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

CNH

Cre 7-23862GB

Copyright 2005 CNH France S.A. Printed in France November 2005

TABLE OF CONTENTS
TECHNICAL SPECIFICATIONS ...............................................................................................................................3 Overall dimensions................................................................................................................................................3 SPECIFICATIONS.....................................................................................................................................................5 TORQUE SETTINGS ................................................................................................................................................6 TOOLS REQUIRED ..................................................................................................................................................7 REPLACING A HYDRAULIC HAMMER....................................................................................................................9 HANDLING THE HYDRAULIC HAMMER ...............................................................................................................11 RELEASING THE HYDRAULIC PRESSURE IN THE HYDRAULIC HAMMER......................................................12 COMPONENT IDENTIFICATION............................................................................................................................13 LOCATION OF MAIN COMPONENTS ...................................................................................................................14 CB200 S - CB260 S - CB320 S - CB400 S - CB550 S - CB700 S .................................................................14 HOUSING AND VIBRATION DAMPER ..................................................................................................................15 PRESSURE ACCUMULATOR PRESSURE RELEASE..........................................................................................18 PRESSURE ACCUMULATOR ................................................................................................................................18 CHARGING THE ACCUMULATOR ........................................................................................................................21 DISCHARGE VALVE...............................................................................................................................................23 NON-RETURN VALVE............................................................................................................................................26 PRESSURE REGULATOR .....................................................................................................................................28 PRESSURE SEQUENCING VALVE (CB400 S - CB550 S)....................................................................................30 Removal ..............................................................................................................................................................30 TIE-ROD..................................................................................................................................................................34 CONTROL VALVE BODY COMPONENTS (CB200S - CB260 S - CB320 S) ........................................................37 Removal ..............................................................................................................................................................37 CB400 S - CB550 S ............................................................................................................................................41 FRONT PART..........................................................................................................................................................44 Removal ..............................................................................................................................................................44 CHANGING A TOOL ...............................................................................................................................................47 Removal ..............................................................................................................................................................47 Installation ...........................................................................................................................................................47 CHANGING THE TOOL BUSHING.........................................................................................................................49 Removal ..............................................................................................................................................................49 Installation ...........................................................................................................................................................49 WEAR LIMITS .........................................................................................................................................................50 Types: CB200 S, CB260 S, CB320 S, CB400 S, CB550 S, CB700 S ................................................................50 Tools ...................................................................................................................................................................50 INSPECTION AND MEASUREMENT OF HYDRAULIC HAMMER CIRCUIT.........................................................51 Measurement/Inspection points ..........................................................................................................................51
Cre 7-23862GB Issued 11- 05

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

Cre 7-23862GB

Issued 11- 05

TECHNICAL SPECIFICATIONS Overall dimensions CB200 S - CB260 S CB320 S

C040033

C040035

Types Codes A B C D E F G H I CB200 S 550 mm 510 mm 358 mm 2015 mm 1605 mm 570 mm 115 mm 252 mm 252 mm CB260 S 630 mm 510 mm 359 mm 2141 mm 1763 mm 570 mm 125 mm 266 mm 252 mm CB320 S 630 mm 510 mm 434 mm 2282 mm 1863 mm 570 mm 130 mm . 295 mm 217 mm

Cre 7-23862GB

Issued 11- 05

TECHNICAL SPECIFICATIONS Overall dimensions CB400 S CB550 S

C040042

C040038

Types Codes A B C D E F G H I CB400 S 640 mm 540 mm 462 mm 2621 mm 2157 mm 585 mm 140 mm 319 mm 319 mm CB550 S 730 mm 475 mm 2958 mm 2358 mm 730 mm 160 mm 337 mm 238 mm

Cre 7-23862GB

Issued 11- 05

SPECIFICATIONS
Section Operating weight (1) Impact rate (2) Operating pressure Minimum pressure setting (3) Maximum pressure setting Oil flow Maximum output pressure Input power Tool diameter Pressure line union (in) Return line union (out) Grease fitting Air union (A) Pressure line dimension (minimum internal diameter) Return line dimension (minimum internal diameter) Optimum oil temperature CB200 S 1040 kg 400-800 bpm 135-145 bar 185 bar CB260 S 1330 kg 360-650 bpm 125-145 bar 190 bar CB320 S 1710 kg 330-580 bpm 125-145 bar 190 bar CB400 S 2350 kg 300-450 bpm 140-150 bar 210 bar CB550 S 3150 kg 350-480 bpm 140-150 bar 190 bar CB700 S 3800 kg 300-480 bpm 140-155 bar 190 bar

220 bar 220 bar 220 bar 230 bar 230 bar 220 bar 80-130 l/ 100-170 l/ 120-200 l/ 160-230 l/ 210-310 l/ 220-320 l/ min min min min min min 10 bar 10 bar 10 bar 8 bar 8 bar 31 kW 40 kW 48 kW 58 kW 78 kW 83 kW 115 mm 125 mm 130 mm 140 mm 160 mm 1" 1" 1/4 1" 1/4 1" 1/4 1" 1/4 1" 1" 1/4 1" 1/4 1" 1/4 1" 1/4 1/4" 3/8" 3/8" 3/8" 3/8" 1/4" 3/8" 3/8" 3/8" 3/8" 26 mm 26 mm 26 mm 32 mm 32 mm 26 mm 26 mm 32 mm 32 mm 36 mm +40 +60 C -20 +80 C -

+40 +60 +40 +60 +40 +60 +40 +60 +40 +60 C C C C C Maximum permitted oil -20 +80 -20 +80 -20 +80 -20 +80 -20 +80 temperature range C C C C C Optimum oil viscosity at working 30-60 cSt 30-60 cSt 30-60 cSt 30-60 cSt 30-60 cSt temperature Maximum oil viscosity 20-1000 20-1000 20-1000 20-1000 20-1000 cSt cSt cSt cSt cSt 12-20 18-26 21-32 27-40 35-55 Weight of tool-carrier (4) tonnes tonnes tonnes tonnes tonnes
Table of applications of the hydraulic breaker See the Operators Manual. See the Operators Manual.

Noise level

1. Includes the medium installation hook and the standard tool. 2. The real impact frequency depends on the oil flow and its viscosity, the temperature and the material which is being broken. 3. Minimum setting = real working pressure +50 bar (730 psi). 4. The application recommendations for the implement are intended to provide optimum stability when the implement is used on a tool-carrier with standard load undercarriage, boom and dipper. For applications using other tool-carriers, contact your Dealer to check the compatibility and stability of the tool-carrier.
Cre 7-23862GB Issued 11- 05

TORQUE SETTINGS
Torque settings Component CB200 S
Hammer hydraulic pressure release plug (A) Screws which retain plate on hammer Accumulator retaining screws (A) Accumulator (B) cover retaining screws Accumulator filler orifice plug Relief valve (A) cover retaining screws Non-return valve retaining screws Pressure regulator retaining screws (A) Pressure regulating housing (B) Guide (C) Pressure regulating plug (D) Pressure sequencing valve (B) retaining screws Spring (A) housing retaining screws Flange plug (C) Flange plug (D) Tie-rod Supplementary tightening angle after heating Taper plug 1/4" 1 component Component located in the control valve body or the seal-carrier Breather BSP 1/4" 1 component Breather BSP 1/2" Flange plug BSP 3/8" Flange plug BSP 1/2" Flange plug BSP 1/4" Breather BSP 3/8" Flange plug BSP 1" Flange plug 3/4" Breather BSP 3/4" Plug A on front part Plug B on front part 30 Nm 1050 Nm 500 Nm 300 Nm 20 Nm 200 Nm 83 Nm 83 Nm 300 Nm 300 Nm 220 Nm 500 Nm 100 33 Nm

CB260 S
30 Nm 1050 Nm 500 Nm 450 Nm 20 Nm 120 Nm 200 Nm 200 Nm 300 Nm 300 Nm 500 Nm 120 33 Nm

CB320 S
30 Nm 1050 Nm 500 Nm 450 Nm 20 Nm 200 Nm 200 Nm 200 Nm 300 Nm 300 Nm 500 Nm 120 33 Nm

CB400 S
30 Nm 1050 Nm 700 Nm 450 Nm 20 Nm 200 Nm 200 Nm 200 Nm 300 Nm 300 Nm 125 Nm 125 Nm 80 Nm 10 Nm 700 Nm 90 -

CB550 S
2100 Nm 1350 Nm 700 Nm 20 Nm 340 Nm 200 Nm 200 Nm 300 Nm 300 Nm 125 Nm 125 Nm 80 Nm 10 Nm 700 Nm 90 -

CB700 S
-

30 Nm 120 Nm 50 Nm 80 Nm 30 Nm 33 Nm

120 Nm 50 Nm 30 Nm 40 Nm 120 Nm -

120 Nm 50 Nm 40 Nm 120 Nm 100 Nm -

50 Nm 30 Nm 40 Nm 120 Nm 175 Nm 100 Nm 50 Nm

50 Nm 80 Nm 30 Nm 40 Nm 200 Nm 175 Nm 100 Nm 50 Nm

Cre 7-23862GB

Issued 11- 05

TOOLS REQUIRED

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

SPECIAL TOOLS
R050253

R050065

R050066

380002526 - Accumulator charging kit (components 1.1 to 1.4) - Charging device (1.1) - Socket (1.2) - Adaptor (1.3) - O-ring (1.4)

380002532 - Bushing extraction tool (including 1.1 to 1.5) (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 to 1.5) (CB550 S) - Puller frame (1.1) - Threaded rod (1.2) - Puller plate lower tool bushing (1.3) - Washer (1.4) - Nut (1.5)

Cre 7-23862GB

Issued 11- 05

R050068

R050256

380002536 - Hammer support assembly (CB260 S CB320 S - CB400 S- CB550 S) 380002524 - Hammer support assembly (CB200 S)

380002529 - Support for cylinder and piston seal-carrier moulding (CB260 S) 380002533 - Support for cylinder and piston seal-carrier moulding (CB320 S) 380002534 - Support for cylinder and piston seal-carrier moulding (CB400 S)

R050067

380002537 - Hydraulic hammer lifting adaptor (CB260 S - CB320 S - CB400 S - CB550 S)

R050257

380002548 - Knock pin M24 (CB200 S - CB260 S)

R050069

380002530 - Accumulator assembly bracket (CB260 S - CB320 S - CB400 S) 380002525 - Accumulator assembly bracket (CB550 S)

R050254

380002549 - Accumulator assembly stand (CB320 S)

R050255

380002535 - Centring piece (CB320 S)

R050070

380002531 - Extractor (CB260 S - CB320 S - CB400 S - CB550 S)

R050685

380002539 - Extractor (CB400 S - CB550 S)

Cre 7-23862GB

Issued 11- 05

R050072

R050075

380002528 - 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)

380002527 - Hammer lifting adaptater (CB200 S)

REPLACING A HYDRAULIC HAMMER Removal

STEP 1 STEP 2
Shut down the engine and remove the starter switch key. Release the pressure in the hydraulic hammer circuit. See "Releasing pressure in the hydraulic circuit" in the "Lubrication/Filters/Fluids" Section of the Operators Manual for the machine concerned.

CT02D444

Position the hydraulic hammer horizontally on flat, hard ground.

Cre 7-23862GB

Issued 11- 05

10

STEP 3

Installation
STEP 1
Operate the attachment controls to bring the dipper into the hydraulic hammer.

STEP 2
Shut down the engine and remove the starter switch key. Release the pressure in the hydraulic hammer circuit. See "Releasing pressure in the hydraulic circuit" in the "Lubrication/Filters/Fluids" Section of the Operators Manual for the machine concerned.

STEP 3
CT02D444

Place a receptacle of a suitable capacity under the piping. Close the valves (circuit opening and closing valves) in the piping (if fitted). Disconnect the hoses from the pipes. Plug them if necessary.

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

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

STEP 4
Remove the retaining hardware (as fitted) from the pins.

STEP 5
Remove the connecting rod/hydraulic hammer pin, then the dipper/hydraulic hammer pin.

STEP 5
Install the connecting rod/hydraulic hammer pin and then install the retaining hardware (as fitted) for the pins.

STEP 6
Operate the machines controls to disengage the hammer.

STEP 6
Open the valves (circuit opening and closing valves) in the piping (if fitted).

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

STEP 7
Remove the lifting ring and install the plugging screw.

STEP 8
Grease the linkages.

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

Cre 7-23862GB

Issued 11- 05

11

HANDLING THE HYDRAULIC HAMMER

The lifting equipment must be able to withstand the weight of the hydraulic hammer. See "Hydraulic hammer weight 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 screw before operating the hydraulic hammer.

Cre 7-23862GB

Issued 11- 05

12

RELEASING THE HYDRAULIC PRESSURE IN THE HYDRAULIC HAMMER

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

R050214

1 - Supply port 2 - Outlet port

STEP 1
Shut down the machine engine. Operate the boom and hydraulic hammer controls to release all pressure from the hoses.

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

STEP 2
Close the hydraulic hammer inlet and outlet lines. If quick couplers are used, shutting off the circuit will automatically close the hydraulic hammer lines. If the hydraulic hammer line has ball valves, make sure that they are correctly closed.

STEP 3
Unscrew the pressure release plugs (A) and (B). Watch out for oil leaks.
R050081

WARNING: This procedure does not release pressure from the accumulator. Carefully follow the instructions concerning the accumulator before disassembling the accumulator. See "Pressure accumulator" on page 18.

Cre 7-23862GB

Issued 11- 05

13

COMPONENT IDENTIFICATION

1 4 5

6 7

8 2

CT04K003

1 - Housing 2 - Tool 3 - Accumulator 4 - Load handling eye

5 6 7 8

- Vibration damper - Grease fittings - Tool retaining hardware - Tool bushing retaining hardware

Cre 7-23862GB

Issued 11- 05

14

LOCATION OF MAIN COMPONENTS CB200 S - CB260 S - CB320 S- CB400 S - CB550 S - CB700 S

R050156

A B C D E F G H I -

PRESSURE TEST PLUG RELIEF VALVE NON-RETURN VALVE PRESSURE CONTROL VALVE TENSION RODS VALVE BODY PISTON AND CYLINDER FRONT CHASSIS HYDRAULIC ACCUMULATOR

Cre 7-23862GB

Issued 11- 05

15

HOUSING AND VIBRATION DAMPER Removal

R050004

Component Minimum buffer thickness (D1) Minimum pad thickness (D2) Max clearance between hydraulic hammer and housing (D3) Max distance between wear plates (D4) Max distance between wear plates (D5) Bracket retaining screw threads and bearing surfaces

CB200 S 70 mm 112 mm -10...10 mm 239 mm 238 mm grease for thread

CB260 S 70 mm 112 mm -10...10 mm 264 mm 263 mm grease for thread

CB320 S 70 mm 112 mm -10...10 mm 304 mm 303 mm grease for thread

CB400 S 106 mm 133 mm -10...10 mm 324 mm 323 mm grease for thread

CB550 S 103 mm 130 mm -10...10 mm 344 mm 344 mm grease for thread

CB700 S -

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

STEP 1
Remove the tool and disconnect the hydraulic hammer from the tool-carrier

STEP 3

STEP 2

R050266

Disconnect the hydraulic hoses.

R050266

Remove the retaining screws and lift the cover.

Cre 7-23862GB

Issued 11- 05

16

STEP 4

STEP 7

R050006

R050007

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

STEP 5

Move the hydraulic hammer horizontally in both directions inside the housing. Measure the clearance at the control valve body shoulders. If the maximum clearance is exceeded, the wear plates located in the housing must be replaced (clearance = 10 mm).

STEP 8

R050006

Remove the buffer.

STEP 6 STEP 9

C050008

Lift the hammer and remove it from the housing.

R050007

Install the lifting adaptor. Lift the hydraulic hammer so as to arrive at a clearance of 10 mm between the control valve body shoulders and the pads.

C050008

Remove the pads.

Cre 7-23862GB

Issued 11- 05

17

STEP 10

STEP 6

R050009

C050010

Place the hammer housing horizontally on the ground or on a bench. Remove, if necessary, the wear plates, using a screwdriver as a lever.

Install the pads.

STEP 7

STEP 11

C050010

R050009

Lower the hammer into the housing. Check the clearance by moving the hammer horizontally in both directions.

Remove the seal.

STEP 8
Install the buffer.

Installation
STEP 1
Check all components for leaks and excessive wear.

STEP 9
Install the bracket.

STEP 2
Measure the thickness of the pads and buffers. If the readings found are below specifications or if cracks are found, these components must be changed. NOTE: Pads must be changed in pairs.

STEP 10
Install the bracket retaining screws. Tighten the retaining screws to the specified torque.

STEP 11
Connect the hoses.

STEP 3
Put the wear plates back in place.

STEP 12
Assemble the covers.

STEP 4
Install the hammer housing in the vertical position.

STEP 13
Install the hydraulic hammer on the tool-carrier.

STEP 5
Install the seal.

Cre 7-23862GB

Issued 11- 05

18

PRESSURE ACCUMULATOR PRESSURE RELEASE

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

STEP 1

STEP 3

R050015

R050015

Remove the protective plug and the O-ring.

STEP 2

After all pressure has been released, remove the filler orifice plug and the snap ring.

R050015

Carefully loosen the filler orifice plug and allow the nitrogen to escape.

PRESSURE ACCUMULATOR Removal

R050014

Component Retaining screw threads and bearing surfaces of retaining screws and lock-washers Accumulator cover (gas end) All seals and O-rings Contact surfaces of control valve body and accumulator
Cre 7-23862GB

Lubricant Grease for threads Silicone grease Grease for O-rings Anticorrosion product (for example: CRC 3-36)
Issued 11- 05

19

STEP 1

STEP 2

R050016

R050017

Remove the retaining screws and the lock-washers from the accumulator.

Remove the accumulator cover retaining screws.

STEP 3

STEP 2

R050017 R050016

Using lifting equipment, raise the accumulator out of its housing.

Remove the bottom of the accumulator, the diaphragm and the cylindrical pins.

Disassembly
WARNING: Make sure that all pressure in the accumulator is released

Assembly
STEP 1

STEP 1

R050018

R050017

Install the accumulator on a bench, with the top downwards. Remove the seal

Clean and dry the parts very carefully. Install the lower 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.

Cre 7-23862GB

Issued 11- 05

20

STEP 2

Installation
STEP 1

R050018

Apply a thin coat of silicone grease in the accumulator cover. Lower the cover onto the lower part of the accumulator. Grease the threads and the bearing surfaces of the accumulator cover retaining screws.

R050020

Lower the accumulator to its correct position, using lifting equipment. Apply an anticorrosion product to the contact surfaces of the control valve body and the accumulator.

STEP 3

STEP 2

R050019

R050097

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

Grease the threads and the bearing surfaces of the accumulator retaining screws and lock-washers.

STEP 3

STEP 4

R050020 R050019

Install the O-ring.

Insert the accumulator retaining screws. Tighten the retaining screws to the specified torque setting.

Cre 7-23862GB

Issued 11- 05

21

CHARGING THE ACCUMULATOR Charging

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

R050021

Pressure charge (Nitrogen N2) Component Pressure accumulator CB200 S CB260 S CB320 S CB400 S CB550 S 40 bar (580 psi) 40 bar (580psi) 40 bar (580 psi) 40 bar (580 psi) 40 bar (580 psi)

STEP 1

STEP 3

R050022

R050023

Install a new snap ring.

STEP 2

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

R050022

Install the filler orifice plug. Install the adaptor with the O-ring. Insert the pin.
Cre 7-23862GB Issued 11- 05

22

STEP 4

STEP 6

R050023

R050025

Fully open the charging device discharge valve. Carefully open the nitrogen bottle valve and adjust the gas flow to minimum. WARNING: The charging device does not have a pressure relief valve. Close the valve on the gas bottle when the gauge shows that the pressure charge is correct. Close the pressure discharge valve on the charging device and charge the accumulator 2 to 3 bar above the specified pressure. Watch the reading on the pressure gauge carefully. Close the nitrogen bottle. Wait 10 minutes for the nitrogen pressure in the accumulator to stabilise. Carefully open the discharge valve to adjust the pressure in the accumulator to the correct setting. Tighten the charging device filler plug to the specified torque setting. Release the pressure in the charging hose, by opening the discharge valve.

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

STEP 7

R050025

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

STEP 5

R050024

Remove the charging device from the accumulator.

Cre 7-23862GB

Issued 11- 05

23

DISCHARGE VALVE Removal

R050027

Component Screw threads, contact surfaces and thrust washers All seals and O-rings All bushings and guides

Lubricant Grease for threads Grease for O-rings Hydraulic fluid

STEP 2
WARNING: Before removing a plug or a valve, make sure that all hydraulic pressure contained in the hydraulic hammer has been released. Read the instructions concerning release of hydraulic pressure in the hydraulic hammer. See "Releasing hydraulic pressure in the hydraulic hammer" on page 12.

STEP 1
R050028

Insert two of the retaining screws into the cover. Use them as forcing screws and remove the cover.

STEP 3

R050028

Remove the discharge valve cover retaining screws and washers

R050029

Remove the main spool and the other spools.

Cre 7-23862GB

Issued 11- 05

24

STEP 4

Installation
STEP 1
Check all components for wear or damage. If necessary, use emery paper or a polishing compound. Clean and lubricate all components.

STEP 2

R050029

Install the extractor, using the retaining screw holes in the cover. Insert the extractor flanges between the extractor screw and the discharge valve bushing. Extract the discharge valve bushing.

STEP 5 STEP 3

R050031

Install new seals on the discharge valve bushing.

Carefully install the discharge valve bushing in position.

STEP 4

R050030

Remove the used seals and O-rings from the discharge valve bushing and from the covers.

R050031

Install the extractor on the end of the control valve which has the X mark. Install the bushing. Install the main spool with the end with the X mark installed at the same end as the end of the control valve body and the discharge valve bushing with the X mark.

Cre 7-23862GB

Issued 11- 05

25

STEP 5
Install the spools. Make sure that all the spools slide freely.

STEP 6

R050032

Install 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 assembled components appear on the same end as the X mark on the control valve body.

STEP 7

R050180

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

STEP 8
Lubricate the threads and bearing surfaces of the retaining screws and thrust washers before installing them in position.

STEP 9
Tighten the retaining screws to the specified torque setting.

Cre 7-23862GB

Issued 11- 05

26

NON-RETURN VALVE Removal

R050033

Component Screw threads and bearing surfaces, thrust washers All seals and O-rings All bushings and guides

Lubricant Grease for threads Grease for O-rings Hydraulic fluid

WARNING: Before removing a plug or a valve, make sure that all the hydraulic pressure in the hydraulic hammer 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. NOTE: The non-return valve is in the control valve body, at the pressure end (oil inlet port). It is also possible to remove it without removing the hydraulic hammer mechanism from its housing.

STEP 1

STEP 2

R050034

R050034

Remove the retaining screws and the washers from the non-return valve.

Insert two retaining screws in the housing of the nonreturn valve, using them as forcing screws, and remove the non-return valve.

Cre 7-23862GB

Issued 11- 05

27

STEP 3

Installation
STEP 1
Check all components for wear or damage. If necessary, use emery paper or a polishing compound. Clean and lubricate all components.

STEP 2
Install the spool, the spring and the spring guide.

STEP 3
R050035

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

Install the flange. Make sure that the spool moves freely against the spring.

STEP 4
Install new O-rings.

STEP 4

STEP 5
Place the non-return valve in the control valve body.

STEP 6
Lubricate the threads and bearing surfaces of the retaining screws and washers before assembling them.

STEP 7
R050035

Remove the spring guide, the spring and the spool.

Tighten the retaining screws to the specified torque setting.

Cre 7-23862GB

Issued 11- 05

28

PRESSURE REGULATOR Removal

R050591

R050265

CB200 S Spring free length (D1) Thickness shims (E) Component 68.2 - 68,8 mm 0...1,5 mm

CB260 S 78,3 mm -

CB320 S 71.5 mm -

CB400 S 82.5 mm Lubricant

CB550 S 88.3 - 88,9 mm -

CB700 S -

Screw threads and bearing surfaces, thrust washers All seals and O-rings All bushings and guides

Grease for threads Grease for O-rings Hydraulic fluid

WARNING: Before removing a plug or a valve, make sure that all the hydraulic pressure in the hydraulic hammer has been released. Read the instructions concerning releasing the hydraulic pressure in the hydraulic hammer. See "Releasing hydraulic pressure in the hydraulic hammer" on page 12. NOTE: The pressure regulator is in the control valve body, at the pressure end (oil outlet port). It is also possible to remove it without removing the hydraulic hammer mechanism from its housing.

STEP 1

STEP 2

R050037

R050037

Remove the retaining screws and the washers from the pressure regulator.

Insert two of the removed retaining screws into the cover, using them as forcing screws, and remove the pressure regulator.

Cre 7-23862GB

Issued 11- 05

29

STEP 3

STEP 6

R050150

R050151

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

Remove the spool, the spring and the spring guide.

STEP 7

STEP 4

R050151 R050150

Remove the shims.

Decompress the spring by unscrewing the guide and the regulator housing at the same time.

Installation
STEP 1
Check all components for wear or damage. If necessary, use emery paper or a polishing compound. Clean and lubricate all components.

STEP 5

STEP 2
Install and tighten the pressure regulator cover in a vice.

R050150

Remove the guide and its spool. Remove the pressure regulator housing.

Cre 7-23862GB

Issued 11- 05

30

STEP 3

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 correct installation method.

STEP 6
Insert the spool in position.
R050149

Install the shims, the spring guide, the spring and the spool. Measure the free length to obtain the correct spring pre-load. The normal operating pressure, which is pre-set in the factory, corresponds to the average obtained when the measured height is in accordance with the specified height. Adjust the spring pre-load in accordance with specifications, by adding or removing shims. After each adjustment of the regulator, always measure the hammer operating pressure by means of a pressure gauge.

STEP 7
Place the regulator in the control valve body.

STEP 8
Lubricate the threads and bearing surfaces of the retaining screws and washers.

STEP 9
Tighten the retaining screws to the specified torque setting.

PRESSURE SEQUENCING VALVE (CB400 S - CB550 S) Removal

R050039

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

Cre 7-23862GB

Issued 11- 05

31

R050040

Component Spring free length (D1) Component Screw threads and bearing surfaces, thrust washers All seals and O-rings All bushings and guides

CB400 S 36,5 - 37, 0 mm Lubricant Grease for threads Grease for O-rings Hydraulic fluid

CB550 S 35,9 - 36,4 mm

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

STEP 1

STEP 3
Remove the O-rings.

STEP 4

R050041

Remove the valve retaining screws and washers.

STEP 2

R050041

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

R050041

Install the valve in a vice.

Cre 7-23862GB

Issued 11- 05

32

STEP 5

STEP 2

R050042

R050310

Remove the spring guides, the spring, the adjusting plates and the spring housing O-ring.

Using a fine, small needle, check that the jets are not clogged.

STEP 6

STEP 3
Install and tighten the pressure sequencing valve cover in a vice.

STEP 4
Install the flange plug and tighten it to the specified torque setting.

STEP 5
R050042

Install the spools and make sure that they slide freely.

Remove the flange plug. Remove the spool.

STEP 6
Install the other flange plug. Tighten it to the specified torque setting.

STEP 7

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-load for the spring. Add or remove shims.

STEP 9
R050042

Remove the flange plug.

Insert the spring guide and install the spring in its housing.

Installation
STEP 1
Check all components for wear or damage. If necessary, use emery paper or a polishing compound. Clean and lubricate all components.

Cre 7-23862GB

Issued 11- 05

33

STEP 10
Lubricate the threads and bearing surfaces of the retaining screws and install the screws and washers.

STEP 11
Tighten the retaining screws to the specified torque setting.

STEP 12
Install new O-rings.

STEP 13
Lubricate the threads and bearing surfaces of the retaining screws.

STEP 14
Install the pressure sequencing valve in position. Insert the retaining screws and the washers.

STEP 15
Tighten the retaining screws to the specified torque setting.

Cre 7-23862GB

Issued 11- 05

34

TIE-ROD Removal

R050044

Component (all) Tie-rod threads and bearing surfaces; tie-rod nuts Tie-rod central portion

Lubricant Grease for threads Heat-resistant paint

STEP 1

STEP 2

R050045

R050045

Remove the rubber bushings and locking plates. WARNING: Before heating the tie-rods, make sure that the pressure sequencing valve has been removed from the hydraulic hammer.

Make a mark on each tie-rod and on the corresponding nut. Also mark the location of each of the tie-rods in the hydraulic hammer.

Cre 7-23862GB

Issued 11- 05

35

STEP 3

STEP 3
Apply heat-resistant paint to the tie-rods located inside the front part.

STEP 4
Lubricate the threads and bearing surfaces of the tierods, the control valve body and the tie-rod nuts.

STEP 5
R050045

Heat the tie-rods with a welding torch until it becomes possible to unscrew them with a wrench. Heat the tie-rods over their entire length (and not at any special point), without exceeding 300C. Make sure the flame is directed onto the tie-rods (and not onto the hammer body).

STEP 4
R050047

Install the tie-rod nuts and tie-rods in their correct positions. Identify the arrow and the UP stamped on the nut. Make sure that each tie-rod is used with its corresponding nut. Also make sure that each tie-rod is back in the same position it occupied in the hydraulic hammer before removal.

STEP 6
R050046

- Remove the nuts. - Use suitable lifting equipment to remove the tierods. Watch out for hot parts.

Installation
STEP 1
Clean all the components carefully.
R050047

STEP 2
Use a crack detection device to check for cracks in the tie-rod threads and under their front part. If cracks are detected, change the tie-rod(s) and the corresponding nuts. Also make sure that each tie-rod is placed back in the same position it occupied on the hydraulic hammer before removal.

Use a torque wrench to tighten the tie-rods in several successive stages until reaching the torque setting they had before removal.

Cre 7-23862GB

Issued 11- 05

36

STEP 7

R050047

Make a mark to show the additional tightening angle on the control valve body and the tie-rods.

STEP 8
Heat all the tie-rods with a welding torch until it becomes possible to tighten them to the correct tightening angle with a wrench. Never exceed 300C.

STEP 9

R050048

When the tie-rods have cooled down sufficiently, fill the grooves between the tie-rods and the front part of the tool with a silicone product.

STEP 10
Install the locking plates.

STEP 11
Install the rubber bushings.

Cre 7-23862GB

Issued 11- 05

37

CONTROL VALVE BODY COMPONENTS Removal CB200 S CB260 S CB320 S

R050589

R050684

R050153

Component Plugs and breathers All seals and O-rings Contact surfaces between the control valve body, the seal-carrier and the cylinder Contact surfaces between the cylinder and the front part All components, the piston in particular

Lubricant Thread-lock fluid (Loctite 275 for example) Grease for O-rings Anti-corrosion product (CRC 3-36 for example) Grease for threads Hydraulic fluid

STEP 1

STEP 2

R050137

R050137

Screw the lifting rings into the control valve body and remove the control valve body.

Remove the seals. Remove the parallel pin.

Cre 7-23862GB

Issued 11- 05

38

STEP 3

STEP 6

R050138

R050546

Carefully lift and remove the piston, the cylinder and the seal-carrier. Take care not to drop the seal-carrier.

Remove nylon screw from the seal carrier (CB260 S).

STEP 7

STEP 4

R050139

Screw the pins into the seal-carrier.

R050138

Position the sheet of plywood (See special tools page). On the top of the front part, place the piston, the cylinder and the seal-carrier on the plywood sheet.

STEP 8

STEP 5

R050139

Push the seal-carrier down by tapping on the pins to separate them. Watch out for oil flowing out.
R050139

STEP 9

Screw the lifting rings into the cylinder and lift it so that there is a distance of about 50 mm between the plywood sheet and the seal-carrier.

R050140

Carefully remove the cylinder.

Cre 7-23862GB Issued 11- 05

39

STEP 10

STEP 13

R050140

R050142

Carefully remove the piston.

STEP 11

Remove the wiper seal and the O-rings from the cylinder.

Installation
STEP 1
Check all components for wear or damage. If necessary, use emery paper or a polishing compound. Clean and lubricate all components.

STEP 2
Lubricate the seal, the O-rings and the cylinder wiper seal and install them.

R050141

Remove the parallel pin and the O-rings.

STEP 3
Place the seal-carrier on the sheet of plywood located on top of the front part.

STEP 12

STEP 4

R050141

Remove the seals and the seal-carrier wiper.

R050145

Lubricate the piston and lift it to install it in the sealcarrier. Tap the piston into position with a plastic hammer.

Cre 7-23862GB

Issued 11- 05

40

STEP 5

STEP 8
Apply a thin coating of grease on the upper surface of the front part. NOTE: It is possible to install the hydraulic hammer so that it can be used by a left-handed or a righthanded person (by connecting the pressure supply line to the right-hand or to the left-hand side of the control valve body). Hydraulic hammers are manufactured in standard form with the oil inlet port connected to the right-hand side of the control valve body and the oil outlet port connected to the left-hand side. The cylinder is equipped with two installation grooves, for this purpose. To set up the hydraulic hammer for a right-handed person (standard version) install the cylinder so that the corner of the front part is housed in the groove marked with a small dot (See illustration at Step 9). To set up the hydraulic hammer for a left-handed person, use the groove located on the other side.

R050143

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

STEP 6

STEP 9

R050147

Spray MoS2 on the contact surfaces of the seal-carrier and the cylinder. Install the cylinder on the piston. Tap the cylinder to push it down onto the piston. Use a plastic hammer. Install nylon screw to seal carrier (CB260 S).

STEP 7
Screw a lifting ring into the piston and lift the assembly, remove the sheet of plywood (See special tools page).

R050148

R050146

Lower the piston, cylinder and seal-carrier assembly into its correct position inside the front top part. Make sure not to drop the seal-carrier. Remove the lifting ring.

STEP 10
Install the seals, the O-rings and the parallel pin between the control valve body and the cylinder.

STEP 11
Spray MoS2 on the contact surfaces of the cylinder and the control valve body. Install the control valve assembly.

Cre 7-23862GB

Issued 11- 05

41

CB400 S

CB550 S

R050049

Component Plugs and breathers All seals and O-rings Contact surfaces between the control valve body, the seal-carrier and the cylinder Contact surfaces between the cylinder and the front part All components, the piston in particular

Lubricant Thread-lock fluid (Loctite 275 for example) Grease for O-rings Anti-corrosion product (CRC 3-36 for example) Grease for threads Hydraulic fluid

STEP 1

STEP 2

R050050

R050050

Screw the lifting rings into the control valve body and remove the control valve body.

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

Cre 7-23862GB

Issued 11- 05

42

STEP 3

STEP 6

R050051

R050052

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

Lift the cylinder and remove it from the front part.

STEP 7

STEP 4

R050053 R050052

Remove the wiper seal and the seal-carrier seals.

Carefully lift the piston and remove it.

STEP 8

STEP 5

R050054 R050052

Remove the O-rings and the parallel pin.

Remove the wiper seal, the seal and the O-rings from the cylinder.

Cre 7-23862GB

Issued 11- 05

43

Installation
STEP 1
Check all components for wear or damage. If necessary, use emery paper or a polishing compound. Clean and lubricate all components.

STEP 5

STEP 2

R050056

Install the cylinder in the front part. NOTE: It is possible to install the hydraulic hammer so that it can be used by a left-handed or a righthanded person (by connecting the pressure supply line to the right-hand or to the left-hand side of the control valve body). Hydraulic hammers are manufactured in standard form with the oil inlet port on the right-hand side of and the oil outlet (return) port on the left-hand side. The cylinder is equipped with two installation grooves for this purpose. To set up the hydraulic hammer for a right-handed person (standard version) install the cylinder so that the corner of the front part is housed in the groove marked with a small dot (See illustration at Step 9). To set up the hydraulic hammer for a left-handed person, use the groove located on the other side.

R050055

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

STEP 3

STEP 6
Lubricate the piston and place it in the cylinder.

STEP 7
R050055

Lubricate the seals and the seal-carrier wiper seal and install them.

Install the O-rings and the parallel pin.

STEP 8
Install the seal in the seal-carrier groove. Use a thin coating of grease to prevent the seal falling when reassembling.

STEP 4
Apply thread grease to the contact surfaces of the front part and the cylinder.

STEP 9
Spray MoS2 on the contact surfaces of the seal-carrier 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-carrier and the control valve body. Install the control valve body.

Cre 7-23862GB

Issued 11- 05

44

FRONT PART Removal CB200 S CB260 S CB320 S CB400 S - CB550 S

R050590

R050269

R050268

R050057

Wear limit Component Maximum length of thrust ring (D1) Maximum diameter of tool upper bushing (D2) Tool lower bushing Component All seals and O-rings Contact surfaces between components Tool inner bushings CB200 S 10 mm 109,2 mm CB 260 S 8,5 mm 118,2 mm CB320 S 9,4 mm 132,8 mm CB400 S 10,2 mm 143,4 mm CB550 S 11,3 mm 161,5 mm

See "Tool lower bushing" on page 50 Lubricant Grease for O-rings Grease for threads Grease for tools

STEP 1

STEP 2

R050058

R050058

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

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

Cre 7-23862GB

Issued 11- 05

45

STEP 3

STEP 6

R050058

R050060

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

STEP 4

Turn 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

R050059

Install a bushing extractor. Place the extractor flanges as shown in the illustration. Remove the bushing using a hydraulic ram (CB200 S, 260 S, 320 S, 400 S, 550 S).

R050060

Remove the tool lower bushing, using the bushing extractor (CB200 S, 260 S, 320 S, 400 S, 550 S).

STEP 8

STEP 5

R050062 R050059

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

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

Cre 7-23862GB

Issued 11- 05

46

STEP 9

STEP 2
Install the grease fittings.

STEP 3
Insert the retaining pin and the spring (CB320 S, 400 S, 550 S).

STEP 4
Install the spring guide and the separator pin (CB320 S, 400 S, 550 S).
R050061

Carefully clean the threads in the front part (hole marked with a cross) before installing the extractor (CB320 S, 400 S, 550 S).

STEP 5
Install the tool seal and the O-ring on the tool lower bushing (CB200 S, 260 S, 320 S, 400 S, 550 S).

STEP 10

STEP 6
Apply thread grease on the contact surfaces of the tool lower bushing and the front part. Install the tool lower bushing.

STEP 7
Insert the retaining pin and the separator pin (CB200 S, 260 S, 320 S, 400 S, 550 S).

STEP 8
R050061 R050061

Remove the separator bushing and the spring guide from the front part, using two wrenches (CB320 S, 400 S, 550 S).

Lubricate the inner surface of the tool lower bushing with tool grease.

STEP 9
Install the front part on the ground, resting it on the tool lower bushing (CB200 S, 260 S, 320 S, 400 S, 550 S).

STEP 11

STEP 10
Apply thread grease to the outer surfaces of the tool upper bushing and the thrust ring. Lubricate the inner surface of the tool upper bushing with tool grease (CB200 S, 260 S, 320 S, 400 S, 550 S).

STEP 11
R050062

Remove the spring and the retaining pin.

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

Installation
STEP 1
Carefully clean and dry all the components. Check all components for cracks and excessive wear. For wear limits of the thrust ring and the tool bushing, see page 50. For the tool lower bushing, see page 50 (CB200 S, 260 S, 320 S, 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.

Cre 7-23862GB

Issued 11- 05

47

CHANGING A TOOL Removal

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

STEP 4

STEP 1

CT02D446

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

STEP 5

CT02D444

Place the hydraulic hammer horizontally on flat, hard ground.

STEP 2
Shut down the engine and remove the starter switch key.

STEP 3
CT02D447

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

Installation
Tools required
- One hammer - One bronze or copper drift
CT02D445

Move the rubber plate upwards (if fitted). Remove the pins and plugs from both sides of the hydraulic hammer.

- One flat-headed screwdriver

Cre 7-23862GB

Issued 11- 05

48

STEP 1

STEP 4
Install the pins and make sure that the tool is firmly gripped.

STEP 5

CT02D448

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

STEP 2
Clean and grease the tool and the retaining pins.

CT02D450

Install the plugs and pins. Move the rubber plate back to its lower position (if fitted).

STEP 3

CT02D449

Insert the tool, aligning its grooves with the holes in the retaining pins.

Cre 7-23862GB

Issued 11- 05

49

CHANGING THE TOOL BUSHING

Removal
Tools required
- One hammer - A bronze or copper drift

Installation
Tools required
- One hammer - A bronze or copper drift

STEP 1
Remove the tool. See "Changing a tool".

STEP 1

STEP 2

CT02D453

Check the condition of the seals, change them if necessary.

CT02D451

Drift out the pins and plugs.

STEP 2
Lubricate the contact surfaces of the tool bushing and its housing.

STEP 3

STEP 3

CT02D452

Remove the tool bushing.

CT02D452

Insert the tool bushing into its housing, then install the pins and plugs.

STEP 4
Install the tool. See "Changing a tool".

Cre 7-23862GB

Issued 11- 05

50

WEAR LIMITS Types: CB200 S to CB700 S

CS99C629

The 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 unworn area. Carry out the same operation for the second groove (2) using the retaining groove (3) The tool bushing must be changed when both grooves (1) and (2) are worn. See "Changing the tool bushing".

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".

Cre 7-23862GB

Issued 11- 05

51

INSPECTION AND MEASUREMENT OF HYDRAULIC HAMMER CIRCUIT Measurement/Inspection points

A B

R050064

A B C Q2 P2 T2 P3

Flowmeter Hydraulic hammer control valve Safety valve Flow passing through hydraulic hammer Hydraulic hammer supply pressure Hydraulic oil temperature Return pressure

Procedure for taking measurements

Hydraulic hammer circuit measurement and adjustment procedure: NOTE: Check and calibrate all gauges: pressure gauges which are to be used. Change any defective pressure gauge. NOTE: If the flow towards the hydraulic hammer is adjusted by changing the speed of the engine, the flow should always 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.

Cre 7-23862GB

Issued 11- 05

52

STEP 8
WARNING: The pressure setting of the tool-carrier relief valve must never be exceeded. Operate the hydraulic hammer "ON" control so as to reach the normal operating pressure of the hammer at pressure gauge p2.

STEP 1
Check the condition of the pipes and hoses, couplings, flanges, etc. Change any worn or damaged components and retighten joints as necessary.

STEP 9
Make sure that the oil flow from the hydraulic hammer 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 regards the oil flow from the hydraulic hammer.

STEP 2
Make sure that the hydraulic hammer supply line is correctly equipped with a pressure relief valve.

STEP 3
Make sure that the hydraulic fluid in the tool-carrier has reached its normal operating temperature.

STEP 11
Make sure that the oil flow from the hydraulic hammer does not increase when the working pressure of the machine exceeds the hydraulic hammer supply line pressure (flow compensation). To do this, push the boom, dipper and bucket cylinders against the stops, while at the same time operating the hammer "ON" control.

STEP 4
Connect the flowmeter in place of the hydraulic hammer. It is preferable to use the same hoses and couplings as those of the hydraulic hammer, particularly when the hoses have quick couplings.

STEP 12
Shut down the engine.

STEP 5
Operate the hydraulic hammer "ON" control.

STEP 13
Connect the hydraulic hammer in place of the flowmeter.

STEP 6
Plug the hydraulic hammer supply line and set the pressure relief valve 50 bar (pressure gauge p2) higher than the maximum operating pressure of the hydraulic hammer as shown in the technical specifications (See the Service Manuals concerned).

STEP 14
Measure the operating pressure of the hydraulic hammer. See "Measuring the hydraulic hammer operating pressure" on page 53.

STEP 7
Reconnect the hydraulic hammer supply line to the flowmeter.

STEP 15
When installing a new hydraulic hammer, check all measurements after about 50 hours operation of the hydraulic hammer.

Cre 7-23862GB

Issued 11- 05

53

MEASURING THE HYDRAULIC HAMMER OPERATING PRESSURE

R050063

A -

Pressure measurement port plug. WARNING: Taking hydraulic hammer pressure measurements while the hammer is working constitutes a danger area. Provide yourself with effective protection against oil jets.

STEP 1
In order to measure the operating pressure of the hydraulic hammer, the hydraulic hammer hydraulic circuit must have reached its normal operating temperature. Before starting the hydraulic hammer operating pressure measurement procedure, run the hydraulic hammer until the hydraulic fluid is sufficiently hot.

STEP 5
Start the hydraulic hammer and adjust the engine speed. Adjust engine speed to the speed of the hydraulic hammer. If the machine has several working power modes, select the mode for working with a hydraulic hammer.

STEP 6
Position the tool on, for example, a thick steel plate and start the hydraulic hammer operating.

STEP 2
Shut down the machine engine. Operate the boom and hydraulic hammer controls to release pressure in the hoses.

STEP 7
Read the average operating pressure shown on the low pressure gauge. A - Average pressure needle fluctuation * - Average pressure

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 hose at least 10 metres long, to the high pressure measurement port (A).

R050252

Cre 7-23862GB

Issued 11- 05

54

STEP 8
The average operating pressure should be within the specified range limits. NOTE: When the operating pressure is being measured with the hydraulic hammer on a thick steel plate or equivalent hard material, the reading should be in the lower half of the specified pressure range. If the hydraulic hammer is being used with a lighter material, the operating pressure of the hydraulic hammer should have a tendency to increase. See "Hydraulic hammer specifications".

STEP 9
If the readings taken are not in accordance with specifications, the pressure regulator spring pre-load should be adjusted and the measurements taken again. See "Pressure regulator", on page 28.

STEP 10
Shut down the engine. Wait 10 minutes for the oil pressure to drop and then remove the pressure gauge. Tighten the plug (A) to the specified torque setting.

Cre 7-23862GB

Issued 11- 05

55

WORKING PRINCIPLES

CS99E531

CS99E532

Starting
The hydraulic fluid passes through the non-return valve (A) before entering the accumulator (B) and the space (C) located under the piston (P). The pressure regulator (D) has closed the outlet passage from space (E) and prevents any movement of the piston. The pressure increases inside the hammer and compresses the nitrogen contained in the accumulator (B).

Return stroke
When the pre-determined operating pressure is reached, the valve (D) opens the outlet passage between space (E) and the hydraulic reservoir line. The pressure accumulated under the piston (C) forces the piston to perform its return stroke (moving upwards).

Cre 7-23862GB

Issued 11- 05

56

CS99E533

CS99E534

Impact stroke
When the piston reaches the top of its upwards stroke, it allows the pilot pressure to pass through passage (H) up to the top end of the relief valve (G). The relief valve changes its position and opens the high pressure passage between the accumulator (B) and the cylinder space (E). The piston starts its impact stroke (moving downwards). The hydraulic fluid used for this stroke comes from the accumulator and the supply line.

Impact stroke (final stage)

The piston descends faster and faster. The groove (K) in the piston makes a connection between the pilot passage (H) and the reservoir line (L). The relief valve (G) starts to slow down the high pressure flow between the accumulator and the space (E) and begins to open the connection with the pressure regulator (D). Pressure in the accumulator drops during the impact stroke. This causes the outlet passage to be closed by the pressure regulator (D). After the impact, the piston stays motionless in position until the hydraulic fluid pressure increases again and the cycle is repeated (phase 1). The hydraulic brake (X) protects the piston and the cylinder against any uncontrolled stroke.

Cre 7-23862GB

Issued 11- 05

57

TROUBLESHOOTING
Failure The hydraulic hammer does not start Cause Solution

The supply or return circuit is closed Open the circuits The supply and return hoses are reversed The piston is in the hydraulic brake position Connect the supply and return hoses correctly Operate the hammer control and press the tool against an object to push the piston out of its braking position. Remove the tool and wipe away the excess grease Check that the spool pilots correctly. If it does not, check the control valve control circuit Check the pressure setting and operation of the safety valve

There is grease between the piston and the tool contact area The hammer control valve spool does not pilot The hydraulic circuit safety valve opens at low pressure

Excessive pressure in the return cir- Check the return circuit. Change the cuit filter in the return circuit Check the pump and the hydraulic Internal leak between supply and return circuits (the required flow can- components not be attained) Incorrect operation of hydraulic hammer control valve Piston defect The hydraulic hammer operates irregularly, but at full power The control valve must be overhauled. See pages 37 and 41 The cylinder must be overhauled. See pages 37 and 41

Insufficient supply force coming from See operating methods in Operahost machine tors Manual The hydraulic circuit safety valve opens at low pressure Incorrect operation of hydraulic hammer control valve Check the pressure setting and operation of the safety valve The control valve must be overhauled. See pages 37 and 41 Refer to operating methods in the Operators Manual Check the pressure setting and the operation of the safety valve

The hydraulic hammer operates poorly and lacks power

The working method is not being respected The hydraulic circuit safety valve opens at low pressure

The pressure setting of the pressure The hammer must be overhauled. regulating valve is incorrect See pages 28 and 30 Drop in accumulator pressure Incorrect operation of hydraulic hammer control valve Check the accumulator pressure The control valve must be overhauled. See pages 37 and 41

Cre 7-23862GB

Issued 11- 05

58 Failure The impact rhythm of the hydraulic hammer decreases Cause Overheated oil (over 80 C) Solution 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/ hoses Replace the hydraulic oil by oil which meets specifications Check the return circuit. Change the filter if necessary Check the dimensions of the return circuit piping Check the pressure setting and the operation of the safety valve

The viscosity of the oil is too low The return circuit pressure is too high The hydraulic circuit safety valve opens at low pressure

Internal leak between the supply Check the pump and the hydraulic and return circuits (the required flow components 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 Check: operating correctly - the hydraulic oil cooling circuit, - the correct operation of the safety valve The viscosity of the hydraulic oil is too low Replace the hydraulic oil by oil which meets specifications

Internal leak between the supply Check the pump and the hydraulic and return circuits (the required flow components cannot be attained) Internal leak in the hydraulic hammer Check the hydraulic components of the hammer

Cre 7-23862GB

Issued 11- 05