jack hammer

CNHCopyright 2005 CNH France S.A.

Printed in FranceNovember 2005Cre 7-23862GB

HYDRAULIC HAMMERS

CB200 S - CB260 S - CB320 S - CB400 S

CB550 S - CB700 S

1Cre 7-23862GB Issued 11- 05

TABLE OF CONTENTSTECHNICAL SPECIFICATIONS ...............................................................................................................................3

Overall dimensions................................................................................................................................................3SPECIFICATIONS.....................................................................................................................................................5TORQUE SETTINGS ................................................................................................................................................6TOOLS REQUIRED ..................................................................................................................................................7REPLACING A HYDRAULIC HAMMER....................................................................................................................9HANDLING THE HYDRAULIC HAMMER ...............................................................................................................11RELEASING THE HYDRAULIC PRESSURE IN THE HYDRAULIC HAMMER......................................................12COMPONENT IDENTIFICATION............................................................................................................................13LOCATION OF MAIN COMPONENTS ...................................................................................................................14

CB200 S - CB260 S - CB320 S - CB400 S - CB550 S - CB700 S.................................................................14HOUSING AND VIBRATION DAMPER ..................................................................................................................15PRESSURE ACCUMULATOR PRESSURE RELEASE..........................................................................................18PRESSURE ACCUMULATOR ................................................................................................................................18CHARGING THE ACCUMULATOR ........................................................................................................................21DISCHARGE VALVE...............................................................................................................................................23NON-RETURN VALVE............................................................................................................................................26PRESSURE REGULATOR .....................................................................................................................................28PRESSURE SEQUENCING VALVE (CB400 S - CB550 S)....................................................................................30

Removal ..............................................................................................................................................................30

TIE-ROD..................................................................................................................................................................34CONTROL VALVE BODY COMPONENTS (CB200S - CB260 S - CB320 S) ........................................................37

Removal ..............................................................................................................................................................37

CB400 S - CB550 S ............................................................................................................................................41FRONT PART..........................................................................................................................................................44

Removal ..............................................................................................................................................................44

CHANGING A TOOL ...............................................................................................................................................47Removal ..............................................................................................................................................................47

Installation ...........................................................................................................................................................47

CHANGING THE TOOL BUSHING.........................................................................................................................49Removal ..............................................................................................................................................................49

Installation ...........................................................................................................................................................49

WEAR LIMITS .........................................................................................................................................................50Types: CB200 S, CB260 S, CB320 S, CB400 S, CB550 S, CB700 S ................................................................50Tools ...................................................................................................................................................................50

INSPECTION AND MEASUREMENT OF HYDRAULIC HAMMER CIRCUIT.........................................................51Measurement/Inspection points ..........................................................................................................................51

2Cre 7-23862GB Issued 11- 05

MEASURING THE HYDRAULIC HAMMER OPERATING PRESSURE.................................................................53WORKING PRINCIPLES.........................................................................................................................................55TROUBLESHOOTING ............................................................................................................................................57

3Cre 7-23862GB Issued 11- 05

TECHNICAL SPECIFICATIONS

Overall dimensions

CB200 S - CB260 S

C040033

CB320 S

C040035

Types

Codes CB200 S CB260 S CB320 S

A 550 mm 630 mm 630 mm

B 510 mm 510 mm 510 mm

C 358 mm 359 mm 434 mm

D 2015 mm 2141 mm 2282 mm

E 1605 mm 1763 mm 1863 mm

F 570 mm 570 mm 570 mm

G 115 mm 125 mm 130 mm .

H 252 mm 266 mm 295 mm

I 252 mm 252 mm 217 mm

4Cre 7-23862GB Issued 11- 05

TECHNICAL SPECIFICATIONS

Overall dimensions

CB400 S

C040042

CB550 S

C040038

Types

Codes CB400 S CB550 S

A 640 mm -

B 540 mm 730 mm

C 462 mm 475 mm

D 2621 mm 2958 mm

E 2157 mm 2358 mm

F 585 mm 730 mm

G 140 mm 160 mm

H 319 mm 337 mm

I 319 mm 238 mm

5Cre 7-23862GB Issued 11- 05

SPECIFICATIONS

Section CB200 S CB260 S CB320 S CB400 S CB550 S CB700 S

Operating weight (1)

1. Includes the medium installation hook and the standard tool.

1040 kg 1330 kg 1710 kg 2350 kg 3150 kg 3800 kg

Impact rate (2)

2. The real impact frequency depends on the oil flow and its viscosity, the temperature and the ma-terial which is being broken.

400-800 bpm

360-650 bpm

330-580 bpm

300-450 bpm

350-480bpm

300-480bpm

Operating pressure 135-145 bar

125-145 bar

125-145 bar

140-150 bar

140-150 bar

140-155 bar

Minimum pressure setting (3)

3. Minimum setting = real working pressure +50 bar (730 psi).

185 bar 190 bar 190 bar 210 bar 190 bar 190 barMaximum pressure setting 220 bar 220 bar 220 bar 230 bar 230 bar 220 barOil flow 80-130 l/

min100-170 l/

min120-200 l/

min160-230 l/

min210-310 l/

min220-320 l/

minMaximum output pressure 10 bar 10 bar 10 bar 8 bar 8 bar -Input power 31 kW 40 kW 48 kW 58 kW 78 kW 83 kWTool diameter 115 mm 125 mm 130 mm 140 mm 160 mm -Pressure line union (in) 1" 1" 1/4 1" 1/4 1" 1/4 1" 1/4 -Return line union (out) 1" 1" 1/4 1" 1/4 1" 1/4 1" 1/4 -Grease fitting 1/4" 3/8" 3/8" 3/8" 3/8" -Air union (A) 1/4" 3/8" 3/8" 3/8" 3/8" -Pressure line dimension (mini-mum internal diameter)

26 mm 26 mm 26 mm 32 mm 32 mm -

Return line dimension (mini-mum internal diameter)

26 mm 26 mm 32 mm 32 mm 36 mm -

Optimum oil temperature +40 +60 C

+40 +60 C

+40 +60 C

+40 +60 C

+40 +60 C

+40 +60 C

Maximum permitted oil temperature range

-20 +80 C

-20 +80 C

-20 +80 C

-20 +80 C

-20 +80 C

-20 +80 C

Optimum oil viscosity at working temperature

30-60 cSt 30-60 cSt 30-60 cSt 30-60 cSt 30-60 cSt -

Maximum oil viscosity 20-1000 cSt

20-1000 cSt

20-1000 cSt

20-1000 cSt

20-1000 cSt

-

Weight of tool-carrier (4)

4. The application recommendations for the implement are intended to provide optimum stabilitywhen the implement is used on a tool-carrier with standard load undercarriage, boom and dip-per. For applications using other tool-carriers, contact your Dealer to check the compatibility andstability of the tool-carrier.

12-20 tonnes

18-26 tonnes

21-32 tonnes

27-40 tonnes

35-55 tonnes

-

Table of applications of the hydraulic breaker

See the Operators Manual.

Noise level See the Operators Manual.

6Cre 7-23862GB Issued 11- 05

TORQUE SETTINGS

ComponentTorque settings

CB200 S CB260 S CB320 S CB400 S CB550 S CB700 S

Hammer hydraulic pressure release plug (A)

30 Nm 30 Nm 30 Nm 30 Nm - -

Screws which retain plate onhammer

1050 Nm 1050 Nm 1050 Nm 1050 Nm 2100 Nm -

Accumulator retaining screws (A) 500 Nm 500 Nm 500 Nm 700 Nm 1350 Nm -Accumulator (B) cover retaining screws

300 Nm 450 Nm 450 Nm 450 Nm 700 Nm -

Accumulator filler orifice plug 20 Nm 20 Nm 20 Nm 20 Nm 20 Nm -Relief valve (A) cover retaining screws

200 Nm 120 Nm 200 Nm 200 Nm 340 Nm -

Non-return valve retaining screws 83 Nm 200 Nm 200 Nm 200 Nm 200 Nm -Pressure regulator retaining screws (A)

83 Nm 200 Nm 200 Nm 200 Nm 200 Nm -

Pressure regulating housing (B) 300 Nm 300 Nm 300 Nm 300 Nm 300 Nm -Guide (C) 300 Nm 300 Nm 300 Nm 300 Nm 300 Nm -Pressure regulating plug (D) 220 Nm - - - - -Pressure sequencing valve (B) retaining screws

- - - 125 Nm 125 Nm -

Spring (A) housing retaining screws

- - - 125 Nm 125 Nm -

Flange plug (C) - - - 80 Nm 80 Nm -Flange plug (D) - - - 10 Nm 10 Nm -Tie-rod 500 Nm 500 Nm 500 Nm 700 Nm 700 Nm -Supplementary tightening angle after heating

100 120 120 90 90 -

Taper plug 1/4" 1 component Component located in the control valve body or the seal-carrier

33 Nm 33 Nm 33 Nm - - -

Breather BSP 1/4" 1 component 30 Nm - - - - -Breather BSP 1/2" 120 Nm 120 Nm 120 Nm - - -Flange plug BSP 3/8" 50 Nm 50 Nm 50 Nm 50 Nm 50 Nm -Flange plug BSP 1/2" 80 Nm - - - 80 Nm -Flange plug BSP 1/4" 30 Nm 30 Nm - 30 Nm 30 Nm -Breather BSP 3/8" - 40 Nm 40 Nm 40 Nm 40 Nm -Flange plug BSP 1" - - - - 200 Nm -Flange plug 3/4" - 120 Nm 120 Nm 120 Nm - -Breather BSP 3/4" - - - 175 Nm 175 Nm -Plug A on front part - - 100 Nm 100 Nm 100 Nm -Plug B on front part 33 Nm - - 50 Nm 50 Nm -

7Cre 7-23862GB Issued 11- 05

TOOLS REQUIRED

- Torque wrench (150 to 700 Nm)- Torque wrench (20 to 200 Nm)

SPECIAL TOOLSR050253

R050065380002526 - Accumulator charging kit (components1.1 to 1.4)- Charging device (1.1)- Socket (1.2)- Adaptor (1.3)- O-ring (1.4)

R050066380002532 - Bushing extraction tool (including 1.1 to1.5) (CB260 S - CB320 S - CB400 S)- Puller frame (1.1)- Threaded rod (1.2)- Puller plate lower tool bushing (1.3)- Washer (1.4)- Nut (1.5)380002540 - Bushing extraction tool (including 1.1 to1.5) (CB550 S)- Puller frame (1.1)- Threaded rod (1.2)- Puller plate lower tool bushing (1.3)- Washer (1.4)- Nut (1.5)

8Cre 7-23862GB Issued 11- 05

R050068380002536 - Hammer support assembly (CB260 S -CB320 S - CB400 S- CB550 S)380002524 - Hammer support assembly (CB200 S)

R050067380002537 - Hydraulic hammer lifting adaptor(CB260 S - CB320 S - CB400 S - CB550 S)

R050069380002530 - Accumulator assembly bracket (CB260S - CB320 S - CB400 S)380002525 - Accumulator assembly bracket (CB550S)

R050070380002531 - Extractor (CB260 S - CB320 S - CB400S - CB550 S)

R050256380002529 - Support for cylinder and piston seal-car-rier moulding (CB260 S)380002533 - Support for cylinder and piston seal-car-rier moulding (CB320 S)380002534 - Support for cylinder and piston seal-car-rier moulding (CB400 S)

R050257380002548 - Knock pin M24 (CB200 S - CB260 S)

R050254380002549 - Accumulator assembly stand (CB320 S)

R050255380002535 - Centring piece (CB320 S)

R050685380002539 - Extractor (CB400 S - CB550 S)

9Cre 7-23862GB Issued 11- 05

R050072380002528 - Drift pin D9 (CB260 S - CB320 S)380002543 - Drift pin D11 (CB260 S - CB320 S -CB400 S)380002541 - Drift pin D12 (CB260 S - CB320 S)380002544 - Drift pin D15,5 (CB260 S - CB320 S -CB400 - CB550 S)380002545 - Drift pin D20,5 (CB400 S - CB550 S)380002542 - Drift pin D25 (CB260 S - CB320 S)380002546 - Drift pin D28 (CB400 S - CB550 S)

R050075380002527 - Hammer lifting adaptater (CB200 S)

REPLACING A HYDRAULIC HAMMER

RemovalSTEP 1

CT02D444Position the hydraulic hammer horizontally on flat,hard ground.

STEP 2

Shut down the engine and remove the starter switchkey. Release the pressure in the hydraulic hammercircuit. See "Releasing pressure in the hydraulic cir-cuit" in the "Lubrication/Filters/Fluids" Section of theOperators Manual for the machine concerned.

10

Cre 7-23862GB Issued 11- 05

STEP 3

CT02D444Place a receptacle of a suitable capacity under thepiping. Close the valves (circuit opening and closingvalves) in the piping (if fitted). Disconnect the hosesfrom the pipes. Plug them if necessary.

STEP 4

Remove the retaining hardware (as fitted) from thepins.

STEP 5

Remove the connecting rod/hydraulic hammer pin,then the dipper/hydraulic hammer pin.

STEP 6Operate the machines controls to disengage thehammer.

STEP 7Remove the plugging screw and install the lifting ring(depending on type fitted). See "Handling the hydrau-lic hammer" in the "Operating instructions" Section.

Installation

STEP 1Operate the attachment controls to bring the dipperinto the hydraulic hammer.

STEP 2Shut down the engine and remove the starter switchkey. Release the pressure in the hydraulic hammercircuit. See "Releasing pressure in the hydraulic cir-cuit" in the "Lubrication/Filters/Fluids" Section of theOperators Manual for the machine concerned.

STEP 3Install the dipper/hydraulic hammer pin. Place areceptacle of a suitable capacity under the piping.Connect the hydraulic hammer hoses.

STEP 4Operate the connecting rod control to bring it into thehydraulic hammer, then shut down the engine andremove the starter switch key.

STEP 5Install the connecting rod/hydraulic hammer pin andthen install the retaining hardware (as fitted) for thepins.STEP 6Open the valves (circuit opening and closing valves)in the piping (if fitted).STEP 7Remove the lifting ring and install the plugging screw.STEP 8Grease the linkages.

STEP 9For the hydraulic hammer control, see "Option pedal"in the "Controls/Instruments/Accessories" Section ofthe Operator's Manual for the machine concerned.

11


HANDLING THE HYDRAULIC HAMMER

The lifting equipment must be able to withstand the weight of the hydraulic hammer. See "Hydraulic hammerweight specifications".- Use slings, straps, accessories and chains in perfect condition, with effective devices to prevent unhooking.- Install guidance systems for handling and use handling machines in accordance with regulations.- Do not allow any person within the working area of the hydraulic hammer during handling.- Position chains and slings as shown below.

C010002

NOTE: The lifting ring must always be removed from the hydraulic hammer and replaced by a plugging screwbefore operating the hydraulic hammer.

12


RELEASING THE HYDRAULIC PRESSURE IN THE HYDRAULIC HAMMER

R0502141 - Supply port2 - Outlet port

WARNING: When the hydraulic hammer is connected to the tool-carrier, the hydraulic pressure contained inthe hydraulic hammer must always be released before carrying out any adjustment or repair. The hydraulichammer can still contain oil under pressure even when it is no longer connected to the tool-carrier. Releasethe hydraulic pressure in accordance with the following instructions, or wait at least 10 mins before openingplugs or control valve caps.

STEP 1Shut down the machine engine. Operate the boomand hydraulic hammer controls to release all pres-sure from the hoses.

STEP 2Close the hydraulic hammer inlet and outlet lines. Ifquick couplers are used, shutting off the circuit willautomatically close the hydraulic hammer lines. If thehydraulic hammer line has ball valves, make surethat they are correctly closed.

STEP 3Unscrew the pressure release plugs (A) and (B).Watch out for oil leaks.

STEP 4Retighten the pressure release plugs (A) and (B) tothe specified torque setting (30 Nm).

R050081

WARNING: This procedure does not releasepressure from the accumulator. Carefully fol-low the instructions concerning the accumula-tor before disassembling the accumulator.See "Pressure accumulator" on page 18.

13


COMPONENT IDENTIFICATION

CT04K0031 - Housing 5 - Vibration damper2 - Tool 6 - Grease fittings3 - Accumulator 7 - Tool retaining hardware4 - Load handling eye 8 - Tool bushing retaining hardware

3

5

1

6

8

7

4

2

7

14


LOCATION OF MAIN COMPONENTS

CB200 S - CB260 S - CB320 S- CB400 S - CB550 S - CB700 S

R050156

A - PRESSURE TEST PLUGB - RELIEF VALVEC - NON-RETURN VALVED - PRESSURE CONTROL VALVEE - TENSION RODSF - VALVE BODYG - PISTON AND CYLINDERH - FRONT CHASSISI - HYDRAULIC ACCUMULATOR

15


HOUSING AND VIBRATION DAMPER

Removal

R050004

Component CB200 S CB260 S CB320 S CB400 S CB550 S CB700 S

Minimum buffer thickness (D1) 70 mm 70 mm 70 mm 106 mm 103 mm -Minimum pad thickness (D2) 112 mm 112 mm 112 mm 133 mm 130 mm -Max clearance between hydraulic hammer and housing (D3)

-10...10 mm

-10...10mm

-10...10mm

-10...10mm

-10...10mm

Max distance between wear plates (D4) 239 mm 264 mm 304 mm 324 mm 344 mm -Max distance between wear plates (D5) 238 mm 263 mm 303 mm 323 mm 344 mm -Bracket retaining screw threads and bearing surfaces

grease for

thread

grease for

thread

grease for

thread

grease for

thread

grease for

thread

-

STEP 1

Remove the tool and disconnect the hydraulic ham-mer from the tool-carrier

STEP 2

R050266Remove the retaining screws and lift the cover.

WARNING: The hydraulic hammer must be protected against falling during handling. Check that the liftingequipment is of sufficient capacity to carry out the operation. See "Lifting instructions". See "Hydraulic ham-mer specifications"

STEP 3

R050266Disconnect the hydraulic hoses.

16


STEP 4

R050006Unscrew the bracket retaining screws.Lift and remove the bracket.

STEP 5

R050006Remove the buffer.

STEP 6

R050007Install the lifting adaptor.Lift the hydraulic hammer so as to arrive at a clear-ance of 10 mm between the control valve body shoul-ders and the pads.

STEP 7

R050007Move the hydraulic hammer horizontally in bothdirections inside the housing. Measure the clearanceat the control valve body shoulders. If the maximumclearance is exceeded, the wear plates located in thehousing must be replaced (clearance = 10 mm).STEP 8

C050008Lift the hammer and remove it from the housing.

STEP 9

C050008Remove the pads.

17


STEP 10

R050009Place the hammer housing horizontally on the groundor on a bench.Remove, if necessary, the wear plates, using ascrewdriver as a lever.

STEP 11

R050009Remove the seal.

Installation

STEP 1

Check all components for leaks and excessive wear.

STEP 2

Measure the thickness of the pads and buffers. If thereadings found are below specifications or if cracksare found, these components must be changed.NOTE: Pads must be changed in pairs.

STEP 3

Put the wear plates back in place.

STEP 4

Install the hammer housing in the vertical position.

STEP 5

Install the seal.

STEP 6

C050010Install the pads.

STEP 7

C050010Lower the hammer into the housing. Check the clear-ance by moving the hammer horizontally in bothdirections.

STEP 8

Install the buffer.

STEP 9

Install the bracket.

STEP 10

Install the bracket retaining screws. Tighten theretaining screws to the specified torque.

STEP 11

Connect the hoses.

STEP 12

Assemble the covers.

STEP 13

Install the hydraulic hammer on the tool-carrier.

18


PRESSURE ACCUMULATOR PRESSURE RELEASE

WARNING: Never disassemble the hydraulic hammer before releasing all pressure from the accumulator

STEP 1

R050015Remove the protective plug and the O-ring.

STEP 2

R050015Carefully loosen the filler orifice plug and allow thenitrogen to escape.

STEP 3

R050015After all pressure has been released, remove the fillerorifice plug and the snap ring.

PRESSURE ACCUMULATOR

Removal

R050014

Component Lubricant

Retaining screw threads and bearing surfaces of retaining screws and lock-washers

Grease for threads

Accumulator cover (gas end) Silicone greaseAll seals and O-rings Grease for O-ringsContact surfaces of control valve body and accumulator Anticorrosion product (for example: CRC 3-36)

19


STEP 1

R050016Remove the retaining screws and the lock-washersfrom the accumulator.

STEP 2

R050016Using lifting equipment, raise the accumulator out ofits housing.

Disassembly

STEP 1

R050017Install the accumulator on a bench, with the topdownwards.Remove the seal

WARNING: Make sure that all pressure in theaccumulator is released

STEP 2

R050017Remove the accumulator cover retaining screws.

STEP 3

R050017Remove the bottom of the accumulator, the dia-phragm and the cylindrical pins.

Assembly

STEP 1

R050018Clean and dry the parts very carefully. Install thelower part of the accumulator on a bench.Install a new diaphragm.Make sure that it is correctly seated in its groove.Insert the cylindrical pins.

20


STEP 2

R050018Apply a thin coat of silicone grease in the accumula-tor cover.Lower the cover onto the lower part of the accumula-tor.Grease the threads and the bearing surfaces of theaccumulator cover retaining screws.

STEP 3

R050019Install the accumulator upside-down on the bench,with the top downwards.Tighten the accumulator cover retaining screws tothe specified torque setting.

STEP 4

R050019Install the O-ring.

Installation

STEP 1

R050020Lower the accumulator to its correct position, usinglifting equipment.Apply an anticorrosion product to the contact sur-faces of the control valve body and the accumulator.

STEP 2

R050097Grease the threads and the bearing surfaces of theaccumulator retaining screws and lock-washers.

STEP 3

R050020Insert the accumulator retaining screws.Tighten the retaining screws to the specified torquesetting.

21


CHARGING THE ACCUMULATOR

Charging

R050021

WARNING: Use only nitrogen (N2) to charge the accumulator. The use of other gases can cause the accu-mulator to explode.

Pressure charge (Nitrogen N2)

Component CB200 S CB260 S CB320 S CB400 S CB550 S

Pressure accumulator 40 bar (580 psi) 40 bar (580psi) 40 bar (580 psi) 40 bar (580 psi) 40 bar (580 psi)

STEP 1

R050022Install a new snap ring.

STEP 2

R050022Install the filler orifice plug.Install the adaptor with the O-ring.Insert the pin.

STEP 3

R050023Install the charging device.Connect the charging system to the nitrogen bottle.Carefully tighten the filler orifice plug through thecharging device until you feel it stop.Then unscrew it three turns.

22


STEP 4

R050023Fully open the charging device discharge valve.Carefully open the nitrogen bottle valve and adjustthe gas flow to minimum.

STEP 5

R050024Remove the charging device from the accumulator.

WARNING: The charging device does nothave a pressure relief valve.Close the valve on the gas bottle when thegauge shows that the pressure charge is cor-rect. Close the pressure discharge valve onthe charging device and charge the accumu-lator 2 to 3 bar above the specified pressure.Watch the reading on the pressure gaugecarefully.Close the nitrogen bottle.Wait 10 minutes for the nitrogen pressure inthe accumulator to stabilise. Carefully open the discharge valve to adjustthe pressure in the accumulator to the correctsetting.Tighten the charging device filler plug to thespecified torque setting.Release the pressure in the charging hose, byopening the discharge valve.

STEP 6

R050025Check for nitrogen leaks at the accumulator by fillingthe snap ring area with thin oil.If gas bubbles appear, release the pressure in theaccumulator and change the snap ring.

STEP 7

R050025Install the protective plug.Tighten the plug to the specified torque setting.

23


DISCHARGE VALVE

Removal

R050027

Component Lubricant

Screw threads, contact surfaces and thrust washers Grease for threadsAll seals and O-rings Grease for O-ringsAll bushings and guides Hydraulic fluid

STEP 1

R050028Remove the discharge valve cover retaining screwsand washers

WARNING: Before removing a plug or avalve, make sure that all hydraulic pressurecontained in the hydraulic hammer has beenreleased. Read the instructions concerningrelease of hydraulic pressure in the hydraulichammer. See "Releasing hydraulic pressurein the hydraulic hammer" on page 12.

STEP 2

R050028Insert two of the retaining screws into the cover. Usethem as forcing screws and remove the cover.

STEP 3

R050029Remove the main spool and the other spools.

24


STEP 4

R050029Install the extractor, using the retaining screw holesin the cover.Insert the extractor flanges between the extractorscrew and the discharge valve bushing.Extract the discharge valve bushing.

STEP 5

R050030Remove the used seals and O-rings from the dis-charge valve bushing and from the covers.

Installation

STEP 1

Check all components for wear or damage. If neces-sary, use emery paper or a polishing compound.Clean and lubricate all components.

STEP 2

R050031Install new seals on the discharge valve bushing.

STEP 3

Carefully install the discharge valve bushing in posi-tion.

STEP 4

R050031Install the extractor on the end of the control valvewhich has the X mark.Install the bushing.Install the main spool with the end with the X markinstalled at the same end as the end of the controlvalve body and the discharge valve bushing with theX mark.

25


STEP 5

Install the spools. Make sure that all the spools slidefreely.

STEP 6

R050032Install new O-rings on the discharge valve covers.NOTE: Before installing the covers back in place,make sure that all the X marks on all the assembledcomponents appear on the same end as the X markon the control valve body.

STEP 7

R050180Install the covers in place.Make sure that the cover with the X mark is fitted onthe same end as the end of the control valve with theX mark.

STEP 8

Lubricate the threads and bearing surfaces of theretaining screws and thrust washers before installingthem in position.

STEP 9

Tighten the retaining screws to the specified torquesetting.

26


NON-RETURN VALVE

Removal

R050033

NOTE: The non-return valve is in the control valve body, at the pressure end (oil inlet port). It is also possible toremove it without removing the hydraulic hammer mechanism from its housing.

Component Lubricant

Screw threads and bearing surfaces, thrust washers Grease for threadsAll seals and O-rings Grease for O-ringsAll bushings and guides Hydraulic fluid

WARNING: Before removing a plug or a valve, make sure that all the hydraulic pressure in the hydraulic ham-mer has been released. Read the instructions concerning releasing the pressure in the hydraulic hammer.See "Releasing hydraulic pressure in the hydraulic hammer on page xxxx.

STEP 1

R050034Remove the retaining screws and the washers fromthe non-return valve.

STEP 2

R050034Insert two retaining screws in the housing of the non-return valve, using them as forcing screws, andremove the non-return valve.

27


STEP 3

R050035Install and tighten the non-return valve in a vice.Remove the O-rings.Remove the flange.

STEP 4

R050035Remove the spring guide, the spring and the spool.

Installation

STEP 1


STEP 2

Install the spool, the spring and the spring guide.

STEP 3

Install the flange. Make sure that the spool movesfreely against the spring.

STEP 4

Install new O-rings.

STEP 5

Place the non-return valve in the control valve body.

STEP 6

Lubricate the threads and bearing surfaces of theretaining screws and washers before assemblingthem.

STEP 7


28


PRESSURE REGULATOR

Removal

NOTE: The pressure regulator is in the control valve body, at the pressure end (oil outlet port). It is also possible toremove it without removing the hydraulic hammer mechanism from its housing.

CB200 S CB260 S CB320 S CB400 S CB550 S CB700 S

Spring free length (D1) 68.2 - 68,8 mm

78,3 mm 71.5 mm 82.5 mm 88.3 - 88,9 mm

-

Thickness shims (E) 0...1,5 mm - - - - -

Component Lubricant


WARNING: Before removing a plug or a valve, make sure that all the hydraulic pressure in the hydraulic ham-mer has been released. Read the instructions concerning releasing the hydraulic pressure in the hydraulichammer. See "Releasing hydraulic pressure in the hydraulic hammer" on page 12.

R050591 R050265

STEP 1

R050037Remove the retaining screws and the washers fromthe pressure regulator.

STEP 2

R050037Insert two of the removed retaining screws into thecover, using them as forcing screws, and remove thepressure regulator.

29


STEP 3

R050150Install and tighten the pressure regulator in a vice.Remove the seals and the O-ring.

STEP 4

R050150Decompress the spring by unscrewing the guide andthe regulator housing at the same time.

STEP 5

R050150Remove the guide and its spool. Remove the pres-sure regulator housing.

STEP 6

R050151Remove the spool, the spring and the spring guide.

STEP 7

R050151Remove the shims.

Installation

STEP 1


STEP 2Install and tighten the pressure regulator cover in avice.

30


STEP 3

R050149Install the shims, the spring guide, the spring and thespool. Measure the free length to obtain the correctspring pre-load. The normal operating pressure,which is pre-set in the factory, corresponds to theaverage obtained when the measured height is inaccordance with the specified height.Adjust the spring pre-load in accordance with specifi-cations, by adding or removing shims. After eachadjustment of the regulator, always measure thehammer operating pressure by means of a pressuregauge.

STEP 4

Install the housing and the pressure regulator guide.Tighten the components to the specified torque.

STEP 5

Install new seals. See the illustration for the correctinstallation method.

STEP 6

Insert the spool in position.

STEP 7

Place the regulator in the control valve body.

STEP 8

Lubricate the threads and bearing surfaces of theretaining screws and washers.

STEP 9


PRESSURE SEQUENCING VALVE(CB400 S - CB550 S)

Removal

R050039A, B, C: See torque setting on page 10.

31


R050040

Component CB400 S CB550 S

Spring free length (D1) 36,5 - 37, 0 mm 35,9 - 36,4 mm

Component Lubricant


WARNING: Before removing a plug or a valve, make sure that all the hydraulic pressure in the hydraulic ham-mer has been released. Read the instructions concerning releasing the hydraulic pressure in the hydraulichammer. See "Releasing the hydraulic pressure in the hydraulic hammer" on page 12.

STEP 1

R050041Remove the valve retaining screws and washers.

STEP 2

R050041Install the valve in a vice.

STEP 3

Remove the O-rings.

STEP 4

R050041Remove the retaining screws and the washers.Remove the spring housing.

32


STEP 5

R050042Remove the spring guides, the spring, the adjustingplates and the spring housing O-ring.

STEP 6

R050042Remove the flange plug.Remove the spool.

STEP 7

R050042Remove the flange plug.

Installation

STEP 1


STEP 2

R050310Using a fine, small needle, check that the jets are notclogged.

STEP 3

Install and tighten the pressure sequencing valvecover in a vice.

STEP 4

Install the flange plug and tighten it to the specifiedtorque setting.

STEP 5

Install the spools and make sure that they slidefreely.

STEP 6

Install the other flange plug.Tighten it to the specified torque setting.

STEP 7

Install a new O-ring.

STEP 8

Insert the shims, the spring guides and the spring.Measure the free length to obtain the correct pre-loadfor the spring. Add or remove shims.

STEP 9

Insert the spring guide and install the spring in itshousing.

33


STEP 10

Lubricate the threads and bearing surfaces of theretaining screws and install the screws and washers.

STEP 11


STEP 12

Install new O-rings.

STEP 13

Lubricate the threads and bearing surfaces of theretaining screws.

STEP 14

Install the pressure sequencing valve in position.Insert the retaining screws and the washers.

STEP 15


34


TIE-ROD

Removal

R050044

Component (all) LubricantTie-rod threads and bearing surfaces; tie-rod nuts Grease for threadsTie-rod central portion Heat-resistant paint

STEP 1

R050045Remove the rubber bushings and locking plates.

WARNING: Before heating the tie-rods, makesure that the pressure sequencing valve hasbeen removed from the hydraulic hammer.

STEP 2

R050045Make a mark on each tie-rod and on the correspond-ing nut. Also mark the location of each of the tie-rodsin the hydraulic hammer.

35


STEP 3

R050045Heat the tie-rods with a welding torch until it becomespossible to unscrew them with a wrench.Heat the tie-rods over their entire length (and not atany special point), without exceeding 300C. Makesure the flame is directed onto the tie-rods (and notonto the hammer body).STEP 4

R050046

- Remove the nuts.

- Use suitable lifting equipment to remove the tie-rods. Watch out for hot parts.

Installation

STEP 1

Clean all the components carefully.

STEP 2

Use a crack detection device to check for cracks inthe tie-rod threads and under their front part. If cracksare detected, change the tie-rod(s) and the corre-sponding nuts. Also make sure that each tie-rod isplaced back in the same position it occupied on thehydraulic hammer before removal.

STEP 3

Apply heat-resistant paint to the tie-rods locatedinside the front part.

STEP 4

Lubricate the threads and bearing surfaces of the tie-rods, the control valve body and the tie-rod nuts.

STEP 5

R050047Install the tie-rod nuts and tie-rods in their correctpositions. Identify the arrow and the UP stamped onthe nut. Make sure that each tie-rod is used with itscorresponding nut. Also make sure that each tie-rodis back in the same position it occupied in the hydrau-lic hammer before removal.

STEP 6

R050047Use a torque wrench to tighten the tie-rods in severalsuccessive stages until reaching the torque settingthey had before removal.

36


STEP 7

R050047Make a mark to show the additional tightening angleon the control valve body and the tie-rods.

STEP 8

Heat all the tie-rods with a welding torch until itbecomes possible to tighten them to the correct tight-ening angle with a wrench.Never exceed 300C.

STEP 9

R050048When the tie-rods have cooled down sufficiently, fillthe grooves between the tie-rods and the front part ofthe tool with a silicone product.

STEP 10

Install the locking plates.

STEP 11

Install the rubber bushings.

37


CONTROL VALVE BODY COMPONENTS

Removal

CB200 S CB260 S CB320 S

R050589 R050684 R050153

Component Lubricant

Plugs and breathers Thread-lock fluid (Loctite 275 for example)All seals and O-rings Grease for O-ringsContact surfaces between the control valve body, the seal-carrier and the cylinder

Anti-corrosion product (CRC 3-36 for example)

Contact surfaces between the cylinder and the front part Grease for threadsAll components, the piston in particular Hydraulic fluid

STEP 1

R050137Screw the lifting rings into the control valve body andremove the control valve body.

STEP 2

R050137Remove the seals.Remove the parallel pin.

38


STEP 3

R050138Carefully lift and remove the piston, the cylinder andthe seal-carrier. Take care not to drop the seal-car-rier.

STEP 4

R050138Position the sheet of plywood (See special toolspage).On the top of the front part, place the piston, the cyl-inder and the seal-carrier on the plywood sheet.

STEP 5

R050139Screw the lifting rings into the cylinder and lift it sothat there is a distance of about 50 mm between theplywood sheet and the seal-carrier.

STEP 6

R050546Remove nylon screw from the seal carrier (CB260 S).STEP 7

R050139Screw the pins into the seal-carrier.

STEP 8

R050139Push the seal-carrier down by tapping on the pins toseparate them.Watch out for oil flowing out.

STEP 9

R050140Carefully remove the cylinder.

39


STEP 10

R050140Carefully remove the piston.

STEP 11

R050141Remove the parallel pin and the O-rings.

STEP 12

R050141Remove the seals and the seal-carrier wiper.

STEP 13

R050142Remove the wiper seal and the O-rings from the cyl-inder.

Installation

STEP 1


STEP 2

Lubricate the seal, the O-rings and the cylinder wiperseal and install them.

STEP 3

Place the seal-carrier on the sheet of plywoodlocated on top of the front part.

STEP 4

R050145Lubricate the piston and lift it to install it in the seal-carrier.Tap the piston into position with a plastic hammer.

40


STEP 5

R050143Install the O-rings and the wiper seal on the cylinder.

STEP 6

R050147Spray MoS2 on the contact surfaces of the seal-car-rier and the cylinder. Install the cylinder on the piston.Tap the cylinder to push it down onto the piston. Usea plastic hammer.Install nylon screw to seal carrier (CB260 S).STEP 7

Screw a lifting ring into the piston and lift the assem-bly, remove the sheet of plywood (See special toolspage).

STEP 8

Apply a thin coating of grease on the upper surface ofthe front part.NOTE: It is possible to install the hydraulic hammerso that it can be used by a left-handed or a right-handed person (by connecting the pressure supplyline to the right-hand or to the left-hand side of thecontrol valve body). Hydraulic hammers are manu-factured in standard form with the oil inlet port con-nected to the right-hand side of the control valvebody and the oil outlet port connected to the left-handside. The cylinder is equipped with two installationgrooves, for this purpose. To set up the hydraulichammer for a right-handed person (standard version)install the cylinder so that the corner of the front partis housed in the groove marked with a small dot (Seeillustration at Step 9). To set up the hydraulic hammerfor a left-handed person, use the groove located onthe other side.

STEP 9

R050148 R050146Lower the piston, cylinder and seal-carrier assemblyinto its correct position inside the front top part. Makesure not to drop the seal-carrier. Remove the liftingring.

STEP 10

Install the seals, the O-rings and the parallel pinbetween the control valve body and the cylinder.

STEP 11

Spray MoS2 on the contact surfaces of the cylinderand the control valve body. Install the control valveassembly.

41


CB400 S

R050049

Component Lubricant

Plugs and breathers Thread-lock fluid (Loctite 275 for example)All seals and O-rings Grease for O-ringsContact surfaces between the control valve body, the seal-carrier and the cylinder

Anti-corrosion product (CRC 3-36 for example)

Contact surfaces between the cylinder and the front part Grease for threadsAll components, the piston in particular Hydraulic fluid

STEP 1

R050050Screw the lifting rings into the control valve body andremove the control valve body.

STEP 2

R050050Remove the seals.Remove the O-rings.Remove the parallel pin.

CB550 S

42


STEP 3

R050051Lift the seal-carrier and remove it.Remove the seal.

STEP 4

R050052Carefully lift the piston and remove it.

STEP 5

R050052Remove the O-rings and the parallel pin.

STEP 6

R050052Lift the cylinder and remove it from the front part.

STEP 7

R050053Remove the wiper seal and the seal-carrier seals.

STEP 8

R050054Remove the wiper seal, the seal and the O-rings fromthe cylinder.

43


Installation

STEP 1


STEP 2

R050055Lubricate the cylinder seal, wiper seal and O-ringsand install them.

STEP 3

R050055Lubricate the seals and the seal-carrier wiper sealand install them.

STEP 4

Apply thread grease to the contact surfaces of thefront part and the cylinder.

STEP 5

R050056Install the cylinder in the front part.NOTE: It is possible to install the hydraulic hammerso that it can be used by a left-handed or a right-handed person (by connecting the pressure supplyline to the right-hand or to the left-hand side of thecontrol valve body). Hydraulic hammers are manu-factured in standard form with the oil inlet port on theright-hand side of and the oil outlet (return) port onthe left-hand side. The cylinder is equipped with twoinstallation grooves for this purpose.To set up the hydraulic hammer for a right-handedperson (standard version) install the cylinder so thatthe corner of the front part is housed in the groovemarked with a small dot (See illustration at Step 9).To set up the hydraulic hammer for a left-handed per-son, use the groove located on the other side.

STEP 6

Lubricate the piston and place it in the cylinder.

STEP 7

Install the O-rings and the parallel pin.

STEP 8

Install the seal in the seal-carrier groove. Use a thincoating of grease to prevent the seal falling whenreassembling.

STEP 9

Spray MoS2 on the contact surfaces of the seal-car-rier and the cylinder.Install the seal-carrier in its correct position.

STEP 10

Install the seals, the O-rings and the parallel pin.

STEP 11

Spray MoS2 on the contact surfaces of the seal-car-rier and the control valve body.Install the control valve body.

44


FRONT PART

Removal

CB200 S CB260 S CB320 S CB400 S - CB550 S

R050590 R050269 R050268 R050057

Wear limit

Component CB200 S CB 260 S CB320 S CB400 S CB550 S

Maximum length of thrust ring (D1) 10 mm 8,5 mm 9,4 mm 10,2 mm 11,3 mmMaximum diameter of tool upper bushing (D2) 109,2 mm 118,2 mm 132,8 mm 143,4 mm 161,5 mmTool lower bushing See "Tool lower bushing" on page 50

STEP 1

R050058Remove the wedge and the O-ring, using a pin-drift(CB200 S, 260 S, 320 S, 400 S, 550 S).

Component Lubricant

All seals and O-rings Grease for O-ringsContact surfaces between components Grease for threadsTool inner bushings Grease for tools

STEP 2

R050058Lift and remove the thrust ring (CB200 S, 260 S, 320S, 400 S, 550 S).

45


STEP 3

R050058Remove the O-ring from the thrust ring (CB200 S,260 S, 320 S, 400 S, 550 S).STEP 4

R050059Install a bushing extractor. Place the extractorflanges as shown in the illustration.Remove the bushing using a hydraulic ram (CB200S, 260 S, 320 S, 400 S, 550 S).STEP 5

R050059Remove the bushing from the front part (CB200 S,260 S, 320 S, 400 S, 550 S).

STEP 6

R050060Turn the front part upside-down.Remove the separator pin and the retaining ring(CB200 S, 260 S, 320 S, 400 S, 550 S).STEP 7

R050060Remove the tool lower bushing, using the bushingextractor (CB200 S, 260 S, 320 S, 400 S, 550 S).STEP 8

R050062Remove the grease fittings, if necessary (CB200 S,260 S, 320 S, 400 S, 550 S).

46


STEP 9

R050061Carefully clean the threads in the front part (holemarked with a cross) before installing the extractor(CB320 S, 400 S, 550 S).STEP 10

R050061 R050061Remove the separator bushing and the spring guidefrom the front part, using two wrenches (CB320 S,400 S, 550 S).STEP 11

R050062Remove the spring and the retaining pin.

Installation

STEP 1

Carefully clean and dry all the components. Check allcomponents for cracks and excessive wear. For wearlimits of the thrust ring and the tool bushing, see page50.For the tool lower bushing, see page 50 (CB200 S,260 S, 320 S, 400 S, 550 S).

STEP 2

Install the grease fittings.

STEP 3

Insert the retaining pin and the spring (CB320 S, 400S, 550 S).STEP 4

Install the spring guide and the separator pin (CB320S, 400 S, 550 S).STEP 5

Install the tool seal and the O-ring on the tool lowerbushing (CB200 S, 260 S, 320 S, 400 S, 550 S).STEP 6

Apply thread grease on the contact surfaces of thetool lower bushing and the front part. Install the toollower bushing.

STEP 7

Insert the retaining pin and the separator pin (CB200S, 260 S, 320 S, 400 S, 550 S).STEP 8

Lubricate the inner surface of the tool lower bushingwith tool grease.

STEP 9

Install the front part on the ground, resting it on thetool lower bushing (CB200 S, 260 S, 320 S, 400 S,550 S).STEP 10

Apply thread grease to the outer surfaces of the toolupper bushing and the thrust ring. Lubricate the innersurface of the tool upper bushing with tool grease(CB200 S, 260 S, 320 S, 400 S, 550 S).STEP 11

Install the tool upper bushing (CB200 S, 260 S, 320S, 400 S, 550 S).STEP 12

Install the thrust ring and the O-ring (CB200 S, 260 S,320 S, 400 S, 550 S).STEP 13

Install the wedge and the O-ring.

47


CHANGING A TOOL

RemovalTools required

- One hammer- One bronze or copper drift- One flat-headed screwdriver

STEP 1

CT02D444Place the hydraulic hammer horizontally on flat, hardground.

STEP 2Shut down the engine and remove the starter switchkey.

STEP 3

CT02D445Move the rubber plate upwards (if fitted). Remove thepins and plugs from both sides of the hydraulic ham-mer.

STEP 4

CT02D446Press out the pins, using the bronze or copper drift.

STEP 5

CT02D447Remove the tool. Use lifting equipment if necessary.NOTE : If the hydraulic hammer is still mounted onthe machine, it will be possible to place the point ofthe tool on the ground and then raise the hydraulichammer. Make sure the tool is firmly held.

InstallationTools required

- One hammer- One bronze or copper drift- One flat-headed screwdriver

48


STEP 1

CT02D448Check the tool bushing and the seal for wear.Change them if necessary. See "Changing the toolbushing".

STEP 2

Clean and grease the tool and the retaining pins.

STEP 3

CT02D449Insert the tool, aligning its grooves with the holes inthe retaining pins.

STEP 4

Install the pins and make sure that the tool is firmlygripped.

STEP 5

CT02D450Install the plugs and pins. Move the rubber plate backto its lower position (if fitted).

49


CHANGING THE TOOL BUSHING

RemovalTools required

- One hammer- A bronze or copper drift

STEP 1

Remove the tool. See "Changing a tool".

STEP 2

CT02D451Drift out the pins and plugs.

STEP 3

CT02D452Remove the tool bushing.

InstallationTools required

- One hammer- A bronze or copper drift

STEP 1

CT02D453Check the condition of the seals, change them if nec-essary.

STEP 2

Lubricate the contact surfaces of the tool bushing andits housing.

STEP 3

CT02D452Insert the tool bushing into its housing, then installthe pins and plugs.

STEP 4

Install the tool. See "Changing a tool".

50


WEAR LIMITS

Types: CB200 S to CB700 S

CS99C629The first groove (1) is worn away, but the second (2)is visible. The tool bushing can be installed again.Turn the tool bushing 90 so as to use the unwornarea.Carry out the same operation for the second groove(2) using the retaining groove (3)The tool bushing must be changed when bothgrooves (1) and (2) are worn. See "Changing the toolbushing".

1

3

2

Tools

CS99C630

Type Original dimension Wear limit

CB200 S 115 mm 113 mm

CB260 S 125 mm 123 mm

CB320 S 130 mm 128 mm

CB400 S 140 mm 138 mm

CB550 S 160 mm 158 mm

CB700 S 175 mm 173 mm

When it is necessary to change, see "Changing a tool".

51


INSPECTION AND MEASUREMENT OF HYDRAULIC HAMMER CIRCUIT

Measurement/Inspection points

R050064A - FlowmeterB - Hydraulic hammer control valveC - Safety valveQ2 - Flow passing through hydraulic hammerP2 - Hydraulic hammer supply pressureT2 - Hydraulic oil temperatureP3 - Return pressure

Procedure for taking measurementsHydraulic hammer circuit measurement and adjustment procedure:NOTE: Check and calibrate all gauges: pressure gauges which are to be used. Change any defective pressuregauge.

NOTE: If the flow towards the hydraulic hammer is adjusted by changing the speed of the engine, the flow shouldalways be checked with the engine running at full speed.

NOTE: It is strictly forbidden to operate the hydraulic hammer at a higher flow than the specified flow.

B

C

A

52


STEP 1

Check the condition of the pipes and hoses, cou-plings, flanges, etc. Change any worn or damagedcomponents and retighten joints as necessary.STEP 2

Make sure that the hydraulic hammer supply line iscorrectly equipped with a pressure relief valve.

STEP 3

Make sure that the hydraulic fluid in the tool-carrierhas reached its normal operating temperature.

STEP 4

Connect the flowmeter in place of the hydraulic ham-mer. It is preferable to use the same hoses and cou-plings as those of the hydraulic hammer, particularlywhen the hoses have quick couplings.

STEP 5

Operate the hydraulic hammer "ON" control.

STEP 6

Plug the hydraulic hammer supply line and set thepressure relief valve 50 bar (pressure gauge p2)higher than the maximum operating pressure of thehydraulic hammer as shown in the technical specifi-cations (See the Service Manuals concerned).STEP 7

Reconnect the hydraulic hammer supply line to theflowmeter.

WARNING: The pressure setting of thetool-carrier relief valve must never beexceeded.

STEP 8

Operate the hydraulic hammer "ON" control so as toreach the normal operating pressure of the hammerat pressure gauge p2.

STEP 9

Make sure that the oil flow from the hydraulic ham-mer is within the specified limits.

STEP 10

Make sure that the counter-pressure in the return line(p3) does not exceed the permitted values as regardsthe oil flow from the hydraulic hammer.

STEP 11

Make sure that the oil flow from the hydraulic ham-mer does not increase when the working pressure ofthe machine exceeds the hydraulic hammer supplyline pressure (flow compensation). To do this, pushthe boom, dipper and bucket cylinders against thestops, while at the same time operating the hammer"ON" control.

STEP 12

Shut down the engine.

STEP 13

Connect the hydraulic hammer in place of the flowm-eter.

STEP 14

Measure the operating pressure of the hydraulichammer. See "Measuring the hydraulic hammeroperating pressure" on page 53.

STEP 15

When installing a new hydraulic hammer, check allmeasurements after about 50 hours operation of thehydraulic hammer.

53


MEASURING THE HYDRAULIC HAMMER OPERATING PRESSURE

R050063A - Pressure measurement port plug.

WARNING: Taking hydraulic hammer pressure measurements while the hammer is working constitutes adanger area. Provide yourself with effective protection against oil jets.

STEP 1

In order to measure the operating pressure of thehydraulic hammer, the hydraulic hammer hydrauliccircuit must have reached its normal operating tem-perature. Before starting the hydraulic hammer oper-ating pressure measurement procedure, run thehydraulic hammer until the hydraulic fluid is suffi-ciently hot.

STEP 2

Shut down the machine engine. Operate the boomand hydraulic hammer controls to release pressure inthe hoses.

STEP 3

Slowly unscrew the pressure measurement plugs (A)and (B). Watch out for oil leaks.STEP 4

Connect a 250 bar pressure gauge, fitted with a hoseat least 10 metres long, to the high pressure meas-urement port (A).

STEP 5

Start the hydraulic hammer and adjust the enginespeed. Adjust engine speed to the speed of thehydraulic hammer. If the machine has several work-ing power modes, select the mode for working with ahydraulic hammer.

STEP 6

Position the tool on, for example, a thick steel plateand start the hydraulic hammer operating.

STEP 7

Read the average operating pressure shown on thelow pressure gauge.A - Average pressure needle fluctuation* - Average pressure

R050252

54


STEP 8

The average operating pressure should be within thespecified range limits.NOTE: When the operating pressure is being meas-ured with the hydraulic hammer on a thick steel plateor equivalent hard material, the reading should be inthe lower half of the specified pressure range. If thehydraulic hammer is being used with a lighter mate-rial, the operating pressure of the hydraulic hammershould have a tendency to increase. See "Hydraulichammer specifications".

STEP 9

If the readings taken are not in accordance with spec-ifications, the pressure regulator spring pre-loadshould be adjusted and the measurements takenagain. See "Pressure regulator", on page 28.

STEP 10

Shut down the engine. Wait 10 minutes for the oilpressure to drop and then remove the pressuregauge. Tighten the plug (A) to the specified torquesetting.

55


WORKING PRINCIPLES

CS99E531

StartingThe hydraulic fluid passes through the non-returnvalve (A) before entering the accumulator (B) and thespace (C) located under the piston (P). The pressureregulator (D) has closed the outlet passage fromspace (E) and prevents any movement of the piston.The pressure increases inside the hammer and com-presses the nitrogen contained in the accumulator(B).

CS99E532

Return strokeWhen the pre-determined operating pressure isreached, the valve (D) opens the outlet passagebetween space (E) and the hydraulic reservoir line.The pressure accumulated under the piston (C)forces the piston to perform its return stroke (movingupwards).

56


CS99E533

Impact strokeWhen the piston reaches the top of its upwardsstroke, it allows the pilot pressure to pass throughpassage (H) up to the top end of the relief valve (G).The relief valve changes its position and opens thehigh pressure passage between the accumulator (B)and the cylinder space (E). The piston starts itsimpact stroke (moving downwards). The hydraulicfluid used for this stroke comes from the accumulatorand the supply line.

CS99E534

Impact stroke (final stage)The piston descends faster and faster. The groove(K) in the piston makes a connection between thepilot passage (H) and the reservoir line (L). The reliefvalve (G) starts to slow down the high pressure flowbetween the accumulator and the space (E) andbegins to open the connection with the pressure reg-ulator (D). Pressure in the accumulator drops duringthe impact stroke. This causes the outlet passage tobe closed by the pressure regulator (D). After theimpact, the piston stays motionless in position untilthe hydraulic fluid pressure increases again and thecycle is repeated (phase 1). The hydraulic brake (X)protects the piston and the cylinder against anyuncontrolled stroke.

57


TROUBLESHOOTING

Failure Cause Solution

The hydraulic hammer does not start

The supply or return circuit is closed Open the circuitsThe supply and return hoses are reversed

Connect the supply and return hoses correctly

The piston is in the hydraulic brake position

Operate the hammer control and press the tool against an object to push the piston out of its braking position.

There is grease between the piston and the tool contact area

Remove the tool and wipe away the excess grease

The hammer control valve spool does not pilot

Check that the spool pilots correctly. If it does not, check the control valve control circuit

The hydraulic circuit safety valve opens at low pressure

Check the pressure setting and operation of the safety valve

Excessive pressure in the return cir-cuit

Check the return circuit. Change the filter in the return circuit

Internal leak between supply and return circuits (the required flow can-not be attained)

Check the pump and the hydraulic components

Incorrect operation of hydraulic hammer control valve

The control valve must be over-hauled. See pages 37 and 41

Piston defect The cylinder must be overhauled. See pages 37 and 41

The hydraulic hammer operates irregularly, but at full power

Insufficient supply force coming from host machine

See operating methods in Opera-tors Manual


Check the pressure setting and operation of the safety valve

Incorrect operation of hydraulic hammer control valve


The hydraulic hammer operates poorly and lacks power

The working method is not being respected

Refer to operating methods in the Operators Manual


Check the pressure setting and the operation of the safety valve

The pressure setting of the pressure regulating valve is incorrect

The hammer must be overhauled. See pages 28 and 30

Drop in accumulator pressure Check the accumulator pressureIncorrect operation of hydraulic hammer control valve


58


The impact rhythm of the hydraulic hammer decreases

Overheated oil (over 80 C) Check:- the hydraulic oil cooling circuit,- that there is no internal leak in the

hammer,- the correct operation of the safety

valve,- the dimensions of the pipes/

hosesThe viscosity of the oil is too low Replace the hydraulic oil by oil

which meets specificationsThe return circuit pressure is too high

Check the return circuit. Change the filter if necessary Check the dimen-sions of the return circuit piping


Check the pressure setting and the operation of the safety valve

Internal leak between the supply and return circuits (the required flow cannot be attained)


The hydraulic oil temperature is too high

The operating method is not being respected

See the operating methods in the Operators Manual

The hydraulic oil cooling circuit is not operating correctly

Check:- the hydraulic oil cooling circuit,- the correct operation of the safety

valveThe viscosity of the hydraulic oil is too low

Replace the hydraulic oil by oil which meets specifications

Internal leak between the supply and return circuits (the required flow cannot be attained)


Internal leak in the hydraulic ham-mer

Check the hydraulic components of the hammer

Failure Cause Solution

jack hammer

Documents

cnh france s

hydraulic pressure

accumulator pressure

main components

vibration damper