Atlas Copco PP 100 Maintenance and service guide

Safety and operating instructions
Hydraulic power packs
© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
PP 100

Contents
Introduction........................................................................5
About the Safety and operating instructions..........................................5
Safety instructions.................................................................6
Safety signal words..............................................................6
Personal precautions and qualifications...........................................6
Personal protective equipment...................................................6
Drugs, alcohol or medication....................................................6
Installation, precautions..........................................................6
Operation, precautions...........................................................7
Maintenance, precautions........................................................8
Storage, precautions.............................................................9
Overview.........................................................................10
Design and function............................................................10
Main parts.....................................................................10
Labels.........................................................................10
Dataplate....................................................................11
Safety label..................................................................11
Caution: fill with oil beforeuse..................................................11
Electrical hazard label.........................................................11
Water pressure label..........................................................12
Electricalconnectionlabel......................................................12
Installation........................................................................12
Quick-release couplings........................................................12
Hydraulic oil ...................................................................12
Hoses and connections.........................................................12
Connecting hoses.............................................................12
Connecting newhydraulic hoses................................................12
Disconnecting hoses..........................................................12
Hose length..................................................................13
Water connection.............................................................13
Electrical connection..........................................................13
Transport.........................................................................13
Lifting the power pack ..........................................................13
Operation.........................................................................14
Operating......................................................................14
Preparation before starting.....................................................14
Start and stop..................................................................15
Power on demand............................................................15
Emergency stop..............................................................15
Reinforced cooling and power reduction.........................................15
When taking a break............................................................16
Maintenance......................................................................16
Hydraulic oil refill...............................................................16
Every day......................................................................17
Every 300 hours................................................................17
Disposal..........................................................................17
Storage...........................................................................17
3© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
ContentsPP 100

Technical data.....................................................................18
Machine data...................................................................18
Noise declaration statement.....................................................18
Troubleshooting...................................................................20
Advanced Troubleshooting.........................................................21
Service data download..........................................................21
.............................................................................21
Diagnostic files.................................................................22
EC Declaration of Conformity......................................................24
EC Declaration of Conformity (EC Directive 2006/42/EC)...........................24
© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
4
PP 100Contents

Introduction
Thank you for choosing a product from Atlas Copco. Since 1873, we have been
committed to finding new and better ways of fulfilling our customers' needs.
Through the years, we have developed innovative and ergonomic product
designs that have helped customers improve and rationalize their daily work.
Atlas Copco has a strong global sales and service network, consisting of
customer centers and distributors worldwide. Our experts are highly trained
professionals with extensive product knowledge and application experience.
In all corners of the world, we can offer product support and expertise to ensure
that our customers can work at maximum efficiency at all times.
For more information please visit: www.atlascopco.com
Construction Tools PC AB
Box 703
391 27 Kalmar
Sweden
About the Safety and operating
instructions
The aim of the instructions is to provide you with knowledge of how to use the
power pack in an efficient, safe way. The instructions also give you advice and
tell you how to perform regular maintenance on the power pack.
Before using the power pack for the first time you must read these instructions
carefully and understand all of them.
5© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
Safety and operating instructionsPP 100

Safety instructions
To reduce the risk of serious injury or death to
yourself or others, read and understand the Safety
and operating instruction before installing, operating,
repairing, maintaining, or changing accessories on
the machine.
Post this Safety and operating instruction at work
locations, provide copies to employees, and make
sure that everyone reads the Safety and operating
instruction before operating or servicing the machine.
For professional use only.
In addition, the operator or the operator's employer
must assess the specific risks that may be present
as a result of each use of the machine.
Safety signal words
The safety signal words Danger, Warning and
Caution have the following meanings:
Indicates a hazardous situation
which, if not avoided, will result
in death or serious injury.
DANGER
Indicates a hazardous situation
which, if not avoided, could
result in death or serious injury.
WARNING
Indicates a hazardous situation
which, if not avoided, could
result in minor or moderate
injury.
CAUTION
Personal precautions and
qualifications
Only qualified and trained persons may operate or
maintain the machine. They must be physically able
to handle the bulk, weight, and power of the tool.
Always use your common sense and good
judgement.
Personal protective equipment
Always use approved protective equipment.
Operators and all other persons in the working area
must wear protective equipment, including at a
minimum:
●Protective helmet
●Hearing protection
●Impact resistant eye protection with side protection
●Respiratory protection when appropriate
●Protective gloves
●Proper protective boots
●Appropriate work overall or similar clothing (not
loose-fitting) that covers your arms and legs.
Drugs, alcohol or medication
WARNING Drugs, alcohol or medication
Drugs, alcohol or medication may impair your
judgment and powers of concentration. Poor
reactions and incorrect assessments can lead to
severe accidents or death.
►Never use the machine when you are tired or
under the influence of drugs, alcohol or
medication.
►No person who is under the influence of drugs,
alcohol or medication may operate the machine.
Installation, precautions
DANGER Electrical hazard
The machine is not electrically insulated. There is a
risk of electrical shocks if the electrical cable is not
treated correctly. If the machine is not connected
correctly, serious injuries or death may result.
►See section "Operation, precautions" for more
information regarding electrical hazards.
WARNING Hydraulic oil at high pressure
Thin jets of hydraulic oil under high pressure can
penetrate the skin and cause permanent injury.
►Immediately consult a doctor if hydraulic oil has
penetrated the skin.
►Never use your fingers to check for hydraulic fluid
leaks.
►Keep your face away from any possible leaks.
►Never operate the machine without covers.
WARNING Hydraulic oil
Spilled hydraulic oil can cause burns, accidents due
to slippery conditions and will also harm the
environment.
►Take care of all spilled oil and handle it according
to your safety and environmental regulations.
►Never dismount the hydraulic machine when the
hydraulic oil is hot.
CAUTION Skin eczema
Hydraulic oil can cause eczema if it comes in contact
with the skin.
►Avoid getting hydraulic oil on your hands.
►Always use protective gloves when working with
hydraulic oil.
►Wash hands after contact with hydraulic oil.
© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
6
PP 100Safety and operating instructions

CAUTION Moving parts
Risk for crushed hands and fingers.
►Never check bores or passages with hands or
fingers.
Operation, precautions
DANGER Fire hazard
If a fire starts in the machine, it can cause injury.
►If possible use an ABE-class powder extinguisher,
otherwise use a BE-type carbon dioxide fire
extinguisher.
DANGER Explosion hazard
When working on certain materials and when using
certain materials in machine parts, sparks and
ignition can occur. Explosions will lead to severe
injuries or death.
►Never operate the machine in any explosive
environment.
►Never use the machine near flammable materials,
fumes or dust.
►Make sure that there are no undetected sources
of gas or explosives.
DANGER Electrical hazard
The machine is not electrically insulated. If the
machine is not connected correctly, serious injuries
or death may result.
►Never place the power pack in a position where it
risks being drowned by water.
►Ensure that the machine is earthed and that the
earth connection has been checked at regular
intervals for correct functionality. Operation of the
machine without an earth connection presents a
risk of fatal accident.
►Use a DC-sensitive residual current circuit breaker
(RCCB) protected supply. The RCCB must be
checked for correct functionality according to the
specifications from the manufacturer.
►Never modify the electrical plug or socket.
►Check that the mains voltage corresponds with
the information stated on the data plate on the
machine.
►Only cerified technicians are allowed to service
the electrical motor. Do not open any of the motor
covers. Unauthorized service work on the motor
might lead to power pack malfunction and possibly
serious injuries or death.
DANGER Electrical cable hazard
There is a risk of electrical shocks if the electrical
cable is not treated correctly, this can lead to serious
injuries or death.
►Never move the machine by dragging the electrical
cable.
►Disconnect the cable only by pulling the socket,
never pull the electrical cable.
►Do not expose the electrical cable to heat, oil, and
sharp edges.
►Make sure the electrical cable is not pinched in
doors, fences or similar.
►Check that the electrical cable, extension cable,
and cable plug are intact and in good condition.
Never connect a damaged electrical cable to the
machine.
►Never touch the electrical cable if it becomes
damaged while working. Disconnect the main
supply and then disconnect the electrical plug from
the socket.
WARNING Whipping hose
Hoses under pressure can whip uncontrollably if the
hose connection becomes loose. A whipping hose
can cause severe injuries. To reduce this risk:
►Turn of the power pack before loosening the
connection of a hose.
►Check that the hose and the connections are not
damaged.
►Never carry or drag the machine by the hoses.
WARNING Abuse hazard
Never abuse or strike the power pack. This may
cause machine breakdown.
►Never strike or abuse the equipment.
►Make sure that the frame is clean and free of oil.
►Never rest on the power pack.
►Never throw objects on the power pack.
WARNING Cover protection
The covers of the power pack must be in place. Thin
jets of hydraulic oil under high pressure can penetrate
the skin and cause permanent injury.
►Never operate the machine without covers.
►Immediately consult a doctor if hydraulic oil has
penetrated the skin.
7© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
Safety and operating instructionsPP 100

WARNING Dust and fume hazard
Dusts and/or fumes generated or dispersed when
using the machine may cause serious and permanent
respiratory disease, illness, or other bodily injury (for
example, silicosis or other irreversible lung disease
that can be fatal, cancer, birth defects, and/or skin
inflammation).
Some dusts and fumes created by drilling, breaking,
hammering, sawing, grinding and other construction
activities contain substances known to the State of
California and other authorities to cause respiratory
disease, cancer, birth defects, or other reproductive
harm. Some examples of such substances are:
●Crystalline silica, cement, and other masonry
products.
●Arsenic and chromium from chemically-treated
rubber.
●Lead from lead-based paints.
Dust and fumes in the air can be invisible to the
naked eye, so do not rely on eye sight to determine
if there is dust or fumes in the air.
To reduce the risk of exposure to dust and fumes,
do all of the following:
►Operate and maintain the machine as
recommended in the safety and operating
instructions.
►Read the attached machine's safety and operating
instructions.
WARNING Overheated power pack
The power pack can become overheated and cause
burns.
►Never turn off the cooling water.
WARNING Falling power pack
If the power pack tips over and fall, it may cause
serious injury.
►Place the power pack in a safe position where it
cannot fall and cause damage.
WARNING Slipping, tripping and falling
hazards
There is a risk of slipping or tripping or falling, for
example tripping on the hoses or on other objects.
Slipping or tripping or falling can cause injury. To
reduce this risk:
►Always make sure that no hose or other object is
in your way or in any other person's way.
►Always make sure you are in a stable position with
your feet as far apart as your shoulders width and
keeping a balanced body weight.
WARNING Slipping hazard
There is a risk of slipping on spilled oil, it may cause
serious injury. To reduce this risk:
►Wipe immediately up spilled oil from the ground.
►Make sure that the frame is clean and free of oil.
WARNING Involuntary start
Involuntary start of the machine may cause injury.
►Keep your hands away from the start and stop
device until you are ready to start the machine.
►Learn how the machine is switched off in the event
of an emergency.
►Stop the machine immediately in all cases of
power supply interruption.
WARNING Noise hazard
High noise can cause permanent loss of hearing and
other problems such as tinnitus (ringing, buzzing,
whistling or humming in the ears). To reduce risk and
prevent an unnecessary increase of noise levels:
►Operate and maintain the machine as
recommended in these instructions.
►Read the attached machine's safety and operating
instructions.
WARNING Nominal pressure
If the maximum nominal pressure for the hydraulic
machine is exceeded, it can result in material
damage and personal injury.
►Always run the hydraulic machine with a tool (in
this case, only RD 100) that does not require a
continuously higher pressure than the stated
nominal pressure. See section "Technical data".
Maintenance, precautions
WARNING Machine modification
Any machine modification may result in bodily injuries
to yourself or others.
►Never modify the machine. Modified machines are
not covered by warranty or product liability.
►Always use original parts and accessories.
►Change damaged parts immediately.
►Replace worn components in good time.
WARNING Accessory hazards
Accidental engagement of accessories during
maintenance or installation can cause serious
injuries, when the power source is connected.
►Never inspect, clean, install, or remove
accessories while the power source is connected.
© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
8
PP 100Safety and operating instructions

Storage, precautions
♦Keep the machine and tools in a safe place, out
of the reach of children and locked up.
9© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
Safety and operating instructionsPP 100

Overview
To reduce the risk of serious injury or death to
yourself or others, read the Safety instructions
section found on the previous pages of this
manual before operating the machine.
Design and function
PP 100 is a hydraulic power pack designed for
operating hydraulic rock drills of type RD 100. No
other use is permitted.
PP 100 is fitted with a (10 kW) electric motor. The
oil flow for PP 100 is 38 l.p.m (10 US gal/min) and
nominal pressure 120 bar (1,740 psi).
The motor is cooled by a water flow of minimum 12
l/min (US 3.2 gal/min) with a maximum temperature
of 20 ˚C and pressure below 13 bar (189 psi), in
normal operation.
See the spare parts list for accessories, spare parts
and electrical schematics. See the overhauling
instructions for service guide.
Main parts
Fluid connection side
A
BC
D
E
A. Hydraulic oil inlet
B. Water outlet
C. Hydraulic oil outlet
D. Water inlet
E. Reinforced cooling water outlet
Electrical connection side
K
L
I
H
G
F
M
N OP
J
Q
F. Hydraulic oil volume indicator
G. Electrical connector
H. Emergency stop
I. On/Off button
J. Data plate
K. USB memory stick connector
L. Safety label (Top)
M. Oil drainage
N. LED 3, oil error
O. LED 2, temperature error
P. LED 1, operation error
Q. Electrical connection label
NOTICE Do not use the USB memory stick
connector for other than the USB stick. For the use
of the USB memory stick connector, see chapter
Advanced diagnostics.
Labels
The machine is fitted with labels containing important
information about personal safety and machine
maintenance. The labels must be in such condition
that they are easy to read. New labels can be ordered
from the spare parts list.
© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
10
PP 100Safety and operating instructions

Data plate
ACB G
HI
xxxx
J
DE F
A. Machine type
B. Serial number
C. The warning symbol together with the book
symbol means that the user must read the
safety and operating instructions before the
machine is used for the first time.
D. Maximum nominal operating pressure
E. Maximum permitted hydraulic oil flow
F. Document number of the Safety and operating
instructions.
G. Maximum relief valve setting
H. Electrical data
I. Year of manufacture.
J. The CE symbol means that the machine is
EC-approved. See the EC Declaration of
Conformity which is delivered with the machine
for more information.
Safety label
To avoid injury, before using or servicing tool, read
and understand separately provided safety
instructions.
Caution: fill with oil before use
Electrical hazard label
11© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
Safety and operating instructionsPP 100

Water pressure label
Electrical connection label
E
P
L1 L2
L3
L1 - Phase 1
L2 - Phase 2
L3 - Phase 3
P - Pilot wire
E - Earth
Installation
Quick-release couplings
The original hydraulic hoses are fitted with Flat-Face
quick-release couplings that are strong and easy to
clean.
NOTICE Wipe all couplings clean before
connecting. Ensure that couplings are clean and
correctly engaged before operation. Failure to do so
may result in damage to the quick couplings and
cause overheating and cause foreign matter to enter
the hydraulic system.
Hydraulic oil
In order to protect the environment, use of biologically
degradable hydraulic oil (HFD-U) is recommended.
No other fluids must be used.
♦Viscosity (preferred) 40-50 cSt.
Make sure to only use clean oil and filling equipment.
When the machine is used continuously, the oil
temperature will stabilise at a working temperature
level. This will, depending on the type of work and
the cooling capacity of the hydraulic system, be
between 35-45°C (95-113°F). At working
temperature, the oil viscosity must be within the
preferred limits. The viscosity index indicates the
connection between viscosity and temperature. The
machine must not be used, if oil viscosity fails to
remain within the permitted area, or if the working
temperature of the oil does not fall between 20°C
(68°F) and 60°C (140°F).
Hoses and connections
Connecting hoses
NOTICE Make sure that the hydraulic oil hoses are
filled before connection.
1. Put the power pack in standby mode by pressing
the On/Off-button.
2. Make sure that the couplings are clean and
operational.
3. Attach the return line hose and the pressure line
hose according to matching colors. The red color
is for pressure line, the blue color is for return
line.
4. Start the unit by pressing the On/Off-button. Run
the power pack to fill up the hydraulic circuit.
Check the hydraulic oil volume, LED 3.
Connecting new hydraulic hoses
Fill up the hoses with oil prior to first usage. The
hoses will require approximately 2 liters (0,53 US
gal) of oil per 10 meter (32,8 feet) hose length.
NOTICE Empty hoses will drain the power pack of
oil and might prevent it from starting.
1. Connect the pressure and return line hoses to
the power pack and then connect them in a
closed loop.
2. Start and run the power pack for 2 minutes in
idle mode. The oil in the hoses will pass through
the oil filter and will be cleaned.
3. Disconnect the pressure and return line from
each other and connect them to the RD 100.
Disconnecting hoses
1. Put the power pack in standby mode by pressing
the On/Off-button.
2. Remove the feed line hose and the return line
hose.
The couplings are unlocked by moving the collar
back on the coupling.
© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
12
PP 100Safety and operating instructions

Hose length
A one way hose length of maximum 10 m (33 ft) is
recommended.
Water connection
The power pack is water-cooled. The water has a
flushing function for the attached machine during
operation.
NOTICE Ensure that all couplings are clean before
connection.
♦Connect the water hose to the water inlet
connection on the power pack and connect the
attached machine's water hose to the water outlet
connection, see section "Main parts".
♦Check the flow of the water. Make sure that water
is sprayed out from the bores on the attached
machine's working tool.
Electrical connection
NOTICE Ensure that all connectors are clean before
connection.
♦The power pack must be connected to alternating
current supply that complies with the information
given on the data plate.
♦The electrical cable must be between a minimum
of 20 meters (65,6 feet) and a maximum of 100
meters (328 feet).
♦Use an electrical cable with conductors of
adequate cross section in order to avoid a drop in
the machine's performance and overheating of
the extension cord. The recommended conductor
cross section is 2.5 mm2over a length of 100
meter. See section "Main parts" for electrical
connection.
NOTICE Failure to comply with the cable length
specification can lead to equipment damage.
The power pack is equipped with a 2-wire module
for ground supervision. The remaining steps to
ensure electrical connection safety needs to be
applied on the power supply side.
♦Ensure that the main supply is equipped with an
emergency stop.
♦Connect the power pack to the main supply only
when it is ready for use. Disconnection from the
main supply must be by way of an isolating switch.
♦Shut off the main supply prior to disconnecting the
electrical cable.
♦Always connect the power pack to main supply
that is equipped with a DC-sensitive residual
current circuit breaker (RCCB) rated at max 30
mA. The RCCB must be checked for correct
functionality according to the specifications of the
manufacturer of the RCCB. Ensure that the earth
connection has been checked for correct
functionality.
♦The power pack must be connected to a Pilot
relay. An example of a compliant relay is the
5001-011 MSR-9 by Switching Systems (Pty) Ltd.
The connection must be made acccording to the
Pilot relay manufacturer instruction.
♦The monitoring circuit must be intrinsically safe in
accordance with EN 50020.
NOTICE The circuit diagram for the installation of
the power pack can be found in the power pack spare
parts list (nr 9800 1538).
Transport
WARNING Falling power pack
If the power pack tips over and fall, it may cause
serious injury.
►Place the power pack in a safe position where it
cannot fall and cause damage.
During transport make sure the power pack is
secured. Ensure that the power pack is upright during
transportation and lifted with approved lifting
equipment.
Drain the water system if there is risk of freezing to
avoid damage to the power pack motor.
Lifting the power pack
Two persons are required when lifting the machine.
Grasp the frame on the machine's short sides, see
illustration below. Lift the power pack and move it to
its intended destination.
13© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
Safety and operating instructionsPP 100

When moving the machine a shorter distance, grasp
frame on the power pack's short side, see illustration
below. Pull the machine to its intended destination.
When lifting the power pack with a forklift, fit the lifting
strap in the manner shown in the illustration below.
Operation
WARNING Involuntary start
Involuntary start of the machine may cause injury.
►Keep your hands away from the start and stop
device until you are ready to start the machine.
►Learn how the machine is switched off in the event
of an emergency.
►Stop the machine immediately in all cases of
power supply interruption.
Operating
NOTICE A new PP 100 is delievered without oil in
the tank. Always fill with hydraulic oil before operating
a new power pack.
♦Same procedure as in "Hydraulic oil refill".
Preparation before starting
The following checks must be made each time the
power pack is used. All these checks concern the
operation of the power pack. Some concern safety:
♦Clean all safety labels. Replace the missing or
damaged labels.
♦Remove dirt and debris.
♦Inspect the power pack and hoses generally for
signs of damage.
♦Check that all cables are intact and in a good
condition.
♦Fill up the hydraulic hoses with oil before start.
♦Check for oil leakages under the power pack.
♦Ensure that the hydraulic couplings are clean and
operational.
♦Check all fastenings.
♦Place the power pack in a safe position, to prevent
tilting during operation. Maximum 45º tilt. The
prefered position is the hydraulic end as highest
point.
♦Check that the machine is connected to an earthed
electrical outlet socket, according to instructions
in section "Electrical connection".
© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
14
PP 100Safety and operating instructions

♦Connect the power supply (A), see illustration
below.
B
A
♦Check the hydraulic oil level, LED 3 (B).
♦Inspect the LED indicators (B). Flashing or
continuous lighting LEDs indicate errors that need
to be adressed before start.
Start and stop
A
1. Switch on the main supply. The On/Off button
(A) on the top of the power pack is flashing (0,5
Hz), the machine is in stand-by mode.
2. Start the power pack by pressing the On/Off
button, the button lights up.
3. Stop the power pack by pressing the On/Off
button, the button is flashing (0,5 Hz). The
machine is in stand-by mode.
4. If the On/Off button, in stand-by mode, is flashing
fast (2 Hz) the machine must be serviced.
Power on demand
The power pack is equipped with a power on demand
function. When pressing the On/Off-button, the RD
100 is in idling mode with a low RPM. When pressing
the attached machine's throttle the engine is
increasing to work mode. Release the throttle and
the power pack returns to idling mode.
Emergency stop
In case of emergency during operation, press the
emergency stop (A). The power pack will stop and
the LED 1 (B) indicator lights continuously.
A B
C
1. Check and correct the error before restarting the
power pack.
2. Reset the emergency stop (A) by turning the
emergency stop button.
3. Press the On/Off button (C) to get the power pack
in stand-by mode.
4. Start the power pack by pressing the On/Off
button (C).
NOTICE Do not use the emergency stop to shut off
the power pack during normal operation.
Reinforced cooling and power
reduction
The cooling water outlet (A) is used during reinforced
cooling.
15© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
Safety and operating instructionsPP 100

A
Water flows from the cooling water outlet if the
machine is starting to be overheated.
LED 2 indicates enhanced cooling and power
reduction. Following scenario is possible:
♦If the power pack becomes slightly overheated, it
will drain out water from the cooling water outlet.
LED 2 is flashing slow (0,5 Hz).
♦If the machine still is overheated, the power will
be reduced. LED 2 is flashing fast (2 Hz).
♦If the power pack is very overheated it will shut
down. LED 2 lights continuously.
Allow the power pack to cool before restarting it.
When taking a break
♦During all breaks the machine must be placed in
such a way that there is no risk for it to be
unintentionally started. Make sure to place the
machine on the ground, so that it can not fall.
♦Switch off the main supply in the event of a longer
break or when leaving the workplace. Disconnect
the electrical cable and use caps to protect the
contacts.
♦Switch off the water supply in the event of a longer
break or when leaving the workplace.
Maintenance
Regular maintenance is a basic requirement for the
continued safe and efficient use of the machine.
Follow the maintenance instructions carefully.
♦Before starting maintenance on the machine, clean
it in order to avoid exposure to hazardous
substances.
♦Use only authorised parts. Any damage or
malfunction caused by the use of unauthorised
parts is not covered by warranty or product liability.
♦When cleaning mechanical parts with solvent,
comply with appropriate health and safety
regulations and ensure there is satisfactory
ventilation.
♦For major service to the machine, contact the
nearest authorised workshop.
♦After each service, check that the machine's
vibration level is normal. If not, contact the nearest
authorised workshop.
WARNING Slipping hazard
There is a risk of slipping on spilled oil, it may cause
serious injury. To reduce this risk:
►Wipe immediately up spilled oil from the ground.
►Make sure that the frame is clean and free of oil.
Hydraulic oil refill
Refill oil when LED 3 is flashing, see "Hydraulic oil".
1. The power pack must be in stand-by mode,
flashing 0,5 Hz.
2. Disconnect the hydraulic hoses.
3. Connect the top-up tank to the hydraulic oil inlet,
see "Main parts" (A).
4. Refill oil until the oil volum indicator pin pops out
(can be felt with finger), see "Main parts" (F).
5. Disconnect the top-up tank.
6. Tilt the power pack, approximate 30° with the
fluid connection side as the highest point. The
tank ventilating system will be automatically
activated to ventilate trapped air in the oil tank.
7. Level the power pack.
8. If the oil volume indicator pin does not pop out,
repeat the steps 3-7 again until the oil volume
indicator pin pops out.
9. Fill up the hydraulic hoses with oil and connect
them.
10. Wipe up any spilled oil from the ground and
manage it in respect to local restrictions.
© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
16
PP 100Safety and operating instructions

Every day
Never perform maintenance when the power pack
is running.
♦Clean and inspect the machine and its functions
each day before starting work.
♦Do not use a pressure washer for cleaning.
♦Conduct a general inspection for leaks and
damage and wear.
♦Change damaged parts immediately.
♦Replace worn components in good time.
♦Never use the equipment if there is suspicion that
it is damaged.
♦Never strike or abuse the equipment.
♦Make sure that all the attached and related
equipment, such as hoses, cable connectors, and
couplings are in good condition.
♦Check the hydraulic oil volume.
♦Check the hydraulic couplings and the hoses.
♦All fasteners and other threaded components to
be tightened according to the torque stated in the
spare parts list.
Every 300 hours
♦The on/off button will signal (flashing 2Hz) that the
service inteval is reached.
♦The machine must be inspected and serviced by
authorised staff, trained for this task.
Disposal
A used machine must be treated and scrapped in
such a way that the greatest possible portion of the
material can be recycled and any negative influence
on the environment is kept as low as possible.
Before a used machine is scrapped it must be
emptied and cleaned from all hydraulic oil. The
remaining hydraulic oil must be deposited and any
negative influence on the environment is to be kept
as low as possible.
Storage
♦Check that the machine is properly cleaned before
putting it away for storage.
♦Store the machine in a dry place.
♦Keep the machine in a safe place, out of the reach
of children and locked up.
♦Drain the water system if there is a risk of freezing.
♦Up to three units can be stacked on top of each
other for convenient storage.
17© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
Safety and operating instructionsPP 100

Technical data
Machine data
PP 100
831103045083110304608311030420
380 V ± 10%, 50/60 Hz, 17 A440 V ± 10%, 50/60 Hz, 17 A525 V ± 10%, 50 Hz, 12 APower supply
21 A (< 4 ms)21 A (< 4 ms)15 A (< 4 ms)Peak current
10 (13.4)Input power, kW (HP)
352 (13.9)Height, mm (in.)
402 (15.8)Width, mm (in.)
695 (27.4)Length, mm (in.)
5 to 40 (41 to 104)Ambient temperature range, °C (°F)
45 (99)Weight incl oil, kg (lb)
38 (1.4)Flow, l/m (ft3/min)
20 to 60 (68 to 140)Hydraulic oil temperature, °C (°F)
120 (1,740)Nominal pressure, bar (psi)
Helical rotor pump, directly driven from the motor shaft.Pump type
8.7 (2.3)Oil tank capacity, litres (US gal)
10 µ filter in return line. Filter by-pass valve.Filtration
WaterCooling system
Inverter controled 3 phase PM motor.Motor type
Supply interrupted or at zero voltage for not more than 3 ms at any random time in the supply
cycle with more than 1 s between successive interruptions.
Voltage interruption limit
Voltage dips not exceeding 20 % of the peak voltage of the supply for more than one cycle
(20ms) with more than 1 s between successive dips.
Voltage dips limit
Transient voltage increase 0,5s repeated < 1time/min: 20 %
Transient voltage increase 3ms repeated < 1time/min: 40 %
Overvoltage limit
PC1 5 pole, 3P, Pilot +ESocket
Installed with residual current device
Earth supervision
Earth in cable screen
Electrical safety
IP66IP class
Noise declaration statement
Noise
Declared values
Sound powerSound pressure
2000/14/ECEN ISO 11203
Lw
measured dB(A) rel
1pW
Lw2
guaranteed dB(A) rel
1pW
Lp1
dB(A) rel
20uPaType
879074PP 100
1Sound pressure level according to EN ISO 11203 at 1 metre distance.
2Guaranteed sound power according to EN ISO 3744 in accordance with directive 2000/14/EC inclusive spread
in production.
These declared values were obtained by laboratory type testing in accordance with the stated directive or
standards and are suitable for comparison with the declared values of other tools tested in accordance with
the same directive or standards. These declared values are not adequate for use in risk assessments and
values measured in individual work places may be higher. The actual exposure values and risk of harm
experienced by an individual user are unique and depend upon the way the user works, in what material the
© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
18
PP 100Safety and operating instructions

breaker is used, as well as upon the exposure time and the physical condition of the user, and the condition of
the breaker.
We, Construction Tools PC AB, cannot be held liable for the consequences of using the declared values, instead
of values reflecting the actual exposure, in an individual risk assessment in a work place situation over which
we have no control.
19© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
Safety and operating instructionsPP 100

Troubleshooting
Operation status, LED 1
RemedyLED 1Status
Connect the hydraulic hoses.Lights continuouslyStart with unconnected hydraulic hoses
Check and remedy the power supply.Lights continuouslyOvervoltage
Check and remedy the power supply.Lights continuouslyUndervoltage, <30% nominal voltage
Check and remedy the power supply or drill with reduced
power.
Flashing (0.5 Hz)Low voltage, power reduction
Check and remedy the power supply.Lights continuouslyPhase failure, phase diconnected
Contact authorized service workshop if the problem
persists after power pack restart.
Lights continuouslyMotor failure
Temperature status, LED 2
RemedyLED 2Status
-Flashing slow (0.5 Hz)High temperature enables enhanced
cooling
-Flashing (2 Hz)High temperature enables power reduction
Cool down for 15 minutes, use cooling water flow.Lights continuouslyOverheated, engine stopped
Oil status, LED 3
RemedyLED 3Status
No disruption.Flashing slow (0.5 Hz)Low oil level warning
Top up hydraulic oil.Lights continuouslyLow oil level, engine stopped
Only venting in stand-by mode. Never start the power
pack when the ventilating valve is activated.
Flashing (2 Hz), when the
ventilating valve is activated.
Air in the oil tank
Check water supply. Cool down for 30 minutes. Repeated
indication, service is needed. Contact nearest authorised
workshop.
Lights continuouslyOil temperature
Water pressure status, LED 1, LED 2, LED 3
RemedyLED 1, LED 2, LED 3Status
Check water supply. Water pressure needs to be above
4 Bar.
All LEDs flash slowly (0.5 Hz)Low water pressure
Service status, On/off button
RemedyOn/off buttonStatus
Service interval reached (by default set to 300 hours).
Perform service according to maintenance instructions.
Flashing (2 Hz)Service interval reached
© 2016 Construction Tools PC AB | No. 9800 1364 01c | 2016-04-06
Original instructions
20
PP 100Safety and operating instructions