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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

Pressure accumulators on Atlas Copco


hydraulic hammers
Design and maintenance

E Atlas Copco Construction Tools GmbH

Atlas Copco Construction Tools GmbH


P. O. Box: 102152, D  45021 Essen
Helenenstrasse 149, D  45143 Essen
Federal Republic of Germany
Telephone
+49 201 633  0
Telefax
+49 201 633  2281
Telefax Customer Support: +49 201 633  1352

Explanation of the symbols used in this operating manual


Certain instructions in the operating manual are marked with symbols to emphasise
their importance.
The symbols used are described below:

Please note!

The marked text provides instructions on the cor


rect use of the pressure accumulator aimed at
avoiding incorrect operation or errors during work.

WARNING!

The marked text provides safety regula


tions and instructions aimed at avoiding
damage to equipment.

CAUTION!

The marked text provides safety regula


tions and instructions aimed at avoiding
accidents and possible injuries.

Table of contents
1.

2.

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

1.1

Accumulator design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Function of the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety regulations for pressure accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

Statutory regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Accident prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.

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

10

4.1

10

5.

Pressure accumulator specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5.2.1

Presentation pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

5.2.2

Spare parts list pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

5.2.3

Tools required for dismantling and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

5.2.4

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

14

5.2.5

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

14

5.3

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

15

5.3.1

Presentation pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

5.3.2

Spare parts list pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

5.3.3

Tools required for dismantling and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

5.3.4

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

16

5.3.5

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

16

5.3.6

Assembling the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

5.4

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

17

5.4.1

Presentation pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

5.4.2

Spare parts list pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

5.4.3

Tools required for dismantling and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

5.4.4

Dismantling the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

5.4.5

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

18

5.4.6

Assembling the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

5.5

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

19

5.5.1

Presentation pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

5.5.2

Spare parts list pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19
5

6.

7.

8.

5.5.3

Tools required for dismantling and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

5.5.4

Dismantling the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

5.5.5

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

20

5.5.6

Assembling the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

5.6

Pressure accumulator 1.5 litres (flange design, 12hole) 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

5.7.1

Presentation pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

5.7.2

Spare parts list pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

5.7.3

Tools required for dismantling and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

5.7.4

Dismantling the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

5.7.5

Checking parts prior to assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

5.7.6

Assembling the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

5.8

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

24

5.8.1

Presentation pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

5.8.2

Spare parts list pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

5.8.3

Tools required for dismantling and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

5.8.4

Removing the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

5.8.5

Checking parts prior to assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

5.8.6

Fitting the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

5.9

Pressure accumulator 1 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

5.9.1

Presentation pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

5.9.2

Spare parts list pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

5.9.3

Restrictions on accumulator repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

5.9.4

Tools required for dismantling and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

5.9.5

Removing the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

5.9.6

Checking parts prior to assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

5.9.7

Fitting the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

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

Presentation Accumulator Filling Device and Nitrogen Bottle . . . . . . . . . . . . . . . . .

28

7.1

28

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

Filling the pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

8.1

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

29

8.2

Filling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

8.3

Filling the highpressure accumulator: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30

1.

What are hydraulic pressure accumulators and what do


they 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 precompressed 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 shortterm
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.

2.2

Accident prevention

Special 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 they
may 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 it
unusable 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, such
as compressed air or hydrogen, could result in an explosion.
Risk of accident!
H The use of nonAtlas Copco accumulators or repair parts is strictly forbidden. The quality of genuine Atlas
Copco 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, prototypetested pres
surerelief 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 nonprototypetested pressurerelief
valves. 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!

3.

Warranty

The pressure accumulators used are diaphragm accumulators.


The diaphragms in the accumulators are not covered by the terms of the warranty. These are wear parts
which 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 of
all pressure accumulators with the exception of those with 0.5 litre and 1.0 litre capacity, which must be
replaced in their entirety upon failure.

4.

Accumulator specifications and allocation to Atlas Copco


hydraulic tools

The table in section 4.1 provides an overview of accumulator specifications and lists the Atlas Copco
hydraulic 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 flangemounted 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

Capacity
(litres)
Group
0,09
Group II

0,25
Group II

Design

integrated
design
g

0,25
Group II
0,9
Group II

1,5
Group III

1,0
Group II
K
KK
KKK

10

Opera<ting
pressure
(bar)

40

180

HM 12,

50

180

HM 25, 32

50

180

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

50

180

60

210
KKK

HM 7201/2, HM 1500

40

200
KKK

HM 702, HM 712

flange
g
d i
design
60

2,0
Group*/**
0,5
Group II

Filling pres<
sure pGas
(bar)

60 * / 2 **

200
KKK
180/30

2
threaded
pin

60 * / 2 **

Allocation to tools

HM 110

5.1
52
5.2
5.3
5.4

5.5
HM 901, 902, 951, 952, 9601, 9602,
HM 1200, 1300, 1800, 2000,
HM 2100, 2200, 2300, 2500, 2600,
3000, 4000
HM 600
Cooler

180/

Described
in section

HM 200

= for connection to the highpressure side of the hammer, Group III vessels
= for connection to the lowpressure side of the hammer, Group II vessels
Accumulators marked with DN" on the upper shell can be serviced with max. operation
pressure of 230 bars.

5.6

5.7
5.8
5.9

5.

List of individual pressure accumulators

In order to avoid confusion between accumulator models, aspects such as design, components, dismantling
and assembly are covered in the following modelspecific sections.

5.1

Pressure accumulator 0.09 litres (integrated design)

5.1.1

Presentation pressure accumulator

Line marking to be
made for tightening

1
After pretightening, lines marked
on parts 7 and 8 must align

7
3
4

5.1.2

Spare parts list pressure accumulator

Part no.

Part ident. no.

Quantity

Designation

Tightening torque
(Nm)

3360 9817 85

Diaphragm

3360 3322 59

Filler screw

3360 3144 60

Oring

3361 3350 25

Protective cap

3360 9818 53

Cap

400"40

Basic body *

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

11

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 OLube
 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 off
any remaining gas.
D remove filler screw (part 2) and Oring (part 3).
To remove cap (part 7), clamp basic body in a vice (or similar) with protective jaws with cap facing upwards
D place face spanner on cap (part 7), ensuring that it fits perfectly
D release cap (part 7) and then screw out by hand
D 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 the
threaded 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 OLube
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 Oring (part 3), screw new filler screw (part 2) loosely into cap
Fill pressure accumulator as described in section 7.

12

5.2

Pressure accumulator 0.25 litres (integrated design)

5.2.1

Presentation pressure accumulator

Line marking to be
made for tightening

1
After pretightening, lines marked
on parts 7 and 8 must align

7
3
4

5.2.2

Spare parts list pressure accumulator

Part no.

Part ident. no.

Quantity

Designation

Tightening torque
(Nm)

3360 3302 68

Diaphragm

3360 3322 59

Filler screw

3360 3144 60

Oring

3361 3350 25

Protective cap

3360 3302 64

Cap (with parts 2 + 4)

see section 5.2.6

Basic body *

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

13

5.2.3

Tools required for dismantling and assembly

In general, the following tools and materials are required:


 size 2 Phillips screwdriver
 5 kg sledgehammer
 Vaseline or Parker OLube
 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 off
any remaining gas.
H remove filler screw (part 2) and Oring (part 3).
To remove cap (part 7), clamp basic body 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)

5.2.5

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.
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 the
threaded 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 OLube
H insert new diaphragm (aluminium button must be facing basic body). See diagram in section 5.2.1.
H screw in cap by hand without filler screw
H using face spanner (part ident. no. 1331091) handtighten cap until contact is made
For HM 25/32
H using face spanner and torque wrench tighten to 450 " 45 Nm.
Fr 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 required
tightening torque is then achieved by turning the cap by a further 67 mm.
H insert new Oring (part 3), screw new filler screw (part 2) loosely into cap
Fill pressure accumulator as described in section 7.

14

5.3

Pressure accumulator 0.25 litres (flange design)

5.3.1

Presentation pressure accumulator

3
4
2

9
10

5.3.2

Spare parts list pressure accumulator

Part no.

Part ident. no.

Quantity

Designation

Tightening torque
(Nm)

3360 3302 68

Diaphragm

3360 3322 59

Filler screw

3360 3144 60

Oring

3361 3350 25

Protective cap

3360 3302 64

Cap (with parts 2 + 4)

2000 200

3360 9161 19

Lower shell

3360 2033 39

Hexagonal nut **

10

3360 4801 87

Washer **

KK Parts required to fix pressure accumulator to mounting

15

5.3.3

Tools required for dismantling and assembly

In general, the following tools and materials are required:


 size 2 Phillips screwdriver
 5 kg sledgehammer
 Vaseline or Parker OLube
 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)

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 off
any remaining gas.
H remove filler screw (part 2) and Oring (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)

5.3.5

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.

5.3.6

Assembling the pressure accumulator

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 or
Parker OLube
H insert new diaphragm (aluminium button must be facing basic body). See diagram in section 5.3.1.
H screw in cap by hand without filler screw
H using face spanner (part ident. no. 3361 3310 91) handtighten 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 line
on the upper face of the cap and lower shell using a scriber. The required tightening torque is then
achieved by turning the cap by a further 67 mm.
H insert new Oring (part 3), screw new filler screw (part 2) loosely into cap
Fill pressure accumulator as described in section 7.

16

5.4

Pressure accumulator 0.9 litres (flange design)

5.4.1

Presentation pressure accumulator


10

2
4

11

3
8

Backup ring
7
1
6

5.4.2

Spare parts list pressure accumulator

Part no.

Part ident. no.

Quantity

3362 2616 47

Diaphragm incl. backup ring *

3360 3322 59

Filler screw

3360 3144 60

Oring

3361 3350 25

Protective cap

3361 0319 12

Oring

3361 8505 29

Backup ring

3360 1060 71

18

Hexagonal socket head screw

3363 0704 85

Upper shell

3362 616 45

Lower shell

3363 0344 81
10
11

3363 0704 90
3361 3337 03

Designation

Tightening torque
(Nm)

125+5

Hex. screw ** (for HM 720)


6
6

Hex. screw ** (for HM 1500)

200 + 10

Washer **

K Diaphragm incl. backup ring always supplied together and must always be replaced together
KK Parts required to fix pressure accumulator to mounting

17

5.4.3

Tools required for dismantling and assembly

In general, the following tools and materials are required:


 size 2 Phillips screwdriver
 Vaseline or Parker OLube
 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

5.4.4

Dismantling the pressure accumulator

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 off
any remaining gas.
H remove filler screw (part 2) and Oring (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 backup ring

5.4.5

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.

5.4.6

Assembling the pressure accumulator

To ensure the safety of the unit, use only genuine Atlas Copco spares.
H coat metal surfaces on the upper and lower shells which come into contact with the diaphragm with Vas
eline or Parker OLube
H insert new diaphragm incl. backup 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 preassemble using two opposite hexagonal
socket head screws (part 7)
H clamp in a vice with protective jaws, insert remaining hexagonal socket head screws and pretighten to a
torque of 50 Nm
H finishtighten hexagonal socket head screws in opposing pairs using torque wrench to prescribed
tightening torque of 125 + 5 Nm
H insert new Oring (part 3), screw new filler screw (part 2) loosely into filler adapter
Fill pressure accumulator as described in section 7.

18

5.5

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

5.5.1

Presentation pressure accumulator

Hex. nut for


section 5.6

(12)
10

11
7

backup ring

9
1
6
5

5.5.2

Spare parts list pressure accumulator

Part no.

Part ident. no.

Quantity

3361 3290 22

Diaphragm incl. backup ring*

3360 3322 59

Filler screw

3360 3144 60

Oring

3361 3350 25

Protective cap

3360 3143 64

Oring

3360 3280 46

Backup ring

3363 0704 91

16

Hexagonal socket head screw

3363 0704 88

Upper shell

3363 0704 89

Lower shell

10

3361 8515 91

Expansion bolt ** (head design)

11

3361 8515 93

Washer **

Designation

Tightening torque
(Nm)

240+20

380

K Diaphragm incl. backup ring always supplied together and must always be replaced together
KK Parts required to fix pressure accumulator to mounting

19

5.5.3

Tools required for dismantling and assembly

In general, the following tools and materials are required:


 size 2 Phillips screwdriver
 Vaseline or Parker OLube
Following additional tools required for 1.5 ltr. accumulator:
 size 12 hexagonal socket screwdriver
 torque wrench to 500 Nm with size 12 insert

5.5.4

Dismantling the pressure accumulator

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 off
any remaining gas.
H remove filler screw (part 2) and Oring (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 backup ring

5.5.5

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.

5.5.6

Assembling the pressure accumulator

To ensure the safety of the unit, use only genuine Atlas Copco spares.
H coat metal surfaces on the upper and lower shells which come into contact with the diaphragm with Vas
eline or Parker OLube
H insert new diaphragm incl. backup 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 preassemble using two opposite hexagonal
socket head screws (part 7)
H clamp in a vice with protective jaws, insert remaining hexagonal socket head screws and pretighten to a
torque of 50 Nm
H finishtighten hexagonal socket head screws in opposing pairs using torque wrench to prescribed tighten
ing torque of 240 + 20 Nm.
H insert new Oring (part 3), screw new filler screw (part 2) loosely into filler adapter
Fill pressure accumulator as described in section 7.

20

5.6

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


models

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 (part
9) have different bore diameters for the expansion bolts used to attach the pressure accumulator.

Part no.

Part ident. no.

Quantity

Designation

Tightening torque
(Nm)

3361 3290 22

Diaphragm incl. backup ring*

3360 3322 59

Filler screw

3360 3144 60

Oring

3361 3350 25

Protective cap

3360 3143 64

Oring

3360 3280 46

Backup ring

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

Upper shell (bore dia. 18)

3361 3290 20

Lower shell (bore dia. 18)

10

3360 9963 49

Expansion bolt**
(threaded at each end)

11

3360 4801 87

Washer**

12

3360 1032 50

Hex. nut M 16**

21 mm dia. bores on pressure accumulator. Thread in upper part/cylinder = M 16. Additional hex. nut
(part 12) required.
8

3361 3297 00

Upper shell (bore dia. 21)

3361 3296 99

Lower shell (bore dia. 21)

10

3361 3307 73

Expansion bolt**
(threaded at each end)

11

3360 4801 85

Washer**

12

3361 3293 92

Hex. nut M 20**

21 mm dia. bores on pressure accumulator. Thread in upper part/cylinder = M 20. Additional hex. nut
(part 12) required.
8

3361 3297 00

Upper shell (bore dia. 21)

3361 3296 99

Lower shell (bore dia. 21)

10***

3361 3304 59

Expansion bolt**
(threaded at each end)

11***

3360 4801 85

Washer**

12***

3361 3293 92

Hex. nut M 20**

* Diaphragm incl. backup 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. 1012.
21

5.7

Pressure accumulator 2.0 litres

5.7.1

Presentation pressure accumulator


4
2
3
7
9

clamping point

clamping point

10
11
8
6
5

contour of lower shell HM 700

5.7.2

Spare parts list pressure accumulator

Part no.

Part ident. no.

Quantity

Designation

Tightening torque
(Nm)

3360 9166 88

Diaphragm

3360 33 22 59

Filler screw

3360 3144 60

Oring

3361 3350 25

Protective cap

3360 3143 64

Oring

3360 3280 46

Backup ring

3360 9209 38

Upper shell

3400+500

8
9

**

22

3362 26 38 56
3360 9207 23
3360 4765 70

Lower shell for HM 700


Lower shell for HM 600

Clamping ring

10

screw **

11

Washer **

Parts required to fix pressure accumulator to mounting

5.7.3

Tools required for dismantling and assembly

In general, the following tools and materials are required:


 size 2 Phillips screwdriver
 5 kg sledgehammer
 thread paste
 Vaseline or Parker OLube
Following additional tools required for 2 ltr. accumulator:
 ring spanner, part ident. no. 0479834

5.7.4

Dismantling the pressure accumulator

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 off
any remaining gas.
H remove filler screw (part 2) and Oring (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.

5.7.6

Assembling the pressure accumulator

To ensure the safety of the unit, use only genuine Atlas Copco spares.
H coat metal surfaces on the upper and lower shells which come into contact with the diaphragm with Vas
eline or Parker OLube
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 Nm
To 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 57 mm.
H insert new Oring (part 3), screw new filler screw (part 2) loosely into filler adapter
Fill pressure accumulator as described in section 7.

23

5.8

Pressure accumulator 0.5 litres (for use with cooler 0050)

5.8.1

Presentation pressure accumulator

5.8.2

Spare parts list pressure accumulator

Part no.

Part ident. no.

Quantity

Designation

Tightening torque
(Nm)

3360 9802 62

Pressure accumulator

5.8.3

Tools required for dismantling and assembly

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

5.8.5

Checking parts prior to assembly

H does not apply.

5.8.6

Fitting the pressure accumulator

H screw in by hand
H tighten using abovementioned jaw spanner to prescribed tightening torque of 450 " 45 Nm.

24

5.9

Pressure accumulator 1 litre

5.9.1

Presentation pressure accumulator

5.9.2

Spare parts list pressure accumulator

Part no.

Part ident. no.

Quantity

3360 3282 82

Pressure accumulator HP

450 45

3360 3282 83

Pressure accumulator LP

450 45

3360 3282 81

Sealing ring

5.9.3

Designation

Tightening torque
(Nm)

Restrictions on accumulator repair

(applying in Federal Republic of Germany)


No restrictions. Use new pressure accumulators.

5.9.4

Tools required for dismantling and assembly

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

5.9.6

Checking parts prior to assembly

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 abovementioned jaw spanner to prescribed tightening torque of 450 " 45 Nm.

25

6.

Assembling pressure accumulators

The 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 Bautechniks 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 accumulatorrelated 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 noncorrosive washing fluids which effectively
remove any dirt particles, grease and preservation agents adhering to the parts.
After washing, the parts must be blowdried 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.

26

6.2.1

Visual check

This applies to parts such as: caps, upper shells, lower shells, basic bodies on integrateddesign 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.

27

7.

Presentation Accumulator Filling Device and Nitrogen


Bottle

4
5

7.1

Spare Parts List for Accumulator Filling Device

Part No.

28

Designation

Pt. Id.No.

accumulator filling device

3360 9204 15

adapter

3361 3298 89

Phillips driver head

3361 3298 90

Fine adjustment regulator

3360 9204 14

nitrogen bottle

3360 4798 26

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

Filling
pressure
(bar)

40

Hammer
model

HM 12
HM 20

0,25

50

HM 25
HM 32

0,9

60

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

60

HM 7201
HM 7202
HM 1500

1,5

2,0

40

60

60

HM 702
HM 712

HM 901,902
951, 952
9601, 2
1300, 1800
2000, 2100,
2300, 2500,
2600, 3000,
4000

HM 600
LP *

HM 600
HP **

K For attachment to highpressure 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 pressure
accumulator.
From the available or supplied tool box you will require:
nitrogen cylinder with pressurerelief fitting
When filling the pressure accumulator, please observe the diagram below and follow the instructions provided
step by step.

Preparations:
1. Connect pressurerelief fitting (part 8) to nitrogen cylinder. Screw nipple (part 16) of accumulator filling
device onto pressurerelief fitting.
2.

Slide filling device (part 9) onto filler adapter (part 14) of upper shell and screw tight.
(Please note: lefthand 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 pressurerelief fitting and filling device.

4.

Close bleed valve (part 10) on filling device.

5.

Close check valve (part 13) on pressurerelief fitting.

6.

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

29

8.3

Filling the high<pressure accumulator:

7.

Open gas cylinder valve slowly.

8.

Open check valve (part 13) on pressurerelief 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.

11 Socket spanner

13 Check valve

8 Pressurerelief fitting

cylinder valve
10 Bleed valve
16 Nipple
9 Filling device
14 Filler adapter
with filler screw
on accumulator

15 High pressure gauge

12 Connecting hose

30

nitrogen cylinder

Index
A
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 Atlas
Copco 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

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,
12hole) older models, 21
H Pressure accumulator 1.5 litres (flange design,
16hole), 19
H Pressure accumulator 2.0 litres, 22
H Pressure accumulator specifications, 10

R
D
H Dismantling the pressure accumulator, 12 , 18 ,
20 , 23
H Dismantling the pressure accumulator (flange de
sign), 16
H Dismantling the pressure accumulator (integrated
design), 14

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

F
H Filling pressures (gas pretensioning) for pressure
accumulators, 29
H Filling procedure, 29

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

H Filling the highpressure accumulator:, 30


H Filling the pressure accumulator, 29
H Fitting the pressure accumulator, 24
H Function of the pressure accumulator, 7

V
H Visual check, 27

W
L
H List of individual pressure accumulators, 11

H Warranty, 9
H What are hydraulic pressure accumulators and
what do they do?, 7

31

Atlas Copco Construction Tools GmbH


Helenenstrasse 149 S 45143 Essen
P. O. Box 10 21 52 S 45021 Essen
Federal Republic of Germany
Telephone +49 201 633 0
Telefax +49 201 633 2281
Telefax Customers Support +49 201 633 1352
Internet: www.hydraulicattachments.com

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