Epiroc EC 90T - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document provides instructions for prefilling high-pressure accumulators and piston accumulators on hydraulic breakers. It is a supplementary guide to the hydraulic breaker's Safety and Operating Instructions, specifically for breakers delivered in a depressurized state.

Function Description

The primary function of this instruction manual is to guide users through the process of prefilling both high-pressure (HP) accumulators and piston accumulators with nitrogen (N₂). This is a critical step for ensuring the safe and proper operation of hydraulic breakers, as these components are delivered depressurized from the factory. The manual emphasizes the importance of using only nitrogen for prefilling to prevent explosions and serious injuries. It also details the necessary safety precautions, qualifications for personnel, and specific procedures for each type of accumulator.

Important Technical Specifications

Nitrogen Purity: Accumulators must be filled with nitrogen of minimum class 4.0, ultra-clean, N₂ 99.9 vol. %.
Ambient Temperature Range for Prefilling: The prefilling process should be carried out within an ambient temperature range of -20 °C to +40 °C (-4 °F to +104 °F).
HP-Accumulator Prefilling Pressures:
- HP-accumulator 0.9 L and 1.5 L: Prefilling pressures vary with ambient temperature, as detailed in a provided diagram. For example, at 0°C, the prefilling pressure is approximately 57.5 bar, increasing to about 62.5 bar at +40°C.
Piston Accumulator Prefilling Pressures: Prefilling pressures for piston accumulators vary significantly based on the hydraulic breaker model. Examples include:
- EC 90T: 10.4 bar
- EC 100T: 6.7 bar
- HB 2000: 10.4 bar
- HB 10000: 7.5 bar
Required Nitrogen Quantity: The manual provides tables detailing the required quantity of gas (in litre x bar) for prefilling HP-accumulators only, piston accumulators only, or both, depending on the hydraulic breaker type. For instance, an EC 140T requires 54 litre x bar for the HP-accumulator only, 34 litre x bar for the piston accumulator only, and 88 litre x bar for both.
Bolt Connections / Tightening Torques:
- Piston accumulator filling valve (threaded plug): Key size 5, Tightening torque 20 Nm (15 ft lbs).
- Service opening plate (Allen screw): Key size 10, Tightening torque 85 Nm (63 ft lbs).
Applicable Hydraulic Breaker Models:
- EC 90T - EC 180T
- MB 750 - MB 1650
- HB 2000 - HB 10000
- C 135 - C 165
Required Accessories (HP-accumulator filling):
- 1 accumulator filling device with accessories, part number 3360 9204 15
- 1 nitrogen cylinder (2 L or 5 L), part number 3363 0345 04 or 3363 0345 06
- 1 pressure-relief valve, part number 3361 3295 16
- 1 country-specific adapter (if required), document number 3390 7106 01
Required Accessories (Piston accumulator filling):
- 1 filling valve with pressure gauge 0-100 bar, part number 3361 3295 16
- 1 filling hose 700 mm length, part number 3361 3295 17 (or 4000 mm length, part number 3360 4792 59)
- 1 test pressure gauge ¼", 0-25 bar, test category 1.6, part number 3361 3295 18
- 1 nitrogen cylinder (2 L or 5 L), part number 3363 0345 04 or 3363 0345 06
- 1 country-specific adapter (if required), document number 3390 7106 01

Usage Features

Safety First: The manual prominently features safety instructions, including signal words (DANGER, WARNING, CAUTION, NOTICE) to highlight potential hazards such as suffocation from nitrogen, explosions from using incorrect gases, and risks from abruptly loosening components.
Qualified Personnel: Prefilling HP-accumulators is restricted to authorized professionals who are knowledgeable about national/regional safety provisions and accident prevention rules, and who have read and understood this instruction. Prefilling piston accumulators also requires personnel to be familiar with safety rules and this instruction.
Personal Protective Equipment: Users are mandated to wear safety glasses with side protectors, protective gloves, and protective shoes during the prefilling process.
Step-by-Step Procedures: Detailed, numbered steps are provided for both HP-accumulator and piston accumulator filling, ensuring a systematic and safe approach.
Visual Aids: Diagrams and tables are included to illustrate connections and provide specific prefilling pressures and gas quantities for various hydraulic breaker models and ambient temperatures.
Temperature Compensation: The prefilling pressure for HP-accumulators is dependent on ambient temperature, and a graph is provided to determine the correct pressure. Users are instructed to adjust to the correct pressure at operating temperature during commissioning.
Labeling: Hydraulic breakers delivered with depressurized accumulators are marked with a specific label on the hose connection, which must be removed after prefilling.

Maintenance Features

Preventive Maintenance: This instruction is a key part of the preventive maintenance for hydraulic breakers, ensuring that accumulators are correctly pressurized before operation.
Component Protection: Proper prefilling protects the HP-accumulator, piston accumulator, and other property from material damage that could result from incorrect pressure or gas.
Environmental Protection: Following the instructions helps protect the environment from potential damage related to improper handling of gases.
Documentation: The instruction emphasizes storing the manual in the workshop for future reference and adhering to all national/regional laws and regulations.
Tightening Torques: Specific tightening torques for critical bolt connections (e.g., piston accumulator filling valve plug, service opening plate Allen screws) are provided to ensure secure assembly and prevent leaks or component failure.