H140GC & H140GCS Hydraulic Breakers
H140GC & H140GCS Hydraulic Breakers
H140GC & H140GCS Hydraulic Breakers
June 2019
Service Manual
H140GC & H140GCS Hydraulic Breakers
KSX 1 - UP
WHC 1 - UP
1
FOREWORD
WARNING
In order for CAT to conduct optimum performance on your jobsite, understand all the detail information
of this manual. You must observe all relevant laws and regulation before and after operation. Otherwise
you and others can be seriously injured.
This manual instructs you on safe operation and maintenance of your CAT hammer.
◆ This hammer is a powerful tool. Used without proper care, it can cause damage of product or serious
injury.
◆ Use it properly and use it well. Pay particular attention to all safety messages.
◆ To use the hammer correctly, you must also be competent operator (assistant) of the carrier machine.
◆ Do not use or install the hammer if you cannot use the carrier machine.
◆ Do not rush the job of learning. Take your time and most important, take it safely.
◆ If there is anything you do not understand, ask your CAT dealer. He will be pleased to advise you.
◆ It may cause serious injury and death when operators do not follow operational manuals and
warnings.
◆ Operators should not overlook the guidelines of which they don't understand and should fully
understand all safety guidelines and warnings before operating machines.
◆ Operation manual and warning symbols in the manual are very important for safety.
◆ Operators should maintain those manuals in a good condition and replace them if damaged.
◆ It is strongly recommended that genuine spare parts supplied by CAT must be used at all times.
◆ Use the right tools to install, remove, repair or replace the hammer and spare parts.
◆ Although this manual does not cover all possible cases, personnel in work site must be alert to
potential hazards himself.
2
TABLE OF CONTENTS
SERVICE MANUAL
◆ FOREWORD ................................................................................................................................................................................. 2
◆ TABLE OF CONTENTS ................................................................................................................................................................. 3
◆ SAFETY ALERT SYMBOLS .......................................................................................................................................................... 5
◆ INTRODUCTION OF HYDRAULIC BREAKER ............................................................................................................................... 6
◆ PRODUCT SERIAL NO. ............................................................................................................................................................ - 7 -
◆ PRODUCT WARNING LABEL ................................................................................................................................................... - 7 -
SAFETY INFORMATION
1. BASIC INFORMATION ...................................................................................................................................................................... 12
2. PRECAUTION BEFORE OPERATION .............................................................................................................................................. 14
3. PRECAUTION DURING OPERATION ............................................................................................................................................... 16
4. PRECAUTION AFTER OPERATION ................................................................................................................................................. 19
OPERATION
1. HAMMER INFORMATION ................................................................................................................................................................. 21
1-1. PART NAME & STRUCTURE.................................................................................................................................................. 21
1-2. GENERAL SPECIFICATION ................................................................................................................................................... 22
1-3. ADVANTAGE OF “B-SERIES” BREAKER................................................................................................................................ 24
1-4. FUNCTION & FEATURES ....................................................................................................................................................... 25
1-5. EXTERNAL DIMENSIONS OF EACH MODEL ........................................................................................................................ 30
2. INSTALLATION & REMOVAL OF BREAKER ..................................................................................................................................... 32
2-1 KEY POINTS FOR SELECTING HAMMER .............................................................................................................................. 32
2-2 HYDRAULIC CIRCUIT ............................................................................................................................................................. 33
2-3 INSTALLATION ........................................................................................................................................................................ 34
1) DIMENSION OF TOP PLATE ................................................................................................................................................. 34
2) TOP BRACKET ASSEMBLY................................................................................................................................................... 35
3) PIPE FLUSHING.................................................................................................................................................................... 36
4) INSTALLATION OF BREAKER .............................................................................................................................................. 37
5) CONNECTING IN/OUT LINE HOSE....................................................................................................................................... 39
6) CONNECTION PORTS OF THE HAMMER ............................................................................................................................ 40
2-4 REMOVAL OF BREAKER ........................................................................................................................................................ 41
2-5. CHECK POINTS WHEN SETTING HYDRAULIC LINE TO BREAKER..................................................................................... 43
2-6. WARMING UP OPERATION GUIDELINE................................................................................................................................ 44
1) WARM-UP OPERATION GUIDELINE FOR DAILY BREAKER OPERATION ........................................................................... 44
2) WARM-UP OPERATION GUIDELINE AFTER LONG TERM STORAGE ................................................................................. 45
2-7. OPERATION PROCEDURE .................................................................................................................................................... 47
1) PREPARATION OF SAFE OPERATION ................................................................................................................................. 47
2) PRECAUTION BEFORE OPERATION ................................................................................................................................... 48
2-8. CORRECT OPERATION ......................................................................................................................................................... 49
3. STORAGE ........................................................................................................................................................................................ 55
3-1. SHORT TERM STORAGE ...................................................................................................................................................... 55
3-2. LONG TERM STORAGE ......................................................................................................................................................... 56
3-3. OPERATION AFTER LONG TERM STORAGE ....................................................................................................................... 57
4. TROUBLE SHOOTING ..................................................................................................................................................................... 58
5. OPERATING PRINCIPLE .................................................................................................................................................................. 60
6. SPECIAL APPLICATION ................................................................................................................................................................... 64
6-1. UNDERWATER JOB ............................................................................................................................................................... 64
MAINTENANCE
1. GENERAL PRECAUTION ................................................................................................................................................................. 71
2. PERIODICAL INSPECTION & SCHEDULE ....................................................................................................................................... 73
2-1. EVERY 2 HOURS INSPECTION ............................................................................................................................................. 73
2-2. DAILY INSPECTION ............................................................................................................................................................... 73
2-3. MONTHLY INSPECTION ........................................................................................................................................................ 74
2-4. YEARLY INSPECTION OR EVERY 600 HOURS..................................................................................................................... 75
3. HYDRAULIC OIL............................................................................................................................................................................... 76
4. LUBRICATION .................................................................................................................................................................................. 79
5. NITROGEN GAS CHARGING ........................................................................................................................................................... 81
5-1. INSTRUCTIONS FOR NITROGEN GAS CHARGING OF BACK HEAD ................................................................................... 81
5-2. SPECIFIED NITROGEN GAS PRESSURE FOR BACK HEAD ................................................................................................ 86
5-3. INSTRUCTIONS FOR GAS PRESSURE INSPECTION .......................................................................................................... 87
5-4. INSTRUCTIONS FOR NITROGEN GAS CHARGING OF ACCUMULATOR ............................................................................ 90
5-5. SPECIFIED NITROGEN GAS PRESSURE FOR ACCUMULATOR.......................................................................................... 96
6. WEAR LIMIT FOR CONSUMABLES ................................................................................................................................................. 97
3
TABLE OF CONTENTS
4
SAFETY ALERT SYMBOLS
1. SAFETY INFORMATION
The manual is intended to provide safety information necessary for safe and efficient use of “B-series”
hydraulic breaker. "DANGER", "WARNING", "CAUTION" symbols may appear in the text of this manual.
It is used to alert the operator of an action that can cause serious injury or death to him/her or other
personnel.
In general, most safety accidents are caused by carelessness, or negligence of safety instructions or
equipment maintenance. Those accidents can enough be prevented by understanding safety
information and potential hazards.
The safety messages can not cover all the possibilities that could cause injury, death or damage to the
product. Nevertheless, it is the operator's duty to obey safety rules and precaution.
Safety symbols are provided in this manual and on the machine. Serious injury or death could occur, if
person in site ignores and disregards the warnings.
Always read the information in this manual before operation the hammer.
DANGER
DANGER indicates an imminently hazardous situation which, if not heeded, will result in serious injury
or death.
WARNING
WARNING indicates a potentially hazardous situation which, if not heeded, could result in serious
injury or death.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not heeded, could result in serious
injury or death.
NOTICE
NOTICE indicates general safety measure and information regarding product property and damage.
NOTE
Special technical notice or other notices for preserving standards are necessary with performing the
work.
5
INTRODUCTION OF HYDRAULIC BREAKER
HYDRAULIC BREAKER, much larger than portable ones, is powered by hydraulic system from the
excavator, and fitted to mechanical excavators or backhoes.
- ROAD WORK
- QUARRYING
- GENERAL DEMOLITION
- CONSTRUCTION GROUND WORK
- MINING WORK
6
PRODUCT SERIAL NO.
The serial number is stamped on the back head of the breaker main body.
It is important to make correct reference to the serial number of the machine when asking for repairs
or ordering spare parts. Identification of the serial number is the only proper means of maintaining and
identifying parts for a specific product.
WHC
KSX WHC
H140GC H140GC S
-7-
PRODUCT WARNING LABEL
HAMMER LABEL
8
PRODUCT WARNING LABEL (OPEN TYPE)
HOUSING LABEL L
9
PRODUCT WARNING LABEL (BOX TYPE)
HOUSING LABEL L
10
SAFETY
INFORMATION
WARNING
11
SAFETY INFORMATION
1. BASIC INFORMATION
Not observing operational guidelines may cause serious injury or death in extreme case. Operator
should follow operating guidelines of excavator & hammer, and operate machines after fully understand
those guidelines. Operation manual and guidelines should always be attached to excavator.
It may cause serious injury and death when operators do not follow operation manuals and warnings.
Operators should not overlook the guidelines of which they don't understand and should fully
understand all safety guidelines and warnings before operating machines. Operation manuals and
warnings are very important for safety. Operator should maintain those manuals in a good condition
and replace them if damaged.
Operators should not operate machine if not in operative condition due to tiredness, lack of sleep
and medication. Operators should take regular medical check up to maintain good health condition.
12
SAFETY INFORMATION
Operators should keep emergency aid kit and fire extinguisher near-by to use them in an emergency.
Operators should learn how to handle fire extinguisher and keep emergency contact numbers.
Operators should follow safety rules, guidelines, and procedure of the work site to maintain safe work
environment.
13
SAFETY INFORMATION
Operators should install guard or tops to the excavator cabin in order to prevent potential risk caused by
the scattered or fallen rocks from the breaker work site.
Window safety guard should be always be used with the hydraulic hammer.
Operators should check the geological or soil condition before the machine operation to detect any
possible accident.
Before starting engine, operator should check the machine condition and replace any damaged part if
found.
14
SAFETY INFORMATION
BREAKER INSTALLATION
Breaker should be installed to the correct specification excavators. If the breaker is too heavy for the
excavator, it could be overturned during operation. Thus, the breakers should be installed as CAT
recommends. The installer should refer to the breaker operation manual for proper installation. In case
of using quick coupler, operator should check the specification of total working weight including the
weight of quick coupler.
Quick coupler attachment status to the breaker should be checked before operation when the breaker is
assembled to the excavator with quick coupler. If the breaker is detached from the quick coupler during
operation, it could cause serious injury or death. Operator should check the coupling status between
coupler and breaker. Also quick coupler safety pin must be installed before operation.
Hydraulic hose damage or joint part loosening could lead to serious injury or death by oil leakage.
Operator should check the hydraulic hose and joint parts carefully before operation. It is high
recommended to use CAT standard hydraulic hose or comparable ones which can meet the breaker
operation pressure in a good capacity.
Breaker and excavator have different operation pressure and oil flow respectively. If the oil flow and
pressure deviate from each equipment specification, excavator vibration or hose shaking could damage
hydraulic hose. Proper oil flow and pressure should be set based on the operation manual. Operators
should always communicate with the product manufacturer regarding oil flow and pressure setting.
15
SAFETY INFORMATION
Check if the operating site is bright enough to work. Operators should stop until they can secure a clear
view enough to operate machine when it is hard to work due to fog, rain or snow.
DOWNTOWN WORK
It is very dangerous for unauthorized person to access the work site. Stand <no entry> signpost and
barrier if the worksite is located near the downtown. Security personnel should be also needed at
downtown work.
Supervisor instruction should be followed at the work site for safety. Supervisor should be in the
dangerous area at the work site. Operators should follow the instructions of the safety supervisor.
Safety supervisor should be present at the work site, especially in dangerous area.
Each specification of lever, pedal and switch are different by manufacturer. Operator should check
operating switch, lever and pedal before the breaker operation. If the excavator has changeable system
by operation mode operator should understand related function before operation and check the system
at the safe place.
Main carrier may overturn while operating on a slope due to instability. To avoid this, operator should drive
slowly on a slope. Also, maintain height of the breaker lower than on flat ground. (held 20~30cm above
land surface)
High Voltage Cable access can cause electric shock with serious injury or death. Breaker operation
should be operated as far as possible from the electric cable. Before operation, ask electric company
for technical support to protect machine and person safely.
VENTILATION IMPORTANCE
Operation without proper ventilation could lack of oxygen or difficulty in breathing caused by exhauster
gas or dust from breaker blow. Install ventilation pipe or open the window for fresh air.
16
SAFETY INFORMATION
Improper operating of travel lever may cause serious injury. Before traveling, check the direction of
traveling motor. If the traveling motor is positioned at the front side from the operator’s seat, the main
carrier should travel in the reverse direction.
Generally, excavator has higher horizontal stability than vertical stability. Sudden turning side may cause
overturning of excavator.
Before breaker operation, pre-check the location with related authorities of gas pipes, water pipes, cables,
and other underground utilities.
When operating breaker with the cylinder of excavator arm, boom, and bucket at the stroke end position,
the cylinders will be damaged by strike impact and pressure. Also the boom can be separated and it may
cause serious injury or damage.
If operating excavator on a soil pile, the pile may crumble by weight and vibration of excavator.
Operate the excavator carefully at a pile work site.
When operate breaker on cliff or bank, excavator could fall down and serious injury or damage can be
caused. Do not operate in such conditions to avoid collapse
17
SAFETY INFORMATION
When operates breaker close to the high cliff, serious damage or accident can arise due to fallen rocks
or landslide. When breaking objects at the cliff, excavator should be parallel to the cliff. Operator should
be ready to jump out immediately at emergency case by putting driving motor back side.
SAFE DRIVING
If possible, it is good to drive the excavator at the flat land to prevent any accident. Tool edge should be
40 ~ 50 cm higher than the land. The equipment should be distant from the electricity pole, building, or
obstacle. Be careful to travel slowly in the snowy or freezing area. Excavator could be overturned by the
sudden start or stop from the unstable land surface.
Rocks or other breaking object could be fallen from unexpected direction which could cause serious
injury or death. Operators should always be careful for the fallen rocks from unexpected direction and
install over head guard at the excavator.
If operator finds oil leakage from the breaker hydraulic hose or excavator operation system, stop operation
immediately and fix the leakage.
If using the breaker for crane work or suspending heavy objects, serious injury, accident, or death may
occur.
COLLISION WARNING
18
SAFETY INFORMATION
Flammable fluids such as fuel and oil should be handled carefully. Keep away flammable material from
equipment. Do not smoke when re-fueling. Stop engine completely when re-fueling.
Be careful not to over flow fuel tank.
SAFE PARKING
Park the excavator on flat and solid ground. Put the breaker down on the ground and hold the track with
supporting bar to prevent excavator from moving.
ROAD PARKING
When you park excavator on the road, place fence and warning sign to be visible in dark.
Operator should follow safety guideline set by manufacturer when he leaves work site as follows.
19
OPERATION
WARNING
20
OPERATION
1. HAMMER INFORMATION
21
OPERATION
H140 GC
MODEL
UNIT TOP MOUNT
WORKING
kg 2981 3077 3134
WEIGHT
OPERATING
bar 160~180
PRESSURE
RELIEF
bar 240~250
PRESSURE
TOOL
mm 153
DIAMETER
PRESSURE LINE
mm 32
SIZE
RETURN LINE
mm 32
SIZE
SUITABLE
ton 30~40
CARRIER WEIGHT
ACCUMULATOR
bar 60
PRESSURE
BACK HEAD
bar 9
PRESSURE
OIL ℃ -20~+80
TEMPERATURE (℉) (-4+176)
22
OPERATION
H140 GC S
MODEL TOP MOUNT
UNIT
OPERATING
bar 160~180
PRESSURE
RELIEF
bar 240~250
PRESSURE
TOOL
mm 153
DIAMETER
PRESSURE LINE
mm 32
SIZE
RETURN LINE
mm 32
SIZE
SUITABLE
ton 30~40
CARRIER WEIGHT
ACCUMULATOR
bar 60
PRESSURE
BACK HEAD
bar 9
PRESSURE
OIL ℃ -20~+80
TEMPERATURE (℉) (-4+176)
23
OPERATION
4. BACK HEAD
Bigger N2 gas chamber.
(High volume back head provides greater power)
5. PISTON
Piston design provides better performance and oil retention resulting in better seal life.
9. ACCUMULATOR
Protect carrier hydraulic circuit by absorbing pulsation spikes created during firing stroke.
10. HOUSING
Reinforcement plates at bottom part.
11. PRODUCTIVITY
Optimized chisel (tool) length & design by high grade steel and heat treatment provides
high out-put.
14. DURABILITY
Hammer design, manufacturing practices, quality inspection and testing of hammers
provides durability required for tough applications
24
OPERATION
SEAL HOUSING
BACK HEAD VALVE BLOCK
ACCUMULATOR
CYLINDER
PISTON
FRONT HEAD
TOOL BUSHING
UPPER BUSHING
TOOL PIN
BUSHING PIN
The oil pressure connection port and gas charging valve are built into the back head and the back head
is charged with N2 gas.
25
OPERATION
The accumulator compensates for the pressure in the hydraulic circuit and minimizes pulsation. The
accumulator is charged with N2 gas and sealed with membrane.
The main spool is built into the valve block and controls piston movement. As this spool is pilot control
type, the efficiency and reliability are improved.
26
OPERATION
The front head, cylinder and back head are secured with the four side rods.
UP SIDE UP SIDE
The cylinder provided guidance for piston during operation and adjustment of stroke can be done with
adjustment bolt. Cylinder adjust bolt provides frequency control by changing length of piston stroke and
frequency can be controlled, meanwhile keeping working pressure and flow rate of oil fixed.
27
OPERATION
The piston kinetic energy is converted into hammering energy to break rock.
Important factors are the hardness, toughness and surface finish..
To allow the piston to prove its merits even under severe conditions, a special alloy is used and the
piston is hardened by special heat treatment. Further, the surface of piston is super finished to result in
excessively improved hammering force.
NOTE
The piston is NOT chromed and cannot be chromed as a repair process.
28
OPERATION
<TOOL>
TYPE OF
SHAPE GENERAL APPLICATIONS
TOOL
Multi-use application, breaking
MOIL hard rock. concrete and
bedrock, etc.
Breaking concrete, bedrock,
CHISEL trenching, and operation on
slopes.
Breaking concrete, bedrock,
BLUNT trenching, and operation on
slopes.
Multi-use application, breaking
CONE hard rock, concrete and
bedrock.
※ CAT offers 4 major types of tool. Those types are mostly and often used at the job site. According to
the working conditions and the objects to break, make a proper choice of tools.
MODEL
UNIT H140
DESCRIPTION
WEIGHT kg 175
29
OPERATION
30
OPERATION
31
OPERATION
WARNING
Failure to heed this manual can lead to premature failures, product damage, personal injury or death.
Do not install or perform the machine and the hammer until you have understood and follow the
required information and regulation for the machine and the hammer.
Below is basic guideline for selecting the proper breaker and the main carrier on which it will be
installed.
The breaker must be selected properly for optimum performance and the mounting capability. First,
consider the application work, and then decide the main carrier which size of breaker will be mounted. If
the operating weight of the main carrier can meet within the range of breaker, the main carrier can hold
the weight of breaker enough.
If the weight of the breaker that you want to install is out of the recommended range, contact
manufacturer or your CAT technical engineer for more information.
2) LIFTING CAPACITY
The weight of the breaker must not exceed the maximum lifting capacity. The main carrier is always
required to maintain its balance at any position. Most excavators, backhoe, or skid loaders have their
own provided value of lifting capability. Keep in mind that the maximum lifting capacity of main carrier is
the lowest when the boom of carrier is at full each.
3) OIL FLOW
For optimum performance, the setting of oil flow is important before operation. Breaker will operate
within a required range of oil flow, and this range is specified for each breaker. Check if the main carrier
has enough capacity of supplying oil flow to avoid abnormal operation of breaker.
32
OPERATION
Hydraulic oil flow and pressure are needed to operate the hydraulic breaker. The hydraulic oil pipe line
in the main carrier should be directed out the left side of the boom and the return line on the right. The
hydraulic breaker will operate within a required range of oil flow. The operating pressure will depend on
the amount of oil flow, the return line pressure.
33
OPERATION
2-3 INSTALLATION
Following is dimension of top plate. Use those data when preparing for the top bracket which is mounted
on the main carrier.
UNIT : mm
MODEL A B C D E F G H I J K
OPEN 12-Ø39 175 220 175 730 130 275 130 635 50 80
H140
BOX 12-Ø39 240 250 240 830 200 200 200 700 50 50
34
OPERATION
WARNING
To remove or install breaker from or to main carrier at the slope or unstable surface could cause serious
injury or death. Disassembling or assembling should be done at the flat land without any obstacle or
men.
1. Stand the hammer vertically on the stable ground or service pallet with housing assembled.
2. Tighten the top cover bolts (No.2 to No.4 bolts assembly) to fix the bracket to the housing.
3. All the bolts should be tightened with torque wrench. The torque value and the size of each
model are as follows :
35
OPERATION
WARNING
At least two persons (one is the operator of main carrier) are needed for installing and removing the
breaker. Always check and follow the signals for operation in advance.
Be sure to use a crane to handle pins, brackets, bushes, and other heavy parts.
MODEL H140
3) PIPE FLUSHING
After setting of relief pressure finished, open both of stop valves and push the pedal to flush the
hydraulic oil pipe line. This operation is very important for breaker and the main carrier to remove the
dirt, dust, little particles in the piping. Flush sufficiently for at least 20 minutes. For efficient flushing
work, press down and sometimes release the pedal for pulsation to pipe line.
After flushing work, discharge air from the hydraulic oil tank, clean the line filter and remove the foreign
particles.
36
OPERATION
4) INSTALLATION OF BREAKER
DANGER
Operator should check for any possible dangers when he install or remove the mounting pin.
Be careful not to put arm or finger into the pin hole and not to touch pin with hand nor hit the pin too
strongly. Do not stand at the position where the pin exits.
After fixing the top bracket to the housing, prepare for installing the breaker to the main carrier.
1. Slowly move the operation lever of the excavator to align the pin holes of the arm end with the pin hole
of the breaker's top bracket(4).
2. Insert the mounting pin (4) from the left side so that the Hex. bolts (6) can be seen from the operator
seat.
3. Insert the mounting pin (3) into the pin hole, set the stopper (5) and attach the Hex. bolt (6).
1. Hydraulic Breaker
2. Excavator arm
3. Mounting pin (Arm side)
4. Top bracket
5. Stopper
6. Hex. bolt
7. Double nut
37
OPERATION
5. Extend the bucket cylinder (8) so that the mounting pin (9) can be inserted through the bore of link.
6. Insert the mounting pin (9) into the pin hole, set the stopper (5) and attach the Hex bolts (6). (Same
as procedure No.3)
5. Stopper
6. Hex. bolt
7. Double nut
8. Bucket cylinder
9. Mounting pin ( Link side )
WARNING
When the stopper attached to the pin is missing, it may detach breaker from the excavator. Operators
must check pin stopper attached properly before and during operation.
Breaker detachment from the main carrier while working could cause serious injury or death.
NOTICE
Secure Hex bolt by double nut, periodically check the looseness of double nut during operation.
38
OPERATION
5) CONNECTING IN/OUT LINE HOSE
1. Stop the engine of the main carrier, discharge pressure from the hydraulic oil tank and do not move
the operation lever.
2. Check that stop valves on both side of the arm are fully "CLOSED". If not, use the spanner and turn
them to the close position.
3. Remove the union cap and hose plug from the breaker pipe line attached to the end of the arm.
NOTICE
Pay attention to keep the union cap and plug clean. Dust or particles can cause the contamination of
hydraulic oil and result in serious damage of breaker and excavator.
4. Connect the "IN" & "OUT" hoses to the stop valves on both sides of arm and secure.
5. Fully open the stop valves at the high and low pressure sides to connect the hydraulic circuit.
1. Stop valve
2. In - line hose (High pressure)
3. Out - line hose (Low pressure)
4. Union cap
5. Hose plug
CAUTION
When connecting or disconnecting oil hoses, prepare the metal pail and put it under to prevent spilt oil.
39
OPERATION
40
OPERATION
WARNING
To remove or install breaker from or to main carrier at the slope or unstable surface could cause serious
injury or death. Removal or installation procedure should be done at the flat land without any obstacle
or men.
CAUTION
When connecting or disconnecting oil-hoses, prepare the metal pail and put it under to prevent spilt oil.
1. Lay down the breaker with valve block (control valve) facing upwards on the flat, safe place.
2. Stop the engine of main carrier, and release the pressure trapped inside the hoses and oil tank.
Wait tem minutes for oil pressure to drop.
3. Turn the stop valves (1) of both sides to the fully closed position.
4. Remove the oil hose. (The residual pressure may remain in the pipe-line. Loosen the oil hose joint
little by little to release the residual pressure)
5. After removing hoses, tighten the union caps (4) and hose plugs (5) securely to avoid oil
contamination. (Prevent the dust or particles from entering)
1. Stop valve
4. Union cap
5. Hose plug
41
OPERATION
6. Loosen the double nuts (7) at the link side and remove the Hex bolt (6) and stopper (5).
※ If the pin cannot be removed easily, slightly move the main carrier arm for easy removing.
5. Stopper
6. Hex. bolt
7. Double nut
8. Bucket cylinder
DANGER
Operator should check for any possible dangers when he install or remove the mounting pin.
Be careful not to put arm or finger into the pin hole and not to touch pin with hand nor hit the pin too
strongly. Do not stand at the position where the pin exits.
8. In the same way, loosen the double nuts on the arm side, remove the Hex bolt and stopper, and
pull out the mounting pin.
9. Be sure to check the condition of mounting pin, bushing whether they are worn out or damaged.
Also, check the condition of arm and link.
(If there is a problem with them, replace or repair)
10. Start the engine, and slowly operate the MCV to check the oil leakage from the pipe line.
NOTE
Nitrogen charge must be installed prior to initial start up of hammer.
NOT charged from factory.
42
OPERATION
1) RELIEF PRESSURE
Remove high pressure hose from hammer INLET and connect to return line ball valve with test gage
installed. Close return line ball valve to dead head oil and measure auxiliary relief valve setting
(Maximum setting 25000 kPa).
⚫ Stop the carrier engine. Assemble the high pressure gauge on the hammer (350 bar gauge)
measuring port.
⚫ Start the engine. Set the tool of the breaker for example on a thick steel plate. Adjust operating
engine revolution and start to operate the breaker.
⚫ Read the average pressure from the high pressure gauge of operating pressure.
⚫ Stop the carrier and remove the gauge. Tighten the plug of the pressure measuring port.
43
OPERATION
⚫ Temperature Range
The hydraulic oil intended for the main carrier can be utilized for hammer operation. Warm up
procedure is required depending on the ambient temperature.
A. The standard oil temperature for breaker operation is recommended between 10 ℃ (50 ℉)
and 80 ℃ (176 ℉) and the lowest oil temperature should be 10 ℃ (50 ℉).
B. High ambient temperature [above 30 ℃ (86 ℉)]: Use oil with sufficient viscosity. If the
hydraulic oil is too thin in high ambient temperature, the operator may find slow and irregular
strokes on the breaker operation. In high ambient temperature and summer, daily warm up
procedure is also carried out to protect seals and diaphragm of breaker.
C. Low ambient temperature [below 0 ℃ (32 ℉)]: If the oil is too thick, the operator may find
start up difficult. The breaker should not be operated until the oil temperature is over
10 ℃. If the temperature of the core breaker parts such as cylinder, piston and
accumulator have similar temperature level of the oil temperature (over 10 ℃), seals and
diaphragm may have lower risk from unexpected damage. Keep minimum oil temperature
requirement through the warm up operation to protect and improve functionality of seals and
diaphragm of breaker.
D. The proper temperature range of the hydraulic oil is between 50℃ (122 ℉) and 80℃ (176
℉).
E. If the temperature of the hydraulic oil exceeds 80℃ (176 ℉), the hydraulic oil cooling
system needs to be checked whether it is working properly. Otherwise, an auxiliary oil
cooling system is needed. IF the breaker is operated over 80℃ (176 ℉), the life of the
seals and the membrane can be reduced.
F. Consult your CAT dealer and also refer to the Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” for more information.
G. If the working tool is exposed to temperatures below 0 ℃(32 ℉), it can break with sudden
operation. The working tool has to be carefully warmed up by following the daily warm up
procedure of the breaker below.
A. Before breaker operation, the operator should let the excavator idle to increase the
temperature of the oil in the main carrier, see guidelines from excavator manufacturer on
idling operation.
44
B. Once the idling operation is completed, the operator should conduct warm up operation for
the breaker. The operator conducts the breaker operation with the lowest operation mode
such as engine speed dial 2 or 3 for 5 seconds and repeat 5 times. Then, the operator can
increase the engine speed dial to 4 or 5 and operate for 20 and 30 minutes to complete the
daily warm up operation.
C. After the completion of “B” above, the operator can operate the breaker normally.
D. Operate the breaker at 90 degrees to the working surface and do not operate in one spot
for more than 15 seconds if the tool is not penetrating.
E. Without sufficient warm up operation for daily breaker operation, the sudden operation
under high pressure can cause seizure due to the breakage of the oil film.
B. Check N2 gas pressure level in the back head and keep or charge the level of 6 bar.
D. Conduct the idling operation for the hydraulic circuit on the main excavator.
E. Operate the breaker at the lowest operation mode such as engine speed dial 2 or 3 for 5
seconds and continue operating at this mode for minimum 10 minutes after the breaker is
vertically set up on the obstacle to break.
F. Operate the breaker at engine speed dial 4 or 5 for minimum 10 minutes after the breaker is
vertically set up on the obstacle to break.
G. Operate the breaker at engine speed dial 6 for minimum 10 minutes after the breaker is
vertically set up on the obstacle to break.
H. During the warm up procedure, the operator should check for consistent BPM and oil
leakage.
45
I. Operate the breaker based on the procedures above for 1 day after long term storage.
Breaker can be operated normally thereafter.
Warning:
46
OPERATION
WARNING
It may cause serious injury and death when operators do not follow operation manuals and warnings.
Operators should not overlook the guidelines of which they don't understand and should fully understand
all safety guidelines and warnings before operating machines. Operation manuals and warnings are very
important for safety. Operators should maintain those manuals in a good condition and replace them if
damaged.
⚫ LINE INSTALLATION
It is very important to install a line for breaker in excavator. Correct oil flow and pressure setting
improves durability and efficiency of the breaker.
Most excavators have two main pumps. It is recommended to use of these two pumps for hydraulic
energy to operate breaker.
⚫ PIPE SPECIFICATION
It is very important to select a right size of pipe line breaker operation. If the pipe is too smaller than
recommended specification, hydraulic system will be overheated. Resistance in the pipe will decrease
efficiency and create an early damage of excavator hydraulic system.
47
OPERATION
48
OPERATION
- Before rotating excavator, operator should warn any nearby people by buzzing
- Operators should check any person aside or back side of the excavator
- Signal person should be placed at the blind angle area
Generally, excavator has higher horizontal stability than vertical stability. Sudden turning side may cause
overturning of excavator.
49
OPERATION
Operator should concentrate on the operating. Careless operation could lead to serious injury and
death.
When operate breaker on cliff or bank, excavator could fall down and serious injury or damage can be
caused. Do not operate in such conditions to avoid collapse.
50
OPERATION
When operating breaker with the cylinder of excavator arm, boom, and bucket at the stroke end
position, the cylinders will be damaged by strike impact and pressure. Also the boom can be separated
and it may cause serious injury or damage.
Do not use the breaker for bending or operate at the same spot for a long time. It could cause serious
injury or accident by crashed rocks fallen from unexpected direction or damaged tools.
Operate the breaker properly, otherwise it also could cause early damage of various joint parts of the
excavator.
51
OPERATION
If operator lifts excavator using breaker or tool, tool could slip out from the striking object which causes
a serious injury or death due to the instability of main carrier.
If using the breaker for crane work or suspending heavy objects, serious injury, an accident, or death may
occur.
52
OPERATION
Breaker should not be operated when the front head is under water. If the operation is required under the
water, an air compressor must be attached to prevent damage.
Pushing or pulling object with tool could cause early wearing of the tool or breakage.
Even the bolts of breaker may be broken, the bracket damage, the tool broken.
53
OPERATION
Operator should be careful in pushing or pulling object with breaker housing because it could break joint
parts or deform the housing.
Operator should always be careful to avoid blank firing which may cause serious trouble or early damage
of the breaker.
54
OPERATION
3. STORAGE
If the hammer will be stored for up to two weeks, it is regarded as "Short term storage". Following is the
instruction how to store the breaker.
⚫ Dismantle the tool, and apply grease to piston bottom, tool bushing, tool pin, the inside of front
head
⚫ After sufficient greasing, re-install the tool, and cover with the waterproof tarpaulin (tarp)
55
OPERATION
⚫ The breaker must be stored standing up in a vertical position. If unavoidable, store it horizontal on
the wooden block.
⚫ Store the hammer in a sufficient airy room, if avoidable to store outdoors, place it with good
ventilation and drainage, and cover with a tarp.
◼ Standing up
⚫ The breaker must be stored in a storage-stand
⚫ Clean the exterior of the breaker, and check out each part for defects
⚫ Dismantle the Tool, and apply grease to piston bottom, tool bushing, tool pin, inside the front
head
⚫ Remove the gas pressure from back head
⚫ Load the hammer by letting the tool or fixture on the stand push the piston up into the cylinder.
⚫ Seal the high-pressure supplying port with plug
⚫ Cover with the waterproof tarpaulin (tarp)
MODEL “A”(mm)
H140 796.5
56
OPERATION
Generally, when operating the breaker which is stored for a long period, careful inspection must be
carried out before using. Moreover, after long term storage, oil film could be broken naturally. Or sudden
operation under high pressure can also cause seizure due to the breakage of oil film.
Before starting the breaker, slow operation at idle mode will not only prevent the breakage of oil film, but
protect the piston and cylinder against seizure.
Following is the instruction how to inspect the breaker.
⚫ Before starting operation, remove the tool and check the corrosion on the piston bottom.
⚫ In the event of horizontal storage for a long period, check deformation of seals on hammer before
using.
⚫ Warm up the hammer at idle for 10~15 minutes without nitrogen gas in the back head.
⚫ Check the regularity of hammer frequency during warming up.
⚫ Check the hose and pipe line for oil leakage and damage.
⚫ When all are in good working order, charge the gas in the back head, and then start operation.
57
OPERATION
4. TROUBLE SHOOTING
The table below is prepared for the person in charge of maintenance to be able to take corrective
measures immediately when the breaker trouble occurs. When trouble has occurred, check conditions
shown below, and contact our dealer.
(1) No hydraulic oil supplied to (a) Failure of hose and pipe (a) Inspection, repair, or
breaker. replacement of piping system
(b) Stop valve is closed. (b) Open stop valve.
(c) Failure of operation valve (c) Inspection, repair, or
system replacement of valves
(d) Insufficient hydraulic oil (d) Add oil into the oil tank until
specified level.
(2) Sufficient hydraulic oil supplied (e) Failure inside the breaker (e) Ask the dealer for inspection
to breaker. and maintenance.
(f) Nitrogen gas pressure at the (f) Adjust the nitrogen gas
back head is excessively high. pressure.
(1) Insufficient hydraulic oil (a) Failure of hose and pipe (a) Inspection, repair or
supplied to breaker. • Clogged piping system replacement of piping system
• Oil leakage
(c) Insufficient hydraulic oil (c) Add oil into the oil tank until
specified level.
(f) Drop of the relief valve pressure (f) Ask the excavator dealer for
maintenance.
58
OPERATION
(b) Drop in nitrogen gas pressure (b) Adjust the nitrogen gas
at the back head. pressure.
5. Cylinder adjuster
(a) Damage of O-ring or backup (a) Replace the of O-ring or
(1) Oil leakage from cylinder adjuster
ring from the adjust bolts backup ring
area
(b) Damage of threads of adjust (b) Replace the cylinder adjust
(2) Sudden increase of piston stroke
bolt bolt
59
OPERATION
5. OPERATING PRINCIPLE
STEP 1
60
OPERATION
STEP 2
A5
A3
A4
DETAIL A
61
OPERATION
STEP 3
62
OPERATION
STEP 4
63
OPERATION
6. SPECIAL APPLICATION
1) PRINCIPLE OF OPERATION
Although the piston sliding section of the hydraulic hammer is sealed everywhere, water will enter into
the area where the piston and the chisel with impact each other, when used in underwater job.
When the hammer is used in this condition, the piston is forced against the water.
Therefore, part of the water that is equal is volume to the piston stoke can find no way out except
through a small clearance between the chisel and the bushing.
During that time, the water is discharged with extremely high pressure and velocity, which will damage
the hydraulic hammer in a short period of time.
The water will also get into the hydraulic system of the excavator, causing damaged to the pump, etc.
AIR PRESSURE
MODEL
bar Psi
(2) Setting of supplied air pressure depends on the working depth of the hydraulic hammer used.
To 10m 22
To 20m 37
64
OPERATION
WARNING
Do not supply the compressed air 6bar (87psi) from the compressor to the hammer directly, otherwise
the air may be forced into the hammer through the sealed area.
Be sure to reduce the pressure of the compressed air with the regulator as instructed above.
1) After installation of the underwater piping, operate the compressor to supply the air to the hammer
before it is submerged in the water. Maintain the air pressure with the regulator at this time.
2) Extend the boom and the arm of the hydraulic excavator up to the maximum working depth used in
the job site and keep the hammer submerged in the water.
Be sure that bubbles are generated from the chisel area due to air supply.
3) While maintaining the above condition, reduce the air pressure with the regulator and set the
supplied air pressure at the minimum level required to produce bubbles. Bubbles should be still
produced even in this state.
65
OPERATION
WARNING
Operate the hammer more carefully underwater because the hammer is exposed to severe condition and
environment of the water.
Do not shut off air while hammer is under water. Damage to hammer and contamination of carrier
hydraulic circuit may happen.
(1) At the starting the hammer which has been stored for a long term, place the hammer vertical and
take out the hydraulic oil from a clearance between the tool bushing.
(3) Start to operate the hammer after the compressor pressure reaches 6bar (87psi).
(4) Stop the hammer immediately and determine the cause if the air supply stopped during operation.
In case of it, there will be no bubbles.
(5) Lay the hammer in the water as <FIG 3>, and check the bubbling point.
(6) Do not hammer in the same position for a long time. In case of the excavator is on a barge, the tool
is liable to break because the down force and the force of away from the barge are able to make
damage on the tool easily.
(7) Grease the tool more than ordinary lubrication because the grease is blown off by supplied air.
66
OPERATION
4) STORAGE
WARNING
Perform routine maintenance before storage. Otherwise, the hammer will have corrosion and be
damaged in the underwater job.
B) If it is difficult to operate the hammer on land as the above, run the engine at low RPM idle the
hammer 5 to 6 times during maintaining air supply.
B) Then pour one liter of hydraulic oil into a clearance between the tool and tool bushing <FIG 5>.
C) Cover the tool and the tool bushing with a waterproof tarpaulin (tarp).
67
OPERATION
5) SAFETY DEVICE
In order to minimize the risk of water entering the hammer, a pressure switch must be added to the
hammer circuit. The purpose of this connection is to stop the hammer immediately, if the air pressure
decreases below the adjusted minimum level.
OPERATING
FILTER AIR DRYER
VALVE
OPERATING
COOLER OIL PUMP
SWITCH
68
OPERATION
The Caterpillar hammer can be used in an underwater application, modifications are required (See
special instructions on page 62). During underwater operation, the hammer must be inspected every
half hour operation.
A) Grease the tool shank and tool bushing through grease nipples.
B) Check all hoses and connections.
C) Check the operation of air pressure switch.
DAILY MAINTENANCE
A) Remove the retaining pin and the tool for inspection. Grind the burrs away if necessary.
B) Check that the tool has received sufficient grease.
A) The hammer must be totally dismantle and serviced after working underwater. Clean and check all
hammer parts and either replace or repair damaged parts.
B) Assemble the hammer with new seals.
C) Neglecting hammer service after underwater work can cause severe damage to the hammer.
The piston could rust even in a few days depending on the environment.
In underwater applications, the productivity of a hydraulic hammer is considerably lower than in normal
work. This is caused by :
A) The breaking object is not visible to operator. This causes misalignment between tool and object and
unnecessary idle strokes.
B) Hammer must be inspected and greased more often than in normal work.
69
MAINTENANCE
NOTICE
70
MAINTENANCE
Maintenance manual provides personal guide line to keep the breaker operating in best condition. Check
every part and component of the machine before and after operating the hydraulic breaker for extending
machine's life. Keep in mind how to maintain your breaker.
1. GENERAL PRECAUTION
Operator should follow the safe guideline related regular inspection and maintenance. Operator should
wear safety gear before equipment check and follow safety procedure.
Equipment check and maintenance without safety gear may cause serious injury or death. Operator
should always wear eye protection goggle, safety hat, safety shoes & gloves, earplugs for hearing
protection.
Using hammer or grinder, you should wear goggle and safety mask to protect yourself from flying
debris.
FIRE PREVENTION
In checking and maintaining equipment, operator handles flammable materials such as fuel, and
battery. The followings are required.
71
MAINTENANCE
Improper lighting creates narrow vision and may cause serious injury. Work site should always be
bright. Fixed light and explosion protection lantern should be used when operator checks fuel and
battery.
Use right tool for maintenance to avoid any serious injury or accident. Do not use tool or hammer to
prevent steel part from flying. It is highly recommended to use CAT tool.
Work site should be clean and not be contaminated to avoid any accident or injury. Before maintenance
and check, used oil and replaced parts should be cleared from the work site to maintain clean work site.
Damaged or broken parts may not be seen because of the dirt stick to breaker housing.
Breaker housing should be cleaned before maintenance for safe check.
The wet floor is very dangerous. Wear non slippery boots when you clean the machine. Wear goggle
and protection gear because the high pressure cleaner may hurt your skin and eye.
Water and steam should not touch with battery, electric connector or electronic parts, which may cause
breaking or electric leak.
Checking in slope side may not allow accurate check or maintenance, which may cause serious injury
or accident. Breaker checking should be done at solid and safe flat land. Breaker should be down
completely into the floor. Excavator engine should stop and start key should be separated. Supporting
bar should be fixed in the track.
Do not fix or replace the hose or joint parts when the breaker is lifted from the land surface.
Breaker should be down to the land or supported by safety bar. Do not work without equipment
supporting bar.
72
MAINTENANCE
NOTICE
Read the inspection schedule chart thoroughly and conduct an inspection and repair or replace the
related items for safe use of machine.
NOTE
The times given refer to the machine hours while the breaker is installed.
INSPECTION
ITEM DETAIL PART SOLUTION
POINT
Looseness
PIPE LINE • Piping line of hose joint • Re-tighten to specified torque
OIL HOSE • In/Out line hose Damage • Replace when damaged
Oil leakage
73
MAINTENANCE
INSPECTION
ITEM DETAIL PART SOLUTION
POINT
74
MAINTENANCE
INSPECTION
PART CHECK ITEM
DESCRIPTION CORRECTION
FRONT HEAD
TOOL BUSHING • Check the wear amount • Measure the wear amount
THRUST RING • Check the grease • Visual inspection
TOOL PIN
HOUSING
• Check the crack & damage • Visual inspection
TOP BRACKET
HOUSING
HOUSING JOINT
BOLT • The tightening torque • Check the torque
TOP BRACKET BOLT
• Oil leakage
• Visual inspection
OIL HOSE • Check the damage
• Check the torque, and tighten
• Check the looseness of joint
75
MAINTENANCE
3. HYDRAULIC OIL
※ When the breaker is used continuously, the temperature of the hydraulic oil normalizes at a certain
level depending on conditions and on the carrier. At this temperature, the viscosity of the hydraulic oil
should be 20~40 cSt. (2.90~5.35˚E)
※ The hydraulic breaker must not be started if the viscosity of the hydraulic oil is above 1000cSt(131˚E)
or operated when the viscosity of the hydraulic oil is below 15cSt(2.35˚E)
1) When the oil is too thick, the following problems may occur;
2) When the oil is too thin, the following problems may occur;
3) Special oil
※ In some cases, special oils(e.g. biological oils and non inflammable oil) can be used, please observe
following aspects when considering the use of special oil;
※ The viscosity range of the special oil must be in the given range of 15~1,000cSt (2.35~131˚E)
76
MAINTENANCE
※ The hydraulic oil filter of the carrier will clean the oil flowing through the breaker.
※ The purpose of the oil filter is to remove impurities from the hydraulic oil since they cause
accelerated component wear, blockages and even seizure.
5) Oil filter
※ When working with hydraulic breaker, the carrier oil filter must fulfill the following specifications;
77
MAINTENANCE
a. In front of the radiator, in which case an additional fan is not required, ie. maximum rise of the
cooling air is 5℃(40℉).
b. Any other suitable place, using a fan either hydraulically or electrically driven.
7) Damage caused by hydraulic oil contamination in the carrier and breaker circuits;
78
MAINTENANCE
4. LUBRICATION
※ Grease interval
a) Tool shank must be well lubricated before installing tool.
b) 5~10 strokes from grease gun to tool bushing and tool at regular intervals.
c) Adapt interval and amount of grease to decrease wearing of tool and good working conditions.
This should be done every 2 hours.
※ Insufficient greasing or improper grease may cause:
- Abnormal wear of tool bushing and tool
- Tool breakage
※ Technical data:
- NLGI grade 2
- Synthetic oil base with aluminum complex soap
- Approximately 15% graphite copper solids to reduce metal to metal contact damage
- Dropping point 260℃ (500℉)
- Viscosity 15 cSt
- Temperature range -30℃ ~ 230℃ (-20℉ ~ 450℉)
79
MAINTENANCE
NOTICE
Grease tool and bushing to prevent economic loss. If the tool is not greased before working, this can
cause accelerated wear of tool bushing and damage or broken tool.
80
MAINTENANCE
WARNING
⚫ Use Nitrogen Gas Only.
The nitrogen gas is only injected into the back head and the accumulator for the hammer operation
⚫ Charge Back Head After Completion of Powercell Assembly.
While in gas charging operation into the back head, the gas pressure may push the piston and the tool
out consequently. Do not stand in front of the tool during the gas charging process. Do not charge the
back head before the powercell assembly is conducted. The inlet and outlet ports must be plugged to
prevent the oil spraying..
81
3) Connect one end of the gas hose to the nitrogen
gas tank.
82
6) Install the charging block to the charging valve of
the back head (Ensure that an O-ring is installed
on the charging block).
83
9) After checking the gas pressure in step 8) is set
to 5-10 bar more than the specified pressure level
in the specification, then slowly open the exhaust
valve while continuously pressing on the switch
to discharge excess nitrogen gas until the gas
pressure drops down to the specified pressure
level in the specification.
84
10) When the gas pressure is set to the specified
pressure level, release the switch and open the
exhaust valve to discharge the nitrogen gas
from the gas hose.
85
MAINTENANCE
Temperature
H140
(Breaker body)
℃ ℉ bar psi
86
MAINTENANCE
87
5) Remove the Hex. head bolt from the accumulator.
88
7) Install the charging block to the gas charging valve
of the accumulator (Ensure that an O-ring is
installed on the charging block).
89
MAINTENANCE
90
4) Connect the other end of the gas hose to the
charging block.
91
6) After removing the Hex. head bolt, then slowly
remove the gas charging cap from the gas charging
bolt.
92
8) Loosen the gas charging bolt by turning it half a
turn anticlockwise using an allen wrench (hex key)
of size 5mm.
93
11) After closing the handle, then slowly open the
exhaust valve while the gas charging bolt is still
loosened to discharge excess nitrogen gas until the
gas pressure drops down to the specified pressure
level in the specification.
94
13) Check for gas leakage using soap bubbles around
the gas charging valve and gas charging bolt.
14) Install the Hex. head bolt and the gas charging cap.
(Ensure that an O-ring is installed on the gas
charging cap).
95
MAINTENANCE
Temperature
H140
(Breaker body)
℃ ℉ bar psi
96
MAINTENANCE
※ Wear parts
1. When damaged or worn, your attention is highly recommended to exchange these items.
- Tool
- Tool bushing
- Tool pins, hydraulic seals
- Stopper pin, bushing pin, rubber plug, bushing pin plug
- Side bolts
- Hydraulic hoses
2. We recommend the user to stock wearing parts, such as tool pin stopper, rubber plugs, bolts and
hydraulic hoses.
4. Tool pin
- When each tool pin is excessively deformed, it is difficult to replace the tool.
- Therefore, every 100 to 150 hours of operation, change the face if each pin which comes in contact
with the tool. The two faces of each pin can be used. If the tool you use is not the genuine part, we
cannot guarantee the breaker parts for their good performance.
- When replacing each part, check each part wear, breakage, scours, etc., especially, after removing
burrs and swelling on tool pins.
- Replace tool after grinding the worn parts of front head and tool pin. Insert a new tool pin after
grinding the scuffed parts of front head in use.
97
MAINTENANCE
98
MAINTENANCE
※ E, F : Original Dimensions
G, H : Wear Limit Dimensions
99
MAINTENANCE
7. T ORQU E
HOUSING
6
7
4
1
2
3
8
5
100
MAINTENANCE
HAMMER
MODEL TORQUE
(N.m) TORQUE
SPECIFICATION SPECIFICATION
(N.m)
1st 2nd
101
MAINTENANCE
102
MAINTENANCE
ACCUMULATOR ACCUMULATOR
COVER BOLT Ⓐ BOTTOM BOLT Ⓑ
MODEL
TORQUE TORQUE
SPECIFICATION SPECIFICATION
(N.m) (N.m)
103
MAINTENANCE
1) Using the socket bolt (12), fix both sides of set plate (10) and tighten securely.
2) Lay left side of housing (3) down on the supporting block on the flat ground.
3) Place the set plate (11) to the assembling position on the left side of housing. And then, lay the
hammer down on it.
4) Place the set plate (11) to the assembling position on the hammer. After that, lay the right side of
housing (2) down.
5) Install housing joint bolts (4) into housing join nuts and washers (5,6), then insert them from holes of
housing (2) to pass through the holes of housing (3).
6) Tighten the housing joint bolts with nuts and washers (7,8,9).
(Be sure to follow the assembly procedure)
7) After tightening the housing joint bolt securely, stand the hammer up and install top plate with hex,
bolts, washers, and nuts.
104
MAINTENANCE
105
MAINTENANCE
Release the back head gas pressure before loosening side rods.
Otherwise during removal of the side rods, a serious accident could occur.
1) Discharge N2 gas from back head completely before loosening side rods.
2) Remove four side rods, and inspect for any cracks and damages using crack detection die.
NOTICE
When one side rod is damaged, recommended to replace the opposite side rod.
3) When installing side rods, tighten bolts one turn at a time in diagonal sequence. Use torque wrench
as specified range.
Tightening
Loosening
106
MAINTENANCE
H140 HEX.85 x 65
107
MAINTENANCE
NOTICE
Each seal has different diameter and shape. Check the part list and compare the details (part name, direction, etc).
Be sure to follow the cross-sections of seal housing and lower cylinder.
108
MAINTENANCE
NOTE
109
MAINTENANCE
8-4. PISTON
If the piston has hairline scratch which are visible with the naked eye, the piston can be reused by
polishing.
Polishing job must be done in the clean place, and authorized person only should be allowed to carry
out restoration job in authorized place.
During the breaking operation, tool impact surface of the piston, wear into a concave area. Measure the
deformation, and change the piston if it exceeded allowable wear limit.
- H140 : 1 mm
110
MAINTENANCE
H140 M8 x 1.25P
111
MAINTENANCE
Note
Heating up of upper bushing area to 100
degrees Celsius may be required for
assembly of upper bushing.
112
MAINTENANCE
113
MAINTENANCE
DANGER
Before disassembling breaker, all remaining gas should be discharged completely from back head.
Otherwise, it could result in serious injury or death.
CAUTION
Wear goggle to protect eyes from discharging gas or dust emission. Don't be too close to the emission
valve.
114
MAINTENANCE
CAUTION
Do not disassemble accumulator without releasing
nitrogen gas.
CAUTION
Back head nitrogen charge MUST be released before
removing side rods.
115
MAINTENANCE
Loosen and remove the side rod nuts & washers, and
install lifting eye bolts into back head.
WARNING
Be sure to use a crane to handle or move the heavy parts.
116
MAINTENANCE
Note
Use dye check for detecting cracks
During loosening side rod bolts, slightly hit the side rod
lower nuts with a mallet for easy loosening.
Install the eye bolt on the lifting point of piston and pull
out the piston slowly. When you pull the piston out, seal
housing will come up. To remove seal housing from
piston, tap with rubber hammer.
NOTICE
Always you must pay attention to handle the core parts like piston, cylinder, seal housing valve block.
Be careful to use rubber hammer if necessary, but do not damage the core parts.
117
MAINTENANCE
118
MAINTENANCE
10. ADJUSTMENT
One of the most potentially damaging events in a breaker's life is blank firing. The "blank firing", that is,
when the piston slams down to the bottom of its stroke without contacting the tool, the energy which
should have been transmitted to the workpiece is absorbed in the breaker body. This can cause so
much damage to the inside of a breaker. To lessen the effect of blank firing, Auto Shut-Off (ASO)
system is available.
The operator can selectively adjust On & Off Modes of Auto Shut-Off function according to the given
working condition.
In ASO On Mode, the hammer automatically stops when the tool tip is no longer in contact with the
material. It reveals its benefits in a work condition where visibility is poor(e.g. underwater). This reduces
the strain on breaker, and ultimately increases the hammer lifespan.
In ASO Off Mode, the breaker starts without load applied to the tool, thus simplifying handling by saving
time to position the breaker. This provides great productivity through increased efficiency of hammer
operation.
119
TOOL FAILURE
ANALYSIS
120
TOOL FAILURE ANALYSIS
CAT hydraulic breaker tools are made from top quality grade steel, heat treated, machined, and inspected
for maximum consistency and reliability.
Breaker tools are consumable parts, used under severe conditions.
Breaker tool failures result from various conditions, maintenance, grease interval/type, application, tool
selection, and operator experience.
In general, the tool can withstand vertical hammering, if the tool is bent, twisted or blank firing is performed,
tool failure can happen. When operating more than 15 seconds in one spot without tool penetrating, the
tool will overheat causing mushrooming of the tip.
121
TOOL FAILURE ANALYSIS
TOOL TROUBLESHOOTING
122
TOOL FAILURE ANALYSIS
MATERIAL FAULT
Fatigue failure is started from the inside of breaker tool. This is the only kind of failure pattern that is
always acceptable for goodwill coverage.
123
TOOL FAILURE ANALYSIS
b. Size of "Y" area is dependent on how far fatigue has progressed through section before check all
hammer parts and either replace or repair damaged parts.
124
TOOL FAILURE ANALYSIS
Bending stress exceeds material strength causing tools to snap off. It is caused by wrong working angle
or use of tool for mechanical leverage. Failure generally occurs near front face of tool bushing. Failure
type is brittle fracture with a typical lip formation.
125
TOOL FAILURE ANALYSIS
Strong side load and striking at the same time can cause damage tool and tool bushing surface. This
pattern is caused by wrong working angle, wrong or insufficient lubrication or both.
Failure generally occurs in front tool bushing area.
126
TOOL FAILURE ANALYSIS
Overheating of tool due to driving the tool end into hard dense material for too long period of time without
penetration will incur fast wear in tool end. The overheating will soften the tool end causing it to mushroom
and peel.
127
TOOL FAILURE ANALYSIS
Blank firing will incur heavy wear on tool retainer groove. It may cause the serious wear or damage at tool pin
groove area. Therefore, tool pin also could be often cracked, even broken.
128
REUSABILITY GUIDELINE
FOR PISTON & CYLINDER
129
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
130
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
1) The piston is the main part which works in the cylinder. Thus, sliding friction occurs between inner
circumferential surface of the cylinder and outer circumferential surface of the piston.
2) Since the piston moves up & down with the contact of the seal on the cylinder, the contact areas at upper and
lower side of the piston has some glossy reflection due to the result of the contact.
3) For inspection of the piston, the hammer should be disassembled while it is standing upright to avoid
unexpected scratches.
4) After disassembly of the hammer, a visual inspection of the piston surface under any illumination giving
sufficient level of luminous intensity for detailed observation of markings on the piston surface needs to be
conducted after cleaning the piston.
5) When scratches are found, please refer to the pictorial guidelines to determine reusability. If it is determined
to be reusable, grinding is conducted to eliminate or minimize the surface scratches of the piston.
6) The reuse of the piston is only allowed when it satisfies the wear limit in the dimensional guideline.
131
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
1) CASE 1
GUIDELINE TIP(S)
132
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
2) CASE 2
GUIDELINE TIP(S)
3) CASE 3
GUIDELINE TIP(S)
133
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
4) CASE 4
GUIDELINE TIP(S)
134
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
1) CASE 1
GUIDELINE TIP(S)
135
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
2) CASE 2
Serious galling.
GUIDELINE TIP(S)
3) CASE 3
GUIDELINE TIP(S)
136
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
4) CASE 4
GUIDELINE TIP(S)
5) CASE 5
GUIDELINE TIP(S)
137
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
1) The cylinder guides the piston movements with an upper seal of the seal housing mounted in the cylinder and
a lower seal of the cylinder. The cylinder is normally assembled with a gap to the piston so that hydraulic oil
with high pressure does not leak out and small amount of hydraulic oil film is formed therein.
2) In order to investigate the cylinder, the piston has to be removed from the cylinder completely. During the
disassembly of the piston, the hammer should be disassembled while it is standing upright to avoid unexpected
scratches.
3) After disassembly of the hammer, a visual inspection of the cylinder surface under any illumination giving
sufficient level of luminous intensity for detailed observation of markings on the cylinder surface needs to be
conducted after cleaning the cylinder. Meanwhile, once some scratches are found on the piston, there is high
possibility that other scratches can be found in the cylinder.
4) When scratches are found, please refer to the pictorial guidelines to determine reusability. If it is determined
to be reusable, grinding is conducted to eliminate or minimize the surface scratches of the cylinder.
5) The reuse of the cylinder is only allowed when it satisfies the wear limit in the dimensional guideline.
138
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
1) CASE 1
Normal condition.
GUIDELINE TIP(S)
139
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
2) CASE 2
GUIDELINE TIP(S)
3) CASE 3
GUIDELINE TIP(S)
140
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
4) CASE 4
GUIDELINE TIP(S)
141
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
1) CASE 1
GUIDELINE TIP(S)
142
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
2) CASE 2
Serious galling.
GUIDELINE TIP(S)
3) CASE 3
Serious galling.
GUIDELINE TIP(S)
143
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
4) CASE 4
Serious galling.
GUIDELINE TIP(S)
144
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
⚫ Grinding and buffing should be conducted along the circumference and not along the length of the piston as
shown in the above picture. Use a rotary table to facilitate repairs.
⚫ The grit of the hand grinder or sandpaper needs to be between #1000 and #2000.
⚫ After the scratches found are completely eliminated, carefully measure to check whether it is within
tolerance.
⚫ Once the repair service is successfully done, clean the piston surface again before reassembly of the piston.
145
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
⚫ Grinding and buffing should be conducted along the circumference and not along the length of the cylinder
as shown in the above picture.
⚫ After the grinding, smooth the sharpened edges of inner circumferential grooves.
⚫ Once the repair service is successfully done, clean the piston surface again before reassembly of the
cylinder.
146
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
147
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
WEAR
H140 159.92 160.03 0.11 172.42 172.53 0.11 154.92 155.26 0.34
LIMIT
1) The guideline should be applied based on Max clearance level. If the item has measured dimension over
tolerance range, it can be reused when the clearance is within the specified Max clearance. For example, when
A is 159.90 and D is 160.00, the clearance A-D is 0.10 and they can be reused although A is beyond the
tolerance.
2) The depth of the galling/scratches is more of a concern than the length of the galling/scratches.
148
REUSABILITY GUIDELINE FOR PISTON & CYLINDER
7. REASSEMBLY GUIDELINE
3) The reassembly should be conducted in a clean environment with the hammer upright.
149
WARRANTY
SELF5453
NOTE
150