© 2010 Morath GmbH

Operating Instructions
Doc.-No.: 2200258/1
State 10/10

Operating- and
Maintenance Instructions

Hydraulic hammer
HB70-GD100
HB70-GD100/M2

To read carefully before start-up

DECLARATION OF INCORPORATION
We,

Morath GmbH
Bohrtechnik für Umwelt und Energie
Am Riedbach 7
D-79774 Albbruck-Birndorf

hereby declare that the product listed below,

Design: Hydraulic hammer Brand: Morath

Type: HB70-GD100 Year of manufacture:
Serial-no.:

as supplied by us complies with the following directives:

2006/42 EC Machinery Directive,

The following harmonised standards and technical specifications were applied and observed during the production of the
product:
EN ISO 12100-1, -2 Safety of machinery
DIN EN 982 Safety of machinery; Safety requirements for fluid power systems and their
components - hydraulic

Further national technical regulations were applied and adhered to:

Equipment Safety Act
Requirements of the Equipment Safety Act

The machine is intended to be incorporated into a drill rig. The operation of the machine is forbidden until it is verfied and
certified that the completed drill rig corresponds as an unit to the EC declaration of conformity. This declaration of Incor-
poration is only valid for the machine including specification according to serial number and order number. In case of
substantial modifications of this machine this declaration becomes unvalid. For this machine the relevant technical docu-
mentation is compiled in accordance with Directive 2006/42/EC, part B of Annex VII. In response to a reasoned request
by the national authorities, the relevant technical documentation can be transmitted in a printed version.
The safety instructions of the operational manual are obligating. In case of doubt the german text is binding.

Albbruck-Birndorf, 27.6.12 Franz Morath, Managing Director

Daniel Morath, Managing Director
 Index

Index

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Purpose of this operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Content of these operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Handling of these operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.1 Description of activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.2 Designations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3.3 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Manufacturer’s address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Generell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Use in accordance with regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Generell information on machine safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 Obligations of the plant operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6.1 Working instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6.2 Qualification of the staff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.3 Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.4 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.6.5 Measurements to determine responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6.6 Check up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7 General obligations of the staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8 Location requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.9 Safety equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.9.1 Information, warning and prohibition signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.10 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.10.1 General protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.11 Danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.12 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.12.1 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.12.2 Dust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.13 Drilling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.14 Changes to the hydraulic hammer HB70-GD100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.15 Oils and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Safety regulations . . . . . . . . . . . . .. . .. .. . .. . .. .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1.1 Personnel qualifications . . . . . . .. . .. .. . .. . .. .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1.2 General safety regulations . . . . .. . .. .. . .. . .. .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Loading of the hydraulic hammer . .. . .. .. . .. . .. .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.1 Loading with a crane . . . . . . . . .. . .. .. . .. . .. .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.1 Hydraulic hammer HB70-GD100 / HB70-GD100/M2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.2 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3 Type plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4 Machine data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4.1 HB70-GD100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4.2 HB70-GD100/M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4.3 Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.4.4 Sound power level LWA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2200258/1 5
Index

4.5 Recommended operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5 Installation / Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

5.1 Initial commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6 Operation of the hydraulic hammer HB70-GD100 . . . . . . . . . . . . . . . . . . . . . . .39

6.1 Requirements for operating personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 39
6.2 Hydraulic hammer mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 40
6.3 Change shank adaptor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 41
6.4 Reversing valve HB100-GD100/M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 44
6.5 Hydraulic hammer demounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 44
6.5.1 Greasing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 45
6.6 After end of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. . .. .. . ..... 45

7 Settings and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.2.1 Qualification of the employed staff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.2.2 General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.2.3 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.3 Change gearing oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.4 Hammer mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.4.1 Maintenance and fillung of the hydraulic accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.5 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.5.1 Explanation to the maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.5.2 Regular maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.5.3 Maintenance weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.5.4 Maintenance every 6 month . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.6 Qick overview of the maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.7 Maintenance record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

8 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

9 Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

6 2200258/1
 General
Purpose of this operating manual 1
1 General
© 2000 MORATH GmbH
These operating instructions are protected by copyright, all usual
rights reserved. Duplication of these operating instructions, either
in full or as excerpts, is only allowed with the express approval of
the MORATH Company. Non-compliance results in the obligation to
pay damages, and may also lead to prosecution. All rights reserved
in the case of patents being granted or utility models being
registered.
We reserve the rigth to make technical modifications without notifi-
cation.

1.1 Purpose of this operating manual

This operating manual is part of the documentation for the

MORATH scope of supply and contains important details in order to
operate the machine safe,appropriate and economical. The obser-
vance helps to avoid dangers, reduce costs of repair and down
times and to increase reliability and lifetime of the machinery.
This operating manual is addressed to the customer of the machine
and exclusively appointed for the operator and staff.
This operating manual has to be completed by the operator on the
basis of present national directions in regard to safety at work,
healts protection and protection of envrionment.
The operating manual has to be kept at the place of installation.
The operation manual must be read and understood by all opera-
tors which are charged with the following jobs to operate the
machine:
operating the machíne inclusive setting up (Assembling)
trouble shooting during operation
maintain and disposal of agents and auxilliary products
maintenance (servicing, upkeeping)
transport

Especially to respect:
chapter SECURITY
safety instructions of all chapters

If unclarities please contact the MORATH Service Department

2200258/1 7
1 General
Content of these operating instructions

1.2 Content of these operating instructions

No. Section Contents

1 GENERAL Information on the use of these operating instructions

2 SAFETY General safety information

3 TRANSPORT Information regarding the transport of the machine

4 TECHNICAL DATA Technical data and operating media

5 INSTALLATION / COMMISSIONING Preparation for operation

6 OPERATION Operation

7 SETTINGS AND MAINTENANCE Maintenance schedules and information on care and

maintenance

8 GLOSSARY Index

9 ATTACHMENT
Tabelle 1: Overview of sections and contents

1.3 Handling of these operating instructions

1.3.1 Description of activities

Activities, which must be performed in several steps, are preceeded
by a number, e.g.:
1. Release of the locking mechanism (spring lock),
2. Swivelling of the support into position,
3. Engagement of the locking mechanism.

1.3.2 Designations
Proper names and reference to other passages in the text are rep-
resented in capital letters, e.g.
“Please observe the information in the SAFETY section!“

8 2200258/1
 General
Handling of these operating instructions 1
1.3.3 Pictographs
In these operating instructions you will find information marked
with symbols. The meaning of these symbols is described below.

Sign for general danger. This symbol appears particularly in con-

junction with safety instructions.

Additional information on correct working with the machine,

useful application tips,
additional information.

Wear a safety helmet!

Wear ear protection!

Wear protective gloves to protect you against cuts!

Wear protective shoes with penetration protection and steel cap!

Wear a dust mask to protect you against respiratory deseases!!

2200258/1 9
1 General
Abbreviations

1.4 Abbreviations

The following abbreviations are used in these operating

instructions:

Abbreviations Meaning
e.g. for example

if app. if applicable

poss. possibly

approx. approximately

min. minimum, at least

max. maximum

perm. permissible
Tabelle 2: Abbreviations

1.5 Warranty and liability

Our "General Conditions of Sale and Supply" generally apply.

Warranty and liability claims for personal injury and damage to
property are excluded by MORATH if they are due to one or more of
the following causes:
improper use of the machine (see section 2.3 USE IN
ACCORDANCE WITH REGULATIONS ON PAGE 13),
incorrect installation, commissioning and operation of the
machine,
operation of the machine with safety equipment that has not
been properly fitted or which is not functioning correctly,
non-observance of instructions, directions and prohibitions in
the operating instructions,
unauthorised structural alterations to the machine,
unauthorised alterations to the control systems,
inadequate monitoring of machine parts that are subject to
wear,
improper or late performance of repair work.

10 2200258/1
 General
Manufacturer’s address 1
1.6 Manufacturer’s address

Company
Morath GmbH

Bohrtechnik für Umwelt und Energie

Am Riedbach 7

D 79774 Albbruck-Birndorf

Tel. 07753 93 96 0

Fax 07753 93 96 69

www.morath.eu

email: info@morath.eu

2200258/1 11
 Safety
Generell 2
2 Safety

2.1 Generell

This chapter contains safety instructions which have to be

considered carefully for operating and maintenance of the machine.
This operating manual contains further safety instructions in other
chapters which have to be considered carefully. Those indications
preceed the activities. Read the safety instructions carefully before
starting.
Supplier safety indications you will find with the appropriate
supplier documentation. Consider those indications as well.
Ignoring safety indications may cause serious or lethal injuries to
persons, in some cases death damage to property and damage to
the invorinment.

2.2 Warnings

The warnings in these operating instructions are marked with a

danger symbol. Below this symbol is a signal word that points out
the degree of danger involved. Please observe the measures
described for the prevention of hazards.

This symbol indicates an immediate threat to

human life or health.

DANGER! Failure to observe such instructions can result in severe

damage to health up to life-threatening injuries.

This symbol indicates a dangerous situation.

Failure to observe such instructions has slight to moderate

effects on health and/or may result in damage to property
CAUTION! and to the environment.

2.3 Use in accordance with regulations

The use of the hydraulic hammer HB70-GD100 is only

permissible with a MORATH-drilling unit. Any other use requires the
permit of MORATH GmbH. The hammer is usable for blast hole-
and anchor drilling in fields and mountains, on buildings and in all
areas
injections in brickworks or subsoil are required.
The hammer may only be operated by Morath technicians or by
qualified staff, trained by Morath.

2200258/1 13
2 Safety
Improper use

2.4 Improper use

Any use other or beyond that described in USE IN ACCORDANCE

WITH REGULATIONS shall be deemed to be used in contravention
of regulations.
The hydraulic hammer HB70-GD100 may not be used in explosible
athmospheres.

2.5 Generell information on machine safety

The machine has been constructed in accordance with the state of

the art and with recognised technical safety rules. Its use may
nevertheless create hazards to life and limb of the user or third
parties or lead to impairment of the machine or other assets. The
machine may only be used in technically perfect condition, paying
attention to safety and danger aspects. This presupposes that the
machine is serviced and maintained in accordance with the
specifications. Any changes on the machine must be immediately
remedied. This particularly applies to changes impairing personal
safety and material protection.

2.6 Obligations of the plant operator

2.6.1 Working instructions

The operator provides working instructions for the operating staff
which grant a safe operating of the machine.
Further the legal regulations in regard to safety at work, health
protection and protection of environment of the home countries
have to be considered.
The operating manual has to be amended by appropriate
instructions e.g.
working instructions
duty of supervision and reporting obligation
work flow
staff in charge
emergency call number, steps and measures for rescue and
first aid

Emergeny call numbers have to be placed on adequate places.

14 2200258/1
 Safety
Obligations of the plant operator 2
2.6.2 Qualification of the staff
The machine may only be operated and maintained by qualified and
instructed staff, authorized by the responsible persons. The job
specifications are described at the beginning of the relative chapter
of the operating manual.
The legal minimum age must be respected.
Apprentices or trainees may only operate the machine under
supervision of an experienced person.

2.6.3 Instruction
The operating- and maintenance staff will be instructed by qualified
persons on the part of the manufacturer.
The customer commit itself to instruct new staff on the same base
and with the same care in the operating- and maintenance of the
machine considering all safety instructions.
The staff have to be instructed especially in
dangers to safety and health during work
protective measures against accidents
handling of hazardours substances
wear individuel protective clothing

during operation and maintenance of the machine.

Before starting work, persons in charge of assemblage, operating
and maintenance, have to read and understand the instructions,
especially of Chapter Safety, the safety instructions of the supplier
components and safety references for the analogical operations.
The staff should confirm the knowledge in written.
The safety references are especially important for persons who are
working on the machine only casually.

2.6.4 Equipment
The staff must be equipped with the neccessary resources:
individual protectice clothing
appropriate equipment for maintenance

2200258/1 15
2 Safety
Obligations of the plant operator

2.6.5 Measurements to determine responsibility

commitment to responsibility to operate the machine
commitment to responsiblity for an ecological disposal of
agents, auxilliary products and replaced parts.

2.6.6 Check up
The customer is obliged to check regularly whether his instructions,
how to operate the machine, are followed. This is for:
qualification of the staff
not qualified staff have to be kept away
the operating manual must be placed at/near the machine
knowledge of the safety instructions according operating
manual and other instructions
wearing of individual protective clothes
keeping the recommended periods for maintenance

16 2200258/1
 Safety
General obligations of the staff 2
2.7 General obligations of the staff

The following safety instructions apply for all persons working at or

on the machine, in order to avoid personal injury and damage to
property:
Observe the advises in the operating manual of the
hydraulic hammer HB70-GD100 and of the carrier.
Assemble properly the hammer.
Only work with a safe and functional machine.
The operator must have the required qualification for the
efficiency of the machine and the understanding for a correct
use and the danger of a wrong operation, or working under
supervision of a qualified instructor.
In the event of dysfunctions, immediately stop the machine
and fuse. Report any faults and remedy defects immediately.
Refrain from any working procedure if its safety is questio-
nable.
Third parties have to be kept away. Block working area.
Do not bypass, dismantle or disconnect safety equipment.
Safety equipment protects the operator.
Before each start-up, make sure there are no persons within
the danger zone.Bursting of parts of the drill cuttings may
cause injuries..
In case of dust formation, use an exhaust device to avoid
health damages.
During horizontal or overhead drilling care in regard to
falling material.
During overhead drilling make sure that the outcomming drill
cuttings ist not hammer depositing or taking in.
Disregard may cause heavy machine damage.
Do not touch rotating parts and do not reach over them.
Never wear loose clothing, parts of can be easily caught
hammer. This can lead to life-threatening injuries.
If any oil leakage, stop machine immediately and remedy
defect. Oil can penetrate skin. In this case, seek medical
assistance immediately.
Keep the operator areas and the access to them clear of
tools, auxiliary equipment and other objects.
Never leave the hammer unsupervised as long as in opera-
tion.
Never do any inspection tasks, cleanings, changings of shank
adaptors or uncouplings of hoses, during connection of the
hammer to the hydraulic driven group, as an unintended
actuation of the hammer may cause serious damages.
Only use spare parts which are accepted by MORATH GmbH.
Make sure that the hoses are mounted correctly. Before con-
necting, clean all couplings.
The flushing head must always be in a proper condition as
outflowing suspensions may cause damages to persons.

2200258/1 17
2 Safety
Location requirements

Befor coupling or uncoupling the hydraulic hoses, always

clause the energy supply. Otherwise the quick couplings can
be damaged or the hydraulic circuit overheated.
Connect hoses and check all quick couplings in regard to
density always before switching on the energy source.
Do not work with the hammer if the oil temperature exceeds
70 C°. If the hammer is operated at higher temperatures,
the hammer can be damaged due to lower
lubricating quality. Furthermore, there is a risk of burning due
to the hot surfaces.
The operator must be exceedingly careful in all difficult
operating areas e.g.steep slopes, uneven grounds.
Wear personal protective equipment(see section 2.10 PER-
SONAL PROTECTIVE EQUIPMENT ON PAGE 20).
For the avoidance of personal- and machine damages,
maintenance work should only be done by qualified and
authorised staff.
Make sure that labels and warning labels of the machine are
readable.

2.8 Location requirements

For the sake of the safety of the operating staff and the avoidance
of property and environmental damage, it is necessary to inspect
the operating location for its suitability. The suitability of the
operating location is determined by the person responsible (e.g.
site manager).
This includes:
the inspection of the load-bearing capacity of the floor,
making sure the substrate is firm,
the inspection of the operating location for gas, water and
electrical lines using diagrams or appropriate locating
equipment,
sufficient illumination of the working area with a light
intensity of at least 100 lux in enclosed areas.
the reliable provision of a sufficient fresh air supply in
enclosed areas.

18 2200258/1
 Safety
Safety equipment 2
2.9 Safety equipment

2.9.1 Information, warning and prohibition signs

Observe the stated safety advices for your own safety.
The safety advice shows possible hazards. In same time it contains
instructions how the hazards can be avoided by correct handlings.
You find safety advices always on that positions, where the dangers
may occur.
The following symbols are used in this operating manual:

Please carefully read the operating instructions before beginning

any work on or at the hydraulic hammer!

Keep away from rotating parts. There is a danger that you will be
caught and drawn in.

Keep at a safe distance away from live lines.

Hook the machine lifting equipment into the lugs marked for this
purpose. Observe the load-bearing capacity of lifting accessories.

It is strictly prohibited to stay within the danger zone.

Wear a safety helmet when working on or with the hydraulic ham-

mer.

2200258/1 19
2 Safety
Personal protective equipment

2.10 Personal protective equipment

2.10.1 General protective equipment

Personal protective equipment must be worn when working on the
hydraulic hammer HB70-GD100:

1001496

Bild 1: Required protective equipment

Wear a safety helmet to protect you against falling objects

and concussion.
Wear protective shoes with penetration protection to protect
you against falling objects and sharp objects jutting out of
the ground.
Wear safety goggles to protect you against drilling dust and
stone splitters.
Wear ear protection to protect you against damage to your
hearing.
Wear safety gloves to protect you against cuts.
Wear a dust mask of at least protection class P2 to protect
you against respiratory diseases.

In addition, protect yourself by:

refraining from wearing jewellery such as watches, rings,
necklaces and bracelets to avoid accidents,
taking off items of clothing such as ties, neckerchiefs, scarves
etc., before beginning work,
wearing tight-fitting clothing and fastening your jacket.

20 2200258/1
 Safety
Danger zones 2
2.11 Danger zones

The hydraulic hammer HB70-GD100 has been constructed in accor-

dance with the state-of-the-art technology and the recognised tech-
nical specifications. However, dangers that cannot be eliminated
may still occur during operation. The following picture shows areas
of the machine which may pose personal danger if the operator is
inadvertent.

2
1

1015298

Bild 2: Danger zones at the hydraulic hammer HB70-GD100

Item Danger zones Danger Safety Instructions

1 rotating parts Danger of injury by catching During drilling, stay out of the danger
(drilling tubes/drilling zone. wear tight fitting clothes. Close
anchors) open coats.

2 percussive parts (dril- Danger of violent pressure During drilling, stay out of the danger
ling rods/anchors) zone.

3 complete hammer Danger of burning Do not touch the hammer during and
after drilling works.

4 Hydraulic lines Danger of bursting Keep a sufficient safe distance to the

pressure lines and hoses
Leackages

5 Suspension hose Danger of bursting Keep a sufficient safe distance to the

pressure lines and hoses
Tabelle 3: Danger zones at the hydraulic hammer HB70-GD100

2200258/1 21
2 Safety
Emissions

2.12 Emissions

2.12.1 Noise
Continuous sound pressure level of the hydraulic hammer HB70-
GD100: (see section 4.4.4 SOUND POWER LEVEL LWA ON
PAGE 34).

2.12.2 Dust
A great deal of dust may arise during drilling work. The operating
staff must therefore be protected by appropriate safety equipment
or other measures.

2.13 Drilling Equipment

The drilling equipment must be suitable and safe for the intended
type of application and the corresponding method. Please observe
the instructions of the respective manufacturer.
Please observe the permissible drilling diameters and total drilling
depths. Adhere to the prescribed drilling speeds and working pres-
sures.
When using other drilling equipment - e.g. high-pressure injection
method – an arresting device must be available as protection
against the automatic release of hoses.

2.14 Changes to the hydraulic hammer HB70-GD100

Changes to the hydraulic hammer HB70-GD100 require the written

approval of the MORATH Company. This applies:
alterations to the machine
attachments and conversions of the machine
welding on load-bearing parts
Changing from one drilling process to another

2.15 Oils and lubricants

The relevant product safety regulations must be followed when

handling oils, greases or other chemical substances.
Particular attention must be paid to health protection, accident
prevention and environmental protection when selecting these
substances. Appropriate skin protection must be provided when
handling aggressive substances. The necessary skin protection can
be found in the manufacturer’s information.
Corresponding disposal regulations must be observed.

22 2200258/1
 Safety
Oils and lubricants 2
Hydraulic oils and lubricants on the floor and on machine parts can
easily lead to slipping. They therefore pose a substantial risk of
injury. Therefore, for accident prevention reasons – and for the
sake of environmental protection – please pay attention to
cleanliness when handling these fluids.

2200258/1 23
 Transport
Safety regulations 3
3 Transport

3.1 Safety regulations

DANGER TO LIFE!

By non-observance of safety regulations.

DANGER!
Non-observance of the following instructions leads to danger to the
life of all those involved in the transport and others.

Make absolutely sure to adhere to the instructions!

3.1.1 Personnel qualifications

Loading and unloading of the machine by means of a lifting device
must only be performed by persons who are particularly acquainted
with such work.

3.1.2 General safety regulations

The relevant accident prevention regulations (VBG 9 / 9a) and road
traffic regulations (StVO) must be observed.

DANGER TO LIFE!

Due to falling loads.

DANGER!
Never under any circumstances move underneath suspended
loads.
Make sure that there are no persons standing underneath
suspended loads.

Staying below suspended loads poses a risk of death and is

therefore strictly forbidden.

2200258/1 25
3 Transport
Loading of the hydraulic hammer

3.2 Loading of the hydraulic hammer

3.2.1 Loading with a crane

Procedure
1. Before transport detach the hydraulic hoses or detach from
quick couplings.
2. Close open screwings and hose ends with a dummy plug.
3. During loading, observe the weight of the HB70-GD100.
(approx. 110 kg.)Use a lifting platform with suitable belts pic-
ture 3 on page 26.
4. Operators must lift and set down loads such that accidental
falling over, falling apart, sliding or rolling off are avoided.
5. Transport machine horizontally.
6. Secure the machine on the transport (e.g. truck, low-trai-
ler...) using chains, lashing straps or other suitable lashing
means against slipping.

1015024

Bild 3: Loading of the hydraulic hammer

26 2200258/1
 Technical Data
Hydraulic hammer HB70-GD100 / HB70-GD100/M2 4
4 Technical Data

4.1 Hydraulic hammer HB70-GD100 / HB70-GD100/M2

22
23

P 13 14 T

12
11
10
9
8 15
7
6 16
5 17
4

3
18
2

1
19
20
21
1017295

Bild 4: System sub-assemblies

Item Description Item Description

1 Shanks 13 P-Line to the hammer mechanism
(hammer) (P=pump connection)

2 Greasing line (flushing housing) 14 T-Line to the hammer mechanism

(hammer) (T=tank connection)

3 Greasing line (flushing head) 15 Hammer

mechanism

4 Hose connection for mortar, air and 16 Lines-drive motor (turning)

water
(HB70-GD100/M2)

5 Flushing head 17 Drive motor (oil motor)

Tabelle 4: System sub-assemblies

2200258/1 27
4 Technical Data
General description

Item Description Item Description

6 Greasing line (flushing head) 18 Lines-drive motor (turning)

7 Flushing housing 19 Gearing

8 Greasing line (flushing housing) 20 Lines-drive motor (turning)

(HB70-GD100/M2)

9 Type plate 21 Drive motor (oil motor)

(HB70-GD100/M2)

10 Lines-drive motor (turning) 22 Adaptor set

11 Feed lines rotary drive (A+B) 23 Hydraulic accumulator of the hammer

mechanism
(HB70-GD100/M2)

12 Reversing valve
(HB70-GD100/M2)
Tabelle 4: System sub-assemblies

4.2 General description

The HB70-GD100/M2 is a hydraulic, radio

controlled hydraulic hammer and consists of gear (19), a hammer
mechanism (15) and a drive motor (17+21).
Mounted on the gear is the deposit housing (7) with integrated
flushing head (5) and shank adaptor (1) for the drilling anchor.
The connection for the suspension (mortar) (4) is based laterally at
flushing housing.
The hydraulic hammer works with two hydraulic circuits; rotating
mechanism and hammer mechanism. A high hydraulic
pressure accumulator is integrated in the hammer mechanism. The
hydraulic accumulator is filled with nitrogen.
The lubrication of the shank adaptor is realised by a separate lubri-
cator mounted on the carrier unit. When using the hydraulic
hammer the lubricator is automatically started.

28 2200258/1
 Technical Data
Type plate 4
4.3 Type plate

The type plate is fixed on the upper part of the gearing.

Bohrtechnik für Umwelt und Energie

D-79774 Albbruck-Birndorf
Tel. 07753-9396-0

3 4
Typ Gewicht
2 SN-Nr. Baujahr
5
I: 9002855

1015028

Bild 5: Type plate

1 Gear transmission
2 Serial number
3 Type description
4 Weight
5 Year of construction

2200258/1 29
4 Technical Data
Machine data

4.4 Machine data

4.4.1 HB70-GD100

A B
D1

C
D

E1
B1

C1
F E
A1

1017289

Description Value
Type HB70-GD100

Dimensions

A / A1 934 / 135,5 mm

B / B1 330 / 290 mm

C / C1 236 / 20 mm

D / D1 115 / 121 mm

E / E1 22,5 / 35,5 mm

F Flusher G 3/4“i., UM38

total weight 105 kg

Tabelle 5: Machine data

30 2200258/1
 Technical Data
Machine data 4
Description Value
Oil motor

possible types TE080 TE100 TE130 TE195

max. operating pressure 200 200 200 200

[bar]

max. absorption capacity 60 60 60 60

[l/min]

max. torque [Nm] 697 837 1.116 1.671

max. speed [1/min] 219 184 138 92

Tabelle 6: Machine data

Description Value
Shanks
D 63 mm Titan 30/xx,
Titan 40/xx,
Titan 52/xx
R25, R32, R38, T38, T45
D 100 mm Titan 52/xx
Titan 73/xx
Titan 103/xx
R51,R76, T76, API 2 3/8“

Hammer mechanism

hammer mechanism type MH70

max. operating pressure 180 bar

max. impacts 3.300 1/min.

max. impact energy 110 Joule

Oil flow 28-40 l/min.

max. oil temperature 70 C°

max. backpressure recirculation 5-10 bar

Tabelle 7: Machine data

2200258/1 31
4 Technical Data
Machine data

4.4.2 HB70-GD100/M2

A B
D1

C
D

E1

C1
F B1
E
A1

1017290

Description Value
Type HB70-GD100/M2

Dimensions

A / A1 935 / 136 mm

B / B1 330 / 290 mm

C / C1 320 / 20 mm

D / D1 115 / 205 mm

E / E1 22,5 / 35,5 mm

F Flusher G 3/4“i., UM38

total weight 113 kg

Tabelle 8: Machine data

32 2200258/1
 Technical Data
Machine data 4
Description Value
Oil motor

possible types 2xTE080 2xTE100 2xTE130 2xTE195

max. operating pressure 200 200 200 200

[bar]

max. absorption capacity 60 60 60 60

[l/min]

max. torque [Nm] 1. Gang 1.395 1.674 2.232 3.341

2. Gang 697 837 1.116 1.672

max. speed [1/min] 1. Gang 109 92 69 46

2. Gang 219 184 138 92
Tabelle 9: Machine data

Description Value
Shanks
D 63 mm Titan 30/xx,
Titan 40/xx,
Titan 52/xx
R25, R32, R38, T38, T45
D 100 mm Titan 52/xx
Titan 73/xx
Titan 103/xx
R51,R76, T76, API 2 3/8“

Hammer mechanism

hammer mechanism type MH70

max. operating pressure 180 bar

max. impacts 3.300 1/min.

max. impact energy 110 Joule

Oil flow 28-40 l/min.

max. oil temperature 70 C°

max. backpressure recirculation 5-10 bar

Tabelle 10: Machine data

2200258/1 33
4 Technical Data
Recommended operating media

4.4.3 Environmental conditions

Description Value
Temperature range -20 bis +45 °C

Location illumination min. 100 Lux

Tabelle 11: Environmental conditions

4.4.4 Sound power level LWA

Description Value
Sound level (LPA) 1 m 96 dB

Sound power level (LWA) guaranteed 108 dB

Tabelle 12: Sound power level

4.5 Recommended operating media

DANGER TO HEALTH!

Due to incorrect handling of operating media.

CAUTION!
Please observe the regulations for health and environmental protec-
tion when handling operating media.

Non-observance can cause damage to your health and the environ-

ment.

The safety and health protections regulations must also be obser-

ved when handling operating media.
Safety data sheets regarding the operating media must be obtained
from the manufacturer/supplier of the operating media.

ENVIRONMENTAL DAMAGE!

Due to incorrect handling / disposal of operating media.

CAUTION!
During operation and maintenance of the machine, oils and other
environmentally harmful substances must under no circumstances
penetrate the soil, groundwater or wastewater systems.

34 2200258/1
 Technical Data
Recommended operating media 4
Usage Capacity Operating medium Notes
Hydraulic system SHELL Tellus TD46 The use of bio-oil (e.g. Panolin
[Art.No. 5003109] HLPSYNTH46F) is only permitted
Panolin HLPSYNTH46F after MORATH has given its
[Art.No. 5009248] approval..

Gearing 0,5 l SHELL Alvania

GL00
[Art.No. 5011104]

Lubrication system as required Multi-purpose grease, with EP- Multi-purpose grease NLGI
Additiv: class 2
Lagermeister WHS2002
[Art.No. 5010956]

Hammer 90 bar Nitrogen N2 (filling gas) only use pure nitrogen

mechanism
Tabelle 13: Recommended operating media

2200258/1 35
 Installation / Commissioning
Initial commissioning 5
5 Installation / Commissioning

5.1 Initial commissioning

Start-up of the hydraulic hammer to be carried out by a

service technician trained by MORATH GmbH.

5.2 Installation

Before setting up the job site, convince yourself that the operating
location enables safe operation.
This includes:
the procurement of drawings, indicating water, wastewater,
gas and electrical cables,
taking into account of special requirements, e.g. with regard
to environmental protection, noise emission, water protection
area, exhaust gas post-treatment,
adequate clearance to edges posing a risk of falling,
the load-bearing capacity of the ground (e.g. boggy ground,
cavities),
sufficient illumination of the operating location with a light
intensity of at least 100 Lux in enclosed areas (cellars,
tunnels),
sufficient ventilation of the operating location in enclosed
areas (cellars, tunnels),
that sufficient space remains for escape routes in the event
of an emergency,
that sufficient clearance from high-voltage overhead power
cables including a safety margin is given to avoid sparking.

The hydraulic hammer may only be mounted on mounting

elements of the MORATH company.

2200258/1 37
5 Installation / Commissioning
Commissioning

5.3 Commissioning

Before the beginning of each shift, convince yourself of the proper

condition of the hydraulic hammer and the power station. You will
find additional information on the checks listed below in the corres-
ponding sections.
Check:
the function of all safety equipment (see section 2.9 SAFETY
EQUIPMENT ON PAGE 19)
the perfect condition of all pressure hoses, cables and
connections,
the leak tightness of all oil-conducting components,
the completeness and legibility of the stickers attached to the
hydraulic hammer,
the level of the hydraulic oil tank,
Wear protective clothing (see section 2.10 PERSONAL PRO-
TECTIVE EQUIPMENT ON PAGE 20).

38 2200258/1
 Operation of the hydraulic hammer HB70-GD100
Requirements for operating personnel 6
6 Operation of the hydraulic hammer HB70-GD100

6.1 Requirements for operating personnel

Only persons must be charged with the independent operation of

the drilling crawler, who:
who are physically and mentally suitable for the job,
who have been instructed in the operation of the hydraulic
hammer HB70-GD100 by the Morath Company and have pro-
ven this capability to the plant operator,
and who can be expected to reliably fulfil the tasks charged
to them.

They must be charged by the company with the operation of the

drilling unit.

Hydraulic lines and grouting hose may be under

pressure

CAUTION! Before mounting or demounting the hydraulic pipe

check the following:

Shut off the drive of hydraulic hammer HB70-GD100 (power

station) .
Remove ignition key in order to relieve the line pressure.
The remaining line pressure can be relieved as follows:Move
operating lever of the remote- or manual control
repeatedly in both directions and again
bring it into central position

Before mounting or demounting the grouting hose, check

the following.

External equipment such as; injection pump, water pump or

compressor, shut them down and fuse against restart and
relieve pressure.

2200258/1 39
6 Operation of the hydraulic hammer HB70-GD100
Hydraulic hammer mounting

6.2 Hydraulic hammer mounting

Procedure
1. Place the mast, is possible, horizontally.
2. Move the hydraulic hammer by means of a lifting device on
the saddle.
3. Fix the hydraulic hammer with mounting angles or by the
provided impact key on the saddle.
4. Connect the greasing lines.
5. Connect the feed line A+B to the drive motor.
6. Connect the tank and pressure lines to the hammer mecha-
nism.
7. Connect the injection station.
8. Again check the connectings of the lines and the fixings of
the hydraulic hammer.

At wrong rotation direction, both feed lines A+B can be as

well interchanged.

CAUTION!

Immediately prior to start the machine, safety checks are

necessary.
Check:
Hydraulic hoses and lines in regard to density, tightness and dama-
ges.

40 2200258/1
 Operation of the hydraulic hammer HB70-GD100
Change shank adaptor 6
6.3 Change shank adaptor

1017282

Bild 6: Change shank adaptor

1 Shank adaptor deposit
2 Screws
3 Shank adaptor

Detach the 4 screws (2) of the shank adaptor deposit

2200258/1 41
6 Operation of the hydraulic hammer HB70-GD100
Change shank adaptor

1 2 3 4 5 6 7 8

9
1017283

Bild 7: Change shank adaptor

1 Housing
2 Impact ring
3 rubber ring
4 Housing
5 Flushing ring
6 Rubber ring
7 Housing
8 Screw with spring washer
9 Shank adaptor

Dismantle the shank adaptor deposit. Change shank adaptor (9).

Check sealings and guiding rings of the flushing ring and as well
theguiding rings and scraper of the deposit housing in regard to
wear and replace if necessary.
Check the rubber rings and the impact ring in regard to wear and
replace if necessary.

42 2200258/1
 Operation of the hydraulic hammer HB70-GD100
Change shank adaptor 6

1 2 3 4 5
1017284

Bild 8: Change shank adaptor

1 Shank adaptor
2 Impact ring
3 Rubber ring
4 Housing
5 Rubber ring

Put the shank adaptor (1), impact ring (2) rubber ring (3) housing
with flushing ring (4) and the rubber ring (5) together. In order to
ensure a safe operation, follow each of these stages in turn.

1017285

Bild 9: Change shank adaptor

Bolt together the housing by means of the 4 screws.

2200258/1 43
6 Operation of the hydraulic hammer HB70-GD100
Reversing valve HB100-GD100/M2

6.4 Reversing valve HB100-GD100/M2

If the gearing of the hammer is equipped with two oil motors, than
the gearing step can be switched by means of the reversing valve.
In 1st gear the oil motors are connected parallely, thereby a higher
torque is reached at in same time lower rotational speed.
In 2nd gear the oil motors are switched in series whereby a higher
rotational speed is reached at in same time lower torque.
Due to the switchable gear stages the rotational speed and torque
of the hydraulic hammer can be optimally adapted to the required
case of application.
The reversing valve is electriclly or manually operated - depending
type of set up - at an operating voltage of 12 or 24 V.

6.5 Hydraulic hammer demounting

Before dismantling safe the hydraulic hammer by means of

a lifting device and tensioning belts against falling down.

CAUTION!

Collect possible out flowing oil with a suitable vessel and discharge
according the national environmental regulations.

44 2200258/1
 Operation of the hydraulic hammer HB70-GD100
After end of operation 6
Procedure
1. Place the mast horizontally and if possible above the hydrau-
lic oil tank level.
2. Shut off the power station and remove ignition key
3. Relieve the hydraulic oil tank by opening the filler cap on the
hydraulic oil tank.
4. Relieve all lines from pressure before dismantling them. Turn
the screw nut one rotation and tap with the screw-wrench
slightly against the screwing to loosen the conical fixing (this
is a further checking in regard to possible remaining pressure
in the lines).
5. Unscrewing lines:
- greasing lines of the greasing oil distributor
- feeding lines A+B of the driving motor
- pressure- and tank line of the hose fixed point
- mortar hose of the deposit house and hose fixed point
6. After unscrewing close all line ends and greasing oil distribu-
tor with a dummy plug. Prevent the entrance of dust and
dirt.
7. Unscrew mounting angles and detach the hydraulic hammer
by means of a lifting device

6.5.1 Greasing device

The greasing system serves for the lubrication of the shank adapter,
based in the gearing. Depending on the type of the carrier, an elec-
tric, hydraulic or manually driven Greasing pump is used.

The greasing system must allways be filled with grease.

The the hydraulic hammer may not be operated without
lubrication

CAUTION!

6.6 After end of operation

PROPERTY DAMAGES!

If the injection works are finished or stopped for a longer

period of time, the hydraulic hammer HB70-GD100 must be
CAUTION! immediately cleaned with water or a steam jet to prevent
the mortar from hardening.

2200258/1 45
6 Operation of the hydraulic hammer HB70-GD100
After end of operation

PROPERTY DAMAGES!

On the housing under-side is a relief notch (1). This notch

must be sealed before starting the cleaning process.
CAUTION! No dirt may enter into the hydraulic hammer.

1017291

Bild 10: HB70 - Gearing relief nut

1 Relief nut

46 2200258/1
 Operation of the hydraulic hammer HB70-GD100
After end of operation 6

1 2

1017292

Bild 11: HB70-GD100 - Cleaning

1 shank adaptor
2 Hose connection for mortar, aif and water

Procedure
1. Run water through the injection hose (2) as long as at the
end only clear water flows out of of the shank adaptor (1).
2. Unscrew the injection hose (2) .
3. Clean again the shank adaptor (1) and the hose connection
thoroughly with a steam jet as no any mortar remains.
4. Clean the hydraulic hammer of all dirt.

2200258/1 47
 Settings and Maintenance
General 7
7 Settings and Maintenance

7.1 General

All activities and schedules in this section of these operating

instructions must be adhered to. This particularly applies to:
settings,
maintenance,
replacement of parts and partial equipment.

The Morath GmbH disclaims any and all warranties or

gesture of goodwill if not exclusively Morath original parts
or components are used. This includes as well wear parts
and shank adaptors and other.

The MORATH company will be pleased to assist you in matters of

trouble shooting, extensive maintenance and repair work or accom-
plishment.

7.2 Safety

The following sections contain safety instructions for maintenance

work. In addition, the section SAFETY and all valid laws and
regulations pertaining to safety when performing the following
activities shall apply.

OBSERVE THE SAFETY AND ACCIDENT

PREVENTION REGULATIONS!

DANGER! All valid safety and accident prevention regulations of the country
of operation and other regulations valid for the plant operator must
be observed and adhered to. The plant operator is responsible for
the observance and procurement of the valid regulations and
corresponding documents.

For the maintenance of accessories or components not sourced

from the MORATH Company, please refer to the relevant technical
documentation of the respective component.

2200258/1 49
7 Settings and Maintenance
Safety

7.2.1 Qualification of the employed staff

MAINTENANCE BY SUITABLE PERSONNEL ONLY!

The performance of maintenance work by unqualified

personnel leads to unpredictable risks.
DANGER!

Servicing and maintenance work may only be carried out by

sufficiently qualified personnel.

In case of disregarding the instructions for maintenance

work - according maintenance schedule - no warranty will
be granted.

The following qualifications are required:

Good mechanical knowlegde, such as is acquired during an
appropriate apprenticeship.
Knowledge of the maintenance and care of special machines
and vehicles.
Safety instruction and maintenance training by MORATH
Company.
Special knowledge and experience in the respective field are
required for work on hydraulic or pneumatic systems.

50 2200258/1
 Settings and Maintenance
Safety 7
7.2.2 General safety information
Never carry out servicing and maintenance work when the
machine is in operation. Secure the drilling crawler against
inadvertent switching on.
For safety reasons, only spare parts must be used and
installed, which have been manufactured or approved by the
MORATH Company.
The procedures for switching on and off must be observed
for all tasks related to inspection, maintenance and repairs.
Equipment subject to tests must be re-tested if required.
Assembly above body height may only be performed using
safety-tested climbing aids and working platforms. Machine
parts must not be used as climbing aids. When working at
great heights, safety-tested protection against falling must
be used.
Keep all handles, steps, rails, landings, platforms and ladders
free from dirt and lubricants.
Suitable workshop equipment is absolutely necessary for car-
rying out maintenance work.
After completion of the maintenance and repair work, loose-
ned screw connections must always be firmly tightened. Fur-
thermore it must be observed that all locked suction, tank
and pressure lines are returned to their original operating
condition.

7.2.3 Safety equipment

DANGER TO LIFE!

Due to incomplete or faulty safety equipment.

DANGER!
There is danger to the life of the operator, if protective guards and
safety equipment is not fully installed again after inspection, main-
tenance and service work.

Protective guards and safety equipment must be fully re-installed

and checked for function immediately after completion of the work.
Operation of the machine only with complete and fully functional
safety equipment!

Procedure
1. For cleaning use a steam jet or a common water jet.

2200258/1 51
7 Settings and Maintenance
Change gearing oil

7.3 Change gearing oil

6
1017294

Bild 12: Change gearing oil

1 Plug
2 Air discharge screw
3 Alu-ring
4 Oil level eye Maximum
5 Oil level eye Minimum
6 Magnetic plug with Alu-ring

Change gearing oil at the latest every 6 months. In case of

heavy use and operation, optionally earlier.

52 2200258/1
 Settings and Maintenance
Hammer mechanism 7
Procedure
1. Demount hydraulic hammer (see section 6.5 HYDRAULIC
HAMMER DEMOUNTING ON PAGE 44).
2. Collect outflowing oil with a suitable vessel
3. Unscrew plug (1), air discharge screw (2) and magnetic plug
(5) and discharge oil
4. Screw on magnetic plug (5) and tighten. Check fitting of the
Alu-ring .
5. Fill in gearing grease SHELL Alvania GL00 [Art.No,
5011104]into the opening of the air discharge screw (2)
(see section 4.5 RECOMMENDED OPERATING MEDIA ON
PAGE 34).
6. Screw on and close air discharge screw (2) and plug (1))

Discharge waste oil according environment protection regulations.

7.4 Hammer mechanism

The hammer mechanism (3) is mounted on the gearing (1), beside

the gear drive (oil motor) (4).

3
4

1017293

Bild 13: Hammer mechanism

1 Gearing
2 Hydraulic accumulator
3 Hammer mechanism
4 Drive motor (oil motor)

2200258/1 53
7 Settings and Maintenance
Hammer mechanism

DANGER OF INJURY!

The hydraulic accumulator is filled with nitrogene and is

therefore under high pressure
CAUTION! Any work on the hydraulic accumulator may be carried out
only by qualified personnel.
Fill hydraulic accumulator only with nitrogen. No other gas
is permitted.

7.4.1 Maintenance and fillung of the hydraulic accumulator

1017257

Bild 14: Hydraulic accumulator - maintenance and filling

Loosen cover- and filling screw. If the hydraulic accumulator is

working properly one can hear a clear fizzling of the escaping
nitrogen. In this case refill hydraulic accumulator without further
maintenance. If the fizzling is not appearing then most probably the
membrane is defect and has to be exchanged.

54 2200258/1
 Settings and Maintenance
Hammer mechanism 7

1017258

Bild 15: Hydraulic accumulator - maintenance and filling

Remove cover of hydraulic accumulator by means of the MORATH

special tool [Id.No. 9019060]. If there is hydraulic oil on the gas
side of the membrane, then the membrane must be exchanged.

1017259

Bild 16: Hydraulic accumulator - maintenance and filling

If the new membrane is inserted, grease the rims with silikon oil.
Tighten cover of hydraulic accumulator.

2200258/1 55
7 Settings and Maintenance
Hammer mechanism

1017260

Bild 17: Hydraulic accumulator - maintenance and filling

Filling device order no. 5005652 with adaptor order no. 5013694.
We are able to deliver adaptors for other filling devices - as well
between bottle and filling device as between filling device and filling
screw. Ask for further information.

1017261

Bild 18: Hydraulic accumulator - maintenance and filling

Remove cover screw of the hydraulic accumulator. Below based is

the filling screw. Mount the filling device (2) by means of the handle
bar (1), above the filling device, open the filling screw.

IMPORTANT!
Always use nitrogen (N2) for the filling of the gas
accumulators. The use of other gases may cause explosions
and damages on persons.

56 2200258/1
 Settings and Maintenance
Hammer mechanism 7

1017263

Bild 19: Hydraulic accumulator - maintenance and filling

Check whether valve (based on the side of the filling device) is

closed, turn on carefully gas of the gas bottle until the manometer
shows 60-80 bar. Tap gas off.

A B C

1017264

Bild 20: Hydraulic accumulator - maintenance and filling

Open valve (side based on the filling device) carefully (photo A) and
close as soon as manometer shows 90 bar.
Close the filling screw with the handle bar above the filling device
(photo B) and after it discharge the remaining oil by opening the
valve on the filling device (photo C).

2200258/1 57
7 Settings and Maintenance
Maintenance schedule

1017265

Bild 21: Hydraulic accumulator - maintenance and filling

Screw on cover screw and tighten.

7.5 Maintenance schedule

Observe the safety instructions and the accident prevention

regulations for all maintenance work.
Enter the performed maintenance work in the maintenance
schedule (see section 7.7 MAINTENANCE RECORD ON
PAGE 62).

Only dispose of the operating agents to the valid environmental

protection regulations.

7.5.1 Explanation to the maintenance schedule

The maintenance intervals are printed on the maintenance
schedules in tabular form:

Example:

Maintenance work Instructions

Check hydraulic oil temperature Within this column is recorded where one can find
further notices. As far as a detailed picture is
available a link to it is shown here.
Tabelle 14: Example of a maintenance schedule

58 2200258/1
 Settings and Maintenance
Maintenance schedule 7
7.5.2 Regular maintenance
The following maintenance work must be carried out regularly by
the operator:

Tasks to be carried out Notes

Safety equipment
Safety scwitch (safety catch).

Immediately repair defective equipment.

Check control elements for:

Function,
Damages,
Completeness,
Visibility,
Cleanliness,

Repair if necessary.

Mandatory, prohibition, warning and information

signs
completeness,
readability,
availability at the machine.

Repair if necessary.

Check the operating instructions for:

completeness,
readability,
availability at the machine.

Procure and/or supplement if necessary.

Clean hydraulic hammer (see picture 11: HB70-GD100 - CLEANING ON

PAGE 47)

Check shank adaptor, lines, hoses and screwing in

regard to damages.

Check flushing head in regard to density

For drilling crawler and excavator attachment: (see section 4.5 RECOMMENDED OPERATING
Greasing device - check grease level MEDIA ON PAGE 34)

Hydraulic greasing pump - check cartridge

For portable drilling equipment

Use manual grease gun regularly and check
cartridge.
Tabelle 15: Regular maintenance

2200258/1 59
7 Settings and Maintenance
Qick overview of the maintenance schedule

7.5.3 Maintenance weekly

The following maintenance work must be carried out weekly. The
regular maintenance work must be carried out additionally at the
same time.

Tasks to be carried out Notes

Hydraulic hoses and lines in regard to density, tight-
ness and damages.

Check screw connections in regard to tightness.

Check strip and sealings of the shank adaptor.

Replace if necessary
Tabelle 16: Maintenance weekly

7.5.4 Maintenance every 6 month

The following maintenance work must be carried out every 6
month. The regular maintenance work must be carried out additio-
nally at the same time.

Tasks to be carried out Notes

Dismantle gearing and check.

Change gearing grease (see section 4.5 RECOMMENDED OPERATING

MEDIA ON PAGE 34)

Hammer mechanism - check accumulator pressure (SEE SECTION 7.4 HAMMER MECHANISM ON
PAGE 53)

Hammer mechanism - change sealings

Tabelle 17: Maintenance every 6 month

7.6 Qick overview of the maintenance schedule

DANGER OF INJURY!

By non-observance of safety instructions.

DANGER!
Read and follow the section dealing with maintenance as well as
the signs attached to the Hydr. Bohrhammer before
beginning maintenance work.

60 2200258/1
 Settings and Maintenance
Qick overview of the maintenance schedule 7
Maintenance schedule Operating hours
Maintenance point Maintenance task Regu- weekly 6
lar months
Control panels, Check for completeness, legibility and X
control elements, cleanliness. Repair if necessary.
EMERGENCY-STOP

Mandatory, prohibition, Check for completeness, legibility and X

warning and information availability at the engine. Repair if
signs necessary.

Operating instructions Check for completeness, legibility and X

availability at the engine. Procure
and/or supplement if necessary.

Hydraulic hammer Clean X

Shank adaptors, lines, Check in regard to damages X

hoses and
screwings

Lubrication system Check grease level X

Hydr. Greasing pump Check cartridge
Grease gun Use regularly and check cartridge

Hydraulic hoses and lines Check in regard to density, X

tightness and damages

Hose connection Check in regard to tightness X

Hose and cable Replace if necessary X

connections

Strips and sealings of the Check for wear and firm seating X
shank adaptor

Gearing Dismantle and check X

Gearing Change grease X

Hammer Hammer X
mechanism mechanism

Hammer Exchange sealings X

mechanism
Tabelle 18: Qick overview of the maintenance schedule

2200258/1 61
7 Settings and Maintenance
Maintenance record

7.7 Maintenance record

Type:
Serial-no.:
Date Operating hours Description of work Signature

Tabelle 19: Maintenance record

62 2200258/1
 8 Glossary
8
8 Glossary
A H media 34
Abbreviations 10 Hose connection for mortar, air pressure 31, 33
Absorption capacity 31, 33 and water 27
Accumulator hydr. 28, 53, 54 Hydraulic hammer P
Adaptor set 28, 56 clean 45 Proceeding changings 17
Assemblage 15 demounting 44 Prohibition signs 19
mounting 40
B Hydraulic hoses 60
R
Backpressure recirculation 31 Hydraulic lines 21, 39
Recommended operating
media 34
C I Reversing valve 28, 44
Change Impact energy 31
gearing oil 52 Improper use 10, 14
S
shank adaptor 41 Information signs 19
Safety 13, 49
Check up 16 Installation 37
equipment 19, 22
Commissioning 37, 38 Instruction 15
Settings 49
Signs 19
D L Sound power level 34
Danger zones 21 Lashing means 26 Speed 31, 33
Dimensions 30, 32 Liability 10 Suspension hose 21
Disposal regulations 22 Lines-drive motor (turning) 28
Drive motor 28 Loading with a crane 26
T
Lubricants 22
Technical Data 27
E Torque 31, 33
Emissions 22 M Transport 25
Environmental Machine data 30, 31, 32, 33 Type plate 28
conditions 18, 34 dimensions 30, 32
Equipment 15, 38 Maintenance 49
U
Escape routes 37 schedule 58
Use 13
Means of transport 26
Measurements 16
F W
Flushing Warning signs 19
head 17, 27 O
Warnings 13
housing 27, 28 Oil 22 Warranty 10
flow 31, 33
Working
motor 33, 44, 53
G end 45
temperature 18, 58
Gearing 28, 29 instructions 14
Greasing line Operating
flushing head 27, 28 manual 7
flushing housing 28

2200258/1 63
 Attachment
9
9 Attachment

2200258/1 65