitted if carried out by professionalstrained by Construction Tools GmbH. Theseprofessionals must follow all safety instructionsand guidelines for repair.
► These professionals are only permitted to repairthe percussion unit if they use the sling gearsprescribed by Construction Tools GmbH when:• removing the complete percussion unit.• mounting or dismounting parts of the
percussion unit.
Changes to the hydraulicattachment, precautions
WARNING Changes to the hydraulicattachmentChanges to the hydraulic attachment or theadapter 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 assessingconformity.
WARNING Changes to the HP-accumulatorChanges to the HP-accumulator may lead toserious injury.► Never carry out any changes to the HP-
accumulator.► Any modification will result in immediate
invalidation of the operating licence.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
14 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Environmental pollution,precautions
NOTICE Environmental pollution due to hydraulicoil
Hydraulic oil is permanently environmentallyharmful. Escaped hydraulic oil will lead togroundwater and soil contamination. Organismsmay die.► Collect any hydraulic oil which escapes to avoid
environmental pollution. For minor volumes usean absorbing medium (in case of an emergencyuse soil). In case of major leakages contain thehydraulic oil. It must not drain off and penetratethe ground or enter the water table or watersupplies.
► Collect contaminated absorbing medium or soilin a watertight box/container and close it tight.
► Contact an authorized waste managementcompany.
► Dispose of all contaminated material inaccordance with the applicable environmentalregulations.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
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Overview
Equipment description
The picture gives an overview of the main partsand components of the hydraulic attachment.Actual details may differ.
A
B
C
H
D
E
F
G
I
J
L
K
M
A. The hydraulic breaker is connected to thecarrier by the adapter plate. The adapter plateis not included in the scope of supply of thehydraulic breaker.
B. StartSelect valve (only on MB 1500/DP,MB 1200/DP)
C. Automatic lubrication system ContiLube® IID. Tank line »T«E. Non-return valve of percussion compartment
ventilationexact location may differ depending on breakertype
F. Pressure line »P«G. The breaker box protects the percussion unit.
H. Working tool aperture protective capI. The working tool can be replaced as required.
The working tool is not included in the scope ofsupply of the hydraulic breaker.
J. The DustProtector system prevents dust fromentering the percussion compartment (only onthe DP version).
K. The working tool is retained in the lowerbreaker part.
L. The percussion piston is guided in the cylinder.M. The cylinder cover houses the nitrogen gas
(N2) filled piston accumulator and the controlmechanism.
Function
The operation of a hydraulic breaker is describedin a greatly simplified version below:The pressure line »P« supplies oil at the operatingpressure of the carrier to the hydraulic breaker.The tank line »T« returns the oil to the tank of thecarrier.The percussion piston moves up and down in thecylinder. When the percussion piston is in its lowerposition, it impacts the working tool. Thepercussion energy is transferred to the material tobe broken via the working tool.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
16 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Signs / labels
WARNING Missing warningsThe name plate and the labels on the hydraulicattachment contain important information about thehydraulic attachment and for personal safety. Amissing warning can cause personal hazards. Thesigns 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
Construction Tools GmbH
A B C D E F G H
A. ModelB. Year of construction of hydraulic attachmentC. Max. permissible operating pressureD. Weight of hydraulic attachmentE. Serial numberF. Name and address of manufacturerG. The warning symbol and the book symbol
indicate that the Safety and OperatingInstructions must be read prior to use of thehydraulic attachment and in particular thechapter on Safety.
H. The CE symbol indicates that the hydraulicattachment was produced in conformity withCE. You can find further information about thisin the enclosed EC Declaration of Conformity.
Labels
Sound Power
WA
xxx dB
The label states theguaranteed sound power levelin accordance with ECdirective 2000/14/EC.
Transport warning Never lift the hydraulicbreaker by the transportsafety device. This was notdesigned for lifting and mightbreak, causing the hydraulicbreaker to fall
Lubrication symbol The label identifies alubrication point.
Gas pressure
Gasdruck nur bei betriebswarmem Hammer prüfen!Only check the gas pressure
when the hammer is at operating temperature!Ne contrôler la pression d´azote que si le marteau
est à température de service!Controllare la pressione del gas solo a mortello
a temperature d´esercizio!¡Controlar la presión del gas sólo con el martillo
a temperatura de régimen!
The label indicates that thegas pressure can only bechecked if the breaker hasreached operatingtemperature.
Signs
The warning symbol and thebook symbol indicate that theSafety and OperatingInstructions must be read priorto use of the hydraulicattachment and in particularthe chapter on Safety.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
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Applications
Field Type of applicationGeneral construction work Tearing up concrete and
asphalt road surfacesTrenchwork for utilities,foundation work
Demolition Masonry and non-reinforcedconcreteReinforced concrete
Rock mining/breaking(not for MB 750/DP)
Secondary breaking, benchleveling, trenchwork,foundation work
Tunneling*, mining* Roof clearing
Bench levelling
High temperatureapplications*
Removing encrustations
Breaking out ladles and molds
Underwater applications* Demolition, Deepeningshipping channels
* only after consulting the Atlas Copco Customer Center/Dealer in your area
Guarantee
The guarantee or product liability will beinvalidated by the following:• Use other than intended• Maintenance work not being carried out or
being carried out incorrectly• The use of the wrong consumables• The use of non-approved parts• Damage due to wear• Special applications without the required safety
facilities• Damage due to improper storage• Changes not carried out by or in consultation
with the manufacturer
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 hydraulic breaker is delivered complete with:• Hydraulic breaker• Test gauge lower wear bush• Safety and Operating instructions• Spare parts list• EC Declaration of ConformityAccessories as ordered:• Working tool• Hoses• Service boxSpecial 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• e.g. piston retainer• e.g. calliper upper wear bush
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
18 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Transport
WARNING Hoist tipping over / hydraulicattachment fallingThe hydraulic attachment is heavy. The hoist/liftingequipment and/or hydraulic attachment tippingover or falling may cause serious injury andmaterial damage.► Only transport the hydraulic attachment with
lifting equipment with the right load-bearingcapacity for the weight of the hydraulicattachment.
► Only lift and secure the hydraulic attachmentwith lifting gear (ropes, chains, shackles etc.)with the right load-bearing capacity for theweight to be lifted.
► Make sure that there is nobody near or underthe suspended hydraulic attachment.
WARNING Percussion unit fallingThe percussion unit slides out of the breaker box ifnot secured by the adapter plate or the transportsafety device. The falling percussion unit maycause serious injury and material damage.► Never transport a hydraulic breaker without
mounted adapter plate or transport safetydevice.
► Immediately mount the transport safety deviceafter removal of the adapter plate.
► The percussion unit must not move in thebreaker box even if the transport safety deviceis mounted. A sliding percussion unit candestroy the transport safety device.
► Replace a missing elastic pad, if necessary e.g.with a wooden block. This keeps the percussionunit fixed in the breaker box during transport.
► Immediately replace a defective transport safetydevice. Use the spare parts list to order a newtransport safety device. If not in use save thetransport safety device for future use.
WARNING Hydraulic breaker fallingThe lifting eye may fail and cause the hydraulicbreaker to fall. This may cause serious injury andmaterial damage.► Check the lifting eye before you lift the hydraulic
breaker. Never lift the hydraulic breaker with thelifting eye if:• the checkpoints (A) are worn and not
protruding anymoreorthe checkpoints (B) are worn and notrecessed anymore.
A
B
• the material is worn up to the checkpoints(A, B).
Use permitted
Use prohibited• the lifting eye is bent.• you detect cracks in the lifting eye or the
weld seam.► Contact the Atlas Copco Customer Center/
Dealer in your area if the lifting eye is worn inany way.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
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19
Transport using a crane
◆ Secure the hydraulic attachment with ropes orchains as shown in the following illustration.
◆ Slowly lift the hydraulic attachment.◆ Place the hydraulic attachment on timber
support blocks.
Transport using a forklifttruck
WARNING Hydraulic attachment tippingoverThe hydraulic attachment tipping off the fork of theforklift truck or the pallet may cause serious injury.► Place the hydraulic attachment on a pallet.► Strap the hydraulic attachment to the pallet
using suitable strapping, as shown in theillustration below.
► Move the fork of the forklift truck under thepallet so that the centre of gravity is betweenthe prongs.
◆ Move the fork of the forklift truck under thepallet so that the hydraulic attachment cannottip over.
◆ Slowly lift the pallet with the hydraulicattachment.
◆ Transport the pallet with the hydraulicattachment to the location provided for.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
20 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Transport using a truck
WARNING Hydraulic attachment tippingover / slippingThe hydraulic attachment slipping or tipping overand falling from the loading area of a lorry maycause serious injury.► Place the hydraulic attachment on a pallet.► Strap the hydraulic attachment to the pallet
using suitable strapping (see illustration inchapter Transport using a forklift truck).
► Place the pallet with the hydraulic attachmenton an anti-slip mat.
► Secure the hydraulic attachment to the loadingarea with ropes or chains; use any availabletransport lugs.
◆ Secure the hydraulic attachment on the palletand the loading surface as shown in thefollowing illustration.
◆ Observe all the applicable national/regionalregulations on securing loads.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
21
Installation
WARNING Hot hydraulic oil squirting outThe hydraulic system is under high pressure. Ifhydraulic connections come loose or aredisconnected, hydraulic oil will squirt out underhigh pressure. Hydraulic oil squirting out can leadto serious injury.► Depressurise the hydraulic system before
connecting or disconnecting the hydrauliccircuits of the hydraulic attachment (see chapterDepressurising the hydraulic system).
NOTICE Environmental damage due to hydraulicoil
Hydraulic oil is environmentally harmful and mustnot penetrate the ground or enter the water tableor water supplies.► Collect any hydraulic oil which escapes.► Dispose of it in accordance with the applicable
environmental regulations.
Media/consumables
The following consumables are used whenoperating the hydraulic attachment:
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 non-mineral oil can result in damage to both thehydraulic attachment and the carrier. Non-mineraloil loses its biodegradability.► Only use one type of hydraulic oil.If you are using non-mineral oil it is imperative thatthe name of the oil in use be indicated whenreturning the hydraulic attachment for repair.In order to protect the environment or on technicalgrounds, hydraulic oils are currently being usedwhich are not classified as HLP mineral oils.Before using hydraulic oils of this kind it isimperative to ask the carrier manufacturer whetheroperations with such fluids are possible.Our hydraulic attachments are basically designedfor use with mineral oils. Consult the Atlas CopcoCustomer Center/Dealer in your area before usingother hydraulic oils approved by the carriermanufacturer. Following initial assembly and afterany workshop repairs, our hydraulic attachments
are subjected to a test run on a test bed poweredby mineral oil.
Grease◆ When handling oils and greases observe the
safety instructions that apply to these products.
Media /consumables Part number
Chisel paste(for ContiLube® II)
3363 0912 00
Parker O-Lube
GasNormal nitrogen, purity degree 99.8 %
Media /consumables Part number
Nitrogen bottle 2 l 3363 0345 04
Nitrogen bottle 5 l 3363 0345 06
Mineral hydraulic oilAll hydraulic oil brands prescribed by the carriermanufacturer are also suitable for use whenoperating the hydraulic attachment.However, the oil should comply with viscosity classHLP 32 or higher.In summer and in hot climates, oils of viscosityclass HLP 68 or higher should be used.In all other respects the regulations of the carriermanufacturer 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 hydraulicattachment at low temperatures (see chapter Lowambient temperature).◆ Check the oil filter!
An oil filter must be integrated in the tank line ofthe hydraulic system. The maximum meshwidth allowed for the oil filter is 50 microns; itmust have a magnetic separator.
Manufacturing the adapterplate
Construction Tools GmbH also supplies baseplates to manufacture adapter plates alternativelyto the adapter plates supplied.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
22 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
NOTICE Adapter plate cracking
The adapter plate may crack if it is not designedfor the high load.► Take not only the weight of the hydraulic
attachment but also the crowd force of thecarrier, possible vibration etc. into accountwhen dimensioning the adapter plate.
► Ensure that the design conforms to the state ofthe art.
► Have the web plates welded to the adapterplate base plate by a qualified weldingspecialist.
The base plate is made of the material EN10025-S355 J2G3.◆ Have the web plates designed and
manufactured or procure web plates to fit yourcarrier.
◆ Ensure that the web plates are welded to thebase plate side marked "TOP".
The adapter plate must not strike in any positionduring operation of the hydraulic attachment.Construction Tools GmbH does not design,manufacture or sell web plates for adapter plates.
Installing the adapter plate
NOTICE Adapter plate can come loose
The adapter plate can come loose if the fasteningscrews are not designed for local high loads.► Only use the Allen screws of strength category
8.8 and the pairs of lock washers included inthe delivery to attach the adapter plate or thebase plate.
◆ Place the hydraulic breaker on timber supportblocks within the range of the carrier. Thebreaker box service opening must be facingupwards.
◆ Remove the transport safety device whichkeeps the elastic pad (C) and the percussionunit in the breaker box.
◆ Apply Anti-Seize to the Allen screw threads (A)before inserting them.The contact faces of the screw head and thelock washers (B) must not be lubricated.
WARNING Hands and fingers being cut offor hurtBores and surfaces can act like a pair of scissorsand cut off or hurt parts of your body.► Never use your fingers to check bores or fitting
surfaces.
◆ Align the adapter plate (D) to the hydraulicbreaker as shown.
AB
C
D
◆ Fit a pair of lock washers (B) onto every screw.◆ Tighten the Allen screws (A) with an Allen key.◆ Tighten the Allen screws (A) with the required
tightening torque.
Type Key size Tightening torque
MB 750 /MB 750 DP
17 390 Nm
MB 1000 /MB 1000 DP
17 390 Nm
MB 1200 /MB 1200 DP
22 1500 Nm
MB 1500 /MB 1500 DP
22 1500 Nm
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
23
Attaching the hydraulicattachment to the carrier
Mechanical mounting aspectsYou need an assistant to attach the hydraulicattachment to the carrier.◆ Agree on hand signals with your assistant, to
enable him to help you placing the carrier in theproper position to attach the hydraulicattachment.
◆ Lower the stick of the carrier into the holderprovided on the adapter plate.
WARNING Injury by impactsA sudden movement of the carrier may cause yourassistant to be hit and injured by the boom or thehydraulic attachment.► Only move the boom very slowly and in a
controlled manner while an assistant is withinthe danger zone.
► Always keep sight of your assistant.
WARNING Hands and fingers being cut offor hurtBores and surfaces can act like a pair of scissorsand cut off or hurt parts of your body.► Never use your fingers to check bores or fitting
surfaces.
◆ Let your assistant instruct you until the bores inthe adapter plate (B) and in the stick (A) areproperly aligned.
◆ Install the stick bolt (C) and lock it.
A
B
C
D
◆ Lift the hydraulic attachment (D).
A
B
G
E
F
◆ Extend the bucket cylinder (E) until the bore inthe linkage (F) links up with the bore in theadapter plate (B).
◆ Install the linkage bolt (G) and lock it.◆ Carefully move the bucket cylinder (E) into both
end positions.The adapter plate must not be stopped bymechanical stops in either position. Consult theAtlas Copco Customer Center/Dealer in your areaif the adapter plate is stopped by a mechanicalstop.
Making the hydraulic connections
NOTICE Faulty hydraulic installation
The carrier must have a suitable hydraulicinstallation to operate the hydraulic attachment.Improperly installed lines and incorrect rated sizesmay cause the oil to heat up and the hydraulicattachment to be damaged.► Only use hydraulic lines of the rated sizes as
instructed (see chapter TechnicalSpecifications).
► Check the rated size of the hydraulic lines onexisting hydraulic installations! Pressure andtank lines for the hydraulic oil must have asufficient inside diameter and wall thickness.
► Lay all hydraulic hoses so that they are torsion-free.
◆ Switch off the carrier.◆ Depressurise the hydraulic system according to
the manufacturer's safety and operatinginstructions for the carrier.
◆ If no quick couplings are used, close all shut-offvalves in the installation at the boom.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
24 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
NOTICE Total damage to the hydraulicattachment
Polluted hydraulic lines and connections mayenable sand, fragments of material and dirt topenetrate the hydraulic attachment and damage itcompletely.► Clean the hydraulic lines and connections
before connecting the hydraulic hoses. Lay allhydraulic hoses so that they are torsion-free.
◆ Install the pressure and tank hoses.◆ Connect the pressure and tank hoses.
◆ If no quick couplings are used, open the shut-offvalves in the installation at the boom.
◆ Switch on the carrier.◆ Let the hydraulic oil run through the carrier oil
filter for approx. three minutes to make surethat the hoses are clean.
◆ Switch off the carrier.◆ Depressurise the hydraulic system according to
the manufacturer's safety and operatinginstructions for the carrier.
◆ If no quick couplings are used, close all shut-offvalves in the installation at the boom.
◆ Disconnect the pressure and tank hoses.◆ Unscrew the blind flanges from the
ports »P« and »T« and save them for futureuse.
◆ Check that the ports and connections on thehydraulic breaker and/or on the hydraulic hosesare not damaged.
◆ Replace any damaged connections.◆ Grease the O-rings of the connection flanges
with Parker O-Lube and install them.
◆ Fit a pair of lock washers onto every fasteningscrew.
◆ Attach the flange of the pressure hose toport »P«, using the fastening screws andmaking sure it is torsion-free.
◆ Attach the flange of the tank hose to port »T«,using the fastening screws and making sure it istorsion-free.
WARNING Hydraulic hose flailing aboutPressurised hydraulic hoses will flail about whenbolted connections have come loose or have beenloosened. A hydraulic hose flailing about maycause serious injuries.► Tighten the fastening screws with the right
tightening torque.
Tightening torque (see chapter Bolt connections /Tightening torques)
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
25
Removing the hydraulicattachment from the carrier
◆ Place the hydraulic attachment on timbersupport blocks.
Dismantling the hydraulic connections
WARNING Unexpected movementSudden movements of the carrier may causeserious injury.► Secure the carrier such that it cannot move
unexpectedly.► Observe the carrier manufacturer’s instructions.
WARNING Hydraulic hose flailing aboutPressurised hydraulic hoses will flail about whenbolted connections have come loose or have beenloosened. A hydraulic hose flailing about maycause serious injuries.► Depressurise the hydraulic system before
disconnecting a hydraulic hose (see chapterDepressurising the hydraulic system).
WARNING Hot partsThe percussion unit, the working tool, hoses, pipesand fittings become very hot during operation.Touching them may lead to burns.► Never touch hot parts.► If you have to carry out activities where you
have to touch the parts, wait for them to cooldown first.
◆ Close all shut-off valves in the installation at theboom if no quick couplings are used.
◆ Disconnect the hose lines to and from thehydraulic attachment at the boom side.
◆ Close off all open hose ends.
Mechanical disassembly◆ You need an assistant to remove the hydraulic
attachment.◆ Agree on hand signals with your assistant, to
enable him to help you move the boom.
WARNING Injury by impactsA sudden movement of the carrier may cause yourassistant to be hit and injured by the boom or thehydraulic attachment.
► Only move the boom very slowly and in acontrolled manner while an assistant is withinthe danger zone.
► Always keep sight of your assistant.
WARNING Metal chips shooting offWhen hammering out bolts, chips may shoot offand cause serious eye injuries.► Wear safety glasses when hammering out the
bolts.
◆ Remove the bolt locks from the stick andlinkage bolts.
◆ Drive out the linkage bolt with a steel arbor anda hammer.
◆ Switch on the carrier.◆ Retract the bucket cylinder.◆ Drive out the stick bolt with a steel arbor and a
hammer.◆ Move the carrier stick out of the adapter plate.
Removing the adapter plate
◆ Loosen the fastening screws of the adapterplate.
◆ Lift the adapter plate with a suitable liftingequipment and put it down on timber supportblocks.
◆ Lock the elastic pad with the transport safetydevice.
◆ Save the fastening screws and the pairs of lockwashers for future use.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
26 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
DustProtector
◆ Place the hydraulic breaker on timber supportblocks.
WARNING Unexpected movementSudden movements of the carrier may causeserious injury.► Secure the carrier such that it cannot move
unexpectedly.► Observe the carrier manufacturer’s instructions.
WARNING Metal chips shooting offWhen hammering out bolts, chips may shoot offand cause serious eye injuries.► Wear safety glasses when hammering out the
bolts.
C
A
B
B
FE
D
Removal◆ Remove the working tool (see chapter Working
tool/Removal) before removing theDustProtector.
◆ Remove the plugs (B) from the breaker box.◆ Drive out the lock bolts (C) of the DustProtector
using a break pin punch and a hammer.◆ Remove the guide ring (F), floating ring (E) and
counter ring (D) of the DustProtector system.◆ Remove the wiper (A).To make the wiper (A) easier to remove:
Push the sealing lip of the wiper inwards with yourthumb. This pushes the wiper out of the wipersleeve ring groove.
Installation◆ Before installing the DustProtector, install the
working tool (see chapter Working tool/Installation).
◆ Manually push the wiper (A) over the workingtool and let it click into place in the wiper sleevering groove.
◆ Use a tool (hammer handle) to push on thewiper (A) at several points.
◆ Use your thumbs to push the wiper into placealong its circumference.
◆ Apply chisel paste to the guide ring (F), floatingring (E) and counter ring (D).
◆ Install the floating ring (E) and counter ring (D)in the guide ring (F).
◆ Push the rings over the working tool and installthem in the lower part of the breaker box.
◆ Turn the guide ring (F) so that the apertures inthe breaker box and the guide ring are lined up.
◆ Drive the lock bolts (C) into place using a breakpin punch and a hammer.
◆ Seal the apertures in the breaker box with theplugs (B).
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
27
Working tool
WARNING Unexpected movementSudden movements of the carrier may causeserious injury.► Secure the carrier such that it cannot move
unexpectedly.► Observe the carrier manufacturer’s instructions.
WARNING Metal chips shooting offWhen hammering out bolts, chips may shoot offand cause serious eye injuries.► Wear safety glasses when hammering out the
bolts.
WARNING Heavy working toolThe working tool is heavy; if it falls it may causeserious injury. Lifting the working tool withoutsuitable lifting equipment may lead to physicalinjury.► Lift the working tool with lifting equipment
designed for the weight of the working tool.
WARNING Hands and fingers being cut offor hurtBores and surfaces can act like a pair of scissorsand cut off or hurt parts of your body.► Never use your fingers to check bores or fitting
surfaces.► Do not reach into the aperture in the lower
breaker part or between the working tool andthe lower breaker part.
Selecting the right working toolThe standard available working tools are shown.The different cutter geometries may influence theproduction result, depending on the actual use.Please consult the following table forrecommended uses.
Conical moil point
Suitable for universal use
Very good penetrationEven splitting effect distributionNo torsion effect
Pyramidal moil point
Suitable for universal use
Very good penetrationEven splitting effect distributionSlight torsion effect
Chisel and spade
Mining, demolition work, ground work,foundations
Very good splitting effect distributionVery good penetrationTorsion effect
Blunt tool
Mining, block holing, demolition work
Very good energy transferOptimum in-cutting effectNo torsion effect
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
28 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Installation◆ Place the hydraulic breaker on timber support
blocks.
NOTICE The working tool will break
There is an increased risk of the working toolbreaking if it has not been stored in frostfreeconditions.► Store the working tool in a frostfree
environment for one day before installing it.or
► Heat up the working tool for several hours, e.g.with a heating blanket, until it has warmed upthoroughly.
A BC
D
E
F
G
H
Wiper installed(only hydraulic breakers with DustProtector):When installing the working tool for the first timeafter it has been delivered, you first have toremove the wiper (H) of the DustProtector.◆ Remove the wiper (H) of the DustProtector (see
chapter DustProtector/Removal).
NOTICE Damage to the wiper
If the wiper is not removed it will bend back wheninstalling the working tool. The wiper can no longerbe used then.► Remove the wiper before installing the working
tool.Retainer bar installed:When installing the working tool for the first timeafter it has been delivered, you must remove theprotective cap and the retainer bars.◆ Remove the protective cap from the aperture
for the working tool.◆ Store the protective cap for future use.
◆ Remove the plugs (B) and (E) from the breakerbox.
◆ Use a break pin punch and a hammer to drivethe pin (G) for the retainer bars (D) out of thelower breaker part (F) from the side.
◆ Remove the two plugs (C) from the slottedholes for the retainer bars (D).
◆ Screw one screw (M 12) into the bore on thefront side of the retainer bars.
◆ Pull out the retainer bars with the screw.Retainer bar and wiper removed:If the retainer bars and the wiper (only on hydraulicbreakers with DustProtector) have been removed,proceed as follows:◆ Clean the insertion area of the working tool (A).◆ Grease the insertion area of the working
tool (A) with chisel paste.◆ Grease both retainer bars (D) with chisel paste.◆ Install the working tool (A).◆ Put the retainer bars (D) in place.◆ Turn the working tool (A) until the retainer
bars (D) slide into place in the slotted holes ofthe lower breaker part (F).
◆ Remove the screw from the retainer bars (D).◆ Install the sealing plugs (C).◆ Drive the bolt (G) into place using a break pin
punch and a hammer.◆ Install the plugs (B) and (E) in the breaker box
apertures.◆ If the hydraulic breaker is a DustProtector type,
install the wiper (H) (see chapter DustProtector/Installing).
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
29
Removal◆ Place the hydraulic breaker on timber support
blocks.
WARNING The working tool suddenlycomes looseA clamped working tool is still under the pressureof the piston accumulator. When the working tool isloosened, it will partly jump out of the hydraulicbreaker; this may lead to serious injury.► Never position yourself directly in front of the
installed working tool.
WARNING Hot working toolThe tip of the working tool gets very hot duringoperation. Touching it may lead to burns.► Never touch the hot working tool.► If you have to carry out any activities, wait for
the working tool to cool down first.
◆ Remove the plugs (E) and (H) from the breakerbox.
A B C D E
G
H
F
◆ Use a break pin punch and a hammer to drivethe bolt (B) for the retainer bars (C) out of thelower breaker part (A) from the side.
◆ Remove the two plugs (D) from the slottedholes for the retainer bars.
◆ Screw one screw (M 12) into the bore on thefront side of the retainer bars.
◆ Pull out the retainer bars by the screw.◆ Pull the working tool (G) out of the lower
breaker part.◆ If the hydraulic breaker is a DustProtector type,
remove the wiper (F) (see chapterDustProtector/Removal).
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
30 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Operation
WARNING Hot hydraulic oil squirting outThe hydraulic system is under high pressure. Ifhydraulic connections come loose, hydraulic oil willsquirt out under high pressure. Hydraulic oilsquirting out can lead to serious injury.► Immediately switch off the hydraulic attachment
and the carrier if you detect any leaks in thehydraulic circuits.
► Depressurise the hydraulic system (see chapterDepressurising the hydraulic system).
► Repair any leaks before operating the hydraulicattachment again.
WARNING Hot partsThe percussion unit, the working tool, hoses, pipesand fittings become very hot during operation.Touching them may lead to burns.► Never touch hot parts.► If you have to carry out activities where you
have to touch the parts, wait for them to cooldown first.
NOTICE Environmental damage due to hydraulicoil
Hydraulic oil is environmentally harmful and mustnot penetrate the ground or enter the water tableor water supplies.► Collect any hydraulic oil which escapes.► Dispose of it in accordance with the applicable
environmental regulations.
NOTICE Hydraulic oil too hot
The temperature of the hydraulic oil must notexceed 80 °C. Higher temperatures will damagethe seals of the hydraulic breaker and thediaphragm of the HP-accumulator.► The temperature of the hydraulic oil must be
monitored.► Shut off the carrier and the hydraulic breaker if
you measure an increased temperature in thetank.
► Check the hydraulic installation and thepressure relief valve.
NOTICE Damage due to idling strokes
If the percussion piston carries out a hammeraction without hitting the working tool, it is carryingout an idling stroke. If this happens it will lead tohydraulic peak pressures which may damage theseals of the hydraulic breaker and the carrier.
► Do not allow the percussion piston to carry outidling strokes for a prolonged period of time.
Initial operation andoperation after long storage
Prior to first use and after more than eight weeksstorage of the hydraulic breaker, the pressure inthe piston accumulator must be checked.◆ Remove the protective cap from the aperture
for the working tool.◆ Remove the retainer bars.◆ Check the pressure in the piston accumulator
without exerting pressure (see chapter Pistonaccumulator).
◆ Fill up the piston accumulator or release thepressure from the piston accumulator until thepiston accumulator has reached the minimumgas pressure (see chapter Piston accumulator).Use the tabular value at ambient temperature,not at operating temperature in this case.
◆ Install the hydraulic breaker (see chapterINSTALLATION).
◆ Operate the hydraulic breaker until theoperating temperature 60 – 70 °C has beenreached.
◆ Follow all instructions as described in thechapter OPERATION.
◆ Check the pressure in the piston accumulatorwithout exerting pressure of the working tool(see chapter Piston accumulator).
◆ Fill up the piston accumulator to the requiredgas pressure (see chapter Piston accumulator).
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
31
Preparations before starting
WARNING Falling carrierA carrier falling or tipping over due to the surfacenot being level may cause serious injury andmaterial damage.► Always observe great care when moving the
carrier.► Do not use the hydraulic attachment until the
carrier is positioned stably.
WARNING Fragments flying aroundFragments of material which come loose whileoperating the hydraulic attachment may be flungaway and can cause serious injury if people are hitby them. Small objects falling from a great heightcan also cause serious damage.During hydraulic attachment operation the dangerzone is considerably greater than during theexcavation operation due to fragments of stoneand pieces of steel flying around, and for thisreason the danger zone must, depending on thetype of material to be worked on, be enlargedcorrespondingly, or secured in a suitable mannerthrough corresponding measures.► Secure the danger zone.► Stop the hydraulic attachment immediately if
anyone enters the danger zone.► Close the windscreen and the side windows of
the driver's cab.
The preparations required prior to starting thehydraulic attachment depend on the ambienttemperature:• Ambient temperature below 0 °C
(see chapter Low ambient temperature).• Ambient temperature above 30 °C
(see chapter High ambient temperature).The oil temperature in the hydraulic attachmentmust be between 0 °C and +80 °C when operatingthe breaker.The full capacity of the hydraulic attachment canbe achieved when the oil temperature is approx.60 °C.◆ Make sure that there are no people in the
danger zone.◆ Start the carrier as instructed by the carrier
manufacturer.◆ Let the carrier heat up until the operating
temperature prescribed by the carriermanufacturer has been reached.
◆ Put the carrier in its working position.
◆ Put the working tool on the material to bebroken.
Switching the hydraulicbreaker on and off
After properly attaching the hydraulic attachment tothe carrier, the hydraulic attachment can beoperated using the carrier‘s hydraulic system. Allfunctions for normal carrier operation remain intact.The hydraulic attachment is switched on and offusing electrical and hydraulic signals.If you have any questions about electric/hydrauliccommands, consult the carrier manufacturer and/orthe Atlas Copco Customer Center/Dealer in yourarea.◆ Switch the hydraulic attachment on and off, as
described in the carrier‘s operating instructions.◆ When leaving the driver’s cab, set the safety
switch/lever for the electrical/hydraulicattachment installation to the „OFF“ position.
Carry out the above actions to prevent anyunintended start-up of the hydraulic attachment.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
32 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Functional test
Always carry out a functional test before puttingthe hydraulic attachment into use to check that allhydraulic lines and connections are tight and thatthe hydraulic attachment works without anyproblems.◆ Prepare the hydraulic attachment so that you
can start using it.◆ Carry out a couple of test impacts on the
material to be broken.◆ Check the hydraulic lines and make sure that
the hydraulic attachment works without anyproblems.
◆ Immediately switch off the hydraulic attachmentif oil escapes from the hydraulic lines or if otherdefects in functioning occur.
◆ Depressurise the hydraulic system (see chapterDepressurising the hydraulic system).
◆ Only use the hydraulic attachment again afterhaving repaired all leaks and operating defects.
Correct operation
Working angle◆ Always position the tool so that it hits the
material to be broken at a right angle.
90°
If you do not do this, the hydraulic breaker willwear faster and damage will occur after a while.
◆ Slightly swing the hydraulic breaker to and frowhen carrying out the hammer impacts, butnever swing it through more than approx. 5°.
90°
-5˚ +5˚
This swing action enables any dust under thetip or the cutter of the working tool to escape.Otherwise a layer of dust is created whichwould prevent the full percussion energy beingtransferred to the material to be broken. The tipof the working tool then becomes hot and losesits hardness.Larger swing angles would lead to bendingloads and damage to the working tool and thehydraulic breaker.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
33
AdvanceSelect the distance marked with "V“ such that thefragment is released within 30 seconds. If this isnot the case decrease the advance or apply thetool again to another location.Excessive advances do not improve the workingresult. The working tool will then penetrate thematerial without a satisfactory breaking result. Thetip of the working tool then becomes hot and losesits hardness. Work step by step to achieve theoptimum work result.◆ Start near the edge of the material to be broken
and work your way back to its centre.
V
Impact time◆ Never apply the hydraulic breaker to the same
point for more than 30 seconds.
30 s
◆ If the material fails to break, apply the tool to anew location.
High ambient temperature◆ Only use hydraulic oils of sufficient viscosity.
In summer and in tropical climates, theminimum requirement is a hydraulic oil of typeHLP 68.
Low ambient temperatureAmbient temperature below 0 °C:
NOTICE The working tool may break
There is an increased risk of the working toolbreaking if it has not been stored in frostfreeconditions.► Store the working tool in a frostfree
environment for one day before installing it.or
► Heat up the working tool for several hours, e.g.with a heating blanket, until it has warmed upthoroughly.
Additional instructions when working at anambient temperature of below -20 °C:You must heat up the hydraulic attachment and thecarrier when working at ambient temperatures ofbelow -20 °C.Preferably park the carrier and the hydraulicattachment in a heated, sheltered space while notin use.
NOTICE Hydraulic oil too cold
Operating the hydraulic breaker while the hydraulicoil is still cold will damage the seals of thehydraulic breaker and the diaphragm in the HP-accumulator.► Do not operate the hydraulic breaker until the
temperature of the hydraulic oil is at least 0 °C.◆ Start the carrier as instructed by the carrier
manufacturer.◆ Let the carrier heat up until the operating
temperature prescribed by the carriermanufacturer has been reached.
NOTICE Damage to hydraulic parts
If a hydraulic breaker which has not reachedoperating temperature is operated with hothydraulic oil this will lead to tensions and thehydraulic breaker will stop working.► Do not fill the hydraulic system with hot
hydraulic oil.The temperature of the hydraulic oil of the carriermust be at least 0 °C.◆ Start the hydraulic attachment when the
temperature has risen to 0 °C.◆ During operations, leave the carrier engine and
pumps running even during breaks.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
34 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Prohibited operation
Lifting/Transporting
WARNING Falling loadThe lifted object can fall and cause serious injuriesor death.► Never lift or transport loads with the hydraulic
attachment.
The hydraulic attachment was not constructed tolift or transport loads. The hydraulic attachment willbe damaged by such use.
Impacting◆ Do not use the hydraulic breaker as a sledge
hammer to demolish the material.
This will damage the hydraulic breaker, theworking tool and the carrier.
Moving objects◆ Never use the hydraulic attachment to move
debris.This would damage the hydraulic attachment.
Levering◆ Never use the working tool for crowbar-type
applications.
This might cause the working tool to break.Listen to the sound of the hydraulic breaker – itchanges when stresses occur between theworking tool and the wear bush.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
35
Blank firing of the working toolThe working tool "blank fires" if the percussionenergy is transferred to the retainer bars instead ofto the material to be broken.This happens when the working tool breaksthrough the material or slips off it, e.g.: whenworking on thin concrete slabs or layers of looserocks.Blank firing of the working tool subjects thehydraulic breaker and the carrier to increasedloads.Blank firing of the working tool generates a typicalmetallic sound.◆ Try to avoid blank firing of the working tool by:
• observing the material to be broken toidentify whether there is any risk of theworking tool breaking through the material orslipping off it.
• listening to the sound of the hydraulicbreaker. You can hear a metallic twang whenthe working tool is blank firing.
◆ Stop the hydraulic breaker when blank firingoccurs.
Cylinder end positions◆ Avoid operating the hydraulic attachment when
the carrier stick and bucket cylinder is in one ofits end positions.
These end positions have damping facilities;the hydraulic cylinder may be damaged byprolonged use while in its end positions.
◆ Reposition the carrier so that you do not haveto work with the cylinder in its end positions.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
36 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Working with safetyequipment
Underwater applicationsUsing the hydraulic breaker in and under water ispossible if it has been fitted out with special safetyequipment.A special connection kit for underwater use wasdeveloped to avoid damage to the hydraulicbreaker. It contains all the necessary componentsincluding the safety facilities to keep the interior ofthe lower breaker part free from water by usingexternal compressed air.Specific documentation, has been drawn up,including operating instructions and a spare partslist, for underwater usage.◆ Before using the hydraulic breaker in or under
water, consult the Atlas Copco CustomerCenter/Dealer in your area.
Usage in tunnelsUsing the hydraulic breaker for tunnelling withoverhead operations and horizontal applications orfor river bed excavation/slope construction ispossible if it has been fitted out with special safetyequipment.Dust and stone particles and/or water penetratingthe hydraulic breaker can lead to operating failuresand can even cause the hydraulic breaker tomalfunction completely.Preventative measures to protect the hydraulicbreaker have been collected in separatedocumentation.◆ Before using the hydraulic breaker for tunnelling
work, consult the Atlas Copco CustomerCenter/Dealer in your area.
Hot applicationsUsing the hydraulic breaker in a hot environment ispossible if it has been fitted out with special safetyequipment.◆ Before using the hydraulic in a hot environment,
consult the Atlas Copco Customer Center/Dealer in your area.
AutoControl System
Not for MB 750/DPThe AutoControl System is a combination of apressure-maintaining and reversing valve.The AutoControl System protects the breaker fromdamage if blank firing occurs.The pressure-maintaining valve makes sure thatthe hydraulic breaker switches correctly in alloperating situations. It enables up to 30 % energyto be recovered when working on hard rock.The reversing valve automatically switches overthe hydraulic breaker to a shorter stroke to reducethe single-impact energy.
AutoControl in daily useThe system works automatically without anymanual intervention by the carrier operator andautomatically adjusts to the conditions of use.If the situation requires a high single blow energy,the system produces a full stroke and a high singleblow energy.
AutoControl in special applicationsFor special applications, e.g. work with very littlepercussion, the AutoControl System can beblocked mechanically at a high impact rate with areduced single-impact energy.For further information, please contact the AtlasCopco Customer Center/Dealer in your area.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
37
StartSelect System AutoStop/AutoStart
Not for MB 750/DP, MB 1000/DPThe StartSelect System enables you set the startand switch-off behaviour of the hydraulic breaker tothe relevant conditions.The hydraulic breaker is factory-set to the“AutoStop” setting (=automatic switch-off), i.e. thebreaker is switched on while exerting pressure onthe working tool in the “AutoStop”. However it willswitch off automatically during operation when thepercussion piston no longer hits the working tool.Idling strokes are avoided this way.This setting is an advantage when using thebreaker on a stable surface:• trenching• slope construction in quarry operations• digging foundations in rocks• reducing large concrete structuresYou can integrate the StartSelect valve the otherway around to quickly adjust the hydraulic breakerto the “AutoStart” (=easy start) integration setting.The hydraulic breaker starts in its working positionafter switching on without exerting pressure on theworking tool in the “AutoStart” (=easy start)integration setting.This start behaviour enables greater productivityand easier handling when working on unstablesurfaces, e.g.:• block holing in broken ground or debris• working in horizontal and/or overhead positions• reducing light concrete structures
Switching between AutoStop/AutoStart◆ Place the hydraulic breaker on timber support
blocks.
WARNING Unexpected movementSudden movements of the carrier may causeserious injury.► Secure the carrier such that it cannot move
unexpectedly.► Observe the carrier manufacturer’s instructions.
WARNING Jets of hot hydraulic oil canescapeThe hydraulic system is under high pressure. Ifhydraulic connections come loose or aredisconnected, hydraulic oil will squirt out underhigh pressure. Hydraulic lines may spring a leak orburst. Hydraulic oil squirting out can lead to seriousinjury.► Depressurise the hydraulic system before
connecting or disconnecting the hydrauliccircuits of the hydraulic attachment (see chapterDepressurising the hydraulic system).
◆ Close all shut-off valves in the system at theboom if no quick couplings are used.
◆ Disconnect the hoses to and from the hydraulicbreaker on the boom side.
◆ Plug up all open hose ends.“AutoStart” integration setting
D
B
C
A
“AutoStop” integration setting
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
38 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
D
B
C
A
◆ Remove the plug (B) from the breaker box.◆ Remove the plug (C). It is located in the
cylinder behind plug (B).◆ Screw a screw (M 10) into the valve piston (D).◆ Pull the valve piston (D) by its screw from the
bore in cylinder (A).◆ Remove the screw from the valve piston (D)
and install it again the other way around.◆ Screw in the plug (C) and tighten it to the
required tightening torque (see chapter Boltconnections / Tightening torques).
◆ Install the plug (B) in the breaker box.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
39
MaintenanceThe maintenance activities are carried out by thecarrier driver.
WARNING Hot hydraulic oil squirting outThe hydraulic system is under high pressure. Ifhydraulic connections come loose, hydraulic oil willsquirt out under high pressure. Hydraulic oilsquirting out can lead to serious injury.► Immediately switch off the hydraulic attachment
and the carrier if you detect any leaks in thehydraulic circuits.
► Depressurise the hydraulic system (see chapterDepressurising the hydraulic system).
► Repair any leaks before operating the hydraulicattachment again.
WARNING Hot hydraulic oil squirting outThe hydraulic system is under high pressure.Hydraulic oil escaping out can lead to seriousinjury.► Immediately switch off the hydraulic attachment
and the carrier if you detect any leaks in thehydraulic circuits.
► Do not inspect for possible leaks with yourfingers or other parts of the body, but use apiece of cardboard instead, holding it up to thesuspected leakage site.
► Examine the cardboard for traces of liquid.► Depressurise the hydraulic system (see chapter
Depressurising the hydraulic system).► Repair any leaks before operating the hydraulic
attachment again.
WARNING Hot partsThe percussion unit, the working tool, hoses, pipesand fittings become very hot during operation.Touching them may lead to burns.► Never touch hot parts.► If you have to carry out activities where you
have to touch the parts, wait for them to cooldown first.
WARNING Accidental startIf the hydraulic attachment is started by accidentthis may lead to serious injury.► Follow the instructions in the Operating
Instructions of the carrier to prevent thehydraulic attachment starting by accident.
WARNING Unexpected movementSudden movements of the carrier may causeserious injury.► Secure the carrier so that it cannot move
unexpectedly.► Observe the carrier manufacturer’s instructions.
NOTICE Environmental damage due to hydraulicoil
Hydraulic oil is environmentally harmful and mustnot penetrate the ground or enter the water tableor water supplies.► Collect any hydraulic oil which escapes.► Dispose of it in accordance with the applicable
environmental regulations.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
40 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Maintenance schedule
during a shift Monitor the filling level of the grease cartridge of the ContiLube® II lubrication system andimmediately replace an empty cartridge.Monitor the lubricant film on the shaft of the working tool.Manual lubrication of the working tool approx. every 2 hours.
daily Check the hydraulic lines for leaks.Check that the pipe clamps on the carrier are tight.
during and after the first 50 operatinghours
Tighten the screw connections daily during the first 50 operating hours.Replace the oil filter cartridges after the first 50 operating hours.
weekly Visual check of the tensioning bolts through the service openings placed at the top of thebreaker box's rear side.Check the screw connections and tighten as required.Check the pins in the retainer bars.Check that the plugs of the retainer bars are in place and are not damaged.Replace any damaged plugs.Check the adapter plate and the breaker box for cracks.In normal use:Clean and grease the DustProtector system.
Check the connecting fittings of the ContiLube® II system for leaks.
monthly Check the gas pressure in the piston accumulator monthly, and in cases of decreasing poweror failure of the hydraulic breaker.
every 500 operating hours Check the oil filter and replace as required.
when replacing the working tool, and atleast every 100 operating hours
Check the working tool for wear.Check the lower and upper wear bush for wear.Check that the piston impact surface is not chipped.Check that the working tool impact surface is not chipped.Check the working tool for burrs.Check the retainer bar for burrs.
if necessary Replace bent and damaged pipes.Replace damaged hoses.Check the pressure in the piston accumulator.In case of dusty conditions:Clean and grease the DustProtector system.Check the adapter plate bolts for wear.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
41
Depressurising the hydraulicsystem
Even when you have switched off the carrier, aconsiderable residual pressure can still be presentin the hydraulic system.A residual pressure can still be present in thehydraulic breaker even after you havedisconnected the quick-release couplings or closedthe shut-off valves.The hydraulic breaker can only be depressurisedusing the hydraulic system of the carrier, byallowing hydraulic oil to drain to the tank via thereturn connection.If the hydraulic breaker is fitted with a high-pressure accumulator, it can take longer to relievethe pressure in the hydraulic system to the tank,since a larger volume of oil has to be drainedaway.Depending on the type of hydraulic breaker, theinternal leaks, the oil temperature, the type ofhydraulic oil and the design of the hydraulicinstallation of the carrier, the time required torelieve the pressure can vary.Depending on the hydraulic system of the carrieryou will have to consider using various measuresin order to depressurise the hydraulic system.Case 1:If measurement connections are present in thesupply pipe to the hydraulic breaker, with which thedepressurised state can be checked using asuitable gage. In order to depressurise thehydraulic breaker you must observe the followingsteps:1. The hydraulic breaker must be connected to
the hydraulic system of the carrier device, i.e.the hydraulic hoses must be connected up andthe respective shut-off valves in the supply pipeand in the connection to the tank must beopened.
2. Depressurise the hydraulic system according tothe manufacturer's safety and operatinginstructions for the carrier.
3. Measure the pressure with a suitable gage at ameasurement connection in the supply pipe tothe hydraulic breaker.
4. If residual pressure is still present, wait until thepressure has been completely relieved.
5. When you have made sure that no morepressure is present in the hydraulic system,you must disconnect the hydraulic connectionto the carrier. Close the shut-off valves or
disconnect the quick-release couplings, so thatno hydraulic oil can flow back from the carrier.
Case 2:If no facility for measuring the pressure is presentin the supply pipe to the hydraulic breaker and thereturn pipe is connected to the tank without anintermediate valve connection, you must observethe following steps in order to depressurise thehydraulic breaker:1. Ensure that the hydraulic oil in the hydraulic
breaker and in the carrier has a temperature ofat least 0 °C. If necessary, pre-heat it to at least0 °C.
2. The hydraulic breaker must be connected tothe hydraulic system of the carrier, i.e. thehydraulic hoses must be connected up and therespective shut-off valves in the supply pipeand in the connection to the tank must beopened.
3. Depressurise the hydraulic system according tothe manufacturer's safety and operatinginstructions for the carrier.
4. You must wait at least another 30 minutes untilthe pressure has been relieved throughleakages.Only after this period of time will there be nomore residual pressure present in the hydraulicsystem of the hydraulic breaker.
5. When you have made sure that no morepressure is present in the hydraulic system,you must disconnect the hydraulic connectionto the carrier. Close the shut-off valves ordisconnect the quick-release couplings, so thatno hydraulic oil can flow back from the carrier.
Case 3:If no facility for measuring the pressure is presentin the supply pipe to the hydraulic breaker and thereturn pipe is connected to the tank viaintermediate valves, which for example close off orpressurise the return pipe, you must observe thefollowing steps in order to depressurise thehydraulic breaker:1. The hydraulic breaker must be connected to
the hydraulic system of the carrier, i.e. thehydraulic hoses must be connected up and therespective shut-off valves in the supply pipeand in the connection to the tank must beopened.
2. Depressurise the hydraulic system according tothe safety and operating instructions from thecarrier manufacturer, and where appropriate,those of the manufacturer of the hydraulicinstallation for the attachment.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
42 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
3. When you have made sure that no morepressure is present in the hydraulic system,you must disconnect the hydraulic connectionto the carrier device. Close the shut-off valvesor disconnect the quick-release couplings, sothat no hydraulic oil can flow back from thecarrier.
Cleaning
NOTICE Environmental damage due to pollutedwater
Hydraulic oil and chisel paste are environmentallyharmful and must not penetrate the ground orenter the water table or water supplies.► Collect the water used for cleaning if it has
been contaminated by hydraulic oil and chiselpaste.
► Dispose of the water in accordance with theapplicable regulations to avoid environmentalhazards.
PreparationsHydraulic breaker installed:◆ Place the breaker on the working tool and exert
a slight pressure.This prevents water penetrating the percussionpiston.
Hydraulic breaker not installed, working toolremoved:◆ Plug up all hydraulic ports.◆ Seal the aperture for the working tool with the
protective cap.
Procedure
NOTICE Damage to the hydraulic breaker
Water can penetrate the percussion chamber viathe percussion chamber ventilation non-returnvalve. This may cause the percussion piston to rustwhich may result in damage to the seals and thecylinder.► Never direct the pressure cleaner jet onto the
percussion chamber non-return valve.◆ Use a pressure cleaner to remove dirt from the
hydraulic breaker.
Lubrication
Checking the lubricant filmThe lubricant film on the shaft of the working toolmust be checked during the work shift.◆ Let the hydraulic breaker hang freely from the
carrier boom.When the working tool is hanging from the retainerbars, the lubricant film on the shaft of the workingtool becomes visible. There must be an even filmof lubricant on the entire shaft.
◆ Increase the lubricant supply if the film oflubricant comes away or dry spots can be seen:• Automatic lubrication:
increase the lubricant supply via themetering screw of the ContiLube® II.
• Manual lubrication:increase the lubrication interval and thenumber of strokes from the manual greasegun.
NOTICE Damage due to excessive lubrication
Excessive lubrication may damage the hydraulicbreaker and the carrier. The impact surface of theworking tool must be free of grease.► Do not over-lubricate the working tool.If the ContiLube® II automatic lubrication systemhas been installed, a lubrication pulse is triggeredwhenever the hydraulic breaker is switched on.◆ Adjust the lubricant supply to your work
method.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
43
Automatic lubricationThe hydraulic breaker is lubricated automaticallyby the ContiLube® II.The ContiLube® II has been installed near theservice opening in the upper section of the breakerbox.Instructions on how to operate and maintain theContiLube® II is described in a seperatedocumentation.◆ If you have questions how to use the
ContiLube® II, contact the Atlas CopcoCustomer Center/dealer in your area.
Replacing the lubricant cartridge◆ Unscrew and remove the empty lubricant
cartridge and the old seal by turning counterclockwise.
◆ Remove the cover from the new cartridge.Make sure not to damage the sealing cone (A).
◆ Place the seal (B) on the cartridge.
A
B
◆ Use your thumb to push the cartridge pistondown until lubricant escapes from the screwthread.
◆ Screw the cartridge until the stop into the guidehole of the grease pump.The ContiLube® II is ready for use.
ContiLube® II operationPlease remember the following:• The ContiLube® II (C) is self-venting, i.e. the
system does not require you to vent it.• The lubricant level in the transparent cartridge
(E) of recyclable PE plastic can always bechecked from the cab by looking at the positionof the red piston.
• The piston side of the cartridge (E) must neverbe sealed, otherwise no grease supply will bepossible.
• You can change the supply volume by adjustingthe metering screw (A), depending on theactual use.
• Tighten the screw clockwise = less grease• Loosen the screw counter-clockwise = more
greaseC
B
A
E
The pump unit (C) must always be sealed toprevent the ingestion of water and dust.◆ Use a dust cover or leave the empty cartridge in
the pump until a new cartridge is available.◆ Check the tightness of the connections of all
hoses for the ContiLube® II operation once aweek.
Emergency lubrication is possible via the greasenipple (B) on the side of the ContiLube® II.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
44 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Manual lubricationManual lubrication is required if the automaticlubrication system fails to work.◆ Place the hydraulic breaker at a right angle on
the working tool and exert pressure.◆ Only use chisel paste for lubrication.◆ Put the manual grease gun on the grease
nipple of the emergency lubrication system andinject chisel paste.
• Lubrication interval: approx. every 2 hours• Hydraulic breaker without DustProtector:
5 to 15 strokes from the manual grease gun• Hydraulic breaker with DustProtector:
5 to 10 strokes from the manual grease gun
Chisel paste filling deviceConstruction Tools GmbH offers a device forrefilling empty cartridges. This can be mounted ona 15-kg or 45-kg hobbock to fill empty cartridgesas required.500-g chisel paste cartridgespacked per 12 cartridges:part number 3363 0912 00 for ContiLube® IIManual grease gun for ContiLube® II cartridges:part number 3363 0345 6715-kg chisel paste container,part number 3362 2639 00Filling device for use with 15-kg containers:part number 3363 0946 6945-kg chisel paste container,part number 3362 2632 75Filling device for use with 45-kg containers:part number 3363 0664 11For further information, please contact the AtlasCopco Customer Center/Dealer in your area.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
45
Checking the tensioningbolts
WARNING Rupturing washers becomeprojectilesWashers can rupture and cause serious injuries, ifyou hit the heads of the tensioning bolts or thewashers.► Never check the tensioning bolts by acoustic
test, but by visual test.
The visual check is only an indication. You canonly check doubtless in a repair shop afterremoving the adapter plate and the elastic pad.◆ Remove the covers of the service openings
which are placed at the top of the breaker box’srear side.
◆ Check the seat of the paint marks which areplaced on the heads of the tensioning bolts andwashers.
The paint marks have to be in your visual field. Inother cases, the respective tensioning bolt can beloose or broken. In this case act as follows:◆ Dismount the adapter plate and the elastic pad
(see chapter Removing the adapter plate).◆ Check the tensioning bolt for tight fit.◆ Tighten the loose tensioning bolt with the torque
required. (see chapter Bolt connections/Tightening torques).
◆ Strip the old paint mark.◆ Mark new the tighten tensioning bolt, the
washer and the cylinder cover with a colourcast of 10 mm width vertically over all threeparts. The paint mark shall be seen in thecentre of the service openings.
◆ Have broken tensioning bolts immediatelyreplaced.
◆ If you have any questions about replacement ofbroken tensioning bolts, consult the AtlasCopco Customer Center/Dealer in your area.
You can only check the front tensioning bolts, ifyou dismount the adapter plate and the elastic pad(see chapter Removing the adapter plate).◆ Check the tensioning bolts weekly for tight fit.
Checking the working tool
WARNING Hot working toolThe tip of the working tool gets very hot duringoperation. Touching it may lead to burns.► Never touch the hot working tool.► If you have to carry out any activities, wait for
the working tool to cool down first.
◆ Remove the working tool (see the chapterDismantling the working tool).
◆ Check the impact surface of the working tool forchips and cracks.
◆ Check the impact surface of the working tool fordeformation:A = new working toolB, C = worn working tool
A
B
B
C
◆ Replace the working tool if you detect chips,cracks or deformations (B and C).
◆ Check the wear condition of the impact ring ifyou detect deformations (B). Replace impactring if necessary.
◆ Check the shaft of the working tool for wearwhenever replacing it, but at least once every100 operating hours.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
46 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
D
D
◆ Replace the working tool if the shaft has wornto the minimum diameter Dmin stated below.
Type Dmin
MB 750, MB 750 DP 97 mm
MB 1000, MB 1000 DP 106 mm
MB 1200, MB 1200 DP 116 mm
MB 1500, MB 1500 DP 131 mm
Checking the retainer bars
◆ Check both retainer bars whenever replacingworking tools.
◆ Rework or replace the retainer bars if you findany signs of wear, such as sharp edges,notches or severe erosion.
◆ Deburr the retainer bars by careful grinding.◆ Install the retainer bars in their reversed
orientation if they cannot be reworked anymore.◆ Replace the retainer bars if both sides cannot
be reworked anymore.◆ Check both plugs for the retainer bars.
The plugs must not be damaged.
Checking the percussionpiston impact surface
◆ Check the percussion piston impact surfacewhenever replacing the working tool, but atleast once every 100 operating hours to makesure it is not chipped and has no visible cracks.
◆ Use an electric torch to illuminate the surface ofthe dismantled working tool.
◆ Do not use the hydraulic breaker again if youhave found the surface to be chipped orcracked.
◆ Consult the Atlas Copco Customer Center/Dealer in your area.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
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47
Checking the wear bushesand impact ring
The wear bushes can be checked after removingthe working tool. You can check the diameter usingthe enclosed test gauge.The diameter measured must not exceed themaximum permissible diameter Dmax (measuringpoint see below).
10 mm
Type Size informationon test gauge
Dmax
MB 750,MB 750 DP
Ø 100 103 mm
MB 1000,MB 1000 DP
Ø 110 115 mm
MB 1200,MB 1200 DP
Ø 120 125 mm
MB 1500,MB 1500 DP
Ø 135 140 mm
◆ Check the inside diameter of the lower andupper wear bush whenever replacing theworking tool, but at least once every100 operating hours.
◆ Clean the area around the impact ring to enablea visual check.
The lower wear bush can be replaced on site.Consult the Atlas Copco Customer Center/Dealerin your area.◆ Remove all remnants of lubricant from the
inside of the lower breaker part before installingnew parts.
A
B
C
A. impact ringB. upper wear bushC. lower wear bushThe upper wear bush and the impact ring must bereplaced in a workshop fitted out for this purpose.◆ Replace the lower wear bush when its inside
diameter is greater than the maximumpermissible diameter.
◆ When replacing the lower wear bush check theinside diameter of the upper wear bush usinginside callipers (part number 3363 0949 52).
◆ Replace the upper wear bush and the impactring when the inside diameter is greater thanthe maximum permissible diameter.
◆ Replace the impact ring if you find chips andcracks.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
48 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Checking and cleaning theDustProtector system
An important factor for the DustProtector operationis that the floating ring which moves in a radialdirection can follow the movements of the breakerand the working tool.If dust penetrates it, it may block up the availableinstallation space and interfere with theDustProtector system operation.
C
A
B
B
FE
D
◆ Regularly check that the floating ring (E) canmove freely.
NOTICE Environmental damage due to chiselpaste
Chisel paste is environmentally harmful and mustnot penetrate the ground or enter the water tableor water supplies.► Dispose of chisel paste polluted by dust and of
cloths with chisel paste in accordance with theapplicable regulations to avoid environmentalhazards.
Regular cleaning and greasing of the installedparts and their holders safeguards their operationand improves the availability of the hydraulicbreaker.The inspection frequency depends on how muchdust is generated:Normal dust generation:once a week (assuming 40–50 hours of operation).◆ Check more frequently if the floating ring (E) is
stuck.
◆ Remove the floating ring (E), counter ring (D)and guide ring (F) (see chapter DustProtector/Removal).
◆ Clean the space in front of the flexible wiper (A)of all loose dust.
◆ Check the wiper (A) for damage.◆ Replace the wiper (A) if it is damaged.◆ Check the inside diameter of the floating
ring (E) with a suitable test gauge or with ainside calliper.
Type Size informationon test gauge
Dmax
MB 750 DP Ø 100 103 mm
MB 1000 DP Ø 110 115 mm
MB 1200 DP Ø 120 125 mm
MB 1500 DP Ø 135 140 mm
The diameter measured must not exceed themaximum permissible diameter Dmax.
◆ If it has eroded so much that its inside diameterhas become too great, replace the floatingring (E).
◆ Clean and grease the floating ring (E), counterring (D) and guide ring (F) and install themagain (see chapter DustProtector/Installation).
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
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49
Piston accumulator
The pressure in the piston accumulator ismeasured at the filling valve (G). The pistonaccumulator is also filled through this valve.
G
The following accessories can be supplied:1 nitrogen filling device1 test pressure gauge ¼", 0-25 bar, test category1.61 nitrogen bottle1 adapter, country-specificTo enable the following inspection andmaintenance activities to be carried out, theequipment referred to above has to be directlyavailable at the location of use at all times.
Checking the pressure in the pistonaccumulatorCheck the gas pressure in the piston accumulatormonthly, and in cases of decreasing power orfailure of the hydraulic breaker. Do not top up thepiston accumulator unless the gas pressure isequal to or less than the minimum gas pressure.Check the pressure in the piston accumulatorwhen the hydraulic breaker is at operatingtemperature (60-70 °C).◆ Lay down the hydraulic breaker.
Do not apply pressure to the working tool.B
G
A
◆ Remove the threaded plug (A) from the fillingvalve »G«.
◆ Push the hose end of the test pressuregauge (B) into the filling valve and note thepressure.
◆ If the value measured is below the required gaspressure add nitrogen into the pistonaccumulator.
The required pressure in the piston accumulator is:
if operating temperature 60-70 °C and withoutexerting pressure!Type Minimum gas
pressureRequired gaspressure
MB 750,MB 750 DP
9.6 bar 11.6 bar
MB 1000,MB 1000 DP
6.0 bar 9.0 bar
MB 1200,MB 1200 DP
11.0 bar 14.1 bar
MB 1500,MB 1500 DP
9.8 bar 11.8 bar
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
50 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Release the pressure from the pistonaccumulator◆ Release gas from the piston accumulator to
depressurise the piston accumulator or if thevalue measured is above the required gaspressure.
NOTICE Damage to the filling valve
Nails, screwdrivers or similar objects can damagethe filling valve.► Never use nails, a screwdriver or similar objects
to release nitrogen gas from the pistonaccumulator.
◆ Push the hose end of the test pressure gaugeinto the filling valve again.This will cause gas to escape from the pistonaccumulator.
◆ Repeat this until the required gas pressure hasbeen reached or until the piston accumulator isdepressurized.
◆ Install the threaded plug (A) in the fillingvalve (G).
Filling/topping up the piston accumulator
WARNING Unexpected movementIf the working tool has got stuck, it might comeloose unexpectedly if the pressure in the pistonaccumulator is increased. The unexpected impactmay lead to serious injury.► When filling the piston accumulator make sure
that there is nobody within the direct vicinity ofthe working tool.
If a country-specific adapter (E) is required, it hasto be installed between the nitrogen bottle and thepressure relief valve (D).◆ Connect the pressure relief valve (D) to the
nitrogen bottle.
AB
D
E
F
H
G
C
G
◆ Close the pressure relief valve (D).
◆ Connect the filling hose end (H) to theminimess connection (C) of the pressure reliefvalve (D).
◆ Open the valve of the nitrogen bottle (F).◆ Remove the threaded plug (A) from the filling
valve (G).◆ Push the free filling hose end (H) into the filling
valve (G).◆ Slowly open the pressure relief valve (D) to let
the nitrogen flow into the piston accumulator.◆ Read out the pressure increase from the
pressure gauge (B).◆ Close the pressure relief valve (D) when the
piston accumulator has reached the requiredpressure +10 %.
◆ Pull the filling hose out of the filling valve (G).◆ Check the pressure in the piston accumulator
and let gas escape until the required gaspressure has been reached.
◆ Install the threaded plug (A) in the fillingvalve (G) and tighten it to the requiredtightening torque (see chapter Boltconnections / Tightening torques).
◆ Close the nitrogen bottle valve (F).
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
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51
Checking the hydraulic lines
◆ Before starting your work shift, always carry outa visual check of all lines (pipes and hoses)from the pump to the hydraulic attachment andfrom there to the tank.
◆ Tighten any loose screw connections or hoseclamps.
◆ Replace damaged pipes and/or hoses.
Checking and cleaning thehydraulic oil filter
An oil filter must be integrated in the tank line ofthe hydraulic system. The maximum mesh widthallowed for the oil filter is 50 microns; it must havea magnetic separator.◆ Replace the oil filter cartridges after the first 50
operating hours.◆ Check the oil filter every 500 operating hours
and replace as required.
Checking the adapter plateand the breaker box forcracks and/or wear
◆ Check the adapter plate and the breaker box forcracks every week.
◆ Have rework activities or repairs carried out intime to avoid major damage.
◆ The wear rails (A) in the lower section of thebreaker box can be replaced as required.Please consult the Atlas Copco CustomerCenter/dealer in your area.
A
If the wear rails have worn severely, this maycause damage to the basic body of the breakerbox.
Checking the adapter platebolts for wear
◆ Carry out this visual check whenever thehydraulic attachment has been removed fromthe carrier.
◆ Check the adapter plate bolts for excessivewear such as cracks, pitting or severe erosion.
◆ Rework or replace worn bolts.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
52 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Bolt connections/ Tightening torques MB 750/DP, MB 1000/DP
The bolt connections of hydraulic breakers are subjected to very high loads.◆ Tighten any loose connections without exceeding the recommended tightening torques.
MB 750MB 750 DP
MB 1000MB 1000 DP
Connection point Pos. Interval Type of spanner SizeTorque
Adapter plate*(fastening screws)
A daily Allen key 17 mm390 Nm
Tensioning bolts** B weekly visual check Torque spanner/power wrench
50 mm
Filling valve »G«(threaded plug)
C in case of a repair socket spanner Allen key
22 mm130 Nm5 mm20 Nm
Ports »P« and »T« D weekly open-ended wrench 50 mm275 Nm
Hose connectionsContiLube® II
E weekly Various open-ended spanners with different spanner sizes
Valve (HV) F in case of a repair Allen key 12 mm100 Nm
Percussion chamberventilation
G in case of a repair open-ended wrench 41 mm200 Nm
AutoControl System H in case of a repair Allen key - 24 mm350 Nm
* Apply anti-seize compound to the allen screw threads before inserting them. The contact faces of thescrew head and the lock washers must not be lubricated.
**MB 750/DP The tensioning bolt heads can be seen through the openings in the breaker box.1. Pre-tighten the tensioning bolts to 200 Nm crosswise,2. retighten 120° (2 hexagons) crosswise,3. retighten 90° (1.5 hexagons) crosswise
**MB 1000/DP The tensioning bolt heads can be seen through the openings in the breaker box.1. Pre-tighten the tensioning bolts to 200 Nm crosswise,2. retighten 120° (2 hexagons) crosswise,3. retighten 120° (2 hexagons) crosswise
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
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53
MB 750/DP
A
B
C
D
D
D
E
F
G
MB 1000/DP
HV
CL
AC
P
T
G
A
B
C
D
D
D
E
E
F
G
H
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
54 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Bolt connections/ Tightening torques MB 1200/DP, MB 1500/DP
The bolt connections of hydraulic breakers are subjected to very high loads.◆ Tighten any loose connections without exceeding the recommended tightening torques.
MB 1200MB 1200 DP
MB 1500MB 1500 DP
Connection point Pos. Interval Type of spanner SizeTorque
Adapter plate*(fastening screws)
A daily Allen key 22 mm1500 Nm
Tensioning bolts** B weekly visual check Torque spanner/power wrench
55 mm
Filling valve »G«(threaded plug)
C in case of a repair socket spanner Allen key
22 mm130 Nm5 mm20 Nm
Ports »P« and »T« D weekly open-ended wrench 50 mm275 Nm
Hose connectionsContiLube® II
E weekly Various open-ended spanners with different spanner sizes
Valve (HV) F in case of a repair Allen key 12 mm100 Nm
Percussion chamberventilation
G in case of a repair open-ended wrench 41 mm200 Nm
AutoControl System H in case of a repair Allen key 24 mm350 Nm
StartSelect(plug)
I in case of a repair Allen key 17 mm200 Nm
* Apply anti-seize compound to the allen screw threads before inserting them. The contact faces of thescrew head and the lock washers must not be lubricated.
** The tensioning bolt heads can be seen through the openings in the breaker box.1. Pre-tighten the tensioning bolts to 500 Nm crosswise,2. retighten 120° (2 hexagons) crosswise,3. retighten 120° (2 hexagons) crosswise
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
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55
A
B
C
D
D
D
E
F
G
H
I
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
56 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Troubleshooting
The hydraulic breaker does not start
Cause Remedy ByPressure and tank lines swapped Check the laying of the pressure and tank lines and
connect correctly(see chapter Making the hydraulic connections )
Carrier driver
Shut-off valve in pressure and/or tank lineclosed
Check the shut-off valve and open Carrier driver
Gas pressure in piston accumulator toohigh
Check the gas pressure in the piston accumulator andadjust it to the correct value(see chapterChecking the pressure in the piston accumulator andRelease the pressure from the piston accumulator)
Carrier driver
Oil level in tank too low Check the oil level and top up oil Carrier driver
Defective couplings blocking pressure andtank lines
Check coupling and replace defective coupling halves Workshop
Faults in the electrical system of thehydraulic breaker installation
Check the electrical system of the hydraulic breakerinstallation and clear faults
Workshop
Magnet on switch-on valve damaged Replace the magnet Workshop
Operating pressure too low Check the carrier engine speed, the pump delivery andthe pressure relief valve; check the operating pressureAdjust settings and replace defective parts if required
Carrier driver or Atlas CopcoCustomer Center/Dealer inyour area
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
57
Hydraulic breaker operates too slowly
Cause Remedy ByInsufficient hydraulic oil delivery volume Check the engine speed and/or mode stage of the carrier
and the operation pressure and adjustCarrier driver
The connecting fitting in the pressure andtank line has come loose
Check the connecting fitting and tighten Carrier driver
Shut-off valve in pressure and/or tank linepartly closed
Check the shut-off valve and open Carrier driver
Flow resistance on oil filter or oil coolertoo high
Check the oil filter and oil cooler, clean or renew them Carrier driver
Gas pressure in piston accumulator toohigh
Check the gas pressure in the piston accumulator andrelease some gas if required(see chapterChecking the pressure in the piston accumulator andRelease the pressure from the piston accumulator)
Carrier driver
Working tool jams in the lower breakerpart
Correct the direction of the carrier boom. The pressingforce must act in the axial direction of the hydraulicbreaker.Check the shaft of the working tool and deburr if required.Check the working tool and the wear bush for wear andreplace if required(see chapterChecking the working tool andChecking the wear bushes and impact ring)
Carrier driver
Inside diameter of tank line too small Check the inside diameter and change if requiredObserve the minimum inside diameter!(see chapter Technical specifications)
Workshop
Return pressure too high Check and lower the return pressure Atlas Copco CustomerCenter/Dealer in your area
Hydraulic oil return to the tank via a valvesection
Connect the hydraulic oil return circuit directly to the tankor filter
Carrier driver or Atlas CopcoCustomer Center/Dealer inyour area
Hydraulic oil temperature in the tankhigher than 80 °C
Check the oil level in the hydraulic tank and top up ifrequired
Carrier driver
Hydraulic oil pressure too low Check the pressure; adjust as required; Fit new type-tested pressure relief cartridges where necessary
Workshop
Impact force too low
Cause Remedy ByGas pressure too low Check the gas pressure and fill the piston accumulator
(see chapter Filling/topping up the piston accumulator)Carrier driver
The pump of the hydraulic installationdoes not deliver sufficient oil
Check the pump characteristic with a measuring deviceand compare it to the original details; renew the pump ifrequired
Checking:Atlas Copco CustomerCenter/Dealer in your areaReplacing:by carrier manufacturer’scustomer service
Impact rate too high and impact force too low
Cause Remedy ByNo gas in piston accumulator Check the gas pressure and fill the piston accumulator
(see chapter Filling/topping up the piston accumulator)Carrier driver
O-rings defective Replace O-rings Workshop
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
58 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Oil leaks from ports »P« und »T«
Cause Remedy ByCap nuts loose Check the cap nuts and tighten
(see chapter Bolt connections/Tightening torques)Carrier driver
Hose connection CL to port »P« forContiLube® II or the plug is loose andContiLube® II has not been installed
Check the cap nuts and tightenCheck the plugs and tighten(see chapter Bolt connections/Tightening torques)
Carrier driver
Oil escapes between the cylinder cover and the cylinder
Cause Remedy ByTensioning bolts are loose Check the tensioning bolts and tighten
(see chapter Bolt connections/Tightening torques)Workshop
Seals damaged Replace the seals Workshop
Oil escapes from parts of the hydraulic breaker installation(connecting fittings, hoses etc.)
Cause Remedy ByConnecting fittings are loose; flangeconnections to the valve are loose
Check the connecting fittings and tighten; replace anydefective parts if required(see chapter Bolt connections/Tightening torques)Check the hydraulic breaker installation and replace anydamaged partsOnly use original parts!
Carrier driver or workshop
Oil escapes from the working tool
Cause Remedy ByLower piston seal defective Dismantle the hydraulic breaker
Replace the sealsWorkshop
Oil or grease escapes from the ContiLube® II
Cause Remedy ByConnecting fittings are loose Check the connecting fittings and tighten
(see chapter Bolt connections/Tightening torques)Workshop
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
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59
Operating temperature too high
Cause Remedy ByOil level in tank too low Check the oil level and top up oil Carrier driver or workshop
Carrier pump delivery too high; a constantvolume of oil is squirted out of thepressure relief valve
Check carrier engine speed and lower Carrier driver
Check carrier settings and adjust Atlas Copco CustomerCenter/Dealer in your area
Operation in high outside temperaturewithout oil cooler
Check oil temperature and install an oil cooler if required Workshop or Atlas CopcoCustomer Center/Dealer inyour area
Pressure relief valve defective or valvewith poor characteristic
Fit new type-tested pressure relief cartridges or a moreprecise pressure-limiting valve
Workshop
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
60 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Repair
WARNING Risk of injuryNonprofessional disassembly and assembly of thehydraulic breaker may lead to serious injury andproperty damage.► Never pull the percussion unit out of the
breaker box. Dismounting the percussion unit isonly permitted if carried out by professionalstrained by Construction Tools GmbH. Theseprofessionals must follow all safety instructionsand guidelines for repair.
◆ For technical support contact the Atlas CopcoCustomer Center/Dealer in your area.
Sending in the hydraulicattachment for repairs
NOTICE Mixed hydraulic oil
Never mix mineral and non-mineral hydraulic oils!Even small traces of mineral oil mixed in with non-mineral oil can result in damage to both thehydraulic attachment and the carrier. Non-mineraloil loses its biodegradability.► Only use one type of hydraulic oil.◆ Always specify which hydraulic oil has been
used when sending in the hydraulic attachmentto have it repaired.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
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61
Storage
WARNING Hydraulic breaker / working toolfallThe hydraulic breaker and the working tool areheavy. If they topple over or fall down from wherethey are stored, injury may be the result.► Store the hydraulic breaker and the tool so that
they cannot topple over or fall down.
Hydraulic breaker
The hydraulic breaker must be stored in an uprightposition to avoid its seals being damaged.
Short storageProceed as follows in the case of storage for lessthan eight weeks:◆ Remove the hydraulic breaker from the carrier
(see chapter Removing the hydraulicattachment from the carrier).
◆ Store the hydraulic breaker in a dry, properlyventilated room.
◆ If you can only store the hydraulic breaker inthe open air, cover it with plastic sheeting ortarpaulins to protect it against the weather.
◆ Store the hydraulic breaker in an uprightposition and so that it cannot topple over.
Long storageProceed as follows if storage is expected to be formore than eight weeks:◆ Remove the hydraulic breaker from the carrier
(see chapter Removing the hydraulicattachment from the carrier).
◆ Remove the working tool (see chapter Workingtool/Removal).
◆ Grease the working tool with chisel paste toprevent it corroding.
◆ Grease the wear bushes.◆ Depressurise the piston accumulator (see
chapter Release the pressure from the pistonaccumulator).
◆ Leave the filling hose in the filling valve to letthe gas escape.
NOTICE Environmental damage due to hydraulicoil
Hydraulic oil is environmentally harmful and mustnot penetrate the ground or enter the water tableor water supplies.► Collect any hydraulic oil which escapes.► Dispose of it in accordance with the applicable
environmental regulations.Oil may escape when pushing the percussionpiston up.◆ Remove the covers from the connection hoses.◆ Slide the percussion piston into its upper stroke
position.◆ Slide the percussion piston retainer into the
aperture for the working tool.◆ Install the retainer bar.The percussion piston has now been locked in itsupper stroke position.◆ Remove the filling hose from the filling valve.◆ Seal the connection hoses with the covers.◆ Seal the aperture for the working tool with the
protective cap.◆ Pull the filling hose out of the filling valve.◆ Store the hydraulic breaker in a dry, properly
ventilated room.◆ Store the hydraulic breaker in an upright
position and so that it cannot topple over.◆ Prior to reuse the hydraulic breaker follow the
instructions as described in the chapter Initialoperation and operation after long storage.
How to proceed after more than twelvemonths‘ storage
WARNING Risk of injuryNonprofessional disassembly and assembly of thehydraulic breaker may lead to serious injury andproperty damage.► Never pull the percussion unit out of the
breaker box. Dismounting the percussion unit isonly permitted if carried out by professionalstrained by Construction Tools GmbH. Theseprofessionals must follow all safety instructionsand guidelines for repair.
The following measures are required to preventpremature hydraulic breaker failure, after it hasbeen stored for over twelve months:◆ Contact the Atlas Copco Customer Center/
Dealer in your area.◆ Professionals trained by Construction Tools
GmbH will disassemble the hydraulic breakerproperly and:
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
62 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
• check any parts liable to corrosion(percussion piston, cylinder, control) forcorrosion damage.
• rework or replace corroded parts.• replace all sealing elements.
Working tool
◆ Grease the working tool with chisel paste toprevent it from corroding.
◆ Store the working tool in a dry, properlyventilated room.
◆ Store the working tool so that it cannot toppleover or roll down.
Grease cartridges
WARNING Fire and harmful vaporsChisel paste can burn and cause serious fire.Harmful vapors are generated when chisel paste isburnt.► Never store grease cartridges near fire-
propagating or self-igniting substances.► Do not expose the grease cartridges to direct
sunlight.
◆ Store the grease cartridges in a cool, properlyventilated room.
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
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63
DisposalNOTICE Environmental damage due toconsumables
Hydraulic oil and chisel paste are environmentallyharmful and must not penetrate the ground orenter the water table or water supplies.► Collect any such consumables which may
escape.► Dispose of them in accordance with the
applicable environmental regulations.
Hydraulic breaker
◆ Remove the hydraulic breaker from the carrier(see chapter Removing the hydraulicattachment from the carrier).
◆ Release the gas from the piston accumulator(see chapter Release the pressure from thepiston accumulator).
◆ Remove the working tool (see chapter Workingtool/Removal).
◆ Remove the adapter plate (see chapterRemoving the adapter plate).
◆ Remove the hydraulic hoses from the hydraulicbreaker.
◆ Clean the hydraulic breaker (see chapterCleaning).
◆ Dispose of the hydraulic breaker in line with allapplicable regulations or consult an authorisedand specialised recycling company.
Hydraulic hoses
◆ Drain the hydraulic oil from the hydraulic hosesand collect it.
◆ Dispose of the hydraulic hoses in accordancewith the applicable regulations to avoidenvironmental hazards.
Hydraulic oil
◆ Collect any hydraulic oil that escapes.◆ Dispose of it in accordance with the applicable
environmental regulations.
Chisel paste and greasecartridges
◆ Dispose of chisel paste and not completelyemptied grease cartridges in accordance withthe applicable regulations.
◆ Completely emptied grease cartridges can berecycled.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
64 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
Technical specifications
MB 750/DP, MB 1000/DP
MB 750, MB 750 DP MB 1000, MB 1000 DP
Carrier weight class1) 10 - 17 t22,046 - 37,479 lbs
12 - 21 t26,456 - 46,297 lbs
Service weight2) 750 kg1,654 lbs
1,000 kg2,205 lbs
Delivery weight (Standard version)4) 600 kg1,323 lbs
798 kg1,759 lbs
Delivery weight (DustProtector version)4) 632 kg1,393 lbs
820 kg1,808 lbs
Oil flow rate 80 - 120 l/min21.1 - 31.7 gal/min
85 - 130 l/min22.5 - 34.3 gal/min
Operating pressure 140 - 170 bar2,030 - 2,465 psi
160 - 180 bar2,320 - 2,610 psi
Impact rate 370 - 840 blows/min
AutoControl350 - 750 blows/min
Working tool diameter 100 mm3.94 in.
110 mm4.33 in.
Working length of working tool (Standard version) 550 mm21.65 in.
570 mm22.44 in.
Working length of working tool (DustProtector version) 510 mm20.08 in.
540 mm21.26 in.
Max. hydraulic input power 34 kW 39 kW
Back pressure acceptance8) 30 bar 30 bar
Air pressure (min. gauge pressure in percussion chamber)5) 1.5 bar 1.5 bar
Air flow (up to depth of 10 meters)6) 3 m3/min 3 m3/min
Max static pressure (pressure relief valve on carrier) 190 bar 200 bar
Piston accumulator gas pressure (min, at operating temperature60-70 °C)7)
9.6 bar 6.0 bar
Piston accumulator gas pressure (max (optimum), at operatingtemperature 60-70 °C)7)
11.6 bar 9.0 bar
Hose inside diameter »P« 25 mm1 in.
25 mm1 in.
Hose inside diameter »T« 25 mm1 in.
25 mm1 in.
Start up mode AutoStart AutoStart
Part number (Standard version) 3363 1007 39 3363 0887 85
Part number (DustProtector version) 3363 1046 81 3363 0887 87
1) Weights apply to standard carriers only. Any variances must be agreed with Atlas Copco and/or the carrier manufacturer prior toattachment2) Hydraulic breaker incl. breaker box, working tool and adapter plate of medium size. Please note that the service weight can be considerably higher, depending on the adapter plate.4) Hydraulic breaker, breaker box and ContiLube® II without working tool and adapter plate5) Air pressure at pressure regulator has to be adjusted to 1.5 bar plus 0.1 bar per meter depth6) Air flow for depth of more than 10 meters: Flow = 0.1 x depth [m] x flow up to 10 meters [m3/min]7) Hydraulic breaker in horizontal position, no pressure applied to working tool8) Back pressure acceptance when breaker still runs regular but at significant reduced performance (oil flow)
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
65
Noise declaration statement
MB 750, MB 750 DP MB 1000, MB 1000 DP
Sound pressure 1 dB(A) 88
97*90
Sound power 2 dB(A) 117
127*119
1 Sound pressure level according to EN ISO 3744 in accordance with directive 2000/14/EC at 10 metresdistance.2 Guaranteed sound power according to EN ISO 3744 in accordance with directive 2000/14/EC inclusivespread in production.*High temperature applicationsThese declared values were obtained by laboratory type testing in accordance with the stated directive orstandards and are suitable for comparison with the declared values of other tools tested in accordance withthe same directive or standards. These declared values are not adequate for use in risk assessments andvalues measured in individual work places may be higher. The actual exposure values and risk of harmexperienced by an individual user are unique and depend upon the way the user works, in what material thebreaker is used, as well as upon the exposure time and the physical condition of the user, and the conditionof the breaker.We, Construction Tools GmbH, cannot be held liable for the consequences of using the declared values,instead of values reflecting the actual exposure, in an individual risk assessment in a work place situationover which we have no control.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
66 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
MB 1200/DP, MB 1500/DP
MB 1200, MB 1200 DP MB 1500, MB 1500 DP
Carrier weight class1) 15 - 26 t33,069 - 57,320 lbs
17 - 29 t37,479 - 63,934 lbs
Service weight2) 1,200 kg2,646 lbs
1,500 kg3,307 lbs
Delivery weight (Standard version)4) 948 kg2,090 lbs
1,111 kg2,449 lbs
Delivery weight (DustProtector version)4) 979 kg2,158 lbs
1,148 kg2,531 lbs
Oil flow rate 100 - 140 l/min26.4 - 37.0 gal/min
120 - 155 l/min31.7 - 40.9 gal/min
Operating pressure 160 - 180 bar2,320 - 2,610 psi
160 - 180 bar2,320 - 2,610 psi
Impact rate AutoControl 340 - 680 blows/min
AutoControl330 - 680 blows/min
Working tool diameter 120 mm4.72 in.
135 mm5.32 in.
Working length of working tool (Standard version) 610 mm24.02 in.
630 mm24.80 in.
Working length of working tool (DustProtector version) 585 mm23.03 in.
605 mm23.82 in.
Max. hydraulic input power 42 kW 46 kW
Back pressure acceptance8) 30 bar 30 bar
Air pressure (min. gauge pressure in percussion chamber)5) 1.5 bar 1.5 bar
Air flow (up to depth of 10 meters)6) 3 m3/min 3 m3/min
Max static pressure (pressure relief valve on carrier) 200 bar 200 bar
Piston accumulator gas pressure (min, at operating temperature60-70 °C)7)
11.0 bar 9.8 bar
Piston accumulator gas pressure (max (optimum), at operatingtemperature 60-70 °C)7)
14.1 bar 11.8 bar
Hose inside diameter »P« 25 mm1 in.
25 mm1 in.
Hose inside diameter »T« 25 mm1 in.
25 mm1 in.
Start up mode StartSelect StartSelect
Part number (Standard version) 3363 0904 41 3363 0991 01
Part number (DustProtector version) 3363 0904 43 3363 0991 39
1) Weights apply to standard carriers only. Any variances must be agreed with Atlas Copco and/or the carrier manufacturer prior toattachment2) Hydraulic breaker incl. breaker box, working tool and adapter plate of medium size. Please note that the service weight can be considerably higher, depending on the adapter plate.4) Hydraulic breaker, breaker box and ContiLube® II without working tool and adapter plate5) Air pressure at pressure regulator has to be adjusted to 1.5 bar plus 0.1 bar per meter depth6) Air flow for depth of more than 10 meters: Flow = 0.1 x depth [m] x flow up to 10 meters [m3/min]7) Hydraulic breaker in horizontal position, no pressure applied to working tool8) Back pressure acceptance when breaker still runs regular but at significant reduced performance (oil flow)
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
© Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
67
Noise declaration statement
MB 1200, MB 1200 DP MB 1500, MB 1500 DP
Sound pressure 1 dB(A) 88
95*91
Sound power 2 dB(A) 117
125*120
1 Sound pressure level according to EN ISO 3744 in accordance with directive 2000/14/EC at 10 metresdistance.2 Guaranteed sound power according to EN ISO 3744 in accordance with directive 2000/14/EC inclusivespread in production.*High temperature applicationsThese declared values were obtained by laboratory type testing in accordance with the stated directive orstandards and are suitable for comparison with the declared values of other tools tested in accordance withthe same directive or standards. These declared values are not adequate for use in risk assessments andvalues measured in individual work places may be higher. The actual exposure values and risk of harmexperienced by an individual user are unique and depend upon the way the user works, in what material thebreaker is used, as well as upon the exposure time and the physical condition of the user, and the conditionof the breaker.We, Construction Tools GmbH, cannot be held liable for the consequences of using the declared values,instead of values reflecting the actual exposure, in an individual risk assessment in a work place situationover which we have no control.
Safety and operating instructions MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
68 © Construction Tools GmbH | 3390 5076 01 | 2016-05-13Original instructions
EC Declaration of Conformity (EC Directive 2006/42/EC)We, Construction Tools GmbH, hereby declare that the machines listed below conform to the provisions ofEC Directive 2006/42/EC (Machinery Directive) and 2000/14/EC, ANNEX V (Noise Directive), and theharmonised standards mentioned below.
Hydraulic Breaker Part number Guaranteed soundpower level [dB(A)]
Measured sound powerlevel [dB(A)]
MB 750 3363 1007 39 117 116
MB 750 3363 1119 28 127 125
MB 750 DP 3363 1046 81 117 116
MB 1000 3363 0887 85 119 118
MB 1000 DP 3363 0887 87 119 118
MB 1200 3363 0904 41 117 116
MB 1200 DP 3363 0904 43 117 116
MB 1200 3363 0869 71 125 123
MB 1500 3363 0991 01 120 119
MB 1500 DP 3363 0991 39 120 119
Following harmonised standards were applied:◆ EN ISO 12100◆ EN ISO 3744 Technical Documentation authorised representative:Stephan SchröerConstruction Tools GmbH45143 EssenGermany General Manager:Lothar Sprengnetter Manufacturer:Construction Tools GmbH45143 EssenGermany Place and date:Essen, 2014-04-29
MB 750, 750 DP, 1000, 1000 DP, 1200, 1200 DP, 1500,1500 DP
Safety and operating instructions
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Gm
bH |
3390
507
6 01
| 20
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©
Any unauthorized use or copying of the contents or any part thereof is prohibited. Thisapplies in particular to trademarks, model denominations, part numbers, and drawings.
www.atlascopco.com