Beruflich Dokumente
Kultur Dokumente
3
Foreword
Please read this operating manual before using Die Verantwortung für die Einhaltung aller Sicher
your ContiLube® II lubrication unit for the first time heitsbestimmungen liegt in jedem Fall beim Betrei
so as to avoid errors and breakdowns through ber, d. h. bei Ihnen.
incorrect usage.
Responsibility for observation of these safety
The operating manual includes:
instructions lies at all times with the operator, i.e.
H important safety instructions with you.
H operating instructions for the lubrication unit All safety instructions are in line with the valid laws
and regulations of the European Union. National
H maintenance instructions for the lubrication unit
provisions have also been taken into account
H aids to troubleshooting where applicable.
The operating manual describes how to handle the When using the lubrication unit outside the Euro
lubrication unit on site and should therefore always pean Union, the national laws and regulations of
be kept in the document compartment in the carrier the country of use shall apply.
cab.
It is important that all safety instructions be We wish you every success with your Atlas Copco
observed. These safety instructions are listed at ContiLube® II.
the beginning of the manual and repeated in the
relevant sections of the manual. Atlas Copco Construction Tools GmbH
4
Explanation of the symbols used in this operating manual
To emphasise their importance, certain points in the operating manual are marked with
symbols, which are described below.
5
Table of contents
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1. Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.1. Hydraulic hammers supplied with ContiLube® II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2. Retrofitting with ContiLube® II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3. Hydraulic connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.1. No lubricant at lubrication point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.2. Lubricant delivery too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.3. Lubricant delivery too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6
1. Applications
The ContiLube® II is an automatic lubrication unit for use on hydraulic hammers, providing continuous
lubrication for the wearintensive chisel guide zone in the lower hammer part.
Modelspecific adapter kits are available for all hydraulic hammers from the MB 500 series upwards to allow
direct retrofitting of the ContiLube® II on the hammer box.
Atlas Copco Construction Tools can also supply a universal adapter kit allowing Atlas Copco hydraulic
hammers with hammer brackets or hammer holders to be retrofitted with the automatic lubrication unit. The
unit can be fitted anywhere on the bracket/holder/boom, but for preference it should be as close to the
hydraulic hammer as possible and in a position where it can be easily seen by the operator.
The patented Atlas Copco ContiLube® II lubrication unit offers the following benefits:
Familiarise yourself with the operating manual and the applicable regulations before starting work with the
lubrication unit.
When using the ContiLube« II lubrication unit in states of the European Union, the regulations contained in
the EC machinery directive 98/37/EC must be observed and followed, as must all applicable national acci
dent prevention regulations.
In countries outside the European Union, the valid local statutes and regulations shall apply.
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2.2. Mounting the lubrication unit:
It is important that the system pressure be relieved before opening any hydraulic lines on the carrier.
Please note:
Close the pump casing using the cover or leave the cartridge screwed into the pump casing to avoid conta
mination of the pump.
Warning!
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3. Technical specifications
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Model ContiLube ® II
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Service weight [kg] 5,4
height 90
width 180
length 300
Grease gun for emergency lubrication: part ident. no. 3363 0345 67
Universal adapter kit for mounting lubrication unit on part ident. no. 3363 0674 93
excavator
K ContiLube® II is set to "lowest delivery/stroke" upon delivery. The delivery rate can be adjusted to match
requirements. See Chapter 7.1.3, Operating the ContiLube® II.
9
4. Main components
metering screw
seal cartridge
Fig. 1
5. Mounting
5.1. Hydraulic hammers supplied with ContiLube® II
The ContiLube® II is factory fitted. No further mounting is required.
For further information on this subject please contact Atlas Copco’s Customer Support.
Phone: +49 201 6331619
Fax: +49 201 6331352
The universal adapter kit includes welding rails which are welded to the carrier boom or the sideplate of the
hammer bracket.
The following safety regulations must be observed at all costs.
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Alternative mounting locations on lower end of excavator boom
(only the lubrication unit mount is depicted)
Fig. 2
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Warning!
Before welding the welding rails to the excavator boom, the excavator battery cables must be disconnected
and removed.
Shield hydraulic hoses in the vicinity of the welding work on the boom.
Caution: Risk of fire!
Existing check valves with measuring ports can be used to connect the carrier hydraulics to the ContiLube® II
lubrication unit.
Socalled Minimess connections should never be used!
In order to avoid mixups when connecting up the hoses, the ports have different threads:
the oil supply line has cap nuts with an M 16 x 1.5 thread;
the grease supply line has cap nuts with an M 14 x 1.5 thread.
Warning!
Atlas Copco Construction Tools uses hoses of the same quality and size for both lines. These hoses are
designed to withstand dynamic operating pressures of up to 280 bar.
The port caps included with supply should be kept for future use.
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6.1.1. Changing the lubricant cartridge
D Open the cartridge by taking off the cap (Fig. 3) Important: Do not damage the cone itself!
D Depress the cartridge piston with your thumb until lubricant emerges from the threaded end (Fig. 4).
D Screw the cartridge into the bore provided in the pump unit as far as it will go.
The ContiLube® II is now ready for operation (Fig. 5).
Metering screw
cone Lubrication nipple
for emergency
lubrication
D ContiLube® II is selfbleeding, i.e. the system Turn the screw anticlockwise = greater delivery per
requires no additional bleeding. stroke
D The cartridge is made of transparent, recyclable D When not in use, the pump unit must be sealed off
plastic (PE), so the lubricant level in the cartridge to prevent water or dust penetration. Close the unit
can be monitored at all times from the driver’s cab with a dust cap or simply leave the empty cartridge
by observing the position of the piston, which is red. in position.
D The piston end of the cartridge must never be D Emergency lubrication is possible via the lubrica
sealed off, as this would render delivery impossible. tion nipple on the front of the
D The amount of lubricant delivery per stroke can be ContiLube® II.
set using the metering screw, allowing the unit to be D The connections for all hoses used to operate the
adapted to differing requirements. ContiLube® II unit must be checked once a week to
Turn the screw clockwise = smaller delivery per ensure they have not come loose.
stroke
Important
Upon delivery, the ContiLube® II is always factory set so as to ensure that the hammer chisel receives
set to "lowest delivery per stroke". The factory set adequate lubrication. This will depend both on the
ting is 18.6 mm. kind of lubricant used and the job involved.
When using versions of hydraulic hammers with
DustProtector, or when performing tunnelling jobs
with the hammer overhead, the metering screw set
ting should be kept low (in the minimum range) since
for these versions/ applications the lubricant remains
x in the lubrication zone for longer than on standard
versions/vertical applications.
x = 18,6 mm
Factory setting
Excessive lubrication is indicated by high amounts
of lubricant being scraped off by the chisel.
Insufficient lubrication is indicated by dry areas on
When starting up the unit, the delivery rate must be the chisel.
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6.1.3. Manual lubrication upon failure of ContiLube® II
Should the ContiLube® II fail during operation, or the cartridge runs out and no replacement is immediately to
hand, manual lubrication is possible. As shown in Fig. 6, a grease gun is attached to the lubrication nipple on
the ContiLube® II.
To this end stand the hydraulic hammer upright on the working tool and apply contact pressure. As a rule, 5
to 10 shots from a grease gun are sufficient in each case.
To lubricate the working tool use only Atlas Copco chisel paste, available in fully selfemptying standard car
tridges. Fully emptied cartridges can be recycled.
Fig. 6
ContiLube ® II
CL
For ContiLube® II and manual grease gun (part ident. no. 3363 0345 67)
For further information on this subject please contact Atlas Copco’s Customer Support.
Phone: +49 201 / 6331619
Fax: +49 201 / 6331352
New hydraulic hammers supplied from our Essen factory are prefilled with lubricant.
If the hammer has been taken out of use for repairs, it is important before restarting operation that all internal
lubricant bores in the hydraulic hammer from the pump to the lower hammer part are filled with lubricant. The
system is filled up using a lever type hand gun attached to the lubrication nipple on the pump casing of the
lubrication unit. To check filling, remove the working tool: the system is full when lubricant is seen to emerge
directly at the point of lubrication.
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6.2. Operating in high/low outside temperatures
The lubrication unit is powered by hydraulic oil from the carrier. The maximum oil temperature for the lubrica
tion unit must not exceed 80o C, i.e. in line with the carrier manufacturer’s general regulations.
It is important that lubricants with viscosity ranges appropriate to the outside temperature are used.
Atlas Copco chisel paste is recommended for use on Atlas Copco hydraulic hammers.
This paste can be employed in temperatures ranging from 20o C to +50o C.
If the hammer is to be used in temperatures below 20o C, please contact Atlas Copco’s Customer Support.
The part ident. no. for Atlas Copco’s chisel paste is listed in the "Technical specifications" on page 9.
H The unit and its mount must be above water level. If necessary, reposition the mount and use longer
hoses.
Only use hoses which comply with the quality requirements listed in Chapter 6.3.
H The screw couplings for the lubricant lines must be tightened with particular care so as to avoid any possi
bility of leakage.
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8. Troubleshooting
8.1. No lubricant at lubrication point
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Lubricant cartridge is empty Fit new cartridge Excavator driver
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8.2. Lubricant delivery too low
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Cause
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Release lock nut, turn metering
screw anticlockwise until required
Metering screw set too low Excavator driver
delivery/stroke is achieved. Relock
at this setting.
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Cause Remedy by
Please note:
Should the lubrication unit fail and the cause of failure cannot be detected, please call Atlas Copco’s
Customer Support.
To bridge such downtimes there are two possible remedies:
1. Emergency lubrication using a lever type hand gun via the lubrication nipple.
2. Unscrew lubricant line from hammer, remove lubrication nipple from lubrication unit and screw directly
into the hammer.
Emergency lubrication using a lever type hand gun on the hammer itself.
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9. Removing the lubrication unit when not in use
Prior to a lengthy period of nonuse, fill the pump chamber with grease and close off using the cover or a car
tridge. Part ident. no. of cover: 3066062
Unscrew both hoses from the lubrication unit and close off the screw couplings (e.g. using conical plugs) to
provide effective protection against dirt contamination.
Then release the fixing screws for the lubrication unit.
The entire unit can now be removed and placed in storage.
Unscrew the hydraulic line to the lubrication unit at the branchoff point from the hammer supply line.
The open Tscrew coupling or the check valve on the boom should now be closed appropriately so as to
avoid any unnecessary leakage.
The lubricant line can remain attached to the hammer, but it is imperative that the open end be closed off.
The existing lubricant line must first be cleaned and any blockages caused by old lubricant removed.
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10. Hose set for lubrication unit
Oil and lubricant connections to the lubrication unit can be made using the universal adapter kit (part ident.
no. 3363 0674 93). Ensure the hoses are connected the right way round (see Fig. 8).
It is possible that when using a lubrication unit on a hydraulic hammer and mounting as shown in Fig. 2, the
hoses may need to be shortened.
For this reason the hoses are supplied with couplings at one end only.
Please note:
The hose set does not include parts such as Ttype and reducing couplings for the branchoff point in the
pressure oil line of the hydraulic hammer (Fig. 8, page 20).
2 1 3, 5 4, 5
Fig. 7
19
10.3. Presentation connecting parts for universal adapter kit
23 26 25
hydraulic hammer
grease line grease line
20, 22 10 11
10 23
grease side
grease port for
manual lubrication
20, 22
ContiLube® II 20, 21
15
oil side
20, 21, 27
27, 28, 35
23
Items 29, 30 and 31 are used to close off lines when dismounting the lubrication unit.
Fig. 8
20
Index
H Maintenance before starting work, 15
A H Manual lubrication upon failure of ContiLube® II,
H Accident prevention regulations, 7 14
H Applications, 7 H Mounting, 10
H Mounting the lubrication unit:, 8
B
H Before starting work:, 7 N
H No lubricant at lubrication point, 16
C
H Changing the lubricant cartridge, 13 O
H Operating in high/low outside temperatures, 15
H Operating the ContiLube® II, 13
D H Operating the ContiLube® II lubrication unit, 12
H Dismounting the unit, 18
P
E H Parts list − universal adapter kit, 19 , 20
H Explanation of the symbols used in this opera H Prefilling the lubricant lines, 14
ting manual, 5 H Presentation connecting parts for universal
adapter kit, 20
H Presentation universal adapter kit, 19
F
H Function of the lubrication unit, 12
R
H Remounting after lengthy period of non−use, 18
H H Removing the hoses, 18
H Hose set for lubrication unit, 19 H Removing the lubrication unit when not in use,
H Hydraulic connections, 12 18
H Hydraulic hammers supplied with ContiLube® II, H Removing the lubrication unit:, 8
10 H Retrofitting with ContiLube® II, 10
L T
H Lubricant delivery too high, 17 H Technical specifications, 9
H Lubricant delivery too low, 17 H Troubleshooting, 16
M W
H Main components, 10 H Working underwater, 15
21
Notes:
22
23
Atlas Copco Construction Tools GmbH
Helenenstrasse 149 S 45143 Essen
P. O. Box 10 21 52 S 45021 Essen
Federal Republic of Germany
Telephone +49 201 633 − 0
Internet: www.atlascopco.com
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