Atlas Copco HB 3100 Maintenance and service guide

Safety and operating instructions
Hydraulic breakers
Valid from serial number
50HB 3100
50HB 3100 DP
51HB 3600
51HB 3600 DP
DEQ110250HB 4100
DEQ110250HB 4100 DP
50HB 4700
50HB 4700 DP
© 2012 Atlas Copco Construction Tools GmbH | No. 3390 5096 01 | 2012-04-26
Original instructions
HB 3100, 3100 DP, 3600, 3600 DP, 4100, 4100 DP, 4700, 4700 DP

Contents
INTRODUCTION ....................................................................7
About these Safety and Operating Instructions....................................7
SAFETY INSTRUCTIONS ...........................................................9
Signal words ....................................................................9
Qualification...................................................................10
Intended use ...................................................................10
Use other than intended ........................................................10
Protective equipment...........................................................10
Transport, precautions..........................................................11
Hydraulic installation, precautions...............................................11
Special parts, precautions.......................................................11
HP-accumulator ..............................................................11
Piston accumulator ...........................................................11
Media/consumables, precautions................................................12
Explosion and fire, precautions..................................................12
Electrical shock, precautions....................................................12
Falling stones, precautions......................................................13
Emissions, precautions.........................................................13
Handling machines, precautions.................................................13
Repair, precautions.............................................................13
Changes to the hydraulic attachment, precautions................................13
Environmental pollution, precautions............................................14
OVERVIEW........................................................................15
Equipment description..........................................................15
Function.......................................................................15
Signs / labels...................................................................16
Name plate ..................................................................16
Labels.......................................................................16
Signs..........................................................................16
Applications...................................................................17
Guarantee .....................................................................17
Removing the packaging .......................................................17
Scope of delivery ..............................................................17
TRANSPORT .....................................................................18
Transport using a crane.........................................................18
Transport using a forklift truck...................................................19
Transport using a truck.........................................................19
INSTALLATION ...................................................................20
Media/consumables............................................................20
Mineral hydraulic oil...........................................................20
Non-mineralhydraulicoil.......................................................20
Grease......................................................................20
Gas.........................................................................20
Manufacturing the adapter plate .................................................21
Installing the adapter plate ......................................................21
Attaching the hydraulic attachment to the carrier .................................22
Mechanicalmountingaspects..................................................22
Making the hydraulic connections...............................................23
Removing the hydraulic attachment from the carrier ..............................25
Dismantling the hydraulic connections...........................................25
Mechanical disassembly ......................................................25
3© 2012 Atlas Copco Construction Tools GmbH | No. 3390 5096 01 | 2012-04-26
Original instructions
ContentsHB 3100, 3100 DP, 3600, 3600 DP, 4100, 4100 DP,
4700, 4700 DP

Removing the adapter plate.....................................................25
DustProtector..................................................................26
Removal.....................................................................26
Installation...................................................................26
Working tool...................................................................27
Selecting the right working tool.................................................27
Installation...................................................................28
Removal.....................................................................29
OPERATION.......................................................................30
Preparations before starting.....................................................30
Switching the hydraulic breaker on and off .......................................31
Functional test .................................................................31
Correct operation...............................................................31
Working angle ...............................................................31
Advance.....................................................................32
Impact time ..................................................................32
Highambienttemperature......................................................32
Low ambient temperature......................................................32
Prohibited operation ...........................................................33
Lifting/Transporting............................................................33
Impacting....................................................................33
Moving objects...............................................................33
Levering.....................................................................33
Blank firing of the working tool .................................................34
Cylinder end positions.........................................................34
Working with safety equipment .................................................35
Underwater applications.......................................................35
Usage in tunnels..............................................................35
Hot applications..............................................................35
AutoControl System ............................................................35
AutoControlindailyuse........................................................35
AutoControlinspecialapplications..............................................35
StartSelect System AutoStart/AutoStop..........................................36
SwitchingbetweenAutoStart/AutoStop..........................................36
PowerAdapt ...................................................................37
MAINTENANCE ...................................................................38
Maintenance schedule..........................................................39
Depressurising the hydraulic system............................................40
Cleaning.......................................................................41
Preparations.................................................................41
Procedure...................................................................41
Lubrication.....................................................................41
Checkingthelubricantfilm.....................................................41
Automaticlubrication..........................................................42
Replacing the lubricant cartridge ...............................................42
ContiLube®IIoperation........................................................42
Manual lubrication............................................................43
Chiselpastefillingdevice......................................................43
Checking the tensioning bolts...................................................44
Checking the working tool ......................................................44
Checking the retainer bars ......................................................45
Checking the percussion piston impact surface ..................................45
Checking the wear bushes and impact ring ......................................45
Checking and cleaning the DustProtector system ................................46
Piston accumulator ............................................................47
Checking the pressure in the piston accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Release the pressure from the piston accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Filling/topping up the piston accumulator ........................................49
© 2012 Atlas Copco Construction Tools GmbH | No. 3390 5096 01 | 2012-04-26
Original instructions
4
HB 3100, 3100 DP, 3600, 3600 DP, 4100, 4100 DP,
4700, 4700 DP
Contents

HP-accumulator ................................................................50
Checkingtheexpansionbolts...................................................50
Checking the gas pressure ....................................................50
Checking the hydraulic lines....................................................50
Checking and cleaning the hydraulic oil filter ....................................50
Checking the adapter plate and the breaker box for cracks and/or wear.............51
Checking the adapter plate bolts for wear ........................................51
Bolt connections/Tightening torques ............................................52
TROUBLESHOOTING..............................................................54
The hydraulic breaker does not start ............................................54
Hydraulic breaker operates too slowly ...........................................55
Impact force too low ............................................................55
Impact rate too high and impact force too low ....................................55
Oil leaks from ports »P« und »T« ................................................56
Oil escapes between the cylinder cover and the cylinder ..........................56
Oil escapes from parts of the hydraulic breaker installation (connecting fittings, hoses
etc.) ...........................................................................56
Oil escapes from the working tool ...............................................56
Oil escapes from the high pressure accumulator .................................56
Oil or grease escapes from the ContiLube®II .....................................56
Operating temperature too high .................................................57
REPAIR...........................................................................58
Sending in the hydraulic attachment for repairs ..................................58
STORAGE ........................................................................59
Hydraulic breaker ..............................................................59
Short storage ................................................................59
Long storage ................................................................59
How to proceed after more than twelve months‘ storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Working tool ...................................................................60
Grease cartridges ..............................................................60
DISPOSAL........................................................................61
Hydraulic breaker ..............................................................61
Hydraulic hoses ...............................................................61
Hydraulic oil ...................................................................61
Chisel paste and grease cartridges ..............................................61
TECHNICAL SPECIFICATIONS .....................................................62
Noise declaration statement ....................................................62
EC Declaration of Conformity (EC Directive 2006/42/EC) .............................64
5© 2012 Atlas Copco Construction Tools GmbH | No. 3390 5096 01 | 2012-04-26
Original instructions
ContentsHB 3100, 3100 DP, 3600, 3600 DP, 4100, 4100 DP,
4700, 4700 DP