Manual Reparación HB-7000

Repair manual Hydraulic breaker
HB 7000 and HB 7000 DustProtector

T.Id.Nr. 3390 5082 01 20080131

Repair manual

Hydraulic hammers

HB 7000 and HB 7000 DustProtector

Atlas Copco Construction Tools GmbH


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

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

Federal Republic of Germany

Repair manual HB 7000 / HB 7000 DustProtector
5
Content

1 General .................................................................................................................................................7
1.1 Explanation of the symbols in the repair manual .............................................................................7
2 Operational safety...............................................................................................................................8
2.1 General.............................................................................................................................................8
2.2 Accident prevention regulations ......................................................................................................8
2.3 Tools, measuring and testing equipment.........................................................................................9
2.4 Operating media / consumables.......................................................................................................9
3 Tools...................................................................................................................................................10
3.1 General tools ..................................................................................................................................10
3.2 Service box.....................................................................................................................................11
3.3 Special accessories........................................................................................................................12
3.3.1 Accumulator filling device...............................................................................................................12
3.3.2 Power wrench.................................................................................................................................13
3.3.3 HeliCoil-tools...................................................................................................................................13
3.3.4 Fitting aid for percussion piston......................................................................................................14
3.3.5 Press-out aid for wear bushes HB 7000.........................................................................................14
4 Dismantling the hydraulic hammer ................................................................................................15
4.1 Removing working tool ...................................................................................................................15
4.2 Removing the percussion mechanism from the hammer box......................................................16
4.3 Removing high-pressure accumulator............................................................................................19
4.3.1 Removing adapter plate under high-pressure accumulator...........................................................20
4.4 Removing control valve..................................................................................................................21
4.5 Removing AutoControl-valve..........................................................................................................22
4.6 Removing perforated disk...............................................................................................................23
4.7 Removing cylinder cover................................................................................................................23
4.8 Removing seal flange.....................................................................................................................25
4.9 Removing percussion piston.........................................................................................................25
4.10 Removing cylinder..........................................................................................................................25
4.11 Removing DustProtector ................................................................................................................26
4.12 Removing the locking pins for the retainer bars and wear bushes in the lower hammer part.......27
4.13 Removing locking bushes...............................................................................................................27
5 Checking the hammer box ...............................................................................................................28
5.1 Checking for cracks and indentations ...........................................................................................28
5.2 Wear to bottom plate......................................................................................................................28
5.3 Checking elastic pad......................................................................................................................29
5.4 Checking damping elements..........................................................................................................29
5.5 Checking damping plate.................................................................................................................29
5.6 Checking guide plates ....................................................................................................................30
5.6.1 Checking lower guide plates ..........................................................................................................30
5.6.2 Checking upper guide plates..........................................................................................................31
6 Assembling the hydraulic hammer .................................................................................................32
6.1 Tightening torques for screws and screw couplings ......................................................................32
6.2 Fitting cylinder.................................................................................................................................33
6.3 Fitting percussion piston.................................................................................................................33
6.4 Fitting seal flange ...........................................................................................................................34
6.5 Fitting cylinder cover.......................................................................................................................34
6.6 Fitting AutoControl valve ................................................................................................................36
6
6.7 Fitting control slide valve................................................................................................................37
6.8 Fitting perforated disk.....................................................................................................................38
6.9 Fitting high-pressure accumulator.................................................................................................38
4.7.1 Mount adapter plate under high-pressure accumulator .................................................................38
4.7.2 Mount high-pressure accumulator..................................................................................................39
6.10 Filling the piston accumulator........................................................................................................40
6.11 Fitting the percussion mechanism in the hammer box...................................................................42
6.12 Fitting the swivel joints....................................................................................................................43
6.13 Connecting ContiLube
II ...............................................................................................................44
6.14 Fitting the working tool....................................................................................................................45
6.15 Fitting the DustProtector.................................................................................................................46
7 Changing the seals ...........................................................................................................................47
7.1 Changing the cylinder seals ...........................................................................................................47
7.2 Changing the seals between cylinder and cylinder cover.............................................................49
7.3 Changing the seals on the sealing bush........................................................................................49
7.4 Changing the seals on the high-pressure accumulator and the adapter plate.............................50
7.5 Changing the seal on the filling valve............................................................................................51
7.6 Changing the seal on the AutoControl-valve.................................................................................51
7.7 Changing the seal an the control casing cover..............................................................................52
7.8 Changing the seals on the swivel joint...........................................................................................52
8 Repair work .......................................................................................................................................53
8.1 Changing the expansion bolts on the high-pressure accumulator................................................53
8.2 Changing the high-pressure accumulator .....................................................................................53
8.3 Changing the tie rods .....................................................................................................................54
8.4 Removing scores from control slide valve and bore.....................................................................56
8.5 Removing scores on percussion piston and cylinder bore.............................................................56
8.6 Replacing retainer bars and working tool......................................................................................57
8.7 Changing the wear bushes.............................................................................................................58
8.8 Replacing the complete hammer box............................................................................................60
8.9 Replacing guide plates and damping elements in hammer box...................................................60
8.10 Replacing the wear protection set.................................................................................................61
8.11 Replacing the DustProtector ..........................................................................................................61
8.12 Repairing cracked welds ................................................................................................................62
8.13 Replacing the bottom plate on the hammer box...........................................................................62
8.14 Reworking the retainer pins for the damping elements.................................................................63
8.15 Weld seam preparation..................................................................................................................63
8.16 Preheating temperature..................................................................................................................63
8.17 Fillers ..............................................................................................................................................63
8.18 Post-treatment of welds..................................................................................................................63

7
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 hydraulic
hammer, 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 avoiding
damage.

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

Note
DANGER!
CAUTION!
8
2 Operational safety

2.1 General

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

2.2 Accident prevention
regulations

To avoid the possibility of injury, please
observe the following instructions!

Before starting work:
Please familiarise yourself with the repair manual
and the appropriate regulations before starting
work on the hydraulic hammer.
When using or working on hydraulic hammers in
the countries of the European Union, the regula-
tions of the EC machinery directive 98/37/EG must
be observed and followed, as must national acci-
dent prevention regulations and regulations cover-
ing pressurised vessels.
In countries outside the European Union, the valid
local statutes and regulations will apply.
The hydraulic hammer should only be repaired by
specialists.
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 the
hoist operator beforehand.
Never stand beneath hoisted loads.
Stand the hydraulic hammer in a suitable device
and 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 may
fly off when hammering out the locking pins.
Working tools should only be fitted as described in
the operating manual.

The hammer's integrated piston accumulator is
pressurised.
Before dismantling the hydraulic hammer and be-
fore removing the complete filling valve G , the
piston accumulator must be fully depressurised.
Never use nails, screwdrivers or similar objects to
bleed off the gas since this would damage the fill-
ing valve. Bleed off the gas using only the nozzle
of the filling/test hose.
Never use your fingers to check the alignment of
the working tool recesses to the oblong holes for
the locking bars.
Never dismantle a hydraulic hammer which is still
hot from running as there is a high risk of injury
through burns. Always wait until the hammer has
cooled down before dismantling it.
Collect any oil which runs out and dispose of it in
accordance with the applicable statutory provisions
to 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) is
allowed into the piston accumulator.
When attaching the adapter use only the special
steel screws included in supply.
DANGER!
DANGER!
Risk of explosion!
DANGER!
9
2.3 Tools, measuring and testing
equipment

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

The special accessories used in this section are
listed in Chapter 3.3.

2.4 Operating media / consum-
ables

Use Comments
HP oil
HLP 32
Running the
hydraulic
hammer
In warmer cli-
mates, oils with a
higher viscosity
class should be
used
High-
performance
bearing grease
with solids
content
Working tool
lubrication
Chisel paste
(see Operating
manual)
Nitrogen N
2
Filling the
high-
pressure
accumulator*
piston
accumulator

Abrasive pol-
ishing paper,
grain 600
Removing
scores

Anti-Seize Fitting the wear
bushes

Grease
Parker O-Lube
Lubrication of
sealings

*
If any significant changes are made to the
hydraulic system, a new acceptance inspection is
to be carried out in accordance with the relevant
national safety provisions.

DANGER!
10
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
J aw spanner size 55/60 3361 0316 75 1
J aw spanner size 50/55 3361 0316 74 1
J aw spanner size 46/50 3360 4379 43 1
J aw spanner size 41/46 3360 4306 13 1
J aw spanner size 36/41 3360 4306 12 1
J aw spanner size 13/15 3360 1195 82 1
J aw spanner size 10/13 3361 0318 34 1
Socket spanner size 24/27 3360 4310 02 1
Socket spanner size 22 3361 0318 35 1
Socket 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
11
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 1
Pin punch
d =15,5, L =130
3361 8488 19
6 1 Socket spanner 3363 0663 76
7 1
Hexagonal head bolt
M 12x150
3360 1038 66
7 1
Hexagonal head bolt
M 20x160
3360 1031 54

Fig. 1
Service tools
12
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 filling device

The tools listed in the table below are used to fill
the high-pressure accumulator. The filling process
also requires the nitrogen cylinder and the filler
valve from Service box.

Designation Pt. ID no.
Filling device cpl. 3360 9204 15

hydraulic system, a new acceptance inspection is
to be carried out in accordance with the relevant
national safety provisions

Fig. 2
Accumulator filling device
13
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
1
Screw tap
M 20 HC
3360 9203 59
2
Threaded insert
M 20 HC
3361 0315 29
3
Screw-in tool
M 20 HC
3360 9203 55
Cylinder
cover
(Control
system)
1
Screw tap
M 20 HC
3360 9203 59
4
Threaded insert
M 20 HC
From SN 169
3363 0899 16
4
Threaded insert
M 20 HC
Up to SN 168
3361 0315 29
3
Screw-in tool
M 20 HC
3360 9203 55
High-
pressure
accumu-
lator
5
Screw tap
M 36HC
3360 9203 61
6
Threaded insert
M 36 HC
3360 4783 06
7
Screw-in tool
M 36 HC
3360 9203 57
Adapter
8
Threaded insert
RD 48x5
3363 0854 99
9
Screw-in tool
RD 48x5
3363 0857 46
Lower
breaker
part
(tie rods)

Fig. 3
Torque Multiplier

Fig. 4
Hydraulic Torque Multiplier

Fig. 5
HeliCoil-tools
14
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 bushes
HB 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
4
Press-out element,
bottom
3363 0327 17

Fig. 6
Fitting aid

Fig. 7
Press-out aid
15
4 Dismantling the
hydraulic 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 locking
pins (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) from
the oblong holes for the retainer bars.

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

The retainer bars have an M 20 thread on the
front end.

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

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

Fig. 8
Removing the working tool
DANGER!
16
4.2 Removing the percussion
mechanism from the
hammer box

Stand hammer box with hydraulic hammer
vertically and secure against falling over.
Remove Allen screws (Fig. 9/2) using allen
key size 27 (Fig. 9/3) and remove adapter
(Fig. 9/1) from hammer box using a
hoist/crane.
Remove elastic pad (Fig. 10).

Remove Allen screws using Allen key size 12
from the cover with ContiLube
II (Fig. 11).
Lift the cover so that grease/oil line between
ContiLube
II and percussion unit can be dis-

mantled.

Remove grease/oil line at the percussion unit.
Remove the cover with ContiLube
II from
breaker box (Fig. 12).
Lock connection boring p (connection oil line
for ContiLube
II) so that no oil runs out.

Fig. 9
Unscrewing the adapter from the hammer box

Fig. 10
Removing the elastic pad

Fig. 11
Loosen the cover with ContiLube

Fig. 12
Remove the cover with ContiLube
DANGER!
17
Removing the swivel joints:

Remove the lock ring (Fig. 13/1) from the
flange body (Fig. 13/6) using lock ring pliers.
Remove the washer (Fig. 13/4).
Pull connector element (Fig. 13/2) from flange
body.
Remove rubber cover (Fig. 13/5).
Release Allen screws (Fig. 13/3) using a
size 10 Allen key and unscrew them.

accordance with the applicable statutory provi-
sions to avoid environmental hazards!

Remove both flange bodies in this way.
Plug the connecting borings in the cylinder
cover so that no oil runs out.

Fig. 13
Remove swivel joint

1
2
3
4
5
6
CAUTION!
18
Lifting out the percussion unit

Rupturing washers become projectiles
When loosen the tie rods the washer under the
head of the tie rods may rupture and become
projectiles. Rupturing parts may cause serious
injuries.

Place the dismantling rings (Fig. 14/1) (Part-
Id.-No. 3363 0979 13) over the head of all tie
rods (Fig. 14/2) before lifting the percussion
unit out of the hammer box.
For safety reasons the dismantling rings are
removed only if the tie rods are dismounted.

Screw two vertebral blocks M 42 into the two
threaded bores on the upper face of the cylin-
der cover as far as they will go.
Using a hoist/crane, lift the percussion unit of
the hydraulic hammer out of the hammer box
(Fig. 15).

If the percussion mechanism has jammed in the
hammer box, e.g. due to heavy contamination, the
hoist 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 wear
bush.
Stand percussion unit vertically and secure
against falling over (e.g. place on a stand
similar to that in Fig. 16).

Fig. 14
Secure washers

Fig. 15
Lifting the percussion unit out of the hammer box

Fig. 16
Stand
DANGER!
DANGER!
1
2
1
19
4.3 Removing high-pressure
accumulator
Stand hydraulic hammer vertically and secure
against falling over (e.g. on a stand similar to
Fig. 16 or lay flat).

If the hydraulic hammer is still attached to the
carrier, 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 (open
the 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 spanner
and screw them out, removing the washers at
the same time.


Remove high-pressure accumulator (Fig. 18).
Check threaded insert (Fig. 19/1) replace if
necessary.
Check expansion bolts (Fig. 19/2) replace if
necessary.

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

hydraulic system, a new acceptance inspec-
tion is to be carried out in accordance with the
relevant national safety provisions.

Fig. 17
Releasing and unscrewing the expansion bolts

Fig. 18
Removing the high-pressure accumulator

Fig. 19
Check threaded inserts and expansion bolts
DANGER!
CAUTION!
CAUTION!
1
2
20
4.3.1 Removing adapter plate under
high-pressure accumulator

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

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

Remove the adapter plate from the cylinder
cover (Fig. 21).

Check threaded insert (Fig. 22/1) replace if
necessary.

Fig. 20
Unscrewing the Allen screws

Fig. 21
Removing the adapter plate

Fig. 22
Check threaded inserts
1
21
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 two
threaded bores in the cover and pull the cover
out of the cylinder cover bore (Fig. 24).

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

Fig. 23
Removing the Allen screws

Fig. 24
Removing the cover

Fig. 25
Removing the control slide valve
1
22
4.5 Removing AutoControl-valve

Release threaded plug (Fig. 26/2) using a
size 22 Allen key and unscrew from the bore
in the cylinder cover.

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

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

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

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

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

Fig. 27
Removing the AutoControl valve

1
2
1
2
23
4.6 Removing perforated disk

Replace perforated disk if necessary (visual ex-
amination).

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

Note
The threaded plug is fixed with Loctite.

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

4.7 Removing cylinder cover

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

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

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

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

Fig. 28
Unscrewing the threaded plug

Fig. 29
Pulling out the perforated disk

Fig. 30
Removing screw plug from port G

Fig. 31
Relieving piston accumulator pressure
DANGER!
24

Risk of injury when supporting power wrench.

Note
Tie rods and the matching holes in the lower
hammer part have to be marked for later remount-
ing.

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

Pull out tie rods.

Remove washers and dismantling rings.

Note
Dispose of washers of the old version. Exclusively
washers (Part-Id.-No. 3363 0936 55) of the new
version may be installed at the assembly.

der cover as far as they will go and lift off the
cylinder cover using a hoist/crane (Fig. 33).


Fig. 32
Releasing tie rods with a power wrench

Fig. 33
Removing the cylinder cover
DANGER!
CAUTION!
25
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 percussion
piston

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 the
threaded bore on the percussion piston as far
as it will go.
Pull out the percussion piston using a
hoist/crane (Fig. 35).

4.10 Removing cylinder

bores of the cylinder as far as they will go.
Lift the cylinder from the lower hammer part
using a crane/hoist (Fig. 36).


Fig. 34
Removing the seal flange

Fig. 35
Removing the percussion piston

Fig. 36
Removing the cylinder
CAUTION!
CAUTION!
26
4.11 Removing DustProtector

Risk of injury from flying metal splinters.

Knock out the locking pins (Fig. 37/1) for the
DustProtector using a pin punch and a hand
hammer.

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

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

Remove stripper (Fig. 36/3).

Note
To facilitate removal of the stripper:
Press the sealing lip of the stripper inward using
your thumb. This presses the stripper out of the
annular grove in the seat.

Fig. 37
Removing the DustProtector

DANGER!
27
4.12 Removing the locking pins
for the retainer bars and
wear bushes in the lower
hammer part


Knock out of the locking pin using the pin
punch 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 bush
out of the bore. The bush must be replaced if
the locking pin can be pushed out of the bore
by pressing on it firmly with a finger.

Fig. 38
Knocking out the locking pin

Fig. 39
Removing the locking bush

DANGER!
Repair manual HB 7000 /HB 7000 DustProtector
28
5 Checking the hammer
box

5.1 Checking for cracks and
indentations

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

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

The cause is wear to the guide plates in the lower
zone, which allows greater freedom of movement
in 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 bottom
plate. To avoid having to replace the complete
hammer box in such cases there are two possible
remedies:

Replacement of complete bottom plate (see
chapter 8.13).
New bottom plates and seat for DustProtector
can be purchased from Atlas Copco Construc-
tion Tools.
In special cases the worn bottom plate can be
repaired by build-up welding.

Additional requirements for hydraulic hammers
with DustProtector

The reinforcement in the lower area of the hammer
box is frequently subject to wear. To avoid having
to replace the hammer box, the worn parts can be
removed 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 (see
Chapter 8.10).

Fig. 40
Indentation at damping element bearing points

Fig. 41
Indentation on intermediate plate/high-pressure
accumulator

Fig. 42
Worn bottom plate

Fig. 43
Wear in wear protection zone
29
5.3 Checking elastic pad

Once the adapter has been removed, the elastic
pad can be taken out and subjected to a visual and
dimensional check.
The figure on the right shows the check dimension
h. This dimension is reduced the longer the pad
is used, either due to the material "settling" or due
to wear through relative movement. After a service
life of approx. 5001000 operating hours, dimen-
sion h may fall below its lower limit, at which point
the elastic pad must be replaced. The lower limit
for 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 upper
hammer part, causing the material to crack and
leaving notches.
As time goes on these notches get bigger and can
cause larger pieces of the elastic pad to break off
or 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 which
then necessitate replacement in pairs.
The check dimension h should also be measured
upon dismantling to decide whether replacement in
pairs is necessary. The table shows the lower limit
for 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 wear
during normal use. The penetration of dust and dirt
strengthens 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. 44
Check dimension h and cracks/notches in the
elastic pad

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

Fig. 46
Check dimension h on the damping plate
Notches / Cracking
Notches / Cracking
h
30
5.6 Checking guide plates

5.6.1 Checking lower guide plates

The guide plates (Fig. 49/3) are subject to wear
during normal use. The penetration of dust and dirt
along with surface pressure cause heavy abrasion
to the plates.

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

Depending on condition, the guide plates should
be 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 one
2 mm thick must be inserted on each side.
However, shimming must be restricted to max. two
2 mm on each side.

Service openings must remain accessible!

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

Fig. 47
Possible wear and damage to the guide plates

Fig. 48
Check dimension h and arrangement of shims
Shim

Guide
plate
Wall of
hammer
box
Abrasion
Conchoidal fracture
Dirt deposits
Abrasion
CAUTION!
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) and
therefore have a certain degree of elasticity.

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

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

Fig. 49
Checking the upper guide plates
1
2
3
4
5
32
6 Assembling the hydraulic hammer
6.1 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 diagonally
opposed pairs to 500 Nm,
Then tighten in diagonally op-
posed pairs by a further 180
(3 sides of hexagonal head),
Then finish tighten in diagonally
opposed pairs by 180 (3 sides
of hexagonal head)

Allen screw
Valve cover/control valve
Allen key size 17 380 Nm
AutoControl-system Allen key size 22 300 Nm
Hose connections
ContiLube
II
Socket and jaw spanners
of varying sizes

Ports P and T J aw spanner size 55 / 60 400 Nm
Filling valve G
Screw plug
Socket spanner size 22
Allen key size 5
130 Nm
20 Nm
Start-Select Allen key size 17 200 Nm
High-pressure
accumulator
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 fashion
4. 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.
33
6.2 Fitting cylinder

Stand lower hammer part upright and secure
against falling over.

Clean contact faces on lower hammer part and
cylinder.

Grease O-rings (Fig. 50/1) with Parker
O-Lube (Part-Id.-No. 3363 0852 30) and then
insert in the appropriate groove on the upper
face of the lower hammer part.

bores of the cylinder as far as they will go.

Position the cylinder on the lower hammer part
using 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 piston
into cylinder as far as it will go, avoiding tilting
(Fig. 51).

Remove eye bolt from percussion piston.

Fig. 50
Fitting the cylinder

Fig. 51
Fitting the percussion piston
1
1
1
2
34
6.4 Fitting 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.
bores of the seal flange as far as they will go.
Position the seal flange on the cylinder using a
hoist/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 7.2
and 7.3)!

6.5 Fitting cylinder cover

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 in
the appropriate groove in the cylinder cover.
Grease O-ring grooves on the upper face of
the 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 tie
rods (locking pin (Fig. 53/5)).

Note
The O-ring (Fig. 53/1) may fall out of the bore
when 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. 52
Fitting the seal flange

Fig. 53
Fitting the cylinder cover
1
2
3
4
1
2
3
4
5
35

When loosen the tie rods the old version of wash-
ers under the head of the tie rods may rupture and
become projectiles. Rupturing parts may cause se-
rious injuries.
Exclusively install washers of the new version
(Part-Id.-No. 3363 0936 55) at the installation
of 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 washer
each (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 hydraulic
power wrench (Fig. 55), pre-tighten tie rods in
diagonally opposing pairs to 500 Nm (tighten-
ing torques, and turning angles, see chap-
ter 6.1).

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

Fig. 54
Fitting the tie rods

Fig. 55
Tightening tie rods with a power wrench
1
2
CAUTION!
DANGER!
DANGER!
36
6.6 Fitting AutoControl valve

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

Note
Ensure 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.

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

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

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

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

Fig. 56
Fitting the AutoControl valve

Fig. 57
Fitting the threaded plug

1
2
1
2
37
6.7 Fitting control slide valve

Check condition and function of HeliCoil in-
serts (Fig. 58/5) in the cylinder cover, replace
if necessary.
Lubricate control slide valve (Fig. 58/4) with
hydraulic oil.
Fit control slide valve (Fig. 58/4) in bore in cyl-
inder cover.

Note
Ensure valve is fitted the right way round.

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

(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 straight
and not tilted.

Screw the two Allen screws M 20 out of the
control 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 with
size 17 allen key (Tightening torque, see
Chapter 6.1)

Fig. 58
Fitting the control slide valve
1
2
3
4
5
CAUTION!
38
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 cylinder
cover.

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

6.9 Fitting high-pressure
accumulator

4.7.1 Mount adapter plate under high-
pressure accumulator

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

(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.

serts (Fig. 60/1) in the cylinder cover and the
adapter plate, replace if necessary.

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

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

Fig. 59
Fitting the perforated disk

Fig. 60
Fitting the adapter plate
3
4 5
2
1
1
1 2
39
4.7.2 Mount high-pressure accumula-
tor

(Part-Id.-No. 3363 0852 30).

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

serts (Fig. 61/1) in the cylinder cover, replace
if necessary.

Note
Replace broken expansion bolts (Fig. 61/3). If
damage 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 expansions
bolts (Fig. 61/3) insert them through the bores
in the accumulator and screw them into the
threaded bores in the cylinder cover/adapter
plate.

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

Expansions bolts must be tightened in opposing
pairs to the required torque (tightening torque see
Chapter 6.1)

Fig. 61
Fitting the high-pressure accumulator

Fig. 62
Attaching the high-pressure accumulator
1
2
3
4 5
CAUTION!
40
6.10 Filling the piston
accumulator

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

When filling the piston accumulator, ensure no one
is standing in the area of the working tool. If the
tool has jammed, it may shoot out of the lower
hammer part by a few centimetres.

Note
If a country specific adapter (Fig. 63/6) is required
it has to be fitted between nitrogen cylinder and
pressure-relief valve.

When filling the piston accumulator, the hammer
must be lying flat with no contact pressure applied
to the working tool. Filling can be performed with
the 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 bar
below 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 filler
valve (port G on cylinder cover).

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

Open pressure-relief valve (Fig. 63/1) slowly to
allow nitrogen to flow into piston accumulator.
Pressure increase can be read off on pressure
gauge (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 . The
gas in the filler hose can escape.

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

Model
Min. gas
pressure
Reference
pressure
HB 7000 9,0 bar 11,5 bar

Fig. 63
Filling the piston accumulator
6
DANGER!
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 pushing
in/pulling out nozzle.

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

Repeat this process until the reference pressure
has been attained.

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

Fig. 64
Measuring piston accumulator pressure

CAUTION!
42
6.11 Fitting the percussion
mechanism in the hammer
box

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 using
double-sided adhesive tape; if wear is de-
tected, insert shims. (Service openings must
remain accessible).

Lift up percussion mechanism using a
crane/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 hammer
box.

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 the
cylinder cover.

Fit elastic pad (Fig. 65/1).

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

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

Fig. 65
Fitting the percussion mechanism in the hammer
box
1
2
3
4
5
6
DANGER!
DANGER!
43
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 Parker
O-Lube (Part-Id.-No. 3363 0852 30).

Position flange body at the bores on the side of
the 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 tightened
to the required torque (tightening torque see 6.1)

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

Provide connecting element (Fig. 66/7) with
O-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 element
with a locking ring (Fig. 66/5).

Fig. 66
Fitting the swivel joints
1
2
3
4
5
6
6
7
8
CAUTION!
44
6.13 Connecting ContiLube
II

The grease line (Fig. 67/1) and pressure line
(Fig. 67/2) must be routed as shown, depending
on the serial number. It must be ensured that the
grease line and the hydraulic hose can move freely
in the hammer box and do not come into contact
with the hammer box at any point.

Note
The ports for the grease line and the hydraulic
hose and the screw coupling on the external-
thread flange P and the ContiLube
II are 8S and
8L. These thread sizes are almost identical and
can lead to mix-ups.

For this reason:
Never use force during assembly as the threads
could be damaged.
Screw couplings will leak.
It must be possible to tighten the hose connections
on 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 with
ContiLube to the hammer box, using an
size 12 Allen key (Fig. 68).

Fig. 67
Connecting the ContiLube
II

Fig. 68
Fitting cover with ContiLube
CL
p
1
2
CL
p
CAUTION!
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 chisel
paste.
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 the
hammer 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 turned
the 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).

Risk of injury from flying metal splinters.

Drive in locking pins (Fig. 69/7) using pin
punch (Fig. 69/8) and hand hammer
(Fig. 69/9). (If locking bush (part no. 47) has
been removed or is worn, fit a new one be-
forehand).
After all the above- mentioned parts have been
fitted fit the plugs (Fig. 69/2) and (Fig. 69/5)
into the openings in the hammer box.

Fig. 69
Fitting the working tool

Additional requirements for hydraulic hammer
with DustProtector:

Push stripper (Fig. 70/3) over working tool
(Fig. 70/1) by hand and snap into groove in
base 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. 70
Fitting the stripper
2
1
3
4
CAUTION!
DANGER!
46
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 way
that the bores in the hammer box and in the
guide ring are aligned.

Insert locking pins (Fig. 70/1).


Knock in locking pins using pin punch and
hand hammer.

Fig. 71
Fitting the DustProtector

DANGER!
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 sealing
area of the cylinder:

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

Before fitting, check percussion piston and cylinder
bore for possible scoring. In the majority of cases
such scoring can be smoothed off using grain 600
emery cloth.

Once piston and cylinder bore have been washed
clean and lightly coated with hydraulic oil, the new
sealing elements can be fitted.

Use only new and genuine spare parts.

When fitting the back-up ring, observe position of
radius.

Fig. 72
Changing the cylinder seals
CAUTION!
48
The following diagrams indicate how the sealing
elements should be pressed out of shape for fitting
in the appropriate inner grooves.

Coat sealing points lightly with hydraulic oil.

The order of fitting is as follows: First insert the
groove rings (Fig. 72/1) in the appropriate
groove. Carefully press the seal out of shape
as 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 appropriate
groove.

After snapping into the groove, check the fit of
the seal visually and using your fingers.

Roll a clean round wooden or plastic rod
around the circumference to press the seal
back 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. 73
Pressing the seal out of shape for fitting in groove
CAUTION!
Groove ring
49
7.2 Changing the seals between
cylinder 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 the
sealing 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)

Note
Gas sealing (Fig. 75/1) is no longer tight if bubbles
are observed in the oil of the articulated joint after
raising 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 no
longer tight if hydraulic oil is detected in the piston
accumulator chamber. When changing the oil seal-
ings, ensure that the groove is facing the oil side.

Provide seal flange with new sealings. Lightly
oil 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. 74
Seal arrangement

Fig. 75
Changing the seals on the seal flange
1
2
3
4
1
2
3
4
1
2
3
2
3
50
high-pressure accumulator
and the adapter plate

Version without adapter plate:

Remove high-pressure accumulator (see
Chapter 4.3).

Clean seat for high-pressure accumulator on
cylinder cover.

serts (Fig. 76/1) in cylinder cover, replace if
necessary.

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

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

Version with adapter plate:

Chapter 4.3).

adapter plate.

Remove adapter plate (see Chapter 4.3.1).

serts (Fig. 77/1) in cylinder cover and adapter
plate, replace if necessary.

Replace O-ring (Fig. 77/2) and back-up ring
(Fig. 77/3) and insert with grease Parker
O-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. 76
Changing the seal on high-pressure accumulator

Fig. 77
Changing the seal on adapter plate

3 2
1
3 2
1
51
7.5 Changing the seal on the
filling valve

Before removing the cylinder cover, the gas must
be bled from the piston accumulator!
(Do not remove piston accumulator filling valve in
cylinder 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 cylinder
cover using a size 22 socket wrench.
Replace O-ring (Fig. 78/1) on filling valve
(Fig. 78/2) and grease with Parker
O-Lube (Part-Id.-No. 3363 0852 30).
Screw filling valve back into cylinder cover and
tighten 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 the
AutoControl-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 with
Parker O-Lube (Part-Id.-No. 3363 0852 30).

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

Fig. 78
Changing the seal on the filling valve

Fig. 79
Changing the seal on the AutoControl valve
1
2
1
2
DANGER!
52
7.7 Changing the seal an the
control casing cover

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

serts (Fig. 80/3) in cylinder cover, replace if
necessary.

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

Fit control casing cover (see Chapter 6.7).

swivel 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. 80
Changing the seal on the control casing cover

Fig. 81
Changing the seals on the swivel joint
1
2
3
1
2
3
3
53
8 Repair work

8.1 Changing the expansion
bolts on the high-pressure
accumulator

Chapter 4.3).

serts in cylinder cover, replace if necessary.

cylinder 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 new
expansion bolts and washers and attach (see
Chapter 6.9).

Tighten expansion bolts in diagonally opposed
pairs.

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

Note
Always replace an expansion bolt if it fractures.
For examination purpose, release and remove all
other expansion bolts. If galling is detected in the
thread, these should also be replaced.

8.2 Changing the high-pressure
accumulator

Chapter 4.3).

serts in cylinder cover, replace if necessary.

cylinder.

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

Attach new high-pressure accumulator (see
Chapter 6.9).

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

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

Note
Check the pressure accumulator in accordance
with the national safety provisions. We recommend
five-yearly maintenance intervals.

CAUTION!
54
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 tie
rods if the hammer was no longer used (or only for
a very short period) after the defect/fracture oc-
curred.
However, if the part has been damaged for some
time, all head-type tie rods must be replaced.

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

Removing:

When 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 tie
rods (Fig. 82/2) before removing the tie rods.

Fig. 82
Place dismantling rings over the washers

Risk of injury when supporting power wrench.

Note
Tie 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) and
unscrew from lower hammer part.

Fig. 83
Releasing tie rods with a power wrench

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

1
2
1
DANGER!
DANGER!
DANGER!
55
Fitting:

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 with anti-seize
agent.

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

Fig. 84
Fitting 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 hydraulic
power wrench (Fig. 85), pre-tighten tie rods in
diagonally 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 the
piston accumulator must be filled with nitrogen
(see chapter 6.10).

1
2
CAUTION!
CAUTION!
DANGER!
56
8.4 Removing scores from
control slide valve and bore

Note
The control slide valve must be able to move easily
in the bore. If this is not the case, check to see
whether 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 off
using emery cloth.

Carefully clean treated surfaces then oil lightly
with hydraulic oil.

Fit control slide valve (see Chapter 6.7).

When restarting the hydraulic hammer, observe
for malfunctions. If there are start-up problems
or the hammer does not run smoothly, inform
your local Atlas Copco Customer Center /
dealer.

If scores or galling cannot be fully removed by
careful polishing, a decision must be taken in
each case as to whether to fit new parts or
have 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 emery
cloth. The piston diameter may not be reduced
by more than 0.05 mm by mechanical rework-
ing.

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

Score ends in the grooved area of the piston must
be carefully deburred. The same applies for the
sealing grooves in the cylinder.

Thoroughly clean treated parts and all grooves
and 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 problems
or the hammer dos not run smoothly, inform
your local Atlas Copco Customer Center /
dealer.

If scores or galling cannot be fully removed by
careful polishing, a decision must be taken in
each case as to whether to fit new parts or
have the parts in question reworked in the fac-
tory.
CAUTION!
57
8.6 Replacing retainer bars and
working tool

If burring is detected when removing the working
tool or the two retainer bars it must be ground off
carefully. If excessive wear such as sharp edges,
notches or heavy indentations are detected, the re-
tainer bars must be replaced. In addition all four
sealing plugs must be checked or replacements
provided if any are missing.

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

Model Minimum diameter D
HB 7000 205 mm

Fig. 86
Checking minimum diameter on working tool

58
8.7 Changing the wear bushes

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

Note
This work can only be performed in a well-
equipped workshop with a hydraulic press of
200 tonnes or more capacity.

Remove stripper (only for hydraulic hammer
with DustProtector).

Note
To facilitate removal of the stripper:
Press the sealing lip of the stripper inward using
your thumb. This presses the stripper out of the
annular grove in the seat.

Risk of injury by trapping fingers etc.!

Knock out locking bolt using pin punch and
hand hammer.
Fit grip of press-out-aid (1) into screw (2) and
screw in press-out-element, bottom (4) (see
Chapter 3.3.5).
Fit the press-out aid into the lower hammer
part 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 lower
bush.

Fit grip of press-out-aid (1) into screw (2) and
screw 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 wear
bush together with buffer ring.

Fig. 87
Removing the lower wear bush

Fig. 88
Removing the upper wear bush and buffer ring
DANGER!
59
For direction of removal for bushes see (Fig. 89).
Before fitting buffer ring, supercool it in liquid
nitrogen (N
2
).
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, never
use your hands!

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

Note
The wear bush recesses must be aligned with the
bores for the locking pins in the lower hammer
part.


Fit locking pin and locking pin bushes.

Note
If no press is available to press out the bushes, the
following procedure is possible:

Apply thick axial or radial welding beads to the
inside 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 is not possible to replace the wear bushes,
a complete replacement lower hammer part can
be purchased from your local Atlas Copco Cus-
tomer Center / dealer!

Fig. 89
Direction of removal for wear bushes

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

Fig. 91
Bush with radial/axial welding beads
10 mm
measuring
point
Lock-
ing bolt
DANGER!
DANGER!
60
8.8 Replacing the complete
hammer 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 or
damage (see Chapter 5.5).

Clean side faces of percussion mechanism.

Position guide elements in new hammer box
and 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 and
damping elements in
hammer box

Remove percussion mechanism from hammer
box (see Chapter 4.2).

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

Fit percussion mechanism in hammer box (see
Chapter 6.11).
61
Additional requirements for hydraulic hammers
with DustProtector

8.10 Replacing the wear
protection set

If wear is detected on part or all of the wear protec-
tion set on the lower part of the hammer box, the
parts 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, the
worn parts can be removed by an expert using a
flame cutter or the weld seams removed using a
cutting wheel.

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

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

Before attaching the new wear set, the following
preparations must be made:

Flame-cut areas on the hammer box must be
ground 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).

Model
Dim. a
(mm)
Dim. b
(mm)
Dim. c
(mm)
HB 7000 2815 225 65
HB 7000 DP 2905 250 115

Fig. 92
Replacing 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).

62
8.12 Repairing cracked welds

If cracked welds are detected, they can be repair-
welded after the hammer and the plastic elements
have been removed from the hammer box.
After the necessary preparations have been made
by a specialist, repairs can be carried out.

Possible weld cracks:
Side plate/top plate/front plate joint
Side plate/ damping element bearing joint
Side 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 and
welded from both sides.

8.13 Replacing the bottom plate
on the hammer box

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

After removing the percussion piston and various
guide elements from the hammer box, a specialist
can remove the bottom plate by flame cutting and
replace it with a new one.

This job requires the following preparations:

Flame-cut areas on the hammer box must be
ground 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. 94
Replacing the bottom plate

X

60
Direction of
flame cutting
Flame cut-
ting position
HB 7000 x = 2748 mm
63
8.14 Reworking the retainer pins
for the damping elements

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

The following steps are necessary:

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

Remove the two damping elements from the
hammer box and the plastic parts in the upper
section 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 weld
seam.

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

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

Fig. 95
Reworking 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 can
jeopardise welding results and result in cracks.

8.16 Preheating temperature

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

Combined sheet thickness of: 50 mm 75 C
70 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 in
the 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 avoid
any moisture absorption.

8.18 Post-treatment of welds

Welds must be made without notches or ground
free of notches in order to reduce tension.
X
HB 7000 x = 25 mm
Your partner:
Helenenstrasse 149 S 45143 Essen
P. O. Box 10 21 52 S 45021 Essen
Federal Republic of Germany
Telephone +49 201 633 0
Internet: www.atlascopco.com

Manual Reparación HB-7000

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Manual Reparación HB-7000

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Repair manual Hydraulic breaker

HB 7000 and HB 7000 DustProtector

II and percussion unit can be dis-

II) so that no oil runs out.

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