0203037en 002 06.2006 Electrik-breaker EHB 11 BLM/... Operator s Manual
1. Foreword Foreword For your own safety and protection from bodily injuries, carefully read, understand and follow the safety instructions in this manual. Please operate and maintain your Wacker machine in accordance with the instructions in this manual. Your Wacker machine will reward your attention by giving trouble-free operation and a high degree of availability. Replace faulty or defective components Immediately. All rights, especially the right for copying and distribution are reserved Copyright 2006 by Wacker Construction Equipment AG No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express permission in writing from Wacker Construction Equipment AG. Any type or manner of reproduction, distribution or storage on data carriers or storage mediums not authorized by Wacker represents an infringement of valid copyrights and will be prosecuted. We expressly reserve the right to make technical modifications - even without due notice - which aim at improving our machines or increasing their safety standards. 1
Table of contents 1. Foreword 1 2. Safety instructions 3 2.1 General Instructions...3 2.2 Operation...3 2.3 Safety checks...5 2.4 Maintenance...6 2.5 Transport...6 2.6 Maintenance checks...6 3. Technical data 7 4. Description 10 4.1 Application...10 4.2 Putting into operation...10 4.3 During operation...11 4.4 Disassembly...11 4.5 Assembly...12 5. Maintenance 13 5.1 Maintenance schedule...13 5.2 Maintenance and lubrication...13 6. Malfunction 14 6.1 Equipment failure...14 7. Electric wiring diagram 15 8. Labels 16 9. Disposal 17 9.1 Environmentally friendly reuse...17 EC - Conformity Certificate 19 DIN EN ISO 9001 CERTIFICATE 21 2
Drilling and breaking hammers Safety instructions 2. Safety instructions for the use of drilling and breaking hammers with electric drive 2.1 General Instructions 2.1.1 Drilling and breaking hammers may only be operated by persons who are at least 18 years of age, are physically and mentally fit for this job, have been instructed in operating drilling and breaking hammers and proven their ability for the job to the employer may be expected to carry out the job they are charged with carefully. The persons must be assigned the job of operating drilling and breaking hammers by the employer. 2.1.2 Drilling and breaking hammers are to be applied for their proper use. Both the manufacturer s operating instructions and these safety instructions have to be observed. 2.1.3 The persons charged with the operation of these hammers have to be made familiar with the necessary safety measures relating to the machine. In case of extraordinary uses, the employer shall give the necessary additional instructions. 2.1.4 It is possible that these drilling and breaking hammers exceed the admissible sound level of 89 db(a). Operators must wear personal hearing protection if the admissible assessment sound level equals or exceeds 89 db (A). 2.2 Operation 2.2.1 The function of operation levers or elements is not to be influenced or rendered ineffective. 2.2.2 Make sure that the machine is connected only to voltage and frequency as indicated on its name plate. Choose correct cross section for extension cord. SV00046GB.fm 3
Safety instructions Drilling and breaking hammers 2.2.3 The operator has to switch off drilling and breaking hammers, to disconnect them from the electric mains and to store them in such a manner that they do not turn over be fore leaving the machines or going on breaks. 2.2.4 Wear safety goggles in order to avoid injuries to the eyes. 2.2.5 We recommend wearing suitable working gloves. 2.2.6 Wear safety shoes while working with drilling and breaking hammers. 2.2.7 Drilling and breaking hammers are always to be operated with both hands on the handles provided for this purpose. 2.2.8 When working with drilling and breaking hammers, especially when carrying out drilling jobs, the operator has to have a firm stand, particularly when working on scaffolding and ladders. 2.2.9 Drilling and breaking hammers are to be guided such that hand injuries caused by solid objects are avoided. When carrying out demolition jobs at elevated places, special care is required to prevent the machine or the operator from falling. 2.2.10 Avoid body contact with earthed components. When breaking connecting passages, make sure that there are no electric wires or gas pipes. No one may stay in the room to which the passage is broken through, as there is danger of injuries because of falling stones or tools. 2.2.11 During operation the tool holder must be closed. Tools and tool holder must be checked for wear in order to guarantee proper functioning of holder. 2.2.12 The operation of this machine may cause broken - off pieces to be flung away. Therefore, during operation, no one except the operator is to come near this machine. 2.2.13 Drilling and breaking hammers have to be disconnected from the electric mains before changing tools. SV00046GB.fm 4
Drilling and breaking hammers 2.2.14 The tools always have to be in perfect conditions. Safety instructions 2.2.15 Do not operate this machine in areas where explosions may occur. 2.2.16 Do not misuse the electric cable to pull or lift up the unit or to pull the plug out of the socket. Protect cable from heat, oil and sharp edges. 2.2.17 Electric equipment and material may only be used if they comply with the operational and local safety requirements. They must be in proper conditions and they must be maintained in this condition. 2.2.18 Do not expose electric tools to rain. Do not use electric tools in damp or wet surroundings. 2.3 Safety checks 2.3.1 Drilling and breaking hammers may only be operated with all safety devices installed. 2.3.2 Before starting operation, the operator has to check that all control and safety devices function properly. 2.3.3 Before starting operation, the overload clutch of drilling hammers has to be checked for proper functioning. 2.3.4 Regularly check cable for damage. 2.3.5 In case of defects of the safety devices or other defects reducing the operational safety of the drilling and breaking hammers, the supervisor has to be informed immediately. 2.3.6 The machine must to be switched off immediately in case of defects jeopardizing the operational safety of the equipment. SV00046GB.fm 5
Safety instructions 2.4 Maintenance Drilling and breaking hammers 2.4.1 Only use original spare parts. Modifications to this machine are subject to the express approval of the Wacker Company. All liabilities shall be refused in case of nonobservance. 2.4.2 Disconnect the drilling and breaking hammer from the electric mains before carrying out maintenance and repair jobs. 2.4.3 Work on the electric parts of the machines may only be carried out by skilled technicians. 2.4.4 All safety devices must be reinstalled properly immediately after maintenance and repair jobs have been completed. 2.5 Transport 2.5.1 When being transported on vehicles, precautions have to be taken that these hammers do not slip or turn over. 2.6 Maintenance checks 2.6.1 According to the conditions and frequency of use, drilling and breaking hammers have to be checked for safe operation at least once every 6 months by skilled technicians, such as those found at Wacker-service depots and have to be repaired if necessary. Please also observe the corresponding rules and regulations valid in your country. SV00046GB.fm 6
3. Technical data Technical data EHB 11BLM/230 Item no 0008731... 0008920... 0008743... 0008997... Length x width x height (without tool) Operating weight (mass) without tool mm: kg: 620 x 105 x 245 11,7 Voltage V: 220-240 1~ Power input kw: 1,38 Minimum generator output requirements for single connection kw: 3,3 Current consumption A: 7,5 Frequency Hz: 50 / 60 Percussion rate electronic control Percussion rate electronic control Special lubricating grease Drill speed electronic control min -1 : min -1 : 1300-2150 140-220 grease Retinax LX2 SDS - max Shaft for drilling tools and breaking tools Power transmission drilling drive Drive motor From motor via crank mechanism to air-percussion system From motor via crank mechanism to bevel gear, safety clutch, drive shaft, tool holder bushing Frequency converter driven three-phase AC motor, with protective insulation Single drill work J: 19 Breaking output (Concrete B25) kg/h: 600 Sound pressure level at operators station L PA : The weighted effective acceleration value, determined according to EN ISO 5349 m/s 2 : 94 db(a) is 9,8 TD00709GB.fm 7
Technical data EHB 11BLM/230 Required cable cross-section in case of cable extensions Max. cable length m: 26 44 70 104 Cable cross-section mm 2 : 1,5 2,5 4 6 TD00709GB.fm 8
Technical data EHB 11BLM/115 Item no 0008744... 0008745... Length x width x height (without tool) Operating weight (mass) without tool mm: 620 x 105 x 245 kg: 11,7 Voltage V: 110-127 1~ Power input kw: 1,2 Minimum generator output requirements for single connection kw: 3,3 Current consumption A: 13 Frequency Hz: 50 / 60 Percussion rate electronic control min -1 : 1300-2150 Percussion rate electronic control Drill speed electronic control Special lubricating grease Shaft for drilling tools and breaking tools Power transmission drilling drive Drive motor min -1 : 140-220 grease Retinax LX2 SDS - max From motor via crank mechanism to air-percussion system From motor via crank mechanism to bevel gear, safety clutch, drive shaft, tool holder bushing Frequency converter driven three-phase AC motor, with protective insulation Single drill work J: 19 Breaking output (Concrete B25) kg/h: 600 Sound pressure level at operators station L PA : 94 db(a) The weighted effective acceleration value, determined according to EN ISO 5349 m/s 2 : is 9,8 Required cable cross-section in case of cable extensions Max. cable length m: 7 12 20 30 Cable cross-section mm 2 : 1,5 2,5 4 6 TD00709GB.fm 9
Description 4. Description 4.1 Application 4.1.1 Wacker s drilling and breaking hammer is commonly used in building construction, civil engineering, facilities construction, municipal projects, concrete plants, artificial stone plants, foundries, installation projects, and many other applications. The drilling and breaking hammer is very well suited for handling natural and artificial stone and every type of masonry and concrete. Various quick-change tools facilitate drilling of holes ranging from 12 to 125 mm, as well as chasing, chiseling, breaking, digging, puddling, knocking, ramming, and deburring. 4.2 Putting into operation 4.2.1 Placing and removing of tool. Pull plug from electric socket. Turn the tool until it distinctly locks in. Latch by applying firm axial pressure (in direction of the shaft). Try to pull out tool to determine if it has engaged correctly. The tool should have a few centimeters longitudinal play in the tool holder. To remove the tool push the collar backwards and then pull out the tool. Only use perfectly sharp tools with tool shank in perfect conditions. It is advisable to lightly grease or oil tool shank and tool holder to avoid dry running and premature excessive wear. 4.2.2 Connection This electric hammer is powered by A. C. (single phase) (see technicla data). A suitable plug is provided for connection. T00764GB.fm 10
4.3 During operation Description 4.3.1 Changing the application The position for breaking or drilling is indicated by the arrow on the cylinder housing and the respective symbol situated opposite on the control lever. To change application turn lever 1/2 turn to the next notch. 4.3.2 Tool adjustment for chipping applications Turn adjusting lever to drilling position to bring e.g. a flat chisel to required working position. Turn chisel until required position is reached. Then turn adjusting lever back to breaking position. 4.3.3 Speed control To reduce the power of the hammer turn knurling wheel in handle in anti-clockwise direction (-). Turn wheel as far as it will go. (Operation at reduced power is necessary for spot drilling and for work on brittle material). To set hammer to full power turn knurling wheel in clockwise direction (+). 4.3.4 Handle system at tool holder (consisting of two handle pieces) Offset handle Than handle can be turned perpendicularly to the tool shaft direction and according to the application requirements by approx. 270 o. Loosen the adjusting ring for turning of handle. The handle can be adjusted in 22,5 o steps by tightening the adjusting ring. Radial handle This handle can be screwed into either the additional handle or at the side of the housing. 4.3.5 The complete handle system can additionally be turned by 360 o, perpendicularly to the tool shaft direction. It must be tightened with the SW13 hex of the radial handle before starting any application (approx. 14 Nm). 4.4 Disassembly 4.4.1 Tool holder Pull collar backwards and then remove rubber cap by hand. Remove collar. Press damping ring together and then take off snap ring. The remaining parts can now be removed. T00764GB.fm 11
Description 4.4.2 Cylinder housing Alternately parially unscrew the cheese head screws until all the screws have been completely loosened. Then remove tool holder with intermediate piston, support and intermediate plate and then take off the cylinder housing with drive shaft from the crank housing. Remove the percussion piston. 4.4.3 Crankcase Access to rotor circlip: Remove screws, take bearing cover and crank mechanism out of crankcase. 4.4.4 Disassembly of handle Remove screws. Remove handle half and back handle. 4.4.5 Motor Access to stator pack and rotor: Remove screws, remove bearing bracket from crankcase. Remove stator pack. Then pull out O-ring and air guiding bushing. Remove circlip and force out rotor. 4.5 Assembly For assembly proceed in the reverse order to dismantling. The following has to be observed in particular: All parts must be carefully cleaned and checked. Grease bearings, crank mechanism and percussion system with special grease (see technicla data. The longer of the two shoulders of the intermediate piston must be pointing towards the tool during assembly of the cylinder housing. Be careful to avoid having the support tilt or jam during assembly. Clean front surfaces of cylinder housing and crankcase and seal with Omni Visc, model 1002. Use Omnifit 230L to glue outer race of deep groove ball bearing. After completion of any kind of repairs, test-run with increasing load. T00764GB.fm 12
5. Maintenance Maintenance 5.1 Maintenance schedule Component Maintenance work Maintenance interval Feed line Miscellaneous Tools Check for perfect condition - if cable defective, replace. Fan slits dirt - free - clean if necessary. Check the shafts and cutting edges - ifnecessary, sharpen, reforge or replace. daily Miscellaneous Regrease via grease nipples. 20 hours Tool holder Check for wear - change if necessary. monthly Miscellaneous Regrease crankshaft drive. 600 hours 5.2 Maintenance and lubrication 5.2.1 General instructions Keep hammer and tools clean. 5.2.2 Mechanical part Every 20 hours of operation moderately grease crank mechanism and percussion system via lubricating nipple situated on crankcase. Use special grease (see technicla data). Check tool holder brushing for wear. The tool may have a play of max. 6 mm at a distance of approx. 200 mm from the entrance. If the bushing is worn to a greater degree, replace it to avoid damages and operational failures. T00757GB.fm 13
Malfunction 6. Malfunction 6.1 Equipment failure Cause for 115V machines: Input voltage to high (>150V) or to low (<45V) for 230V machines: Input voltage to high (>300V) or to low (<170V) Converter temperature to high Supply cable interruption Switch defect Broken cable between converter and switch Defect the converter electronics Broken cable between converter and stator Remedy Make sure to have the correct voltage. Check extension cable for sufficient conductor cross section Let equipment cool off Check supply cable incl. clamp contacts and replace if necessary Replace Replace cable (incl. plug) with converter-switch repair set Replace converter Replace cable (incl. plug) with converter-stator repair set Replace stator Stator defect *Let equipment run warm in warmer environment (e.g. warm room) * remove excessive grease from percussion system * replace defective components * blow out boring, check for reinforcing steel Blocked percussion system: * due to high grease resistance because of low external termperatures * due to over-greasing * due to seizing of moving parts (e.g. due to prolonged dry running) * due to seizing of tool Make sure to have the correct voltage. Check extension cable for sufficient conductor cross section T01041GB.fm 14
Electric wiring diagram 7. Electric wiring diagram Plug Conducting Switch white grey black brown blue Engine Frequency converter SK00686GB.fm 15
Labels 8. Labels for the following machines: 0008395..., 0008731..., 0008740..., 0008741..., 0008743..., 0008744..., 0008754..., 0008919..., 0008920..., 0008997... 1 Decal-sound power level for the following machines: 0008733..., 0008742..., 0008745... 1 Decal - Attention 2 Warning Do not operate without safety guards. Read and understand instruction book. SK00685GB.fm 16
9. Disposal Disposal 9.1 Environmentally friendly reuse Provide for environmentally friendly reuse of the machine. Comply with all regional regulations and directives such as the European directive regarding old electric and electronic devices. Do not add the device to normal waste disposal. Instead, it should be collected separately. T01088GB.fm 17
Disposal T01088GB.fm 18
EC - Conformity Certificate Wacker Construction Equipment AG, Preußenstraße 41, 80809 München hereby certify that the construction equipment specified hereunder: 1. Category: Breaking / Drilling hammer 2. Type: EHB 11 BLM/... 3. Equipment item number: 0008731..., 0008920..., 0008743..., 0008744..., 0008745..., 0008997... 4. Operating weight: 11,7 kg has been evaluated in conformity with Directive 2000/14/EC: Conformity assessment procedure At the following notified body Measured sound power level Guaranteed sound power level Annex VIII VDE Prüf- und Zertifizierungsinstitut Zertifizierungsstelle Merianstraße 28 63069 Offenbach/Main 104 db(a) 105 db(a) and has been manufactured in accordance with the following directives: * 2000/14/EG * 89/336/EG * 98/37/EG * 73/23/EG File certificate carefully C0029004GB.fm Dr. Stenzel Research and Development Management
DIN EN ISO 9001 CERTIFICATE
Wacker Construction Equipment AG - Preußenstraße 41-80809 München - Tel.: +49-(0)89-3 54 02-0 - Fax: +49-(0)89-3 54 02-390 Wacker Corporation - P.O. Box 9007 - Menomonee Falls, WI 53052-9007 - Tel.: +1-(1)(262)-255-0500 - Fax: +1-(1)(262)-255-0550 - Tel.: (800)770-0957 Wacker Asia Pacific Operations-Skyline Tower, Suite 2303, 23/F, 39 Wang Kwong Road, Kowloon Bay, Hong Kong-Tel.: +852 2406 6032-Fax: +852 2406 6021