Atlas Copco CombiCutter CC 1501 User manual

Operating instructions CombiCutter
hydraulic cutter
CC 1501, CC 2100 and CC 4000
Valid from: 07/2003 GBT.Id.Nr. 3363 0028 88
CC 2100

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Operating instructions CombiCutter
hydraulic cutter
CC 1501
CC 2100
CC 4000
E Atlas Copco Co structio Tools GmbH
Atlas Copco Construction Tools GmbH
P. O. Box: 102152, D  45021 Esse
Hele e strasse 149, D  45143 Esse
Federal Republic of Germa y
Telepho e: [phone]  0
Telefax: [phone]  2281
Telefax Customer Support: [phone]  1352

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oreword
Please read this operati g ma ual before usi g
your Atlas Copco CombiCutter for the first time so
as to avoid errors a d breakdow s through i cor
rect usage.
These operati g i structio s co tai :
Himporta t safety regulatio s
Hoperati g i structio s for the hydraulic cutter
Hmai te a ce i structio s for the hydraulic cutter
Haids to troubleshooti g
The operati g i structio s describe how to use the
hammer o site a d should therefore be kept i the
docume t compartme t of the excavator cab.
Please pay careful atte tio to the safety regula
tio s which are listed at the begi i g of this ma 
ual a d repeated i the releva t sectio s.
Respo sibility for the observatio of these safety
regulatio s lies at all times with the operator.
All safety regulatio s listed i this ma ual comply
with the laws a d regulatio s of the Europea
U io . Additio al atio al regulatio s have also
bee take i to co sideratio wherever applicable.
Hydraulic cutter operatio outside the Europea
U io is subject to the laws a d regulatio s valid i
the cou try of use.
Please ote that reliable operatio of the hydraulic
cutter ca o ly be guara teed if ge ui e spare
parts are used.
We wish you every success with your hydraulic
cutter.
Atlas Copco Construction Tools GmbH

5
Explanation of the symbols used in this operating manual
Certai i structio s i the operati g ma ual are marked with symbols to emphasise
their importa ce.
The symbols used are described below:
CAUTION!
Please note!
The marked text provides i structio s
o the correct use of the hydraulic tool
aimed at avoidi g i correct operatio or
errors duri g work.
The marked text provides safety regula
tio s a d i structio s aimed at avoiding
damage to equipment.
WARNING!
The marked text provides safety regula
tio s a d i structio s aimed at avoiding
accidents and possible injuries.

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Table of contents
oreword 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Accident prevention regulations 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Identifying the hydraulic cutter 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1. Scope of supply 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. CE markings (EU directive on machinery 98/37/EC) 11 . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Technical specifications 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Applications 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. Transportation and storage 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. Main components 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. Mounting the hydraulic cutter 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1. Co ecti g the cutter to the carrier’s hydraulic system 15 . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.1. Co ecti g for the first time 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.2. Co verti g from hammer operatio to cutter operatio 15 . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.3. Checki g existi g hydraulic facility for cutter operatio 15 . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2. Mecha ical attachme t 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.1. Attachi g the adapter to the hydraulic cutter 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.2. Mou ti g the hydraulic cutter o the carrier 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. Operating the hydraulic cutter 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1. Media/co sumables 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.1. Mi eral hydraulic fluids 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1.2. E viro me t−frie dly fluids 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2. Start−up 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3. Fu ctio al test 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4. Limitatio s whe cutti g steel 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5. I structio s o the correct use of the hydraulic cutter 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6. U derwater applicatio s 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. Care and maintenance of the hydraulic cutter 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1. Ge eral i formatio 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2. Mai te a ce work 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.1. Mai te a ce work to be performed by the carrier driver 28 . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3. Care a d replaceme t of cutter blades 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4. Checki g a d correcti g the blade cleara ce 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5. Replaci g the cutter teeth 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6. Weldi g i structio s for cutter jaws a d teeth 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7. Prese tatio − Cutter jaw 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.1. Prese tatio − Cutter jaw CC 1501 U (si gle) 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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10.7.2. Prese tatio − Cutter jaw CC 1501 U (double) 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.3. Prese tatio − Cutter jaw CC 1501 S (double) 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.4. Prese tatio − Cutter jaw CC 2100 U (si gle) 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.5. Prese tatio − Cutter jaw CC 2100 U (double) 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.6. Prese tatio − Cutter jaw CC 2100 S (double) 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.7. Prese tatio − Cutter jaw CC4000 U (si gle) 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.8. Prese tatio − Cutter jaw CC 4000 U (double) 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.9. Prese tatio − Cutter jaw CC 4000 S (double) 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.10. Prese tatio − Cutter jaw CC 1501 S (si gle) 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.11. Prese tatio − Cutter jaw CC 2100 S (si gle) 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7.12. Prese tatio − Cutter jaw CC4000 S (si gle) 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8. Mai te a ce schedule 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.9. Lubrica t recomme datio s 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.9.1. Prese tatio − Lubricatio poi ts o the hydraulic cutters
CC 1501, CC 2100 a d CC 4000 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11. Troubleshooting 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1. Hydraulic cutter does ot work 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2. I sufficie t breaki g force 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3. Hydraulic cutter does ot cut 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4. Hydraulic cutter ca ot be rotated 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.5. Operati g temperature too high 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.6. Oil leaks from hydraulic ports 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.7. I sufficie t lubricatio 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12. Dismounting the hydraulic cutter 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.1. Shutdow 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1. Accident prevention regulations
Caution!
To avoid the risk of i jury, please observe the
followi g i structio s.
Before starting work:
Familiarise yourself with the operati g ma ual a d
the applicable regulatio s before starti g work with
the hydraulic cutter.
Whe usi g hydraulic cutters i states of the
Europea U io , the regulatio s co tai ed i the EC
machi ery directive 98/37/EC must be observed a d
followed, as must all applicable atio al accide t
preve tio regulatio s.
I cou tries outside the Europea U io , the valid
local statutes a d regulatio s shall apply.
Whe tra sporti g the carrier with the hydraulic
cutter attached, the carrier ma ufacturer’s safety
i structio s shall apply.
Mounting the hydraulic cutter:
Check the omi al width of the hydraulic li es o
existi g hydraulic systems. All feed a d retur li es
for the hydraulic oil must have a adequate i side
diameter. (Refer to Sectio 4 "Tech ical
Specificatio s").
Use o ly hoses/pipes which satisfy the followi g
quality criteria:
Hydraulic hoses with 4 wire spiral layers to
DIN 20023.
Hydraulic pipes: seamless, cold draw steel pipes to
DIN 2391, page 2, grade C.
Check the ports o the hydraulic cutter a d the hose
co ectio s. The threads must be free of damage.
Clea off a y sa d or similar foreig bodies i the
threads.
Do ot ru a y hydraulic li es through the driver’s
cab.
Mou ti g the hydraulic cutter requires the prese ce
of a assista t, who must be i structed by the carrier
driver. The carrier driver a d assista t should agree
beforeha d o clear ha d sig als.
For tra sport purposes, use o ly the lug provided
a d hoisti g equipme t of sufficie t capacity.
The hydraulic cutter should o ly be mou ted o a
carrier with sufficie t load capacity. For Atlas Copco
hydraulic cutters this ormally mea s a carrier as
show i the table below:
ÂÂÂÂÂÂÂÂ
Â
ÂÂÂÂÂÂ
Â
ÂÂÂÂÂÂÂÂ
Cutter model
ÂÂÂÂÂÂÂÂÂ
Â
ÂÂÂÂÂÂÂ
Â
ÂÂÂÂÂÂÂÂÂ
Carrier weight class
CC 1501
CC 2100
CC 4000
15 − 25 t
22 − 35 t
35 − 50 t
Check the pressure relief valve for the cutter circuit
o the hydraulic system to e sure it is set exactly to
the refere ce value.
Caution!
Collect a y oil which ru s out a d dispose of it
correctly.
The oil ca be very hot, risk of burns!
Cutter operation:
Before fitting and removing the hydraulic cutter
and/or performing service work on the cutter or
carrier hydraulics, ensure that the hydraulic
system has been depressurized!
(see section 10)
Observe the carrier ma ufacturer’s safety regulatio s
Whe worki g with a hydraulic cutter, carrier
operatio is gover ed by the carrier ma ufacturer’s
i structio s.
The hydraulic cutter may o ly be used for the
applicatio s described.
Close the fro t scree /spli ter guard o the driver’s
cab to protect the driver from flyi g rock spli ters
duri g cutter operatio s.
The hydraulic cutter should o ly be operated from
the driver’s cab.
Do ot start up the hydraulic cutter u til both carrier
a d hydraulic cutter are i the correct positio .
If the cutter is to be used i or u der water, prior
co sultatio with Atlas Copco’s Customer Support is
ecessary to clarify the special requireme ts for such
applicatio s.
Use o ly approved hydraulic oils.
All mi eral hydraulic oil bra ds prescribed by the
carrier ma ufacturer are suitable for cutter operatio .
The use of other hydraulic fluids is subject to prior
co sultatio .
Use o ly hydraulic oils of sufficie t viscosity.
I summer a d i tropical climates, oils of viscosity
class HLP 68 or higher should be used.
Observe the oil temperature at all times.
The temperature of the hydraulic oil must ever
exceed 80oC.
Do ot start up the hydraulic cutter at temperatures
below mi us 20oC u til the hydraulic oil has bee
warmed up.
Caution!
Stop the hydraulic cutter immediately if a yo e
moves i to the da ger zo e, i. e. a radius of at least
7 metres arou d the hydraulic cutter.

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Depe di g o the applicatio a d the material
greater dista ces may have to be observed or the
site must be cordo ed off.
Danger by flying splinters!
Maintenance and repairs:
Before fitting and removing the hydraulic cutter
and/or performing service work on the cutter or
carrier hydraulics, ensure that the hydraulic
system has been depressurized!
(see section 10)
Use Atlas Copco cutter grease to lubricate the tool.
Observe the mai te a ce schedule a d carry out all
the preve tive checks listed.
Dismou ti g the hydraulic cutter:
Dismou ti g the hydraulic cutter requires the
prese ce of a assista t, who must be i structed by
the carrier driver. The carrier driver a d assista t
should agree beforeha d o clear ha d sig als.
Observe the carrier ma ufacturer’s safety
regulatio s.
Whe putti g the carrier out of operatio , the carrier
ma ufacturer’s i structio s shall apply.
Caution!
Collect a y oil which ru s out a d dispose of it
correctly.
Please note:
The oil ca be very hot. Risk of bur s!
Please note:
After cutter operatio , oil−beari g parts are very hot.
Risk of bur s!
After dismou ti g store the cutter i such a way that
it ca ot fall over.

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2. Identifying the hydraulic cutter
The ameplate (see Fig. 1 for locatio ) provides the followi g i formatio ide tifyi g the cutter:
Hma ufacturer
Hhydraulic cutter model
Hweight
Hyear built
Hpart ide t. o.
Please note: The serial umber is stamped o to the cutter below the lifti g lug.
These data should be quoted i all correspo de ce − especially whe orderi g spare parts − so as to clearly
ide tify the cutter.
Fig. 1
CC 2100
Nameplate
2.1. Scope of supply
The ge eral scope of supply for a Atlas Copco CombiCutter i cludes:
Hhydraulic cutter
Hoperati g ma ual
Hspare parts list
Hi fo. sheet
Hspecial accessories as ordered, e.g. hydraulic
co versio kit for carrier, adapter
Subject to modificatio .