HPB45 Hydraulic Paving Breaker

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INSTRUCTION MANUALHPB45Hydraulic Paving BreakerRead and understand all of the instructions andsafety information in this manual before operatingor servicing this tool.99925427 REV 4 2005 Greenlee Textron Inc.11/05

HPB45 Hydraulic Paving BreakerTable of ContentsDescriptionDescription . 2Safety . 2Purpose of this Manual . 2Other Publications . 2Important Safety Information . 3–5Identification . 6Specifications . 7–8Hoses and Fittings . 9Hose Connections . 9Typical Setup . 9Setup . 10Operation . 10Maintenance . 10–11Troubleshooting . 12Illustrations and Parts Lists . 13–17Accessories . 18The HPB45 Fairmont Paving Breaker is intended tobreak up asphalt, concrete, and hard clay.Accessories available from Fairmont allow the HPB45to drive ground rods.The HPB45 breaker is available in a standard versionas well as an ergonomic version, provided withvibration-dampened handles.SafetySafety is essential in the use and maintenance ofFairmont tools and equipment. This manual and anymarkings on the tool provide information for avoidinghazards and unsafe practices related to the use of thistool. Observe all of the safety information provided.Purpose of this ManualThis manual is intended to familiarize personnel withthe safe operation and maintenance procedures forthe following Fairmont Paving Breakers: HPB45-11-1/8" x 6" shank withstandard handles HPB45-21" x 4-1/4" shank withstandard handles HPB45-1AVS 1-1/8" x 6" shank withdampening handles HPB45-2AVS 1" x 4-1/4" shank withdampening handlesKeep this manual available to all personnel.Replacement manuals are available upon request atno charge.Other PublicationsTool Owners/UsersSAE Standard J1273 (Hose and Hose Assemblies):Publication 999 3032.3All specifications are nominal and may change as design improvements occur. Greenlee Textron Inc. shall not be liable for damagesresulting from misapplication or misuse of its products.KEEP THIS MANUALGreenlee / A Textron Company24455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerIMPORTANT SAFETY INFORMATIONSAFETYALERTSYMBOLSkin injection hazard:Oil under pressure easily punctures skin causing serious injury,gangrene or death. If you areinjured by escaping oil, seekmedical attention immediately. Do not use hands to check forleaks. Do not hold hose or couplerswhile the hydraulic system ispressurized. Depressurize the hydraulicsystem before servicing.This symbol is used to call your attention tohazards or unsafe practices which could result inan injury or property damage. The signal word,defined below, indicates the severity of the hazard.The message after the signal word providesinformation for preventing or avoiding the hazard.Immediate hazards which, if not avoided, WILLresult in severe injury or death.Do not exceed the following hydraulic powersource maximums: Hydraulic flow: 30 l/min (8 gpm) Pressure relief: 160 bar (2300 psi) Back pressure: 15 bar (200 psi)Failure to observe this warning could result insevere injury or death.Hazards which, if not avoided, COULD result insevere injury or death.Hazards or unsafe practices which, if not avoided,MAY result in injury or property damage.Wear eye protection whenoperating or servicing this tool.Failure to wear eye protectioncould result in serious eye injuryfrom flying debris or hydraulic oil.Read and understand all of theinstructions and safety informationin this manual before operatingor servicing this tool.Failure to observe this warning couldresult in severe injury or death.Wear hearing protection whenusing this tool.Failure to observe this warningcould result in serious injury.Wear foot protection when usingthis tool.Failure to observe this warningcould result in serious injury.Greenlee / A Textron Company34455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerIMPORTANT SAFETY INFORMATIONTool, bit, and other componentsmay be hot during and afteroperation. Allow to cool beforehandling, or handle with heatresistant gloves.Failure to observe this warningcould result in severe injury.Serious injury can result if the operator does notmaintain control of the tool. Wear slip-proof gloves when operating this tool. Maintain a firm grip on the tool, using bothhands at all times. Do not lock the trigger in the power-ON position.Operator cannot stop tool when the trigger islocked.Failure to observe these warnings could result insevere injury or death.Do not disconnect tool, hoses or fittings while thepower source is running or if the hydraulic fluid ishot. Hot hydraulic fluid can cause serious burns.Accumulator is charged with nitrogen under highpressure. This pressure must be unloaded beforedismounting.Failure to observe this warning could result insevere injury or death.Do not reverse hydraulic flow. Operation withhydraulic flow reversed can cause tool malfunction. Connect the supply (pressure) hose andreturn (tank) hose to the proper ports.Failure to observe this warning could result insevere injury or death.Vibration hazard:Apply just enough pressure to do the work.Applying excess pressure to the breaker cancause operator discomfort or temporarynumbness.Failure to observe this precaution may result ininjury.Do not change accessories, inspect, adjust orclean tool when it is connected to a power source.Accidental start-up can result in serious injury.Failure to observe these warnings could result insevere injury or death.Greenlee / A Textron Company44455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerIMPORTANT SAFETY INFORMATION Do not operate the breaker unless the bit isproperly installed and placed against the worksurface. Damage to the breaker can result. Inspect the hydraulic hoses and couplingsevery operating day. Repair or replace ifleakage, cracking, wear or damage is evident.Damaged hoses or couplings can fail, resultingin injury or property damage. Use this tool for manufacturer’s intendedpurpose only. Use other than that which isdescribed in this manual can result in injury orproperty damage. Make sure all bystanders are clear of the workarea when handling, starting, and operating thetool. Nearby personnel can be injured by flyingor falling debris or by flying parts in the event ofa tool malfunction.Emergency stop procedure:1. Release the trigger.2. Shut off the hydraulic power source.Procedure for connecting or disconnectinghydraulic hoses, fittings or components:1. Move the flow lever on the power source tothe OFF position.2. Stop the hydraulic power source.3. Follow the sequence under “Hose Connections” to prevent pressure buildup. In casesome pressure has built up, loosen hoses,fittings or components slowly.Note: Keep decals clean and legible. Replace decalswhen necessary.Hydraulic oil can cause skin irritation. Handle the tool and hoses with care to preventskin contact with hydraulic oil. In case of accidental skin contact with hydraulicoil, wash the affected area immediately toremove the oil.Failure to observe these precautions may resultin injury.Greenlee / A Textron Company54455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerIdentification1455 mm (18")2Hex 1":682 mm (26.5")Hex 1-1/8": 731 mm (28.5")3456HPB45 Hydraulic Paving BreakerGreenlee / A Textron Company1. Handle4. Return Port2. Trigger5. Front End3. Pressure Port6. Latch64455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerSpecificationsHydraulic Power SourceHPB45Type of Hydraulic System . Open-centerWeight (without hoses and tool)Standard HandleHex 1" . 20.9 kg (46 lb)Hex 1-1/8" . 24.1 kg (53 lb)Dampening HandleHex 1" . 21.8 kg (48 lb)Hex 1-1/8" . 25.0 kg (55 lb)Steel Size (standard) . Hex 1" x 4-1/4", 1-1/8" x 6"Working Pressure . 105 to 125 bar (1500 to 1800 psi)Hydraulic OilWorking Temperature . 30 to 70 C (86 to 158 F)Accumulator ChargingPressure (nitrogen) . 50 bar (723 psi)Blow Frequency . 22 to 36 Hz (1320 to 2160/min)Impact Energy . 85 JouleHydraulic Port Connections . 1/2" BSPVibration LevelStandard Handle . a 11.4 m/s2Dampening Handle . a 4.9 m/s2Sound Power LevelGuaranteedHex 1" . LWA 109 dBHex 1-1/8" . LWA 110 dBMeasuredHex 1" . LWA 107 dBHex 1-1/8" . LWA 106 dBDo not exceed the following hydraulic powersource maximums: Hydraulic flow: 30 l/min (8 gpm) Pressure relief: 160 bar (2300 psi) Back pressure: 15 bar (200 psi)Failure to observe this warning could result insevere injury or death.Type of Hydraulic System . Open-centerFlowMinimum . 18 l/min (5 gpm)Maximum . 30 l/min (8 gpm)Filtration . 10 micron (nominal)Pressure Relief Setting . 160 bar (2300 psi)Back Pressure (maximum) . 15 bar (200 psi) Optimal performance occurs at maximum flow. Maximum hydraulic fluid temperature must notexceed 70 C (158 F). A sufficient oil coolingcapacity is needed to limit the hydraulic fluidtemperature. Hydraulic flow must not exceed 30 l/min (8 gpm).Install a flow meter in the return line to measure therate of hydraulic flow before using the tool. Pressure relief valve setting must not exceed160 bar (2300 psi) at your tool’s maximum flow.Locate the pressure relief valve in the supply circuitto limit excessive hydraulic pressure to the tool.Hydraulic SchematicFILTER(10 MICRON)RESERVOIRRELIEFVALVE160 bar(2300 psi)CONTROLVALVECOOLERTFLOW METERPTOOLPUMPPOWER SOURCEGreenlee / A Textron Company74455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerSpecifications (cont’d)Recommended Hydraulic FluidViscosityIdeal . 20 to 40 cStAllowable . 15 to 1000 cStViscosity Index . Min. 100Standard mineral or synthetic oil can be used.When the tool works continuously, the oil temperaturewill steady at a certain level called the oil workingtemperature. Depending on the nature of the job andthe cooling capacity of the system, the oil workingtemperature will be 20 C to 40 C (68 F to 104 F)above the air temperature. At working temperature, theoil viscosity must be within the ideal area. The toolmay not be operated if the oil viscosity is not within theallowable area or if the temperature is not within–20 C to 70 C (–4 F to 158 F).The viscosity index expresses the dependence of theviscosity on the temperature. Thus, a high viscosityindex is preferable so that the oil can be used within awide temperature interval.Applicable Oil Types(–4 F)–20 CTYPE OF OIL(14 F)–10 C(32 F)0C(50 F)10 C(68 F)20 C(86 F) (104 F) (122 F) (140 F) (158 F)30 C40 C50 C60 C70 CViscosityat 40 C(104 F)BP Biohyd 3236.0 cStBP Biohyd 4644.0 cStBP Biohyd SE 4646.0 cStBP Biohyd SE 6872.2 cStCASTROL Biotech HTG 3236.8 cStMOBIL EAL 224 H36.0 cStQ8 Holbein 4648.4 cStSHELL Naturelle HF35.0 cStSTATOIL M 32-6847.4 cStSHELL Tellus oil T4646.0 cStESSO Univis N4645.7 cStTEXACO Rando oil HDZ4651.0 cStMOBIL DTE 1544.9 cStPermitted oil temperatureGreenlee / A Textron CompanyRecommended oil temperature84455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerHose ConnectionsHoses and FittingsInstallation and MaintenanceRefer to publication 999 3032.3, SAE J1273(Hose and Hose Assemblies).Do not disconnect tool, hoses or fittings whilethe power source is running or if the hydraulicfluid is hot. Hot hydraulic fluid can cause seriousburns.ReplacementAdaptors: Breakers are installed with 1/2" BSP male–1/2" BSP male adaptors.Hoses: Hoses are produced according to EN 853 withtwo layers of wire and have a maximum pressure of275 bar (4000 psi). Hoses are approximately 300 mm(12") long.Fittings: 1/2" BSP female for connecting to thebreaker; 1/2" NPTF male for connecting to quickrelease couplings.Connecting Hoses1. Move the flow lever on the hydraulic power sourceto the OFF position.2. Stop the hydraulic power source.3. Connect the return hose to the return port on thehydraulic power source, then to the return port onthe tool.4. Connect the pressure hose to the pressure port onthe tool, then to the pressure port on the hydraulicpower source.Disconnecting Hoses1. Move the flow lever on the hydraulic power sourceto the OFF position.2. Stop the hydraulic power source.3. Disconnect the pressure hose from the hydraulicpower source, then from the tool.4. Disconnect the return hose from the tool, thenfrom the hydraulic power source.5. Install dust caps over the ports to preventcontamination.Typical SetupGreenlee / A Textron Company94455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerSetupOperation1. Start the hydraulic power source.Note: Allow the hydraulic power source to run fora few minutes to warm the hydraulic fluid.Inspect accessories before use. Discard accessories that have cracks, chips, or gouges.Failure to observe this warning could result insevere injury or death.2. Position the bit against the surface (material to bebroken, ground rod to be driven, etc.).3. Grasp both handles firmly.4. To start the tool, activate the trigger.5. To stop the tool, release the trigger.6. When the tool is not in use, stop the hydraulicpower source to reduce heat and wear on toolcomponents.Do not change accessories, inspect, adjust, orclean tool when it is connected to a power source.Accidental start-up can result in serious injury.Failure to observe this warning could result insevere injury or death.1.2.3.4.5.MaintenanceUse this maintenance schedule to maximize the tool’sservice life.Note: Keep all decals clean and legible. Replacedecals when necessary.Stop the hydraulic power source.Unlock the latch with a downward motion.Insert the accessory into the front head.Lock the latch with an upward motion.Connect the hydraulic hoses according to theinstructions under “Hose Connections.”Daily1. Wipe all tool surfaces clean.2. Inspect the hydraulic hoses and fittings for signsof leaks, cracks, wear, or damage. Replace ifnecessary.3. Install dust caps over the hydraulic ports when thetool is disconnected.MonthlyPerform a thorough inspection of the hydraulic hosesand fittings as described in publication 999 3032.3,SAE J1273 (Hose and Hose Assemblies).AnnuallyIf required by your organization, have the toolinspected by an authorized Fairmont service center.Greenlee / A Textron Company104455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerMaintenance (cont’d)Accumulator Recharging Procedure17. Close the charging screw (9) of the accumulatorby turning the handle (2) clockwise.18. Unload the nitrogen hose by opening the bleedervalve (5).19. Dismount the filling device and check the chargingscrew (9) for leakage with drops of oil.20. Fit the protective cap over the accumulator.Accumulator is charged with nitrogen under highpressure. This pressure must be unloaded beforedismounting.Failure to observe this warning could result insevere injury or death.11. Check that the oil inlet of the accumulator isdepressurized.2. Remove the protective cap over the chargingscrew (9) of the accumulator. The socket headscrew must be perfectly clean.3. Loosen the charging screw on top of the accumulator (maximum of two turns). Totally neutralize thepressure before dismounting the accumulator.4. Unscrew the accumulator cover (10), take out thediaphragm (11), and check for leakage anddamage.5. Clean, check, and replace damaged or worn parts.6. Grease the seal faces of the accumulator body(12) and the accumulator cover (10) with silicone.7. Spray both sides of the diaphragm with silicone.Place the diaphragm with its bead pointing downward so that it fits in the groove of the accumulatorbody (12).8. Unscrew the charging screw and replace the sealring (13).9. Grease the thread of the accumulator cover (10)with copper grease and tighten to approximately300 Nm (221 ft-lb).10. Fasten the charging screw lightly, and loosen ittwo turns afterward.11. Mount the filling device on the filling socket of theaccumulator cover and fasten it lightly whileturning the handle (2) forward and backward,ensuring that the hexagon resiliently fits into thecharging screw.12. Close the bleeder valve (5) by turning it clockwise.13. Connect the hose (7) to the check valve (6).14. Connect the free end of the hose directly to thenitrogen bottle by using the reducing nipple.Note: Use only pure nitrogen.7N223465139101112500 2718.2 Accumulator filling device(includes items 2–8)500 2717.4 Accumulator kit (fully charged)(includes items 9–14)(1)(2)(3)(4)(5)(6)(7)Valve of nitrogen bottleHandleFilling adaptorGaugeBleeder valveCheck valveHose, approximately3 m (10 ft)(8) Reducing nipple(24.32-14WFG)15. Read the pressure on the gauge (4). Carefullyopen the valve of the nitrogen bottle (1) andcharge with nitrogen until the pressure is approximately 20% higher than required charging pressure. Close the valve of the nitrogen bottle.16. If the gauge (4) shows too high a nitrogen pressure, loosen the bleeder valve (5) until the required pressure is achieved.Greenlee / A Textron Company811(9) Charging screw(10) Accumulatorcover(11) Diaphragm(12) Accumulatorbody(13) Seal ring(14) Protective cap(not shown)4455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerTroubleshootingBefore troubleshooting, determine whether the problemis in the tool, the hoses, or the power source. Substitutea tool, hoses, or power source known to be in goodworking order to eliminate the item that is not operating.ProblemTool does not operate.Tool operates slowly orerratically.Tool feels hot.Strike rate is normal;blow energy is weak.If the problem is in the tool, refer to the troubleshootingtable in this manual. If the problem is in the powersource, refer to the troubleshooting section of thepower source instruction manual.Probable CauseProbable RemedyImproper power source.Verify that the power source meets thespecifications.Hydraulic fluid level low.Check the fluid level. Check system for leaks.Incorrect hydraulic fluid viscosity.Use hydraulic fluid with the correct viscosity.Hydraulic fluid cold.Allow fluid to warm to the operatingtemperature. Actuate the tool intermittently toreduce the warming time.Power source not adjusted correctly.Refer to the power source operator’s manual.Set the flow and pressure to correspond withthe tool.Hydraulic fluid level low.Check the fluid level. Check system for leaks.Air in the hydraulic system.Refer to the power source manufacturer’sinstructions for removing air from the system.Incorrect hydraulic fluid viscosity.Use hydraulic fluid with the correct viscosity.Hydraulic fluid level low.Check the fluid level. Check for leaks.Incorrect hydraulic fluid viscosity.Use hydraulic fluid with the correct viscosity.Hydraulic fluid dirty.Refer to the power source owner’s manual forprocedure to replace hydraulic oil and filter.Low accumulator gas pressure.Return tool to an authorized Fairmontservice center.Broken accumulator diaphragm.Return tool to an authorized Fairmontservice center.Greenlee / A Textron Company124455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerIllustration—Main16710568* 70 Nm (52 ft-lb)5511880 Nm (59 ft-lb) 9*20431942100 Nm (74 ft-lb) 15*39*17112141214* 100 Nm (74 2545330338*2732235051*Loctite 2422422Greenlee / A Textron Company134455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerParts List—MainKeyPart ptionQtyAccumulator body .Valve housing .Cylinder .Striking piston .Accumulator cover .Diaphragm .Charging screw .Screw, M10x30 .Screw, M10x35 .Seal ring, Ø8.7/Ø13x1 .Spool .Guide socket .Spool socket .Protective cap, M24x1.5 .O-ring, Ø24x1.5 .O-ring, Ø18x2 .O-ring, Ø30x2 .O-ring, Ø32x2 .O-ring, Ø25x1.5 .Locking ring .Seal, Ø32/Ø40x6 .Seal, Ø32/Ø45x7/10 .Seal ring, 1/2" .Connector, 1/2" BSP .Seeger spring ring .Shim PS, 8x14x0.5 .Trigger spool .Trigger rod .Packing gland .Spring .Greenlee / A Textron Company111111144111111411111122211111KeyPart g, Ø8.3x2.4 .O-ring, Ø16.3x2.4 .Seal, Ø8/Ø14x3.5/5 .Backup ring .Seeger spring ring .Fitting, 02 KRG .Fitting, 04 KRG .Protective cap, 1/2" BSP .O-ring, Ø6x2 .O-ring, Ø8x2 .Backup washer .Screw .Check valve ball .Seal ring, Ø9/Ø14x1 .O-ring, Ø82x1.5 .O-ring, Ø16x1.5 .O-ring, Ø13x1.5 .Backup washer, Ø32.7/45x2.5 .Locking ring .Plate, identification .Decal, sound level 110 dB (HPB45-1) .Decal, sound level 109 dB (HPB45-2) .Decal, weight (HPB45-1) .Decal, weight (HPB45-2) .Decal, accumulator .50023101Seal kit (includes items 10, 16–25, 27, 28,33–37, 41, 42, 46–51, and 68/91)Trigger valve kit (includes items 27–37)Whip hose . 1111111111114455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerIllustration and Parts List—Standard Handle with Cover77766663696845 Nm (33 ft-lb) 6761736574647362616070757172KeyPart onQtyStandard handle with coverBracket, standard handle .Handle, standard .Rubber handle .Rubber handle .Trigger lever, standard .Roll pin, Ø8x40 .Top cover .Screw, M10x20 .Greenlee / A Textron Company1211111415KeyPart DescriptionQtyNab .Handle spacer .Nylon guide .Slotted pin, Ø6x22 .Safety trigger .Washer, nylon Ø21/Ø37x3 .Lock plate .Spring .Decal, Fairmont .Decal, warning .24111211214455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerIllustration and Parts List—Dampening Handle with Cover105981041011009945 Nm(33 ft-lb)8684939680929110395 94978189901028583828788KeyPart ning handle with coverFrame .Handle rod .Bottom plate .Spring guide .Roll pin, Ø6x12 .Spring .Nylon guide .Washer, Ø8 .Screw, M8x16 .Pin latch, right .Pin latch, left .Trigger pawl .Greenlee / A Textron Company11142484411116KeyPart riptionQtyPin, pawl Ø6x30 .Trigger lever .Roll pin, Ø6x24 .Thrust pad with screw .Nut, M8 .Nut, cap, M8-hex 13 black .Top cover .Screw, M10x20 .Nab .Handle spacer .Rubber handle .Rubber handle .Decal, Fairmont .Decal, warning .111111142411214455 Boeing Dr. Rockford, IL 61109-2988 USA 815-397-7070

HPB45 Hydraulic Paving BreakerIllustration and Parts List—Nose110116Loctite 24260 Nm (44 ft-lb)120113117118114111Loctite 6351151121191" x 4-1/4" Hex ShankKeyPart 500238025002382950109570Description1-1/8" x 6" Hex ShankQtyNose part, hex 1" .Bushing, hex 1" x 4-1/4" .Chisel bellows, hex 1" .

Q8 Holbein 46 48.4 cSt SHELL Naturelle HF 35.0 cSt STATOIL M 32-68 47.4 cSt SHELL Tellus oil T46 46.0 cSt ESSO Univis N46 45.7 cSt TEXACO Rando oil HDZ46 51.0 cSt MOBIL DTE 15 44.9 cSt Permitted oil temperat

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