LMB 5545 User Manual - Stanley Infrastructure

Original instructions
R
5/17
LaBounty
LMB5545
HYDRAULIC BREAKER
User manual
Part Number: OMLMB5545ENX.517
TABLE OF CONTENTS
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Machine numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Breaker tool greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Carrier hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Routine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower tool bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
59
62
63
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Breaker specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Tool specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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OPERATION1
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FOREWORD
FOREWORD
Important safety information
Basic safety precautions are outlined in the "Safety" section of this manual and in the
description of operations where hazards exist. Warning labels have also been put on
the machine to provide instructions and to identify specific hazards which if not
observed could cause bodily injury or death to you or other persons. These warnings
in the guide and on the machine labels are identified by the warning symbol.
To use the attachment correctly, you must also be a competent operator of the carrier
machine. Do not use or install it if you can not use the carrier machine properly. The
attachment is a powerful tool. If used without proper care, it can cause damage.
Do not rush when you are learning to use the product. Take your time and most
importantly, take it safely. Do not guess. If there is anything you do not understand, ask
your local dealer.
Improper operation, lubrication or maintenance of this machine can be dangerous and
could result in injury.
Do not operate this machine until you have read and understood the instructions in this
manual.
Do not perform any lubrication and maintenance on this machine until you have read
and understood the instructions in this manual.
Warranty
A complete warranty claim for a hydraulic breaker attachment includes at least the
following information.
-
Model and serial number
-
Carrier model
-
Installation: Oil flow, operating pressure and return line pressure if known
-
Working hours and service history
-
Application
Providing this information makes it easy to handle the warranty claim properly and
swiftly.
Installation inspection
An installation inspection must be carried out after the product has been installed on
the carrier. In the installation inspection certain specifications (such as operating
pressure and oil flow) are checked so that they are within given limits. See “Breaker
specifications” on page 70.
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FOREWORD
Spare part orders
When you need spare parts or some information concerning maintenance to your
machinery, please contact your local dealer. Quick deliveries are ensured by exact
orders.
Required information:
1. Name of customer, contact person
2. Order number (when available)
3. Delivery address
4. Mode of delivery
5. Required delivery date
6. Invoicing address
7. Model and serial number of product
8. Name, number and required amount of spare parts
9. Certified LaBounty purchase order
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MACHINE NUMBERS
MACHINE NUMBERS
Model and serial number
The equipment serial number is stamped on the valve body. The model and serial
number are also located on the CE marking. Check that the model corresponds to the
one given on the cover of this manual.
It is important to make correct reference to the serial number of the attachment when
making repairs or ordering spare parts. Identification of the serial number is the only
proper means of maintaining and identifying parts for a specific product.
LaBounty, 1538 Highway 2,
Two Harbors, MN 55616 USA
Hydraulic Hammer
Model:
Serial number:
Hammer weight:
Min. working weight:
Operating pressure:
XXX - XXX bar
Oil flow:
XXX - XXX lpm
XXXXX
XXXXXXXX
XXXXX lb
XXXXX lb
XXX - XXX psi
XXX - XXX gpm
Manufacturing date:
XX / XXXX
Manufacturer:
Sandvik Mining and Construction Oy
Taivalkatu 8, 15170, Finland
LB010004
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PRODUCT INTRODUCTION
PRODUCT INTRODUCTION
Overview
The product is a hydraulically operated hammer. It can be used on any carrier which
meets the necessary hydraulic and mechanical installation requirements. The unit
functions by repeatedly raising a steel piston and driving it down onto the head of a
removable breaking tool.
No additional pressure accumulators are necessary since the integrated pressure
accumulator absorbs hydraulic pressure peaks. The impact energy of the breaker is
almost constant and independent of the carrier's hydraulic system.
Removal from package
Remove all the steel belts from the package. Open the package and remove all plastics
covering the product.
Check that the product is in good condition and that there is no visible damage. Check
that all ordered parts and accessories have been enclosed with the product. Some
options may be provided by your local dealer like installation kits; including hoses and
mounting bracket.
Lifting instructions
Use a hoist when lifting components which weigh 23 kg (50 lb) or more, to avoid back
injury. Make sure all lifting equipment is in good condition and are in the correct
capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded
during a lifting operation. Do not use the breaker's tools for lifting.
Provided lifting points
Use the lifting eyes located on the product housing only to lift or handle the product
itself. The lifting capacity calculation is based on the product's working weight including
a normal working tool and an average sized mounting bracket.
Warning! To avoid falling objects, do not use the product to lift other products.
Use the lifting eyes located on the product housing only to lift or handle the
product itself.
The maximum allowed total weight is shown on the product's CE-plate and
specification page. See “Breaker specifications” on page 70. If the weight exceeds the
maximum allowed total weight shown on the CE-plate and specification page, you have
to use other lifting points/methods than originally provided on the product.
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PRODUCT INTRODUCTION
The other threaded holes on the product (for example on the breaker impact unit) are
intended for handling single parts only. It is forbidden to lift the entire assembly by using
these threaded holes (for example on the cylinder outer surfaces). For handling the
parts, see product workshop documentation for suitable lifting methods and lifting
adapters.
Lifting eye screws
Tighten the lifting eye screws completely. Put a burden on the lifting eye only if the
screw is properly tightened to the housing.
Failure to properly tighten the screw before allowing load pressure on the lifting
eye may cause lifting eye to break and free fall of the product.
If you use mechanical tools for tightening, make sure not to overstrain the shank.
Before lifting make sure that the chain and/or hook is stretched.
When two lifting eye screws are used, the lifting capacity depends on the angle of the
lifting chains. The angle should not be less than 45°, as shown in the illustration. When
the lifting eye screws are tightened, both rings should be aligned.
The loading capacity calculation applies to temperatures between -10 °C (14 °F) and
40 °C (104 °F).
Before reuse of lifting eye screws make sure there are no surface flaws (for example
rust, pits, voids, folds and seams, deformation of the ring, or missing or broken
threads).
The local, national safety standards for machines and lifting-equipments must always
be strictly observed.
Note: Before starting to operate the breaker, always replace the lifting eye with a
blanking screw.
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PRODUCT INTRODUCTION
R010266
Lifting devices must safely carry the working weight of the product. See “Breaker
specifications” on page 70. Place chains or slings, as shown by the illustration, to lift
the product.
LB010008
Note: Before starting to operate the breaker, always replace the lifting eye with a
blanking screw.
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PRODUCT INTRODUCTION
Safety instructions for lifting
Below are some common safety instructions concerning lifting operations. In addition
to this, the local, national standards for machines and lifting-equipments must always
be strictly observed. Please note that the list below is not all inclusive, you must always
ensure the procedure you choose is safe for you and others.
● Do not lift load over people. No one shall be under the hoisted load.
● Do not lift people and never ride the hoisted load.
● Keep people clear from lift area.
● Avoid side pull of the load. Make sure you take up the slack slowly. Start and stop
carefully.
● Lift the load a few inches and verify it before proceeding. Make sure the load is well
balanced. Check for any loose items.
● Never leave the suspended load unattended. Maintain load control at all times.
● Never lift the load over the rated capacity (see product's operating weight from
specification page).
● Inspect all lifting equipment before use. Do not use twisted or damaged lifting
equipment. Protect lifting equipment from sharp corners.
● Obey all local safety instructions.
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PRODUCT INTRODUCTION
Main parts
The main parts of the breaker are shown below.
B
E
C
H
F
D
H
A
G
I
C010321
A. Housing
B. Mounting flange
C. Vibration dampening elements
D. Hose connections (pressure and return lines)
E. Pressure accumulator
F. Greasing device
G. Tool retaining mechanism
H. Grease zerk
I.
Wear plates
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PRODUCT INTRODUCTION
Greasing device
The breaker can be equipped with an automatic greasing device. The tool grease is
supplied from the greasing device into the breaker by the grease lines.
Advantages of the automatic lubrication system are:
● Longer service life for wear parts
● Higher utilization rate of the breaker
● Possibility to grease manually
● Reduced grease waste
Note: Some breaker models are equipped with an adapter kit for manual greasing and
do not include an automatic greasing device.
Service indicator
The SDC service indicator system is designed to help the breaker operators and
service personnel in getting information about the service interval status, service
history and accumulated working history of a breaker. Therefore the breaker serial
number is always needed to complete service operations on the SDC device.
SDC device
LB010010
Possible operations with the SDC service indicator
● Checking the service interval status
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SAFETY
SAFETY
General safety
All mechanical equipment can be hazardous if operated without due care or correct
maintenance. Most accidents involving machine operation and maintenance are
caused by failure to observe basic safety rules or precautions. An accident can often
be avoided by recognizing potentially hazardous situations before an accident occurs.
Because it is impossible to anticipate every possible circumstance that might involve a
potential hazard, the warnings in this guide and on the machine are not all inclusive. If
a procedure, tool, working method or operating technique not specifically
recommended by manufacturer is used, you must satisfy yourself that it is safe for you
and others. You should also ensure that the product will not be damaged or made
unsafe by the method of operation or maintenance procedures you choose.
Safety is not just a matter of responding to the warnings. All the time you are working
with your attachment you must pay attention to what hazards there might be and how
to avoid them. Do not work with the product until you are sure that you control it. Do not
start any job until you are sure that you and those around you will be safe.
Warning! Read the following warning messages carefully. They tell you of
different hazards and how to avoid them. If proper precautions are not taken you
or others could be seriously injured.
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SAFETY
Safety instructions
Manuals
Study this manual before installing, operating or maintaining the product. If there is
anything you don't understand, ask your employer or your local dealer to explain it.
Keep this manual clean and in good condition.
The related safety label on the breaker and the text on the label are shown below.
"IGNORING INSTRUCTIONS HAZARD
Faulty handling practice could cause death or serious injury.
Read and follow the instructions in the operator's manual."
WARNING
IGNORING
INSTRUCTIONS HAZARD
Faulty handling practice could
cause death or severe injury.
Read and follow the
instructions in the operator’s
manual.
169400_ENG-3
R010354
Care and alertness
All the time you are working with the product, take care and stay alert. Always be alert
for hazards. The possibility of a serious or even fatal accident is increased when you
are intoxicated.
Personal Protective Equipment
You can be injured if you do not wear proper Personal Protective Equipment (PPE).
Loose clothing can get caught in the machinery. Wear PPE to suit the job.
Examples are: a safety helmet, safety shoes, safety glasses, well-fitting clothing, earprotectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf.
Keep long hair restrained.
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SAFETY
Practice
You and others can be killed or injured if you perform unfamiliar operations without
practising them first. Practice away from the job site, in a clear area.
Keep other people away. Do not perform new operations until you are sure you can do
them safely.
Regulations and laws
Obey all laws, work site and local regulations which affect you and your equipment.
Communications
Bad communications can cause accidents. Keep people around you informed of what
you will be doing. If you will be working with other people make sure they understand
any hand signals you will be using.
Work sites can be noisy. Do not rely only on spoken commands.
Work site
Work sites can be hazardous. Inspect the site before working on it.
Check for potholes, weak ground, hidden rocks and other possible hazards on the
ground. Check for utilities (such as electric cables, gas and water pipes). Mark the
positions of underground cables and pipes if you will be breaking the ground.
Poor visibility can cause accidents and damage. Make sure that visibility and lighting
of the working area are adequate.
Banks and trenches
Banked material and trenches can collapse. Do not work too close to banks and
trenches where there is a danger of collapse.
Safety barriers
Unguarded equipment in public places can be dangerous. Place barriers around the
machine to keep people away.
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SAFETY
Airborne pollutants
The related safety label on the breaker and the text on the label are shown below.
"DUST HAZARD
Breathing dust will cause death or severe injury.
Always wear approved respirator."
DANGER
DUST HAZARD
Breathing dust will cause death
or severe injury.
Always wear approved
respirator.
169400_ENG-1
R010356
Airborne pollutants are microscopic particles, which will damage your health, when
inhaled. Airborne pollutants on construction sites can be, for example, silica dust, oil
fumes or diesel exhaust particles, visible or invisible. Especially in demolition sites,
there may be other dangerous substances, such as asbestos or lead paints or other
chemical substances.
The effect of airborne pollutants may be immediate if the substance is poisonous. The
main danger with airborne pollutants comes from long term exposure, where particles
are inhaled but not removed from the lungs. The disease is called silicosis, asbestosis
or other, and will result in death or serious injury.
To protect yourself from airborne pollutants, always keep excavator doors and windows
closed during operation. Excavators with pressurized cabins should be utilized in
breaker operation. Proper maintenance of fresh air filters of the excavator is essential.
Where pressurized cabins are not available, proper respirators must be utilized.
Stop working, when bystanders are in the area of airborne pollutants and make sure
they have proper respirators. Respirators are as important for bystanders as hard hats.
Respirators for both operator and bystanders must be approved by the respirator
manufacturer for the application in question. It is essential that the respirators protect
from the tiny dust particles which cause silicosis and which may cause other serious
lung diseases. You should not use the equipment until you are sure the respirators are
working properly. This means the respirators must be checked to make sure that it is
clean, that its filter has been changed, and to otherwise make sure the respirator will
protect in the way it is meant to.
Always make sure dust has been cleaned off your boots and clothes when you leave
your shift. The smallest particles of dust are the most harmful. They may be so fine that
you can not see them. Remember, you MUST protect yourself and bystanders from the
danger of breathing or inhaling dust.
Always follow local laws and regulations for airborne pollutants in the working
environment.
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SAFETY
Flying chips of rock
The safety label on the breaker is shown below:
"FLYING OBJECTS HAZARD
Fragments fly up to 40 m (130 ft) and could cause death or serious injury.
Stop operation when a person enters hazard zone.
Wear approved personal protective equipment."
WARNING
FLYING OBJECTS
HAZARD
Fragments fly up to 40 m
(130 ft) and could cause death
or severe injury.
Stop operation when a person
enters hazard zone.
Wear approved personal
protective equipment.
169400_ENG-2
R010355
Protect yourself and your neighbourhood against flying chips of rock. Do not operate
the product or carrier if someone is too close.
The ISO standard 20474-1 on safety of earth-moving machinery requires that adequate
operator's protection, such as impact-resistant material, a mesh guard or an equivalent
protection is used.
Keep the cabin windows and doors closed during operation. Window bars are
recommended to protect the windows from flying chips of rock.
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SAFETY
High noise level
A breaker in operation creates a high noise level. Always wear ear protection to prevent
personal injury.
The safety label on the breaker is shown below:
"NOISE HAZARD
Continuous exposure to noise above 80 dB(A) will cause hearing impairment.
Wear approved hearing protectors."
WARNING
NOISE HAZARD
Continuous exposure to noise
above 80 dB(A) could cause
hearing impairment.
Wear approved hearing
protectors.
169400_ENG-4
R010353
Equipment limits
Operating the product beyond its design limits can cause damage. It can also be
dangerous. See “Breaker specifications” on page 70.
Do not try to enhance the product's performance by unapproved modifications.
Hydraulic fluid
Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your
fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks.
Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for
signs of hydraulic fluid. If hydraulic fluid penetrates your skin seek medical attention
immediately.
Hot hydraulic fluid can cause severe injuries.
Hydraulic hoses and fittings
Ensure all hydraulic components will withstand maximum pressure and mechanical
stresses caused by operation of the attachment. Consult your local dealer for
instructions.
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SAFETY
Fire hazard
Most hydraulic fluids are flammable and might ignite when contacting hot surface.
Avoid spilling hydraulic fluid to hot surfaces.
Working with the product on certain materials can cause sparks and hot splinters to get
loose. These can ignite flammable materials around working area.
Ensure that adequate extinguisher is available.
Hydraulic pressure
Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting
hydraulic hoses, stop the carrier engine, operate the controls to release pressure
trapped in the hoses and wait ten (10) minutes. During the operation, keep people
away from the hydraulic hoses.
There might be pressurized oil trapped inside the product even if it is disconnected from
the carrier. Be aware of possible blank firing while greasing or removing and installing
breaker tools. See “Changing the tool” on page 59.
Pressure accumulators
The safety label on or near the accumulator is shown below.
"HIGH PRESSURE HAZARD
Improper handling of pressurized accumulator will cause death or severe injury.
Read workshop manual before disassembly.
Release pressure before disassembly.
Recharge with nitrogen (N2) only."
DANGER
HIGH PRESSURE HAZARD
Improper handling of pressurized
accumulator will cause death or
severe injury.
Read workshop manual before
disassembly.
Release pressure before
disassembly.
Recharge with nitrogen (N2) only.
169410_ENG-5
R010352
The breaker incorporates one or two pressure accumulators, depending on the model.
The accumulators are pressurized even when there is no hydraulic pressure to the
breaker. Attempting to dismantle the accumulators without first releasing the pressure
can cause injury or death. Do not try to dismantle pressure accumulators, contact your
local dealer first.
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SAFETY
Lifting equipment
You can be injured if you use faulty lifting equipment. Make sure that lifting equipment
is in good condition. Make sure that the lifting equipment complies with all local
regulations and is suitable for the job. Make sure that the lifting equipment is strong
enough for the job and that you know how to use it.
Do not use this product or any of its parts for lifting. See “Lifting instructions” on page
7. Contact your carrier dealer to find out how to lift with your carrier.
Spare parts
Use only genuine spare parts. Use only genuine tools with hydraulic breakers. The use
of other spare part or breaker tool brands may damage the product.
The use of other spare part or breaker tool brands may also void the warranty.
Equipment condition
Defective equipment can injure you or others. Do not operate equipment which is
defective or has missing parts.
Make sure the maintenance procedures in this manual are completed before using the
product.
Repairs and maintenance
Do not try to do repairs or any other maintenance work you do not understand.
Modifications and welding
Non-approved modifications can cause injury and damage. Contact your local dealer
for advice before modifying the product. Before welding on the product while it is
installed on the carrier, disconnect the carrier alternator and battery. Note that welding
of the breaker tools will render them useless and make the warranty void.
Metal splinters
You can be injured by flying splinters when driving metal pins in and out. Use a softfaced hammer or drifts to remove and fit metal pins, such as pivot pins. Always wear
safety glasses.
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SAFETY
Labels on the Product
Safety labels communicate the following four things:
● The severity level of the risk (that is, signal word "DANGER" or "WARNING").
● The nature of the hazard (such as high pressure, or dust).
● The consequence of interaction with the hazard.
● How to avoid the hazard.
You must ALWAYS follow the instructions of the safety messages and symbols of the
product safety labels and the instructions set forth in the manuals to avoid death or
severe injury!
Keep the safety labels clean and visible at all times. Check the condition of safety labels
daily. Safety labels and instructions which have disappeared, been damaged, painted
over, come loose or do not meet the legibility requirements for safe viewing distance,
must be replaced before operating the product.
If a safety label is attached to a part that is replaced, install a new safety label on the
replacement part. If this manual is available in your language, then the safety labels
should be available in the same language.
There are several specific safety labels on this breaker. Please become familiarized
with all safety labels. The location of the safety labels is shown in the illustration below.
When you clean the safety labels, use a cloth, water and soap. Do not use solvent,
gasoline or other harsh chemicals to clean the safety labels.
Solvents, gasoline or harsh chemicals could loosen the adhesive that secures the
safety labels. Loose adhesive will allow the safety label to fall.
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SAFETY
WARNING
IGNORING
INSTRUCTIONS HAZARD
Faulty handling practice could
cause death or severe injury.
Read and follow the
instructions in the operator’s
manual.
169400_ENG-3
DANGER
DUST HAZARD
Breathing dust will cause death
or severe injury.
Always wear approved
respirator.
169400_ENG-1
WARNING
FLYING OBJECTS
HAZARD
Fragments fly up to 40 m
(130 ft) and could cause death
or severe injury.
Stop operation when a person
enters hazard zone.
Wear approved personal
protective equipment.
169400_ENG-2
WARNING
NOISE HAZARD
Continuous exposure to noise
above 80 dB(A) could cause
hearing impairment.
Wear approved hearing
protectors.
169400_ENG-4
San
d v i k 168 9 0 7
DANGER
HIGH PRESSURE HAZARD
Improper handling of pressurized
accumulator will cause death or
severe injury.
Read workshop manual before
disassembly.
Release pressure before
disassembly.
Recharge with nitrogen (N2) only.
169410_ENG-5
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R010407
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OPERATION
OPERATION
Operating instructions
Recommended use
The hammer is designed to be used in breaking oversized boulders, demolishing
heavily reinforced concrete structures and for major heavy excavation and clearing
work. It can be also used for primary breaking, tunnelling and removal of metallurgical
slag. Your local dealer will gladly give you more information.
Operating conditions
Principle of installation
Almost all carriers meeting mechanical and hydraulic requirements can be used to
operate the attachment. See “Breaker specifications” on page 70. The product is
installed on the carrier much in the same manner as installing a bucket or other
attachments. A flange mounted attachment requires a separate mounting bracket.
The attachment is connected to a carrier's hydraulic circuit with an installation kit. If the
carrier is already equipped with an installation kit, the installation requires only suitable
hoses and fittings. If the carrier does not have suitable kit to run the attachment, one
must be built. This may require more complex installation including new piping and
additional valves such as directional valve and pressure relief valve.
Suitable kits can be ordered from the manufacturer or local dealers, from carrier
manufacturers and their dealers or from third party suppliers.
Hydraulic oil
In general the hydraulic oil originally intended for the carrier can be used with this
product. See “Requirements for hydraulic oil” on page 50.
Operating temperature
The operating temperature is -20 °C (-4 °F) to 80 °C (176 °F). If the temperature is
lower than -20 °C (-4 °F), the breaker and tool have to be preheated before any
operations can begin, in order to avoid breaking the accumulator's membrane and the
tool. During operation they will remain warm. See “Preheating the hammer” on page
27.
Note: The temperature of the hydraulic oil must be monitored. Ensure that oil grade and
monitored oil temperature together guarantee correct oil viscosity. See “Oil
specifications” on page 51.
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OPERATION
Noise dampening
Operating the breaker near residential areas or other noise sensitive areas can cause
noise pollution. In order to avoid unnecessary noise, please follow these basic rules:
1. When operating the breaker, keep the tool at a 90 degree angle to the material and
the feed force in-line with the tool.
2. Replace or fix all parts that are worn out, damaged or loosened. This not only saves
your breaker but it also decreases the noise level.
Principles of breaking
To increase the breaker's working life, pay particular attention to correct working
methods and how to choose the correct tool for the job. There are essentially two ways
of breaking with a hydraulic breaker.
Penetrative breaking (or cutting)
In this form of breaking a moil point or chisel tool is forced inside the material. This
method is most effective in soft, layered or plastic, low abrasive material. The high
impact rate of the small breakers makes them ideal for penetrative breaking.
Impact breaking
With impact breaking, the material is broken by transferring very strong mechanical
stress waves from the tool into the material. Impact breaking is most effective in hard,
brittle and very abrasive materials. The high impact energy of the big breakers makes
them ideal for impact breaking. The best possible energy transfer between the tool and
the object is achieved with a blunt tool. The use of a chisel tool in hard material will
cause the sharp edge to wear very quickly.
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OPERATION
Choosing tools
Chisel, moil point and pyramid
● For sedimentary (e.g. sandstone) and weak metamorphic rock into which the tool
penetrates.
● Concrete.
● Trenching and benching.
Blunt tool
● For igneous (e.g. granite) and tough metamorphic rock (e.g. gneiss) into which the
tool doesn't penetrate.
● Concrete.
● Breaking boulders.
It is important to choose a tool, which is suitable for your breaker and for the application
you are working on. The tool selection available depend on breaker model. See “Tool
specifications” on page 72.
Idle selector
The hammer includes idle stroke preventing system as a standard feature. Frequent
idle strokes have a deteriorating effect on the breaker. Idle stroke preventing system
can be turned ON or OFF by the operator.
Idle selector can be used to warm up the hammer and oil before operation. See
“Operating conditions” on page 23. See “Requirements for hydraulic oil” on page 50.
Idle selector ON (factory setting)
It is recommended to keep the mechanism turned ON in normal breaker work. In ONposition the idle stroke prevention system is activated and it prevents idle strokes. See
illustration 1. Note that the hammer can be started only after feeding the tool against
object.
1.
ON
R010304
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OPERATION
Idle selector OFF
Idle selector can be turned OFF when breaking very soft material or in demolition
application where it is difficult to apply enough feeding force. See illustration 2.
2.
OFF
R010305
Turning idle selector on and off
1. Remove shield plate.
2. Turn the screw clockwise (to ON-position) or counter-clockwise (to OFF-position)
as shown in illustration below.
OFF
ON
R010303
3. Insert shield plate.
Note: Idle selector has only two positions, ON and OFF. Do not apply any other
positions in between.
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OPERATION
Preheating the hammer
If the ambient temperature is lower than 0 °C (32 °F), it is recommended to preheat the
hammer according to the instructions below.
1. Ensure that the idle selector is turned ON.
2. Lift the breaker off the ground.
R010175
3. Press the breaker operating switch and drive oil through the hammer for a couple
of minutes.
Stroke selector valve
Long piston stroke mode (factory setting)
Long piston stroke mode gives the hammer high impact energy. Use long stroke mode
when breaking hard rock (impact breaking). See illustration 1.
1.
LONG
R010306
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OPERATION
Short piston stroke mode
Short piston stroke mode gives the hammer high impact rate. Use short stroke mode
when breaking concrete or soft rock (penetrative breaking). See illustration 2.
2.
SHORT
R010307
Note: Stroke selector has only two positions, long and short piston stroke mode. Do not
apply any other positions in between.
Selecting long and short stroke mode
1. Remove shield plate.
2. Turn the screw clockwise (to short stroke mode) or counter-clockwise (to long
stroke mode) as shown in illustration below.
LONG
SHORT
R010308
3. Insert shield plate.
Note: Stroke selector has only two positions, short stroke and long stroke. Do not apply
any other positions in between.
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OPERATION
Checking the service interval status
You can check the service interval status by firmly tapping the sensor three (3) times
in 1- to 3-second intervals. If the pulse is not timed correctly, you need to wait five
seconds before trying again.
Tap
(1 s)
Tap
(1 s)
Tap
R010381
One (1) flash
Indicates that the breaker is operating at 0-25% of the service interval.
Two (2) flashes
Indicates that the breaker is operating at 25-50% of the service interval.
Three (3) flashes
Indicates that the breaker is operating at 50-75% of the service interval.
Four (4) flashes
Indicates that the breaker is operating at 75-100% of the service interval.
Five (5) flashes
Indicates that the service interval of the breaker is completed and the
breaker must be serviced.
The sensor repeats the signal about every 20 seconds for the next four minutes. The
status of the service interval should be checked weekly. It is also recommended that
you keep a log of the status of the LED display.
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OPERATION
Daily operation
General guidelines
30
-
A safety screen is recommended to protect the operator from flying debris. Keep
the cabin windows and doors closed during operation.
-
Keep the tool at a 90 degree angle at all times. If the object moves or its surface
breaks, correct the angle immediately. Keep the feed force and tool aligned.
-
Keep the tool shank well greased during operation. Regular visual inspections
during operation are recommended. An unlubricated tool shank requires more
frequent greasing intervals. A tool shank covered with excessive grease requires
less frequent greasing intervals.
-
To use the breaker most efficiently when breaking large objects, concentrate on
small steps from the outer edge towards the middle.
User manual LMB5545
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OPERATION
-
Do not strike in one spot for more than 15 seconds at a time. If the object does not
break, or if the tool does not penetrate, stop the breaker and change the position of
the tool. Working too long in one spot will create stone dust under the tool. Dust
dampens the impact effect and produces heat.
-
Listen to the breaker's sound when you are using it. If the sound becomes weaker
and the impact less efficient, the tool is misaligned with the material and/or there is
not enough down force on the tool. Realign the tool and press the tool firmly against
the material.
-
Do not let the tool move outwards from the breaker when it penetrates. Keep the
down-pressure on the breaker while breaking.
-
When demolishing vertical structures (such as brick walls), place the tool against
the wall at a 90 degree angle.
-
When breaking concrete, hard or frozen ground, never strike and pry with the tool
at the same time. The tool may break. Bending may be caused by stones inside
hard or frozen ground. Be careful and stop striking if you find sudden resistance
under the tool.
-
When breaking hard or frozen ground, use the benching method. Start with clearing
a small area from the edge. Then continue by breaking material towards the open
area.
-
Do not use the breaker tools to move rocks. The stone claws are designed for this
purposes.
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OPERATION
32
-
Do not use the breaker to sweep the ground of debris. This may damage the
breaker and the housing will wear out more quickly.
-
When operating the breaker, make sure that it does not make contact with the
carrier boom or hydraulic lines.
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OPERATION
-
Do not operate the breaker with the carrier's boom, stick or bucket cylinders at the
end of their stroke (either fully extended or fully retracted). Damage to the carrier
may result.
-
Do not use the breaker or breaker tools for lifting. Lifting eyes on the breaker are
for storage and maintenance purposes only.
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OPERATION
Working procedure
Warning! Protect yourself and your neighbourhood against flying chips of rock.
Do not operate the breaker or carrier if someone is too close to the breaker.
Do not use the breaker, as a standard assembly, under water. If water fills the
space where the piston strikes the tool, this generates a strong pressure wave
that may damage the breaker.
Warning! To avoid falling objects, do not use the product to lift other products.
The lifting eyes located on the product housing are to be used solely to lift or
handle the product itself. See “Lifting instructions” on page 7.
1. Prepare the carrier for normal excavation work. Move the carrier to the required
position. Set the drive to neutral.
2. Set the engine speed to the recommended engine RPM for correct amount of oil
supply.
3. Carefully operate the carrier controls to place the breaker and boom into the
breaking position. Quick and careless boom movements can result in damage to
the breaker.
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OPERATION
4. Use the excavator boom to press the breaker firmly against the object. Do not pry
the breaker with the boom. Do not press too hard or too gently with the boom. The
correct force is applied, when the tracks start to lift slightly from the ground.
5. Place the tool against the object at a 90 degree angle. Avoid small irregularities on
the object which will break easily and cause either idle strokes or an incorrect
working angle.
6. Start the breaker.
7. Stop the breaker quickly. Do not allow the breaker to fall down and make idle
strokes when an object breaks. Frequent idle strokes have a deteriorating effect on
the breaker. If the breaker falls through, the housing wears out more quickly.
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OPERATION
Mounting and dismounting the breaker
Removal from carrier
Warning! The breaker must be secured from rolling over when disconnecting
from the carrier. Only use a skilled operator to position the carrier for breaker
removal!
Warning! Hydraulic pressure inside the breaker must always be released before
opening hose connections!
Warning! Hot hydraulic fluid can cause severe injuries!
1. Position hammer horizontally on the floor. If the breaker is going to service, remove
the tool.
2. Stop the carrier engine. Operate boom and breaker controls to release pressure
trapped inside hoses. Wait ten minutes for oil pressure to drop.
3. Close hammer inlet and outlet lines. If quick couplers are used, disconnection
automatically closes breaker lines. If breaker line includes ball valves, please make
sure that they are closed.
4. Disconnect hoses. NOTICE! Protect environment from oil spills. Plug the hoses
and the breaker inlet and outlet ports to keep dirt out from hydraulic circuit.
5. Remove bucket pins and other parts.
6. The carrier can be moved aside.
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OPERATION
Installation
1. Install breaker in the same manner as mounting a bucket. Install bucket pins.
2. Connect hoses. Breaker inlet port is marked on the valve body with "IN" and outlet
port with "OUT". An installation inspection must be carried out after the product has
been mounted on the carrier. In the installation inspection certain specifications
(such as operating pressure, oil flow) are checked so that they are within given
limits. See “Breaker specifications” on page 70.
3. Open hammer inlet and outlet lines.
Turning breaker left- or right-handed
It is possible to make the breaker either left- or right-handed by turning the breaker
inside the housing180 degrees.
Warning! The hydraulic pressure inside the breaker must always be released
before removing any of the plugs or valves. Read the instructions on releasing
the hydraulic pressure from the breaker.
Warning! Hot hydraulic fluid can cause severe injuries!
Warning! The breaker must be secured from falling down in either direction when
handling it. Check that the lifting capacity of the hoist you are using is sufficient
for the job. See “Lifting instructions” on page 7. See “Breaker specifications” on
page 70.
1. Remove the tool and disconnect the breaker from the carrier.
2. Remove cover out of way.
3. Disconnect hose couplings from breaker.
R010329
4. Open mounting bracket screws.
5. Lift mounting bracket off.
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OPERATION
6. Remove buffer.
R010330
7. Disconnect grease hose and pressure hose from breaker.
R010332
8. Install two lifting eyes. Lift breaker out of housing.
9. Turn breaker around 180 degrees.
R010331
10. Check that wear plates are in correct positions.
11. Lower breaker into housing.
12. Connect grease hose and pressure hose to breaker.
13. Install buffer and mounting bracket.
14. Connect hose couplings to breaker.
15. Install cover.
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OPERATION
Movement
The transportation and parking positions are shown below. When moving with the
breaker, ensure that it isn't too close and doesn't point at the cabin window.
Special conditions of use
Special conditions of use are conditions in which the breaker is used for some work
other than normal breaking or demolition, such as:
● Hammer tunneling
● Foundry cleaning
● Underwater operations
● Operations in extremely low or high temperatures
● Use of special hydraulic fluids
● Breaker operations with a special carrier (e.g., an extra long boom)
● Other special conditions
Special conditions of use may require modifications to the attachment, special
operating techniques, increased maintenance or special wear items. If you are
planning to use the breaker under a special condition of use, please consult your local
dealer and/or LaBounty service department for instructions.
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OPERATION
Underwater operation
Use environmental friendly oil and tool grease when you are using the breaker
under water.
Warning! If you are using the breaker under water, protect yourself and your
surroundings against compressed water/air spray and possible broken
compressed air hoses.
Warning! If you are using the breaker under water, check the stability of the
carrier and the breaker. Water gets inside the breaker, causing it to weigh more.
Due to the added water weight, lift the breaker carefully out of the water.
The breaker as a standard assembly, must not be used under water. If water fills
the space where the piston strikes the tool, a strong pressure wave is generated
and the breaker may be damaged.
The wear resistance of the breaker parts is considerably lower under water than in
normal use. This is caused by corrosion and by the abrasive effect of mud in water.
After starting underwater breaking, the breaker must be inspected regularly, for
example after every half hour operation. Adapt the inspection intervals to the working
conditions. See “Maintenance intervals in underwater use” on page 58.
In underwater applications, the productivity of a hydraulic breaker is considerably lower
than in normal work. This is caused by:
1. The breaking object is not visible to the operator. This causes misalignment
between the tool and the object and unnecessary idle strokes.
2. The breaker must be inspected and greased more often than in normal situations.
3. The breaker must always be completely serviced after working on
underwater job sites.
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OPERATION
Storage
Long term storage
Observe the following points when the breaker is stored. In this way the vital parts of
the attachment are protected from rust and the machine is ready to be used whenever
necessary.
1. The storage area must be dry.
2. The tool must be removed in hydraulic breakers.
3. The lower end of the piston, tool and tool bushings must be well protected with
grease in all hydraulic breakers.
4. Connections must be sealed with clean plugs to prevent oil leakage and dirt from
getting into couplings.
5. The product must be stored in the vertical position.
6. Make sure the product cannot fall.
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OPERATION
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LUBRICATION2
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BREAKER TOOL GREASING
BREAKER TOOL GREASING
Recommended greases
● No dropping point or very high, over 250 °C (480 °F).
● Maximum service temperature at least 150 °C (300 °F).
● Minimum working temperature below lowest ambient temperature.
● Additives: molybdenum disulfide (MoS2), graphite or equivalent.
● Penetration 0 ... 2 (NLGI).
● No reaction with hydraulic oils.
● Water resistant.
● Good adhesion with steel.
Automatic greasing
● GREASE CARTRIDGE, part no. 77726
Wear gloves when handling the grease containers. If you get grease onto your
skin, wash it away with water.
R020112
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BREAKER TOOL GREASING
Automatic greasing
Dispose of empty grease containers appropriately.
The breaker can be equipped with an automatic greasing device. See “Greasing
device” on page 12.
Do not remove the grease cartridge unnecessarily. Always keep the grease cartridge
in the greasing device to prevent dirt from entering the greasing device.
Note: Some breaker models are equipped with an adapter kit for manual greasing and
do not include an automatic greasing device.
Replacing the grease cartridge
200 mm
Measure the distance from the top of the grease cartridge. Replace the grease
cartridge if the distance is more than 200 mm (7.87 in). The grease cartridge is empty
and has to be replaced when the distance is 210 mm (8.27 in).
R020105
1. Unscrew and remove the grease cartridge.
2. Dispose the used cartridge appropriately. Note: The grease cartridge is disposable;
it can not be refilled.
3. Check and clean the grease cartridge seat in the cartridge holder. Remove the old
grease cartridge seal.
4. Remove the protective cap from the new cartridge.
R020110
5. Check the grease cartridge seal.
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BREAKER TOOL GREASING
6. Push the cartridge piston with fingers until approximately 15 mm of grease comes
out.
7. Insert the cartridge and tighten it.
R020111
Adjusting the dose
Note: Some breaker models are equipped with an adapter kit for manual greasing and
do not include an automatic greasing device.
A
H
H
F
G
D
E
B
C
R020126
A. Grease hose to upper tool bushing
B. Grease hose to lower tool bushing
C. Pressure hose
D. Grease zerk for manual greasing to upper tool bushing
E. Grease zerk for manual greasing to lower tool bushing
F. Adjusting screw for grease dosage to upper tool bushing
G. Adjusting screw for grease dosage to lower tool bushing
H. Locking nut for the adjusting screw
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BREAKER TOOL GREASING
Adjusting the dose
Please note that the actual amount of grease needed for proper lubrication varies
according to:
● breaker size
● application: the amount of grease depends on the number of working cycles within
a given time. In practice this means that, in an application where the working cycles
are short but the quantity is high, a smaller dose can be used.
● wear rate of the tool shank and bushing
● condition of the tool seal
● operators working techniques
● grease quality
1. Turn the locking plate and plug aside.
R020121
2. Open the locking nut.
R020123
3. Turn the adjusting screw for grease dosage clockwise to close it completely.
R020124
4. Next open the adjusting screw for grease dosage by turning it counter-clockwise as
needed. See table below.
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BREAKER TOOL GREASING
5. Tighten the locking nut to the specified torque setting. See table below.
6. Turn the locking plate and plug to the correct positions.
Item
Specification/Torque
Shield screws
175 Nm (129 lbf ft)
Adjusting screw locking nut
50 Nm (37 lbf ft)
Adjusting range
Linear 0 ... 7 turns (7 mm)
Basic adjustment
4 turns open / means 0.25 g grease/
impact period
1-turn adjustment
0.053 g grease/impact period
Manual greasing
Follow the product's greasing instructions and avoid excessive greasing.
Dispose of empty grease containers appropriately.
Manual greasing is always possible even if the breaker is equipped with the automatic
greasing device. Manual greasing is necessary if there is no grease available for the
greasing device, greasing device has malfunction or pressure hose is damaged. Check
also the grease hose conditions inside the housing.
Greasing interval
1. Tool shank must be well lubricated before installing tool.
2. 5-10 strokes from grease gun to tool bushings and tool at regular intervals.
Insufficient greasing or improper grease may cause:
● Abnormal wear of tool bushing and tool
● Tool breakage
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BREAKER TOOL GREASING
Correct greasing
1. Position the breaker standing upright resting on the tool on firm surface.
2. Stop carrier engine and wait 10 minutes for oil pressure to drop inside breaker.
3. Apply tool grease from grease gun to greasing points marked with the following
sticker.
Note: The breaker must stand upright resting on the tool to ensure that the grease will
penetrate downwards between the tool and the bushing.
Do not fill the space between the piston and the tool with grease. A lower piston seal
failure can result and the breaker will subsequently leak oil.
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CARRIER HYDRAULIC OIL
CARRIER HYDRAULIC OIL
Requirements for hydraulic oil
General requirements
In general the hydraulic oil originally intended for the carrier can be used with this
product. However, since working with the product heats the oil more than the usual
excavation work, the temperature of the oil must be monitored.
If the temperature of the hydraulic oil exceeds 80 °C (176 °F), an auxiliary oil cooler is
needed. The oil viscosity must be between 20-1000 cSt while the attachment is being
used.
When the product is used continuously, the temperature of the hydraulic oil normalizes
at a certain level depending on conditions and on the carrier. The temperature in the
tank must not exceed the maximum allowed.
The breaker must not be started if the ambient temperature is below freezing and the
oil is very thick. The machine must be moved to bring the oil temperature above 0 °C
(32 °F) before breaking can start (viscosity 1000 cSt or 131 °E).
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CARRIER HYDRAULIC OIL
Oil specifications
Table below shows hydraulic oils recommended for breaker use. The most suitable oil
is selected in such a way that the temperature of the hydraulic oil in continuous use is
in the ideal area on the chart and the hydraulic system is used to best advantage.
Problems due to incorrect hydraulic oil viscosity in the breaker:
Oil too thick
● Difficult start up
● Stiff operation
● Breaker strikes slowly
● Danger of cavitation in pumps and in the hydraulic breaker
● Sticky valves
● Filter bypass opens, impurities in the oil are not removed
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CARRIER HYDRAULIC OIL
Oil too thin
● Efficiency losses (internal leaks)
● Damage to gaskets and seals, leaks
● Accelerated wearing of parts, because of decreased lubrication efficiency
● Breaker strikes irregularly and slowly
● Danger of cavitation in pumps and in the hydraulic breaker
Note: We strongly recommend the use of different hydraulic oils in the summer and in
the winter if there is an average temperature difference of more than 35 °C (63 °F). The
correct hydraulic oil viscosity is thus ensured.
Special oils
In some cases special oils (for example biological oils and non-inflammable oils) can
be used with hydraulic breakers. Observe the following aspects when considering the
use of special oils:
● The viscosity range in the special oil must be in the given range (20-1000 cSt)
● The lubrication properties must be sufficient
● The corrosion resistance properties must be good enough
Note: Although a special oil could be used in the carrier, always check its suitability with
the breaker due to high piston speed of the breaker. Contact the oil manufacturer or
your local dealer for more information about special oils.
Oil cooler
The correct place to connect the breaker return line is between the oil cooler and the
main filters. The breaker return line should not be connected before the oil cooler.
Routing the breaker return flow through the cooler, might damage either the cooler, due
to pulsating flow, or the breaker, due to increased back pressure.
The carrier hydraulic system must be able to maintain the temperature within an
acceptable level during the breaker operation. This is for two reasons.
1. Seals, wipers, membranes and other parts manufactured from the corresponding
materials can normally stand temperatures up to 80 °C (176 °F).
2. The higher the temperature is, the less viscous the oil gets thus losing its capability
to lubricate.
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CARRIER HYDRAULIC OIL
A standard carrier, with a proper breaker circuit, meets the requirements of the
necessary cooling capacity. If the oil temperature tends to be too high during the
breaker operation, the following things must be checked:
● The breaker circuit pressure relief valve is not open when the breaker is operated.
● The breaker circuit pressure drops are reasonable. Less than 10 bar (145 psi) in
the pressure line and less than 5 bar (75 psi) in the return line.
● Hydraulic pumps, valves, cylinders, motors etc. and breaker do not have internal
leakages.
If all of the above mentioned things are in order, and the temperature of the hydraulic
oil still tends to be too high, extra cooling capacity is needed. Consult the carrier
manufacturer or dealer for details.
Oil filter
The purpose of the oil filter is to remove impurities from the hydraulic oil. Air and water
are also impurities in oil. Not all impurities can be seen with the naked eye.
Impurities enter the hydraulic system:
● During hydraulic oil changes and refilling.
● When components are repaired or serviced.
● When the breaker is being installed on the carrier.
● Because of component wear.
Normally the existing main oil filters of the carrier are used as breaker circuit return line
filters. Consult the carrier manufacturer or your local dealer concerning instructions for
the filter change intervals.
In hydraulic breaker work the carrier oil filter must fulfil the following specifications:
● The oil filter must allow maximum particle size of 25 microns (0.025 mm).
● The oil filter material must be artificial fibre cloth or very fine gauge metallic mesh
to withstand pressure fluctuations.
● The oil filter must have a nominal flow capacity of at least twice the breaker's
maximum flow.
In general, oil companies guarantee new oils to have a particle count of 40 microns
maximum. Filter the oil when filling the tank.
The damage caused by hydraulic oil impurities in the carrier and breaker circuits:
1. The working life of the pumps and other components is significantly shortened.
● Rapid wear of parts.
● Cavitation.
2. Wear of cylinder and gaskets.
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CARRIER HYDRAULIC OIL
3. Reduced breaker efficiency.
● Accelerated wear of moving parts and seals.
● Danger of piston seizing up.
● Oil leakages.
4. Shortened working life and reduced lubricating capability of oil.
● Oil overheats.
● Oil quality deteriorates.
● Electro-chemical changes in hydraulic oil.
5. Valves do not function properly.
● Spools bind.
● Rapid wear of parts.
● Blocking of small holes.
Note: Component damage is only a symptom. The trouble itself will not be cured by
removing the symptom. After any component damage due to impurities in the oil, the
entire hydraulic system has to be cleaned. Dismantle, clean and reassemble the
breaker and change the hydraulic oil.
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MAINTENANCE3
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ROUTINE MAINTENANCE
ROUTINE MAINTENANCE
Overview
This product is a precision made hydraulic machine. Therefore great care and
cleanliness should be taken when handling any of the hydraulic components. Dirt is the
worst enemy in hydraulic systems.
Handle the parts carefully and remember to cover any cleaned and dried parts with
clean lint-free cloth. Do not use anything other than purpose designed materials for
cleaning hydraulic parts. Never use water, paint thinners or carbon tetrachloride.
Components, gaskets and seals in the hydraulic system should be oiled with clean
hydraulic oil before assembly.
Inspection and maintenance by the operator
Note: The time intervals given refer to the carrier hours while the attachment is
installed.
Every two hours
● Check that the grease cartridge is not empty. Replace if necessary.
● Check that the tool has received sufficient grease.
● Grease manually if the automatic greasing device is not in use. See “Manual
greasing” on page 48.
● Observe hydraulic oil temperature, all lines and connections as well as impact
efficiency and evenness of operation.
Every 10 hours or at least once a week
● Remove the tool retaining pin and the tool and check their condition. Grind the burrs
away if necessary. See “Changing the tool” on page 59.
● Check that the tool has received sufficient greasing. Adjust greasing setting more
frequently, if necessary.
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Every 50 hours or at least once a month
● Check the tool shank and tool bushings for wear. See “Changing the tool” on page
59. See “Lower tool bushing” on page 62.
● Check the hydraulic hoses. Replace if necessary. Do not let dirt get into the breaker
or hoses.
● Check that the breaker moves normally inside the housing and that vibration
dampening elements (pads and buffers) are in good condition.
● Check the condition of wear plates by moving breaker with a pry bar from side to
side inside housing. The maximum allowed clearance is approximately ±10 mm.
Inspection and maintenance by the dealer
Note: The times given refer to the carrier hours while the attachment is installed.
Initial 50-hour inspection
It is recommended to have the first inspection done by your local dealer after 50 to 100
operating hours. Contact your local dealer for more information about the initial 50-hour
inspection.
Every 1000 hours or once a year
This service is recommended to be done by your local dealer after 1000 operating
hours or at least once a year. Neglecting the annual service can cause severe damage
to the breaker.
Your local dealer will reseal the breaker, replace the accumulator membranes and
replace safety decals as needed. Contact your local dealer for more information about
annual servicing.
During this maintenance you should do the following tasks.
● Check all hydraulic connections.
● Check that the hydraulic hoses do not rub against anything in any boom position.
● Replace and inspect the hydraulic oil filters of the carrier.
Maintenance intervals in special applications
The service interval is considerably shorter in special applications. See “Special
conditions of use” on page 39. In special applications, please consult your local dealer
and/or LaBounty service department and/or LaBounty service department and/or
LaBounty service department for the correct service intervals.
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ROUTINE MAINTENANCE
Maintenance intervals in underwater use
After every half hour operation
● Grease the tool shank and the tool bushings through the grease zerks.
● Check that the breaker moves normally inside the housing and that the buffers are
in good condition.
● Check all hoses and connections.
● Check the operation of the air pressure switch.
Daily maintenance
● Remove the retaining pin and the tool for inspection. Grind the burrs away if
necessary.
● Check that the tool has received sufficient grease.
● Service the hammer after underwater jobs.
The breaker must be totally dismantled and serviced after working underwater.
Neglecting a breaker service after underwater work can cause severe damage to the
breaker.
The breaker as a standard assembly, must not be used under water. If water fills
the space where the piston strikes the tool, a strong pressure wave is generated
and the breaker may be damaged.
Other maintenance procedures
Washing the attachment
When working with attachment and removing it from the carrier, dirt (mud, rock powder
etc.) can become attached to it. Wash the outside of the product with a steam washer
before sending it to the workshop. Dirt can cause difficulties in disassembly and
assembly otherwise.
CAUTION! Plug the pressure and return line and other connections before washing the
product or else dirt can enter into it and this may cause damage to the components.
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CHANGING THE TOOL
CHANGING THE TOOL
Wear limits and lubricants for tool removal
Item
Wear limit
Tool diameter X (worn out)
164 mm (6.46 in)
Tool diameter Y (worn out)
162 mm (6.38 in)
Z
R030149
R
Item
Wear limit
Tool retaining pin diameter Z (worn out)
76 mm (2.99 in)
Item
Lubricant
Tool and tool retaining pins
Tool grease
User manual LMB5545
59
CHANGING THE TOOL
Removal of tool
Warning! The hydraulic pressure inside the breaker must always be released
before removing the tool. After operating the breaker, wait 10 minutes for oil
pressure to drop inside breaker.
Warning! Hot tool can cause severe injuries.
1. Set the breaker on level ground.
2. Make sure the carrier's transmission is in neutral and the parking brake is engaged.
3. Stop the carrier engine.
4. Remove plugs.
5. Remove rubber rings.
6. Remove tool retaining pins by using t-puller.
R030114
7. Remove tool. Use lifting device if necessary. If the tool cannot be removed contact
your local dealer.
R030097
Note: If breaker is still on carrier, it may be easier to stick the tool in the ground and lift
the breaker off the tool. Make sure that the tool cannot fall.
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CHANGING THE TOOL
Installation of tool
1. Clean all parts carefully.
2. Measure the tool diameters (X and Y) from the areas marked on the illustration.
Replace tool if necessary. See “Changing the tool” on page 59.
3. Measure the tool retaining pin diameter (Z). Replace tool if necessary. See
“Changing the tool” on page 59.
4. Check tool seal. Replace if necessary.
R030098
5. Clean the tool and retaining pins and lubricate them with grease.
6. Install tool and align the grooves of the tool with the pin bores.
7. Install tool retaining pins.
8. Install rubber rings.
9. Install plugs.
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User manual LMB5545
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LOWER TOOL BUSHING
LOWER TOOL BUSHING
Wear limits and lubricants for lower tool bushing
Grooves
R030085
Item
Wear limit
Tool bushing (worn out)
First three grease grooves are worn out.
Bushing must be replaced.
Item
Lubricant
Contact surfaces of front head
Thread grease
Removal of lower tool bushing
The lower tool bushing can not be removed without removing the breaker from the
housing. Contact your local dealer for more information.
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TROUBLESHOOTING
TROUBLESHOOTING
The breaker does not start
PRESSURE OR RETURN LINES CLOSED
Check the operation of quick couplings in breaker line. Open breaker line ball valves if
closed.
PRESSURE AND RETURN HOSES INSTALLED BACKWARDS
Swap the pressure and return hoses.
IDLE SELECTOR TURNED ON AND FEEDING FORCE IS TOO LOW
Turn idle selector off or increase feeding force against object.
PISTON IS IN ITS LOWER HYDRAULIC BRAKE
Keep the breaker control valve open and force the tool against an object. The tool head
will push the piston out of its brake area. See “Daily operation” on page 30.
GREASE BETWEEN PISTON AND TOOL CONTACT AREA
Remove the tool and wipe excessive grease off. See “Manual greasing” on page 48.
BREAKER CONTROL VALVE DOES NOT OPEN
When operating the breaker control valve, check that the pressure line pulsates (this
indicates the breaker control valve is opening). If the valve does not operate, check the
operating means: mechanical connections, pilot pressure and electrical control.
RELIEF VALVE IN HYDRAULIC CIRCUIT OPENS AT A LOW PRESSURE.
BREAKER OPERATING PRESSURE IS NOT REACHED
Check the installation. Check the relief valve operation. Adjust the relief valve in
hydraulic circuit. Measure the high pressure in the breaker inlet line. Contact your local
dealer for more information.
EXCESSIVE BACK PRESSURE IN RETURN LINE
Check the installation. Check the size of the return line.
LEAKAGE FROM PRESSURE TO RETURN IN EXCAVATOR HYDRAULIC CIRCUIT
Check the installation. Check the pump and the other hydraulic components.
FAILURE IN BREAKER VALVE OPERATION
The breaker must be serviced in an authorized LaBounty service shop.
PISTON FAILURE
The breaker must be serviced in an authorized LaBounty service shop.
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TROUBLESHOOTING
The breaker operates irregularly but the blow has full power
NOT ENOUGH FEED FORCE FROM EXCAVATOR
Refer to the correct working methods. See “Daily operation” on page 30.
RELIEF VALVE IN HYDRAULIC CIRCUIT OPENS AT A LOW PRESSURE.
BREAKER OPERATING PRESSURE IS NOT REACHED
Check the installation. Check the relief valve operation. Adjust the relief valve in
hydraulic circuit. Measure the high pressure in the breaker inlet line. Contact your local
dealer for more information.
FAILURE IN BREAKER VALVE OPERATION
The breaker must be serviced in an authorized LaBounty service shop.
FAILURE IN GREASING DEVICE HYDRAULIC CIRCUIT
The breaker must be serviced in an authorized LaBounty service shop.
The breaker operates irregularly and blow has no power
THE WORKING METHOD IS NOT CORRECT
Refer to the correct working methods. See “Daily operation” on page 30.
RELIEF VALVE IN HYDRAULIC CIRCUIT OPENS AT A LOW PRESSURE.
BREAKER OPERATING PRESSURE IS NOT REACHED
Check the installation. Check the relief valve operation. Adjust the relief valve in
hydraulic circuit. Measure the high pressure in the breaker inlet line. Contact your local
dealer for more information.
PRESSURE CONTROL VALVE SETTING IS INCORRECT
The breaker must be serviced in an authorized LaBounty service shop.
PRESSURE LOSS IN PRESSURE ACCUMULATOR
The breaker must be serviced in an authorized LaBounty service shop.
FAILURE IN BREAKER VALVE OPERATION
The breaker must be serviced in an authorized LaBounty service shop.
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TROUBLESHOOTING
Impact rate slows down
OIL HAS OVERHEATED (OVER +80 °C/+176 °F)
Check for a fault in the oil cooling system or an internal leak in the breaker. Check the
hydraulic circuit of the carrier. Check the relief valve operation in the carrier. Check the
line size. Assemble an extra oil cooler.
HYDRAULIC OIL VISCOSITY TOO LOW
Check hydraulic oil. See “Requirements for hydraulic oil” on page 50.
EXCESSIVE BACK PRESSURE IN RETURN LINE
Check the installation. Check the size of the return line.
RELIEF VALVE IN HYDRAULIC CIRCUIT OPENS AT A LOW PRESSURE.
BREAKER OPERATING PRESSURE IS NOT REACHED
Check the installation. Check the relief valve operation. Adjust the relief valve in
hydraulic circuit. Measure the high pressure in the breaker inlet line. Contact your local
dealer for more information.
LEAKAGE FROM PRESSURE TO RETURN IN EXCAVATOR HYDRAULIC CIRCUIT
Check the installation. Check the pump and the other hydraulic components.
OIL FLOW FROM THE CARRIER IS TOO HIGH
The hammer is equipped with a built-in Ramvalve which is designed to decrease oil
flow to the breaker when oil flow from the carrier is too high. If impact rate is too slow
check the oil flow. Contact your local carrier dealer for more information.
PRESSURE LOSS IN PRESSURE ACCUMULATOR
The breaker must be serviced in an authorized LaBounty service shop.
FAILURE IN BREAKER VALVE OPERATION
The breaker must be serviced in an authorized LaBounty service shop.
The breaker does not stop or has run-on
INTERNAL OIL LEAK IN THE BREAKER
The breaker must be serviced in an authorized LaBounty service shop.
FAILURE IN BREAKER CONTROL VALVE OPERATION
Check the breaker control valve in the carrier.
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User manual LMB5545
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TROUBLESHOOTING
Oil overheats
APPLICATION NOT CORRECT FOR BREAKER
Refer to recommended use and to correct working methods. See “Daily operation” on
page 30.
COOLING CAPACITY OF THE FACTORY OIL COOLER IS TOO SMALL
Assemble an extra oil cooler.
RELIEF VALVE IN HYDRAULIC CIRCUIT OPENS AT A LOW PRESSURE.
BREAKER OPERATING PRESSURE IS NOT REACHED
Check the installation. Check the relief valve operation. Adjust the relief valve in
hydraulic circuit. Measure the high pressure in the breaker inlet line. Contact your local
dealer for more information.
HYDRAULIC OIL VISCOSITY TOO LOW
Check hydraulic oil. See “Requirements for hydraulic oil” on page 50.
LEAKAGE FROM PRESSURE TO RETURN IN EXCAVATOR HYDRAULIC CIRCUIT
Check the installation. Check the pump and the other hydraulic components.
INTERNAL OIL LEAK IN THE BREAKER
The breaker must be serviced in an authorized LaBounty service shop.
EXCESSIVE BACK PRESSURE IN RETURN LINE
Check the installation. Check the size of the return line.
Recurrent tool failure
APPLICATION NOT CORRECT FOR BREAKER
Refer to recommended use and to correct working methods. See “Operating
instructions” on page 23.
ROUGH OPERATING PRACTICES
Refer to recommended use and to correct working methods. See “Daily operation” on
page 30.
TOOL DOES NOT GET ENOUGH LUBRICANT
Refer to recommended use and to correct working methods.
TOO LONG TOOL
Use shortest tool possible. Refer to recommended use and to correct working methods.
RAPID WEAR OF TOOL
Refer to recommended use and to correct working methods. See “Daily operation” on
page 30. There is a wider selection of tools available for different applications. Consult
with your local dealer for more information.
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TROUBLESHOOTING
Automatic greasing device problems
UPPER OR LOWER TOOL BUSHING DOES NOT GET ENOUGH LUBRICANT
● Cold conditions. Apply grease from grease gun to grease zerks.
● Doser adjusting is wrong for the application. The doser must be readjusted. See
“Adjusting the dose” on page 46.
● Blockage in greasing device. Contact your local dealer for more information.
UPPER OR LOWER TOOL BUSHING GETS TOO MUCH LUBRICANT
● Doser adjusting is wrong for the application. The doser must be readjusted. See
“Adjusting the dose” on page 46.
● Leak in the doser. The doser must be replaced. Contact your local dealer for more
information.
TOOL DOES NOT GET LUBRICANT AT ALL
● Grease cartridge is empty or damaged. Replace the grease cartridge. See
“Automatic greasing” on page 45.
● Grease cartridge is empty or damaged. Replace the grease cartridge.
● Doser defective. The doser must be replaced. Contact your local dealer for more
information.
● Leak in the grease hose or pressure hose. Inspect the hoses and replace if
necessary.
● Grease and pressure hoses are installed backwards. Swap the hoses.
● To continue troubleshooting, disconnect the grease hose from the breaker valve
body and operate the breaker. After 10 minutes of operation check if grease has
protruded from the grease hose.
LUBRICATION DEVICE IS WORKING (WHILE THE GREASE HOSE IS
DISCONNECTED)
● Leak in breaker lubrication channel. The breaker must be serviced in an authorized
LaBounty service shop.
● Breaker lubrication channel is blocked. The breaker must be serviced in an
authorized LaBounty service shop.
LUBRICATION DEVICE DOES NOT WORK (WHILE THE GREASE HOSE IS
DISCONNECTED)
● Remove the lubrication device from the breaker and deliver it for service in an
authorized LaBounty service shop.
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TROUBLESHOOTING
Further assistance
FURTHER ASSISTANCE
If further assistance is required, please prepare to answer the following questions
before calling your dealer.
● Model and serial number
● Working hours and service history
● SDC report if available
● Carrier model
● Installation: Oil flow, operating pressure and return line pressure if known
● Application
● Has the product operated normally before
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SPECIFICATIONS4
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LMB5545
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BREAKER SPECIFICATIONS
BREAKER SPECIFICATIONS
Technical specifications
Item
Specification
Minimum working weight1
3380 kg (7450 lb)
Breaker weight
2800 kg (6170 lb)
Impact rate, Long stroke2
400...560 bpm
Impact rate, Short stroke3
520...700 bpm
Operating pressure4
150...160 bar (2175...2320 psi)
Pressure relief, min5
210 bar (3045 psi)
Pressure relief, max
230 bar (3335 psi)
Oil flow range
250...350 l/min (66.0...92.5 gal/min)
Back pressure, max
12 bar (175 psi)
Input power
93 kW (125 hp)
Tool diameter
166 mm (6.54 in)
Pressure line connection (IN)
SAE 6000 psi 1 1/4"
Return line connection (OUT)
SAE 6000 psi 1 1/4"
Grease connection (G)
6
BSPP-internal 3/8"
Air connection (A)7
BSPP-internal 3/8"
Pressure line size
(minimum inner diameter)
32 mm (1.26 in)
Return line size (minimum inner diameter)
32 mm (1.26 in)
Optimum oil temperature
40...60 °C (104...140 °F)
Allowed oil temperature range
-20...80 °C (-4...176 °F)
Optimum oil viscosity at operating
temperature
30...60 cSt
Allowed oil viscosity range
20...1000 cSt
Carrier weight8
35...60 t (7866000...132300 lb)
Noise level, measured sound power level,
LWA9
126 dB (126 dB)
Noise level, guaranteed sound power level, 130 dB (130 dB)
LWA10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
70
LMB5545
Includes average mounting bracket and standard tool
Actual impact frequency depends on oil flow, oil viscosity, temperature, and material to be broken
Actual impact frequency depends on oil flow, oil viscosity, temperature, and material to be broken
Actual pressure depends on oil flow, oil viscosity, temperature, material to be broken and back pressure
Minimum setting = actual operating pressure + 50 bar (730 psi)
Located on the same side of the valve body as the pressure line (IN) connection
Located on the same side of the valve body as the return line (OUT) connection
Check carrier's lifting capacity from carrier manufacturer
According to European Union DIRECTIVE 2000/14/EC
According to European Union DIRECTIVE 2000/14/EC
R
BREAKER SPECIFICATIONS
Main dimensions
730
(730)
2962
2393
792
730
Ø166
508
604
C040170
Mounting bracket specifications
Y
X
R040219
Item
Specification
After welding check flatness of the plate and mill surface as needed. Maximum
acceptable deviation from flatness is 1 mm (0.04 in)
R
Bottom plate recommended minimum
thickness (X)
30 mm (1.18 in)
Side plate recommended minimum
thickness (Y)
30 mm (1.18 in)
LMB5545
71
TOOL SPECIFICATIONS
TOOL SPECIFICATIONS
Tool
Part no.
Length
Weight
Diameter
Chisel (A)
79039
1450 mm
(57.09 in)
226 kg
(500 lb)
166 mm
(6.54 in)
Moil point (B)
79040
1450 mm
(57.09 in)
217 kg
(480 lb)
166 mm
(6.54 in)
Blunt (C)
79041
1265 mm
(49.80 in)
208 kg
(460 lb)
166 mm
(6.54 in)
There is a wider selection of tools available for different applications. Consult with your
local dealer for more information.
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LMB5545
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R
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LaBounty
1538 Highway 2
Two Harbors, Minnesota 55616-8015 USA
Phone: (218) 834-2123
Fax: (218) 834-3879
6-24-14119-24-156-0
18-24-14119-27-76-378
74
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