HB series HB 4200 DP

Reconditioning kit
Breaker box

© 2010 Atlas Copco Construction Tools GmbH | No. 3390 7418 01 | 2010-07-05
Reconditioning kit HB 4200 DP

Breaker box kit 3363 0946 77

5 Fig. 1
1

Note: Before welding the wear protection you must dismantle the perussion unit.

You must use a qualified professional welding company to weld the wear protection onto the breaker
box.

No. Ordering No. Quantity Description

1 3363 0672 57 1 Wear plate

2 3363 0672 65 1 Wear plate
3 3363 0672 67 2 Wear plate
4 3363 0837 26 1 Wear plate
5 3363 0672 71 2 Wear part

© 2010 Atlas Copco Construction Tools GmbH | No. 3390 7418 01 | 2010-07-05
HB 4200 DP Reconditioning kit

Dismantle percussion unit

™ Remove hydraulic breaker from the carrier
according to the Safety and operating instruc-
tions of the hydraulic breaker.
™ Remove working tool and DustProtector system
according to the Safety and operating instruc- A
tions of the hydraulic breaker.
™ Remove base for wiper from the lower wear B B
bush.

T WARNING! Hoist tipping over / hydraulic

attachment falling
The hydraulic attachment is heavy. The hoist/lifting
equipment and/or hydraulic attachment tipping C
over or falling may cause serious injury and D
material damage.
► Only transport the hydraulic attachment with
lifting equipment with the right load-bearing
capacity for the weight of the hydraulic
attachment.
► Only lift and secure the hydraulic attachment
with lifting gear (ropes, chains, links etc.) with
the right load-bearing capacity for the weight to Fig. 2
be lifted.
► Make sure that there is nobody near or under ™ Remove covers (Fig. 3/D) and (Fig. 3/E).
the suspended hydraulic attachment.
™ Dismantel grease line (Fig. 3/A) and oil line
™ Stand breaker box with percussion unit vertically (Fig. 3/F) between ContiLube® II and percussion
and secure against falling over. unit.
™ Remove Allen screws (Fig. 2/D) using Allen key ™ Remove Allen screws (Fig. 3/C) and the pairs of
size 27 and the pairs of lock washers (Fig. 2/C) lock washers (Fig. 3/B) using Allen key size 10.
and remove adapter from breaker box using a
hoist/crane. ™ Remove ContiLube® II unit.

™ Remove elastic pad (Fig. 2/A).

T WARNING! Rupturing washers become

projectiles
When loosen the tensioning bolts the washers A
under the head of the tensioning bolts may rupture BC
and become projectiles. Rupturing parts may L
D
cause serious injuries.
► Place the dismantling rings (Fig. 2/B) K
(Part-Id.-No. 3363 0979 11) over the head of all F
tensioning bolts before lifting the percussion unit H
G
out of the breaker box. J I

► For safety reasons the dismantling rings are E

removed only if the percussion unit is fitted in Fig. 3
the breaker box again.

™ Remove snapring (Fig. 3/J), disk (Fig. 3/I) and

adapter (Fig. 3/H) from swivel joint.
™ Remove Allen screws (Fig. 3/K) and the pairs of
lock washers (Fig. 3/L).
™ Remove plate (Fig. 3/G).

© 2010 Atlas Copco Construction Tools GmbH | No. 3390 7418 01 | 2010-07-05
Reconditioning kit HB 4200 DP

™ Screw two load rings (Fig. 4/A) M 36x47 ™ Remove plastic parts and plugs from the breaker
(Part-Id.-No. 3363 1067 20) into the two box.
threaded bores on the upper face of the cylinder
cover as far as they will go.
™ Using a hoist/crane, lift the percussion unit of
the hydraulic breaker out of the breaker box.

Fig. 4

T WARNING! Abruptly loosen parts cause

injuries
Using the hoist as a pulling device if the percussion
unit has jammed in the breaker box can cause
serious injuries.
► You must not use the hoist as a pulling device.
™ Secure breaker box against falling over.
™ Stand percussion unit vertically and secure Fig. 5
against falling over.

™ Lay the breaker box horizontal on a suitable

base.

© 2010 Atlas Copco Construction Tools GmbH | No. 3390 7418 01 | 2010-07-05
HB 4200 DP Reconditioning kit

Welding Weld seam preparation

T WARNING! Harmful vapors
Chisel paste is flammable. Harmful vapors are
generated when chisel paste is burnt.
► Remove all chisel paste and other contamination
from the breaker box.
► Provide sufficient ventilation during welding.
► Wear personal protective equipment (ambient
air-independent breathing mask) if no air
extraction system is available.
T WARNING! Risk of fire / explosion
Flammable detergents and chisel paste residues
can ignite or cause an explosion during welding.
► Do not use flammable detergents.
► Carefully remove all detergent residues from the
breaker box.
NOTICE! Damage to the breaker box
As the worn parts burn away, the breaker box may
buckle as high levels of heat are produced and the
steel’s properties may change.
► Once a wear part has burnt away, leave the
breaker box to cool before removing the next
part.
™ Remove worn parts one at a time using a flame
cutter or the weld seams removed using a cut-
ting wheel.
™ Grind flame-cut areas on the breaker box flat.
™ Before starting welding work, remove all con-
tamination on and around the seam edges.
Scale, rust, oil, paint and moisture give off
hydrogen which can jeopardise welding results
and result in cracks.
Preheating temperature
To avoid cracking, a higher working temperature
is recommended depending on steel plate grade,
overall plate thickness and hydrogen content.
™ Preheat new wear parts to 150 °C to 200 °C.
Optional welding processes
arc-welding DIN EN ISO 4063
gas-shielded welding DIN EN ISO 14610
Post-treatment of welds
™ Make welds without notches or grind free of
notches in order to reduce tension.
™ Run a non-destructive surface crack test (but
at least a visual weld seam check) of all weld
seams.
Tack welds and root beads are the points which are
most susceptible to the formation of cold cracks.
™ If you find cold cracks in a welded joint, you
have to grind them out or gouge them out with a
carbon arc (grind joint edges) and then perform
a repair weld.

A-A
B B-B
a8

a8 a8

4
(150)

2
B a6
10

1 492
545

weldment construction
3
a8 general tolerances EN 13920
5
lengths ; angle ..... B .....
from ; position ..... E .....

a8
manufacturing quality DIN EN ISO 5817
quality class ..... C .....
310

pre-heat: temperature 150°C - 200°C

A A optional welding processes
- DIN EN ISO 4063 - arc-welding
- DIN EN ISO 14610 - gas-shielded-welding

5 Fig. 6

© 2010 Atlas Copco Construction Tools GmbH | No. 3390 7418 01 | 2010-07-05
Reconditioning kit HB 4200 DP

Fit percussion unit in breaker

box
™ Stand breaker box upright.
T WARNING! Hands and fingers being cut off
or injured
Bores and surfaces can act like a pair of scissors
and cut off or injure parts of your body.
► Never use your hands to locate or check the
position of the plastic parts fitting the percussion
unit in the breaker box.
™ Fit plastic parts (Fig. 5) and fix in position using
double-sided adhesive tape.
™ Lift up percussion unit using a crane/hoist and
lower into breaker box.
™ Remove the two load rings out of the cylinder
cover.
™ Fit plate (Fig. 3/G).
™ Fit Allen screws (Fig. 3/K) and pairs of washers
(Fig. 3/L).
™ Fit adapter (Fig. 3/H), disk (Fig. 3/I) and
snapring (Fig. 3/J) to swivel joint.
™ Fit ContiLube® II unit.
™ Fit Allen screws (Fig. 3/C) and pairs of washers
(Fig. 3/B) using Allen key size 10.
™ Fit grease line (Fig. 3/A) and oil line (Fig. 3/F)
between ContiLube® II and percussion unit.
™ Fit covers (Fig. 3/D) and (Fig. 3/E).
™ Remove the dismantling rings (Fig. 2/B)
™ Fit elastic pad (Fig. 2/A).
™ Using crane/hoist, place adapter on breaker box
fit pairs of locking rings (Fig. 2/C) and fasten the
Allen screws (Fig. 2/D) using size 27 Allen key
(Tightening torque 2300 Nm).
™ Fit base for wiper to the lower wear bush.
™ Fit the working tool and the DustProtector
system according to the Safety and operating
instructions of the hydraulic breaker.
™ Fit the hydraulic breaker to the carrier according
to the Safety and operating instructions of the
hydraulic breaker.

© 2010 Atlas Copco Construction Tools GmbH | No. 3390 7418 01 | 2010-07-05
HB 4200 DP Reconditioning kit

© 2010 Atlas Copco Construction Tools GmbH | No. 3390 7418 01 | 2010-07-05
 © 2010 Atlas Copco Construction Tools GmbH, Essen, Germany | No. 3390 7418 01 | 2010-07-05

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