Búa phá đá Caterpillar lắp trên máy đào - P6

Nội dung: - Giới thiệu sản phẩm - Đầu búa H45-H100 - Đầu búa H115-H180 - Kiểm tra và điều chỉnh - Bảo dưỡng - Kiểm tra - Serie sản phẩm

Read the manuals I t’s Important!

Hammer Components are machined with close tolerances

Oil components before assembly

Use solvent tank and Krokus cloth to clean

Do not use steam cleaner on internal parts

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Caterpillar Hammers

Maint enance Operator Requirements

Daily - Properly grease hammer

¢ Tighten loose connections in hydraulic system

Weekly

¢ Inspect tool retaining pins

¢ Remove burrs from retaining pin groove on tool

¢ Check lower tool bushing for wear

Monthly

¢ Check top and side buffers for cracks and wear

¢ Check condition of wear parts, hydraulic connections etc

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Lubrication Guide

GREASI NG INTERVAL

» Every two hours; hourly in extreme conditions

m 10-15 strokes from the grease gun Adapt interval and amount according to grease quality, wear rate and working conditions

GREASE TYPE Molybdenum disulfide or graphite grease

Dropping point at over 250° C or 480° F Maximum working temperature >150°C/302°F Minimum working temperature under lowest

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RESULTS of | MPROPER GREASI NG

Without proper down force grease cause premature seal failure

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Automatic Lubrication System -

Grease Pump activated by electrical signal from hammer foot switch or pressure switch, supplies grease to hammer tool bushings

Grease amount is adjusted by dials inside pump/motor housing Greasing cycle is adjusted by both the and OFF dials

¢ BLUE dial controls OFF time in cycle

SMAfL HAMMERS (H45-H100C)

Port located on front

side of lower body

Model # points location port size location port size location port size H45/H45s 1 LH 1/8" BSPP

H50/H50s 2 LH 1/8" BSPP |Front 3/8" BSPP Back 1/2" BSPP H63/H63s 2 LH 1/8" BSPP |Front 3/8" BSPP Back 1/2" BSPP H70/H70s 2 LH 1/8" BSPP

H90C/H90Cs 2 LH 1/8" BSPP |Front 3/8" BSPP Back 1/2" BSPP H100/H100s 2 LH 1/8" BSPP |Front 1/4" BSPP Back 1/2" BSPP

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Autolube - Large Hammers (H115s- H180s)

Port is located on upper valve housing next to the supply or return port - see chart below

Port identifications:

¢ ‘G indentifies autolube port

¢ ‘A’ indentifies ‘Air’ channel port

Manual Grease Points Autolube Connection Air Connection Model # points location (port size location port size location port size H115s 2 LH 1/4" BSPP |Retumn-RH |1/4" BSPP Supply-LH |1/4" BSPP H120Cs 2 LH 1/4" BSPP |Supply-LH 3/8" BSPP Supply-LH |3/8" BSPP H130s 2 LH 1/4" BSPP [Supply-LH_ |3/8" BSPP Return-RH |3/8' BSPP H140s 1 HH 1/4" BSPP

H160s 1 HH 1/4" BSPP see Note H180s 2 LH 1/4" BSPP |Supply-LH |3/8" BSPP | Return-RH } 1/2" BSPP |

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Caterpillar Hammers

Autolube - Important Reminders

Installation:

1)Fasten grease line securely along supply/return line

2)Install pump in convenient location

3)Protect electrical circuit with fuses provided

4)Provide convenient means of deactivation

5)Prime lines with quality grease suitable for hammers

6)Adjust grease amount to recommended dial settings

7)ALWAYS confirm proper operation following installation

8)Consult service manual for more detailed information

Daily Checks:

1)Confirm adequate grease amount, adjust accordingly

2)Check for damaged hoses, fittings, etc

3)Assure grease canister Is full

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Caterpillar Hammers

Check For Burrs in tool retaining pin groove

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Maint enance

¢ Once a year or between 600-1000 machine hours

| Annual Service | - Replace all seals and accumulator membranes

¢ Inspect internal components for wear

¢ Replace warning and safety labels

¢ Inspect tie rods

¢ Machine hydraulic specifications are set properly

¢ engine rpm, relief settings, flow

¢ Hammer hydraulic circuit specifications are set properly

«Flow at Pressure, Return line pressure (Back Pressure)

¢ All hoses and fittings on machine are in good condition

¢ No leakage, No damaged or pinched hoses

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Model H70

Impact Frequency: = 600 - 1800 bpm 1800bpm x 60 min/hr = 108,000 cycles per hour 108,000cycles/hr x 8hrs = 864,000 cycles per day 864,000 cycles/day x5days = 4,320,000 cycles per week

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TOOL RETAINER PIN(S) Maximum Life LOWER TOOL BUSHING Maximum Life THRUST BUSHING

UPPER TOOL BUSHING

TIE RODS HOUSING WEAR PLATES SIDE PLATES MODELS H63-H100 HOUSING MODELS H115s-H195 BUFFER ASSEMBLY H115s-H195 BUFFER PADS H115s-H195

”” Low

Normal Extended

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1) Remove tool 3) Plug hydraulic connections

2) Protect with grease (anti-rust) 4) Store inadry area - 7

Front end of piston 9) Store hammer in vertical position ONLY

Bushing

Tool

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Membranes and Seals

Inspection of components can assist in analyzing cause of failure and /or operating conditions

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1 INCORRECT INSTALLATION

2 LOSS OF NITROGEN CHARGE

3 EXCESSIVE NITROGEN CHARGE

stamped “gas side” for proper installation

¢ Installed and operated upside down changes contact position with accumulator screen

“Gas” side

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Membranes - 2 Loss of Nitrogen Gas

Failure to originate on center section of membrane #2

First, Nitrogen escapes from U-sit seal,

caused by improper torque

Second, rim area tears allowing oil to ente nitrogen chamber and push membrane thru screen

Line size to small

Hose damage causing restriction

Quick coupler failure

Ball valve partially closed

Carrier hydraulic circuit

Relief valve to low or fatigued

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Screen contact surface

Membrane - 6 Blank Firing

stops on retaining pin

The oil volume normally retained

between membrane and screen

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Seals - Temperature

Inspection of seals can indicate symptom of failure

Seal color changes from cycle time and oil temperature

Seals - Heat Failure

Solve the Problem

Heat failure is caused by :

Low relief valve

¢ Areas of Tool Failure

¢ Piston Impact Area

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Working Environment External Factors:

- Temperature Impact loads

- Corrosion (from piston)

- Wear and Tear

- _ Excessive bushing wear

Retainer pin area

Fatigue

Seizures Bushing area - Lower

Blank firing Worn retainer pins

Mechanical damages T ip of Tool

Il.e deep gouges

Mushrooming

Wrong tool in application

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¢ Deformation is caused by:

- Improper impact energy - oil flow and pressure

- High working temperature (e.g foundries)

¢ Chipping or corner loading is caused by:

- Excessively worn bushings

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Blank Firing occurs where tool is not properly preloaded

- Impact energy from piston is absorbed partially or fully by retaining pins

- Prevalent in most applications: Bridge work,quarrying, or trenching

Failure of tool in slot area is caused by: s

- Worn lower tool bushing

- Worn retaining pins - usually with chisel tool

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Fatigue failure starts on surface from stress concentration points :

- Scratches or gouges on working length

- Seizures in bushing areas or retaining pin slots

Fatigue cracks are recognized by patterns

- Semi circular marks around failure point

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Failure occurring on working area lower tool bushing

Heavy gouges or scratches on surface create stress concentration points, leading to fatigue failure

Unexpected breakage can be attributed to:

- High frequency with low loads

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Over 50% of Fatigue Failures are seizures in lower tool bushing area

¢ Seizures occur as tool slides against bushings or retaining pins

¢ Seizures are caused by:

- Wrong working angle

- Insufficient grease

- Wrong type of grease

- Improper greasing interval

¢ Fatigue failure results from stress concentration once crack Is formed

¢« Bending stresses exceed material strength

¢ Excessive bending is caused by:

- Prying with tool

- Wrong working angle

¢ High lip formation occurs in or near lower tool bushing

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Hammering in one spot too long ea

- Produces higher heat loads on tip lá

To small hammer for application

Chipped Edge

Chipping caused by:

- Improper contact with material

- Wrong selection of tool for application

Causes faster wear on retainer pins and tool slot

Welding produces cracks on tool surface leading to fatigue failure

¢ Tools are thru hardened

¢ Resharpen :

- By milling

- By turning on a lathe

- By Sawing at low temperatures (Max 150 C / 300 F)

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- Weak spot in material

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Lowers Owning & Operating Cost by:

- Extended Tool life

- Extended Bushing life

¢ Every TWO hours of machine operation

- Extreme conditions more often

¢ 10 - 15 strokes from grease gun

¢ Optimum for hammers an Autolube system

Grease Type

CAT Multipurpose Molybdenum grease (MPGM)

- Molybdenum based grease

- Dropping point over 250 C / 480 F

- Grade equal to an NGLI Number 0 2