2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01

52, 102, 152, 202, 302, 452, 552 8B

OverhauIing instructions
HydrauIic breakers

3 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
Contents SB 52, 102, 152, 202, 302, 452, 552
Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TooIs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Standard tooIs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
AccumuIator charging tooIs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Drawings for making speciaI tooIs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Safety reguIations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Machine modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
HydrauIic oiI and Iubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
AccumuIator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
GeneraI information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Demands on personneI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Workshop requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Units of measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
OiI spiIIage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Waste disposaI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
SymboIs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DisassembIe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
AccumuIator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Back head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
ControI vaIve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Stop ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Breaker body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
AssembIe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Stop ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
ControI vaIve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Back head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
AccumuIator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Breaker body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Charge the accumuIator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
ENGLISH
2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
4
Introduction
Thank you for choosing a product from Atlas Copco. Since 1873, we have been
committed to finding new and better ways of fulfilling our customers' needs.
Through the years, we have developed innovative and ergonomic product designs
that have helped customers improve and rationalize their daily work.
Atlas Copco has a strong global sales and service network, consisting of customer
centers and distributors worldwide. Our experts are highly trained professionals
with extensive product knowledge and application experience.
n all corners of the world, we can offer product support and expertise to ensure
that our customers can work at maximum efficiency at all times.
All personnel who are to be involved in overhauling the SB breakers must first be
trained by Atlas Copco.
For more information please visit: www.atlascopco.com
Atlas Copco Construction Tools AB
105 23 Stockholm
Sweden
5 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
1. Plastic hammer
2. Circlip pliers
3. Screwdriver
4. Punch 10 mm
5. Torque wrench 0 - 650 Nm
6. Allen keys 5, 6, 8, 10 and 14 mm
7. Sliding callipers
8. Ratchet wrench
9. Scriber
10. U-ring spanners 13, 14, 15, 17, 18, 24, 27
and 30 mm
11. Sockets 15, 17, 18 and 24 mm
12. Sliding hammer
TooIs
Standard tooIs
Suggestion! Use this as a checklist before working with the SB machines.
6 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
AccumuIator charging tooIs
Component Part number Name
3115 1821 80
3115 0642 00
3115 0644 00
Complete, Charging hose
- Nipple
- Nipple
3115 0646 00
3115 0978 00
Complete, Gas regulator
- Pressure gauge
2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01 7
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
Hook for removal of bushing.
Use with sliding hammer.
SB 52 SB 102 SB 152 SB 202 SB 302 SB 452 SB 552
70
55
15
6
35
18
18
44
18
75
60
15
6
40
21
20
52
18
125
105
20
16
60
28
43
75
28
135
110
20
18
73
30
50
90
30
130
105
20
20
88
38
55
105
30
130
105
20
20
92
40
65
110
30
80
65
15
8
45
25
22
58
22
M10 x 130 full treaded
For removal of back head.
Drawings for making speciaI tooIs
2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01 8
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
For removal of slide cover.
Use with sliding hammer.
Material: 0011 2541 03/EN 10083-1
For removal of piston.
Use with sliding hammer.
Material: 0011 2541 03/EN 10083-1
2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01 9
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
5
9

(
S
B

5
2
)
6
7

(
S
B

1
0
2
)
9
4

(
S
B

2
0
2
)
1
0
9

(
S
B

3
0
2
)
7
8

(
S
B

1
5
2
)
1
4
0

(
S
B

4
5
2
,

5
5
2
)
2
8
0
M4 x 80 (SB52)
M6 x 130
E
A
SB 52
SB 102
SB 152
SB 202
A
67.5
SB 302 82.5
SB 452 98.5
SB 552 102.5
52.5
49
44
Model
2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01 10
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
( )
1.6 6.3
M12
25
1
5
1
1
5
1
.
6
EDGE BROKEN
1
.
6
R2 (2x)
8
M12
5
2
0
1
.
6
1x45(2x)
NO HARDENED
15
1
5
36f7
3
0

1
5
5
0
2
SB 52
11 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
( )
1.6 6.3
M12
25
1
5
1
1
5
1
.
6
EDGE BROKEN
1
.
6
R2 (2x)
8
M12
5
2
0
1
.
6
1x45(2x)
NO HARDENED
15
1
5
36f7
3
0

1
5
5
0
2
SB 102
12 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
3
0

( )
1.6 6.3
M12
25
1
5
1
1
5
1
.
6
EDGE BROKEN
1
.
6
R2 (2x)
R8
2
8
M12
5
2
0
1
.
6
2
0
1
5
1x45(2x)
NO HARDENED
6
0
47f7
25
SB 152
13 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
6
0
1x45(2x)
1
5
2
0
2
0
M12
2
1
1
5
1
5
25
M12
61.5f7
40
NO HARDENED
EDGE BROKEN
NITROCARBURIZED
5
8
R8
3
0

SS2541
1
.
6
( )
R2 (2x)
1
.
6
1
.
6
6.3 1.6
SB 202
14 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
R8
EDGE BROKEN
8
8
R2 (2x)
3
0

1.6 6.3
1
.
6
1
.
6
1
.
6
SB 302
M12
25
1
5
1
1
5
NO HARDENED
1x45(2x)
7
0
2
85f6
67
2
0
3
0
1
5
M12
15 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
R8
EDGE BROKEN
80
R2 (2x)
3
0
0
0.4 6.3
0
.
4
0
.
4
0
.
4
M12
25
1
5
1
1
5
NO HARDENED
1x45(2x)
2
3
0
3
0
1
5
M12
150
8
0
62
100f6
SS2511
18
8
0
SB 452
16 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
M12
1
5
3
0
2
0
85
103f6
2
7
0
1x45(2x)
NO HARDENED
1
1
5
1
5
25
M12
3
0

R2 (2x)
8
8
EDGE BROKEN
R8
1
.
6
1
.
6
1
.
6
6.3 1.6
SB 552
17 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
Safety reguIations
The indications Danger, Warning and Caution
have the following meanings:

Danger
Indicates an imminentIy
hazardous situation which,
if not avoided, wiII resuIt in
death or serious injury.

Warning
Indicates a potentiaIIy
hazardous situation which,
if not avoided, couId resuIt
in death or serious injury.

Caution
Indicates a potentiaIIy
hazardous situation which,
if not avoided, may resuIt
in minor or moderate
injury.
Machine modification
Warning
Any machine modification may result in bodily
injuries to yourself or others.
>The hydraulic breaker must not be modified.
>Use only original parts and accessories
approved by Atlas Copco.
HydrauIic oiI and Iubrication
Warning
Thin jets of hydraulic oil under high pressure can
penetrate the skin and cause permanent damages.
>Never use your hands tracing for oil leaks.
>Keep your face away from any possible leaks.
>mmediately consult a doctor if hydraulic oil has
penetrated the skin.
Warning
Spilled hydraulic oil can cause accidents owing to
slippery conditions and will also harm the nature
and the vegetation.
>Handle the hydraulic oil with care.
>Take care of all spilled oil and handle it
according to your local safety and environment
regulations.
>SB hydraulic breakers are equipped with an oil
plug to drain all oil before dismounting. This to
reduce the risk of spilling oil.
Caution
Hot hydraulic oil can cause burns.
>Never dismount the hydraulic breaker when the
hydraulic oil is hot.
Caution
Hydraulic oil can cause eczema when it comes in
contact with the skin.
>Avoid getting hydraulic oil on your hands.
>Always use protective gloves when working with
hydraulic oil.
Caution
Used lubricants contain harmful contaminants.
Precautions for protection when handling used oils:
>Avoid prolonged, excessive or repeated skin
contact with oil.
>Apply barrier cream before handling oil.
>Avoid skin contact with oil-soaked clothing.
>Never keep oily rags in pockets.
Note! When removing oil from the skin:
>Wash your hands thoroughly with soap and
water.
>Using a nail brush will help.
>Use special hand cleansers to help clean dirty
hands.
>Never use petrol, diesel fuel or paraffin when
washing.
AccumuIator
Danger
The hydraulic breaker has a pressure accumulator.
The pressure accumulator may only be charged
with nitrogen gas (N
2
).
>Any other gas can cause explosion. Explosions
will cause serious personal injury or death.
Warning
The accumulator is pressurized even when
hydraulic system is shut off. To dismount the
accumulator without first releasing the nitrogen gas
out can cause serious personal injury or death.
>Only authorized personal are qualified to work
with the accumulator.
>Never do anything to the hydraulic breaker, the
connections or any hoses when the hydraulic
system is pressurized.
Note! f the maximum working pressure for
the hydraulic breaker is exceeded, the
accumulator can be over charged which can
result in material damages.
>Always run the hydraulic breaker with correct
working pressure.
18 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
GeneraI Information
Use these instructions as a guide when
overhauling the hydraulic breaker SB.
Demands on personneI
All personnel who are to be involved in overhauling
the SB breakers must first be trained by Atlas
Copco.
Workshop requirements
Atlas Copco breakers have a hydraulically driven
impact mechanism. Since all hydraulic equipment
is vulnerable to dirt, the breaker should always be
disassembled and assembled in a place that is:
>Separate from all grinding, welding or other
particle-generating activities.
>Thoroughly cleaned and free of dust and dirt.
Units of measurement
All units used are according to the Swedish
Standard nstitute (SS) which is a member of the
European SO and CEN standard organisations.
Spare parts
Use only authorized parts. Any damage or
malfunction caused by the use of unauthorized
parts is not covered by the Warranty or by Product
Liability.
Please refer directly to the spare parts lists when
ordering new spare parts.
OiI spiIIage
Absorb using sand or a locally approved brand of
absorbent granules. Clean it all up and dispose at
an approved chemical disposal area.
Waste disposaI
All waste products must be treated and scrapped
in such a way that the greatest possible portion
of the material can be recycled and any negative
influence on the environment is kept as low as
possible. Spilled oil can cause accidents owing to
slippery conditions and will harm the nature and
vegetation.
>Equipped with washing facilities and
compressed air for drying the parts.
>Equipped with suitable standards and special
tools.
2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01 19
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
Warning, Caution Direction
nspect and if necessary, replace
damaged or worn out parts
New part To be avoided n working order
Force Turning to end position Oil
LOCTTE243
(LOCTTE is a registered trademark of
Henkel Corporation. 243 is a trademark
of Henkel Corporation.) Gas release Scrap
SymboIs
!
2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01 20
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
Turning Cracks
Molykote
Molykote is a registered trademark of Dow
Corning Corporation
Freezed Torque Recycling
Bigger than Smaller than Time
mportant positional relationship n turn
>
<
21 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
DisassembIe
3.
4.
Preparation
1.
2.
Bushing
22 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
5.
6.
100 - 103 mm SB 552
95 - 98 mm SB 452
80 - 83 mm SB 302
65 - 68 mm SB 202
50 - 52 mm SB 152
45 - 47 mm SB 102
40 - 42 mm SB 52
7.
Warning
The accumulator is pressurized even when the
hydraulic system is shut off. Disassembling
the accumulator before letting the gas out can
cause injury.
>Let the gas out slowly by opening the
charging valve.
>Make sure that there is no gas pressure in
the accumulator before disassembling the
accumulator housing.
7.
AccumuIator
23 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
8.
9.
10.
11.

SB 102 - 202 9.5 - 10 mm
SB 302 - 552 N/A
SB 52 8.0 - 8.5 mm
Back head
12.
13.
24 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
14.
15.
16.
17.
ControI vaIve
18.
19.
25 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
20. 23.
Minimum wear limits in mm
D
B A C
C
A
D


B
SB 552 102.94 105.44 93.94 1
SB 452 99.94 101.94 90.94 1
SB 302 84.95 86.05 76.45 1
SB 202 67.95 69.55 61.44 1
SB 152 52.95 54.45 46.95 1
SB 102 46.95 47.95 41.95 1
SB 52 40.95 42.25 35.95 1
Piston
Liner 21.
22.
24.
25.
26 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
26.
27.
TON
5
28.
Stop ring
27 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
29.
30.
31.
32.
33.
34.
Breaker body
SB 202
SB 202
SB 52, 102, 152, 302, 452, 552
SB 52, 102, 152, 302, 452, 552
28 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
SB 202
35.
36.
37.
38.
AssembIe
39.
TON
5
Stop ring
29 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
40.
41.
42.
43.
Liner
30 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
Piston
ControI vaIve
44.

45.
SB 52, 102, 152, 202
46.













Back head
47.
48.
SB 302 = 120 Nm
SB 452 = 300 Nm
SB 552 = 300 Nm
31 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
49. 50.
51.
52.
32 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
AccumuIator
SB 452-552 = 315 Nm
SB 302 = 180 Nm
SB 152-202 = 180 Nm
SB 102 = 75 Nm
SB 52 = 75 Nm
53.



54.


55.
33 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
56.
SB 52 = 75 Nm
SB 102 = 120 Nm
SB 152 = 120 Nm
SB 202 = 120 Nm
SB 302 = 120 Nm
SB 452 = 300 Nm
SB 552 = 300 Nm
SB 202
57.
Breaker body
34 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
58.
80 Nm
59.
SB 202
SB 52, 102, 152, 302, 452, 552
60.
SB 202 = 210 Nm
SB 302 = 210 Nm
SB 452 = 210 Nm
SB 552 = 210 Nm
SB 52 = 80 Nm
SB 102 = 210 Nm
SB 152 = 210 Nm
61.
SB 202
35 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
62.
63.
64.
65.
66.
Danger
The accumulator must only be charged
with Nitrogen (N
2
). Other gases can cause
explosions.
Charge the accumuIator
Bushing
36 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
67.
68.
69.
70.
10
Sec
37 2012 Atlas Copco Construction Tools AB | No 9800 0635 01c | 2012-01-01
OverhauIing instructions SB 52, 102, 152, 202, 302, 452, 552
71.
20 Nm
72.
73.
www.atlascopco.com

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