Manual reparación HB-7000

7/27/2019 Manual reparacin HB-7000

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Re pa ir m anua l H ydr auli c br ea ke r

H B 7 0 00 a n d H B 7 00 0 D u st P ro t ec to r

T.Id. Nr. 3390 5082 01 20080131


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Repair manual

Hydraulic hammers

HB 7000 and HB 7000 DustProtector

At las Copco Construct ion Tools GmbH

At las Copco Construct ion Tools GmbH

P.O. Box address: Postfach 10 21 52, D 45021 EssenPostal address: Helenenstrasse 149, D 45143 Essen

Telephone: +49 2 01 6 33 0Fax Aftermarket Department: +49 2 01 6 33 1352

Federal Republic of Germany


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Repair manual HB 7000 / HB 7000 DustProtector

5

Content

1 General.................................................................................................................................................71.1 Explanation of the symbols in the repair manual .............................................................................72 Operational safety...............................................................................................................................82.1 General .............................................................................................................................................82.2 Accident prevention regulations ......................................................................................................82.3 Tools, measuring and testing equipment .........................................................................................92.4 Operating media / consumables.......................................................................................................93 Tools...................................................................................................................................................103.1 General tools ..................................................................................................................................103.2 Service box.....................................................................................................................................113.3 Special accessories ........................................................................................................................123.3.1 Accumulator filling device...............................................................................................................123.3.2 Power wrench.................................................................................................................................133.3.3 HeliCoil-tools...................................................................................................................................133.3.4 Fitting aid for percussion piston......................................................................................................143.3.5 Press-out aid for wear bushes HB 7000.........................................................................................144 Dismantl ing the hydraul ic hammer ................................................................................................154.1 Removing working tool ...................................................................................................................154.2 Removing the percussion mechanism from the hammer box......................................................164.3 Removing high-pressure accumulator............................................................................................194.3.1 Removing adapter plate under high-pressure accumulator...........................................................204.4 Removing control valve ..................................................................................................................214.5 Removing AutoControl-valve..........................................................................................................224.6 Removing perforated disk...............................................................................................................234.7 Removing cylinder cover ................................................................................................................234.8 Removing seal flange.....................................................................................................................254.9 Removing percussion piston .........................................................................................................254.10 Removing cylinder ..........................................................................................................................254.11 Removing DustProtector ................................................................................................................264.12 Removing the locking pins for the retainer bars and wear bushes in the lower hammer part .......274.13 Removing locking bushes...............................................................................................................275 Checking the hammer box ...............................................................................................................285.1 Checking for cracks and indentations ...........................................................................................285.2 Wear to bottom plate ......................................................................................................................285.3 Checking elastic pad ......................................................................................................................295.4 Checking damping elements ..........................................................................................................295.5 Checking damping plate.................................................................................................................295.6 Checking guide plates ....................................................................................................................305.6.1 Checking lower guide plates ..........................................................................................................305.6.2 Checking upper guide plates..........................................................................................................316 Assembling the hydraulic hammer .................................................................................................326.1 Tightening torques for screws and screw couplings ......................................................................326.2 Fitting cylinder.................................................................................................................................336.3 Fitting percussion piston.................................................................................................................336.4 Fitting seal flange ...........................................................................................................................346.5 Fitting cylinder cover.......................................................................................................................346.6 Fitting AutoControl valve ................................................................................................................36


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6.7 Fitting control slide valve ................................................................................................................376.8 Fitting perforated disk .....................................................................................................................386.9 Fitting high-pressure accumulator .................................................................................................384.7.1 Mount adapter plate under high-pressure accumulator .................................................................384.7.2 Mount high-pressure accumulator..................................................................................................396.10 Filling the piston accumulator ........................................................................................................406.11 Fitting the percussion mechanism in the hammer box...................................................................426.12 Fitting the swivel joints....................................................................................................................436.13 Connecting ContiLubeII ...............................................................................................................446.14 Fitting the working tool....................................................................................................................456.15 Fitting the DustProtector.................................................................................................................467 Changing the seals ...........................................................................................................................477.1 Changing the cylinder seals ...........................................................................................................477.2 Changing the seals between cylinder and cylinder cover.............................................................497.3 Changing the seals on the sealing bush ........................................................................................497.4 Changing the seals on the high-pressure accumulator and the adapter plate .............................507.5 Changing the seal on the filling valve............................................................................................517.6 Changing the seal on the AutoControl-valve.................................................................................517.7 Changing the seal an the control casing cover ..............................................................................527.8 Changing the seals on the swivel joint ...........................................................................................528 Repair work .......................................................................................................................................538.1 Changing the expansion bolts on the high-pressure accumulator ................................................538.2 Changing the high-pressure accumulator .....................................................................................538.3 Changing the tie rods .....................................................................................................................548.4 Removing scores from control slide valve and bore .....................................................................568.5 Removing scores on percussion piston and cylinder bore.............................................................568.6 Replacing retainer bars and working tool......................................................................................578.7 Changing the wear bushes.............................................................................................................588.8 Replacing the complete hammer box............................................................................................608.9 Replacing guide plates and damping elements in hammer box ...................................................608.10 Replacing the wear protection set .................................................................................................618.11 Replacing the DustProtector ..........................................................................................................618.12 Repairing cracked welds ................................................................................................................628.13 Replacing the bottom plate on the hammer box ...........................................................................628.14 Reworking the retainer pins for the damping elements.................................................................638.15 Weld seam preparation ..................................................................................................................638.16 Preheating temperature..................................................................................................................638.17 Fillers ..............................................................................................................................................638.18 Post-treatment of welds..................................................................................................................63


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1 General

This repair manual applies to the hydraulic hammers:

HB 7000

HB 7000 DustProtector

Although this repair manual applies to the hydraulic hammers HB 7000, the manual refers only to hydraulichammer, by way of simplification. Specific differences between the versions are however highlighted.

The hydraulic hammer HB 7000 DustProtector is called HB 7000 DP, by way of simplification.

Ensure that the spare parts list with the exploded diagram of the individual parts is to hand.

1.1 Explanation of the symbols in the repair manual

To emphasize their importance, certain points in the repair manual are marked with symbols, which are de-scribed below.

Passages marked in this way contain safety infor-

mation and instructions aimed at preventing acci-dents and avoiding injury.

Passages marked in this way contain safety infor-mation and instructions aimed at avoidingdamage.

Theses passages contain information on the cor-rect use of the hydraulic tool and are aimed atavoiding mistakes during operation.Note

DANGER!

CAUTION!


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2 Operational safety

2.1 General

In order to maintain the operational safety of thehydraulic hammer, repair work should only be car-ried out by trained specialists using genuine spareparts. This work should therefore only be entrustedto Atlas Copco Construction Tools trained special-ists who know which spare parts need replacingand when.

2.2 Accident preventionregulations

To avoid the possibility of inju ry, pleaseobserve the following instructions!

Before starting work:Please familiarise yourself with the repair manualand the appropriate regulations before starting

work on the hydraulic hammer.When using or working on hydraulic hammers inthe countries of the European Union, the regula-tions of the EC machinery directive 98/37/EG mustbe observed and followed, as must national acci-dent prevention regulations and regulations cover-ing pressurised vessels.In countries outside the European Union, the validlocal statutes and regulations will apply.The hydraulic hammer should only be repaired byspecialists.When lifting/transporting the hydraulic hammer,use only the lug provided and hoisting equipment

with sufficient capacity.Clear hand signals must be agreed on with thehoist operator beforehand.Never stand beneath hoisted loads.Stand the hydraulic hammer in a suitable deviceand secure it against falling over.The repair area must be clear and easily accessi-ble.Always wear protective glasses when fitting or re-moving the working tool since metal splinters mayfly off when hammering out the locking pins.Working tools should only be fitted as described inthe operating manual.

The hammer's integrated piston accumulator ispressurised.Before dismantling the hydraulic hammer and be-fore removing the complete filling valve G , thepiston accumulator must be fully depressurised.Never use nails, screwdrivers or similar objects tobleed off the gas since this would damage the fill-ing valve. Bleed off the gas using only the nozzleof the filling/test hose.Never use your fingers to check the alignment of

the working tool recesses to the oblong holes forthe locking bars.Never dismantle a hydraulic hammer which is stillhot from running as there is a high risk of injurythrough burns. Always wait until the hammer hascooled down before dismantling it.Collect any oil which runs out and dispose of it inaccordance with the applicable statutory provisionsto avoid environmental hazards.

The piston accumulator must only be filled with ni-

trogen from the green cylinder.Make sure that no other gas (e.g. air or oxygen) isallowed into the piston accumulator.When attaching the adapter use only the specialsteel screws included in supply.

DANGER!

DANGER!Risk of explosion!

DANGER!


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2.3 Tools, measuring and testingequipment

The tools required for dismantling and reassem-bling the hydraulic hammer are to be provided bythe user (see Chapter 3.1).

The special accessories used in this section arelisted in Chapter 3.3.

2.4 Operating media / consum-ables

Use Comments

HP oilHLP 32

Running thehydraulichammer

In warmer cli-mates, oils with ahigher viscosityclass should beused

High-performancebearing greasewith solidscontent

Working toollubrication

Chisel paste(see Operatingmanual)

Nitrogen N2 Filling the

high-pressureaccumulator*

pistonaccumulator

Abrasive pol-ishing paper,grain 600

Removingscores

Anti-Seize Fitting the wearbushes

GreaseParker O-Lube

Lubrication ofsealings

*If any significant changes are made to thehydraulic system, a new acceptance inspection isto be carried out in accordance with the relevantnational safety provisions.

DANGER!


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3 Tools

3.1 General tools

The tools required for repair work are listed below:

Designation Part ID no. Qty.

Sledgehammer 2 kg 3361 0318 11 1

Sledgehammer 4 kg 3361 1464 33 1

Grease gun cpl. 3363 0345 67 1

Slugging ring spanner size 65 3360 4371 02 1

Heavy-duty box spanner size 65 3360 4782 81 1

Jaw spanner size 55/60 3361 0316 75 1

Jaw spanner size 50/55 3361 0316 74 1

Jaw spanner size 46/50 3360 4379 43 1

Jaw spanner size 41/46 3360 4306 13 1

Jaw spanner size 36/41 3360 4306 12 1

Jaw spanner size 13/15 3360 1195 82 1

Jaw spanner size 10/13 3361 0318 34 1

Socket spanner size 24/27 3360 4310 02 1

Socket spanner size 22 3361 0318 35 1Socket spanner size 14 3363 0313 96 1

Allen key size 27 3360 4789 49 1

Allen key size 22 3360 2094 45 1

Allen key size 19 3360 2092 53 1

Allen key size 17 3360 2092 52 1

Allen key size 14 3360 2049 63 1

Allen key size 12 3360 2092 51 1

Allen key size 10 3360 2049 62 1

Allen key size 5 3360 2092 49 1

Power screwdriver insert size 65 / 1 " 3363 0918 36 1

Power screwdriver insert(for pneumatic Torque Multiplier )

size 65 / 2 " 3363 0983 62 1

Screwdriver 8 mm 3362 3281 43 1

Adapter "->1" 3363 0942 20 1

Adapter 1"->1" 3363 0942 30 1

Torque wrench 140-760 Nm / " 3363 0942 17 1

Lock ring pliers 3360 4309 61 1


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3.2 Service box

The tools required for service work on the hydrau-lic hammer are contained in the service box.

Service box and contents can be ordered un-der part ident. no. 3363 0898 45.

Item Qty. Designation Pt. ID no.

1 1 Nitrogen cylinder 2l 3363 0345 06

2 1 Filler valve 3361 3295 16

3 1 Test pressure gauge 3361 3295 18

4 1 Hose 3361 3295 17

5 1Pin punchd = 15,5, L = 130

3361 8488 19

6 1 Socket spanner 3363 0663 76

7 1Hexagonal head boltM 12x150

3360 1038 66

7 1Hexagonal head bolt

M 20x160

3360 1031 54

Fig. 1Service tools


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3.3 Special accessories

This chapter lists the special tools and apparatus

which can be purchased from Atlas Copco Con-struction Tools to equip the workshop.

3.3.1 Accumulator fil ling device

The tools listed in the table below are used to fillthe high-pressure accumulator. The filling processalso requires the nitrogen cylinder and the fillervalve from Service box.

Designation Pt. ID no.

Filling device cpl. 3360 9204 15

If any significant changes are made to thehydraulic system, a new acceptance inspection isto be carried out in accordance with the relevantnational safety provisions

Fig. 2Accumulator filling device


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3.3.2 Power wrench

You can choose between a manual, an electronic,a hydraulic or a pneumatic Torque Multiplier.

Designation Pt. ID no.

Manual Torque Multiplier 3363 0918 27

Electronic Torque Multiplier 3363 0918 31

Hydraulic Torque Multiplier 3363 0918 29

Pneumatic Torque Multiplier 3363 0983 59

3.3.3 HeliCoil-tools

The tools listed in the table below are used to re-place the HeliCoil inserts.

Item Designation Pt. ID no. Use

1Screw tapM 20 HC

3360 9203 59

2Threaded insertM 20 HC

3361 0315 29

3Screw-in toolM 20 HC

3360 9203 55

Cylindercover(Controlsystem)

1Screw tapM 20 HC

3360 9203 59


From SN 1693363 0899 16

4

Threaded insert

M 20 HC

Up to SN 168

3361 0315 29


3360 9203 55

High-pressureaccumu-

lator

5Screw tapM 36HC

3360 9203 61


3360 4783 06


3360 9203 57

Adapter

8Threaded insertRD 48x5

3363 0854 99

9

Screw-in tool

RD 48x5 3363 0857 46

Lowerbreakerpart

(tie rods)

Fig. 3Torque Multiplier

Fig. 4Hydraulic Torque Multiplier

Fig. 5HeliCoil-tools


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3.3.4 Fitting aid for percussion piston

Designation Pt. Id No.

Eye bolt M 48 3360 2067 02

3.3.5 Press-out aid for wear bushesHB 7000

Item Designation Pt. Id No.

- Press-out tool, comp. 3363 0314 90

1 Grip 3360 3323 24

2 Screw 3360 3323 23

3 Press-out element, top 3363 0327 15

4Press-out element,bottom

3363 0327 17

Fig. 6Fitting aid

Fig. 7Press-out aid


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4 Dismantling thehydraulic hammer

4.1 Removing working tool

Lay the hydraulic hammer on a suitable base.

Remove the plugs (Fig. 8/5) and (Fig. 8/9)from the hammer box.

Wear protective glasses!Risk of injury from flying metal splinters!

Using the pin punch (Fig. 8/7) and a hand-held hammer (Fig. 8/8), knock the lockingpins (Fig. 8/2) for the retainer bars (Fig. 8/3)out of the side of the lower hammer part(Fig. 8/1).

Remove the two sealing plugs (Fig. 8/4) fromthe oblong holes for the retainer bars.

Remove the retainer bars (Fig. 8/3).

The retainer bars have an M 20 thread on thefront end.

Take an M 20 x 160 hexagonal head screw,screw it into the threaded bore and use it topull out the retainer bar.

Remove the working tool (Fig. 8/6) from thebore in the lower hammer part and deposit sa-fely.

Fig. 8Removing the working tool

DANGER!


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4.2 Removing the percussionmechanism f rom thehammer box

Stand hammer box with hydraulic hammervertically and secure against falling over.

Remove Allen screws (Fig. 9/2) using allenkey size 27 (Fig. 9/3) and remove adapter

(Fig. 9/1) from hammer box using ahoist/crane.

Remove elastic pad (Fig. 10).

Remove Allen screws using Allen key size 12from the cover with ContiLube

II (Fig. 11).

Lift the cover so that grease/oil line betweenContiLube

II and percussion unit can be dis-

mantled.

Remove grease/oil line at the percussion unit.

Remove the cover with ContiLubeII from

breaker box (Fig. 12).

Lock connection boring p (connection oil linefor ContiLube

II) so that no oil runs out.

Fig. 9Unscrewing the adapter from the hammer box

Fig. 10

Removing the elastic pad

Fig. 11Loosen the cover with ContiLube

Fig. 12Remove the cover with ContiLube

DANGER!


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Removing the swivel joints:

Remove the lock ring (Fig. 13/1) from theflange body (Fig. 13/6) using lock ring pliers.

Remove the washer (Fig. 13/4).

Pull connector element (Fig. 13/2) from flangebody.

Remove rubber cover (Fig. 13/5).

Release Allen screws (Fig. 13/3) using asize 10 Allen key and unscrew them.

Collect any oil which runs out and dispose of it inaccordance with the applicable statutory provi-sions to avoid environmental hazards!

Remove both flange bodies in this way.

Plug the connecting borings in the cylindercover so that no oil runs out.

Fig. 13Remove swivel joint

1

2

3

45

6

CAUTION!


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Lifting out the percussion unit

Rupturing washers become projectilesWhen loosen the tie rods the washer under thehead of the tie rods may rupture and becomeprojectiles. Rupturing parts may cause seriousinjuries.

Place the dismantling rings (Fig. 14/1) (Part-Id.-No. 3363 0979 13) over the head of all tierods (Fig. 14/2) before lifting the percussionunit out of the hammer box.

For safety reasons the dismantling rings areremoved only if the tie rods are dismounted.

Screw two vertebral blocks M 42 into the twothreaded bores on the upper face of the cylin-der cover as far as they will go.

Using a hoist/crane, lift the percussion unit ofthe hydraulic hammer out of the hammer box(Fig. 15).

If the percussion mechanism has jammed in thehammer box, e.g. due to heavy contamination, thehoist must not be used as a pulling device with the

hammer box held firmly.

Secure hammer box against falling over.

For hydraulic hammers with DustProtector:Remove base for stripper from the lower wearbush.

Stand percussion unit vertically and secureagainst falling over (e.g. place on a standsimilar to that in Fig. 16).

Fig. 14Secure washers

Fig. 15

Lifting the percussion unit out of the hammer box

Fig. 16

Stand

DANGER!

DANGER!

1

21


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4.3 Removing high-pressureaccumulator

Stand hydraulic hammer vertically and secure

against falling over (e.g. on a stand similar toFig. 16or lay flat).

If the hydraulic hammer is still attached to thecarrier, the hydraulic system must be depressur-ised prior to removing the high-pressure accumu-lator.

e.g.

On hoses with screw couplings, relieve pres-sure on check valves and depressurise (openthe hose ports on the hammer).

Slowly unscrew cap nuts on swivel joints.

Release expansion bolts (Fig. 17) on accu-mulator using a size 30 socket spannerand screw them out, removing the washers atthe same time.


Remove high-pressure accumulator (Fig. 18).

Check threaded insert (Fig. 19/1) replace ifnecessary.

Check expansion bolts (Fig. 19/2) replace if

necessary.

The high-pressure accumulator on the HB 7000has a capacity 1.5 l and a max. permissible oper-ating pressure of 230 bar (3335 psi).

If any significant changes are made to the

hydraulic system, a new acceptance inspec-tion is to be carried out in accordance with therelevant national safety prov isions.

Fig. 17Releasing and unscrewing the expansion bolts

Fig. 18Removing the high-pressure accumulator

Fig. 19

Check threaded inserts and expansion bolts

DANGER!

CAUTION!

CAUTION!

1

2


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4.3.1 Removing adapter plate underhigh-pressure accumulator

Depending on version an adapter plate ismounted under the high-pressure accumulator.

Unscrew Allen screws M 20 from the adapterplate (Fig. 20) using size 17 Allen key.

Remove the adapter plate from the cylindercover (Fig. 21).

Check threaded insert (Fig. 22/1) replace ifnecessary.

Fig. 20Unscrewing the Allen screws

Fig. 21Removing the adapter plate

Fig. 22Check threaded inserts

1


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4.4 Removing control valve

Unscrew Allen screws M 20 from cover

(Fig. 23) using size 17 Allen key.

Screw 2 Allen screws M 20 into the twothreaded bores in the cover and pull the coverout of the cylinder cover bore (Fig. 24).

Remove control slide valve (Fig. 25/1) frombore observing direction of removal.

Fig. 23Removing the Allen screws

Fig. 24Removing the cover

Fig. 25Removing the control slide valve

1


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4.5 Removing AutoControl-valve

Release threaded plug (Fig. 26/2) using a

size 22 Allen key and unscrew from the borein the cylinder cover.

Remove O-ring (Fig. 26/1) from threadedplug.

NoteThe threaded plug (Fig. 26/2) is fixed with Loctite.

Turn a screw M 3 x 50 (Fig. 27/2) into thethreaded bore on the upper face of the Auto-Control valve (Fig. 27/1) and pull the com-plete valve out of the bore.

NoteIf the AutoControl valve is defective or non-functional, replace it.

Fig. 26Removing the threaded plug and the O-ring

Fig. 27Removing the AutoControl valve

1

2

12


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4.6 Removing perforated disk

Replace perforated disk if necessary (visual ex-

amination).

Unscrew the threaded plug from the boreusing a size 14 Allen key (Fig. 28).

NoteThe threaded plug is fixed with Loctite.

Pull the perforated disk (Fig. 29) out of thebore using a hook. Clean perforated disk if

necessary.

4.7 Removing cylinder cover

Before removing the cylinder cover the gas mustbe bled from the piston accumulator.(Do not unscrew filler valve from cylinder coveruntil accumulator has been depressurised).

Unscrew screw plug from filler valve port Gusing size 5 Allen key (Fig. 30).

Push nozzle of filler hose (Fig. 31) into fillervalve and relieve pressure on piston accumu-lator.

Unscrew filling valve from cylinder cover usinga size 22 socket wrench, replace if necessary.

Fig. 28Unscrewing the threaded plug

Fig. 29Pulling out the perforated disk

Fig. 30

Removing screw plug from port G

Fig. 31Relieving piston accumulator pressure

DANGER!


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Risk of injury when supporting power wrench.

NoteTie rods and the matching holes in the lowerhammer part have to be marked for later remount-ing.

Release tie rods using an electronic, pneu-matic or hydraulic power wrench (Fig. 32) andunscrew from lower hammer part.

Pull out tie rods.

Remove washers and dismantling rings.

NoteDispose of washers of the old version. Exclusivelywashers (Part-Id.-No. 3363 0936 55) of the new

version may be installed at the assembly.

Screw two vertebral blocks M 42 into the twothreaded bores on the upper face of the cylin-der cover as far as they will go and lift off thecylinder cover using a hoist/crane (Fig. 33).


Fig. 32Releasing tie rods with a power wrench

Fig. 33Removing the cylinder cover

DANGER!

CAUTION!


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4.8 Removing seal flange

Screw two eye bolts (M 24) into the threaded

bores of the seal flange as far as they will go. Lift the seal flange from the lower hammer

part using a crane/hoist (Fig. 34).

4.9 Removing percussionpiston

Note

Remove the percussion piston in vertical position.


After removal of the cylinder cover, screw the

eye bolt M 48 (see Chapter 3.3.4) into thethreaded bore on the percussion piston as faras it will go.

Pull out the percussion piston using ahoist/crane (Fig. 35).

4.10 Removing cylinder

Screw two eye bolts (M 24) into the threadedbores of the cylinder as far as they will go.

Lift the cylinder from the lower hammer partusing a crane/hoist (Fig. 36).


Fig. 34Removing the seal flange

Fig. 35Removing the percussion piston

Fig. 36Removing the cylinder

CAUTION!

CAUTION!


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4.11 Removing DustProtector

Wear protective glasses!Risk of injury from flying metal splinters.

Knock out the locking pins (Fig. 37/1) for theDustProtector using a pin punch and a handhammer.

Guide ring (Fig. 37/5) may stick in the centri-cal bore due to dust accumulation. Strike theguide ring (Fig. 37/5) a few times with thehand hammer until it comes loose.

Guide ring (Fig. 37/5) with floating ring(Fig. 37/4) and counter-ring (Fig. 37/2) cannow be removed.

Remove stripper (Fig. 36/3).

Note

To facilitate removal of the stripper:Press the sealing lip of the stripper inward usingyour thumb. This presses the stripper out of theannular grove in the seat.

Fig. 37Removing the DustProtector

DANGER!


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4.12 Removing the locking pinsfor the retainer bars andwear bushes in the lowerhammer part


Knock out of the locking pin using the pinpunch and a hand hammer (Fig. 38).

4.13 Removing locking bushes

Insert a screwdriver behind the locking bush(Fig. 39).

Use the screwdriver to lever the locking bushout of the bore. The bush must be replaced ifthe locking pin can be pushed out of the boreby pressing on it firmly with a finger.

Fig. 38Knocking out the locking pin

Fig. 39Removing the locking bush

DANGER!


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Repair manual HB 7000 /HB 7000 DustProtector

28

5 Checking the hammerbox

5.1 Checking for cracks andindentations

Check the complete hammer box for cracks, whichmay be caused if the material is overstressed - fre-quently as a result of metallic contact between thepercussion mechanism and the hammer box.

As shown in the figures on the right, contact be-tween hammer and hammer box at these pointscan cause indentations and marks.

The cause is wear to the guide plates in the lowerzone, which allows greater freedom of movementin the upper zone leading to contact with the ham-mer box.

Check the guide plates for wear.

5.2 Wear to bottom plate

Frequently, repeated contact with the material be-ing broken results in serious wear to the bottomplate. To avoid having to replace the complete

hammer box in such cases there are two possibleremedies:

Replacement of complete bottom plate (seechapter 8.13).New bottom plates and seat for DustProtectorcan be purchased from Atlas Copco Construc-tion Tools.

In special cases the worn bottom plate can berepaired by build-up welding.

Addi tional requirements for hydraulic hammerswith DustProtector

The reinforcement in the lower area of the hammerbox is frequently subject to wear. To avoid havingto replace the hammer box, the worn parts can beremoved and replaced by new ones.The complete wear protection set can be pur-chased from Atlas Copco Construction Tools.Complete replacement of wear protection set (seeChapter 8.10).

Fig. 40Indentation at damping element bearing points

Fig. 41Indentation on intermediate plate/high-pressureaccumulator

Fig. 42

Worn bottom plate

Fig. 43Wear in wear protection zone


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5.3 Checking elastic pad

Once the adapter has been removed, the elastic

pad can be taken out and subjected to a visual anddimensional check.The figure on the right shows the check dimensionh. This dimension is reduced the longer the padis used, either due to the material "settling" or dueto wear through relative movement. After a servicelife of approx. 5001000 operating hours, dimen-sion h may fall below its lower limit, at which pointthe elastic pad must be replaced. The lower limitfor dimension h is 145 mm.The same figure also shows the effects of exces-sive contact pressure on the hammer during use.When contact pressure is too high, the material of

the elastic pad "flows" over the edges of the upperhammer part, causing the material to crack andleaving notches.As time goes on these notches get bigger and cancause larger pieces of the elastic pad to break offor lead to deep cracks.

5.4 Checking damping elements

Here again, excessive loads to the damping ele-ments (Fig. 49/1) may cause cracks/notches whichthen necessitate replacement in pairs.The check dimension h should also be measuredupon dismantling to decide whether replacement inpairs is necessary. The table shows the lower limitfor the check dimension h. The lower limit for di-mension h is 43 mm.

5.5 Checking damping plate

The damping plate (Fig. 49/5) is subject to wearduring normal use. The penetration of dust and dirtstrengthens the wear to the plate. The check di-mension h should also be measured upon dis-mantling to decide whether replacement is neces-sary. The lower limit for dimension h is 70 mm.

Fig. 44Check dimension h and cracks/notches in theelastic pad

Fig. 45Check dimension h and cracks/notches on the

damping element

Fig. 46Check dimension h on the damping plate

Notches / Cracking

Notches / Cracking

h


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5.6 Checking guide plates

5.6.1 Checking lower guide plates

The guide plates (Fig. 49/3) are subject to wearduring normal use. The penetration of dust and dirtalong with surface pressure cause heavy abrasionto the plates.

(Fig. 47) further possible wear and damage..

Depending on condition, the guide plates shouldbe replaced individually or in sets.

By measuring the thickness of the plates it is pos-sible to determine whether replacement can be

postponed by inserting thin sheets as shims(Fig. 48).

When shimming in this way, a sheet at least one2 mm thick must be inserted on each side.However, shimming must be restricted to max. two2 mmon each side.

Service openings must remain accessible!

Plate thickness is mostly only wear-reduced lo-cally. A decision on whether to replace the guideplates therefore depends on the general conditionof the parts in each case.

Fig. 47Possible wear and damage to the guide plates

Fig. 48Check dimension h and arrangement of shims

Shim

Guideplate

Wall ofhammerbox

Abrasion

Conchoidal fracture

Dirt deposits

Abrasion

CAUTION!


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31

5.6.2 Checking upper guide plates

The upper guides plates (Fig. 49/2) and (Fig. 49/4)are made from special foamed plastic (PUR) andtherefore have a certain degree of elasticity.

After removing the hammer, these plates can beremoved from their guides and examined.

Here again, a decision is made depending on theindividual condition of the plates as to whether re-placement is necessary.

Fig. 49Checking the upper guide plates

1

2

3

4

5


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6 Assembling the hydraulic hammer6.1 Tightening torques for screws and screw couplings

Connection point Tool Tightening torque

Adapter Allen key size 27 2300 Nm*

Tie rods Power wrench size 65 Pre-tighten nuts in diagonallyopposed pairs to 500 Nm,

Then tighten in diagonally op-posed pairs by a further 180(3 sides of hexagonal head),

Then finish tighten in diagonallyopposed pairs by 180 (3 sidesof hexagonal head)

Allen screwValve cover/control valve

Allen key size 17 380 Nm

AutoControl-system Allen key size 22 300 Nm

Hose connectionsContiLube

II

Socket and jaw spannersof varying sizes

Ports Pand T Jaw spanner size 55 / 60 400 Nm

Filling valve GScrew plug

Socket spanner size 22Allen key size 5

130 Nm20 Nm

Start-Select Allen key size 17 200 Nm

High-pressureaccumulator

Socket spanner size 30 See **

*Apply anti-seize to the threads of the cylindrical bolts before screwing them in.The contact face of the bolt head and the locking rings must be free of lubricant.

**HB 7000 (up to SN 168):1. Treat the threads and thread inserts for the reduced-shaft bolts with an anti-seize agent.2. Degrease and dry the surfaces between the bolt heads, the washers, and the cover for the high pressure

storage vessel.3. Pre-tighten the reduced-shaft bolts to 50 Nm, proceeding in a crosswise fashion,4. then tighten each bolt through 30 in a crosswise fashion,5. finally tighten each bolt again through 60 in a crosswise fashion.

HB 7000 (from SN 169 on):1. Treat the threads and HeliCoil thread inserts for the reduced-shaft bolts with an anti-seize agent.2. Treat the surfaces between the bolt heads, the washers, and high pressure accumulator cover with

anti-seize.3. Place on the high-pressure accumulator, and tighten the anti-fatigue bolts by had in a crosswise fashion4. Pre-tighten the reduced-shaft bolts to 100 Nm, proceeding in a crosswise fashion,5. then tighten each bolt through 30 in a crosswise fashion,6. finally tighten each bolt again through 60 in a crosswise fashion.


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6.2 Fitting cylinder

Stand lower hammer part upright and secure

against falling over.

Clean contact faces on lower hammer part andcylinder.

Grease O-rings (Fig. 50/1) with ParkerO-Lube (Part-Id.-No. 3363 0852 30) and theninsert in the appropriate groove on the upperface of the lower hammer part.

Screw two eye bolts (M 24) into the threadedbores of the cylinder as far as they will go.

Position the cylinder on the lower hammer partusing a hoist/crane (locking pin (Fig. 50/2)).

Remove eye bolts from the cylinder.

6.3 Fitting percussion piston

Clean percussion piston and coat with hydrau-lic oil.

Screw eye bolt fully into the percussion piston.

Using a crane, insert percussion pistoninto cylinder as far as it will go, avoiding tilting(Fig. 51).

Remove eye bolt from percussion piston.

Fig. 50Fitting the cylinder

Fig. 51

Fitting the percussion piston

1

1

1

2


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6.4 Fitt ing seal flange

Clean the upper face of the cylinder and the

lower face of the seal flange. Grease O-ring grooves on the lower face of the

seal flange with Parker O-Lube (Part-Id.-No.3363 0852 30).

Insert O-rings (Fig. 52/1), (Fig. 52/2) and(Fig. 52/3) in the appropriate grooves.

Screw two eye bolts (M 24) into the threadedbores of the seal flange as far as they will go.

Position the seal flange on the cylinder using ahoist/crane (locking pin (Fig. 52/4)).

Remove eye bolts from seal flange.

Note

Always use seal flange with new seals and ob-serve fitting direction for seal flange (Chapter 7.2and 7.3)!

6.5 Fitting cylinder cover

Screw two vertebral blocks M 42 into the twothreaded bores on the upper face of the cylin-

der cover as far as they will go and lift the cyl-inder cover using a hoist/crane.

Clean the faces of the seal flange and the cyl-inder cover.

Grease O-ring (Fig. 53/1)with Parker O-Lube(Part-Id.-No. 3363 0852 30) and then insert inthe appropriate groove in the cylinder cover.

Grease O-ring grooves on the upper face ofthe seal flange with Parker O-Lube(Part-Id.-No. 3363 0852 30).

Insert O-rings (Fig. 53/2), (Fig. 53/3) and(Fig. 53/4) in the appropriate groove.

Using a hoist/crane, place cylinder cover on

seal flange and locate through bores for tierods (locking pin (Fig. 53/5)).

NoteThe O-ring (Fig. 53/1) may fall out of the borewhen fitting the cylinder cover. Before final posi-tioning, ensure the O-ring is still in its correct posi-tion.

Remove vertebral blocks from cylinder cover.

Fig. 52Fitting the seal flange

Fig. 53Fitting the cylinder cover

1

2

3

4

12

3

4

5


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Rupturing washers become projectilesWhen loosen the tie rods the old version of wash-ers under the head of the tie rods may rupture andbecome projectiles. Rupturing parts may cause se-rious injuries.

Exclusively install washers of the new version(Part-Id.-No. 3363 0936 55) at the installationof the tie rods.

Washers are conical on one side. When fitting,the conical side must be facing head of tie rod.

Treat the threads of the tie rods and the wash-ers with anti-seize agent.

Provide tie rods (Fig. 54/1)with one washereach (Fig. 54/2)and insert in the bore.

Screw the tie rods into the marked nuts or ta-pered holes (in matching pairs).

Risk of injury through power wrench support.

Using an electronic, pneumatic or hydraulicpower wrench (Fig. 55), pre-tighten tie rods indiagonally opposing pairs to 500 Nm (tighten-ing torques, and turning angles, see chap-ter 6.1).

After assembling the percussion mechanism thepiston accumulator must be filled with nitrogen(see chapter 6.10).

Fig. 54Fitting the tie rods

Fig. 55

Tightening tie rods with a power wrench

1

2

CAUTION!

DANGER!

DANGER!


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36

6.6 Fitting AutoControl valve

Insert AutoControl valve (Fig. 56/1) in bore

provided in cylinder cover.

NoteEnsure valve is fitted the right way round!AutoControl valve must fit loosely in bore of bush.

Unscrew screw M 3x50 (Fig. 56/2) from Auto-Control valve.

NoteIf the AutoControl valve is defective or non-functional, replace it.

Grease new O-ring (Fig. 57/1) with ParkerO-Lube (Part-Id.-No. 3363 0852 30).

Provide the threaded plug (Fig. 57/2) with theO-ring (Fig. 57/1).

Tighten screw plug with size 22 Allen key(tightening torque, see Chapter 6.1)

Fig. 56Fitting the AutoControl valve

Fig. 57Fitting the threaded plug

12

1

2


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6.7 Fitting cont rol slide valve

Check condition and function of HeliCoil in-

serts (Fig. 58/5) in the cylinder cover, replaceif necessary.

Lubricate control slide valve (Fig. 58/4) withhydraulic oil.

Fit control slide valve (Fig. 58/4) in bore in cyl-inder cover.

NoteEnsure valve is fitted the right way round.

When fitting the control casing cover, always usenew O-rings (Fig. 58/3)!

Grease O-ring (Fig. 58/3) with Parker O-Lube(Part-Id.-No.3363 0852 30) and insert in con-trol casing cover.

Screw the two Allen screws M 20 into the con-

trol casing cover.

Fit control casing cover, ensuring it is straightand not tilted.

Screw the two Allen screws M 20 out of thecontrol casing cover.

Fit a washer (Fig. 58/2) on each Allen screw(Fig. 58/1).

Fasten control casing cover with allen screws(Fig. 58/1) and tighten in opposing pairs withsize 17 allen key (Tightening torque, seeChapter 6.1)

Fig. 58Fitting the control slide valve

1

2

3

4

5

CAUTION!


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6.8 Fitting perforated disk

Insert perforated disk (Fig. 59/1)in bore.

Clean and degrease threaded plug (Fig. 59/2)Degrease corresponding thread on cylindercover.

Coat the thread of threaded plug (Fig. 59/2)with Loctite 270 and screw in using a size 17Allen key.

6.9 Fitting high-pressureaccumulator

4.7.1 Mount adapter plate under high-pressure accumulator

You must install these at version with adapter diskbefore you mount the high pressure accumulator.

Grease O-ring (Fig. 60/4) with Parker O-Lube(Part-Id.-No. 3363 0852 30).

Fit O-ring (Fig. 60/4) and back-up ring(Fig. 60/5) (part no. 36) on adapter plate.

Check condition and function of HeliCoil in-serts (Fig. 60/1) in the cylinder cover and theadapter plate, replace if necessary.

Place washers (Fig. 60/2) on the Allan screws(Fig. 60/3) insert them through the bores in theadapter plate and screw them into thethreaded bores in the cylinder cover.

Tighten Allan screws (Fig. 60/3) with a size 17Allan key.

Fig. 59Fitting the perforated disk

Fig. 60Fitting the adapter plate

3

45

2

1

1

1 2


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39

4.7.2 Mount high-pressure accumula-tor

Grease O-ring (Fig. 61/4) with Parker O-Lube(Part-Id.-No. 3363 0852 30).

Fit O-ring (Fig. 61/4) and back-up ring(Fig. 61/5) on high-pressure accumulator.

Check condition and function of HeliCoil in-serts (Fig. 61/1) in the cylinder cover, replaceif necessary.

NoteReplace broken expansion bolts (Fig. 61/3). Ifdamage is detected to the threads of the expan-

sion bolts, these should also be replaced.

Fit high-pressure accumulator to cylinder co-ver/adapter plate.

Treat the threads of the expansion bolts(Fig. 61/3) with Anti-Seize agent.

Place washers (Fig. 61/2) on the expansionsbolts (Fig. 61/3) insert them through the boresin the accumulator and screw them into thethreaded bores in the cylinder cover/adapterplate.

Tighten expansion bolts with a size 30 socketspanner (Fig. 62).

Expansions bolts must be tightened in opposingpairs to the required torque (tightening torque seeChapter 6.1)

Fig. 61Fitting the high-pressure accumulator

Fig. 62Attaching the high-pressure accumulator

1

23

45

CAUTION!


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6.10 Filling the pistonaccumulator

The piston accumulator may only be filled with ni-trogen. Filling with air or oxygen runs theRISK OF AN EXPLOSION!

When filling the piston accumulator, ensure no oneis standing in the area of the working tool. If the

tool has jammed, it may shoot out of the lowerhammer part by a few centimetres.

NoteIf a country specific adapter (Fig. 63/6)is requiredit has to be fitted between nitrogen cylinder andpressure-relief valve.

When filling the piston accumulator, the hammermust be lying flat with no contact pressure appliedto the working tool. Filling can be performed withthe hammer cold or at operating temperature(60 to 70 C)!

If the piston accumulator is filled with the ham-mer cold, filling pressure should be set to 1 barbelow the reference value at operating tem-perature. Corrections should be made later.

Fit the filler valve(Fig. 63/5).

Connect pressure-relief valve (Fig. 63/1)to ni-trogen cylinder (green).

Close pressure-relief valve (Fig. 63/1).

Insert nozzle (Fig. 63/2)of filling hose into fillervalve (port G on cylinder cover).

Open gas cylinder valve (Fig. 63/4).

Open pressure-relief valve (Fig. 63/1)slowly toallow nitrogen to flow into piston accumulator.Pressure increase can be read off on pressuregauge (Fig. 63/3).

Close gas cylinder valve (Fig. 63/4)once re-quired pressure + 10 % has been reached in

piston accumulator.

Remove nozzle (Fig. 63/2)from port G . Thegas in the filler hose can escape.

The required pressure in the piston accumulatorwith the hammer at operating temperature is:

ModelMin. gaspressure

Referencepressure

HB 7000 9,0 bar 11,5 bar

Fig. 63Filling the piston accumulator

6

DANGER!


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41

Connect up test pressure gauge (Fig. 64/2)and read off pressure.

If the piston accumulator pressure indicated is be-

low reference pressure, repeat filling process.

If the pressure is higher than 11,5 bar

Insert hose nozzle of test pressure gauge(Fig. 64/2)in filler valve.

Allow gas to escape by repeatedly pushingin/pulling out nozzle.

Never use a nail, screwdriver or similar object forthis instead of the hose nozzle.

Repeat this process until the reference pressurehas been attained.

Close filler valve using screw plug (Fig. 64/1).

Fig. 64Measuring piston accumulator pressure

CAUTION!


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42

6.11 Fitting the percussionmechanism in the hammerbox

Stand hammer box upright.

Replace any defective damping elements(Fig. 65/2), guide plates (Fig. 65/3),(Fig. 65/4), (Fig. 65/5) and plate (Fig. 65/6)(see Chapter 5).

Fit plastic elements and fix in position usingdouble-sided adhesive tape; if wear is de-tected, insert shims. (Service openings mustremain accessible).

Lift up percussion mechanism using acrane/hoist.

For hydraulic hammer with DustProtector:snap the base of the stripper in the inner sup-port groove of the lower wear bush.

Lower the percussion mechanism into hammerbox.

Never use your hands to locate or check the posi-tion of the plastic elements or the shims when fit-ting the percussion mechanism in the hammer box.

Screw the two vertebral blocks M 42 out of thecylinder cover.

Fit elastic pad (Fig. 65/1).

Using crane/hoist, place adapter on hammerbox and fasten using the 14 available Allenscrews, and the locking washers using size 27Allen key (Observe direction of fitting).

Only use the original Allen screws to fasten theadapter.The Allen screws must be tightened to the requiredtorque. (Tightening torque, see Chapter 6.1).

Fig. 65Fitting the percussion mechanism in the hammerbox

1

2

3

4

5

6

DANGER!

DANGER!


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6.12 Fitting the swivel joints

Insert O-ring (Fig. 66/1) in the groove of the

flange body (Fig. 66/2) and grease with ParkerO-Lube (Part-Id.-No. 3363 0852 30).

Position flange body at the bores on the side ofthe cylinder cover.

Screw flange body to cylinder cover using Al-len screws (Fig. 66/8).

Tighten Allen screws with size 10 Allen key.

Hexagonal socket head screws must be tightenedto the required torque (tightening torque see 6.1)

Grease O-rings (Fig. 66/3) with ParkerO-Lube (Part-Id.-No. 3363 0852 30).

Provide connecting element (Fig. 66/7) withO-rings (Fig. 66/3) and back-up rings(Fig. 66/6) and slide it onto the flange body.

Slide washer (Fig. 66/4) onto the flange body(Fig. 66/2) and secure the connecting elementwith a locking ring (Fig. 66/5).

Fig. 66Fitting the swivel joints

1

2

34

56

67

8

CAUTION!


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44

6.13 Connecting ContiLubeII

The grease line (Fig. 67/1)and pressure line(Fig. 67/2)must be routed as shown, dependingon the serial number. It must be ensured that thegrease line and the hydraulic hose can move freelyin the hammer box and do not come into contactwith the hammer box at any point.

NoteThe ports for the grease line and the hydraulichose and the screw coupling on the external-thread flange P and the ContiLube

II are 8S and

8L. These thread sizes are almost identical andcan lead to mix-ups.

For this reason:Never use force during assembly as the threadscould be damaged.Screw couplings will leak.

It must be possible to tighten the hose connectionson the appropriate couplings by hand.

Connect grease line (Fig. 67/1)to the appro-priate boring CL in the cylinder cover.

Connect pressure line (Fig. 67/2)to the appro-priate boring p in the cylinder cover.

Screw in the Allen screws to fix the cover withContiLube to the hammer box, using ansize 12 Allen key (Fig. 68).

Fig. 67Connecting the ContiLube

II

Fig. 68Fitting cover with ContiLube

CL

p

1

2

CL

p

CAUTION!


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45

6.14 Fitting the working tool

Fit percussion mechanism in hammer box (see

Chapter 6.11). Clean any dirt from the insertion zone of the

working tool (Fig. 69/1)and grease with chiselpaste.

Also grease the two retainer bars (Fig. 69/4)with chisel paste.

For hydraulic hammer with DustProtector:Working tool (Fig. 69/1)may only be fitted in thehammer with the stripper (Fig. 70/3)removed.If working tool (Fig. 69/1)is fitted without first re-moving stripper (Fig. 70/3), the latter will be turnedthe wrong way out and will no longer be functional.

Insert working tool (Fig. 69/1).

Insert retainer bars (Fig. 69/4)in the appropri-ate oblong holes and turn the working tool(Fig. 69/1)until the retainer bars (Fig. 69/4)

slide into oblong holes in lower hammer part (Fig. 69/6).

Unscrew M 12 screw from retainer bars(Fig. 69/4).

Insert sealing plug (Fig. 69/3).

Wear protective glasses!Risk of injury from flying metal splinters.

Drive in locking pins (Fig. 69/7)using pinpunch (Fig. 69/8)and hand hammer(Fig. 69/9). (If locking bush (part no. 47) hasbeen removed or is worn, fit a new one be-forehand).

After all the above- mentioned parts have beenfitted fit the plugs (Fig. 69/2)and (Fig. 69/5)into the openings in the hammer box.

Fig. 69Fitting the working tool

Addi tional requirements for hydraulic hammerwith DustProtector:

Push stripper (Fig. 70/3)over working tool(Fig. 70/1)by hand and snap into groove inbase of the stripper (Fig. 70/2).

Use an auxiliary tool (hammer handle)(Fig. 70/4)) to press in the stripper where nec-essary. Run your thumb around the circumfer-ence to complete fitting.

Fig. 70Fitting the stripper

21

3

4

CAUTION!

DANGER!


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6.15 Fitting the DustProtector

Fit working tool (Fig. 71/3) in hammer (see

Chapter 6.13)

Grease floating ring (Fig. 71/2) and counter-ring (Fig. 71/4), insert in guide ring (Fig. 71/5)and fit in the lower part of the hammer box.

Position guide ring (Fig. 71/5) in such a waythat the bores in the hammer box and in theguide ring are aligned.

Insert locking pins (Fig. 70/1).


Knock in locking pins using pin punch andhand hammer.

Fig. 71Fitting the DustProtector

DANGER!


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47

7 Changing the seals

General rule:

If percussion mechanism is dismantled, the com-plete set of seals must be replaced!

7.1 Changing the cylinder seals

Remove the cylinder cover (see Chapter 4.7).

Remove the seal flange (see Chapter 4.8).

Remove the percussion piston (see Chap-ter 4.9).

Remove the cylinder (see Chapter 4.10).

Replace the following seals in the lower sealingarea of the cylinder:

Groove ring (Fig. 72/1)Stripper (Fig. 72/2)Back-up ring (Fig. 72/3)

Before fitting, check percussion piston and cylinderbore for possible scoring. In the majority of casessuch scoring can be smoothed off using grain 600

emery cloth.

Once piston and cylinder bore have been washedclean and lightly coated with hydraulic oil, the newsealing elements can be fitted.

Use only new and genuine spare parts.

When fitting the back-up ring, observe position ofradius.

Fig. 72

Changing the cylinder seals

CAUTION!


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48

The following diagrams indicate how the sealingelements should be pressed out of shape for fittingin the appropriate inner grooves.

Coat sealing points lightly with hydraulic oil.

The order of fitting is as follows: First insert thegroove rings (Fig. 72/1) in the appropriategroove. Carefully press the seal out of shapeas shown in (Fig. 73).Ensure back-up rings (Fig. 72/3) are fitted cor-rectly (must not be bent like groove ring).

Excessive kinking will cause cracks and subse-quent failure!

Ensure seals are fitted the right way round.

Fit the stripper (Fig. 72/2) in the appropriategroove.

After snapping into the groove, check the fit of

the seal visually and using your fingers.

Roll a clean round wooden or plastic rodaround the circumference to press the sealback into shape and ensure a correct fit.

Fit cylinder (see chapter 6.2).

Fit percussion piston (see chapter 6.3).

Fit seal flange (see chapter 6.4).

Fit cylinder cover (see chapter 6.5)

Fig. 73Pressing the seal out of shape for fitting in groove

CAUTION!

Groove ring


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49

7.2 Changing the seals betweencylinder and cylinder cover

Remove cylinder cover (see Chapter 4.7).

Remove seal flange (see Chapter 4.8).

Remove all O-rings.

Grease new O-rings (Fig. 74/1) to (Fig. 74/4)with Parker O-Lube(Part-Id.-No. 3363 0852 30) and refit.

Refit seal flange (see Chapter 6.4).

Refit cylinder cover (see Chapter 6.5).

7.3 Changing the seals on thesealing bush


Remove seal flange (see Chapter 4.8).

Replace the following seals:Gas sealing sealing (Fig. 75/1)Oil sealing groove ring (Fig. 75/3)

back-up ring (Fig. 75/2)

NoteGas sealing (Fig. 75/1) is no longer tight if bubblesare observed in the oil of the articulated joint afterraising the nitrogen pressure in the piston accumu-lator to 2025 bar with the hammer lying flat and

the return line open. When changing the gas seal-ing, ensure that the groove is facing the gas side.

The oil sealings (Fig. 75/3) and (Fig. 75/2) are nolonger tight if hydraulic oil is detected in the pistonaccumulator chamber. When changing the oil seal-ings, ensure that the groove is facing the oil side.

Provide seal flange with new sealings. Lightlyoil sealings and insert in grooves. Ensure seal-ings are fitted as shown in (Fig. 75).

Refit seal flange (see Chapter 6.4).

Refit cylinder cover (see Chapter 6.5).

Fig. 74Seal arrangement

Fig. 75Changing the seals on the seal flange

12

3

41

23

4

1

2

32

3


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50

7.4 Changing the seals on thehigh-pressure accumulatorand the adapter plate

Version withou t adapter plate:

Remove high-pressure accumulator (seeChapter 4.3).

Clean seat for high-pressure accumulator oncylinder cover.

Check condition and function of HeliCoil in-serts (Fig. 76/1) in cylinder cover, replace ifnecessary.

Replace O-ring (Fig. 76/2) and back-up ring(Fig. 76/3) and insert with grease ParkerO-Lube (Part-Id.-No. 3363 0852 30).

Refit high-pressure accumulator (see Chap-ter 6.9.2).

Version with adapter plate:


Clean seat for high-pressure accumulator onadapter plate.

Remove adapter plate (see Chapter 4.3.1).

Check condition and function of HeliCoil in-serts (Fig. 77/1) in cylinder cover and adapterplate, replace if necessary.

Replace O-ring (Fig. 77/2) and back-up ring(Fig. 77/3) and insert with grease ParkerO-Lube (Part-Id.-No. 3363 0852 30).

Refit adapter plate (see Chapter 6.9.1).

Refit high-pressure accumulator (see Chap-ter 6.9.2).

Fig. 76Changing the seal on high-pressure accumulator

Fig. 77Changing the seal on adapter plate

3 2

1

3 2

1


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51

7.5 Changing the seal on thefilling valve

Before removing the cylinder cover, the gas mustbe bled from the piston accumulator!(Do not remove piston accumulator filling valve incylinder cover until accumulator has been depres-surised)!

Unscrew screw plug in filling valve port G using a size 5 Allen key.

Insert filling hose nozzle in filling valve and de-pressurise piston accumulator.

Unscrew filling valve (Fig. 78/2) from cylindercover using a size 22 socket wrench.

Replace O-ring (Fig. 78/1) on filling valve(Fig. 78/2) and grease with ParkerO-Lube (Part-Id.-No. 3363 0852 30).

Screw filling valve back into cylinder cover andtighten using size 22 socket wrench. (Tighten-ing torque, see Chapter 6.1).

Fill piston accumulator with nitrogen (see

Chapter 6.10). Check filling valve is gas tight (using oil).

Screw in screw plug.

7.6 Changing the seal on theAutoControl-valve

Release threaded plug (Fig. 79/2) using a si-ze 22 Allen key and screw out of bore in cylin-der cover.

Replace O-ring (Fig. 79/1) and grease withParker O-Lube (Part-Id.-No. 3363 0852 30).

Fit threaded plug (Fig. 79/2). For tighteningtorque, see Chapter 6.1.

Fig. 78Changing the seal on the filling valve

Fig. 79

Changing the seal on the AutoControl valve

1

2

1

2

DANGER!


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7.7 Changing the seal an thecontrol casing cover

Remove control casing cover (Fig. 79/1) (seeChapter 4.4).

Check condition and function of HeliCoil in-serts (Fig. 80/3) in cylinder cover, replace ifnecessary.

Replace O-ring (Fig. 80/2), grease with ParkerO-Lube (Part-Id.-No. 3363 0852 30) and insert.

Fit control casing cover (see Chapter 6.7).

7.8 Changing the seals on theswivel joint

Removing the swivel joints (see Chapter 4.2).

Replace following seals:O-ring (Fig. 81/1)O-ring (Fig. 81/2)Back-up ring (Fig. 81/3)

Fitting the swivel joints (see Chapter 6.12).

Fig. 80Changing the seal on the control casing cover

Fig. 81Changing the seals on the swivel joint

1

2

3

1

2

3

3


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8 Repair work

8.1 Changing the expansion

bolts on the high-pressureaccumulator


Check condition and function of HeliCoil in-serts in cylinder cover, replace if necessary.

Clean seat for high-pressure accumulator oncylinder cover.

Replace O-ring and back-up ring (see Chap-ter 7.4) and grease with Parker O-Lube(Part-Id.-No. 3363 0852 30).

Provide high-pressure accumulator with newexpansion bolts and washers and attach (seeChapter 6.9).

Tighten expansion bolts in diagonally opposedpairs.

Observe tightening torque for expansion bolts

(see Chapter 6.1).

NoteAlways replace an expansion bolt if it fractures.For examination purpose, release and remove allother expansion bolts. If galling is detected in thethread, these should also be replaced.

8.2 Changing the high-pressure

accumulator


Check condition and function of HeliCoil in-serts in cylinder cover, replace if necessary.

Clean seat for high-pressure accumulator oncylinder.

Provide new high-pressure accumulator withnew seals (see Chapter 7.4).

Attach new high-pressure accumulator (seeChapter 6.9).

Observe tightening torque for expansion bolts(see Chapter 6.1).

If any signi ficant changes are made to the hy-draulic system, a new acceptance inspection isto be carried out in accordance with the rele-vant national safety provisions.

NoteCheck the pressure accumulator in accordancewith the national safety provisions. We recommendfive-yearly maintenance intervals.

CAUTION!


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8.3 Changing the tie rods

If a defective/fractured head-type tie rod is re-

placed, it is not necessary to replace the other tierods if the hammer was no longer used (or only fora very short period) after the defect/fracture oc-curred.However, if the part has been damaged for sometime, all head-type tie rods must be replaced.

Before changing the tie rods the gas must be bledfrom the piston accumulator! (see Chapter 4.7)

Removing:

Rupturing washers become projectilesWhen loosen the tie rods the washer under the

head of the tie rods may rupture and become pro-jectiles. Rupturing parts may cause serious inju-ries.

Place the dismantling rings (Fig. 82/1) (Part-Id.-No. 3363 0979 13) over the head of all tierods (Fig. 82/2) before removing the tie rods.

Fig. 82Place dismantling rings over the washers

Risk of injury when supporting power wrench.

NoteTie rods and the matching holes in the lower ham-mer part have to be marked for later remounting.

Release tie rods using an electronic, pneu-matic or hydraulic power wrench (Fig. 83) andunscrew from lower hammer part.

Fig. 83Releasing tie rods with a power wrench

Screw tie rods out of lower hammer part andpull upwards and out. Avoid damaging the tierods.

1

2

1

DANGER!

DANGER!

DANGER!


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55

Fitting:

Washers are conical on one side. When fitting, theconical side must be facing head of tie rod.

Treat the threads of the tie rods with anti-seizeagent.

Provide tie rods (Fig. 84/1)with one washereach (Fig. 84/2)and insert in the bore.

Fig. 84Fitting the tie rods

Screw the tie rods into the marked nuts or ta-pered holes (in matching pairs).

Risk of injury through power wrench support.

Using an electronic, pneumatic or hydraulicpower wrench (Fig. 85), pre-tighten tie rods indiagonally opposing pairs to 500 Nm (tighten-ing torques, and turning angles, see chap-

ter 6.1).

Fig. 85

Tightening tie rods with a power wrench

After assembling the percussion mechanism thepiston accumulator must be filled with nitrogen(see chapter 6.10).

1

2

CAUTION!

CAUTION!

DANGER!


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8.4 Removing scores fromcontrol slide valve and bore

NoteThe control slide valve must be able to move easilyin the bore. If this is not the case, check to seewhether jamming is caused by scores.

Remove control slide valve (see Chapter 4.4).

Smooth away scores on control slide valve us-ing emery cloth.

Check bore for scores, if necessary smooth offusing emery cloth.

Carefully clean treated surfaces then oil lightlywith hydraulic oil.

Fit control slide valve (see Chapter 6.7).

When restarting the hydraulic hammer, observefor malfunctions. If there are start-up problemsor the hammer does not run smoothly, informyour local Atlas Copco Customer Center /dealer.

If scores or galling cannot be full y removed bycareful pol ishing, a decision must be taken ineach case as to whether to fi t new parts orhave the parts in question reworked in the fac-tory.

8.5 Removing scores on percus-sion piston and cylinder bore


Remove seal flange (see Chapter 4.8)

Remove percussion piston (see Chapter 4.9).

If scores can be seen on the removed percus-sion piston they must be removed by mechani-cal finishing or manual polishing with emerycloth. The piston diameter may not be reducedby more than 0.05 mm by mechanical rework-ing.

Check cylinder bore for scores, polish smoothif necessary using emery cloth.

Score ends in the grooved area of the piston mustbe carefully deburred. The same applies for thesealing grooves in the cylinder.

Thoroughly clean treated parts and all groovesand lubricate with hydraulic oil.

Fit percussion piston (see Chapter 6.3).

Fit seal flange (see Chapter 6.4).

Fit cylinder cover (see Chapter 6.5)

When restarting the hydraulic hammer, observe

for malfunctions. If there are start-up problemsor the hammer dos not run smoothly, informyour local Atlas Copco Customer Center /dealer.

If scores or galling cannot be full y removed bycareful pol ishing, a decision must be taken ineach case as to whether to fi t new parts orhave the parts in question reworked in the fac-tory.

CAUTION!


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8.6 Replacing retainer bars andworking tool

If burring is detected when removing the workingtool or the two retainer bars it must be ground offcarefully. If excessive wear such as sharp edges,notches or heavy indentations are detected, the re-tainer bars must be replaced. In addition all foursealing plugs must be checked or replacementsprovided if any are missing.

If the working tool shank is worn, the diametermust not fall below a minimum of "D" (Fig. 86).

Model Minimum diameter D

HB 7000 205 mm

Fig. 86Checking minimum diameter on working tool


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8.7 Changing the wear bushes

The inside diameter of the lower wear bush has tobe checked every time the working tool is changedand at the latest every 100 operating hours.The wear bushes are to be changed when their in-side diameter has increased from 210 mm to215 mm (measuring point see Fig. 89).When the lower wear bushing is replaced, the in-side diameter of the upper wear bushing must bechecked, replace if necessary. In this case replacebuffering too.

NoteThis work can only be performed in a well-

equipped workshop with a hydraulic press of200 tonnes or more capacity.

Remove stripper (only for hydraulic hammerwith DustProtector).

NoteTo facilitate removal of the stripper:Press the sealing lip of the stripper inward usingyour thumb. This presses the stripper out of theannular grove in the seat.

Wear protective glasses!Risk of injury by trapping fingers etc.!

Knock out locking bolt using pin punch andhand hammer.

Fit grip of press-out-aid (1) into screw (2) andscrew in press-out-element, bottom (4) (seeChapter 3.3.5).

Fit the press-out aid into the lower hammerpart from below, rest on lower bush.

Remove screw (2) and grip (1) from press-out-aid (see Chapter 3.3.5).

Place the press punch (Fig. 87) on the press-out aid from above and press out the lowerbush.

Fit grip of press-out-aid (1) into screw (2) andscrew in press-out-element, top (3) (see Chap-

ter 3.3.5). Insert press-out aid into the lower hammer part

from below, rest on buffer ring.

Remove screw (2) and grip (1) from press-out-aid (see Chapter 3.3.5).

Place the press punch (Fig. 88) on the press-out aid from above and press out upper wearbush together with buffer ring.

Fig. 87Removing the lower wear bush

Fig. 88Removing the upper wear bush and buffer ring

DANGER!


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For direction of removal for bushes see (Fig. 89).

Before fitting buffer ring, supercool it in liquidnitrogen (N2).

Heat lower hammer part to around 200 C.

Freeze both wear bushes for about 8 hours(-18 C).

Use tongs to handle heated/cooled parts, neveruse your hands!

First fit the buffer ring. Wait until lower hammer part has cooled down.

Then fit both bushes.

NoteThe wear bush recesses must be aligned with thebores for the locking pins in the lower hammerpart.

Wear protective glasses!

Fit locking pin and locking pin bushes.

NoteIf no press is available to press out the bushes, thefollowing procedure is possible:

Apply thick axial or radial welding beads to theinside of the worn wear bush using an elec-

trode welder (Fig. 91). Upon cooling the wear bush and buffer ring

contract and loosen in their seats.

If it i s not possible to replace the wear bushes,a complete replacement lower hammer part canbe purchased from your local Atlas Copco Cus-tomer Center / dealer!

Fig. 89Direction of removal for wear bushes

Fig. 90Removing bush with buffer ringRemoval plate welded into buffer ring

Fig. 91Bush with radial/axial welding beads

10 mmmeasuringpoint

Lock-ing bolt

DANGER!

DANGER!


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8.8 Replacing the completehammer box

Remove adapter (see Chapter 4.2).

Remove elastic pad (see Chapter 4.2).

Using a crane/hoist, pull percussion mecha-nism out of hammer box (see Chapter 4.2).

Remove guide elements and check for wear ordamage (see Chapter 5.5).

Clean side faces of percussion mechanism.

Position guide elements in new hammer boxand fix in place (see Chapter 6.11).

Fit percussion mechanism in new hammer box(see Chapter 6.11).

Insert elastic pad.

Fit adapter.

8.9 Replacing guide plates anddamping elements inhammer box

Remove percussion mechanism from hammerbox (see Chapter 4.2).

Remove old guide plates and damping ele-ments and fit new ones.

Fit percussion mechanism in hammer box (seeChapter 6.11).


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Addi tional requirements for hydraulic hammerswith DustProtector

8.10 Replacing the wearprotection set

If wear is detected on part or all of the wear protec-tion set on the lower part of the hammer box, theparts can be replaced to restore the wear protec-tion on the hammer box.

After removing the percussion mechanism and va-rious guide elements from the hammer box, theworn parts can be removed by an expert using aflame cutter or the weld seams removed using acutting wheel.

Once the worn parts have been removed, the newparts can be attached and welded in place.

The new wear protection set can be purchasedfrom Atlas Copco Construction Tools.

Before attaching the new wear set, the followingpreparations must be made:

Flame-cut areas on the hammer box must beground flat.

Prepare weld seams (see Chapter 8.15).

Pre-heating temperature (see Chapter 8.16).

Filler materials (see Chapter 8.17).

Post-treatment of weld seams (see Chap-ter 8.18).

ModelDim. a(mm)

Dim. b(mm)

Dim. c(mm)

HB 7000 2815 225 65

HB 7000 DP 2905 250 115

Fig. 92Replacing the wear protection set

8.11 Replacing the DustProtector Remove the working tool (see Chapter 4.1).

Remove the DustProtector (see Chapter 4.11).

Replace the defective parts.

Refit the working tool (see Chapter 6.14).

Refit the DustProtector (see Chapter 6.15).


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8.12 Repairing cracked welds

If cracked welds are detected, they can be repair-

welded after the hammer and the plastic elementshave been removed from the hammer box.After the necessary preparations have been madeby a specialist, repairs can be carried out.

Possible weld cracks:Side plate/top plate/front plate jointSide plate/ damping element bearing jointSide plate/bottom plate joint

The necessary preparations include:

Cleaning the points in question.

Grinding down the cracks until the weld is

crack-free. Providing suitable weld fillers (electrodes or wi-

re such as used for steel grade St. 52-3, e.g.MAG wire SG2/SG3 or E 5143B10 electrodes).

Preheating the zone to be repair-welded to ap-prox. 100 C.

If possible, the repair zone should be filled andwelded from both sides.

8.13 Replacing the bottom plateon the hammer box

If the bottom plate of a hammer box is heavilyworn, it can be replaced simply with a new one.

After removing the percussion piston and variousguide elements from the hammer box, a specialistcan remove the bottom plate by flame cutting andreplace it with a new one.

This job requires the following preparations:

Flame-cut areas on the hammer box must beground flat.

Prepare weld seams (see Chapter 8.15).

Pre-heating temperature (see Chapter 8.16).

Filler materials (see Chapter 8.17).

Post-treatment of weld seams (see Chap-ter 8.18).

Fig. 93

Possible weld cracks on hammer box

Fig. 94Replacing the bottom plate

X

60

Direction o fflame cutting

Flame cut-ting position

HB 7000 x = 2748 mm


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8.14 Reworking the retainer pinsfor the damping elements

If in the course of time the retainer pins for thedamping elements in the hammer box have be-come loose due to the widening of the bores, theycan be welded back into position (Fig. 95).

The following steps are necessary:

Remove the percussion mechanism from thehammer box (see Chapter 4.2).

Remove the two damping elements from thehammer box and the plastic parts in the uppersection of the hammer box.

Remove the two retainer pins.

Countersink bores D = 22 mm from above

8 x 45 (Fig. 95).

Re-insert retainer pins in bores and align to si-ze (Fig. 95) weld from above and clean weldseam.

Once the weld has cooled, replace dampingelements and other plastic parts.

Refit percussion mechanism in hammer box(see Chapter 6.11).

Fig. 95Reworking the retainer pins

8.15 Weld seam preparation

Before starting welding work, remove all contami-

nation on and around the seam edges. Scale, rust,oil, paint and moisture give off hydrogen which canjeopardise welding results and result in cracks.

8.16 Preheating temperature

To avoid cracking, a higher working temperature isrecommended depending on steel plate grade,overall plate thickness and hydrogen content.

Combined sheet thickness of: 50 mm 75 C70 mm 100 C

100 mm 150 C

8.17 Fillers

Hardox plates should be welded using fillers (elec-trodes/wire) producing a low hydrogen content inthe weld. Filler as for ST 52-3. e.g. MAG wire

SG2/SG3 or electrodes E 5143B10.

Fillers must be stored in such a way as to avoidany moisture absorption.

8.18 Post-treatment of welds

Welds must be made without notches or groundfree of notches in order to reduce tension.

X

HB 7000 x = 25 mm


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A t l a s C o p c o C o n s t ru c t i o n T o ol s G m b H

Helenenstrasse 149 S 45143 Essen

P. O. Box 10 21 52 S 45021 Essen

F e d e ra l R e p u b li c o f G e r m a ny

Telephone +49 201 633 0

Internet: www.atlascopco.com

Manual reparación HB-7000

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