Case CB Serie Hydraulic hammers Service Manual - PDF DOWNLOAD

Hydraulic hammers CB Serie

Service Manual

603.67.221.03

March 2009.

TABLE OF CONTENTS SECTIONS HYDRAULIC HAMMERS

REFERENCE N°

MODELS . . . . . . . CB18S - CB27S - CB37S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SMCB18S-1EN MODEL . . . . . . . . CB90S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SMCB90S-0EN MODELS . . . . . . . CB32 - CB45 - CB65- CB85 - CB120 - CB150 . . . . . . . . . . . . . . . . . . . . . 7-22013EN MODELS . . . . . . . CB200S - CB260S - CB320S - CB400S - CB550S - CB700S . . . . . . . . . 7-23863EN

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Copyright © 2009 CNH France S.A. Printed in France March 2009

HYDRAULIC HAMMERS CB18S - CB27S - CB37S

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Copyright © 2009 CNH France S.A. Printed in France March 2009

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TABLE OF CONTENTS SPECIFICATIONS ............................................................................................................... 3 OVERALL DIMENSIONS ............................................................................................................................. 3 MAIN PARTS ............................................................................................................................................... 6 TECHNICAL SPECIFICATIONS .................................................................................................................. 7 TORQUE SETTING ..................................................................................................................................... 7

MAINTENANCE ................................................................................................................... 8 REMOVAL HAMMER ................................................................................................................................... 8 INSTALLATION HAMMER ........................................................................................................................... 8 HANDLING HAMMER .................................................................................................................................. 9 REMOVAL AND INSTALLATION OF TOOL .............................................................................................. 10 Removal of tool ..................................................................................................................................... 10 Installation of tool .................................................................................................................................. 11 REMOVAL AND INSTALLATION OF TOOL BUSHING ............................................................................ 12 Removal of LOWER tool bushing ......................................................................................................... 12 Installation of LOWER tool bushing ...................................................................................................... 13 TROUBLESHOOTING ............................................................................................................................... 14

WORKSHOP ...................................................................................................................... 17 DISASSEMBLY AND ASSEMBLY ............................................................................................................. 17 Main components .................................................................................................................................. 17 RELEASING HYDRAULIC PRESSURE FROM HAMMER ........................................................................ 18 RELEASING PRESSURE FROM ACCUMULATOR .................................................................................. 18 HOUSING ................................................................................................................................................... 19 Disassembling housing ......................................................................................................................... 20 Assembling housing .............................................................................................................................. 21 VALVE BODY AND DISTRIBUTOR ........................................................................................................... 22 Disassembling valve body and distributor ............................................................................................. 24 assembling valve body and distributor .................................................................................................. 26 PRESSURE ACCUMULATOR ................................................................................................................... 27 Disassembling pressure accumulator ................................................................................................... 27 Assembling pressure accumulator ........................................................................................................ 28 CHARGING ACCUMULATORS ................................................................................................................. 29 BODY PARTS ............................................................................................................................................ 32 Disassembling body parts ..................................................................................................................... 33 Assembling body parts .......................................................................................................................... 34 TESTING .................................................................................................................................................... 35 Measuring hammer circuit ..................................................................................................................... 35 Measuring hammer operating pressure ................................................................................................ 37 SERVICE TOOLS ...................................................................................................................................... 39 Special service tools ............................................................................................................................. 39 STANDARD SERVICE TOOLS .................................................................................................................. 41

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SPECIFICATIONS OVERALL DIMENSIONS Model CB18 "SI" type

Model CB18 "S" type

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Model CB27 "SI" type

Model CB27 "S" type

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Model CB37 "SI" type

Model CB37 "S" type

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MAIN PARTS

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ITEM

Description

A

Side plates (Housing)

B

Mounting flange

C

Mounting pin holes

D

Accumulator

E

Hammer mechanism

F

Hose connections

G

Grease npipples

H

Tool retaining hardware

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TECHNICAL SPECIFICATIONS ITEM

Specifications CB18S

Specifications CB27S

Specifications CB37S

80kg

120kg

160kg

Working weight (1.)

Impact rate (2.)

1300-2500 (bpm)

1600-2600 (bpm)

1000-2000 (bpm)

Operating pressure (3.)

100 - 120 bar

120 - 140 bar

120 - 140 bar

Pressure relief, min (4.)

150 - 170 bar

170 - 190 bar

170 - 190 bar

220 bar

220 bar

220 bar

Pressure relief, max Oil flow range

15 - 33 (L/mn)

20 - 48(L/mn)

30 - 63 (L/mn)

Back pressure, max

20 bar

20 bar

20 bar

Tool diameter

36mm

42mm

50mm

Pressure line connection (IN)

BSPP-internal 1/2"

BSPP-internal 1/2"

BSPP-internal 3/4"

Return line connection (OUT)

BSPP-internal 1/2"

BSPP-internal 1/2"

BSPP-internal 3/4"

Pressure line size (minimum internal diameter)

12 mm

12 mm

15 mm

Return line size (minimum inner diameter)

12 mm

12 mm

15 mm

Optimum oil temperature range

+40(°C) to +60(°C)

+40(°C) to +60(°C)

+40(°C) to +60(°C)

Allowed oil temperature range

-20(°C) to + 80(°C)

-20(°C) to + 80(°C)

-20(°C) to + 80(°C)

30-60 cSt

30-60 cSt

30-60 cSt

20-1000 (cSt)

20-1000 (cSt)

20-1000 (cSt)

0.8 t - 1.8 t

1.3 t - 2.7 t

2.0 t - 4.0 t

Noise level, guaranteed sound power level (6.)

119 dB

123 dB

124 dB

Charging pressure (Nitrogen N²) Accumulator

25 bar

25 bar

25 bar

Optimum oil viscosity at operating temperature Allowed oil viscosity range Carrier weight (5.)

1.

Includes average mounting bracket and standard tool.

2.

Actual impact frequency depends on oil flow, oil viscosity, temperature, and material to be broken.

3.

Actual pressure depends on oil flow, oil viscosity, temperature, and material to be broken and back pressure.

4.

Minimun setting = actual operating pressure +50 bar (730 psi).

5.

Check carrier’s lifting capacity from carrier manufacturer.

6.

Guaranteed sound power level CE 2000/14/EC LWA.

TORQUE SETTING Sections

Torque setting CB18S

CB27S

CB27S

Housing plate mounting screws (B)

170 Nm

175 Nm

175 Nm

Cover screws (A) valve body and distributor

160 Nm

240Nm

460 Nm

Nozzel (B) valve body and distributor

20 Nm

30 Nm

30 Nm

Pressure measuring plug (C) valve body and distributor

30 Nm

30 Nm

30 Nm

Shield plug (A) Charging accumulator

150 Nm

150 Nm

150 Nm

Accumulator filling plug (B)

20 Nm

20 Nm

20 Nm

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MAINTENANCE REMOVAL HAMMER

STEP 5

Warning : The hammer must be secured from rolling over when disconnecting from the carrier. Only use skilled operator to position carrier for removal!

Warning : Hydraulic pressure inside hammer must always be released before opening hose connections!

Warning : Hot hydraulic fluide can cause severe injuries!

STEP 1 R010024

Remove bucket pins and other parts.

STEP 6 The carrier can be moved aside.

INSTALLATION HAMMER STEP 2 Stop the carrier engine.Operate boom and hammer controls to release pressure trapped inside hoses.

Wait ten minutes for oil pressure to drop.

STEP 1 Install hammer in the same manner as mounting a bucket. Install bucket pins.

STEP 2

STEP 3

Connect hoses.

Hammer inlet port is maked on the valve body with "IN" and outlet port with "OUT" An installation inspection must be carried out after the product has been mounted on the carrier.

In the installation inspection certain specifications (operating pressure, oil flow, etc.) are checked so that they are within given limits.

See "Hammer specification" on page 7.

Place a receptacle of a suitable capacity under the piping.

Close hammer inlet and outlet lines. If quick couplers are used, disconnection automatically closes hammer lines.

If hammer line includes ball valves, please make sure that they are closed.

STEP 3 Open hammer inlet and outlet lines.

STEP 4 Disconnect hoses.

Protect environnement from oil spills.

Plug the hoses and the hammer inlet and outlet ports.

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HANDLING HAMMER Use a hoist when lifting components which weigh 23kg or more, to avoid back injury. Make sure all chains, hooks, slings etc., are in good condition and are in the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. Do not use the hammer’s tools for lifting.

Lifting devices must safely carry the working weight of the product. See "Technical specifications" on page 7. Place chains or slings, as shown by the illustration, to lift the product.

SAFETY INSTRUCTIONS FOR LIFTING Below are some common safety instrutions concerning lifting operations. In addition to this, the local, national standards for machines and lifting-tackles must always be strictly observed. Please note that the list below is not all inclusive, you must always ensure the procedure you choose is safe for you and others.

STEP 1

STEP 6

Do not lift load over people. No one shall be under the hoisted load.

Never leave the suspended load unattented. Maintain load control at all times.

STEP 2

STEP 7

Do not lift people and never ride the hoisted load.

Never lift the load over the rated capacity.

STEP 3

STEP 8

Keep people clear from lift area.

STEP 4

Inspect all lifting equipment before use. Do not use twisted or damaged lifting equipment. Protect lifting equipment from sharp corners.

Avoid side pull of the load. Make sure you take up the slack slowly. Start and stop carefully.

STEP 9

STEP 5

Obey all local safety instructions.

Lift load a few centimeters and verify it before proceeding. Make sure the load is well balanced. Check for any loose items.

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REMOVAL AND INSTALLATION OF TOOL WEAR LIMITS AND LUBRICANTS FOR TOOL REMOVAL

C030003

Model

Item

Wear Limit (X)

CB18S

Tool diameter (Worn out)

34mm

CB27S

Tool diameter (Worn out)

40mm

CB37S

Tool diameter (Worn out)

48mm

Tool and tool retaining pins

Lubricant

Tool Grease

REMOVAL OF TOOL Warning : The hydraulic pressure inside the hammer must always be released before removing the tool. After operating the hammer, wait 10 minutes for oil pressure to drop inside hammer.

Warning : Hot tool can cause severe injuries.

STEP 1 Set the hammer on level ground.

STEP 2 Make sure the carrier’s transmission is in neutral and the parking brake is engaged.

STEP 3 Stop the carrier engine.

STEP 4 Remove plug and O-ring.

STEP 5 Remove tool retaining pin.

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STEP 6 Remove tool. Use lifting device if necessary. See "Tool specifications" on page 7

NOTA : If hammer is still on carrier, it may be easier to stick the tool in the ground and lift the hammer off the tool.

Make sure that the the tool can not fall.

INSTALLATION OF TOOL STEP 1 Clean all parts carefully.

STEP 2 Measure the tool diameter (X) from the area marked on the illustration.

Replace tool if necessery.

STEP 3 Check tool bushing for wear. See "Removal and installation of tool Bushing" on page 10.

STEP 4 Check tool seal. Replace if necessary.

STEP 5 Clean and coat tool and retaining pin with grease.

STEP 6 Install tool and align the groove of the tool with the pin bore.

STEP 7 Install tool retaining pin.

STEP 8 Install retaining pin.

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REMOVAL AND INSTALLATION OF TOOL BUSHING WEAR LIMITS AND LUBRICANTS FOR TOOL BUSHING

Model

Item

Wear Limit (Y)

CB18S

Tool bushing inner diameter (Worn out)

38 mm

CB27S

Tool bushing inner diameter (Worn out)

44 mm

CB37S

Tool bushing inner diameter (Worn out)

52 mm

Contact surfaces of front head

Lubricant

Thread grease

REMOVAL OF LOWER TOOL BUSHING STEP 1 Remove tool

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STEP 2 Remove lower tool bushing.

STEP 3 Remove seal from lower tool bushing.

INSTALLATION OF LOWER TOOL BUSHING STEP 1 Clean all parts carefully.

STEP 2 Measure the bushing inner diameter (marked Y).

Replace bushing if necessary.

STEP 3 Install seal.

STEP 4 Lubricate the contact surfaces of the front head.

STEP 5 Install the lower tool bushing. Align the holes in the tool bushing with the holes in the front head.

STEP 6 Install the tool.

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TROUBLESHOOTING Defect

Cause Pressure or return lines closed.

Check the operation of quick couplings in hammer line. Open hammer line ball valves if closed.

Pressure and return hoses installed backwards.

Swap the pressure and return hoses.

Piston is in its lower hydraulic brake.

Keep the hammer control valve open and force the tool against an object.The tool head will push the piston out of its brake area.

Grease between piston and tool contact area.

Remove the tool and wipe excessive grease off.

Hammer control valve does not open.

When operating the hammer control valve, check that the pressure line pulsates (this indicates the hammer control valve is opening). If the valve does not operate, check the operating means: mechanical connections, pilot pressure or electrical control.

THE HAMMER DOES NOT START. Relief valve in hydraulic circuit opens at a low pressure. Hammer operating pressure is not reached.

THE HAMMER OPERATES IRREGULARLY BUT THE BLOW HAS FULL POWER

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Solution

Check the installation. Check the relief valve operation. Adjust the relief valve in hydraulic circuit. Measure the high pressure in the hammer inlet line. (See "Measuring hammer operating pressure" on pages 37 and "Measuring hammer circuit" on page 35).

Excessive back pressure in return line.

Check the installation. See "Measuring hammer circuit" on page 35. Check the size of the return line.

Leakage from pressure to return in excavator hydraulic circuit.

Check the installation. Check the pump and the other hydraulic components.

Failure in hammer valve operation.

The hammer must be serviced in an authorized CNH service shop.

Piston failure.

The hammer must be serviced in an authorized CNH service shop.

Not enough feed force from excavator.

Refer to the correct working methods.

Relief valve in hydraulic circuit opens at a low pressure Hammer operating pressure is not reached.

Check the installation. Check the relief valve operation. Adjust the relief valve in hydraulic circuit. Measure the high pressure in the hammer inlet line. (See on pages 40 and 42)

Failure in hammer valve operation

The hammer must be serviced in an authorized CNH service shop. (See "Body part" on page 29).

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THE HAMMER OPERATES IRREGULARLY AND BLOW HAS NO POWER.

IMPACT RATE SLOWS DOWN.

THE HAMMER DOES NOT STOP OR HAS RUN ON.

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Cause

Solution

The working method is not correct.

Refer to the correct working methods.

Relief valve in hydraulic circuit opens at a low pressure. Hammer operating pressure is not reached.

Check the installation. Check the relief valve operation. Adjust the relief valve in hydraulic circuit. Measure the high pressure in the hammer inlet line. (See "Measuring hammer operating pressure" on pages 40 and 42).

Pressure adjusting valve setting is incorrect.

The hammer must be serviced in an authorized CNH service shop.

Pressure loss in pressure accumulator.

The hammer must be serviced in an authorized CNH service shop. (See "Pressure accumulator" on page 21).

(See "Charging accumulator" on page 27).

Failure in hammer valve operation.

The hammer must be serviced in an authorized CNH service shop. (See "Body parts" on page 29).

Oil has overheated (over +80 °C / +176° F).

Check the following: a) for a fault in the oil cooling system, or an internal leak in the hammer b) the hydraulic circuit of the carrier (See "Measuring hammer circuit" on page 40). c) the relief valve operation in the carrier. d) the line size.

Assemble an extra oil cooler.

Hydraulic oil viscosity too low.

Check hydraulic oil.

Excessive back pressure in return line.

Check the installation. (See "Measuring hammer circuit" on page 40).

Check the size of the return line.

Relief valve in hydraulic circuit opens at a low pressure. Hammer operating pressure is not reached.

Check the installation. Check the relief valve operation. Adjust the relief valve in hydraulic circuit. Measure the high pressure in the hammer inlet line. Contact your local dealer for more information.(See "Measuring hammer circuit" on page 40, and "Measuring hammer operating pressure" on page 42).

Leakage from pressure to return in excavator hydraulic circuit.

Check the installation. Check the pump and the other hydraulic components

Pressure loss in pressure accumulator.

The hammer must be serviced in an authorized CNH service shop. (See " Pressure accumulator" on page 21). (See "Charging accumulator" on page 26).

Failure in breaker valve operation.

The hammer must be serviced in an authorized CNH service shop. (See "Body part" on page 29).

Failure in hammer control valve operation.

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Cause

Solution

Application not correct for hammer.

Refer to recommended use and to correct working methods

Cooling capacity of the factory oil cooler is too small.

Assemble an extra oil cooler.

Relief valve in hydraulic circuit opens at a low pressure. Hammer operating pressure is not reached.

OIL OVERHEATS.

RECURRENT TOOL FAILURE.

FURTHER ASSISTANCE.

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Check the installation. Check the relief valve operation. Adjust the relief valve in hydraulic circuit. Measure the high pressure in the hammer inlet line. Contact your local dealer for more information.(See "Measuring hammer circuit" on page 40, and "Measuring hammer operating pressure" on page 42).

Hydraulic oil viscosity too low

Check hydraulic oil.

Leakage from pressure to return in excavator hydraulic circuit.

Check the installation. Check pump and the other hydraulic components.

Internal oil leak in the hammer.

The hammer must be serviced in an authorized CNH service shop. (See " Body parts" on page 29).

Excessive back pressure in return line.

Check the installation. (See "Measuring hammer circuit" on page 40).Check the size of the return line.

Application not correct for hammer.

Refer to recommended use and to correct working methods

Rough operating practices

Refer to recommended use and to correct working methods

Tool does not get enough lubricant.

Refer to recommended use and to correct working methods

Tool long tool.

Use shortest tool possible. Refer to recommended use and to correct working methods

Rapid wear of tool.

Refer to recommended use and to correct working methods. There is a wider selection of tools available for different applications. Consult with your local dealer for more information.

Further assistance.

If further assistance is required, please prepare to answer the following questions before calling your dealer.

-Model and serial number -Working hours and service history -Carrier model.

-Installation: Oil flow, operating pressure and return line pressure if known.

-Application.

-Has the product operated normally before.

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WORKSHOP DISASSEMBLY AND ASSEMBLY MAIN COMPONENTS LOCATION OF MAIN COMPONENTS (HAMMER MECANISM)

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ITEM

Description

A

Pressure measuring plug

B

Pressure accumulator

C

Valve body

D

Cylinder and front head

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RELEASING HYDRAULIC PRESSURE FROM HAMMER RELEASING PRESSURE Warning : The hydraulic pressure inside the hammer must always be released before making any adjustments or repairs when the hammer is connected to the carrier. There may also be pressurized oil trapped inside the hammer even if the hammer is disconnected from the carrier. Release the hydraulic pressure according to the following instructions before opening any plugs or valve covers.

STEP 1 Stop the carrier engine.

STEP 2 Operate boom and hammer controls to release any pressure trapped inside hoses.

STEP 3 Wait 10 minutes for oil pressure to drop inside hammer.

STEP 4 Close hammer inlet and outlet lines. If quick couplers are used, disconnection automatically closes hammer lines. If hammer line includes ball valves, please make sure that they are closed.

Warning : This procedure does not release the pressure from the pressure accumulators! Read the instructions dealing with the accumulator before disassembling the hammer. See "Releasing pressure from accumulator" on page 18.

RELEASING PRESSURE FROM ACCUMULATOR LOCATION OF ACCUMULATOR REFILLING PLUG

ITEM A

Description Shield plug.

RELEASING PRESSURE FROM ACCUMULATOR Warning : Do not disassemble hammer before releasing pressure from accumulators.

STEP 1 Remove shield plug from accumulator, and open filling plug carefully. Wait until all nitrogen gas escaped.

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HOUSING TORQUES, ADJUSTMENTS AND LUBRICANTS

ITEM B

Housing plate mounting screws All screw threads and bearing surfaces.

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Tightening torque

Lubricant

70 Nm Thread Grease

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DISASSEMBLING HOUSING Warning : The hammer must be secured from falling down in either direction when handling it. Check that the lifting capacity of the hoist you are using is sufficient for the job. (See "Lifting instructions" on page 7, and " Hammer specifications" on page 5).

STEP 1 Remove hydraulic hoses.

STEP 2 Open mounting bracket screws.

STEP 3 Remove screws and lock washers.

STEP 4 Install lifting eye nuts using screws to the housing plate flange.

STEP 5 Lift housing plate off with lifting device.

STEP 6 Lift hammer mechanism out from housing.

STEP 7 Remove dampers.

Remove parallel pins.

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ASSEMBLING HOUSING STEP 1 Install dampers to both housing plates.

STEP 2 Insert parallel pins.

STEP 3 Install hammer mechanism into its place.

STEP 4 Lower remaining housing plate into its correct position.

STEP 5 Install compression screws crosswisely

STEP 6 Compress housing plates together with compression screws.

STEP 7 Grease threads and bearing surfaces of screws and lock washers.

STEP 8 Install screws and lock washers to remaining holes and tighten fully, then replace compression screws.

STEP 9 Torque screws to specified setting.

STEP 10 Install mouting bracket.

STEP 11 Grease screws with lock washers and nuts.

STEP 12 Torque screws to specified setting.

STEP 13 Installhydraulic hoses.

STEP 14 Install hammer to carrier.

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VALVE BODY AND DISTRIBUTOR LUBRICANTS AND TORQUES FOR PRESSURE ACCUMULATORS

ITEM

Tightening torque

A

Cover screws

160 Nm

B

Nozzle,width across flats 7mm

20 Nm

C

Pressure measuring plug

30 Nm

All seals and O-rings All parts Contact surfaces of cover, valve body and cylinder Screw threads and bearing surfaces, lock washers

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Lubricant

O-ring grease Hydraulic oil Anticorrosive agent (e.g. CRC 3-36) Thread Grease

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This is done with a nozzle which is inside the OUT port of the hammer, located on the valve housing.

The nozzle adjust the operating pressure of the hammer.

If the nozzle is not suitable for the excavator, then the hammer power may be low or the oil has a tendency for heating.

In either case please contact your dealer for further instructions.

STEP 1 Remove hose fitting from "OUT" port.

STEP 2 Remove nozzle from inside "OUT" port using socket wrench.

STEP 3 Insert proper nozzle and tighten it to specified setting.

Do not apply locking fluid.

STEP 4 Install hose fitting to "OUT" port.

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DISASSEMBLING VALVE BODY AND DISTRIBUTOR Warning : Make sure that accumulator is depressurized! (See "Releasing pressure from accumulator" on page 18)..

STEP 1 Open cover screws and remove cover.

STEP 2 Remove seals and O-ring from cover.

STEP 3 Remove O-rings from valve body.

Lift valve body off and set valve body upside down on work bench.

STEP 4 Remove O-rings and parallel pin from cylinder.

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STEP 5 Remove steering ring and distributor from valve body.

STEP 6 Lift plastic assembly ring out. Using plastic hammer, tap the accumulator cover’s edge slightly to remove low pressure accumulator cover from cylinder.

STEP 7 Remove O-rings from steering ring.

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ASSEMBLING VALVE BODY AND DISTRIBUTOR STEP 1 Check all parts for wear and damage. If necessary, use fine emery cloth or grinding agent. Clean and oil all parts.

STEP 2 Install O-rings to steering ring.Oil parts properly and insert distributor into steering ring.

STEP 3 Apply oil on distributor parts and valve body hole.

STEP 4 Install steering ring and distributor to the valve body. Check that distributor moves freely inside.

STEP 5 Install O-rings to cylinder. Insert parallel pin.

STEP 6 Apply anticorrosive agent on contact surfaces of valve body and cylinder.

STEP 7 Install valve body.

STEP 8 Install O-rings to valve bod. Install seals and O-rings to cover using suitable pliers. Install cover.

STEP 9 Install cover screws and lock washers.Torque screws to the specified settings.

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PRESSURE ACCUMULATOR LUBRICANTS FOR PRESSURE ACCUMULATOR

ITEM

Lubricant

A

Accumulator cover (gas side)

Thread Grease

B

Accumulator membrane (inner side)

C

Casting burr

Hydraulic oil

DISASSEMBLING PRESSURE ACCUMULATOR Warning : Make sure that accumulator is depressurized! (See releasing pressure from accumulator") on page 18.

STEP 1 Remove cover, valve body and distributor. See "valve body and distributor" on page 22.

STEP 2 Remove support ring.

STEP 3 Remove accumulator cover.

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STEP 4 Remove membrane from cylinder.

ASSEMBLING PRESSURE ACCUMULATOR STEP 1 Clean and dry parts carefully.

STEP 2 Apply thin layer of oil to membrane and accumulator area in cylinder.

STEP 3 Put cylinder on vise.

STEP 4 Install a new membrane on cylinder. Check that the edge of the membrane which have casting burr go first. Be careful not to damage the membrane when pulling it over shoulders of cylinder.

STEP 5 Apply silicone grease inside accumulator cover.

To prevent risk of gas leak be careful not to stain silicone in sealing grooves.

Align split pin between accumulator cover and cylinder.

Install accumulator cover in its place.

Use plastic hammer if necessary.

STEP 6 Install support ring.

STEP 7 Install distributor, valve body and cover. See "Valve body and distributor" on page 22.

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CHARGING ACCUMULATORS TORQUES, ADJUSTMENTS AND LUBRICANTS

ITEM

Tightening torque

A

Shield plug

150 Nm

B

Accumulator filling plug

20 Nm

Accumulator

Charging pressure (Nitrogen N2)

25 bar

CHARGING ACCUMULATOR Warning : Use only nitrogen (N2) for charging accumulator. Use of other gases may cause accumulator to explode.

STEP 1 Install new usit ring.

STEP 2 Install filling plug.

STEP 3 Install adapter with O-ring.

STEP 4 Insert pin.

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STEP 5 Insert pin.

STEP 6 Install charging device.

STEP 7 Connect charging system to nitrogen bottle.

STEP 8 Tighten filling plug carefully through charging device until you feel it stop, then open it three (3) turns.

STEP 9 Open discharge valve on charging device fully.

STEP 10 Carefully open nitrogen gas bottle valve and adjust gas flow to minimum.

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STEP 1 CAUTION! Charging device does not have any pressure relief valve. Shut gas bottle valve when gauge shows correct charging pressure.

STEP 2 Close discharge valve on charging device and charge accumulator 2-3 bar above specified charging pressure.

Observe pressure gauge reading.

STEP 3 Shut nitrogen bottle valve.

STEP 4 Wait 10 minutes for nitrogen gas pressure to stabilize inside accumulator.

STEP 5 Adjust pressure in accumulator to correct setting by carefully opening discharge valve.

STEP 6 Torque filling plug through charging device to specified setting.

STEP 7 Release pressure from charging hose by opening discharge valve.

STEP 8 Remove charging system from accumulator.

STEP 9 Check accumulator for nitrogen leak by filling Usit-ring area with thin oil. If gas bubbles appear, discharge accumulator and replace Usit-ring.

STEP 10 Install shield plug with O-ring.

STEP 11 Torque plug to specified setting.

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BODY PARTS TORQUES, ADJUSTMENTS AND LUBRICANTS

ITEM

Lubricants and accessories

Contact surfaces of cylinder and valve body

Anticorrosive agent (e.g.CRC 3-36)

All seals and O-rings

O-ring grease

Screw threads and bearing surfaces, lock washers. Outer surfaces of the lower tool bushing

Thread grease

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DISASSEMBLING BODY PARTS Warning : The hydraulic pressure inside the hammer must always be released before removing any of the plugs or valves. Read the instrutions on releasing the hydraulic pressure from the hammer. See "Releasing hydraulic pressure from hammer" on page 18.

STEP 1 Remove piston.

STEP 2 Set power cell to horizontal position.

Remove lower tool bushing.

STEP 3 Remove split pins.

STEP 4 Remove seal carrier.

Use hook and sliding hammer.

STEP 5 Remove seals and O-ring from seal carrier.

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ASSEMBLING BODY PARTS STEP 1 Check all parts for wear and damage.

If necessary, use fine emery cloth or grinding agent.

Clean and oil all parts.

STEP 2 Install O-ring and seals to seal carrier using suitable pliers.

STEP 3 Oil seal carrier and cylinder properly and install seal carrier to the cylinder.

Note the seal carriers direction.

Align split pin holes in the the seal carrier and cylinder.

STEP 4 Install lower tool bushing and tool retaining pin.

STEP 5 Install slit pins to the cylinder.

STEP 6 Oil cylinder and piston properly.

Insert piston into cylinder.

Lep SMCB18S-1EN

Issued 03-09

35

TESTING MEASURING HAMMER CIRCUIT MEASURING POINTS

FLOWMETER

HAMMER CONTROL VALVE OR MAIN VALVE BLOCK

p0

tank (with closed circuit from suction pipe of the pump).

p2

straight before the restriction of the flow meter (e.g. Webster flow meter includes pressure gauge for p2)

Q2 & T2 p3

at flow meter, which connects pressure and return line of the hammer circuit. straight after flow meter.

HOW TO MEASURE Procedure for measuring and adjusting the hammer circuit.

Note: Check and calibrate all the gauges you are going to use . Faulty pressure gauges should be changed.

Note: If the flow to the hammer is adjusted by changing the engine revolutions, always check the flow also at full engine revolutions.

Note: It is absolutely forbidden to use hammer above specified oil flow range.

Warning : Don’t exceed the carrier’s main relief valve setting.

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STEP 1 Check the lines, couplings, clamps etc. to ensure their condition.

Replace worn or damaged components and tighten loose joints.

STEP 2 Check that there is a pressure relief valve in the hammer line.

STEP 3 Make sure that carrier’s hydraulic oil temperature is at normal operating level when measuring.

STEP 4 Connect the flowmeter in place of the hammer. It preferable to use same hoses and couplings that are used with the hammer, especially in cases when hoses are equipped with quick couplings.

STEP 5 Check that the adjustable restriction is open.

STEP 6 Start the engine and press the hammer operating switch.

STEP 7 Close the hammer line to adjust the crack point of pressure relief valve 50 bar (gauge p2) above the hammer max. operating pressure shown in the technical data.

STEP 8 Open the restriction so that the hammer’s operating pressure at gauge p2 is reached.

STEP 9 Check that the hammer’s oil flow is within the limits.

STEP 10 Check that the return line back pressure p3 doesn’t exceed the values allowed at the hammer oil flow.

STEP 11 Check that the hammer’s oil flow doesn’t increase when the carrier’s operating pressure exeeds the pressure in the hammer line (pressure compensated flow control). To do that , drive the boom, stick and bucket cylinders to the tilt position while pressing the hammer operating switch and checking the flow.

STEP 12 Open the restriction.

STEP 13 Stop the carrier engine.

STEP 14 Connect the hammer in place of the flow meter.

STEP 15 Measure hammer operating pressure. See "Measuring hammer operating pressure" on page 37.

STEP 16 When installing a new hammer check all the values after working about 50 hours with the hammer.

Lep SMCB18S-1EN

Issued 03-09

37

MEASURING HAMMER OPERATING PRESSURE SPECIFICATIONS FOR MEASURING OPERATING PRESSURE

ITEM Plug A

Lep SMCB18S-1EN

Pressure measuring port

Tightening torque 30 Nm

Issued 03-09

38 MEASURING HAMMER OPERATING PRESSURE Warning : The hydraulic pressure inside the hammer must always be released before making any adjustments or repairs when the hammer is connected to the carrier. There may also be pressurized oil trapped inside the hammer even if the hammer is disconnected from the carrier. Release the hydraulic pressure according to the following instructions, or wait at least 10 minutes before opening any plugs or valve covers.

Warning : When measuring hammer operating pressure, you are working in hammer’s danger area. Protect youself against flying debris.

STEP 1 Hammer operating pressure must be measured with carrier hydraulic circuit in its normal operating temperature.

Before starting hammer operating pressure measuring procedure, operate carrier until hydraulic oil has warmed sufficiently.

STEP 2 Stop the carrier engine.

Operate boom and hammer controls to release any pressure trapped inside hoses.

STEP 3 Start carrier and set correct input oil flow to the hammer e.g. by adjusting engine revolutions or if carrier has power/ work modes, please select mode intended for hammer work.

STEP 4 Position tool e.g. on a thick steel plate and start to operate hammer.

STEP 5 Read average pressure reading on low pressure gauge.

STEP 6 Stop carrier. Wait ten minutes for oil pressure to drop.

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Issued 03-09

39

SERVICE TOOLS SPECIAL SERVICE TOOLS

Name

Part no.

Qt e

1: Accumulator charging kit (incl. part 1.1-1.4)

__

1

1.1: Charging device

ZK40633

1

1.2: Socket

73317906

1

1.3: Adapter

73317907

1

1.4: O-ring

73317908

1

Pressure gauge 250 bar

73318159

1

Pressure gauge 60 bar

73318160

1

Hammer lifting adapter

(CAS2815)

1

Lep SMCB18S-1EN

Picture

Issued 03-09

40

Adapter for French nitrogen bottle

73318164

1

Drift pin D7

__

1

Drift pin D12

(CAS2827)

1

Lifting eye M16

73318167

2

Lifting eye Nut M16

__

2

Lifting eye Nut M20

__

2

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41

STANDARD SERVICE TOOLS Name

Specification

Torque wrench

150 - 700 Nm (3/4")

Torque wrench

20 - 200 Nm (1/2")

Torque wrench

15 Nm (1/2")

Ratchet handle

1/2"

Extension

L = 125 mm (1/2")

Sliding T-handle

3/4"

Adapter

3/4"-> 1/2"

Adapter

1/2"-> 3/4"

Combination spanner

36 mm

Hex. socket

7 mm (1/2")

Hex. socket

9 mm (1/2")

Hex. socket

36 mm (3/4")

Allen type screw socket

3 mm (1/2)"

Allen type screw socket

5 mm (1/2")

Allen type screw socket

6 mm (1/2")

Allen type screw socket

10 mm (1/2")

Pry bars

400 mm

Lifting chain Hammer plastic

1000 g

Hammer ball headed

680 g

Hammer

2000 g

Slide hammer Screwdriver

6 x150 mm

Screwdriver

8 x 250 mm

Oil can

0.5 l

Grease gun

Lep SMCB18S-1EN

Flowmeter

15 - 25 l /min

Flowmeter

20 - 150 l /min

Pressure gauge

40 bar

Issued 03-09

42

NOTE .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. ..................................................................................................................................................................................

Lep SMCB18S-1EN

Issued 03-09

HYDRAULIC HAMMER CB90S

Lep SMCB90S-0EN

Copyright © 2009 CNH France S.A. Printed in France March 2009

2

TABLE OF CONTENTS SPECIFICATIONS ............................................................................................................... 3 OVERALL DIMENSIONS ............................................................................................................................. 3 MAIN PARTS ............................................................................................................................................... 4 TECHNICAL SPECIFICATIONS .................................................................................................................. 5 TORQUE SETTING ..................................................................................................................................... 5

MAINTENANCE ................................................................................................................... 6 REMOVAL HAMMER ................................................................................................................................... 6 INSTALLATION HAMMER ........................................................................................................................... 6 HANDLING HAMMER .................................................................................................................................. 7 REMOVAL AND INSTALLATION OF TOOL ................................................................................................ 8 removal of tool ......................................................................................................................................... 8 installation of tool .................................................................................................................................... 9 REMOVAL AND INSTALLATION OF TOOL BUSHING ............................................................................ 10 removal of tool bushing ......................................................................................................................... 10 installation of tool bushing ..................................................................................................................... 11 TROUBLESHOOTING ............................................................................................................................... 12

WORKSHOP ...................................................................................................................... 15 DISASSEMBLY AND ASSEMBLY ............................................................................................................. 15 main components .................................................................................................................................. 15 RELEASING HYDRAULIC PRESSURE FROM HAMMER ........................................................................ 16 releasing pressure from high pressure accumulator ............................................................................. 16 releasing pressure from low pressure accumulator .............................................................................. 17 HOUSING ................................................................................................................................................... 18 disassembling housing .......................................................................................................................... 19 assembling housing .............................................................................................................................. 20 PRESSURE ACCUMULATORS ................................................................................................................ 21 disassembly pressure accumulators ..................................................................................................... 22 assembling pressure accumulator ........................................................................................................ 23 CHARGING ACCUMULATORS ................................................................................................................. 26 BODY PARTS ............................................................................................................................................ 29 disassembling body parts ...................................................................................................................... 29 assembling body parts .......................................................................................................................... 31 PRESSURE ADJUSTING VALVE .............................................................................................................. 33 disassembling pressure adjusting valve ................................................................................................ 34 assembling pressure adjusting valve .................................................................................................... 35 SWIVEL COUPLINGS ................................................................................................................................ 36 disassembling swivel couplings ............................................................................................................ 37 assembling swivel couplings ................................................................................................................. 38 TESTING .................................................................................................................................................... 40 measuring hammer circuit ..................................................................................................................... 40 MEASURING HAMMER OPERATING PRESSURE .................................................................................. 42 SERVICE TOOLS ...................................................................................................................................... 44 special service tools .............................................................................................................................. 44 STANDARD SERVICE TOOLS .................................................................................................................. 46

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Issued 03-09

3

SPECIFICATIONS OVERALL DIMENSIONS Model CB90S

Lep SMCB90S-0EN

Issued 03-09

4

MAIN PARTS

Lep SMCB90S-0EN

ITEM

Description

A

Side plates (Housing)

B

Mounting flange

C

Hammer mechanism

D

Hose connections

E

Grease nipples

F

Tool and tool bushing retaining mechanism

Issued 03-09

5

TECHNICAL SPECIFICATIONS ITEM

Specifications

Working weight (1.)

360kg

Impact rate (2.)

500-1700 (bpm)

Operating pressure (3.)

80 - 140 bar

Pressure relief, min (4.)

130 - 190 bar

Pressure relief, max

220 bar

Pressure in LP- circuit

32 - 34 bar

Oil flow range

40 - 120 (L/mn)

Back pressure, max

20 bar

Input power

28kW

Tool diameter

80mm

Pressure line connection (IN)

BSPP- external 3/4"

Return line connection (OUT)

BSPP- external 3/4"

Pressure line size (minimum internal diameter) Return line size (minimum inner diameter)

19 mm 19 mm

Optimum oil temperature

+ 40(°C) to + 60(°C)

Allowed oil temperature range

- 20(°C) to + 80(°C)

Optimum oil viscosity at operating temperature Allowed oil viscosity range

30-60 cSt 20-1000 (cSt)

Miniexcavator, tractor backhoe weight (5.)

4.6t - 9t

Skid steer, robot weight (5.)

2.6 - 5t

Noise level, guaranteed sound power level (6.)

127 dB

1.

Includes average mounting bracket and standard tool.

2.

Actual impact frequency depends on oil flow, oil viscosity, temperature, and material to be broken.

3.

Actual pressure depends on oil flow, oil viscosity, temperature, and material to be broken and back pressure.

4.

Minimun setting = actual operating pressure +50 bar (730 psi).

5.

Check carrier’s lifting capacity from carrier manufacturer.

6.

Guaranteed sound power level CE 2000/14/EC LWA.

TORQUE SETTING Sections

Torque setting

Housing plate mounting screws (A)

175 Nm

Top cover’s screws (A)

580 Nm

Spring housing Valve (A)

200 Nm

Flange plug valve (B)

120 Nm

Swivel coupling - Manifold fastenings screws (A)

175 Nm

Swivel coupling - Swivel end screws (B)

120 Nm

Swivel coupling - Plug (C)

80 Nm

Shield plug (A) Charging accumulator

150 Nm

Accumulator filling plug (B)

20 Nm

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Issued 03-09

6

MAINTENANCE REMOVAL HAMMER

STEP 5

Warning : The hammer must be secured from rolling over when disconnecting from the carrier. Only use skilled operator to position carrier for removal!

Warning : Hydraulic pressure inside hammer must always be released before opening hose connections!

Warning : Hot hydraulic fluide can cause severe injuries!

STEP 1 R010024

Remove bucket pins and other parts.

STEP 6 The carrier can be moved aside.

INSTALLATION HAMMER CT02D444

STEP 1

Position hammer horizontally on the floor and remove the tool.

Install hammer in the same manner as mounting a bucket. Install bucket pins.

STEP 2

STEP 2

Stop the carrier engine.Operate boom and hammer controls to release pressure trapped inside hoses.

Wait ten minutes for oil pressure to drop

Connect hoses. Hammer inlet port is maked on the valve body with "IN" and outlet port with "OUT" An installation inspection must be carried out after the product has been mounted on the carrier. In the installation inspection certain specifications (operating pressure, oil flow, etc.) are checked so that they are within given limits. See "Hammer specification" on page 5.

STEP 3

STEP 3 Open hammer inlet and outlet lines.

CT02D444

Place a receptacle of a suitable capacity under the piping. Close hammer inlet and outlet lines. If quick couplers are used, disconnection automatically closes hammer lines. If hammer line includes ball valves, please make sure that they are closed.

STEP 4 Disconnect hoses. Protect environnement from oil spills. Plug the hoses and the hammer inlet and outlet ports.

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Issued 03-09

7

HANDLING HAMMER Use a hoist when lifting components which weigh 23kg or more, to avoid back injury. Make sure all chains, hooks, slings etc., are in good condition and are in the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. Do not use the hammer’s tools for lifting.

Lifting devices must safely carry the working weight of the product. See "Technical specifications" on page 5. Place chains or slings, as shown by the illustration, to lift the product.

SAFETY INSTRUCTIONS FOR LIFTING Below are some common safety instrutions concerning lifting operations. In addition to this, the local, national standards for machines and lifting-tackles must always be strictly observed. Please note that the list below is not all inclusive, you must always ensure the procedure you choose is safe for you and others.

STEP 1

STEP 6

Do not lift load over people. No one shall be under the hoisted load.

Never leave the suspended load unattented. Maintain load control at all times.

STEP 2

STEP 7

Do not lift people and never ride the hoisted load.

Never lift the load over the rated capacity.

STEP 3

STEP 8

Keep people clear from lift area.

STEP 4

Inspect all lifting equipment before use. Do not use twisted or damaged lifting equipment. Protect lifting equipment from sharp corners.

Avoid side pull of the load. Make sure you take up the slack slowly. Start and stop carefully.

STEP 9

STEP 5

Obey all local safety instructions.

Lift load a few centimeters and verify it before proceeding. Make sure the load is well balanced. Check for any loose items.

Lep SMCB90S-0EN

Issued 03-09

8

REMOVAL AND INSTALLATION OF TOOL WEAR LIMITS AND LUBRICANTS FOR TOOL REMOVAL

Item Tool diameter (Worn out) Tool and tool retaining pins

Wear Limit (X)

Lubricant

78mm Tool Grease

REMOVAL OF TOOL Warning : The hydraulic pressure inside the hammer must always be released before removing the tool. After operating the hammer, wait 10 minutes for oil pressure to drop inside hammer.

Warning : Hot tool can cause severe injuries.

STEP 1 Set the hammer on level ground.

STEP 2 Make sure the carrier’s transmission is in neutral and the parking brake is engaged.

STEP 3 Stop the carrier engine.

STEP 4 Remove plug and O-ring.

STEP 5 Remove tool retaining pin.

Lep SMCB90S-0EN

Issued 03-09

9

STEP 6 Remove tool. Use lifting device if necessary. Notice that tool bushing and tool are locked with same tool retaining pin. Prevent tool bushing from dropping on ground when removing the tool.

NOTA : If hammer is still on carrier, it may be easier to stick the tool in the ground and lift the hammer off the tool.

Make sure that the the tool can not fall.

INSTALLATION OF TOOL STEP 1 Clean all parts carefully.

STEP 2 Measure the tool diameter (X) from the area marked on the illustration.

Replace tool if necessery.

STEP 3 Check tool bushing for wear. See "Removal and installation of tool Bushing" on page 10.

STEP 4 Check tool seal. Replace if necessary.

STEP 5 Clean and coat tool and retaining pin with grease.

STEP 6 Install tool and align the groove of the tool with the pin bore.

STEP 7 Install retaining pin and O-ring.

STEP 8 Grease plug and install it.

Lep SMCB90S-0EN

Issued 03-09

10

REMOVAL AND INSTALLATION OF TOOL BUSHING WEAR LIMITS AND LUBRICANTS FOR TOOL BUSHING Item

Wear Limit (Y)

Tool bushing inner diameter (Worn out)

82 mm

Contact surfaces of front head

Lubricant

Thread grease

REMOVAL OF TOOL BUSHING STEP 1 Remove tool. Notice that tool bushing and tool are locked with same tool retaining pin. Prevent tool bushing from dropping on ground when removing the tool.

STEP 2 Remove tool bushing.

STEP 3 Remove seal from tool bushing.

Lep SMCB90S-0EN

Issued 03-09

11

INSTALLATION OF TOOL BUSHING STEP 1 Clean all parts carefully.

STEP 2 Measure the bushing inner diameter (marked Y).

Replace bushing if necessary.

STEP 3 Install seal.

STEP 4 Lubricate the contact surfaces of the front head.

STEP 5 Install the tool bushing. Align the holes in the tool bushing with the holes in the front head.

STEP 6 Install the tool.

Lep SMCB90S-0EN

Issued 03-09

12

TROUBLESHOOTING Defect

Cause Pressure or return lines closed.

Check the operation of quick couplings in hammer line. Open hammer line ball valves if closed.

Pressure and return hoses installed backwards.

Swap the pressure and return hoses.

Piston is in its lower hydraulic brake.

Keep the hammer control valve open and force the tool against an object.The tool head will push the piston out of its brake area.

Grease between piston and tool contact area.

Remove the tool and wipe excessive grease off.

Hammer control valve does not open.

When operating the hammer control valve, check that the pressure line pulsates (this indicates the hammer control valve is opening). If the valve does not operate, check the operating means: mechanical connections, pilot pressure or electrical control.

THE HAMMER DOES NOT START.

Relief valve in hydraulic circuit opens at a low pressure. Hammer operating pressure is not reached.

Excessive back pressure in return line.

THE HAMMER OPERATES IRREGULARLY BUT THE BLOW HAS FULL POWER

Lep SMCB90S-0EN

Solution

Check the installation. Check the relief valve operation. Adjust the relief valve in hydraulic circuit. Measure the high pressure in the hammer inlet line. (See "Measuring hammer operating pressure on pages 42, and " Measuring hammer circuit" on page 40).

Check the installation. Check the size of the return line.

Leakage from pressure to return in excavator hydraulic circuit.

Check the installation. Check the pump and the other hydraulic components.

Failure in hammer valve operation.

The hammer must be serviced in an authorized CNH service shop.

Piston failure.

The hammer must be serviced in an authorized CNH service shop.

Not enough feed force from excavator.

Refer to the correct working methods.

Relief valve in hydraulic circuit opens at a low pressure Hammer operating pressure is not reached.

Check the installation. Check the relief valve operation. Adjust the relief valve in hydraulic circuit. Measure the high pressure in the hammer inlet line. (See "Measuring hammer operating pressure on pages 42, and " Measuring hammer circuit" on page 40).

Failure in hammer valve operation

The hammer must be serviced in an authorized CNH service shop. (See "Body part" on page 29).

Issued 03-09

13 Defect

THE HAMMER OPERATES IRREGULARLY AND BLOW HAS NO POWER.

IMPACT RATE SLOWS DOWN.

THE HAMMER DOES NOT STOP OR HAS RUN ON.

Lep SMCB90S-0EN

Cause

Solution

The working method is not correct.

Refer to the correct working methods.

Relief valve in hydraulic circuit opens at a low pressure. Hammer operating pressure is not reached.

Check the installation. Check the relief valve operation. Adjust the relief valve in hydraulic circuit. Measure the high pressure in the hammer inlet line. (See "Measuring hammer operating pressure on pages 42, and " Measuring hammer circuit" on page 40).

Pressure adjusting valve setting is incorrect.

The hammer must be serviced in an authorized CNH service shop.

Pressure loss in pressure accumulator.

The hammer must be serviced in an authorized CNH service shop. (See "Pressure accumulator" on page 21).

(See "Charging accumulator" on page 27).

Failure in hammer valve operation.

The hammer must be serviced in an authorized CNH service shop. (See "Body parts" on page 29).

Oil has overheated (over +80 °C / +176° F).

Check the following: a) for a fault in the oil cooling system, or an internal leak in the hammer b) the hydraulic circuit of the carrier (See "Measuring hammer circuit" on page 40). c) the relief valve operation in the carrier. d) the line size.

Assemble an extra oil cooler.

Hydraulic oil viscosity too low.

Check hydraulic oil.

Excessive back pressure in return line.

Check the installation. (See "Measuring hammer circuit" on page 40).

Check the size of the return line.

Relief valve in hydraulic circuit opens at a low pressure. Hammer operating pressure is not reached.

Check the installation. Check the relief valve operation. Adjust the relief valve in hydraulic circuit. Measure the high pressure in the hammer inlet line. Contact your local dealer for more information.(See "Measuring hammer circuit" on page 40, and "Measuring hammer operating pressure" on page 42).

Leakage from pressure to return in excavator hydraulic circuit.

Check the installation. Check the pump and the other hydraulic components

Pressure loss in pressure accumulator.

The hammer must be serviced in an authorized CNH service shop. (See " Pressure accumulator" on page 21). (See "Charging accumulator" on page 26).

Failure in breaker valve operation.

The hammer must be serviced in an authorized CNH service shop. (See "Body part" on page 29).

Failure in hammer control valve operation.

Issued 03-09

14 Defect

Cause

Solution

Application not correct for hammer.

Refer to recommended use and to correct working methods

Cooling capacity of the factory oil cooler is too small.

Assemble an extra oil cooler.

Relief valve in hydraulic circuit opens at a low pressure. Hammer operating pressure is not reached.

OIL OVERHEATS.

RECURRENT TOOL FAILURE.

FURTHER ASSISTANCE.

Lep SMCB90S-0EN

Check the installation. Check the relief valve operation. Adjust the relief valve in hydraulic circuit. Measure the high pressure in the hammer inlet line. Contact your local dealer for more information.(See "Measuring hammer circuit" on page 40, and "Measuring hammer operating pressure" on page 42).

Hydraulic oil viscosity too low

Check hydraulic oil.

Leakage from pressure to return in excavator hydraulic circuit.

Check the installation. Check pump and the other hydraulic components.

Internal oil leak in the hammer.

The hammer must be serviced in an authorized CNH service shop. (See " Body parts" on page 29).

Excessive back pressure in return line.

Check the installation. (See "Measuring hammer circuit" on page 40).Check the size of the return line.

Application not correct for hammer.

Refer to recommended use and to correct working methods

Rough operating practices

Refer to recommended use and to correct working methods

Tool does not get enough lubricant.

Refer to recommended use and to correct working methods

Tool long tool.

Use shortest tool possible. Refer to recommended use and to correct working methods

Rapid wear of tool.

Refer to recommended use and to correct working methods. There is a wider selection of tools available for different applications. Consult with your local dealer for more information.

Further assistance.

If further assistance is required, please prepare to answer the following questions before calling your dealer.

-Model and serial number -Working hours and service history -Carrier model.

-Installation: Oil flow, operating pressure and return line pressure if known.

-Application.

-Has the product operated normally before.

Issued 03-09

15

WORKSHOP DISASSEMBLY AND ASSEMBLY MAIN COMPONENTS LOCATION OF MAIN COMPONENTS (HAMMER MECANISM)

Lep SMCB90S-0EN

ITEM

Description

A

High pressure measuring plug

B

Low pressure measuring plug

C

High pressure accumulator

D

Low pressure accumulator

E

Pressure adjusting valve

G

Body parts

Issued 03-09

16

RELEASING HYDRAULIC PRESSURE FROM HAMMER RELEASING PRESSURE Warning : The hydraulic pressure inside the hammer must always be released before making any adjustments or repairs when the hammer is connected to the carrier. There may also be pressurized oil trapped inside the hammer even if the hammer is disconnected from the carrier. Release the hydraulic pressure according to the following instructions before opening any plugs or valve covers.

STEP 1 Stop the carrier engine.

STEP 2 Operate boom and hammer controls to release any pressure trapped inside hoses.

STEP 3 Wait 10 minutes for oil pressure to drop inside hammer.

STEP 4 Close hammer inlet and outlet lines. If quick couplers are used, disconnection automatically closes hammer lines. If hammer line includes ball valves, please make sure that they are closed.

Warning : This procedure does not release the pressure from the pressure accumulators! Read the instructions dealing with the accumulator before disassembling the hammer. See "Releasing pressure from high pressure accumulator" on page 17, and "Releasing pressure from low pressure accumulator" on page 18.

RELEASING PRESSURE FROM HIGH PRESSURE ACCUMULATOR LOCATION OF HIGH PRESSURE ACCUMULATOR REFILLING CONNECTION

ITEM A

Lep SMCB90S-0EN

Description

Tightening torque

High pressure accumulator refilling connection Shield plug.

150 Nm

Accumulator filling plug

20 Nm

Issued 03-09

17 RELEASING PRESSURE FROM HIGH PRESSURE ACCUMULATOR Warning : Do not disassemble hammer before releasing pressure from accumulators.

STEP 1 Remove dust shield plug and O-ring.

STEP 2 Carefully open filling plug and let nitrogen gas escape. When gas is completely released, remove filling plug and Usit-ring.

RELEASING PRESSURE FROM LOW PRESSURE ACCUMULATOR LOCATION OF LOW ACCUMULATOR REFILLING CONNECTION

ITEM B

Lep SMCB90S-0EN

Description

Tightening torque

Low pressure accumulator refilling connection Shield plug.

150 Nm

Accumulator filling plug

20 Nm

Issued 03-09

18 RELEASING PRESSURE FROM LOW PRESSURE ACCUMULATOR Warning : Do not disassemble hammer before releasing pressure from accumulators.

STEP 1 Remove rubber shield plug and unscrew dust shield plug from accumulator refilling connection. Carefully open filling plug and let nitrogen gas escape. When gas is competely released, remove filling plug and Usit-ring. .

HOUSING TORQUES, ADJUSTMENTS AND LUBRICANTS

ITEM A

Housing plate mounting screws All screw threads and bearing surfaces.

Lep SMCB90S-0EN

Tightening torque

Lubricant

175 Nm Thread Grease

Issued 03-09

19

DISASSEMBLING HOUSING Warning : The hammer must be secured from falling down in either direction when handling it. Check that the lifting capacity of the hoist you are using is sufficient for the job. (See "Lifting instructions" on page 7), and (See " Hammer specifications" on page 5).

STEP 1 Remove hydraulic hoses.

STEP 2 Remove screws and lock washers of housing plates.

STEP 3 Install lifting eye nuts using screws to the housing plate flange.

STEP 4 Lift housing plate off with lifting device.

STEP 5 Lift hammer mechanism out from housing.

STEP 6 Remove dampers.

Remove parallel pins.

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20

ASSEMBLING HOUSING STEP 1 Install dampers to both housing plates.

STEP 2 Insert parallel pins.

STEP 3 Install hammer mechanism into its place.

STEP 4 Lower remaining housing plate into its correct position.

STEP 5 Grease threads and bearing surfaces of screws and lock washers.

STEP 6 Install screws and lock washers to holes and tighten fully.

STEP 7 Torque screws to specified setting.

STEP 8 Install hydraulic hoses.

STEP 9 Install hammer to carrier.

Lep SMCB90S-0EN

Issued 03-09

21

PRESSURE ACCUMULATORS LUBRICANTS AND TORQUES FOR PRESSURE ACCUMULATORS

ITEM

Tightening torque

Lubricant

A

Top cover’s screws

B

Top cover (gas side)

C

Accumulator membrane (inner) side

Hydraulic oil

D

Accumulator cover (gas side)

Hydraulic oil

E

Cylinder accumulator area O-rings Seal

580 Nm Silicone grease

Silicone grease O-ring grease Hydraulic oil

Screw threads and bearing surfaces, lock washers

Thread Grease

High pressure accumulator’s bottom

M8 screw for lifting the higt pressure accumulator’s bottom

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DISASSEMBLY PRESSURE ACCUMULATORS Warning : Make sure that both high and low pressure accumulators are depressurized! (See "Releasing pressure from high pressure accumulator" on page 17).(See "Releasing pressure from low pressure accumulator" on page 18).

STEP 1 Remove tool and tool bushing. See "Removal of tool" on page 8).

STEP 2 Remove pressure adjusting valve. See "Pressure adjusting valve" on page 33.

STEP 3 remove swivel couplings. See "Swivel couplings" on page 36.

STEP 4 Set power cell to horizontal position. Protect top covers face using plywood board on the floor. Remove top cover’s screws. If necessary, prevent the rotation of power cell by inserting a suitable rod through tool retaining pin’s bore.

Be careful not to damage surface of bore. When screws are loose, support the power cell to vertical position.

STEP 5 Remove top cover with membrane and high pressure accumulator’s bottom. Remove O-rings from cylinder’s top surface.

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STEP 6 Using M8 screw as handle, lift high pressure accumulator’s bottom out from top cover. Remove membrane and Oring from cover.

STEP 7 Lift plastic assembly ring out. Using plastic hammer, tap the accumulator cover’s edge slightly to remove low pressure accumulator cover from cylinder.

STEP 8 Remove seal and low pressure accumulator’s membrane. If necessary, old membrane can be removed by cutting lengthwise apart. Be careful not to scratch cylinder surfaces .

ASSEMBLING PRESSURE ACCUMULATOR STEP 1 Clean and dry parts carefully.

STEP 2 Insert seal carrier to cylinder . See " Body parts" on page 29.

STEP 3 Insert seal on cylinder.

STEP 4 Apply thin layer of silicone grease to accumulator area in cylinder. To prevent risk any of gas leak be careful not to stain silicone in sealing grooves.

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STEP 5 Oil and install a new low pressure accumulator membrane on cylinder. When inserting the membrane, note that burr in the membrane’s inner edge goes first. Be careful not to damage the membrane when pulling it over shoulders of cylinder.

STEP 6 Apply oil inside accumulator cover. Install accumulator cover in its place. If necessary use plastic hammer. Accumulator cover sits finally when top cover screws are tightened.

STEP 7 Install assembly ring.

STEP 8 Install O-rings to top surface of the cylinder.

STEP 9 Install O-rings to groove in top cover’s high pressure accumulator area.

STEP 10 Install membrane to accumulator bottom.

STEP 11 Apply thin layer of silicone grease inside high pressure accumulator area in top cover.

STEP 12 Lay top cover down onto high pressure accumulator’s bottom. Press top cover so that O-ring goes it’s groove and locks the parts together.

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STEP 13 Install O-ring to groove in high pressure accumulator’s bottom.

STEP 14 Install piston, steering ring, distributor and distributor cover to cylinder. See " Body parts" on page 29.

STEP 15 Oil contact surfaces between top cover and cylinder. Install top cover to cylinder. Insert lock washers and fastening screws. Tighten screws equally so tigh that top cover sits firmly its place.

STEP 16 Set power cell to horizontal position. If necessary, prevent the rotation of power cell by inserting a suitable rod through tool retaining pin’s bore. Be careful not to damage surface of bore. Torque fastening screws crosswise to specified setting.

Lep SMCB90S-0EN

Issued 03-09

26

CHARGING ACCUMULATORS TORQUES, ADJUSTMENTS AND LUBRICANTS

ITEM

Tightening torque

A

Shield plug

150 Nm

B

Accumulator filling plug

20 Nm

Charging pressure (Nitrogen N2)

Low pressure accumulator

15 bar

High pressure accumulator

40 bar

CHARGING ACCUMULATOR Warning : Use only nitrogen (N2) for charging accumulator. Use of other gases may cause accumulator to explode.

STEP 1 Install new usit ring.

STEP 2 Install filling plug.

STEP 3 Install adapter with O-ring.

STEP 4 Insert pin.

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STEP 5 Insert pin.

STEP 6 Install charging device.

STEP 7 Connect charging system to nitrogen bottle.

STEP 8 Tighten filling plug carefully through charging device until you feel it stop, then open it three (3) turns.

STEP 9 Open discharge valve on charging device fully.

STEP 10 Carefully open nitrogen gas bottle valve and adjust gas flow to minimum.

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STEP 11 CAUTION! Charging device does not have any pressure relief valve. Shut gas bottle valve when gauge shows correct charging pressure.

STEP 12 Close discharge valve on charging device and charge accumulator 2-3 bar above specified charging pressure.

Observe pressure gauge reading.

STEP 13 Shut nitrogen bottle valve.

STEP 14 Wait 10 minutes for nitrogen gas pressure to stabilize inside accumulator.

STEP 15 Adjust pressure in accumulator to correct setting by carefully opening discharge valve.

STEP 16 Torque filling plug through charging device to specified setting.

STEP 17 Release pressure from charging hose by opening discharge valve.

STEP 18 Remove charging system from accumulator.

STEP 19 Check accumulator for nitrogen leak by filling Usit-ring area with thin oil. If gas bubbles appear, discharge accumulator and replace Usit-ring.

STEP 20 Install shield plug with O-ring.

STEP 21 Torque plug to specified setting.

Lep SMCB90S-0EN

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29

BODY PARTS TORQUES, ADJUSTMENTS AND LUBRICANTS

Item Contact surfaces of cylinder and top cover

Lubricants and accessories Anticorrosive agent (e.g.CRC 3-36)

All seals and O-rings

O-ring grease

Screw threads and bearing surfaces, lock washers

Thread grease

Distributor cover

M6 screw for lifting the distributor cover

Split pins, inside

silicone compound

DISASSEMBLING BODY PARTS Warning : The hydraulic pressure inside the hammer must always be released before removing any of the plugs or valves. Read the instrutions on releasing the hydraulic pressure from the hammer. See "Releasing hydraulic pressure from hammer" on page 16.

Warning : Make sure that both high and low pressure accumulators are depressurised! See "Releasing pressure from high pressure accumulator" on page 16. See "Releasing pressure from low pressure accumulator" on page 17.

Stop the carrier engine.

STEP 1 Remove tool and tool bushing. See "Removal of tool" on page 8.

STEP 2 Remove high and low pressure accumulator. See "Pressure accumulator" on page 21.

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STEP 3 Using M6 screw lift distributor cover out. Lift distributor out. Screw M12 lifting eye to piston end and lift steering ring and piston out.

STEP 4 Remove seal from steering ring.

STEP 5 Set power cell to horizontal position. Tap split pins out from the cylinder to release seal carrier. Using slide hammer tap and drag the seal carrier out from cylinder bottom.

STEP 6 Remove O-ring and seals from seal carrier.

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ASSEMBLING BODY PARTS STEP 1 Check all parts for wear and damage. If necessary, use fine emery cloth or grinding agent. Clean and oil all parts.

STEP 2 Install O-ring and seals to seal carrier using suitable pliers.

STEP 3 Install seal carrier to cylinder four grooves in top face upwards.

STEP 4 Install split pins to cylinder. Fill split pin with silicone compound.

STEP 5 Install seal to steering ring.

STEP 6 Set power cell to vertical position and install piston to cylinder. If necessary use plastic hammer at the installation.

Install steering ring.

STEP 7 Oil distributor’s parts properly. Install distributor and distributor cover. Check that distributor cover’s upper surface is in same level with cylinder top surface.

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STEP 8 Install low and high pressure accumulator. See " Pressure accumulator" on page 21.

STEP 9 Install pressure adjusting valve. See "Pressure adjusting valve" on page 33.

STEP 10 Install swivel couplings. See "Swivel couplings" on page 36.

STEP 11 Install tool bushing and tool. See "Removal of tool" on page 8.

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33

PRESSURE ADJUSTING VALVE TORQUES AND ADJUSTMENTS

ITEM

Tightening torque

A

Spring housing

200 Nm

B

Flange plug

120 Nm

D1

Gap between body and spring housing Seals O-rings and cavity inside spring housing Spool and valve bore, spring housing and flange plug threads

Lep SMCB90S-0EN

Adjustment

Lubricants

0.5 mm O-ring grease

Hydraulic oil

Issued 03-09

34

DISASSEMBLING PRESSURE ADJUSTING VALVE Warning : The hydraulic pressure inside the hammer must always be released before removing any of the plugs or valves. Read the instructions on releasing the hydraulic pressure from the hammer. See "Releasing hydraulic pressure from hammer" on page 16.

STEP 1 Unscrew spring housing.

STEP 2 Remove shim plates and spring.

STEP 3 Remove flange plug opposite end of valve.

STEP 4 Remove pressure adjusting spool.

STEP 5 Remove O-ring, washer and seal. The seal can be pressed out from using pressure adjusting spool as tool after Oring and washer are removed.

STEP 6 Remove O-ring from spring housing.

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ASSEMBLING PRESSURE ADJUSTING VALVE STEP 1 Check all parts for wear and damage. If necessary, use fine emery cloth or grinding agent. Clean and oil all parts.

STEP 2 Install seal, washer and O-ring to top cover.

STEP 3 Install pressure adjusting spool and flange plug opposite end of valve. Tighten flange plug to the specified setting.

STEP 4 Install O-ring on spring housing. Install shim plates and spring into the spring housing.

STEP 5 Insert spring housing to top cover and tighten it by hand until you feel spring touching it. Do not compress spring.

STEP 6 Check pre-load on spring by measuring the gap (D1) between spring housing and body. Adjust pre-load to specifications by adding or removing shim plates.

Note: Always measure hammer operating pressure with pressure gauge after pressure adjusting valve adjustment.

See "Measuring hammer operating pressure" on page 42.

STEP 7 Remove spring housing and fill it with grease.

STEP 8 Refit spring housing. Torque it to specified setting.

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36

SWIVEL COUPLINGS TORQUES AND LUBRICANTS

ITEM

Tightening torque

Lubricants

A

Manifold fastenings screws

175 Nm

B

Swivel end screws

120 Nm

Locking fluid, medium locking force (e.g. loctite 243)

C

Plug

80 Nm

Locking fluid, (e.g. loctite 275)

O-rings

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O-ring grease

Issued 03-09

37

DISASSEMBLING SWIVEL COUPLINGS It is possible to make the hammer either left or righ handed by turning manifold 180 degree. If this need to be done, loosen first flange plugs from input/output channels, before removing manifold from power cell.

Warning : The hydraulic pressure inside the hammer must always be released before removing any of the plugs or valves. Read the instructions on releaseing the hydraulic pressure from the hammer. See "Releasing hydraulic pressure from hammer" on page 16.

STEP 1 Remove hoses from swivels. Plug hose ends and swivels.

STEP 2 If power cell is out of housing, loose screws from swivel ends.

STEP 3 Remove manifold screws and manifold.

STEP 4 Remove screws from swivel ends, swivels and O-rings.

STEP 5 Remove O-rings from swivel end screws.

STEP 6 Remove seals from swivels.

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ASSEMBLING SWIVEL COUPLINGS STEP 1 Check all parts for wear and damage.

If necessary, use fine emery cloth or grinding agent.

Clean and oil all parts.

STEP 2 If needed to change the left-handed hammer to the right-handed or vice versa, remove flange plugs from the input/ output channels in manifold and install them on the opposite side of the manifold.

STEP 3 Install seals to swivels.

STEP 4I Install O-rings to swivel end screws.

STEP 5 Install swivels and swivel end screws to the manifold.

Tighten screws by hand.

If power cell is into the housing, torque swivel end screws to specified setting.

STEP 6 Install O-rings on swivels.

Inner O-rings can be slide over swivel.

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STEP 7 Install manifold with input/output channel O-rings, lock washers and fastening screws to the power cell.

STEP 8 Torque manifold screws to specified setting.

Torque swivel end screws to specified setting.

If removed, torque flange plugs for input/output channels to specified setting.

STEP 9 Install housing.

STEP 10 Install hydraulic hoses.

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40

TESTING MEASURING HAMMER CIRCUIT MEASURING POINTS

p0

tank (with closed circuit from suction pipe of the pump)

p2

straight before the restriction of the flow meter (e.g. Webster flow meter includes pressure gauge for p2)

Q2 & T2 p3

at flow meter, which connects pressure and return line of the hammer circuit straight after flow meter

HOW TO MEASURE Procedure for measuring and adjusting the hammer circuit Note: Check and calibrate all the gauges you are going to use . Faulty pressure gauges should be changed.

Note: If the flow to the hammer is adjusted by changing the engine revolutions, always check the flow also at full engine revolutions.

Note: It is absolutely forbidden to use hammer above specified oil flow range.

Warning : Don’t exceed the carrier’s main relief valve setting.

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STEP 1 Check the lines, couplings, clamps etc. to ensure their condition. Replace worn or damaged components and tighten loose joints.

STEP 2 Check that there is a pressure relief valve in the hammer line.

STEP 3 Make sure that carrier’s hydraulic oil temperature is at normal operating level when measuring.

STEP 4 Connect the flowmeter in place of the hammer. It preferable to use same hoses and couplings that are used with the hammer, especially in cases when hoses are equipped with quick couplings.

STEP 5 Check that the adjustable restriction is open.

STEP 6 Start the engine and press the hammer operating switch.

STEP 7 Close the hammer line to adjust the crack point of pressure relief valve 50 bar (gauge p2) above the hammer max. operating pressure shown in the technical data.

STEP 8 Open the restriction so that the hammer’s operating pressure at gauge p2 is reached.

STEP 9 Check that the hammer’s oil flow is within the limits.

STEP 10 Check that the return line back pressure p3 doesn’t exceed the values allowed at the hammer oil flow.

STEP 11 Check that the hammer’s oil flow doesn’t increase when the carrier’s operating pressure exeeds the pressure in the hammer line (pressure compensated flow control). To do that , drive the boom, stick and bucket cylinders to the tilt position while pressing the hammer operating switch and checking the flow.

STEP 12 Open the restriction.

STEP 13 Stop the carrier engine.

STEP 14 Connect the hammer in place of the flow meter.

STEP 15 Measure hammer operating pressure. See "Measuring hammer operating pressure" on page 42.

STEP 16 When installing a new hammer check all the values after working about 50 hours with the hammer.

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42

MEASURING HAMMER OPERATING PRESSURE SPECIFICATIONS FOR MEASURING OPERATING PRESSURE

ITEM

Tightening torque

Plug A

High pressure measuring port

30 Nm

Plug B

Low pressure measuring port

30 Nm

MEASURING HAMMER OPERATING PRESSURE Warning : The hydraulic pressure inside the hammer must always be released before making any adjustments or repairs when the hammer is connected to the carrier. There may also be pressurized oil trapped inside the hammer even if the hammer is disconnected from the carrier. Release the hydraulic pressure according to the following instructions, or wait at least 10 minutes before opening any plugs or valve covers.

Warning : When measuring hammer operating pressure, you are working in hammer’s danger area. Protect youself against flying debris.

STEP 1 Hammer operating pressure must be measured with carrier hydraulic circuit in its normal operating temperature.

Before starting hammer operating pressure measuring procedure, operate carrier until hydraulic oil has warmed sufficiently.

STEP 2 Stop the carrier engine. Operate boom and hammer controls to release any pressure trapped inside hoses.

STEP 3 Connect a 60 bar pressure gauge with a minimum10 meter hose to low pressure measuring port (B), BSP 1/4".

STEP 4 Start carrier and set correct input oil flow to the hammer e.g. by adjusting engine revolutions or if carrier has power/ work modes, please select mode intended for hammer work.

STEP 5 Position tool e.g. on a thick steel plate and start to operate hammer.

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STEP 6 Read average pressure reading on low pressure gauge.

STEP 7 During hammer operation the average pressure reading in the low pressure circuit should be within the specified range. See "hammer specifications" on page xx.

STEP 8 If pressure reading is not within specifications, re-adjust pressure adjusting valve spring pre-load and measure low pressure circuit again. See "Pressure adjusting valve" on page 5.

STEP 9 Stop carrier. Wait ten minutes for oil pressure to drop.

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SERVICE TOOLS SPECIAL SERVICE TOOLS Name

Part no.

Qte

1: Accumulator charging kit (incl. part 1.1-1.4)

__

1

1.1: Charging device

ZK40633

1

1.2: Socket

73317906

1

1.3: Adapter

73317907

1

1.4: O-ring

73317908

1

Pressure gauge 250 bar

73318159

1

Pressure gauge 60 bar

73318160

1

hammer lifting adapter

(CAS2815)

1

Adapter for French nitrogen bottle

73318164

1

Lep SMCB90S-0EN

Picture

Issued 03-09

45 Drift pin D7

__

1

Drift pin D15.5

(CAS2833)

1

Drift pin D12

(CAS2827)

1

Lifting eye M12

73318166

2

Lifting eye M16

73318167

2

__

2

Lifting eye Nut M16

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46

STANDARD SERVICE TOOLS Name

Specification

Torque wrench

170-700 Nm (3/4")

Torque wrench

20-200 Nm (1/2")

Torque wrench

15 Nm (1/2")

Ratchet handle

1/2"

Extension

L=125 mm (1/2")

Sliding T-handle

3/4"

Adapter

3/4"-> 1/2"

Adapter

1/2"-> 3/4"

Combination spanner

36 mm

Combination spanner

41 mm

Hex. socket

36 mm (3/4")

Allen type screw socket

6 mm (1/2)"

Allen type screw socket

10 mm (1/2"

Allen type screw socket

12 mm (1/2"

Allen type screw socket

14 mm (1/2"

Allen type screw socket

19 mm (3/4"

Pry bars

400 mm

Lifting chain Hammer plastic

1000 g

Hammer ball headed

680 g

Hammer

2000 g

Slide hammer Screwdriver

6 x150 mm

Screwdriver

8 x 250 mm

Oil can

0.5 l

Grease gun

Lep SMCB90S-0EN

Flowmeter

15 - 25 l /min

Flowmeter

20 - 150 l /min

Pressure gauge

40 bar

Issued 03-09

HYDRAULIC HAMMERS CB32 - CB45 - CB65 - CB85 - CB120 - CB150

Lep 7-22013EN

Copyright © 2009 CNH France S.A. Printed in France March 2009

2

TABLES OF CONTENTS TECHNICAL SPECIFICATIONS .........................................................................................................................................2 OVERALL DIMENSIONS ...............................................................................................................................................2 SPECIFICATIONS ..........................................................................................................................................................8 TORQUE SETTING ............................................................................................................................................................9 TOOLS REQUIRED ............................................................................................................................................................9 SPECIAL TOOLS ..............................................................................................................................................................10 REPLACING A HYDRAULIC HAMMER ...........................................................................................................................12 HANDLING THE HYDRAULIC HAMMER .........................................................................................................................13 LOCATION OF MAIN COMPONENTS .............................................................................................................................14 HAMMER HYDRAULIC PRESSURE DISCHARGE .........................................................................................................15 LOCATION OF MAIN COMPONENTS .............................................................................................................................16 REMOVING THE CHASSIS PLATES ...............................................................................................................................17 INSTALLING THE CHASSIS PLATES ..............................................................................................................................18 LOW PRESSURE ACCUMULATOR .................................................................................................................................19 RELEASING PRESSURE IN THE LOW PRESSURE ACCUMULATOR .....................................................................19 LOW PRESSURE ACCUMULATOR ............................................................................................................................19 REMOVAL LOW PRESSURE ACCUMULATOR .........................................................................................................20 INSTALLATION LOW PRESSURE ACCUMULATOR .................................................................................................21 HIGH PRESSURE ACCUMULATOR ................................................................................................................................22 RELEASING PRESSURE FROM THE HIGH PRESSURE ACCUMULATOR .............................................................22 HIGH PRESSURE ACCUMULATOR ...........................................................................................................................23 REMOVAL HIGH PRESSURE ACCUMULATOR ........................................................................................................23 INSTALLATION HIGH PRESSURE ACCUMULATOR ................................................................................................25 CHARGING THE ACCUMULATOR ..................................................................................................................................26 PRESSURE REGULATIG VALVE ....................................................................................................................................28 TIE-RODS .........................................................................................................................................................................30 REMOVAL TIE-RODS ..................................................................................................................................................30 INSTALLATION TIE-RODS ..........................................................................................................................................31 CONTROL VALVE COMPONENTS (CB32 - CB45) .........................................................................................................32 REMOVAL ....................................................................................................................................................................33 INSTALLATION ............................................................................................................................................................34 CONTROL VALVE BODY COMPONENTS (CB45S - CB65S - CB120S - CB150S) ........................................................35 REMOVAL ....................................................................................................................................................................35 INSTALLATION ............................................................................................................................................................37 CYLINDER ........................................................................................................................................................................39 REMOVAL CYLINDER .................................................................................................................................................39 INSTALLATION CYLINDER .........................................................................................................................................40 FRONT PART ...................................................................................................................................................................41 REMOVAL ....................................................................................................................................................................42 INSTALLATION ............................................................................................................................................................43 CHANGING A TOOL .........................................................................................................................................................44 REMOVAL ....................................................................................................................................................................44 INSTALLATION ............................................................................................................................................................45 CHANGING THE TOOL BUSHING ...................................................................................................................................46 WEAR LIMITS ...................................................................................................................................................................47 TOOL BUSHINGS ........................................................................................................................................................47 TOOLS .........................................................................................................................................................................47 INSPECTION AND MEASUREMENT OF HYDRAULIC HAMMER CIRCUIT ..................................................................48 MEASUREMENT / INSPECTION POINTS ..................................................................................................................48 PROCEDURE FOR TAKING MEASUREMENTS ........................................................................................................49 MEASURING THE HYDRAULIC HAMMER OPERATING PRESSURE ......................................................................50 OPERATING PRINCIPLES ...............................................................................................................................................52 TROUBLESHOOTING ......................................................................................................................................................55

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3

TECHNICAL SPECIFICATIONS OVERALL DIMENSIONS Model CB32 "Standard" type

CT04K008

Model CB32 "S" type

CT04K009

Model CB32 "S" type

CT04K010

Model CB45 "Standard" type Lep 7-22013EN

Issued 03-09

4

CT04K011

Model CB45 "S" type

CT04K012

Model CB45 "P" type

CT04K013

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Issued 03-09

5

Model CB65 "Standard" type

CT04K014

Model CB65 "S" type

CT04K015

Model CB65 "P" type

CT04K016

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Issued 03-09

6

Model CB65 "B" type

CT04K017

Model CB85 "Standard" type

CT04K018

Model CB85 "S" type

CT04K019

Lep 7-22013EN

Issued 03-09

7

Model CB85 "P" type

CT04K020

Model CB120 "Standard" type

CT04K021

Model CB120 "S" type

CT04K022

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Issued 03-09

8

Model CB150 "Standard" type

CT04K023

Model CB150 "S" type

CT04K024

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SPECIFICATIONS Rubrique Operating weight "Standard" Type (1)

CB32

CB45

CB65

CB85

CB120

CB150

130 kg

200 kg

300 kg

425 kg

590 kg

825 kg

590 kg

820 kg

Operating weight "S" Type (1)

140 kg

220 kg

315 kg

430 kg

Operating weight "P" Type (1)

110 kg

185 kg

240 kg

450 kg

Operating weight "B" Type (1) Impact rate (2)

310 kg 7504504006005005002200 bpm 1800 bpm 2000 bpm 1800 bpm 1300 bpm 1000 bpm

Operating pressure

95-120 bar

80-110 bar

100-145 bar

100-130 bar

80-130 bar

125-150 bar

Minimum pressure setting (3)

145175 bar

130160 bar

150195 bar

140185 bar

130180 bar

175200 bar

maximum pressure setting

220 bar

210 bar

220 bar

220 bar

220 bar

220 bar

Oil flow

20-50 l/ mn

20-70 l/ mn

25-100 l/ mn

50-150 l/ mn

60-150 l/ min

60-120 l/ min

Pressure in the low pressure circuit

30-32 bar 34-36 bar 28-32 bar 38-40 bar 28-34 bar 26-28 bar

Counter pressure

30 bar

30 bar

20 bar

30 bar

10 bar

10 bar

Inlet pressure

10 kW

12,8 kW

24 kW

33 kW

32,5 kW

30 kW

Tool diameter

45 mm

50 mm

63 mm

70 mm

84 mm

95 mm

Pressure pipe union (N)

BSP 1/2"

BSP 3/4"

BSP 3/4"

BSP 1"

BSP 1"

BSP 1"

Return pipe union (out)

BSP 1/2"

BSP 3/4"

BSP 3/4"

BSP 1"

BSP 1"

BSP 1"

Grease union (G)

BSP 3/8"

BSP 3/8"

BSP 3/8"

BSP 3/8"

BSP 3/8"

Air union (A)

BSP 1/2"

BSP 1/2"

BSP 1/2"

BSP 1/2"

BSP 1/2"

Pressure pipe dimension (minimum internal diameter)

12 mm

15 mm

19 mm

26 mm

26 mm

26 mm

Return pipe dimension (minimum internal diameter)

12 mm

15 mm

19 mm

26 mm

26 mm

26 mm

Optimum oil temperature

+40 +60 °C

+40 +60 °C

+40 +60 °C

+40 +60 °C

+40 +60 °C

+40 +60 °C

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 operating temperature

30-60 cSt 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

20-1000 cSt

Tool carrier weight (4)

13...3,2 t

2,5...4,5 t

3...6,5 t

5...8,5 t

7...12 t

9...15 t

Table of applications of the hydraulic breaker

See operator’s manual

Noise level

See operator’s manual

1.

Includes average mounting bracket and standard tool.

2.

Actual impact frequency depends on oil flow, oil viscosity, temperature, and material to be broken.

3.

Minimun setting = real operating pressure +50 bar (730 psi).

4.

The recommendations made for the component are intended to provide optimum stability when it is used on a tool-carrier with standard load excavator chassis, boom and dipper. For applications using other tool-carriers, contact your Dealer to check compatibility and stability of the tool-carrier.

Lep 7-22013EN

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TORQUE SETTING Sections

Torque setting CB32

CB45

CB65

CB85

CB120

CB150

Low pressure accumulator retaining screws (A)

70 Nm

175 Nm

175 Nm

175 Nm

175 Nm

340 Nm

Low pressure accumulator retaining screws (B)

70 Nm

175 Nm

175 Nm

175 Nm

175 Nm

175 Nm

Low pressure accumulator cover retaining screws

70 Nm

175 Nm

175 Nm

175 Nm

Nm

340 Nm

High pressure accumulator retaining screws

70 Nm

70 Nm

175 Nm

175 Nm

Nm

340 Nm

High pressure accumulator cover retaining screws

70 Nm

70 Nm

70 Nm

175 Nm

Nm

175 Nm

Spring housing screw (A)

150 Nm

340 Nm

150 Nm

340 Nm

340 Nm

340 Nm

Flange plug (B)

120 Nm

200 Nm

120 Nm

120 Nm

120 Nm

200 Nm

Tie-rod (A) pre-tightening torque setting

70 Nm

175 Nm

175 Nm

500 Nm

500 Nm

340 Nm

Suppplementary tightening angle

60°

60°

90°

60°

90°

90°

Protective plug (A) (for charging accumulator)

150 Nm

150 Nm

150 Nm

150 Nm

150 Nm

150 Nm

Accumulator (B) filler port plug

20 Nm

20 Nm

20 Nm

20 Nm

20 Nm

20 Nm

50 Nm

50 Nm

50 Nm

50 Nm

50 Nm

Plug for front part of flange (A) Plug for front part of flange (B)

80 Nm

80 Nm

80 Nm

80 Nm

80 Nm

High pressure port plug (A)

30 Nm

30 Nm

30 Nm

30 Nm

30 Nm

30 Nm

Plug for high pressure port (B)

30 Nm

30 Nm

30 Nm

30 Nm

30 Nm

30 Nm

Tube spacer (A) retaining screws "B" Type

-

-

820 Nm

-

-

-

Tube spacer (A) retaining screws "P" Type

250 Nm

480 Nm

480 Nm

820 Nm

-

-

Chassis plate retaining screws (A) "Standard" Type

340 Nm

340 Nm

175 Nm

175 Nm

175 Nm

340 Nm

Chassis plate retaining screws (B) "Standard" Type

250 Nm

480 Nm

820 Nm

820 Nm

1600 Nm

1150 Nm

Chassis plate retaining screws (A) "S" Type

340 Nm

340 Nm

175 Nm

340 Nm

340 Nm

340 Nm

Chassis plate retaining screws (B) "S" Type

175 Nm

175 Nm

340 Nm

340 Nm

580 Nm

340 Nm

Chassis plate retaining screws (A) "P" Type

250 Nm

480 Nm

-

820 Nm

-

-

Chassis plate retaining screws (B) "P" Type

250 Nm

480 Nm

-

820 Nm

-

-

TOOLS REQUIRED 1.

- Torque wrench (150 à 700 Nm)

2.

- Torque wrench (20 à 200 Nm)

3.

- Torque wrench (15 Nm)

Lep 7-22013EN

Issued 03-09

11

SPECIAL TOOLS Name

Part no.

Qte

1: Accumulator charging kit (incl. part 1.1-1.4) (CB32 to CB150)

__

1

1.1: Charging device

ZK40633

1

1.2: Socket

73317906

1

1.3: Adapter

73317907

1

1.4: O-ring

73317908

1

Hammer lifting adaptater (CB32 to CB150)

(CAS2815)

1

Pressure gauge 250 Bar (CB32 to CB150)

73318159

1

Pressure gauge 60 Bar (CB32 to CB150)

73318160

1

Hammer assembly stand (CB32 to CB150)

(CAS2812)

1

Lep 7-22013EN

Picture

Issued 03-09

12

Accumulator assembly stand (CB32 to CB150)

(CAS2818)

1

Adapter for French nitrogen bottle (CB32 to CB150)

73318164

1

Liffting eye M12 (CB32 - CB85 - CB120 CB150)

73318166

2

Liffting eye M16 (CB45 - CB65 - CB85 CB120 - CB150)

73318167

2

Liffting eye M20 (CB150)

73318168

2

Liffting eye M24 (CB85 - CB150)

73318169

2

Liffting eye M30 (CB120 - CB150)

73318170

2

Fitting tool distributor (CB45 - CB120 CB150)

(CAS2823)

1

Driff pin D12 (CB45 - CB65 - CB85)

(CAS2827)

1

Driff pin D15.5 (CB120 - CB150)

(CAS2833)

1

Lep 7-22013EN

Issued 03-09

13

REPLACING A HYDRAULIC HAMMER REMOVAL HAMMER

INSTALLATION HAMMER

Warning : The hammer must be secured from rolling over when disconnecting from the carrier. Only use skilled operator to position carrier for removal!

STEP 1

Warning : Hydraulic pressure inside hammer must always be released before opening hose connections!

Warning : Hot hydraulic fluide can cause severe injuries!

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 operator’s manual for the machine concerned.

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

Connect the hydraulic hammer hoses.

STEP 4 Place the hydraulic hammer horizontally on flat, hard ground.

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

STEP 2

STEP 5

Shut down the engine and remove the starter switch key. Release pressure in the hydraulic hammer circuit. See "Releasing pressure in the hydraulic circuit" in the "Lubrication/Filters/Filters" Section of the operator’s manual for the machine concerned.

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

CT02D444

STEP 3

STEP 6 Open the valves (circuit opening and closing) on the piping (if equipped).

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

STEP 8 Grease the linkages.

STEP 9 CT02D444

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

For the hydraulic hammer control, refer to "Option pedal" in the "Controls/Instruments/Accessories" Section of the operator’s manual for the machine concerned.

STEP 4 Remove the pin retaining hardware (as fitted).

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

STEP 6 Operate the machine’s controls to disengage the hammer.

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.

Lep 7-22013EN

Issued 03-09

14

HANDLING THE HYDRAULIC HAMMER The lifting equipment must be able to withstand the weight if the hydraulic hammer. See "Hydraulic hammer weight specifications".

- Use slings, straps, accessories and chains which are in perfect condition, and which have an effective device for preventing unhooking.

- Set up guidance systems for handling and operate handling machines in accordance with regulations.

- Do not allow anyone into the working area of the hydraulic hammer during handling.

- Position chains and slings as shown above.

Types CB32 to CB150

CS99C626

INSTALLATION STEP 1

piping (if equipped).

Operate the attachment controls to bring the dipper into the hydraulic hammer.

STEP 7

STEP 2

STEP 8

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 operator’s manual for the machine concerned.

Grease the linkages.

STEP 3

Remove the lifting ring and install the plugging screw.

STEP 9 For the hydraulic hammer control, refer to "Option pedal" in the "Controls/Instruments/Accessories" Section of the operator’s manual for the machine concerned.

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

STEP 6 Open the valves (circuit opening and closing) on the Lep 7-22013EN

Issued 03-09

15

LOCATION OF MAIN COMPONENTS

1

3

3

4 1

5 4

7 6 8

5

7

6

8 7

9

2

7

6

8 9

5

4

9

2

2

CT04K002

ITEM

Lep 7-22013EN

Description

1

Side plates

2

Tool

3

Low pressure accumulator

4

High pressure accumulator

5

Threaded rods

6

Head

7

Grease fittings

8

Tool retaining hardware

9

Tool bushing retaining hardware

Issued 03-09

16

HAMMER HYDRAULIC PRESSURE DISCHARGE Warning : When the hydraulic hammer is connected to the tool-carrier, the hydraulic pressure inside the hydraulic hammer must always be released before carrying out any adjustment or repair. The hydraulic hammer may still contain oil under pressure even if it is no longer connected to the tool-carrier. Release the hydraulic pressure in accordance with the following instructions, or wait at least 10 minutes before opening plugs or control valve caps.

R0500214

ITEM

Description

1

Inlet port

2

Outlet port

STEP 1

STEP 3

Shut down the tool-carrier engine. Operate the boom and hydraulic hammer controls to ensure complete release of pressure contained in the hoses.

Unscrew the pressure release plugs (A) and (B).

Watch out for oil leaks.

STEP 2

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

Close the hydraulic hammer inlet and outlet ports. If quick couplers are used, shutting off the circuit will automatically close the hydraulic hammer lines. If ball-valves are included in the hydraulic hammer piping, make sure they are correctly closed.

STEP 4

R050081

Warning : This procedure does not release the pressure in the pressure accumulator. Carefully read the instructions concerning the accumulator before disassembling the accumulator. See "Pressure accumulator" on page 22

Lep 7-22013EN

Issued 03-09

17

LOCATION OF MAIN COMPONENTS CB32 - CB45 - CB65 - CB85 - CB120 - CB150

C F

D

E

A

B

G

H

I

R050135

ITEM

Lep 7-22013EN

Description

A

PRESSURE TEST POINT PLUG (HP)

B

PRESSURE TEST POINT PLUG (LP)

C

LOW PRESSURE ACCUMULATOR

D

HIGH PRESSURE ACCUMULATOR

E

PRESSURE REGULATING VALVE

F

VALVE BODY

G

PISTON AND CYLINDER

H

TENSION RODS

I

TOP OF FRONT CHASSIS

Issued 03-09

18

REMOVING THE CHASSIS PLATES CB32 P - CB45 P - CB65 B et P - CB85P

R050086

CB120 - CB150 Standard

C050306

CB32 S - CB45 S - CB65S - CB85 S CB120S - CB150S

C050219

CB32 - CB45 - CB65 -CB85 Standard

R050083

Warning : The hydraulic hammer must be protected against falling during handling. Check that the lifting equipment used has sufficient capacity to perform the operation. See Lifting instructions". See "Hydraulic hammer specifications".

STEP 1 Remove the hydraulic hoses.

R050311 Lep 7-22013EN

Issued 03-09

19

STEP 2

STEP 4

Open mounting bracket screws (types "S" and types "Standard"). Remove the retaining screws, lockwashers and spacers (types "P" and types "Standard").

Remove buffer (types "S").

R050087A

STEP 5 R050084B

STEP 3

Remove screws and lock-washers (types "S").

Lift chassis plate off with lfting device (types "S").

Remove hammer mechanism (types "S").

Remove the chassis plates (types "P" and types "Standard").

R050088

STEP 6 R050085B

Remove dampers (types "S").

Remove parallel pins (types "S").

R050221

INSTALLING THE CHASSIS PLATES STEP 1 Check for cracks and excessive wear on all the components.

STEP 2 Grease the threads and bearing surfaces of the retaining screws and lock-washers.

STEP 3 Install dampers, hammer mechanism, parallel pins and upper chassis plate (types "S").

Install the chassis plate (types "P" and types "Standard"), spacers, retaining screws and lock-washers.

STEP 4 Tighten the retaining screws A and B to the specified torque.

Install buffer (types "S").

STEP 5 Install the hydraulic hoses.

STEP 6 Install the hydraulic hammer on the machine.

Lep 7-22013EN

Issued 03-09

20

LOW PRESSURE ACCUMULATOR RELEASING PRESSURE IN THE LOW PRESSURE ACCUMULATOR Warning : Never disassemble the hydraulic hammer until all pressure in the accumulator has been released.

STEP 1 Remove the protective plug and the O-ring.

STEP 2 Carefully open the filler port plug and allow the nitrogen to escape.

STEP 3 Once all the pressure is released, remove the filler port plug and the snap ring.

R050092

LOW PRESSURE ACCUMULATOR

R050091

Component

Lubricant

Threads and bearing surfaces of retaining screws and lock-washers

Grease for threads

Accumulator cover (gas side)

Silicone grease

All seals and O-rings

Grease for O-rings

Contact surfaces of control valve and accumulator body

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

Lep 7-22013EN

Issued 03-09

21

REMOVAL LOW PRESSURE ACCUMULATOR STEP 1

STEP 2

Remove the accumulator retaining screws and lockwashers.

Remove the accumulator cover retaining screws.

R050094B R050093A

STEP 2 Using a lifting device, raise the accumulator to remove it from its housing.

STEP 3 Remove the bottom of the accumulator and the diaphragm.

R050094C R050093B

DISASSEMBLY

Warning : Make sure that all pressure in the accumulator is released.

STEP 1 Install the accumulator on an assembly bench, top downwards.

Remove the seal

ASSEMBLY

STEP 1 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.

C050095A R050094A

Lep 7-22013EN

Issued 03-09

22

STEP 2

STEP 3

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.

Install the accumulator upside-down on the workbench, with the top downwards.

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

C050095C

STEP 4 C050095B

Install the O-ring.

C050096A

INSTALLATION LOW PRESSURE ACCUMULATOR STEP 1

STEP 2

Lower the accumulator until it reaches the correct position, using lifting equipment.

Apply an anti-corrosion product to the control valve body and accumulator contact surfaces.

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

C050097B C050097A

Lep 7-22013EN

Issued 03-09

23

STEP 3 Insert the accumulator retaining screws.

Tighten the retaining screws to the specified torque.

C050097C

HIGH PRESSURE ACCUMULATOR RELEASING PRESSURE FROM THE HIGH PRESSURE ACCUMULATOR Warning : Never disassemble the hydraulic hammer until you have released all pressure from the accumulator.

STEP 1 Remove the protective plug and the O-ring.

STEP 2 Carefully open the filler orifice plug and allow the nitrogen to escape.

STEP 3 Once all pressure is released, remove the plug and the snap ring from the filler orifice.

R050099

Lep 7-22013EN

Issued 03-09

24

HIGH PRESSURE ACCUMULATOR

R050098

Component

Lubricant

Threads and retaining screw bearing surfaces, lock-washers

Grease for threads

Accumulator cover (gas end)

Silicone grease

All seals and O-rings

Grease for O-rings

Contact surfaces for control valve body and accumulator

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

REMOVAL HIGH PRESSURE ACCUMULATOR STEP 1

STEP 2

Remove the retaining screws and lock-washers from accumulator.

Remove the accumulator.

R050100B R050100A

Lep 7-22013EN

Issued 03-09

25 DISASSEMBLY

ASSEMBLY

Warning : Make sure that all pressure in the accumulator is released.

STEP 1

STEP 1 Install the accumulator on a work bench, with the top downwards.

Remove the O-ring.

Clean and dry the parts very carefully. Install the lower part of the accumulator on a bench.

Install a new diaphragm.

Make sure it is correctly seated in its groove.

C050102A R050101A

STEP 2 Remove the retaining screws from the accumulator cover.

STEP 2 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 and lockwashers Install those components in position.

R050101B

STEP 3 Remove the bottom of the accumulator, and the diaphragm.

R050102B

C050101C

Lep 7-22013EN

Issued 03-09

26

STEP 3

STEP 4

Install the accumulator upside-down on the workbench, with the top downwards.

Tighten the accumulator cover retaining screws to the specified torque.

Position the O-ring in the control valve body.

C050103

R050102C

INSTALLATION HIGH PRESSURE ACCUMULATOR STEP 1

STEP 3

Apply an anti-corrosion product to the contact surfaces of the control valve body and the accumulator.

Position the accumulator in place.

Tighten the retaining screws to the specified torque setting.

C050104C C050104A

STEP 2 Grease the threads and the bearing surfaces of the accumulator retaining screws and lock-washers.

Install those components in their correct positions.

C050104B

Lep 7-22013EN

Issued 03-09

27

CHARGING THE ACCUMULATOR Warning : Use only nitrogen (N2) to charge the accumulator. The use of other gases could cause the accumulator to explode

R050105

Pressure charge (Nitrogen N2) Component

CB32

CB45

CB65

CB85

CB120

CB150

Low pressure accumulator

10bar/ 145psi

10bar/ 145psi

10bar/ 145psi

15bar/ 217psi

15bar/ 217psi

10bar/ 145psi

High pressure accumulator

40bar/ 580psi

30ba/ 435psi

40bar/ 580psi

40bar/ 580psi

40bar/ 580psi

40bar/ 580psi

CHARGING STEP 1

STEP 2

Install a new snap ring.

Install the filler orifice plug.

Install the adaptor with the O-ring.

Insert the pin.

R050106A R050106B

Lep 7-22013EN

Issued 03-09

28

STEP 3

STEP 5

Install the charging device.

Connect the charging system to the nitrogen bottle.

Carefully tighten the filler orifice plug on the charging device until it stops.

Then open it three turns.

Remove the charging device from the accumulator.

R050108A

STEP 6 R050106C

STEP 4

Check for nitrogen leaks at the accumulator by filling the area containing the snap ring with thin oil.

If gas bubbles appear, release the pressure in the accumulator and change the snap ring.

Open the charging device relief valve completely.

Carefully open the nitrogen bottle valve and adjust the gas flow to minimum.

R050108B

STEP 7 R050107

Warning : The charging device is not equipped with a pressure relief valve.

Close the gas bottle valve when the gauge shows that the pressure charge is correct. Close the pressure relief valve of the charging device and charge the accumulator 2 to 3 bar more than the specified pressure. Watch the pressure gauge reading carefully.

Close the nitrogen bottle.

Wait 10 minutes for the nitrogen pressure to stabilise inside the accumulator.

Adjust the pressure in the accumulator to correct the setting, carefully opening the relief valve.

Tighten the charging device filler orifice to the specified torque setting.

Release the pressure in the charging hose by opening the relief valve.

Lep 7-22013EN

Install the protective plug.

Tighten the plug to the specified torque setting.

R050108C

Issued 03-09

29

PRESSURE REGULATIG VALVE

R050109

Adjustment Component Clearance between control valve body and spring housing (D1)

CB32

CB45

CB65

CB85

1.5 mm

3.5 mm

2.5 mm

4.0 mm

Component

CB120 1.5 mm

CB150 2.0 mm

Lubricant

Seals, O-rings and cavity inside the spring housing.

Grease for O-rings

Spool and valve bore, spring housing and flange plug threads

Hydraulic fluid

NOTA : The pressure regulator valve is in the control valve body. It is possible to remove it without removing the hydraulic hammer mechanism from its housing.

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 the release of hydraulic pressure in the hydraulic hammer. See "Releasing the hydraulic pressure in the hydraulic hammer" on page 18.

REMOVAL STEP 1

STEP 2

Open the spring housing.

Remove the shims and the spring.

R050110A

Lep 7-22013EN

Issued 03-09

30

STEP 3

STEP 4

Open the flange plug.

Push the pressure regulating spool out of the control valve.

R050110C R050111A

STEP 5 Remove the seal.

R050111B

ASSEMBLY STEP 1

STEP 2

Check all components for wear or damage. If necessary, use emery paper or a polishing product. Clean and lubricate all the components.

Install the seal in position using a suitable pair of pliers. Refer to the illustration for correct installation.

Make sure that the seal is correctly seated in its groove, using your fingers or a suitable tool.

Install the pressure regulating spool.

Install the spring, the shims and the spring housing.

R050112A

R050112B

NOTA : Make sure that the shims have a central orifice.

Tighten the spring housing by hand until you feel the spring make contact with its housing. Do not compress the spring.

Lep 7-22013EN

Issued 03-09

31

STEP 3 Make sure that the seal is correctly seated in its groove, using your fingers or a suitable tool.

Install the pressure regulating spool.

Install the spring, the shims and the spring housing.

R050113

NOTA : Make sure that the shims have a central orifice. Tighten the spring housing by hand until you feel the spring make contact with its housing. Do not compress the spring.press the spring.

TIE-RODS

R050114

Component

Lubricant

Tie-rod threads and bearing surfaces; tie-rod nuts

Grease for threads

Section of tie-rods located inside the front part

Cold galvanising paint

Grooves between the tie-rods and the front part

Silicone product

REMOVAL TIE-RODS STEP 1

STEP 2

Remove the rubber bushings and the locking plates.

Make sure that the numbers stamped on the tie-rods and the tie-rod nuts are legible. If not, make a mark on each tie-rod and on each corresponding nut.

Make the mark on the top of the nuts.

R050115A

R050115B Lep 7-22013EN

Issued 03-09

32

STEP 3

R050116A

Also identify the position of each of the tie-rods in the hydraulic hammer.

STEP 5 Remove the tie-rods.

R050116B

R050115C

STEP 4

STEP 6

Unscrew the tie-rods.

Remove the washers.

R050116C

INSTALLATION TIE-RODS STEP 1

STEP 2

Carefully clean all the components.

Use a crack detector device to check for cracks in the tie-rod threads or under their front part. If cracks are detected, change the tie-rod(s) and the corresponding nuts.

Spray cold galvanising paint on the section of the tierods located inside the front part.

Lubricate the external surfaces of the tie-rod nuts and install the nuts. Make sure that each tie-rod nut is in the correct location, with the top surface upwards.

Lubricate the washers and install them.

Lubricate the threads and the bearing surfaces of the tie-rods. Install the tie-rods.

Use a torque wrench to tighten each tie-rod to the specified torque.

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

Lep 7-22013EN

C050117A

Issued 03-09

33

STEP 3

STEP 4

Tighten the tie-rods to the calculated additional tightening angle.

Fill the grooves between the tie-rods and the front part of the tool with a silicone product.

R050117B

R050117C

CONTROL VALVE COMPONENTS (CB32 - CB45) CB32

CB85

R050211

R50208

Component

Lubricant

All seals and O-rings

Grease for O-rings

All spools and guides

Hydraulic fluid

Contact surfaces between the control valve body, the back-up ring and the cylinder

Anticorrosion product (CRC 3-36 for example)

Lep 7-22013EN

Issued 03-09

34

REMOVAL STEP 1

STEP 4

Screw the lifting rings into the control valve body and remove the control valve body, lifting it by means of the lifting rings.

Lift up the directional bushing. .

R050237

STEP 5 R050119A

STEP 2

Remove the control valve.

Install the control valve body on a bench, with the top downwards.

R050235A

STEP 6 R050119B

Remove the control valve bushing.

STEP 3 Remove the O-rings.

Remove the parallel pin .

R050235B

STEP 7 Remove the o-rings.

R050119C

R050238A

Lep 7-22013EN

Issued 03-09

35

STEP 8 Remove the seal from the directional bushing.

R050113

INSTALLATION STEP 1

STEP 8

Check all components for wear or damage. If necessary, use emery paper or a polishing product.

Clean and lubricate all components.

Install the O-rings on the cylinder.

STEP 2 Install the seal on the directional bushing.

STEP 3 Install O-rings on all components.

STEP 4 Install the assembly bushing.

STEP 5 R050125A

Correctly lubricate all components and insert the control valve.

STEP 9

STEP 6

Install the parallel pin.

Install the directional bushing. Make sure that the control valve moves freely.

STEP 7 Apply oil to the control valve components and to the control valve body orifice.

STEP 10 Apply an anti-corrosion product to the contact surfaces of the control valve body and the cylinder.

STEP 11 Install the control valve body.

R050125A

Lep 7-22013EN

Issued 03-09

36

CONTROL VALVE BODY COMPONENTS (CB45S - CB65S - CB120S - CB150S) CB45 - CB120 - CB150

CB65

R050118

R050209

Component

Lubricant

All seals and O-rings

Grease for O-rings

All spools and guides

Hydraulic fluid

Contact surfaces between the control valve body, the back-up ring and the cylinder.

Anticorrosion product (CRC 3-36 for example)

REMOVAL STEP 1

STEP 3

Remove distributor cover (CB65).

Install the control valve body on a bench, with the top downwards.

R050232

STEP 2

R050119B

Screw the lifting rings into the control valve body and remove the control valve by means of the lifting rings.

R050119A Lep 7-22013EN

STEP 4 Remove seal (CB65).

R050233

Issued 03-09

37

STEP 5

R050120C

Remove the O-rings.Remove the parallel pin.

STEP 9 Remove the directional bushing (CB45 - 120 - 150).

R050119C

STEP 6

R050121A

Assemble the extractor plate and screw (CB45 CB120 - CB150).

STEP 10 Remove the sliding bushing (CB45 - 120 - 150).

R050120A

STEP 7

R050121B

STEP 11

Remove the control valve assembly from its housing (CB45 - CB120 - CB150).

Remove the control valve from the assembly bushing (CB45 - 120 - 150).

R050120B

R050121C

STEP 8

STEP 12

Remove the control valve assembly from its housing (CB45 - 120 - 150).

Remove the O-rings from the components (CB45 120 - 150).

R050122A Lep 7-22013EN

Issued 03-09

38

STEP 13 Remove the seal from the directional bushing.

(CB45S - CB120S - CB150S).

R050122B

INSTALLATION STEP 1 Check that none of the parts is worn or damaged.

Rectify damage with an abrasive product or emery cloth, as necessary Clean and lubricate all the parts.

STEP 2 Fit the corresponding O-rings on all parts.

STEP 3 Install the extractor plate and the assembly bushing plaque (CB45 - 120 - 150).

Lubricate the parts correctly and install the control valve.

R050123B

STEP 5 Install the upper flange and screw the screw into the extractor plate (CB45 - 120 - 150).

R050123A

STEP 4 Install the sliding bushing and the directional bushing.

Check that the control valve moves freely inside the bushing (CB45 - 120 - 150).

Lep 7-22013EN

R050123C

Issued 03-09

39

STEP 6 Compress the distribution assembly parts by tightening the screw by hand (CB45 - 120 - 150).

R050125A

STEP 10 Install the control valve body.

R050124A

STEP 7 Lubricate the parts and apply oil via the control valve body orifice.

Install the distribution assembly (CB45 - 120 - 150).

R050125B

STEP 11 Install the distributor (CB65).

R050124B

STEP 8 Tap the distribution assembly in, using a plastic hammer.

Remove the screws and the extractor flanges (CB45 - 120 - 150).

R050232A

STEP 12 Install distributor cover (CB65S).

R050124C

STEP 9 Install the O-rings.

Install the parallel pin.

Apply an anti-corrosion product to the contact surfaces of the control valve body and cylinder.

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40

CYLINDER CB32 - CB65 - CB85

CB45

CB120 - CB150-

R050126

R050224

Component

R050222

Lubricant

All seals and O-rings

Grease for O-rings

All components, in particular the piston

Hydraulic fluid

Contact surfaces between the cylinder and the front part

Grease for threads

REMOVAL CYLINDER STEP 1

STEP 3

Remove the cylinder by lifting it, complete with piston, out of the front part.

Tap the piston out of the cylinder, using a plastic hammer.

R050127A

R050127C

STEP 2

STEP 4

Remove the parallel pin.

Remove seals.

R050127B

Lep 7-22013EN

R050128A

Issued 03-09

41

STEP 5 Remove the O-rings.

R050128B

INSTALLATION CYLINDER STEP 1

STEP 4

Check all components for wear or damage. If necessary, use emery paper or a polishing product. Clean and lubricate all components.

Apply grease on the contact surfaces of the front part and the cylinder.

STEP 2 Install the seals.

R050129C

STEP 5 Install the cylinder in the front part.

R050129A

STEP 3 Install the parallel pin.

R050130

R050129B

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42

STEP 6 Fill the groove betheen the cylinder and the front part (CB32S - CB65S - CB85S) with silicone product ( See figure).

R050240B

FRONT PART CB32

R050248

R050244

CB45 - CB65 - CB85

R050131

CB120 - CB150

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Issued 03-09

43 Wear limit Component

CB32

CB45

CB65

CB85

CB120

Minimum length of thrust ring (D1). Note: Use the new tool to measure length D1

58.7 mm

66.5 mm

85.5 mm

93.5 mm

28 mm

Max. diameter of tool upper bushing (D2)

47 mm

52 mm

65 mm

72 mm

86 mm

Tool lower bushing

See "Tool lower bushing", on page 52 Component

CB120 38 mm 97 mm

Lubricant

All seals and O-rings

Grease for O-rings

Contact surfaces between components

Grease for threads

Tool inner bushes

Grease for tools

REMOVAL STEP 1 Drift the thrust ring and the tool upper bushing out of the front part (CB32, CB45, CB65, CB85).

R050132C

NOTA : On the CB120 and CB150, remove the tool lower bushing first.

R050132A

NOTA : On the CB120 and CB150, remove the tool upper bushing from the same end as the lower bushing.

STEP 4 Remove the O-rings (only on CB45 - CB65 - CB85 CB120 - CB150).

STEP 2 Remove the locking pins from the tool lower bushing (CB32, CB45, CB65, CB85).

R050133A

R050132B

NOTA : On the CB150, remove the plastic plugs before removing the pins.

STEP 3 Remove the tool lower bushing (CB32, CB45, CB65, CB85).

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44

STEP 5

STEP 6

Remove the grease fitting if necessary.

Remove the flange plugs, if necessary (CB65 CB150).

R05133B R050133C

NOTA : The plugs are fitted using liquid thread-lock.

To remove them, heat the plugs slightly before removing them.

INSTALLATION STEP 1

STEP 6

Carefully clean and dry all the components. See page 52 for thrust ring and tool upper bushing wear limits.

Apply a thin coat of grease to the contact surfaces.

Install the tool lower bushing.

Install the locking pins (CB32, CB45, CB65, CB85).

Install the thrust ring and the tool upper bushing.

STEP 2 Install the grease fittings.

STEP 3 Assemble the O-rings (CB45 - CB65 - CB85 - CB120 - CB150 only).

STEP 4 Install the flange plugs (CB45 - CB65 - CB85 CB120 - CB150) using liquid thread-lock and tighten to the specified torque setting.

STEP 5 R050485B

Install the tool seal.

R050485A

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45

CHANGING A TOOL REMOVAL TOOLS REQUIRED 1.

One hammer

2.

One copper or bronze drift

3.

One flat-headed screwdriver

STEP 1

STEP 4

Place the hydraulic hammer horizontally on flat, hard ground.

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

CT02D446 CT02D444

STEP 2

STEP 5 Remove the tool. Use lifting equipment if necessary.

Shut down the engine and remove the starter switch key.

STEP 3 Move the rubber plate upwards (if fitted). Remove the pins and the bushings from each side of the hydraulic hammer.

CT02D447

NOTA : If the hydraulic hammer is still mounted on the machine, it is possible to place the point of the tool on the ground and then raise the hydraulic hammer. Make sure that the tool is held firmly.

CT02D445

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46

INSTALLATION TOOLS REQUIRED 1.

One hammer

2.

One copper or bronze drift

3.

One flat-headed screwdriver

STEP 1

STEP 5

Check the tool bushing and seal for wear, change them if necessary. See "Changing a tool bushing".

Install the pins and the plugs. Push the rubber plate back downwards (if fitted).

CT02D448

CT02D450

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

STEP 3 Insert the tool, aligning its grooves with the retaining pin holes.

CT02D449

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

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47

CHANGING THE TOOL BUSHING REMOVAL

INSTALLATION

Tools required

Tools required

1.

One hammer

1.

One hammer

2.

One bronze or copper drift

2.

One bronze or copper drift

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

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

STEP 2 Drift out the pins and plugs.

CT02D453

STEP 2 CT02D451

STEP 3

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

STEP 3 Insert the tool bushing into its housing, then install the pins and plugs.

CT02D452 CT02D452

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

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48

WEAR LIMITS Types: CB32 - CB45 - CB65 - CB85 - CB120 - CB150

TOOL BUSHINGS

CS99C628

Type

The wear limit dimension is as follows

CB32

47mm

CB45

52mm

CB65

65mm

CB85

72mm

CB120

86mm

CB150

97mm

TOOLS

CS99C630

Type

Original dimension (diameter)

Wear limit (diameter)

CB32

45mm

43mm

CB45

50mm

48mm

CB65

63mm

61mm

CB85

70mm

68mm

CB120

84mm

82mm

CB150

95mm

93mm

To change a tool, see section "Changing a tool".

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49

INSPECTION AND MEASUREMENT OF HYDRAULIC HAMMER CIRCUIT MEASUREMENT / INSPECTION POINTS A

B

C

R050064

A

Flowmeter

B

Hydraulic hammer control valve

C

Safety valve

Q2

Flow passing through hydraulic hammer

P2

Supply pressure to hydraulic hammer

T2

Hydraulic oil temperature

P3

Return pressure

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50

PROCEDURE FOR TAKING MEASUREMENTS Procedure for measurement and adjustment of hydraulic hammer: NOTA : Inspect and calibrate all the gauges: pressure gauges which are to be used. Change any defective pressure gauge.

NOTA : If the flow towards the hydraulic hammer is set by changing the speed of the engine, the flow should always be checked with the engine at maximum speed.

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

Warning : The pressure relief valve setting of the tool-carrying machine must never be exceeded.

STEP 1

STEP 8

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

Operate the hydraulic hammer control so as to reach the normal operating pressure of the hammer at pressure gauge p2.

STEP 2

STEP 9

Make sure that the hydraulic hammer supply piping is indeed equipped with a pressure relief valve.

Make sure that the hydraulic hammer oil flow is within the specified limits.

STEP 3

STEP 10

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

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

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 are fitted with quick couplings.

STEP 11

Operate the hydraulic hammer "ON" control.

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

STEP 6

STEP 12

Plug the hydraulic hammer supply pipe and set the pressure relief valve to 50 bar (p2 pressure gauge) higher than the maximum working; pressure of the hydraulic hammer, shown in the technical specifications (See the relevant Service Manuals).

Shut down the engine.

STEP 7

STEP 14

Reconnect the hydraulic hammer supply pipe to the flowmeter.

Measure the hydraulic hammer operating pressure.

See "Measuring the hydraulic hammer operating pressure", on page 55.

STEP 5

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

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

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51

MEASURING THE HYDRAULIC HAMMER OPERATING PRESSURE Specifications concerning taking operating pressure measurements

ITEM

Description

A

High pressure measurement port plug.

B

Low pressure measurement port plug.

Warning : The hydraulic pressure inside the hydraulic hammer must always be released before carrying out any adjustment or repair. The hydraulic hammer can still contain hydraulic oil under pressure even if it is not connected to the hydraulic circuit of the machine. Release the hydraulic pressure in accordance with the following instructions, or wait at least 10 minutes before opening plugs of control valve caps.

Warning : Taking hydraulic hammer measurements while it is operating constitutes a danger area. Use effective protection against danger from hydraulic fluid jets.

STEP 1

STEP 3

The hydraulic hammer hydraulic circuit must have reached its normal operating temperature before the hydraulic hammer operating pressure can be measured. Before starting the procedure for taking the hydraulic hammer operating pressure measurements, operate the hydraulic hammer until the hydraulic fluid is sufficiently hot.

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

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

Lep 7-22013EN

STEP 4 Connect a 250 bar pressure gauge, equipped with a hose at least 10 metres long, to the high pressure measurement port (A).

STEP 5 Connect a 60 bar pressure gauge, equipped with a hose at least 10 metres long, to the low pressure measurement port (B).

Issued 03-09

52

STEP 6

STEP 10

Start the hydraulic hammer and adjust the engine speed. Adjust the engine speed in relation to the hydraulic hammer speed. If the machine has several work power modes, select the mode corresponding to working with hydraulic hammer.

If the readings taken are not in accordance with specifications, the pressure regulating valve spring preload must be adjusted and the low pressure circuit pressure measured again. See section "Pressure regulating valve".

STEP 7

STEP 11

Position the tool on a thick steel plate, for example, and start to operate the hydraulic hammer.

Read the average operating pressure which is shown on the high pressure gauge.

STEP 8

STEP 12

Read the average operating pressure which is shown on the low pressure gauge.

A): Fluctuationof average pressure needle. *): Average pressure.

The average operating pressure of the high pressure circuit must be within the limits of the specified range.

See section "Hydraulic hammer specifications".

STEP 13 Check that the hydraulic hammer circuit relief valve is set to 50 bar above the pressure measured in the high pressure circuit.

STEP 14 Shut down the engine. Wait 10 minutes for the oil pressure to fall.

STEP 15 Carefully remove the two pressure gauges.

STEP 16 R050252

STEP 9 The average operating pressure of the low pressure circuit must be within the limits of the specified range.

See section "Hydraulic hammer specifications".

Lep 7-22013EN

Install the measurement plugs (A) and (B) once again. Tighten the two measurement plugs to the specified torque setting.

Issued 03-09

53

OPERATING PRINCIPLES

CS99E523

CS99E524

Starting

Piston rises

At the beginning of the hammer operating cycle the high and low pressure circuits are common and/or cut off from the return line.

The entire hydraulic hammer is under low pressure, which keeps the piston (1) and the control valve (2) in the lowest possible position.

Hydraulic fluid flowing into the low pressure accumulator (4) causes an increase in pressure and acts on the end (Z) of the spool (5). The increase in pressure compresses the spring on the pressure regulating spool (5). The pressure regulator moves up to the pre-determined setting and closes off the flow between the high pressure circuit and the low pressure circuit (L), which is from now on pre-loaded. The pressure in the high pressure circuit increases and the hammer starts its normal operating cycle.

The hydraulic fluid under pressure acts on area (X) of the control valve, causing it to rise to its highest position. This movement creates a connection between area (A) of the piston and the hydraulic reservoir line. Due to the effect of the hydraulic fluid under pressure acting on its shoulder (B), the piston rises. As it rises, area (C) forces the hydraulic fluid to enter the low pressure accumulator (4), thus storing the energy.

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54

CS99E526

CS99E525

Piston stroke

Piston rises

In its maximum raised position, the piston shoulder (B) opens the high pressure circuit to area (Y) of the control valve, via a pilot passage. The force exerted on area (Y) of the control valve pushes the control valve to its lowest position, and makes a connection between the inlet pressure and the top of piston (A).

This balances the force on the shoulder of piston (B), thus allowing the low pressure to act on shoulder (C) to accelerate the downwards stroke of the piston.

During the piston stroke, the high pressure acting on area (Y) of the control valve is greater than the force acting on area (X) of the control valve (still at high pressure). When the pilot passage provides a connection between area (Y) of the control valve and area (C) of the piston, the control valve moves upwards and the piston starts another operating cycle.

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55

Pressure regulator As a result of its operating principle, the impact energy is always constant. This is due to the fact that at the start of the piston's downwards stroke, the pressure in the low pressure circuit (L) is always the same. The pressure in the low pressure circuit (L) is controlled by the pressure regulator (5).

CS99E529

CS99E527

When the piston raises, the pressure in the low pressure circuit increases. The force acting on the top (Z) of the pressure regulator compresses the spring and the excess hydraulic fluid returns to the hydraulic reservoir. This excess comes from the pilot circuit and it is kept under pressure in the low pressure circuit by the control valve.

When the low pressure is at its correct level, the pressure regulator spool (5) is maintained in its central position by the low pressure which acts on the top (Z) of the pressure regulator.

CS99E528

When the hammer stops, the pressure (that is to say the quantity of hydraulic fluid) in the low pressure circuit reduces and the spring pushes the spool to its highest position. When the hammer starts operating, the hydraulic fluid in the high pressure circuit flows into the low pressure circuit until the low pressure reaches its correct level.

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56

TROUBLESHOOTING Defect

THE HAMMER DOES NOT START.

THE HAMMER OPERATES IRREGULARLY BUT THE BLOW HAS FULL POWER

THE HYDRAULIC HAMMER OPERATES INCORRECTLY AND WITHOUT POWER

Lep 7-22013EN

Cause

Solution

The supply or return circuit is closed

Open the circuits

The 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 brake position

There is grease between the piston and the tool contact area

Remove the tool and wipe off the excess grease

The hammer control valve spool is not piloted

Check that the spool is piloted normally. If it is 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

Excess pressure in the return circuit

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

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

Check the pump and the hydraulic components

Incorrect operation of hydraulic hammer control valve

The control valve must be overhauled. See page 39

Piston failure

The cylinder must be overhauled.

See page 43

Insufficient supply power from the host machine

See operating methods in Operator's Manual

The hydraulic circuit safety valve opens at low pressure

Check the pressure setting and operation of the safety valve

Incorrect operation of hydraulic hammer control valve

The control valve must be overhauled. See page 39

The working method is not being respected

See operating methods in the Operator's Manual

The hydraulic circuit safety valve opens at low pressure

Check the pressure setting and operation of the safety valve

The pressure setting of the pressure regulating valve is incorrect

The hammer must be overhauled

Pressure drop in pressure accumulator

Check the pressure accumulator

Incorrect operation of hydraulic hammer control valve

The control valve must be overhauled. See page 39

Issued 03-09

57 Defect

THE IMPACT RHYTHM OF THE HYDRAULIC HAMMER DECREASES

THE TEMPERATURE OF THE HYDRAULIC FLUID IS TOO HIGH

Lep 7-22013EN

Cause

Solution

Overheated oil (over 80 °C)

Check the following: the hydraulic fluid cooling circuit, that there is no internal leak in the hammer, the correct operation of the safety valve, the dimensions of the pipes and hoses

The viscosity of the hydraulic fluid is too low

Replace the hydraulic fluid by fluid which meets specifications

Return circuit pressure is too high

Check the return circuit, change the filter if necessary. Check the dimensions of the return circuit piping/hoses

The hydraulic circuit safety valve opens at low pressure

Check the pressure setting and operation of the safety valve

Internal leak in supply and return circuits (the required flow cannot be obtained)

Check the pump and the hydraulic components

The working method is not respected

See operating methods in the Operator's Manual

The hydraulic fluid cooling circuit does not operate correctly

Check the following: the hydraulic fluid cooling circuit, the correct operation of the safety valve

The viscosity of the fluid is too low

Replace the hydraulic fluid by fluid which meets specifications

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

Check the pump and the hydraulic components

Internal leak in the hydraulic hammer

Check the hammer's hydraulic components

Issued 03-09

58

NOTE .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. .................................................................................................................................................................................. ..................................................................................................................................................................................

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HYDRAULIC HAMMERS CB200S - CB260S - CB320S - CB400S - CB550S CB700S

Lep 7-23863EN

Copyright © 2009 CNH France S.A. Printed in France March 2009

2

TABLES OF CONTENTS TECHNICAL SPECIFICATIONS .........................................................................................................................................3 OVERALL DIMENSIONS ...............................................................................................................................................3 SPECIFICATIONS ..........................................................................................................................................................5 TORQUE SETTING ............................................................................................................................................................6 TOOLS REQUIRED ............................................................................................................................................................6 SPECIAL TOOLS ................................................................................................................................................................7 REPLACING A HYDRAULIC HAMMER ...........................................................................................................................11 HANDLING THE HYDRAULIC HAMMER .........................................................................................................................12 COMPONENT IDENTIFICATION .....................................................................................................................................13 HAMMER HYDRAULIC PRESSURE DISCHARGE .........................................................................................................14 LOCATION OF MAIN COMPONENTS .............................................................................................................................15 HOUSING AND VIBRATION DAMPER ............................................................................................................................16 REMOVAL ....................................................................................................................................................................16 INSTALLATION ............................................................................................................................................................18 PRESSURE ACCUMULATOR ..........................................................................................................................................19 PRESSURE ACCUMULATOR PRESSURE RELEASE ...............................................................................................19 PRESSURE ACCUMULATOR .....................................................................................................................................19 REMOVAL PRESSURE ACCUMULATOR ..................................................................................................................20 INSTALLATION PRESSURE ACCUMULATOR ..........................................................................................................21 CHARGING THE ACCUMULATOR ..................................................................................................................................22 DISCHARGE VALVE ........................................................................................................................................................24 NON-RETURN VALVE ......................................................................................................................................................26 REMOVAL ....................................................................................................................................................................27 INSTALLATION ............................................................................................................................................................27 PRESSURE REGULATOR ...............................................................................................................................................28 REMOVAL ....................................................................................................................................................................28 INSTALLATION ............................................................................................................................................................29 PRESSURE SEQUENCING VALVE (CB400 S - CB550 S) .............................................................................................30 REMOVAL ....................................................................................................................................................................31 INSTALLATION ............................................................................................................................................................32 TIE - ROD ..........................................................................................................................................................................32 REMOVAL TIE-RODS ..................................................................................................................................................33 INSTALLATION TIE-RODS ..........................................................................................................................................33 CONTROL VALVE BODY COMPONENTS CB200S TO CB320S ...................................................................................35 REMOVAL ....................................................................................................................................................................35 INSTALLATION ............................................................................................................................................................37 CONTROL VALVE BODY COMPONENTS (CB400S TO CB550S) .................................................................................39 REMOVAL ....................................................................................................................................................................39 INSTALLATION ............................................................................................................................................................40 FRONT PART ...................................................................................................................................................................42 REMOVAL ....................................................................................................................................................................43 INSTALLATION ............................................................................................................................................................45 CHANGING A TOOL .........................................................................................................................................................46 REMOVAL ....................................................................................................................................................................46 INSTALLATION ............................................................................................................................................................47 CHANGING THE TOOL BUSHING ...................................................................................................................................48 REMOVAL ....................................................................................................................................................................48 INSTALLATION ............................................................................................................................................................48 WEAR LIMITS ...................................................................................................................................................................49 TOOL BUSHINGS ........................................................................................................................................................49 TOOLS .........................................................................................................................................................................49 INSPECTION AND MEASUREMENT OF HYDRAULIC HAMMER CIRCUIT ..................................................................50 MEASUREMENT / INSPECTION POINTS ..................................................................................................................50 PROCEDURE FOR TAKING MEASUREMENTS ........................................................................................................51 MEASURING THE HYDRAULIC HAMMER OPERATING PRESSURE ......................................................................52 WORKING PRINCIPLES ..................................................................................................................................................53 TROUBLESHOOTING ......................................................................................................................................................55

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3

TECHNICAL SPECIFICATIONS OVERALL DIMENSIONS Model CB200S- CB260S

CB320S

C040033

C040035

Types

Lep 7-23863EN

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

ý 115 mm

∅ 125 mm

∅ 130 mm .

H

252 mm

266 mm

295 mm

I

252 mm

252 mm

217 mm

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4

Model CB400S

CB550S

C040038

C040042

Types

Lep 7-23863EN

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

ý 140 mm

∅ 160 mm

H

319 mm

337 mm

I

319 mm

238 mm

Issued 03-09

5

SPECIFICATIONS Section Operating weightb (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 Maximum permitted oil temperature range Optimum oil viscosity at working temperature Maximum oil viscosity Weight of tool-carrier (4)

CB200 S

CB260 S

CB320 S

CB400 S

CB550 S

CB700 S

1040 kg 1330 kg 1710 kg 2350 kg 3150 kg 3800 kg 400-800 360-650 330-580 300-450 350-480 300-480 bpm bpm bpm bpm bpm bpm 135-145 125-145 125-145 140-150 140-150 140-155 bar bar bar bar bar bar 185 bar 190 bar 190 bar 210 bar 190 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 +40 +60 +40 +60 +40 +60 +40 +60 °C °C °C °C °C -20 +80 -20 +80 -20 +80 -20 +80 -20 +80 °C °C °C °C °C 30-60 cSt 30-60 cSt 30-60 cSt 30-60 cSt 30-60 cSt 20-1000 cSt 12-20 tonnes

20-1000 cSt 18-26 tonnes

Table of applications of the hydraulic breaker Noise level

20-1000 cSt 21-32 tonnes

20-1000 cSt 27-40 tonnes

20-1000 cSt 35-55 tonnes

+40 +60 °C -20 +80 °C -

See the Operator’s Manual.

See the Operator’s Manual.

1.

Includes average mounting bracket and 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.

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6

TORQUE SETTING Torque settings Component

CB200 S

CB260 S

CB320 S

CB400 S

CB550 S

CB700 S

30 Nm

30 Nm

30 Nm

30 Nm

-

-

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

-

Hammer hydraulic pressure release plug (A) Screws which retain plate on hammer

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

-

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

-

-

-

Tie-rod

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

-

TOOLS REQUIRED 1.

- Torque wrench (150 à 700 Nm)

2.

- Torque wrench (20 à 200 Nm)

Lep 7-23863EN

Issued 03-09

7

SPECIAL TOOLS Name

Part no.

Qte

1: Accumulator charging kit (incl. part 1.1-1.4) (CB200S to CB700S)

__

1

1.1: Charging device

ZK40633

1

1.2: Socket

73317906

1

1.3: Adapter

73317907

1

1.4: O-ring

73317908

1

1: Bushing extraction tool (including 1.1 to 1.5)(CB200S - CB260S - CB320S)

(CAS2820)

1

1: Bushing extraction tool (including 1.1 to 1.5)(CB400S - CB550S)

(CAS2829)

1

1: Bushing extraction tool (including 1.1 to 1.5)(CB700S)

73318152

1

1.1: Puller frame

__

__

1.2: Treaded rod

__

__

1.3: Puller plate lower tool bushing

__

__

1.4: Washer

__

__

1.5: Nut

__

__

Hammer lifting adapter (CB200 S - CB260S CB320S - CB400S)

(CAS2826)

1

Hammer lifting adapter (CB550S - CB700S)

(CAS2838)

1

Lep 7-23863EN

Picture

Issued 03-09

8

Puller (CB200 S to CB700S)

(CAS2819)

1

Support for cylinder and piston seal-carrier moulding (CB200S)

(CAS2817)

1

Support for cylinder and piston seal-carrier moulding (CB260S)

(CAS2821)

1

Support for cylinder and piston seal-carrier moulding (CB320S)

(CAS2822)

1

Knock pin M24 (CB200S - CB260S)

73318153

2

Torque convecteur (CB200S to CB700S)

73318154

1

Slogging ring wrench 36mm (CB200S to CB400S)

73318155

1

Slogging ring wrench 55mm (CB550S - CB700S)

73318156

1

Lep 7-23863EN

Issued 03-09

9

Hook spanner DIN 1810A-45/50 (CB200S to CB400S)

73318157

1

Hook spanner DIN 1810B-58/62 (CB550S - CB700S)

73318158

1

Extractor (CB400S - CB550S)

(CAS2828)

1

Pressure gauge 250 Bar (CB200S to CB700S)

73318159

Hammer assembly stand (CB200S to CB700S)

(CAS2825)

1

Accumulator assembly stand (CB200 S CB260S - CB320S)

(CAS2813)

1

Accumulator assembly stand (CB400S)

73318162

1

Accumulator assembly stand (CB550S - CB700S)

73318163

1

Adapter for French nitrogen bottle CB200S to CB700S)

73318164

1

Lep 7-23863EN

Issued 03-09

10 Lifting eye M10 (CB200S - CB260S)

73318165

1

Lifting eye M12 (CB200S to CB700S)

73318166

2

Lifting eye M16 (CB200S - CB260S - CB320S - CB700S)

73318167

2

Lifting eye M20 (CB400S - CB550S - CB700S)

73318168

2

Lifting eye M24 (CB200S - CB700S)

73318169

2

Lifting eye M30 (CB400S - CB550S)

73318170

2

Lifting eye M24x2 (CB200S - CB260S CB320S)

73318171

2

Lifting eye M27x2 (CB400S)

73318172

2

Lifting eye M33x2 (CB550S)

73318173

2

Drift pin D6.5 - D11.5 (CB200S - CB260S)

(CAS2830)

1

Drift pin D9 (CB200S - CB260S)

(CAS2816)

1

Drift pin D11 (CB200S CB260S - CB320S) CB550S)

(CAS2832)

1

Drift pin D12.5 - D20.5 (CB320S - CB400S CB550S)

(CAS2834)

1

Drift pin D14 - D24.5 (CB200S - CB260S)

73318174

1

Drift pin D15.5 (CB200S - CB320S - CB400S CB550S - CB700S)

(CAS2833)

1

Drift pin D16 - D28 (CB320S - CB400S CB700S)

(CAS2837)

1

Drift pin D22 - D38 (CB550S - CB700S)

7331875

1

Lep 7-23863EN

Issued 03-09

11

REPLACING A HYDRAULIC HAMMER REMOVAL HAMMER

INSTALLATION HAMMER

Warning : The hammer must be secured from rolling over when disconnecting from the carrier. Only use skilled operator to position carrier for removal!

STEP 1

Warning : Hydraulic pressure inside hammer must always be released before opening hose connections!

Warning : Hot hydraulic fluide can cause severe injuries!

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 operator’s manual for the machine concerned.

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

Connect the hydraulic hammer hoses.

STEP 4 Place the hydraulic hammer horizontally on flat, hard ground.

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

STEP 2

STEP 5

Shut down the engine and remove the starter switch key. Release pressure in the hydraulic hammer circuit. See "Releasing pressure in the hydraulic circuit" in the "Lubrication/Filters/Filters" Section of the operator’s manual for the machine concerned.

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

CT02D444

STEP 3

STEP 6 Open the valves (circuit opening and closing) on the piping (if equipped).

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

STEP 8 Grease the linkages.

STEP 9 CT02D444

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

For the hydraulic hammer control, refer to "Option pedal" in the "Controls/Instruments/Accessories" Section of the operator’s manual for the machine concerned.

STEP 4 Remove the pin retaining hardware (as fitted).

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

STEP 6 Operate the machine’s controls to disengage the hammer.

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.

Lep 7-23863EN

Issued 03-09

12

HANDLING THE HYDRAULIC HAMMER The lifting equipment must be able to withstand the weight if the hydraulic hammer. See "Hydraulic hammer weight specifications".

- Use slings, straps, accessories and chains which are in perfect condition, and which have an effective device for preventing unhooking.

- Set up guidance systems for handling and operate handling machines in accordance with regulations.

- Do not allow anyone into the working area of the hydraulic hammer during handling.

- Position chains and slings as shown above.

Types CB200 S to CB700 S

C010002

NOTA : The lifting ring must always be removed from the hydraulic hammer and replaced by a plugging screw before starting to operate the hydraulic hammer.

INSTALLATION STEP 1

STEP 6

Operate the attachment controls to bring the dipper into the hydraulic hammer.

Open the valves (circuit opening and closing) on the piping (if equipped).

STEP 2

STEP 7

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 operator’s manual for the machine concerned.

Remove the lifting ring and install the plugging screw.

STEP 3

For the hydraulic hammer control, refer to "Option pedal" in the "Controls/Instruments/Accessories" Section of the operator’s manual for the machine concerned.

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

Connect the hydraulic hammer hoses.

STEP 8 Grease the linkages.

STEP 9

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

Lep 7-23863EN

Issued 03-09

13

COMPONENT IDENTIFICATION

3

5 1

4 7 7 8 6 2 CT04K003

ITEM

Lep 7-23863EN

Description

1

Housing

2

Tool

3

Accumulator

4

Load handling eye

5

Vibration damper

6

Grease fittings

7

Tool retaining hardware

8

Tool bushing retaining hardware

Issued 03-09

14

HAMMER HYDRAULIC PRESSURE DISCHARGE Warning : When the hydraulic hammer is connected to the tool-carrier, the hydraulic pressure inside the hydraulic hammer must always be released before carrying out any adjustment or repair. The hydraulic hammer may still contain oil under pressure even if it is no longer connected to the tool-carrier. Release the hydraulic pressure in accordance with the following instructions, or wait at least 10 minutes before opening plugs or control valve caps.

R0500214

ITEM

Description

1

Supply port

2

Outlet port

STEP 1

STEP 3

Shut down the tool-carrier engine. Operate the boom and hydraulic hammer controls to ensure complete release of pressure contained in the hoses.

Unscrew the pressure release plugs (A) and (B).

Watch out for oil leaks.

STEP 2

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

Close the hydraulic hammer inlet and outlet ports. If quick couplers are used, shutting off the circuit will automatically close the hydraulic hammer lines. If ball-valves are included in the hydraulic hammer piping, make sure they are correctly closed.

STEP 4

R050081

Warning : This procedure does not release the pressure in the pressure accumulator. Carefully read the instructions concerning the accumulator before disassembling the accumulator. See "Pressure accumulator" on page 19

Lep 7-23863EN

Issued 03-09

15

LOCATION OF MAIN COMPONENTS CB200S - CB260S - CB320S - CB400S - CB550S - CB700S

R050156

ITEM

Lep 7-23863EN

Description

A

PRESSURE TEST PLUG

B

RELIEF VALVE

C

NON-RETURN VALVE

D

PRESSURE CONTROL VALVE

E

TENSION RODS

F

VALVE BODY

G

PISTON AND CYLINDER

H

FRONT CHASSIS

I

HYDRAULIC ACCUMULATOR

Issued 03-09

16

HOUSING AND VIBRATION DAMPER

R050004

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...10 mm

-10...10 mm

-10...10 mm

-10...10 mm

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

-

grease for thread

grease for thread

grease for thread

grease for thread

grease for thread

-

Component

Bracket retaining screw threads and bearing surfaces

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"

REMOVAL STEP 1

STEP 3

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

Disconnect the hydraulic hoses.

STEP 2 Remove the retaining screws and lift the cover.

R050266B

R050266A

Lep 7-23863EN

Issued 03-09

17

STEP 4

STEP 7

Unscrew the bracket retaining screws.

Lift and remove the bracket.

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).

R050006A

STEP 5 Remove the buffer.

R050007B

STEP 8 Lift the hammer and remove it from the housing.

R050006B

STEP 6 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.

R050007A

Lep 7-23863EN

C050008A

STEP 9 Remove the pads.

C050008B

Issued 03-09

18

STEP 10

R050009A

Place the hammer housing horizontally on the ground or on a bench.

Remove, if necessary, the wear plates, using a screwdriver as a lever.

STEP 11 Remove the seal.

R050009B

INSTALLATION STEP 1

STEP 7

Check all components for leaks and excessive wear.

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

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.

NOTA : 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.

C050010B

STEP 6

STEP 8

Install the pads.

Install the buffer.

STEP 9 Install the bracket.

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

STEP 11 Connect the hoses.

STEP 12 Assemble the covers.

C050010A

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

Lep 7-23863EN

Issued 03-09

19

PRESSURE ACCUMULATOR PRESSURE ACCUMULATOR PRESSURE RELEASE Warning : Never disassemble the hydraulic hammer before releasing all pressure from the accumulator

STEP 1

STEP 2

Remove the protective plug and the O-ring.

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

R050015A R050015B

STEP 3 After all pressure has been released, remove the filler orifice plug and the snap ring.

R050015C

PRESSURE ACCUMULATOR

R050014

Component

Lubricant

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

Grease for threads

Accumulator cover (gas end) All seals and O-rings Contact surfaces of control valve body and accumulator

Lep 7-23863EN

Silicone grease Grease for O-rings Anticorrosion product (for example: CRC 3-36)

Issued 03-09

20

REMOVAL PRESSURE ACCUMULATOR STEP 1

STEP 2

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

Remove the accumulator cover retaining screws.

R050017B R050016A

STEP 2 Using lifting equipment, raise the accumulator out of its housing.

STEP 3 Remove the bottom of the accumulator, diaphragm and the cylindrical pins.

the

R050017C R050016B

DISASSEMBLY Warning : Make sure that all pressure in the accumulator is released

STEP 1 Install the accumulator on a bench, with the top downwards.

Remove the seal

ASSEMBLY STEP 1 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.

R050018A R050017A

Lep 7-23863EN

Issued 03-09

21

STEP 2 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.

STEP 3 Install the accumulator upside-down on the bench, with the top downwards.

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

R050019A R050018B

STEP 4 Install the O-ring.

R050019B

INSTALLATION PRESSURE ACCUMULATOR STEP 1

STEP 2

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.

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

R050097B R050020A

Lep 7-23863EN

Issued 03-09

22

STEP 3 Insert the accumulator retaining screws.

Tighten the retaining screws to the specified torque setting.

R050020B

CHARGING THE ACCUMULATOR Warning : Use only nitrogen (N2) to charge the accumulator. The use of other gases could cause the accumulator to explode.

R050021

Pressure charge (Nitrogen N2) Component Pressure accumulator

CB200 S 40 bar (580 psi)

CB260 S 40 bar (580psi)

CB320 S 40 bar (580 psi)

CB400 S 40 bar (580 psi)

STEP 1

STEP 2

Install a new snap ring.

Install the filler orifice plug.

Install the adaptor with the O-ring.

Insert the pin.

CB550 S 40 bar (580 psi)

R050022A R050266A

Lep 7-23863EN

Issued 03-09

23

STEP 3

STEP 5

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.

Remove the charging device from the accumulator.

R050024

STEP 6 R050023A

STEP 4

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.

Fully open the charging device discharge valve.

Carefully open the nitrogen bottle valve and adjust the gas flow to minimum.

R050025A

STEP 7 R050023B

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.

Lep 7-23863EN

Install the protective plug.

Tighten the plug to the specified torque setting.

R050025B

Issued 03-09

24

DISCHARGE VALVE

R050027

Component

Lubricant

Screw threads, contact surfaces and thrust washers

Grease for threads

All seals and O-rings

Grease for O-rings

All bushings and guides

Hydraulic fluid

REMOVAL Warning : Before removing a plug or a valve, make STEP 2 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 13.

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

STEP 1 Remove the discharge valve cover retaining screws and washers

R050028B

STEP 3 Remove the main spool and the other spools.

R050028A

R050029A

Lep 7-23863EN

Issued 03-09

25

STEP 4

R050029B

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

R050030

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 new seals on the discharge valve bushing.

R050031B

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

STEP 6 Install new O-rings on the discharge valve covers.

R050031A

STEP 3 ICarefully install the discharge valve bushing in position.

STEP 4 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.

Lep 7-23863EN

R050032

NOTA : 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.

Issued 03-09

26

STEP 7 Install the cover in place.

Make sure that the cover with the X mark is fitted on the same end as the end of the contol valve with the X mark.

STEP 8 C050180B

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.

NON-RETURN VALVE

R050033

Component

Lubricant

Screw threads and bearing surfaces, thrust washers

Grease for threads

All seals and O-rings

Grease for O-rings

All bushings and guides

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 13.

NOTA : 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.

Lep 7-23863EN

Issued 03-09

27

REMOVAL STEP 1

R050034B

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

STEP 3 Install and tighten the non-return valve in a vice.

Remove the O-rings.

Remove the flange.

R050034A

STEP 2 Insert two retaining screws in the housing of the nonreturn valve, using them as forcing screws, and remove the non-return valve.

R050035A

STEP 4 Remove the spring guide, the spring and the spool.

R050035B

INSTALLATION STEP 1

STEP 5

Check all components for wear or damage. If necessary, use emery paper or a polishing compound.

Clean and lubricate all components.

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

STEP 6

Install the spool, the spring and the spring guide.

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

STEP 3

STEP 7

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

Tighten the retaining screws to the specified torque setting.

STEP 2

STEP 4 Install new O-rings.

Lep 7-23863EN

Issued 03-09

28

PRESSURE REGULATOR

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

Screw threads and bearing surfaces, thrust washers

Grease for threads

All seals and O-rings

Grease for O-rings

All bushings and guides

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 13.

NOTA : 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.

REMOVAL STEP 1

STEP 2

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.

R050037A R050037B

Lep 7-23863EN

Issued 03-09

29

STEP 3

STEP 5

Install and tighten the pressure regulator in a vice.

Remove the seals and the O-ring.

R050150

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

R050150A R050150C

STEP 4 Decompress the spring by unscrewing the guide and the regulator housing at the same time.

STEP 6 Remove the spool, the spring and the spring guide.

R050151A

R050150B

STEP 7 Remove the shims.

R050151B

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 and tighten the pressure regulator cover in a vice.

Lep 7-23863EN

Issued 03-09

30

STEP 3

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 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.

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)

A, B, C: See torque setting on page 11.

R050040

Lep 7-23863EN

Issued 03-09

31 Component Spring free length (D1)

CB400 S

CB550 S

36,5 - 37, 0 mm

35,9 - 36,4 mm

Component

Lubricant

Screw threads and bearing surfaces, thrust washers

Grease for threads

All seals and O-rings

Grease for O-rings

All bushings and guides

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 the hydraulic pressure in the hydraulic hammer" on page 13.

REMOVAL STEP 1

STEP 5

Remove the valve retaining screws and washers.

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

R050041A R050042A

STEP 2

STEP 6

Install the valve in a vice.

Remove the flange plug.

Remove the spool.

R050041B

STEP 3

R050042B

Remove the O-rings.

STEP 7

STEP 4

Remove the flange plug.

Remove the retaining screws and the washers.

Remove the spring housing.

R050042C R050041C Lep 7-23863EN

Issued 03-09

32

INSTALLATION STEP 1

STEP 7

Check all components for wear or damage. If necessary, use emery paper or a polishing compound.

Clean and lubricate all components.

Install a new O-ring.

STEP 2 Using a fine, small needle, check that the jets are not clogged.

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

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 R050310

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 Install the spools and make sure that they slide freely.

STEP 6

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.

Install the other flange plug.

Tighten it to the specified torque setting.

TIE - ROD

R050044

Component (all)

Lubricant

Tie-rod threads and bearing surfaces; tie-rod nuts

Grease for threads

Tie-rod central portion

Heat-resistant paint

Lep 7-23863EN

Issued 03-09

33

REMOVAL TIE-RODS STEP 1

STEP 3

Remove the rubber bushings and locking plates.

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 300°C. Make sure the flame is directed onto the tie-rods (and not onto the hammer body).

R050045A

Warning : Before heating the tie-rods, make sure that the pressure sequencing valve has been removed from the hydraulic hammer.

STEP 2

R050045C

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

STEP 4 Remove the nuts.

Use suitable lifting equipment to remove the tie-rods.

Watch out for hot parts.

R050045B R050046

INSTALLATION TIE-RODS STEP 1

STEP 5

Clean all the components carefully.

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 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.

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.

R050047A

Lep 7-23863EN

Issued 03-09

34

STEP 6

STEP 8

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

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 300°C.

STEP 9 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.

R050047B

STEP 7 Make a mark to show the additional tightening angle on the control valve body and the tie-rods.

R050048

STEP 10 Install the locking plates.

STEP 11 Install the rubber bushings.

R050047C

Lep 7-23863EN

Issued 03-09

35

CONTROL VALVE BODY COMPONENTS CB200S TO CB320S CB200S

CB320S

CB260S

R050153

R050684

R050589

Component

Lubricant

Plugs and breathers

Thread-lock fluid (Loctite 275 for example)

All seals and O-rings

Grease for O-rings

Contact 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 threads

All components, the piston in particular

Hydraulic fluid

REMOVAL STEP 1

STEP 2

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

Remove the seals.

Remove the parallel pin.

R050137A R050137B

Lep 7-23863EN

Issued 03-09

36

STEP 3

STEP 6

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).

R050546

STEP 7 R050138A

STEP 4

Screw the pins into the seal-carrier.

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.

R050139B / R050139A

STEP 8

R050138B

Push the seal-carrier down by tapping on the pins to separate them.

Watch out for oil flowing out.

STEP 5 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.

R05139C / R050339B

STEP 9 Carefully remove the cylinder.

R050139A

R050140A

Lep 7-23863EN

Issued 03-09

37

STEP 10

STEP 12

Carefully remove the piston.

Remove the seals and the seal-carrier wiper.

R050140B

R050141B

STEP 11

STEP 13

Remove the parallel pin and the O-rings.

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

R050141A R050142

INSTALLATION STEP 1

STEP 5

Check all components for wear or damage. If necessary, use emery paper or a polishing compound.

Clean and lubricate all components.

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

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

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

STEP 4 Lubricate the piston and lift it to install it in the sealcarrier.

Tap the piston into position with a plastic hammer.

R050143

R050145 Lep 7-23863EN

Issued 03-09

38

STEP 6

STEP 8

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).

Apply a thin coating of grease on the upper surface of the front part.

R050147

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

NOTA : 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 lefthand 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.

STEP 9 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.

R050148 / R050146

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.

Lep 7-23863EN

Issued 03-09

39

CONTROL VALVE BODY COMPONENTS (CB400S TO CB550S) CB400S

CB550S

R050049

R050478

Component

Lubricant

Plugs and breathers

Thread-lock fluid (Loctite 275 for example)

All seals and O-rings

Grease for O-rings

Contact 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 threads

All components, the piston in particular

Hydraulic fluid

REMOVAL STEP 1

STEP 2

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.

R050050A R050050B

Lep 7-23863EN

Issued 03-09

40

STEP 3

STEP 6

Lift the seal-carrier and remove it.

Remove the seal.

Lift the cylinder and remove it from the front part.

R050052C R050051

STEP 4

STEP 7 Remove the wiper seal and the seal-carrier seals.

Carefully lift the piston and remove it.

R050053 R050052A

STEP 5

STEP 8 Remove the wiper seal, the seal and the O-rings from the cylinder.

Remove the O-rings and the parallel pin.

R050052B

R050054

INSTALLATION STEP 1 Check all components for wear or damage. If necessary, use emery paper or a polishing compound.

Clean and lubricate all components.

Lep 7-23863EN

Issued 03-09

41

STEP 2

STEP 5

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

Install the cylinder in the front part.

R050056 R050055A

STEP 3 Lubricate the seals and the seal-carrier wiper seal and install them.

R050055B

NOTA : 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.

STEP 6

STEP 4

Lubricate the piston and place it in the cylinder.

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

STEP 7 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 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.

Lep 7-23863EN

Issued 03-09

42

FRONT PART CB200S

CB320S

R050590

CB260S

R050268

CB400S - CB550S

R050269

R050057

Wear limit Component Maximum length of thrust ring (D1) Maximum diameter of tool upper bushing (D2) Tool lower bushing

CB200 S

CB 260 S

CB320 S

CB400 S

10 mm

8,5 mm

9,4 mm

10,2 mm

11,3 mm

109,2 mm

118,2 mm

132,8 mm

143,4 mm

161,5 mm

See "Tool lower bushing" on page 51 Component

Lubricant

All seals and O-rings

Grease for O-rings

Contact surfaces between components

Grease for threads

Tool inner bushings

Lep 7-23863EN

CB550 S

Grease for tools

Issued 03-09

43

REMOVAL STEP 1

STEP 4

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

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).

R050058A

STEP 2 Lift and remove the thrust ring (CB200 S, 260 S, 320 S, 400 S, 550 S).

R050059A

STEP 5 Remove the bushing from the front part (CB200 S, 260 S, 320 S, 400 S, 550 S).

R050058B

STEP 3 Remove the O-ring from the thrust ring (CB200 S, 260 S, 320 S, 400 S, 550 S).

R050059B

STEP 6 Turn the front part upside-down.

Remove the separator pin and the retaining ring (CB200 S, 260 S, 320 S, 400 S, 550 S).

R050058C

R050060A

Lep 7-23863EN

Issued 03-09

44

STEP 7

STEP 10

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

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

R050060B

STEP 8

R050061B / R050061C

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

R050062B

STEP 11 Remove the spring and the retaining pin.

R050062A

STEP 9 Carefully clean the threads in the front part (hole marked with a cross) before installing the extractor (CB320 S, 400 S, 550 S).

R050061A

Lep 7-23863EN

Issued 03-09

45

INSTALLATION STEP 1

STEP 8

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 51.

For the tool lower bushing, see page 50 (CB200 S, 260 S, 320 S, 400 S, 550 S).

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

STEP 2 Install the grease fittings.

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 10

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

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 4

STEP 11

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

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

STEP 5

STEP 12

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

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

STEP 6

STEP 13

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

Install the wedge and the O-ring.

STEP 3

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

Lep 7-23863EN

Issued 03-09

46

CHANGING A TOOL REMOVAL TOOLS REQUIRED 1.

One hammer

2.

One copper or bronze drift

3.

One flat-headed screwdriver

STEP 1

STEP 4

Place the hydraulic hammer horizontally on flat, hard ground.

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

CT02D446 CT02D444

STEP 2

STEP 5 Remove the tool. Use lifting equipment if necessary.

Shut down the engine and remove the starter switch key.

STEP 3 Move the rubber plate upwards (if fitted). Remove the pins and the bushings from each side of the hydraulic hammer.

CT02D447

NOTA : If the hydraulic hammer is still mounted on the machine, it is possible to place the point of the tool on the ground and then raise the hydraulic hammer. Make sure that the tool is held firmly.

CT02D445

Lep 7-23863EN

Issued 03-09

47

INSTALLATION TOOLS REQUIRED 1.

One hammer

2.

One copper or bronze drift

3.

One flat-headed screwdriver

STEP 1

STEP 4

Check the tool bushing and seal for wear, change them if necessary. See "Changing a tool bushing".

Install the pins and make sure that the tool is firmly held.

STEP 5 Install the pins and the plugs. Push the rubber plate back downwards (if fitted).

CT02D448

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

CT02D450

STEP 3 Insert the tool, aligning its grooves with the retaining pin holes.

CT02D449

Lep 7-23863EN

Issued 03-09

48

CHANGING THE TOOL BUSHING REMOVAL Tools required 1.

One hammer

2.

One bronze or copper drift

STEP 1

CT02D451

Remove the tool. See section "Changing a tool".

STEP 3 Remove the tool bushing.

STEP 2 Drift out the pins and plugs.

CT02D452

INSTALLATION STEP 1T

STEP 2

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

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

STEP 3 Insert the tool bushing into its housing, then install the pins and plugs.

CT02D453

CT02D452

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

Lep 7-23863EN

Issued 03-09

49

WEAR LIMITS Types: CB200S TO CB700S

TOOL BUSHINGS 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".

2

3 1 CS99C629

TOOLS

CS99C630

Type

Original dimension (diameter)

Wear limit (diameter)

CB200S

115 mm

113 mm

CB260S

125 mm

123 mm

CB320S

130 mm

128 mm

CB400S

140 mm

138 mm

CB550S

160 mm

158 mm

CB700S

175 mm

173 mm

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

Lep 7-23863EN

Issued 03-09

50

INSPECTION AND MEASUREMENT OF HYDRAULIC HAMMER CIRCUIT MEASUREMENT / INSPECTION POINTS A

B

C

R050064

A

Flowmeter

B

Hydraulic hammer control valve

C

Safety valve

Q2

Flow passing through hydraulic hammer

P2

Supply pressure to hydraulic hammer

T2

Hydraulic oil temperature

P3

Return pressure

Lep 7-23863EN

Issued 03-09

51

PROCEDURE FOR TAKING MEASUREMENTS Hydraulic hammer circuit measurement and adjustment procedure: NOTA : Check and calibrate all gauges: pressure gauges which are to be used. Change any defective pressure gauge.

NOTA : 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.

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

Warning : The pressure setting of the tool-carrier relief valve must never be exceeded.

STEP 1

STEP 9

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

Make sure that the oil flow from the hydraulic hammer is within the specified limits.

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

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 3

STEP 11

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

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 5 Operate the hydraulic hammer "ON" control.

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 7 Reconnect the hydraulic hammer supply line to the flowmeter.

STEP 8 Operate the hydraulic hammer "ON" control so as to reach the normal operating pressure of the hammer at pressure gauge p2.

Lep 7-23863EN

STEP 10

STEP 12 Shut down the engine.

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

STEP 14 Measure the operating pressure of the hydraulic hammer. See "Measuring the hydraulic hammer operating pressure" on page 54.

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

Issued 03-09

52

MEASURING THE HYDRAULIC HAMMER OPERATING PRESSURE

ITEM A

Description 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

STEP 5

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.

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

STEP 3 Slowly unscrew the pressure measurement plugs (A) and (B). Watch out for oil leaks.

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

STEP 7 Read the average operating pressure which is shown on the low pressure gauge.

A): Fluctuationof average pressure needle. *): Average pressure.

STEP 4 Connect a 250 bar pressure gauge, fitted with a hose at least 10 metres long, to the high pressure measurement port (A).

RR050252

Lep 7-23863EN

Issued 03-09

53

STEP 8

STEP 9

The average operating pressure should be within the specified range limits.

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 29.

NOTA : 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 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.

WORKING PRINCIPLES

CS99E531

CS99E532

Starting

Return stroke

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).

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).

Lep 7-23863EN

Issued 03-09

54

CS99E533

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.

Lep 7-23863EN

CS99E532

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.

Issued 03-09

55

TROUBLESHOOTING Failure

THE HYDRAULIC HAMMER DOES NOT START.

THE HYDRAULIC HAMMER OPERATES IRREGULARLY BUT AT FULL POWER

THE HYDRAULIC HAMMER OPERATES POORLY AND LACKS POWER

Lep 7-23863EN

Cause

Solution

The supply or return circuit is closed

Open the circuits

The 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 circuit

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

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

Check the pump and the hydraulic components

Incorrect operation of hydraulic hammer control valve

The control valve must be overhauled. See pages 38 and 42

Piston defect

The cylinder must be overhauled.

See pages 38 and 42

Insufficient supply force coming from host machine

See operating methods in Operator’s Manual

The hydraulic circuit safety valve opens at low pressure

Check the pressure setting and operation of the safety valve

Incorrect operation of hydraulic hammer control valve

The control valve must be overhauled. See pages 38 and 42

The working method is not being respected

Refer to operating methods in the Operator’s Manual

The hydraulic circuit safety valve opens at low pressure

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 29 and 31

Drop in accumulator pressure

Check the accumulator pressure

Incorrect operation of hydraulic hammer control valve

The control valve must be overhauled. See pages 38 and 42

Issued 03-09

56 Failure

THE IMPACT RHYTHM OF THE HYDRAULIC HAMMER DECREASES

THE HYDRAULIC OIL TEMPERATURE IS TOO HIGH

Lep 7-23863EN

Cause

Solution

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/hoses

The viscosity of the oil is too low

Replace the hydraulic oil by oil which meets specifications

The return circuit pressure is too high

Check the return circuit. Change the filter if necessary Check the dimensions of the return circuit piping

The hydraulic circuit safety valve opens at low pressure

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)

Check the pump and the hydraulic components

The operating method is not being respected

See the operating methods in the Operator’s Manual

The hydraulic oil cooling circuit is not operating correctly

Check: 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 and return circuits (the required flow cannot be attained)

Check the pump and the hydraulic components

Internal leak in the hydraulic hammer

Check the hydraulic components of the hammer

Issued 03-09