Owner’s Manual!

OXE-VPP065-TEC-E-3200-O-VM-001_A
! 15-802 / AMSA

www.tecman.com
OWNER’S MANUAL



TECMAN UA1200 ROCK BREAKER BOOM


SERIAL N°15-783

PRELIMINARY

revu 09/09/2015! ! Page 1 sur 35

Owner’s Manual! ! 15-802 / AMSA

INDEX
!
INDEX 2
1- DESCRIPTION 3
A- DESCRIPTION 3

B- WARRANTY 3

C- SCOPE OF SUPPLY 4

D- DATASHEET 5

E- Hydraulic Schematics 6

F- Electric Schematics 7

2- SAFETY 8
A- FOREWORD 8

B- PRECAUTIONS 8
C- SAFETY 9

3- TRANSPORTATION 16
B- LIFTING 16

4- INSTALLATION 17
5- COMMISIONNING 18
6- OPERATION 19
A- PEDESTAL CONTROL OPERATIONS 19

B- BEST PRACTICE 20

7- BREAKER TOOL REPLACEMENT 23

8- MAINTENANCE 24
9- LUBRICATION 27
A- OIL SPECIFICATIONS 27

B- MANUAL LUBRICATION 28

10 - TROUBLESHOOTING LIST 29
A- BOOM POOR OPERATION 29

B- OIL LEAKAGE 32

C- BREAKER POOR OPERATION 33

11 - SPARE PARTS 34
12- EC DECLARATION OF CONFORMITY 35

revu 09/09/2015! ! Page 2 sur 35

Owner’s Manual! ! 15-802 / AMSA

1- DESCRIPTION
!
A- DESCRIPTION
!
!
Tecman Rock Breakers are designed to safely destroy any oversized or
bridged rock over a crusher. Our machines are used mainly in Mines,
Quarries and Cement plants
!
!
!
!
!
!
B- WARRANTY
!
We thank you for having chosen a TECMAN Rock Breaker. We manufacture our products with care
and pride in our factory based in St-Quentin, FRANCE. Your machine has been fully factory tested
and will give you satisfaction if it is properly installed and operated. This rock breaker is covered by
the following warranty terms:

TECMAN warrants this product and system components to be free from defects in materials and
workmanship for a period of 12 months from the invoice date. They are covered by the original equipment
manufacturer. TECMAN will repair or replace any item, at its sole discretion, covered under the terms of this
warranty provided the item is returned to the factory prepaid. This warranty does not cover o-rings, seals,
fittings, hoses, breaker tools or other items considered as normal wear items. These are covered by the
Limited Warranty period of 30 days.

1. This warranty shall not apply to any product that has been repaired or altered by any other person
than TECMAN, or that has been subjected to misuse, accident, incorrect wiring, negligence,
improper or unprofessional assembly or improper installation by any person. This warranty does not
cover any reimbursement for any person’s time for installation, removal, assembly or repair.
TECMAN retains the right to determine the reason or cause for warranty repair.

2. The obligation assumed by TECMAN under this warranty is limited to repair, replacement or refund
of the product, at the sole discretion of TECMAN.

3. TECMAN is not liable for expenses incurred by the customer or installer due to factory updates,
modifications, improvements, upgrades, changes, or any other alterations to the product that may
affect the form, fit, function or operation of the product.

4. Personal injury or property damage due to misinterpretation or lack of understanding of this

product is solely the user’s responsibility. The user must understand the operation of this product
before using it. Do not allow anyone to operate the product that does not know how it operates.
Keep the instruction manual permanently accessible at the equipment’s location.

5. TECMAN is not responsible for shipping charges or damages incurred under this warranty.

6. No representative is authorized to assume any other liability for TECMAN in connection with the
sale of TECMAN’s products.
revu 09/09/2015! ! Page 3 sur 35
Owner’s Manual! ! 15-802 / AMSA

This warranty is made only to the original user. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES
OR OBLIGATIONS: EXPRESS OR IMPLIED. MANUFACTURER EXPRESSLY DISCLAIMS ALL IMPLIED
WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. PURCHASER AGREES
THAT IN NO EVENT SHALL MANUFACTURER BE LIABLE FOR SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES, INCLUDING LOST PROFITS OR LOSS OF USE OR OTHER ECONOMIC
LOSS. EXCEPT AS EXPRESSLY PROVIDED HEREIN, MANUFACTURER DISCLAIMS ALL OTHER LIABILITY
TO PURCHASER OR ANY OTHER PERSON IN CONNECTION WITH THE USE OR PERFORMANCE OF
MANUFACTURER’S PRODUCTS, INCLUDING SPECIFICALLY LIABILITY IN TORT.

!
!
C- SCOPE OF SUPPLY
!

revu 09/09/2015! ! Page 4 sur 35

Owner’s Manual! ! 15-802 / AMSA

D- DATASHEET
!
!
!
CARACTERISTICAS DEL BRAZO     SUMINISTRO  
!
Alcance de trabajo
Alcance maximo
6500 mm  
9200 mm
Brazo Tecman minero tipo
Martillo Tecman TMB  
!


Profundidad de 5500 mm Grupo hidráulico 75kW
Peso del brazo 8150 kg   Columna 11 metros  
Brazo estacionario muy robusto para uso Kit de Anclajes  
Altura de columna 11000 mm Plataforma con escala
Base de columna 1700x1700 mm Sistema engrase
Kit de anclaje para base de hormigon Panel de control con
Lubricación marca SKF Radiocontrol sin fil
  Sillon de mandos
MARTILLO TECMAN     Conexiones para fibra
Peso 1870 kg   Pruebas en fabrica
Diametro de cuna 135 mm   Entrega y descarga DAP Mina
Energia de Impacto 3300 Joul Supervision Montaje y Puesta en
Clase Impacto 5500 Ft/ Planos y
Frequencia de 350-550 bp
Alto total 2530 mm
   
GRUPO      NO INCLUIDO  
Motor eléctrico 75 kW Obra civil
Bomba hidráulica Danfoss pistones   Toma de corriente 3x380V
Capacidad 600 L   Grua para montar la maquina
Enfriador de aceite incluido Cables de fibra optica
       Cherry picker para el
SISTEMA     600L de Aceite
Electrovalvulas Danfoss con mandos
1. Mandos eléctricos con cable 15m,
2. Radiocontrol sin fil, de alcance 100m
3. Sillon de telecomando con
controlador para connexion al red de
fibra optica. Sistema con camaras HD
      
ROTACION 350 °   GARANTIA 1 año
Tipo Tornamesa        
Diámetro Corona 1200 mm   PLAZO DE ENTREGA 18
Limitas electronicas de rotacion  
      
CILINDROS     
Elevación 200/120/100 mm  
Balancín 200/120/100 mm  
Martillo 120/70/600 mm      
Presión de trabajo 180 bar      
Presión máxima 600 bar      

revu 09/09/2015! ! Page 5 sur 35

Owner’s Manual! ! 15-802 / AMSA

E- Hydraulic Schematics

!
revu 09/09/2015! ! Page 6 sur 35
Owner’s Manual! ! 15-802 / AMSA

F- Electric Schematics


revu 09/09/2015! ! Page 7 sur 35

Owner’s Manual! ! 15-802 / AMSA

2- SAFETY
!
A- FOREWORD
!
The contents of this manual are considered to be proprietary and confidential to TECMAN and should not
be reproduced without the prior written permission from TECMAN.
!
Nothing contained in this document is intended to extend any promise, warranty or representation,
expressed or implied regarding the TECMAN products described herein.
!
Any such warranties or other terms and conditions of sale of products shall be in accordance with the
standard terms and conditions of sale of such products, which are available upon request.
!
This manual contains instructions and technical data to cover all routine operations and scheduled
maintenance tasks by operation and maintenance staff. Major overhauls are outside the scope of this
manual and should be referred to an authorized TECMAN service department.
!
The design specification of this machine has been certified as complying with E.U. directives. Any
modification to any part is absolutely prohibited and will result in the CE certification and marking being
rendered invalid.
!
TECMAN reserves the right to make changes and improvements to products without notice and without
incurring any obligation to make such changes or add such improvements to products sold previously.
!
!
B- PRECAUTIONS
!

"
Before any intervention on the boom or breaker (tool change, hose change, or other...) be sure that
the hydraulic pump engine is switched off (ignition key removed from the control board).
Do not approach moving crusher units, even if the engine is switched off.
Before dismantling any boom component or removing the breaker, switch off hydraulic and electric
supplies.
Wedge the boom before operations on cylinders and hoses.
Never use the boom to lift loads (no non-return valves).
Boom swing is 360°; limit this movement to avoid risk of degradation of electricity supply cable and
hydraulic hoses.
Do not stay under the boom during movement whether it is supplied or not.
Be sure to lubricate regularly.
!

" 

NEVER WELD ON THE BOOM OR ANY OTHERS PARTS WITHOUT BEING ALLOWED BY TECMAN.


revu 09/09/2015! ! Page 8 sur 35

Owner’s Manual! ! 15-802 / AMSA

C- SAFETY
!
1 WARNING SYMBOLS
!
Danger

"
Particular attention must be given to prevent accidents or damage to personnel and/or property.
!
2 INTENDED USE
!
TECMAN's products are designed with safety as major criteria and also manufactured according to the state
of art principals in engineering and safety.
Nevertheless, improper or careless operation can be dangerous. Operating personnel and others must be
made aware of the inherent dangers in operating this type of equipment.
The equipment shall be used only when in proper mechanical condition, according to its "intended use",
and careful consideration given to safe operation and possible danger. Strict attention must be paid to this
instruction manual. Poor mechanical or site conditions that would prejudice safety must be corrected
immediately.
The equipment is intended to be used in ore, rock or rock-based materials handling exclusively. Any
application different from above or exceeding the design limitations of the equipment will not be
considered as intended. The manufacturer will not be liable for any consequential or inconsequential
damages resulting from the product's misuse. The user only, shall incur these risks.
The "intended use" must also include: adherence to all instructions in this manual, proper and safe
operation, and the observing of responsible inspection and maintenance procedures.
!
!
!
3 INSTRUCTIONS MANUAL
!
Keep the instruction manual permanently accessible at the equipment's location.
In addition to the following advice provided in the instruction manual, observe and provide instruction
regarding all general legal and mandatory regulations relating to safety, accidental prevention and
environmental protection.
Such responsibilities also include: handling and disposal of dangerous materials or consumables, wearing of
personal protection apparel and other protective equipment, and observing of materials handling and
transport regulations.
Read the instruction manual completely. Initiate and institute proper training procedures for operator
instruction and education, reporting and control procedures, supervision guidelines and procedures,
personnel supervision, etc.
Before starting assembly or site preparation, personnel in charge must read the instruction manual and in
particular the chapter on safety. This is imperative. Particular attention must be paid to the activities or
safety of personnel not familiar with the equipment and its application, for example those involved in
assembly, startup or maintenance.
Control must be exerted over work performed on or near the equipment to ensure that strict adherence to
this manual is maintained.
The personnel must not wear long hair, loose clothing or jewelry, because of possible danger or injury.
Use personal protection suits and other protective equipment where mandatory.

revu 09/09/2015! ! Page 9 sur 35

Owner’s Manual! ! 15-802 / AMSA

Observe and follow any safety, danger or warning signs on the equipment.
Keep all safety, danger and warning signs on the equipment in legible condition.
If safety-related modifications to the equipment or its performance are required, stop the plant immediately
and before beginning any work notify the person responsible.
Do not make any modifications or repairs to the equipment which would prejudice safety, without the
supplier's written approval. This includes work on attached or remote safety devices, control valves, as well
as the welding of supporting structures, brackets, etc.
Spare and wear parts must meet the manufacturer’s technical specifications. Conformity can only be fully
guaranteed when original manufacturer's parts are used.
Replace hydraulic hoses and pipes at the indicated or appropriate time intervals, even if no safety-related
defects are perceptible! Always replace them immediately when there is any indication of unsafe, worn,
damaged or faulty parts. Always follow the time period guidelines specified in the instruction manual for
inspection and maintenance.
Always use tools and suitable for the work to be performed.
Always know the location and proper use of fire extinguishers.
Always observe the proper procedures for fire alarms and fire fighting.
!
4 PERSONNEL
!
Any work on the equipment must be performed by skilled and trained personnel only. Observe the
minimum legal age requirements.
Clearly state and follow guidelines for personnel skills and requirements necessary for the safe operation,
installation, service, maintenance and repair of the equipment.
Ensure that only personnel with these skills and that meet these requirements work on the equipment. State
clearly the responsibilities of the machine operator. Authorize him to refuse any unsafe instructions by third
parties.
Let personnel in training, in training on the job or in general education work with the equipment only under
permanent supervision of an experienced person.
Work on electrical controls and equipment must only be performed by a licensed electrician or under the
guidance and supervision of an electrician, always according to applicable regulations.
Only trained and experienced hydraulics technicians should perform work on any hydraulic system.
!
5 OPERATIONS
!
Refrain from any work that would endanger safety. Before starting work, familiarize with the surroundings of
the work place, e.g. any possible hindrances (barriers/obstructions/ obstacles) in the reach of work and
traffic, soil bearing capacity and necessary site protection towards the public road traffic area.
Take any necessary measures to ensure that the equipment is operated in a safe manner and when in good
mechanical condition.
If the equipment is used alone, it must be equipped with main switch and emergency switch. Only operate
when all safety devices and safety-related equipment, e.g. removable guards, emergency stops, sound
insulation, dust collector are in proper position and operative.
Check the equipment at least once a shift for visible damage and defects. Notify the responsible person
immediately of any problems including any deviations in normal operating performance. In every case stop
equipment immediately and resolve the problem!
In the case of any malfunction, stop and safeguard the equipment immediately. Have the problem
immediately corrected. Observe starting and stopping procedures, control devices and signals as specified
in the instruction manual.
Before starting the equipment, inspect the general area to ensure that there are no personnel that may be
endangered from starting. Walk around the equipment and make sure that there is nobody on, by or below
the equipment. Warn all persons in the area before starting.

revu 09/09/2015! ! Page 10 sur 35

Owner’s Manual! ! 15-802 / AMSA

Do not climb on the equipment during operation or touch the moving parts.
All the moving parts related to power transmission ie. flywheels, shafts, couplings, V-belt pulleys and V-belts
must be covered guarded properly to eliminate danger to personnel.
Make sure that all the persons operating or maintaining the equipment know the location of the emergency
stop buttons or controls.
Do not try to clear any blockings when the equipment is running.
Rock or other objects may fall from the machine. Always wear a helmet in the dangerous area.
Be very careful near sharp corners, edges or rough surfaces.
!
6 MAINTENANCE AND REPAIR
!
Observe all guidelines outlined in the instruction manual regarding adjustment, maintenance and inspection
schedules, as well as replacement of parts or equipment. Only trained technicians should perform this work.
Inform the maintenance staff of any maintenance or service work required. Ensure proper supervision.
In any work related to the operation, modification, conversion or adjustment of the equipment and its safety
devices including inspection, maintenance and repair, observe all starting, stopping and maintenance
procedures as outlined in the instruction manual.
Ensure as extensively as possible that the immediate area is safe and secure.
When installing or replacing parts, incorrect mounting may be hazardous. Always ensure that the parts are
properly installed.
When the equipment is switched off during maintenance and repair, the motor controls must be locked out/
off. Secure the lock keys and attach a hazard notice at the main disconnect switch. Make sure that the
equipment can’t be started during maintenance and repair.
During replacement of parts or heavy structural components careful handling and hoisting procedures must
be followed to eliminate any possible danger. Only use appropriate, properly designed lifting and handling
equipment with sufficient capacity. Place the parts on ground with sufficient bearing capacity. Never stand
or work underneath a suspended load.
Use only approved lifting equipment and slings when lifting components. Tighten any lifting eyebolts
before lifting.
Allow only skilled personnel to sling loads and direct the crane operators. The hoisting person in charge
must keep in visual or voice contact with the crane operator.
For any work above grade level, use appropriate stairs and working platforms. Do not use machine parts as
platforms. For maintenance work involving any height other than grade level use appropriate safety
equipment and procedures.
Due to small size and mobility of the machine, the accesses may be different from the requirements of the
standards. Always be very careful when walking on the machine.
Keep all handles, steps, railings, platforms, stages and ladders free from dirt, snow, ice and other hazards.
When cleaning hoppers or other hazardous places be very careful to prevent falling and injuries.
Prior to maintenance and repair work, clean the machine. In particularly clean all connections and leads to
remove oil, fuel or other fluids. Do not use harsh cleansers. Use fibre-free cleaning rags.
Before cleaning the machine with water, steam or high-pressure cleaning methods, cover and protect all
openings where water, steam or cleanser must not penetrate, particularly electrical motors and controls.
After cleaning remove any temporary covers or protection completely.
Check all fuel, motor oil and hydraulic oil hoses for leaks, loose screws, fasteners, bolts, fittings, cuts,
shearing or damage. Repair all of these immediately.
After maintenance and/or repair work, tighten any loose fittings, bolts, fasteners, etc. If any maintenance
and repair procedures require the dismantling of safety controls, they must be re-assembled and checked
immediately upon completion of the work.
Care must be taken for the safe and environmentally correct disposal of process materials, parts and other
consumables.

revu 09/09/2015! ! Page 11 sur 35

Owner’s Manual! ! 15-802 / AMSA

Always attach a hazard notice to the main electrical disconnect switch and lock it out, when starting the
equipment may be hazardous or when maintaining or repairing the equipment.
Always attach a hazard notice to the power supply of electrical components and lock them out, when
starting the equipment/component may be hazardous or when maintaining or repairing the equipment/
component.
!
7 OTHER SAFETY CONSIDERATIONS
!
Electricity
!
Only use fuses of proper and recommended capacity. Never use fuses of higher capacity than indicated in
the electrical drawings.
In case of electrical problems, shut down the equipment immediately.
Any work on electrical equipment must only be performed by a licensed electrician or under the guidance
and supervision of a licensed electrician, providing all codes and regulations are followed.
Prior to any inspection, maintenance and repair being performed, the equipment must, if required, be
secured electrically and switched voltage free. Follow all required safety procedures and regulations.
The electrical equipment must be inspected at regular intervals. Defects such as loose connections,
damaged wiring must be repaired immediately. The work must be performed by a licensed electrician or
equivalent as specified by law.
Should work be required on live electrical apparatus, a second person must be assigned to actuate the
emergency stop or disconnect the main switch in case of emergency. Safeguard the working area with a red
and white safety chain and "danger" sign. Use voltage isolated tools only.
Where work is required on high voltage components, connect the supply cable after voltage clearance to
mass, and short-circuit components, e.g. capacitors, by a ground rod.
Use only proper parts in electrical appliances. Electric cables should be properly sized and protected, for
example from falling rocks. Wiring should be long enough to provide for components requiring adjustment.
!
Hydraulic, pneumatic
!
Only persons with special knowledge and experience in hydraulics shall perform work on the hydraulic
equipment.
Check at specified intervals that all conduits, hoses, lines and fittings are free of leaks or visible defects.
Repair any defects immediately. Spurting oil may cause injury and fire.
Prior to any repair work, depressurize any air or hydraulic system, including hoses, lines and fittings to be
opened. This must be done in a safe, approved manner.
Assemble hydraulics and compressed-air piping carefully according to all proper procedures. Take
precautions to not mix up any connections. Fittings, length and quality of the hoses and pipes must satisfy
any requirements set.
When replacing or repairing hydraulic parts, make sure that only parts designed for the operating pressures
of the system are used. This also relates to any pressure hoses.
Never search for leaks from the pressurized hoses with hand. High pressure fluid jet may penetrate the skin
and cause injury. Search for leaks with paper, etc.
!
!
Gas, dust, steam, smoke
!
Perform welding, cutting and grinding work at the equipment only where allowed. Fire hazard may exist
and explosion hazard may occur.
Before welding, cutting and grinding clean the equipment and site to remove dust and combustible
materials. Take the necessary precautions in providing for sufficient ventilation.

revu 09/09/2015! ! Page 12 sur 35

Owner’s Manual! ! 15-802 / AMSA

Dust protection must be fitted to the machine where necessary to prevent injury to personnel or
contamination of the environment. Airborne dust must be minimized while feeding, moving or discharging
the product. Recommended methods for dust prevention are:
1. Dust covers and dust extraction
2. Dust enclosures
3. Water suppression
!
Noise
!
During operation, sound insulation, if available, must be in its proper and safe location.
Wear ear protection.
!
Oil, grease and other chemical materials
!
When using oil, grease and other chemical materials, observe the product safety guidelines and warnings.
Be careful when using any hot materials to protect personnel from burning or scalding.

"
!
Hot surfaces
!
During operation some surfaces become very hot (for example breaker tool and hoses).
!
Fire
!
In case of fire near the equipment:
• Warn all persons in the dangerous area.
• Stop the equipment using emergency stop
• Turn off the main disconnect switch.
• Make sure that all persons are in safe area.
• Start fire fighting and give the alarm if necessary.
• If possible move the equipment away from the dangerous area.
!
In case of fire in the equipment:
• Warn all persons in the dangerous area.
• Stop the equipment using emergency stop.
• Turn off the main disconnect switch (if possible).
• Make sure that all persons are in safe area.
• Start fire fighting and give the alarm if necessary.
Blasting
!
The use of the radio control device is strictly forbidden during blasting operations, as it may cause a
premature explosion.
The equipment must be moved far enough away from the dangerous area when blasting.

revu 09/09/2015! ! Page 13 sur 35

Owner’s Manual! ! 15-802 / AMSA

Explosives must be prevented from entering the equipment.

!
8 TRANSPORTATION
!
Only use appropriate transportation and lifting equipment with adequate capacity.
Provide a supervisor to direct lifting operations. Transport or hoist components, and handle any parts in
accordance with the instructions and advice provided herein.
Fasten the lifting equipment only to the points meant for lifting.
Use only proper means of transport with adequate transporting capacity! Fasten the load carefully! For
lifting, use only the fastenings showed in instructions!
Use only proper means of transport with adequate transporting capacity!
Fasten the load carefully! For lifting, use only the fastenings showed in instructions!
Secure all component parts of the equipment immediately after loading to avoid any accidental shifting.
Attach required warning signs to the load. Remove all temporary supporting structures or brackets before
re-starting the equipment.
Carefully assemble all of the parts previously disassembled.
Disconnect all external power supply before moving any part of the equipment and reconnect it properly
before re-starting.
Perform any start-up in accordance with the instruction manual.
!
!
!
!
!
!

Be sure that the radius of the pedestal boom arm is

clear of personnel or obstacles before operating the
slew rotation system.

"
!
!
NEVER WELD ON THE CRUSHER PLANT WITHOUT UNPLUG THE RADIO RECEIVER
!
revu 09/09/2015! ! Page 14 sur 35
Owner’s Manual! ! 15-802 / AMSA

WELDING PROHIBITED WELDING ALLOWED

ALWAYS UNPLUG THE RADIO RECEIVER BEFORE

ANY WELDING JOB ON THE CRUSHER PLANT

"
!
!

revu 09/09/2015! ! Page 15 sur 35

Owner’s Manual! ! 15-802 / AMSA

!
3- TRANSPORTATION
!
B- LIFTING

PEDESTAL BOOM 6100kg

HYDRAULIC POWERPACK 2200 kg

!
revu 09/09/2015! ! Page 16 sur 35
Owner’s Manual! ! 15-802 / AMSA

4- INSTALLATION
!
!

"
!
1) Connect the powerpack and fil lit with 800L of HV46 hydraulic oil.

2) Connect the power supply 3 x 400V in the control panel.

3) Connect the pedestal controller plug on electrical panel.

4) CHECK THAT ALL VALVES UNDER THE POWERPACK ARE OPENED.

5) Install the pedestal on its base. Tighten the M42 bolts at 3900 N.m

6) Connect hoses and cables between boom and powerpack

7) With the start button on the electrical panel, start the powerpack AND STOP IMMEDIATELY. Check
the direction of the main motor rotation. It has to turn clockwise when looking at the fan. If not,
swap 2 phases on the power supply. Start the powerpack again and check it’s working correctly.

8) Install the dipper on the boom, lift the boom if necessary.

9) Install and secure all pins.

10) Connect all the hoses.

11) Test all the machine fonctions and bleed the air trapped in the cylinders.

!
!
!
revu 09/09/2015! ! Page 17 sur 35
Owner’s Manual! ! 15-802 / AMSA

5- COMMISIONNING
!
!
INSPECTION BEFORE WORK
Inspect every delivered item for damage, leak, etc
Check that boom, breaker, powerpack, controls, column, and all necessary hoses and wires are available
Check that electrical cable for power supply is ready
Check the availability of the recommended amount of hydraulic oil
If it is easier to fill the tank before erection, do it now
"
ASSEMBLING
If the boom has been delivered in several parts, assemble it now
Bolt the breaker onto the top bracket
Put every pin in position and lock them
"
ERECTION
Check the lifting force of the crane
Determine the lifting plan with the crane excavator
Lift, position, and bolt all the elements together. Refer to standard torque values
Remove the crane hook from the machine
"
CONNECTIONS
Connect all hydraulic hoses, refering to the colors painted on the fittings
No additional fitting or hose should be needed
Connect the electric plugs refering to plug size
Connect the power supply inside the electrical panel
Fill the hydraulic tank with hydraulic oil, up to the top of the gauge installed
"
START-UP
Get the power supply to the machine. A test light should turn on on the electrical panel
Position yourself near the main electric motor of the powerpack
Start the machine from the control panel, AND SHUT DOWN IMMEDIATELY by using the emergency stop
Check the rotation direction of the motor. The fan must turn clockwise when you look at it directly
If the rotation direction is wrong, invert 2 phases on the power supply line
Test again the rotation of the motor
Start again the boom, and let it run
Check that the boom does not move. Only hoses might move
Test the different movements SLOWLY
Check that the hoses are correctly pathed and do not risk any damage
Test all the movements of the machine full stroke to get rid of air trapped inside the hydraulics
Test the rockbreaker ON A ROCK, do not blank fire
Check that the machine can work in the desired areas
Adjust the speed if needed on the control valve
Adjust the power if needed on the control valve
Install the rotation stoppers if needed
"
FINISH
Touch-up with paint every scratch on the machine
Cross check the tightening of all installation bolts
Modify the path of hoses if needed
"
TRAINING
Give a full training to operators
Test the machine 1 hour in working conditions
Fill-in the commissioning acceptance shhet with the customer
"
!
! COMMISIONNING SUPERVISOR
Name
Signature
"
!
revu 09/09/2015! ! Page 18 sur 35
Owner’s Manual! ! 15-802 / AMSA

6- OPERATION
!
A- PEDESTAL CONTROL OPERATIONS
!
!
!
!
!
!
!

"
!
!
!
!
!
!
!
!
!
!
!

revu 09/09/2015! ! Page 19 sur 35

Owner’s Manual! ! 15-802 / AMSA

B- BEST PRACTICE
!
15 seconds hammering maximum
!
!
!
!
! Hammering sessions longer
!
! than 15s overheat the tool
! and might cause severe
! damage to piston and tool
! !
! If the rock has not broken
!
! after 15s, you have to change
! the tool position and start
! again
!
!
!
!
!
!
!
Use tool perpendicular to rock


revu 09/09/2015! ! Page 20 sur 35

Owner’s Manual! ! 15-802 / AMSA

Do not use the tool as a lever

!
!
!
DANGER ! HAMMERING CYLINDERS FULL STROKE


Hammering cylinders full stroke prevent the hydraulic safety valves

from protecting the machine from vibrations, and might cause severe
damage to the rock breaker

revu 09/09/2015! ! Page 21 sur 35

Owner’s Manual! ! 15-802 / AMSA

BEWARE OF FLYING OBJECTS BEYOND 10m

!
!
START BREAKING AT THE EDGE / NOT AT THE CENTE


revu 09/09/2015! ! Page 22 sur 35

Owner’s Manual! ! 15-802 / AMSA

7- BREAKER TOOL REPLACEMENT

!
"

"
1. Remove plug.

"
" 2. Remove rubber ring.
!

"
3. Remove tool retaining pin by using t-puller.

"
4. Remove tool.


revu 09/09/2015! ! Page 23 sur 35

Owner’s Manual! ! 15-802 / AMSA

8- MAINTENANCE
INTRODUCTION
To keep your breaker in top operating condition, the following maintenance must be done. Keep in mind
that lubrication is the single most important procedure for sustaining the life of a breaker.
!
"
USE PROPER GREASE
Always use chisel paste or moly-based grease. Only use GP (General Purpose) grease, if chisel paste is not
available.
!
"
GREASE OFTEN
Failure to lubricate regularly reduces the life of the tool, tool bushings and front head.
!
MAINTENANCE SCHEDULE
!
The following items must be serviced on a scheduled basis.
!
PRE SHIFT
!
✓ Check oil level in power pack

✓ Check for leaks, damaged hoses or clamps

✓ Check the pedestal base, turret, and boom sections for cracks or other damage

✓ Check cylinders for leaks

✓ Check all pin connections for broken bolts, collars, and for excessive wear and play

✓ Grease all pin connections with a moly grease

Note: if equipped with auto lube system ensure each connection has adequate grease

✓ Check that all electrical components are in operational condition

✓ Grease the breaker tool with chisel paste. During the shift if the tool becomes dry and shiny, apply
and additional 20 pumps of grease

Note: if equipped with auto lube system ensure there is adequate grease and the pump is
working

✓ Check the breaker housing and top mounting bracket for loose bolts and cracks

✓ Check that the retainer pins, cross pins, and stopper plugs are in place

✓ Check tightening of hammer bracket bolts

revu 09/09/2015! ! Page 24 sur 35

Owner’s Manual! ! 15-802 / AMSA

✓ Check the pressure / return filter indication for by-pass

Note: Boom must be operating and the breaker firing to do this

EVERY 2 HOURS
!
✓ Verify during first few minutes, correct operations of all machine functions

✓ Grease breaker tool bushing

✓ Check general condition of machine and surrounding work area

!
EVERY 8 HOURS / EVERY SHIFT
!
✓ Grease all hinge points

✓ Check hydraulic oil level

✓ Check lubrication system (if equipped)

✓ Check all machine hardware and pedestal bolts for loosening

✓ Check all hydraulic lines, fittings and clamps for leaks or damage

✓ Check for proper operation of electrical components

✓ Check power unit, temperature, radiator cleanliness, oil leaks

✓ Check air breather element on hydraulic reservoir

✓ Check breaker for damage, loose fittings, or hydraulic leaks

!
EVERY 100 HOURS
!
✓ Remove the breaker tool and inspect the wearing surface. Remove any burrs before reinstalling

✓ Inspect the tool retainer pin for wear

✓ After first 100 hrs only, change hydraulic pressure and return line filter elements

✓ After first 100 hrs, torque all bolts to specifications on breaker

!
EVERY 500 HOURS
!
✓ Replace the pressure filter

✓ Replace the return line filter

✓ Replace the air breather filter

✓ Take oil sample – review the results and determine if an increase in filter change and/or oil change
is required. File the results

revu 09/09/2015! ! Page 25 sur 35

Owner’s Manual! ! 15-802 / AMSA

✓ Check the breaker accumulator gas pressure

!
EVERY 1000 HOURS
!
✓ Drain the hydraulic reservoir

✓ Remove and replace the retainer pin

✓ Measure for wear, all pin connections including booms, tilt linkage, turret, and cylinders. Replace
pins, bushings, and/or thrust washers where possible to ensure a tight connection

✓ Measure the flow at the breaker. Check the flow against the requirement setting. Adjust the flow as
required

✓ Measure the main pump relief valve setting and adjust as required

✓ Remove the hydraulic breaker and disassemble to re-seal. Measure the wear limit on the front and
rear bushing. Replace each bushing if the allowable tolerances are exceeded

✓ Check hydraulic flow to breaker, as well as breaker operating pressure

✓ Check and adjust if necessary port relief pressures on main valve bank

✓ Check hydraulic pump flow at relief pressure

✓ Check control valve main relief pressure

!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
revu 09/09/2015! ! Page 26 sur 35
 Owner’s Manual! ! 15-802 / AMSA

9- LUBRICATION
!
A- OIL
2577 SPECIFICATIONS
Heavy Duty, Heavy Duty Primary Breaking Carrier hydraulic oil
!
! OIL SPECIFICATIONS
Table below shows
Table hydraulic
below showsoils recommended
hydraulic for rock breaker
oils recommended use. Theuse.
for hammer mostThe
suitable
most oil is selected in
suitable
such a wayoil
that
is the temperature
selected in suchofa the
wayhydraulic
that the oil in continuous
temperature usehydraulic
of the is in the ideal
oil inarea on the chart and
continuous
the hydraulic
usesystem
is in isthe
used to best
ideal areaadvantage.
on the chart and the hydraulic system is used to best
advantage.
!

Problems due to incorrect hydraulic oil viscosity in the hammer:

Oil too thick
■ Difficult start up
■ Stiff operation
■ Hammer strikes slowly
■ Danger of cavitation in pumps and in the hydraulic hammer
■ Sticky valves
■ Filter bypass opens, impurities in the oil are not removed

revu 09/09/2015! ! Page 27 sur 35

Owner’s Manual! ! 15-802 / AMSA

B- MANUAL LUBRICATION
!

GREASE
DAILY!
USE TYPE EP2
"
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
revu 09/09/2015! ! Page 28 sur 35
Owner’s Manual! ! 15-802 / AMSA

10 - TROUBLESHOOTING LIST
!
A- BOOM POOR OPERATION
!
Problem Cause Countermeasure

System will not function Pump is not running.! Check if pump is running, if it is not be
in any movement of the
controls (electric or
!! sure it is switched on.!
!
manual). !! Check that drive coupling between
pump and motor is not damaged.!
!
Pump is running in wrong direction !
!
Check that if any wiring to the motor
(STOP IMMEDIATELY).! has been changed that it is wired
!! correctly and the motor is rotating in
correct direction.!
Hydraulic oil level is low.!
!! !
Fill hydraulic tank and inspect for
leakage throughout hydraulic system.!
Hydraulic temperature is too low.!
!! !
Check that oil viscosity is correct for
working ambient temperature.!
Pump not coming on line. !
Check pump output pressure and flow.

One function in system Hydraulic hose to cylinder is broken or Replace damaged hydraulic hose.!
does not operate but all punctured.!
others operate ! !!
normally. Hydraulic cylinder failed.! Replace or rebuild cylinder.!
!
Signal from controls to control valve is
!
Use handles manually on control valve
damaged.! to do all functions. If handles all work
!! correctly, check the joysticks on the
stand or remote and check (PVEM’s)
!! coil solenoids in control valve.!
!
Damaged wiring between controls and Change electric plug at the control
control valve.! valve from one of the normal working
!! function circuits to the non responsive
one and try it and see if the function
!! now works properly. (For example if the
boom won’t hoist up move the plug
!! from the tilt function to the hoist
function, then use your tilt function on
!! the controls and see if it then hoists up.
If it does not, replace (PVEM) module
!! (coil solenoids) on the hoist up section
of control valve. If it hoists up normally
!! check wiring between controls and
control valve for damage and replace if
LS signal incorrect.! needed.)!
!
PLVP (shock) (port relief) valve
!
Adjust circuit LS.!
malfunction. !
Replace PLVP (shock) (port relief)
valve.

!
revu 09/09/2015! ! Page 29 sur 35
Owner’s Manual! ! 15-802 / AMSA

!
!
Problem Cause Countermeasure

Excess movement in Pedestal mounting bolts loose or Torque mounting bolts to required
base of boom. broken.! torque specifications. Replace any if
!! needed.!
!
Base or stand holes oversized. Repair holes.

Pin turning causing Bearing/Bushing seized.! Remove and replace bearing/bushing

retaining bolt to break.!! and retaining bolt.!
!
Insufficient amount of grease. Grease more often.

Boom system runs Pump is worn or out of adjustment. Use a flow meter to check the flow out
but is slow. of the case drain hose into the hydraulic
tank. If more than 10% of pump output
is bypassing, then replace pump.!
!
Check stand-by pressure and max
pressure if max pressure is not
achieved adjust pump accordingly.!
!
If max pressure can’t be achieved even
with pump adjustment, remove and
replace pump.

Boom slowly lowers Cylinder may be leaking oil past the Reseal/replace cylinder or PVLP
when left in the air seals or the PVLP (shock) valves may (shock) (port relief) valve.
with joystick in be leaking oil past the seals.
neutral.

One function, the Broken hydraulic cylinder.! Remove and replace hydraulic cylinder.!
pressure is low, but all
others are normal.
!PVLP (shock) valve is not functioning
!
Remove and replace PVLP (shock
properly. valve).

Hammer does not fire. Poor performance of the hydraulic Check pump output. Repair or replace.!
pump.!
! !
Check relief settings and adjust.!
Pressure relief valve set too low.!
! !
Clean or replace.!
Clogged or restricted hoses.!
! !
Replace seals.!
Cushion chamber fills with oil.!
! !
Overhaul and replace worn parts.!
Seizure of breaker.!
! !
Replace hammer switch.!
Hammer switch (located on joystick)
malfunction.!
!!
!
Wiring from joystick control to control
Check wiring, replace if need.!
!!
valve damaged.!
!
Accumulator membrane damaged.
Replace membrane.

revu 09/09/2015! ! Page 30 sur 35

Owner’s Manual! ! 15-802 / AMSA

!
Problem Cause Countermeasure

Erratic hammering. Hydraulic oil temperature too high.! Oil temperature must not exceed 77
!! deg. C (170 deg. F).!
!
Insufficient oil flow and/or pressure.! Check hydraulic pressure and flow to
!! hammer.!
!
Clogged or restricted hoses, or pipes.! Clean or replace.!
!
Not enough down force on the tool.!
!
Ensure tool is free to move inside
!! hammer. If tool is free increase the down
pressure acting on the tool.!
!
Pressure too high in cushion chamber.!
!
Adjust pressure.!
! !
Too much grease in the impact chamber.! Remove tool from front head and clean
!! out excess grease. Follow proper
greasing instructions.!
!
Excessive clearance between tool and
!
Check clearance and replace worn
tool bushing.! parts.!
!
Excessive wear at top of tool.!
!!
!! Remove and inspect the tool. Replace if
necessary.!
Foreign matter in the breaker control
valve.!
!
Disassemble and clean.!
!
Seizure of piston and cylinder.
!
Overhaul the breaker.

Lack of hammering Insufficient oil flow or oil pressure.! Check hydraulic pressure and flow to
power. !! hammer.!
!
Broken tool.! Replace tool, check piston for damage.!
!
Accumulator gas pressure is too low.
!
Check and adjust.

Breaking of tool. Abuse of tool and prying with tool. Apply down force in the direction of tool
only. Check for excess play in arms,
links, and pins.

Mushrooming of tool. Continuous hammering in one place. Use short bursts. Re-position breaker
every 30 seconds.

Rapid increase in oil Insufficient oil cooling. Insufficient oil Check pump output. Check relief valve
temperature. flow. Incorrect oil pressure. setting.

Emulsification of oil. Oil contaminated with water. Locate source of water and repair.
Replace oil.

System will not Joystick, paddle level or switch not in Ensure that all control devices are in
respond after normal center position during start up.! center position when the start button is
start up. !
E-Stop switch engaged.
activated.!
!
Pull out E-Stop switch and restart
system by pushing start/horn button.

!
!
revu 09/09/2015! ! Page 31 sur 35
Owner’s Manual!
B- OIL LEAKAGE
!
Area of leakage
Opening between the chisel
and chisel bushing.
Between the cylinder cover
and cylinder.
Between the cylinder and the
control valve box.
Between the control valve box
and the control valve cap.
Between the cylinder and
hose adapter.
Hose adapter plug.
Stroke adjuster cap.
Pilot valve cap.
!
!
!
!
revu 09/09/2015!
! 15-802 / AMSA
Condition Correction
Wear or damage of oil seal.! Replace oil seal.!
!
Seizure of piston & cylinder.
!
Repair or replace.
Wear or damage of O-Ring or Replace O-Ring and back up ring.!
back up ring.!
! !!
Loosening of the side bolt nut. Retighten the side bolt nut to the
specified torque.
Wear or damage of O-Ring or Replace O-Ring and back up ring.!
back up ring.!
! !!
Loosening of the bolts on the Retighten the bolts for the control
control valve box. valve box to the specified torque.
Wear or damage of O-Ring or Replace O-Ring and back up ring.!
back up ring.!
! !!
Loosening of the bolts on the Retighten the bolts for the control
control valve cap. valve cap to the specified torque.
Wear or damage of O-Ring.! Replace O-Ring.!
!
Loosening of the hose adapter.
!
Retighten the hose adapter to the
specified torque.
Wear or damage of O-Ring.! Replace O-Ring.!
!
Loosening of the hose adapter
!
Retighten the hose adapter plug to
plug. the specified torque.
Wear or damage of O-Ring.! Replace O-Ring.!
!
Loosening of the stroke adjuster
!
Retighten the stroke adjuster cap to
cap. the specified torque.
Wear or damage of O-Ring.! Replace O-Ring.!
!
Loosening of the pilot valve cap.
!
Retighten the pilot valve cap to the
specified torque.
! Page 32 sur 35
Owner’s Manual! ! 15-802 / AMSA

C- BREAKER POOR OPERATION

!
Condition Cause Countermeasure

Does not impact. Temperature of the hydraulic oil is too Warm up the rockbreaker.!
low.!
! !
Set the relief valve to the correct
Pressure setting for the relief valve is pressure setting.!
too low.!
! !
Check the pump performance. If the
Poor performance of the hydraulic performance is poor, repair or replace.
pump on the rockbreaker.

Erratic blows.! Seizure of control valve.! Repair or replace control valve.!

!
(At the beginning
!
Seizure of piston and cylinder.!
!
Repair or replace pilot valve and pilot
breaker operates
normally but later
!
Seizure of pilot valve and pilot bush.!
bush.!
!
blows are erratic) !
Relief valve for the rockbreaker is set
Set the relief valve to the correct
pressure setting.!
too low.!
! !
Check the pump performance. If the
Poor performance of the hydraulic performance is poor, repair or replace.!
pump on the rockbreaker.!
! !!
Lack of down pressure onto the chisel.!
!! !
Operate the arm and bucket so that
pressure is applied to the chisel.!
Nitrogen gas pressure in the
accumulator is too low.
!
Adjust the nitrogen gas to the correct
pressure.

Lack of power. Nitrogen gas pressure in the Adjust the nitrogen gas to the correct
accumulator is too low. pressure.

Lack of blows. Nitrogen gas pressure in the
accumulator is too high.!
!
Lack of down pressure onto the chisel.!
!!
Pressure setting for the relief valve is
too low.!
!
Poor performance of the hydraulic
pump on the rockbreaker.
Adjust the nitrogen gas to the correct
pressure.!
!
Operate the arm and bucket so that
pressure is applied to the chisel.!
!
Set the relief valve to the correct
pressure setting.!
!
Check the pump performance. If the
performance is poor, repair or replace.!
!
Investigate the blocked area of the
piping and repair or replace the piping.

!
!
!
!
!

revu 09/09/2015! ! Page 33 sur 35

Owner’s Manual! ! 15-802 / AMSA

11 - SPARE PARTS
!
!
!
!
!
!
!
!
!
!
!
!
!
!
Please see the
SPARE PARTS MANUAL
supplied for this machine
!
!

revu 09/09/2015! ! Page 34 sur 35

Owner’s Manual! ! 15-802 / AMSA

12- EC DECLARATION OF CONFORMITY

EC Declaration 

of conformity
Manufacturer: ! TECMAN!
Address:!! ZA du Bois de la Chocque, 02100 St-Quentin, FRANCE!
!!
Herewith declares that the Tecman rock breaker boom!
!
Model:! ! UA1200!
Serial Number:! 15-783!
!!
- Is in conformity with all the relevant provisions of the Machinery Directive 2006/42/
EC. The procedure applied for the conformity assessment is «  Assessment of conformity
with internal checks on the manufacture of machinery » (Annex VIII). The risk assessment
is made according to ISO 12100.!
!
- Is in conformity with all the relevant provisions of the Outdoor Equipment Noise
Directive 2000/14/EC. The procedure applied for conformity assessment is «  Internal
control of production » (Annex V).!
! ! ! Measured sound power level:! ! Lwa 120 dB!
! ! ! Guaranteed sound power level:! ! Lwa 124 dB!
!
Technical file!
Kevin DELOFFRE, Quality Manager, is authorized to compile the technical file and confirms
the product design to conform with the essential health ad safety requirements. !
!
Manufacturing conformity!
Christophe GONCZARONEK, Production Manager, confirms compliance of the manufactured
machinery with the technical file. !
!
Kevin DELOFFRE and Christophe GONCZARONEK are empowered to draw up this
declaration of conformity. !
!
This declaration relates exclusively to the machinery in the state in which it was placed on the
market, and excludes components which are added and/or operations carried out
subsequently by the final user!
!
Date of issue: ! 31/10/2014!
Place of Issue:! St-Quentin, France!
!
on behalf of TECMAN,!
!
Kevin DELOFFRE! ! ! ! ! Christophe GONCZARONEK!
Quality Manager! ! ! ! ! ! Production Manager

revu 09/09/2015! ! Page 35 sur 35