acumuladores de ap atlas copco

Operating Manual and Spare Parts List

Pressure accumulators on hydraulic hammers −Design and maintenance

Pt.�Id.�No. 3361 8554 33 Valid from: 06/2003 GB

3

Pressure accumulators on Atlas Copcohydraulic hammersDesign and maintenance

E Atlas Copco Construction Tools GmbH

Atlas Copco Construction Tools GmbH

P. O. Box: 102152, D � 45021 EssenHelenenstrasse 149, D � 45143 Essen

Federal Republic of Germany

Telephone +49 201 633 � 0Telefax +49 201 633 � 2281Telefax Customer Support: +49 201 633 � 1352

4

Explanation of the symbols used in this operating manual

Certain instructions in the operating manual are marked with symbols to emphasisetheir importance.

The symbols used are described below:

CAUTION!

Please note!The marked text provides instructions on the cor�rect use of the pressure accumulator aimed atavoiding incorrect operation or errors during work.

The marked text provides safety regula�tions and instructions aimed at avoidingdamage to equipment.

WARNING!

The marked text provides safety regula�tions and instructions aimed at avoidingaccidents and possible injuries.

5

Table of contents

1. What are hydraulic pressure accumulators and what do they do? 7 . . . . . . . . . . . . . .

1.1 Accumulator design 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Function of the pressure accumulator 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Safety regulations for pressure accumulators 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Statutory regulations 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Accident prevention 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Warranty 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Accumulator specifications and allocation to Atlas Copco hydraulic tools 10 . . . . . .

4.1 Pressure accumulator specifications 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. List of individual pressure accumulators 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Pressure accumulator 0.09 litres (integrated design) 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Presentation pressure accumulator 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.2 Spare parts list pressure accumulator 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.3 Tools required for dismantling and assembly 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.4 Dismantling the pressure accumulator 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.5 Checking and cleaning parts prior to assembly 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.6 Assembling the pressure accumulator 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Pressure accumulator 0.25 litres (integrated design) 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




5.2.4 Dismantling the pressure accumulator (integrated design) 14 . . . . . . . . . . . . . . . . . . . . . . . .


5.3 Pressure accumulator 0.25 litres (flange design) 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




5.3.4 Dismantling the pressure accumulator (flange design) 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . .



5.4 Pressure accumulator 0.9 litres (flange design) 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .







5.5 Pressure accumulator 1.5 litres (flange design, 16�hole) 19 . . . . . . . . . . . . . . . . . . . . . . . . . .



6





5.6 Pressure accumulator 1.5 litres (flange design, 12�hole) older models 21 . . . . . . . . . . . . . .

5.6.1 Accumulator design and components (please refer to diagram in 5.5.1) 21 . . . . . . . . . . . .

5.7 Pressure accumulator 2.0 litres 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .





5.7.5 Checking parts prior to assembly 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.8 Pressure accumulator 0.5 litres (for use with cooler 0050) 24 . . . . . . . . . . . . . . . . . . . . . . . .




5.8.4 Removing the pressure accumulator 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.8.6 Fitting the pressure accumulator 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9 Pressure accumulator 1 litre 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



5.9.3 Restrictions on accumulator repair 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.9.5 Removing the pressure accumulator 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


5.9.7 Fitting the pressure accumulator 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Assembling pressure accumulators 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Cleaning the individual parts of pressure accumulators 26 . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Checking individual pressure accumulator parts 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1 Visual check 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Presentation − Accumulator Filling Device and Nitrogen Bottle 28 . . . . . . . . . . . . . . . . .

7.1 Spare Parts List for Accumulator Filling Device 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Filling the pressure accumulator 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 Filling pressures (gas pretensioning) for pressure accumulators 29 . . . . . . . . . . . . . . . . . . .

8.2 Filling procedure 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Filling the high�pressure accumulator: 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

1. What are hydraulic pressure accumulators and what dothey do?

1.1 Accumulator design

All hydraulic accumulators used on Atlas Copco hydraulic tools are of diaphragm design, i.e. the available

accumulation chamber is split into two by a rubber diaphragm. The upper chamber (above the diaphragm) is

filled with pre�compressed nitrogen (N2), and the lower chamber is connected to the operating medium for

the hydraulic hammer.

1.2 Function of the pressure accumulator

There are two main reasons for using hydraulic accumulators in hydraulic systems: to smooth the flow of oil

from the hydraulic pump(s) and thus compensate for any fluctuations in delivery; and to cover short�term

peak requirements on the system which no pump is capable of meeting. The latter requirement occurs when

the hydraulic power is used to generate extremely quick movements, as is the case with hydraulic hammers.

2. Safety regulations for pressure accumulators

2.1 Statutory regulations

As pressurised vessels, pressure accumulators are safety<relevant components and are thus gov<

erned by the laws and special safety regulations valid in the country of use.

For this reason, we would always recommend that work on pressure accumulators be left to the specially�

trained employees of our regional service centres or of our authorised dealers.

8

2.2 Accident preventionSpecial care and attention is required when using or servicing pressure accumulators.

In order to avoid accidents or damage, please observe the following warnings.

Caution! WARNING!

H Opening pressure accumulators by force, e.g. by sawing them open etc., is strictly forbidden, since theymay still contain compressed nitrogen.Risk of accident!

H Under no circumstances should accumulators be subjected to external heat, e.g. flame or electric welders,since this could change the shape or modify the joints of the component in question, thus rendering itunusable for pressure accumulators.Risk of accident!

H The only gas which may be used for filling accumulators is nitrogen (N2). The use of other gases, suchas compressed air or hydrogen, could result in an explosion.Risk of accident!

H The use of non�Atlas Copco accumulators or repair parts is strictly forbidden. The quality of genuine AtlasCopco parts satisfies (German) statutory pressure vessel requirements. If this quality standard is not met,the pressure accumulator may no longer be safe to use.Risk of accident!

H When using pressure accumulators classified by German regulations as Group III, prototype�tested pres�sure�relief valves are installed in the relevant hydraulic system as a protective measure. Under no circum�stances may these valves be replaced by different models, regardless of how similar they may appear.

H Pressure accumulators classified as Group II are protected by non�prototype�tested pressure�reliefvalves. Here again, their replacement by valves of a different make is forbidden.In both cases, replacement represents an infringement of statutory safety regulations.Risk of accident!

9

3. WarrantyThe pressure accumulators used are diaphragm accumulators.

The diaphragms in the accumulators are not covered by the terms of the warranty. These are wear partswhich will be subject to normal wear and tear when the hydraulic tool is used.

Depending on accumulator model, it may be possible to replace worn or defective diaphragms. This is true ofall pressure accumulators with the exception of those with 0.5 litre and 1.0 litre capacity, which must bereplaced in their entirety upon failure.

10

4. Accumulator specifications and allocation to Atlas Copcohydraulic tools

The table in section 4.1 provides an overview of accumulator specifications and lists the Atlas Copcohydraulic tools on which they are used.

Terms used in table:

Group: Classification of pressure accumulators according to the German pressure vessel code

Design: integrated design means that the lower accumulator shell is integrated in the tool itself (basic body)

Design: flange design means the pressure accumulator is flange�mounted on the tool

Design: threaded pin means the pressure accumulator cannot be dismantled; upon failure it must be replaced by a new accumulator

Filling pressure pGas: prescribed gas pressure (oil side depressurised)

Operating pressure: max. permissible operating pressure for pressure accumulator (oil side) (does not always match the equivalent of the max. permissible operating pressure of the relevant tool)

4.1 Pressure accumulator specifications

ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

Capacity(litres)Group

ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

DesignÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

Filling pres<sure pGas

(bar)


Opera<tingpressure(bar)

ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

Allocation to toolsÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

Describedin section

0,09Group II

integrated

40 180 HM 12, 5.1

0,25

integrateddesign 50 180 HM 25, 32

5 20,25Group II

g

50 180 HM 65, 300, 305, 550, 555, 560, 5805.2

0,25Group II

50 180 HM 110 5.3

0,9Group II

60 210KKK

HM 720�1/�2, HM 1500 5.4

flanged i

40 200KKK

HM 702, HM 712

5.51,5

Group III

gdesign

60 200KKK

HM 901, 902, 951, 952, 960�1, 960�2,HM 1200, 1300, 1800, 2000,HM 2100, 2200, 2300, 2500, 2600,3000, 4000

5.5

5.6

2,0Group*/**

60 * / 2 ** 180/30 HM 600 5.7

0,5Group II threaded

2 Cooler 5.8

1,0Group II

threadedpin

60 * / 2 ** 180/ HM 200 5.9

K = for connection to the high�pressure side of the hammer, Group III vesselsKK = for connection to the low�pressure side of the hammer, Group II vesselsKKK Accumulators marked with DN" on the upper shell can be serviced with max. operation

pressure of 230 bars.

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5. List of individual pressure accumulatorsIn order to avoid confusion between accumulator models, aspects such as design, components, dismantlingand assembly are covered in the following model�specific sections.

5.1 Pressure accumulator 0.09 litres (integrated design)

5.1.1 Presentation pressure accumulator

1

7

8

324

Line marking to bemade for tightening

After pretightening, lines markedon parts 7 and 8 must align

5.1.2 Spare parts list pressure accumulator

ÂÂÂÂÂÂÂÂÂÂÂÂ

Part no.ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

Part ident. no.ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

QuantityÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

DesignationÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

Tightening torque(Nm)

1 3360 9817 85 1 Diaphragm −

2 3360 3322 59 1 Filler screw −

3 3360 3144 60 1 O�ring −

4 3361 3350 25 1 Protective cap −

7 3360 9818 53 1 Cap 400"40

8 − − Basic body * −

K Basic body, e.g. lower handle part to accommodate diaphragm and cap(in the following referred to only as basic body)

12

5.1.3 Tools required for dismantling and assembly

In general, the following tools and materials are required:� size 2 Phillips screwdriver� Vaseline or Parker O�Lube� thread paste

Following additional tools required for 0.09 ltr. accumulator:� ace spanner, part ident. no. 1330461� torque wrench to 500 Nm

5.1.4 Dismantling the pressure accumulator

Depressurise tool (oil side) and disconnect from hydraulic supply.D remove protective cap (part 4) and unscrew filler screw (part 2) slowly using the screwdriver to bleed offany remaining gas.D remove filler screw (part 2) and O�ring (part 3).To remove cap (part 7), clamp basic body in a vice (or similar) with protective jaws with cap facing upwardsD place face spanner on cap (part 7), ensuring that it fits perfectlyD release cap (part 7) and then screw out by handD remove diaphragm (part 1)

5.1.5 Checking and cleaning parts prior to assembly

It is important to check that all accumulator components are in perfect condition prior to assembly.These checks are necessary to ensure the safety of the unit and are described in detail in section 6.1 ff.

5.1.6 Assembling the pressure accumulator

To ensure the safety of the unit, use only genuine Atlas Copco spares.n order to fit the cap onto the basic body, clamp the latter in a vice (or similar) with protective jaws with thethreaded opening facing upwards.

H apply a light coating of HSC thread paste to the threads on the basic body and cap

H coat any metal surfaces on the basic body or cap which come into contact with the diaphragm with Vas�eline or Parker O�Lube

H insert new diaphragm (aluminium button must be facing basic body). See diagram in section 5.1.1.

H screw in cap by hand without filler screw

H using face spanner (part ident. no. 3361 3304 61) screw cap down as far as it will go

H tighten to prescribed torque using face spanner.Tightening torque: 400 Nm ± 40 for HM 12

H insert new O�ring (part 3), screw new filler screw (part 2) loosely into cap

Fill pressure accumulator as described in section 7.

13

5.2 Pressure accumulator 0.25 litres (integrated design)


1

7

8

324

Line marking to bemade for tightening

After pretightening, lines markedon parts 7 and 8 must align





QuantityÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

DesignationÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ


1 3360 3302 68 1 Diaphragm −

2 3360 3322 59 1 Filler screw −

3 3360 3144 60 1 O�ring −

4 3361 3350 25 1 Protective cap −

7 3360 3302 64 1 Cap (with parts 2 + 4) see section 5.2.6

8 − − Basic body * −

K Basic body, e.g. lower handle part to accommodate diaphragm and cap(in the following referred to only as basic body)

14


In general, the following tools and materials are required:� size 2 Phillips screwdriver� 5 kg sledgehammer� Vaseline or Parker O�Lube� thread paste

Following additional tools required for 0.25 ltr. accumulator:� face spanner, part ident. no. 1331091� size 50 slugging ring spanner, part ident. no. 1031467� torque wrench to 500 Nm

5.2.4 Dismantling the pressure accumulator (integrated design)

Depressurise tool (oil side) and disconnect from hydraulic supply.

H remove protective cap (part 4) and unscrew filler screw (part 2) slowly using the screwdriver to bleed offany remaining gas.

H remove filler screw (part 2) and O�ring (part 3).To remove cap (part 7), clamp basic body in a vice (or similar) with protective jaws with cap facingupwards

H place face spanner on cap (part 7), ensuring that it fits perfectly

H release cap (part 7) using slugging ring spanner and sledgehammer, then screw out by hand

H remove diaphragm (part 1)



To ensure the safety of the unit, use only genuine Atlas Copco spares.In order to fit the cap onto the basic body, clamp the latter in a vice (or similar) with protective jaws with thethreaded opening facing upwards.

H apply a light coating of HSC thread paste to the threads on the basic body and cap

H coat any metal surfaces on the basic body or cap which come into contact with the diaphragm with Vas�eline or Parker O�Lube



H using face spanner (part ident. no. 1331091) hand�tighten cap until contact is made

For HM 25/32

H using face spanner and torque wrench tighten to 450 " 45 Nm.

Für HM 65/300/305/550/555/560/580:

H using face spanner and slugging ring spanner tighten to 2.000 " 200 Nm.To this end, scratch a joint line on the upper face of the cap and basic body using a scriber. The requiredtightening torque is then achieved by turning the cap by a further 6�7 mm.



15

5.3 Pressure accumulator 0.25 litres (flange design)


8

1

7

2

910

34






Designation ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ


1 3360 3302 68 1 Diaphragm −

2 3360 3322 59 1 Filler screw

3 3360 3144 60 1 O�ring −

4 3361 3350 25 1 Protective cap −

7 3360 3302 64 1 Cap (with parts 2 + 4) 2000 ± 200

8 3360 9161 19 1 Lower shell −

9 3360 2033 39 4 Hexagonal nut **

10 3360 4801 87 4 Washer ** −

KK Parts required to fix pressure accumulator to mounting

16


In general, the following tools and materials are required:� size 2 Phillips screwdriver� 5 kg sledgehammer� Vaseline or Parker O�Lube� thread paste

Following additional tools required for 0.25 ltr. accumulator:� face spanner, part ident. no. 1331091� size 50 slugging ring spanner, part ident. no. 0990357� torque wrench to 500 Nm

5.3.4 Dismantling the pressure accumulator (flange design)



H remove filler screw (part 2) and O�ring (part 3).Clamp pressure accumulator in a vice (or similar) with protective jaws with cap facing upwards

H place face spanner on cap (part 7), ensuring that it fits perfectly

H release cap (part 7) using slugging ring spanner and sledgehammer, then screw out by hand

H remove diaphragm (part 1)


It is important to check that all accumulator components are in perfect condition prior to assembly.

These checks are necessary to ensure the safety of the unit and are described in detail in section 6.1 ff.


To ensure the safety of the unit, use only genuine Atlas Copco spares.

In order to fit the cap onto the lower shell, clamp the latter in a vice (or similar) with protective jaws with the

threaded opening facing upwards.

H apply a light coating of HSC thread paste to both threads

H coat any metal surfaces on the shell or cap which come into contact with the diaphragm with Vaseline orParker O�Lube



H using face spanner (part ident. no. 3361 3310 91) hand�tighten cap until contact is made

H using face spanner and slugging ring spanner tighten to 2.000 " 200 Nm. To this end, scratch a joint lineon the upper face of the cap and lower shell using a scriber. The required tightening torque is thenachieved by turning the cap by a further 6�7 mm.



17

5.4 Pressure accumulator 0.9 litres (flange design)


8

7

1

96

5

324

10

11

Back�up ring








1 3362 2616 47 1 Diaphragm incl. back�up ring * −

2 3360 3322 59 1 Filler screw −

3 3360 3144 60 1 O�ring −

4 3361 3350 25 1 Protective cap −

5 3361 0319 12 1 O�ring −

6 3361 8505 29 1 Back�up ring −

7 3360 1060 71 18 Hexagonal socket head screw 125+5

8 3363 0704 85 1 Upper shell −

9 3362 616 45 1 Lower shell −

103363 0344 81

6Hex. screw ** (for HM 720)

200 + 10103363 0704 90

6Hex. screw ** (for HM 1500)

200 + 10

11 3361 3337 03 6 Washer **11 3361 3337 03 6 Washer ** −

K Diaphragm incl. back�up ring always supplied together and must always be replaced togetherKK Parts required to fix pressure accumulator to mounting

18


In general, the following tools and materials are required:� size 2 Phillips screwdriver� Vaseline or Parker O�Lube� thread paste

Following additional tools required for 0.9 ltr. accumulator:� size 12 hexagonal socket screwdriver� torque wrench to 500 Nm with size 12 insert




H remove filler screw (part 2) and O�ring (part 3).Clamp pressure accumulator in a vice (or similar) with protective jaws with lower shell facing upwards

H use size 12 hexagonal socket screwdriver to unscrew all 18 hexagonal socket head screws

H separate upper shell from lower shell

H remove diaphragm with back�up ring


It is important to check that all accumulator components are in perfect condition prior to assemblyThese checks are necessary to ensure the safety of the unit and are described in detail in section 6.1 ff.



H coat metal surfaces on the upper and lower shells which come into contact with the diaphragm with Vas�eline or Parker O�Lube

H insert new diaphragm incl. back�up ring (part 1) in lower shell, ensuring it is the right way round. See dia�gram in section 5.4.1.

H position upper shell without filler screw on lower shell and pre�assemble using two opposite hexagonalsocket head screws (part 7)

H clamp in a vice with protective jaws, insert remaining hexagonal socket head screws and pre�tighten to atorque of 50 Nm

H finish�tighten hexagonal socket head screws in opposing pairs using torque wrench to prescribed tightening torque of 125 + 5 Nm

H insert new O�ring (part 3), screw new filler screw (part 2) loosely into filler adapter


19

5.5 Pressure accumulator 1.5 litres (flange design, 16<hole)


1

9

7

8

11

1042

3

65

back�up ring

(12)Hex. nut forsection 5.6



Part no.ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

Part ident. no.ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

QuantityÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

DesignationÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ


1 3361 3290 22 1 Diaphragm incl. back�up ring* −

2 3360 3322 59 1 Filler screw −

3 3360 3144 60 1 O�ring −

4 3361 3350 25 1 Protective cap −

5 3360 3143 64 1 O�ring −

6 3360 3280 46 1 Back�up ring −

7 3363 0704 91 16 Hexagonal socket head screw 240+20

8 3363 0704 88 1 Upper shell −

9 3363 0704 89 1 Lower shell −

10 3361 8515 91 4 Expansion bolt ** (head design) 380

11 3361 8515 93 4 Washer ** −

K Diaphragm incl. back�up ring always supplied together and must always be replaced together

KK Parts required to fix pressure accumulator to mounting

20


In general, the following tools and materials are required:� size 2 Phillips screwdriver� Vaseline or Parker O�Lube

Following additional tools required for 1.5 ltr. accumulator:� size 12 hexagonal socket screwdriver� torque wrench to 500 Nm with size 12 insert




H remove filler screw (part 2) and O�ring (part 3).Clamp pressure accumulator in a vice (or similar) with protective jaws with lower shell facing upwards

H use size 12 hexagonal socket screwdriver to unscrew all 16 hexagonal socket head screws

H separate upper shell from lower shell

H remove diaphragm with back�up ring






H insert new diaphragm incl. back�up ring (part 1) in lower shell, ensuring it is the right way round. See dia�gram in section 5.5.1.

H position upper shell without filler screw on lower shell and pre�assemble using two opposite hexagonalsocket head screws (part 7)

H clamp in a vice with protective jaws, insert remaining hexagonal socket head screws and pre�tighten to atorque of 50 Nm

H finish�tighten hexagonal socket head screws in opposing pairs using torque wrench to prescribed tighten�ing torque of 240 + 20 Nm.



21

5.6 Pressure accumulator 1.5 litres (flange design, 12<hole) oldermodels

5.6.1 Accumulator design and components (please refer to diagram in 5.5.1)

Part nos. 1 to 7 are the same for all designs listed below. However, upper shell (part 8) and lower shell (part9) have different bore diameters for the expansion bolts used to attach the pressure accumulator.







1 3361 3290 22 1 Diaphragm incl. back�up ring* −

2 3360 3322 59 1 Filler screw −

3 3360 3144 60 1 O�ring −

4 3361 3350 25 1 Protective cap −

5 3360 3143 64 1 O�ring −

6 3360 3280 46 1 Back�up ring −

7 3361 3290 23 12 Hexagonal socket head screw 240 + 20

18 mm dia. bores on pressure accumulator. Thread in upper part/cylinder = M 16. Additional hex. nut(part 12) required.

8 3361 3290 21 1 Upper shell (bore dia. 18) −

9 3361 3290 20 1 Lower shell (bore dia. 18) −

10 3360 9963 49 4 Expansion bolt** (threaded at each end)

−

11 3360 4801 87 4 Washer** −

12 3360 1032 50 4 Hex. nut M 16**




10 3361 3307 73 4 Expansion bolt** (threaded at each end)

−

11 3360 4801 85 4 Washer** −

12 3361 3293 92 4 Hex. nut M 20**




10*** 3361 3304 59 4 Expansion bolt** (threaded at each end)

−

11*** 3360 4801 85 4 Washer** −

12*** 3361 3293 92 4 Hex. nut M 20**

* Diaphragm incl. back�up ring always supplied together and must always be replaced together

** Parts required to fix pressure accumulator to mounting

***For preference, use part nos. 10 and 11 from section 5.5.1 instead of part nos. 10�12.

22

5.7 Pressure accumulator 2.0 litres


9

1011

7

8

56

23

4

contour of lower shell HM 700

1

clamping point

clamping point








1 3360 9166 88 1 Diaphragm −

2 3360 33 22 59 1 Filler screw −

3 3360 3144 60 1 O�ring −

4 3361 3350 25 1 Protective cap −

5 3360 3143 64 1 O�ring −

6 3360 3280 46 1 Back�up ring −

7 3360 9209 38 1 Upper shell 3400+500

83362 26 38 56

1Lower shell for HM 700

83360 9207 23

1Lower shell for HM 600

−

9 3360 4765 70 1 Clamping ring −

10 4 screw **

11 4 Washer ** −

** Parts required to fix pressure accumulator to mounting

23


In general, the following tools and materials are required:� size 2 Phillips screwdriver� 5 kg sledgehammer� thread paste� Vaseline or Parker O�Lube

Following additional tools required for 2 ltr. accumulator:� ring spanner, part ident. no. 0479834




H remove filler screw (part 2) and O�ring (part 3).Clamp pressure accumulator with lower shell in a vice with protective jaws

H position ring spanner on upper shell, lock all locating screws

H release upper shell using sledgehammer/pipe extension

H unscrew upper shell from lower shell

H remove diaphragm (part 1) with clamping ring (part 9) and separate from one another

5.7.5 Checking parts prior to assembly

If parts which have been removed are to be reused, it is important to check that they are in perfect condition

prior to assembly.

These checks are necessary to ensure the safety of the unit and are described in detail in section 6.1 ff.




H give the threads on both shells a light coating of thread paste

H fit clamping ring as shown in diagram in section 5.7.1

H insert diaphragm in lower shell, ensuring it is the right way round.

H screw prepared upper shell without filler screw onto lower shell by hand until it no longer turns

H clamp lower shell in a vice with protective jaws

H tighten upper shell using ring spanner and pipe extension to a tightening torque of 3.400 " 300 NmTo this end, scratch a joint line on the outer circumference of the upper and lower shell using a scriber.The required tightening torque is then achieved by turning the upper shell by a further 5�7 mm.



24

5.8 Pressure accumulator 0.5 litres (for use with cooler 0050)









− 3360 9802 62 − Pressure accumulator −


Tool required for 0.5 ltr. pressure accumulator:

� jaw spanner

5.8.4 Removing the pressure accumulator

Depressurise tool (oil side) and remove pressure accumulator.

H pressure accumulator cannot be dismantled. Defective accumulators can only be replaced by new units.

H remove using size 46 jaw spanner


H does not apply.

5.8.6 Fitting the pressure accumulator

H screw in by hand

H tighten using above�mentioned jaw spanner to prescribed tightening torque of 450 " 45 Nm.

25

5.9 Pressure accumulator 1 litre


5








− 3360 3282 82 1 Pressure accumulator HP 450 ± 45

− 3360 3282 83 1 Pressure accumulator LP 450 ± 45

5 3360 3282 81 1 Sealing ring −

5.9.3 Restrictions on accumulator repair

(applying in Federal Republic of Germany)No restrictions. Use new pressure accumulators.


Tool required for 1 ltr. pressure accumulator:

� size 46 jaw spanner

5.9.5 Removing the pressure accumulator

Depressurise tool (oil side) and remove pressure accumulator.

H pressure accumulator cannot be dismantled. Defective accumulators can only be replaced by new units.

H remove using size 46 jaw spanner


H does not apply.

5.9.7 Fitting the pressure accumulator

H screw in by hand, not forgetting sealing element (part 5)

H tighten using above�mentioned jaw spanner to prescribed tightening torque of 450 " 45 Nm.

26

6. Assembling pressure accumulatorsThe simplest way of "repairing" a pressure accumulator is to change it for a new or replacement unit.

Pressure accumulators of integrated and flange design can, however, also be repaired outside of Atlas Copc

Berco Bautechnik’s workshops.

In the majority of cases, a malfunction in the pressure accumulator can be traced to a defect in the fitted dia�

phragm. In order to replace the diaphragm with a new one, it is first necessary to open the pressure accumu�

lator as described in section 5.

Prior to reassembly, all accumulator�related parts must be subjected to stringent tests.

6.1 Cleaning the individual parts of pressure accumulators

Both parts which have been removed from pressure accumulators and new replacement parts must be

cleaned thoroughly before reassembling the accumulator using non�corrosive washing fluids which effectively

remove any dirt particles, grease and preservation agents adhering to the parts.

After washing, the parts must be blow�dried using dry compressed air and then kept in a clean place for

assembly.

6.2 Checking individual pressure accumulator parts

Before reusing pressure accumulator parts during repair work, these parts must be subject to a thorough

visual check, which should also be carried out even when using new and genuine Atlas Copc replacement

parts.

27

6.2.1 Visual check

This applies to parts such as: caps, upper shells, lower shells, basic bodies on integrated�design accumula�

tors, and screws/bolts.

Once all parts have been thoroughly cleaned, the visual check can be performed, looking out in particular for

corrosion damage, traces of wear, external damage and cracks.

Corrosion damage

Light corrosion can be smoothed off using a fine emery cloth (grain 600) in areas such as flange faces,

thread flanks and inner support contours for the diaphragm. If corrosion damage goes deeper and cannot be

smoothed off, the part in question must be replaced by a genuine Atlas Copc spare part.

Wear

Can be smoothed off using a fine emery cloth (grain 600).

External damage

Look particularly for damage to filler adapters and grooves for sealing elements. If there is any doubt, these

parts should be replaced.

Connecting screws between upper and lower shells are made from special materials and no other quality is

suitable for replacement, i.e. always use genuine Atlas Copc spares.

Cracks/fractures

Parts with fractures or cracks which are visible to the naked eye must under no circumstances be reused and

must be replaced by genuine Atlas Copc spare parts.

Caution!

Components with fractures or hairline cracks must not be reused.

Atlas Copco Construction Tools would be grateful for the return of such parts to allow products to be moni�

tored closely.

28

7. Presentation − Accumulator Filling Device and NitrogenBottle

5

4

3 2

1

7.1 Spare Parts List for Accumulator Filling Device

ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

Part No.ÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

DesignationÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂÂ

Pt.− Id.−No.

1 accumulator filling device 3360 9204 15

2 adapter 3361 3298 89

3 Phillips driver head 3361 3298 90

4 Fine adjustment regulator 3360 9204 14

5 nitrogen bottle 3360 4798 26

29

8. Filling the pressure accumulator

8.1 Filling pressures (gas pretensioning) for pressure accumulators

The table below lists the prescribed gas pretensioning for each unit size and the appropriate hammer series

Size(litres)

0,09 0,25 0,9 1,5 2,0


Fillingpressure(bar)


40


50


60


60


40


60


2


60

Hammermodel

HM 12HM 20

HM 25HM 32

HM 65 300,305 550, 555,560, 580

HM 720−1HM 720�2HM 1500

HM 702HM 712

HM 901,902951, 952960�1, �2

1300, 18002000, 2100,2300, 2500,2600, 3000,

4000

HM 600LP *

HM 600HP **

K For attachment to high�pressure side (HP)KK For attachment to low pressure side (LP)

8.2 Filling procedure

The accumulator filling device (part ident. no. 3360 9204 15) with accessories is needed to fill the pressureaccumulator.

From the available or supplied tool box you will require:nitrogen cylinder with pressure�relief fitting

When filling the pressure accumulator, please observe the diagram below and follow the instructions providedstep by step.

Preparations:

1. Connect pressure�relief fitting (part 8) to nitrogen cylinder. Screw nipple (part 16) of accumulator fillingdevice onto pressure�relief fitting.

2. Slide filling device (part 9) onto filler adapter (part 14) of upper shell and screw tight.(Please note: left�hand thread). To this end the filler adapter must be in lower position and the socket spanner (part 11) in upper position.

3. Attach connecting hose (part 12) to pressure�relief fitting and filling device.

4. Close bleed valve (part 10) on filling device.

5. Close check valve (part 13) on pressure�relief fitting.

6. Using socket spanner, screw out filler screw as far as it will go.

30

8.3 Filling the high<pressure accumulator:

7. Open gas cylinder valve slowly.

8. Open check valve (part 13) on pressure�relief fitting slowly until required pressure can be read on the pressure gauge (part 15) of the filling device.

9. Once required pressure has been attained, close check valve (part 13).

10. Wait for temperature in accumulator to balance.

11. If pressure gauge reading is now too high, reduce pressure using bleed valve.

12. If reading is too low, top up gas pressure.

13. If accumulator pressure reading is correct, tighten filler screw firmly using socket spanner.

14. Close gas cylinder valve.

15. Depressurise connecting hose using bleed valve and remove filling device.

16. Close accumulator filler adapter with cap.

8 Pressure�relief fitting13 Check valve

cylinder valve

11 Socket spanner

10 Bleed valve

9 Filling device

15 High pressure gauge

12 Connecting hose

14 Filler adapterwith filler screwon accumulator

nitrogen cylinder

16 Nipple

31

IndexA

H Accident prevention, 8

H Accumulator design, 7

H Accumulator design and components (please re�fer to diagram in 5.5.1), 21

H Accumulator specifications and allocation to AtlasCopco hydraulic tools, 10

H Assembling pressure accumulators, 26

H Assembling the pressure accumulator, 12 , 16 ,18 , 20 , 23

C

H Checking and cleaning parts prior to assembly, 12, 14 , 16 , 18 , 20

H Checking individual pressure accumulator parts,26

H Checking parts prior to assembly, 23 , 24 , 25

H Cleaning the individual parts of pressure accumu�lators, 26

D

H Dismantling the pressure accumulator, 12 , 18 ,20 , 23

H Dismantling the pressure accumulator (flange de�sign), 16

H Dismantling the pressure accumulator (integrateddesign), 14

F

H Filling pressures (gas pretensioning) for pressureaccumulators, 29

H Filling procedure, 29

H Filling the high−pressure accumulator:, 30

H Filling the pressure accumulator, 29

H Fitting the pressure accumulator, 24

H Function of the pressure accumulator, 7

L

H List of individual pressure accumulators, 11

P

H Presentation − Accumulator Filling Device and Ni�trogen Bottle, 28

H Presentation pressure accumulator, 11 , 13 , 15 ,17 , 19 , 22 , 24 , 25

H Pressure accumulator 0.09 litres (integrated de�sign), 11

H Pressure accumulator 0.25 litres (flange design),15

H Pressure accumulator 0.25 litres (integrated de�sign), 13

H Pressure accumulator 0.5 litres (for use with coo�ler 0050), 24

H Pressure accumulator 0.9 litres (flange design),17

H Pressure accumulator 1 litre, 25 H Pressure accumulator 1.5 litres (flange design,

12−hole) older models, 21 H Pressure accumulator 1.5 litres (flange design,

16−hole), 19 H Pressure accumulator 2.0 litres, 22 H Pressure accumulator specifications, 10

R

H Removing the pressure accumulator, 24 , 25 H Restrictions on accumulator repair, 25

S

H Safety regulations for pressure accumulators, 7 H Spare Parts List for Accumulator Filling Device,

28 H Spare parts list pressure accumulator, 11 , 13 , 15

, 17 , 19 , 22 , 24 , 25 H Statutory regulations, 7

T

H Tools required for dismantling and assembly, 12 ,14 , 16 , 18 , 20 , 23 , 24 , 25

V

H Visual check, 27

W

H Warranty, 9 H What are hydraulic pressure accumulators and

what do they do?, 7

Your partner:

Atlas Copco Construction Tools GmbHHelenenstrasse 149 S 45143 EssenP. O. Box 10 21 52 S 45021 EssenFederal Republic of Germany

Telephone +49 201 633 − 0Telefax +49 201 633 − 2281

Telefax Customers Support +49 201 633 − 1352Internet: www.hydraulic−attachments.com

acumuladores de ap atlas copco

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